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T A U R U S T E C H

MOTOCONDENSING WATER CHILLERS

MAINTENANCE AND OPERATING MANUAL

MCTAT 030-065

38178801089Original instructions in Italian language

MAINTENANCE AND OPERATING MANUALUser's quick guide

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The data in this manual are not binding and they can be modified by the manufacturer without notice. Reproduction of this manual is strictly prohibited

USER'S QUICK GUIDEThe units in the MCTAT range are equipped with an electronic control unit that, depending on the signals read by the analogue or digital inputs with which it is equipped, manages the operation of the unit.This quick guide lists the major features of the board, for further details please see the Chapter 7 “Electronic controller”.

0 . 1 U n i t s t a r t / s t o pThe unit can be switched on and off:

• With the keyboard (local or remote)• With the digital input configured as remote ON/OFF

NOTEIn case of a power loss, when power is restored the unit will be ON if it was ON at the time of power loss, and OFF if it wasOFF.

0.1.1 Switching on with the keyboardWith the unit OFF (standby), press and release the button to switch the unit on or off in chiller mode. With the unit

powered on, the LED is on.Stand-by mode is set each time the unit's chiller operation is turned off. In standby mode, too, the controller allows you to:

• Display the measured values.• Manage the alarm situation by displaying and signalling.

When the unit is on stand-by the control displays the label .

0.1.2 Switching on with the digital input You can turn the unit on/off with the digital input configured as remote ON/OFF.The OFF command (local or remote) always takes priority over the ON command. If the unit is turned off locally it must be turned back on locally. When the unit is turned OFF with the digital input the control displays the label . .

For the connection details, please refer to the wiring diagram.

NOTETo start up the MCTAT unit, use the dedicated digital input.

MAINTENANCE AND OPERATING MANUALUser's quick guide

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0 . 2 S e t - p o i n t0.2.1 Display the set-point

To view the set-point, press and release the button.With the unit on stand-by the lower display will show SetC (set chiller). The upper display will show the set value.

0.2.2 Change the set-pointTo change the unit's working set-point press for at least 3 seconds and the working set-point SetC (set chiller) will be shown blinking.

The change is made by pressing buttons or .

To save the new set-point, press or wait for the time-out interval to elapse to exit programming mode.

0 . 3 D i s p l a y a n d r e s e t a l a r m s ( A L r M f u n c t i o n )ATTENTION

With this procedure you can reset all the alarms except for the compressor thermal cut-out alarms for which thepassword will be required: 14.

To access the functions menu, proceed as follows:

• Enter the functions menu by pressing the button .

• With the or buttons select the function ALrM.• Press the button.

If there is no alarm, pressing is not enabled.• The label appears in the lower display with the alarm code, while the upper display, if the displayed alarm is

reset, shows the label rSt or the label no if the alarm condition is still present.• Pressing on the label rSt resets the alarm and moves on to the next one. If this is resettable too then press

to reset it and move on to the next one. • To scroll through all the alarms, you can press or .

To exit the ALrM function and return to normal viewing, press or wait for time-out.

With units on StbY (stand-by) and LED blinking, press scroll with or , select the ALrM function and press

the button to view the active alarm.

NOTETo reset the compressor thermal cut-out alarms, please refer to the relevant paragraph.

0 . 4 I n s t a l l i n g M C T A T m o t o c o n d e n s i n g u n i t sTo install the motocondensing units, follow the instructions given in paragraph 5.6 “Refrigerant circuit and thermostatic valve connections for motocondensing units” and refer to the diagrams attached to this manual.

MAINTENANCE AND OPERATING MANUALTable of contents

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TABLE OF CONTENTSUSER'S QUICK GUIDE.................................................................................................................................... 10.1 Unit start/stop ................................................................................................................................................ 1

0.1.1 Switching on with the keyboard .......................................................................................................................... 10.1.2 Switching on with the digital input ..................................................................................................................... 1

0.2 Set-point ........................................................................................................................................................ 20.2.1 Display the set-point ........................................................................................................................................... 20.2.2 Change the set-point ........................................................................................................................................... 2

0.3 Display and reset alarms (ALrM function) ................................................................................................... 20.4 Installing MCTAT motocondensing units .................................................................................................... 2TABLE OF CONTENTS.................................................................................................................................... 3

Chapter 1

GENERAL INFORMATION.............................................................................................................................. 61.1 Description .................................................................................................................................................... 61.2 How to interpret the model............................................................................................................................ 71.3 How to interpret the codes ............................................................................................................................ 7

Chapter 2

TECHNICAL DATA, PERFORMANCE AND OPERATING LIMITS ..................................................................... 82.1 Declaration of conformity ............................................................................................................................. 92.2 Technical data ............................................................................................................................................... 92.3 Sound level measurements .......................................................................................................................... 10

Chapter 3

SAFETY ........................................................................................................................................................ 113.1 General ........................................................................................................................................................ 113.2 General precautions..................................................................................................................................... 11

3.2.1 Liquid to be chilled ........................................................................................................................................... 113.2.2 Lifting and transport precautions ..................................................................................................................... 123.2.3 Precautions to be adopted during installation ................................................................................................. 123.2.4 Precautions to be adopted during operation .................................................................................................... 133.2.5 Disposal ............................................................................................................................................................ 133.2.6 Maintenance precautions .................................................................................................................................. 13

3.3 Refrigerant gases ......................................................................................................................................... 143.3.1 Refrigerants safety datasheet ............................................................................................................................ 14

Chapter 4

DESCRIPTION .............................................................................................................................................. 164.1 Refrigerant circuit ....................................................................................................................................... 16

4.1.1 Compressors ..................................................................................................................................................... 164.1.2 Condensers ........................................................................................................................................................ 174.1.3 Fans .................................................................................................................................................................. 17

4.2 Refrigerant circuit of the MCTAT motocondensing units .......................................................................... 174.2.1 Cabinet .............................................................................................................................................................. 174.2.2 Protection rating ............................................................................................................................................... 17

4.3 Electrical circuit .......................................................................................................................................... 174.4 Overall dimensions...................................................................................................................................... 17

Chapter 5

INSTALLATION ............................................................................................................................................ 185.1 Inspection .................................................................................................................................................... 185.2 Location....................................................................................................................................................... 185.3 Minimum distances from the walls of the installation environment........................................................... 195.4 Frost protection ........................................................................................................................................... 195.5 Electrical connections ................................................................................................................................. 19

5.5.1 Phase Monitor ................................................................................................................................................... 205.6 Refrigerant circuit and thermostatic valve connections for motocondensing units .................................... 20

5.6.1 Installing and laying down the refrigerant lines .............................................................................................. 215.6.2 Testing the motocondensing unit via digital input (Factory settings) .............................................................. 235.6.3 Testing the motocondensing unit via temperature probes BEWOT and BEWIT .............................................. 24


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Chapter 6

STARTING.................................................................................................................................................... 25Chapter 7

ELECTRONIC CONTROLLER ....................................................................................................................... 267.1 User interface ...............................................................................................................................................267.2 Function of buttons ......................................................................................................................................26

7.2.1 Function of combined buttons ...........................................................................................................................277.3 Remote terminal...........................................................................................................................................277.4 Probe key .....................................................................................................................................................277.5 Unit start/stop...............................................................................................................................................27

7.5.1 Switching on with the keyboard .........................................................................................................................287.5.2 Switching on with the digital input ....................................................................................................................28

7.6 Set-point.......................................................................................................................................................287.6.1 Display the set-point ..........................................................................................................................................287.6.2 Change the set-point ..........................................................................................................................................28

7.7 The “Menu” button functions menu ............................................................................................................297.7.1 CrEn - Enable or disable the single circuit .......................................................................................................297.7.2 COEn - Enable or disable the single compressor .............................................................................................297.7.3 COSn - Display and reset the number of compressor starts .............................................................................307.7.4 Hour - Display and reset the operating hours of the loads ...............................................................................307.7.5 Cond - Display percentage / Number of condensation steps ............................................................................307.7.6 POEn - ENABLE or DISABLE the operation of a water pump using the key ..................................................31

7.8 uS - Display tank resistance probe...............................................................................................................317.9 Alarms..........................................................................................................................................................31

7.9.1 Display and reset alarms (ALrM function) .......................................................................................................317.9.2 How to mute the buzzer .....................................................................................................................................327.9.3 General alarms list ............................................................................................................................................327.9.4 Warnings Table .................................................................................................................................................337.9.5 Faulty probe ......................................................................................................................................................337.9.6 High pressure switch alarm ..............................................................................................................................337.9.7 Low pressure switch alarm ................................................................................................................................347.9.8 High pressure ....................................................................................................................................................347.9.9 Low pressure .....................................................................................................................................................347.9.10 Anti-freeze alarm ...............................................................................................................................................347.9.11 Chiller operating antifreeze alarm ....................................................................................................................347.9.12 Water differential pressure switch alarm ..........................................................................................................357.9.13 Compressor thermal cut-out alarm ...................................................................................................................357.9.14 Fan thermal cut-out alarm ................................................................................................................................357.9.15 Signalling condensation high pressure unloading in chiller mode ...................................................................367.9.16 Signalling condensation high pressure recovery disabling in chiller mode .....................................................367.9.17 Signalling unloading from evaporator inlet water high temperature ...............................................................367.9.18 Evaporator water pumping unit thermal cut-out alarm ....................................................................................367.9.19 Phase monitor alarm .........................................................................................................................................367.9.20 Compressor maintenance alarm .......................................................................................................................377.9.21 Pump maintenance alarm ..................................................................................................................................377.9.22 EEPROM alarm ................................................................................................................................................377.9.23 Remote terminal alarm ......................................................................................................................................377.9.24 Remote terminal alarm ......................................................................................................................................377.9.25 Notes on alarm relay / open - collector / buzzer ...............................................................................................387.9.26 Display and delete the alarm log in memory (ALOG function) ........................................................................38

7.10 Programming by keyboard...........................................................................................................................387.10.1 Access to parameters .........................................................................................................................................397.10.2 How to modify a parameter’s value ..................................................................................................................39

7.11 Using the hot-key (UPL function) ...............................................................................................................407.11.1 Programming the board with the hot-key ..........................................................................................................407.11.2 Programming the hot-key ..................................................................................................................................40

7.12 Adjusting and controlling the unit ...............................................................................................................407.12.1 Compressor control ...........................................................................................................................................407.12.2 Choosing the type of compressor control ..........................................................................................................407.12.3 Proportional control ..........................................................................................................................................407.12.4 Graph of compressor proportional control .......................................................................................................417.12.5 Neutral zone control ..........................................................................................................................................417.12.6 Compressors rotation ........................................................................................................................................41


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7.12.7 Forced compressor rotation ............................................................................................................................. 417.12.8 Time limit for switching on compressors .......................................................................................................... 41

7.13 Unloading function...................................................................................................................................... 427.14 Fan control .................................................................................................................................................. 42

7.14.1 Units configured with “STEP” fans ................................................................................................................. 427.14.2 Units configured with regulated fans ................................................................................................................ 427.14.3 Fan control graphs ........................................................................................................................................... 42

7.15 ModBus ....................................................................................................................................................... 437.16 Motocondensing Unit .................................................................................................................................. 437.17 Automatic restart ......................................................................................................................................... 437.18 Parameter Description-Settings................................................................................................................... 43

7.18.1 Description of parameters ................................................................................................................................ 437.18.2 Parameter settings ............................................................................................................................................ 467.18.3 Parameters depending on remote terminal kit ................................................................................................. 46

Chapter 8

ADJUSTMENT AND CONTROL ..................................................................................................................... 478.1 Refrigerant high and low pressure switches................................................................................................ 478.2 Electrical cabinet forced ventilation............................................................................................................ 488.3 Electrical cabinet heating element (optional).............................................................................................. 488.4 Compressor integral protection (PI)............................................................................................................ 48

Chapter 9

OPERATION AND MAINTENANCE................................................................................................................ 499.1 Operation..................................................................................................................................................... 499.2 Maintenance ................................................................................................................................................ 49

9.2.1 Access to the unit's internal components (see attached drawings) ................................................................... 499.2.2 Maintenance and Inspection Schedule ............................................................................................................. 50

Chapter 10

TROUBLESHOOTING.................................................................................................................................... 51Chapter 11

RISK ANALYSIS: RESIDUAL RISK ................................................................................................................ 54APPENDIX .................................................................................................................................................... 57

MAINTENANCE AND OPERATING MANUALGeneral information

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CHAPTER 1

GENERAL INFORMATION1 . 1 D e s c r i p t i o nATTENTION

Some of the functions, data or elements described in this manual may not apply to (or be present in) the motocondensingunits.

The units described in this manual will be described hereinafter as “CHILLERS”.This manual is addressed to personnel responsible for installing, using and servicing the unit.Top brand components have been used, and the entire process of design, production and control of machinery has been performed in compliance with the standards ISO 9001 and CEI EN 60335-1.Since, in the majority of applications, the liquid to be cooled is water, hereinafter the term “WATER” is used for the sake of simplicity, even if the liquid to be cooled may not be water (e.g. a water and ethylene or propylene glycol solution). Hereinafter the expression “PRESSURE” is used to indicate relative pressure.The following symbols are to be found on the decals affixed to the unit and also in the dimensional drawings and refrigerant circuit diagrams in this manual.The meaning of each symbol is indicated below:

Electric shock risk Thermal exchange air flow

Direction of flow of refrigerant fluid Rotation direction of pump (if installed) and fan

Risk of injury due to sharp edges Risk of burns from contact with high-temperature surfaces

Indication of the axis of reference for lifting operations

Opening to be used for the insertion of bars for the purpose of lifting the unit

Heat recovery exchanger or Desuperheater water inlet (models with heat recovery exchanger or desuperheater only)

Heat recovery exchanger or Desuperheater water outlet (models with heat recovery exchanger or desuperheater only)

Refrigerant inlet into the machine Refrigerant outlet from the machine

MAINTENANCE AND OPERATING MANUALGeneral information

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1 . 2 H o w t o i n t e r p r e t t h e m o d e l

1 . 3 H o w t o i n t e r p r e t t h e c o d e s

* Maximum ambient temperatures referred to a water outlet temperature of 7 °C.

ATTENTION

This manual provides users, installers, and service personnel with all the technical information required to installand work with the unit and to perform the routine maintenance operations required to maximise its working life.Use only genuine parts when carrying out routine maintenance or repairs.Requests for SPARE PARTS and any INFORMATION concerning the unit must be made to your dealer or nearest servicecentre, specifying the MODEL and SERIAL NUMBER shown on the unit's data plate and on the last page of this manual.

MODEL DESCRIPTION MC TAT

Unit version (N, SN, SSN)

Approximate power input from the compressor in HP of N version

Taurus Tech model

MC Taurus Tech model code. MC appears only on motocondensing units

/NWith R410A refrigerant, suitable for a maximum ambient temperature up to 46 °C.(Approximate data: for the precise value refer to the unit data plate or to the tables in the technical catalogues).*

/SN

With R410A refrigerant, suitable for a maximum ambient temperature up to 43 °C.(Approximate data: for the precise value refer to the unit data plate or to the tables in the technical catalogues).*Reduction in noise levels with respect to the N version.

/SSN

With R410A refrigerant, suitable for a maximum ambient temperature up to 46 °C.(Approximate data: for the precise value refer to the unit data plate or to the tables in the technical catalogues).*Reduction in noise levels with respect to the SN version.

MAINTENANCE AND OPERATING MANUALTechnical data, performance and operating limits

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CHAPTER 2

TECHNICAL DATA, PERFORMANCE AND OPERATING LIMITSThe data plate affixed to the unit shows the main technical data.

MODEL and CODE Identify the size of the unit (see Chapter 1 “General information“) and the type of construction.

MANUAL Code number of this manual.SERIAL NUMBER Unit serial number or manufacturing number.MANUFACTURING YEAR This is the year of the final test of the unit.VOLTAGE/PHASE/FREQUENCY Power supply specifications.MAX CURRENT INPUTIMAX

This is electrical current consumed by the unit during the limit working conditions (refrigerant condensing temperature 65 °C = 149 °F; refrigerant evaporating temperature 10 °C = 50 °F).

INSTALLED POWERPMAX

This is electrical power consumption of the unit during limit working conditions (refrigerant condensing temperature 65 °C = 149 °F; refrigerant evaporating temperature 10 °C = 50 °F).

PROTECTION RATING Protection rating of the entire unit, according to European standard EN 60529.REFRIGERANT This is the refrigerant fluid in the unit.REFRIGERANT QUANTITY Quantity of refrigerant supplied to the circuit.MAX. REFRIG. PRESS. This is the design pressure of the refrigeration circuit.MAX. REFRIG. TEMP. This is the design temperature of the refrigeration circuit.USER CIRC. FLUID Fluid cooled by the unit (usually: water).MAX. WORKING PRESSURE Max. design pressure of the user circuit.MAX. TEMPERATURE Maximum design temperature of the user circuit; this should not be confused with the

maximum working temperature which is established when the offer is made.SOUND PRESSURE LEVEL Free field sound pressure level in hemispherical radiation conditions (open field) at a

distance of 1 m from the condenser side of the unit and a height of 1.6 m from the ground.

AMBIENT TEMPERATURE Cooling air minimum and maximum temperature values (chiller).WEIGHT This is the approximate weight of the unit before packing.


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2 . 1 D e c l a r a t i o n o f c o n f o r m i t y

2 . 2 T e c h n i c a l d a t a

List:a) Name of manufacturerb) Definition of responsibilityc) Type of unitd) Unit modele) Serial or construction number of the unitf) Directives and standardsg) PED directiveh) Officer responsible for technical filei) Particulars of the officer responsible for the technical filej) Place and date

Model MCTAT 030 MCTAT 035

Version N SN SSN N SN SSN

Axial flow fanNo. of fans 2 2

Total airflow (m3/h) 47200 36600 27600 46250 35700 26950




Total airflow (m3/h) 45300 34800 26300 70500 54900 41400




Total airflow (m3/h) 68010 51900 39300 68010 51900 39300

M.T.A. S.p.A. VIA ARTIGIANATO, 2 - ZONA INDUSTRIALE - 35026 CONSELVE (PD) - ITALY

Dichiarazione di conformità CE / UEa) Noi:

b) Dichiariamo sotto la nostra sola responsabilità che la macchina

c) Tipo:

d) Modello:

e) Matricola:

f) è conforme a quanto prescritto dalle Direttive e norme:Direttiva Macchine 2006/42/CE - UNI EN ISO 12100

- CEI EN 60204-1 : 2006-09 Direttiva Compatibilità Elettromagnetica 2014/30/UE - CEI EN 61000-6-1 : 2007-10

- CEI EN 61000-6-3 : 2007-11 - CEI EN 61000-6-2 : 2006-10 - CEI EN 61000-6-4 : 2007-11

g) inoltre è stata progettata, costruita e ispezionata conformementeai requisiti richiesti dalla Direttiva PED 2014/68/UE - EN 378 l’insieme ricade in categoria: la procedura di valutazione di conformità utilizzata è secondo il modulo: (rif. Allegati II e III della Direttiva 2014/68/UE) l’organismo notificato incaricato della sorveglianza del sistema di qualità:

estremi dell'Attestato di approvazione del sistema qualità: la macchina è considerata insieme ai fini della direttiva PED. Le attrezzature in pressione che la compongono e le relative procedure di valutazione di conformità sono le seguenti:

Gli altri componenti non recano la marcatura CE in quanto rientrano nelle prescrizioni dell’Art. 1 par. 2 f della Direttiva 2014/68/UE

h) che la persona autorizzata alla costituzione del fascicolo tecnico è: indirizzo:

i) Nome: Cognome: Posizione:j) Luogo, Data Firma

Allegati: Lista dei pericoli considerati secondo l’Allegato I della Direttiva MacchineMUT002/H

FACSIMIL

E


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2 . 3 S o u n d l e v e l m e a s u r e m e n t s

** at a distance of 1 m (3.2 FT).*** global.Test conditionsNoise levels refer to operation of the unit at full load in nominal conditions. Sound pressure level in hemispherical irradiation conditions at a distance of 1 m (3.2 FT) from the condensers side of the unit and height of 1.6 m (5.2 FT) from the ground. Values with tolerance of ±2 dB.Sound pressure level: according to ISO 3744.

Model MCTAT 065

Version N SN

Axial flow fanNo. of fans 3

Total airflow (m3/h) 68010 51900

Model MCTAT 030 MCTAT 035 MCTAT 040Version N SN SSN N SN SSN N SN SSN

Lp dB(A) ** 74.5 69.6 66.6 74.1 69.2 66.4 73.8 68.8 65.9Lw dB(A) *** 87.5 82.6 79.6 87.1 82.2 79.4 86.7 81.8 78.8

Model MCTAT 050 MCTAT 055 MCTAT 060Version N SN SSN N SN SSN N SN SSN

Lp dB(A) ** 77.3 71.3 68.3 77.1 70.9 67.6 75.9 70.5 67.3Lw dB(A) *** 90.3 84.2 81.3 90.1 83.8 80.6 88.8 83.5 80.3

Model MCTAT 065Version N SN

Lp dB(A) ** 76.9 71.0Lw dB(A) *** 89.9 84.0

MAINTENANCE AND OPERATING MANUALSafety

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CHAPTER 3

SAFETYATTENTION

This plant is designed for safety in its intended use, provided it is installed, commissioned, and serviced in compliancewith the instructions given in the present manual.This manual must therefore be studied by all those who want to install, use or maintain the machinery.The machine contains electrical components which operate at the line voltage, and also moving parts, such as fans andpumps (where applicable). The unit must therefore be isolated from the electricity supply network before being opened.Any maintenance operations that call for access to the plant must be executed by skilled or suitably qualified personnel whoare fully aware of all the necessary precautions.

3 . 1 G e n e r a lWhen handling or maintaining the unit and all auxiliary equipment, the personnel must operate with care observing all instructions concerning health and safety at the installation site.Most accidents which occur during the operation and maintenance of the machinery are a result of failure to observe basic safety rules or precautions. An accident can often be avoided by recognising a situation that is potentially hazardous.The user must ensure that all personnel involved in operating and servicing the unit and the auxiliary equipment have readand understood all the warnings, precautions, prohibitions and notes given in this manual and affixed to the unit.

ATTENTION

Improper operation or maintenance of the unit and the auxiliary equipment can be dangerous and can cause serious orfatal accidents.

Do not work with the unit and the auxiliary equipment until the instructions relative to commissioning and operation have been fully understood by the personnel involved.Do not perform any maintenance or repair work until the instructions given in this manual have been clearly understood by all personnel concerned.We cannot anticipate every possible circumstance which might represent a potential hazard. The warning in this manual are therefore not all-inclusive. If the user adopts operational procedures or uses tools or working procedures that are not specifically recommended, care must be taken to ensure that the unit and the auxiliary equipment are not damaged or made unsafe and that no risks emerge in relation to persons or property.Any improper use of the machine will relieve the manufacturer from any liability for possible personal injury or property damage.Arbitrary modifications made to the unit will automatically invalidate all forms of guarantee provided by the manufacturer.

ATTENTION

The hot / chilled water produced by MTA units cannot be used for hygiene/sanitary or food applications.If it is used for the above purposes, the installer must install an intermediate exchanger.If the intermediate exchanger is not present, the installer must affix a warning notice to the effect “non potablewater.”

3 . 2 G e n e r a l p r e c a u t i o n s3.2.1 Liquid to be chil led

The liquids to be chilled must be compatible with the materials used.They can be, for example, water or mixtures of water and ethylene or propylene glycol.We recommend adding anti-corrosive chemical agents to the water and working with pH values of between 7 and 8.In the case of glycol mixtures, too, the use of appropriate chemical additives (consult the glycol supplier) is very important to protect the unit materials from possible corrosion due to the chemical degradation to which glycol is subject.Chemical additives are necessary when the unit is part of a hydraulic circuit that is open to the atmosphere in at least one point. In this case, in fact, the continuous supply of oxygen facilitates possible corrosive reactions inside the unit.The liquids to be chilled must not be flammable.If the liquids to be chilled cannot be discharged into sewers because of the presence of hazardous substances (such as, for example, ethylene or propylene glycol), the unit must be installed in a place with a system for collecting any fluid leaking from


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a loss area to prevent this getting into the drains. This system must be able to contain the entire volume of liquid in the hydraulic circuit.Moreover, when the unit is no longer required for use, the hazardous liquids must be disposed of by consigning them to a specialized company authorised for the treatment of hazardous waste.

3.2.2 Lift ing and transport precautionsAvoid injury by using a hoist to lift heavy loads. Check all chains, hooks, shackles and slings are in good condition and are of the correct capacity. They must be tested and approved according to local safety regulations. Cables, chains or ropes must never be applied directly to lifting eyes. Always use an appropriate shackle or hook properly positioned. Arrange lifting cables so that there are no sharp bends.Use a spreader bar to avoid lateral loading of hooks and eyebolts. When a load is lifted from the ground keep well clear of the area beneath the load and the immediately surrounding area. Keep lifting acceleration and speed well within safety limits and never leave a suspended load attached to a hoist any longer than strictly necessary.Handling of the machine must be carried out in accordance with the annexed diagrams.The manufacturer does not supply load spreaders, lifting straps or hooks with the unit.

3.2.3 Precautions to be adopted during instal lat ionThe installation work must be performed by competent personnel under the guidance of a qualified supervisor.Models MCTAT 030-035-040

Models MCTAT 050-055-060-065

The unit's power supply line must be protected by equipment that must be selected and installed by the user on the basis of the data given on the wiring diagram and in paragraph “5.5 Electrical connections”.If the machine is connected to a hydraulic circuit of the closed type equipped with an automatic supply system and the pressure of the supply system exceeds the unit's maximum working pressure it is necessary to install a pressure limiting device (e.g., a safety valve that trips at a pressure lower than the unit's maximum working pressure and located near to the inlet port).All chilled or cooling water pipelines must be painted and marked clearly in compliance with local safety prescriptions in force in the place of installation.Install manual shut-off valves for the unit so that the hydraulic circuit can be cut out for maintenance operations.All electrical connections must comply with local codes.The unit and its auxiliary equipment must be connected to earth and protected against short circuits and overloads.Should raised platforms be needed in order to access the unit, they must not interfere with the normal operations or obstruct access for lifting or removing components. The platforms and ladders must be grated or paved and must have safety railings on all open sides.If the unit is installed in the open air, ensure that it is not exposed to very strong winds.

1500 min

1000 min

1000

min

1000

min

1000

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1500 min

1000 min

1000

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They can be dangerous for two reasons:• They may reduce the stability of the unit's metal structure and may damage the anchorage of the panels of the

casing.• They may adversely affect the performance of the condenser.

3.2.4 Precautions to be adopted during operationThe unit must be operated by competent personnel under the guidance of a qualified supervisor.Do not remove or tamper with safety devices, protections, or the insulating materials installed in the unit or in the auxiliary equipment.When mains power is switched on, lethal voltages are present in the electrical circuits and extreme caution must be exercised whenever it is necessary to carry out any work on the electrical system.Do not exceed the flow values of the liquid to be cooled indicated in heading “5.5 Electrical connections”.

3.2.5 DisposalIf the product is scrapped, it must be disposed of in accordance with the environmental protection legislation in force in the country of use. The unit may include all or some of the materials listed below:

• Refrigerant fluid R ... • Copper parts• Aluminium parts• Carbon Steel parts• Stainless Steel parts• PVC parts• CFC-free synthetic insulating material• Polystyrene parts• Polyester oil• Brass

3.2.6 Maintenance precautionsMaintenance, overhauls and repair of the unit must be carried out by competent personnel under the guidance of a qualified supervisor.

ATTENTION

During normal operation of the unit, uninsulated surfaces of components of the refrigerant circuit in the compressorcompartment may reach high temperatures and remain very hot for some time after the unit is switched off.This creates a potential burn hazard for anyone who has to access inside the machine.

If replacement parts are needed use only original spares.Keep a written record of all work carried out on the unit and the auxiliary equipment.The frequency and the nature of the work required over a period can reveal adverse operating conditions which should be corrected.Make sure that all instructions concerning operation and maintenance are strictly followed and that the complete unit, with all accessories and safety devices, is kept in good working order.The accuracy of pressure and temperature gauges must be regularly checked. They must be renewed when acceptable tolerances are exceeded.

ATTENTION

When disposing of parts and waste material of any kind make sure that there is no pollution of any drain or naturalwater-course and that no burning of waste takes place which could cause pollution of the air. Protect the environment byusing only approved methods of disposal.

Keep the unit clean at all times.Protect components and exposed openings (by covering them, for example, with clean cloths) during maintenance and repair work.Do not weld or perform work that generates heat close to a system that contains oil or flammable liquids.Systems which may contain oil of flammable liquids must be completely purged and cleaned, e.g. by steam, before carrying out such operations. Never weld on (or in any other way modify) a pressure vessel.To prevent an increase in working temperature and pressure, inspect and clean heat transfer surfaces (i.e. condenser fins) regularly.For all units establish a suitable time interval for cleaning procedures.Avoid damage to safety valves and other pressure relief devices.Avoid plugging by paint, oil or dirt accumulation.


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Precautions must be taken when carrying out welding or any repair operation which generates heat, flames or sparks.Components in the vicinity must be protected with non-inflammable material and, if the operation is to be performed close to parts of the lubrication system or in the vicinity of components that may contain oil or inflammable liquids, the system must first be purged.Never use an open flame as a light source to inspect parts of the unit.Before dismantling parts of a unit ensure that all mobile and heavy parts are securely fixed.When a repair has been completed make sure that no tools, detached parts or rags are left in the unit. Check the direction of rotation of the motors (fans, compressors and pump with three-phase power supply) when starting the unit for the first time after work has been performed on the electrical connections or on the power supply disconnecting device.All guards must be refitted after carrying out repair or maintenance work.

ATTENTION

Use only refrigerant gas specified on the data plate of the unit.

Do not use flammable liquids to clean components while the unit is running.If chlorinated hydrocarbon non-flammable fluids are used for cleaning, safety precautions must be taken against any toxic vapours which may be released.Before removing any panels or dismantling any parts of the electrical cabinet perform the following steps:

• Isolate the unit from the electrical power supply by disconnecting the supply upstream of the power feeding line. Lock out the breaker on the “OFF” position by fitting a padlock and remove fuses, if present.

• Affix a sign to the breaker handle stating “WORK IN PROGRESS - DO NOT SWITCH ON”. Do not set the electrical power switch to ON or attempt to start the unit if the warning sign is displayed.

Coloured tracers can be used in service-maintenance operations.Inspect all refrigerant circuit joints including connectors, flanges, and more generally all critical points (open joints) in order to prevent possible leakage of refrigerant gas.

3 . 3 R e f r i g e r a n t g a s e sThe units are charged with R410ANever replace or mix one gas with another because different gases are not mutually compatible.To clean out a very heavily contaminated refrigerant system, e.g. after a refrigerant compressor burnout, a qualified refrigeration engineer must be consulted to carry out the task.The manufacturer's instructions and local safety regulations should always be observed when handling and storing high pressure gas cylinders.

3.3.1 Refrigerants safety datasheet

Denomination: R410A (50% Difluoromethane (R32); 50% Pentafluoroethane (R125)).INDICATION OF HAZARDS

Major dangers: Suffocation.Specific dangers: Rapid evaporation can cause cold burns.

FIRST AID MEASURESGeneral information: Do not attempt to administer liquids or solids to persons who have lost consciousness.Inhalation: Move victims to the open air. Use oxygen or artificial respiration if necessary.

Do not administer adrenaline or similar substances.Contact with the eyes: Wash thoroughly with plenty of clean water for at least 15 minutes and seek medical

assistance.Contact with the skin: Wash immediately in plenty of clean water. Remove contaminated clothing

immediately.FIRE-FIGHTING MEASURES

Means of extinction: Any.Specific dangers: Pressure rise.Specific methods: Cool containers with water spray.

MEASURES IN THE EVENT OF ACCIDENTAL LEAKAGEIndividual precautions: Evacuate personnel to safe muster points. Provide adequate ventilation. Use personal

protective equipment.Environmental precautions: Evaporates.Cleaning methods: Evaporates.


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HANDLING AND STORAGEHandlingtechnical measures/ precautions: Ensure the presence of sufficient ventilation and/or air extraction means in the

workplace.recommendations for safe use: Do not breath fumes or aerosol.Storage Close hermetically and store in a cool, dry and well-ventilated place. Store in its

original containers. Incompatible products: explosives, flammable materials, organic peroxide

CONTROL OF EXPOSURE/INDIVIDUAL PROTECTIONControl parameters: AEL (8-h and 12-h TWA) = 1000 ml/m3 for each of the two components.Respiratory protection: For rescue and maintenance work in tanks, use autonomous breathing apparatus. The

vapours are heavier than air and can cause suffocation, reducing the oxygen available for breathing.

Protection of the eyes: Safety goggles.Protection of the hands: Rubber gloves.Hygiene measures: Do not smoke.

PHYSICAL AND CHEMICAL PROPERTIESColour: Colourless.Odour: Faint.Boiling point: -52.8 °C at atmospheric pressure.Flash point: Non-flammable.Relative density: 108 kg/l at 25 °C.Solubility in water: Negligible.

STABILITY AND REACTIVITYStability: No reactivity if used in compliance with the relative instructions.Materials to avoid: Highly oxidising materials. Incompatible with magnesium, zinc, sodium, potassium

and aluminium.Incompatibility is more critical if the metal is present in the form of powder or if surfaces have been recently unprotected.

Hazardous decomposition products: These products are halogen compounds, hydrofluoric acid, carbon monoxides (CO, CO2), carbonyl halides.

TOXICOLOGICAL INFORMATIONAcute toxicity: (R32) LC50/inhalation/4 hours/lab. rats >760 ml/l.

(R125) LC50/inhalation/4 hours/lab. rats >3480 mg/l.Local effects: Concentrations significantly above the TLV can cause narcotic effects.

Inhalation of products in decomposition can lead to respiratory difficulty (pulmonary oedema).

Long-term toxicity: No carcinogenic, teratogenic, or mutagenic effects observed in laboratory animals.ECOLOGICAL INFORMATION

Global warming potential GWP (R11=1):

1730

Ozone depletion potential ODP (R11=1):

0

Considerations on disposal: Usable with reconditioning.

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CHAPTER 4

DESCRIPTION4 . 1 R e f r i g e r a n t c i r c u i t

The technical annexes of this manual show the unit's specific refrigerant circuit diagram.The refrigerant in a gaseous state is compressed by the compressors and pumped to the condenser, where it will exchange heat with the ambient air and come out in a liquid state.Information on the components of standard units is given below. In order to meet specific requirements, non-standard components may be used.In this case refer to the offer data.MOTOCONDENSING UNIT REFRIGERANT CIRCUITThe units in the MCTAT range, in their standard configuration, are equipped with the following components:

• receiver drier;• liquid sight-glass;• solenoid valve on the liquid line;• pressure switch with fixed high pressure setting (HP);• pressure switch with fixed low pressure setting (LP);• high pressure transducer for unloading and for regulating the fans;• refrigerant shut-off valves on the suction and discharge lines.

ATTENTION

MCTAT units have no evaporator. The plant must be installed and completed by personnel qualified in the field ofrefrigeration (refrigeration engineers). The manufacturer disclaims all liability for any damage caused by incorrectinstallation or improper matching between the moto-condensing unit and the evaporating unit.

4.1.1 CompressorsThe compressors used, the SCROLL type, feature high energy efficiency and a low level of vibration, which ensures normal operation is extremely quiet.They are moreover equipped with integral protection against overheating of the windings of the electric motor or an internal thermo-switch. In addition, all the compressors have a non-return valve on the discharge side and a by-pass valve between the suction and discharge.

NOTEDuring the short periods of starting and stopping the compressor you may hear a metallic noise due respectively to the initialcontact between the coils and to the momentary reversal of their rotation. This noise is absolutely normal and does not affectthe reliability of the compressor.

NOTEFor the full MCTAT range from 030 to 065 there is the option of starting the compressors with Soft Starter. Soft Starter is matched to each compressor and allows you to limit the inrush current during compressor start-up.- Units equipped with a soft starter can operate up to a maximum ambient temperature of 40 °C, after which the unit willsimply stop, without triggering any alarm.- Soft starters are not compatible with capacitive elements (e.g. capacitors with power factor correction) installed betweenthe soft starter and the compressor motor. Any static or dynamic PFC (Power Factor Correction) systems, installed beforethe main switch, must not operate simultaneously when the soft starter is started up.

On motocondensing units, the valve on the discharge line can be supplied on request, while the valve is standard on the suction line.The compressors on these units are connected in tandem and are equipped with an oil pressure equalizer in the casing.The compressor compartment is covered with acoustic insulation to reduce noise.The compressors are provided with belt casing heating elements.

ATTENTION

When first starting after a stop of several days, ensure that the casing heating element of each compressor is switchedon for at least 12 hours before pressing the start button.

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4.1.2 CondensersThe condensers are heat exchangers of the finned core type and are cooled by a flow of air supplied by a number of fans.The pipes are made of copper and the fins of aluminium. The shoulders are made of galvanized carbon steel.

They may optionally be equipped with:1. condensing coils protection:

• None = the whole machine is open except for the compressor compartment and EP.• Filters = metal mesh filters to protect the condensing coils only. The rest of the unit is open.• Wire Mesh = the unit is enclosed by wire mesh of the same colour as the structural work.

One option excludes the others, that is with wire mesh it is not possible to have the filters protecting only the condensing coils too.

2. prepainted condensing coils:• No = Standard-type condensing coils with copper pipes and manifolds and aluminium fins.• Yes = coils with pre-painted fins for use in marine locations where the environment may be aggressive for the

aluminium fins; the pre-painting consists in applying an epoxy-based primer and polyurethane-based paint which enable corrosion resistance in a saline mist of at least 1500 hours (ASTM B 117). The shoulders are made of galvanized steel or aluminium. The manifolds and the bends are painted.

4.1.3 FansThe axial-type fans are composed of blades coated with aluminium and covered with contoured polypropylene; their profile is like a sickle.The fans protection rating is IP54.All fans feature insulation class F to ensure they are compatible with outdoor operation in all climates.Fan assembly is completed by an aerodynamically profiled port made of galvanised sheet steel and safety grilles downstream of the air flow.

4 . 2 R e f r i g e r a n t c i r c u i t o f t h e M C T A T m o t o c o n d e n s i n g u n i t s

The MCTAT motocondensing units are not equipped with an evaporator and thermostatic valve, which are to be installed by the customer/installer.There are always two shut-off valves on the unit inlet and outlet and a solenoid valve on the liquid line.

ATTENTION

The installation is to be completed by the customer/installer.The sizing and construction of the refrigerant lines connecting the motocondensing units and evaporating units is ofparamount importance and must therefore be performed by qualified personnel.

For installation see heading 5.6 “Refrigerant circuit and thermostatic valve connections for motocondensing units”.Once the remote evaporator has been installed, the MCTAT units will operate as described under heading 4.1 “Refrigerant circuit”.

4.2.1 CabinetThe unit's structure is the “frame” type with closing panels for the compressor compartment and the electrical panel.The base is formed by longitudinal and cross members riveted together on which are fixed the supporting struts of the closing panelling of the compressor compartment.The hydraulic compartment and the condensing coils can be protected with enclosing wire mesh. There is also the option of a casing for the hydraulic compartment too.

4.2.2 Protection rat ingThe protection rating of the entire unit is IP54 with insulation class F to ensure it is compatible with outdoor operation in all climates.

4 . 3 E l e c t r i c a l c i r c u i tThe electrical circuit schematic is given in the annexed diagrams.

4 . 4 O v e r a l l d i m e n s i o n sTo see the dimension drawings, please refer to the attached technical drawings.

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CHAPTER 5

INSTALLATIONATTENTION

Before installing or operating these units, ensure that all personnel involved have read and understood the Chapter 3“Safety“ in this manual.The unit must be installed in accordance with current national legislation in the country of use.

5 . 1 I n s p e c t i o nAs soon as the unit has been unpacked check it carefully for damage.

5 . 2 L o c a t i o n1. The unit can be installed either outdoors or in an enclosed environment, depending on the degree of IP protection

of the electrical panel and the unit itself.2. If the unit is installed indoors the place of installation must be well ventilated. In certain cases it may be necessary

to install ventilation fans or extractor fans in order to reduce room temperature.3. The ambient air must be clean, avoid sea ambients (brackish air), and not contain flammable gas or corrosive

solvents.4. The minimum and maximum working ambient temperature are specified on the unit data plate. Ensure that the

unit is not installed in flows of hot air emitted by other equipment.In extremetemperature conditions, the protection devices may trip.

5. Do not obstruct or interfere with the air flow produced by the unit; comply strictly with the minimum spaces/distances specified in the installation drawings.

6. The machine must be installed on a perfectly horizontal flat surface, built and calculated to withstand themachine’s operating weight, especially in the contact points highlighted in the installation drawing. In the eventof installations which fail to comply with the above requirements, the manufacturer’s warranty cover willimmediately become null and void and the unit could malfunction or even lock out.

7. Leave free space around the unit for access during service interventions (see Attachments).8. Do not install the plant in sites exposed to strong winds; if unavoidable, install suitable windscreens.

See point 1.


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5 . 3 M i n i m u m d i s t a n c e s f r o m t h e w a l l s o f t h e i n s t a l l a t i o n e n v i r o n m e n t

See attachment

5 . 4 F r o s t p r o t e c t i o nEven if the minimum operating ambient temperature is above 0 °C it is possible that the machine, during periods of stoppage in the cold season, may be in an environment where the temperature is below 0 °C. In these cases, if the machine is not emptied, it is necessary (to avoid the formation of ice) to add antifreeze (ethylene or propylene glycol) in the following percentages:

In accordance with the chilled water outlet temperature, to avoid the formation of ice ethylene or propylene glycol should be added to the water in the following percentages:

ATTENTION

Antifreeze set to 5 °C. To lower the antifreeze setting, use parameter AL26.For water outlet temperatures lower than 6 °C you must add a suitable quantity of antifreeze solution.

5 . 5 E l e c t r i c a l c o n n e c t i o n sThe unit's connection to the power supply must be made in compliance with laws and prescriptions in force in the place of installation.The voltage, frequency and number of phases must comply with the data on the unit's nameplate. The power supply voltage must not be outside the tolerances shown on the electrical diagram, even in terms of transients. Unless otherwise specified, the frequency tolerance is +/-1% of the nominal value (+/-2% for short periods).With a three-phase power supply the voltage must be symmetrical (the effective values of phase to phase voltages and consecutive phase angles must be identical). In particular, unless otherwise indicated, the maximum permissible phase imbalance is 2%, calculated for each phase according to the formula

Vavg= average phase voltageThe line conductor and neutral conductor are not interchangeable and their positions cannot be switched.For the electrical power supply:

1. connect the unit (PE terminal in the electrical cabinet) to the electrical earthing system of the building.2. ensure automatic suspension of the power supply in the event of an insulation fault (protection against indirect

contact in compliance with the prescriptions of IEC 60364) by means of a residual current device (the nominaltrip current of which should normally be set to 0.03 A).

3. make sure the level of protection against indirect contact at the source of the power feeding cable is equivalent atleast to IP2X or IPXXB (rifer to CEI EN 60529).

4. at the start of the power cable install a device that protects it from current surges (short-circuits) (refer to theindications given in the electrical diagram).

T ambient to [°C] Ethylene glycol [% by weight] Propylene glycol [% by weight]0 0 0-5 15 20

-10 25 30-15 30 35-20 40 40

T water outlet to [°C] Ethylene or Propylene glycol [% by weight]6 03 200 25-5 30-7 35

-10 40-15 45-20 5

Max Phase Voltage Difference From VavgVavg

------------------------------------------------------------------------------------------------------- 100


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5. use conductors rated to carry the maximum current required at the maximum operating ambient temperature,according to the chosen installation type (IEC 5-60364-523) (see the indications on the electrical diagram).

6. protection devices must be installed to limit the 17 kA peak short circuit current to its own nominal cut-off powerwhen the short circuit current at the operation point is higher than 10 kA effective.

Indications on the electrical diagram:• maximum permissible size of the fuse type gG.

In general, fuses can be replaced by an automatic circuit breaker set in relation to the unit's maximum current input (consult the manufacturer if necessary)

• section and type of power cable (if not already supplied):installation: insulated conductors or a multicore cable in a cable duct, installed overhead or fixed to a masonry structure (type C in compliance with IEC 60364-5-523 1983) without any other cables in contactcable type: copper conductors, 70 °C PVC insulation (unless otherwise specified) or EPR 90 °C insulation

To ensure correct connection of the unit to the mains, see Chapter 6 “Starting“.

5.5.1 Phase MonitorThe electronic control unit, with the aid of a “Phase Monitor” device (see unit's wiring diagram), makes it possible to manage unit power supply monitoring functions, stopping the unit if there are no phases or they are in the wrong sequence.The Phase Monitor stops the unit and displays the ALc1 alarm.A certain level of power supply instability is perfectly normal.If the frequency with which the unit is shut down due to tripping of the Phase Monitor tends to increase unacceptably, contact your electricity provider to find a solution to the problem.

ATTENTION

Do not in any way tamper with the Phase Monitor.

5 . 6 R e f r i g e r a n t c i r c u i t a n d t h e r m o s t a t i c v a l v e c o n n e c t i o n s f o r m o t o c o n d e n s i n g u n i t s

The MCTAT motocondensing units are supplied without an evaporator and plant installation is to be completed by the customer/installer.

ATTENTION

The sizing and construction of the refrigerant lines connecting the motocondensing units and evaporating units is ofparamount importance and must therefore be performed by qualified personnel.


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MCTAT 030-065 models:

On the back of the MCTAT units there are the refrigerant connections for soldering (see figure above).

5.6.1 Instal l ing and laying down the refr igerant l inesDuring installation and commissioning it is necessary to proceed by following the steps below:

1. The first thing to consider is the refrigerant lines for interconnection of the MCTAT unit with the evaporatingsection. In order to minimize the loss of cooling capacity of the unit, make sure that the refrigerant lines are asshort as possible, minimizing the number of bends, trying never to have constrictions in bends with a short radius.It is of paramount importance to observe the equivalent maximum lengths and the maximum gradients given in thefollowing table:

MCTAT

Model Suction line connection diameter

Liquid line connection diameter Equivalent maximum length Unit maximum height

difference

[mm] [mm] [m] [m]

MCTAT 030 42 28 30 13.5

MCTAT 035 42 28 30 13.5

MCTAT 040 42 28 30 13.5

MCTAT 050 54 28 30 13.5

MCTAT 055 54 28 30 13.5

MCTAT 060 54 28 30 13.5

MCTAT 065 54 28 30 13.5

�

��

IN

OUT


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2. When laying down the refrigerant lines, consider all the suitable measures to facilitate oil return to the compressor(e.g., the right slope for the horizontal sections of piping, elbow pipe at the beginning of the vertical sections,traps for the oil in the vertical risers) as shown in the picture below.

3. The following table shows the head losses in equivalent metres for the traps and for the bends according to thediameter of the piping to be used in the calculation of the distance between the motocondensing unit andevaporator.

ATTENTION

Have one trap every 4.5 metres in height.

4. Traps: to facilitate oil return to the compressor, if the motocondensing unit is installed higher than the internal oneand the height difference exceeds 6 m, it is essential to make a trap, in addition to the base, in the vertical portionof the suction piping, every 4.5 metres (see image above).

5. Slope: always, to facilitate oil return to the compressor, give the horizontal portions of the piping a gradient of 2%towards the next trap or towards the compressor (see image above).

6. Insulation: only the gas line must be insulated.

OD/ID K1 K2

[mm] [m] [m]

10/8.5 0.3 1.1

12/10.5 0.38 1.5

16/14 0.48 1.9

18/16 0.60 2.4

22/20 0.80 2.7

28/25 1.1 3.4

35/32 1.4 4.4

42/39 1.8 5.4

OD = piping outside diameter

ID = piping inside diameter

K1 = equivalent length for a bend

K2 = equivalent length for a trap

Slope 2%towards the compressor

Suction

Liquid line

H


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7. After determining the route of the refrigerant lines, using a blowpipe, remove the liquid and gas pipe plugs beingcareful not to put any pressure on the stub pipes (you need to remove the plug from the pressure port on theend of the pipe). At the end of these operations fit a sealing mechanism on the pressure port.

8. Now install the refrigerant piping doing the relevant welding and observing the diameters given in the table above.9. Create a vacuum in the plant, in the section of circuit on the evaporating side, using the valves for measuring the

working pressures (preferably reach 20 Pa).10. Top up the refrigerant (*) to reach the following conditions:

• The liquid sight glass does not signal any bubbles;• Liquid supercooling (**) from 4 to 8 °C;• Gas superheating (***) from 3 to 6 °C;• The discharge temperature must be approximately 25 to 40 °C higher than the condensation temperature

(approximate values);• The condensation temperature must be approximately 15 to 20 °C higher than the outside air temperature

(approximate values).(*) The amount of refrigerant in the circuit of the motocondensing unit is stated on the unit's data plate. The stated charge of refrigerant is only for carrying out the piping seal test at the end of the production lines in the factory. It is absolutely necessary to supplement the refrigerant charge before starting the plant.(**) The difference between the real temperature of the liquid leaving the condenser and its saturation temperature, that is the condensation temperature corresponding to the pressure of the liquid.(**) The difference between the real temperature of the gas leaving the evaporator and its saturation temperature, that is the boiling point temperature corresponding to the pressure of the gas.

ATTENTION

Please note that any malfunctioning or damage due to imperfect execution of the lines, vacuum and refrigerant charge isnot covered by the warranty on the equipment in any way.

ATTENTION

When putting the unit into operation for the first time and after every period of prolonged stoppage, it is important topower the compressor casing oil heating elements for at least 12 hours before starting the compressor.

The table below shows the type of oil and the amount with which the compressors of the different models are filled.

5.6.2 Testing the motocondensing unit via digital input (Factory sett ings)MCTAT motocondensing units leave the factory with the parameters set for testing the unit via digital input on the customer's signal. In particular, in the terminal block (see wiring diagram) there will be the following contacts:

1. contact in terminal block for digital input for Remote ON/OFF;2. contact in terminal block for digital input for switching on and request for first compressor;3. contact in terminal block for digital input for request for second compressor.

Models 030 035 040

Oil filling (litres) 6.5 6.63 8.05

Type of oil EMKARATE RL 32 3 MAF

Models 050 055 060 065

Oil filling (litres) 9.34 11.47 13.6 13.1

Type of oil EMKARATE RL 32 3 MAF


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5.6.3 Testing the motocondensing unit via temperature probes BEWOT and BEWIT

Should the customer wish to use the evaporator water inlet temperature (BEWIT) and evaporator water outlet temperature (BEWOT) probes he will have to perform the steps below:

1. unwire the relays used to control the compressor(s);2. install the evaporator water inlet temperature (BEWIT) probe (supplied as standard) in the dedicated terminal (see

wiring diagram). This probe will be used for temperature control;3. install the evaporator water outlet temperature (BEWOT) probe (supplied as standard) in the dedicated terminal

(see wiring diagram). This probe will be used for the antifreeze function;4. modify the following parameters of the electronic control for using the probes:

CF03=0CF08=8CF09=11

ATTENTION

The evaporator water inlet temperature (BEWIT) and evaporator water outlet temperature (BEWOT) probes aresupplied with the unit. They are to be installed by the customer/installer.BEWIT is used for temperature control.BEWOT is used for the antifreeze function.For proper installation, follow the diagram below and refer to the attached diagrams.

ATTENTION

The maximum distance for remote connection of the probes is 100 m using shielded cable.

MCTAT unit

Remoteevaporator

IN REFRIG.

OUT REFRIG.

INWATER

OUTWATER

-BEWIT-BEWOT

Control uniton the machine

(PB1)

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CHAPTER 6

STARTINGATTENTION

Before starting this type of unit, ensure that all personnel involved have read and understood the Chapter 3 “Safety” inthis manual.

1. Check that the unit shut-off valves are open.2. With a “closed” type hydraulic circuit ensure that a suitably sized expansion vessel has been installed.

3.Check that the ambient temperature is within the range indicated on the unit's data plate.4.Check that the main switch is in the OFF position (“O”).5.Check that the unit power supply voltage is correct.6.Power the unit by means of the line protection device.7.Turn the unit main switch to the ON position (“I”).

The presence of mains voltage is guaranteed by the LED and the display of the control panel coming on.8. Models without a pump:

before switching the unit on make sure the water pump is running and water is flowing through the evaporator.9. Models with discharge valves on compressors:

Check that the compressor discharge valves are open.10. To start the unit follow the steps below (for more information see Chapter 7 “Electronic controller”):

With the unit OFF (standby), press and release the button to switch the unit on or off in chiller mode. With theunit powered on, the LED is on.

11. Compressors and fans have only one correct direction of rotation.If a SCROLL compressor does not rotate in the correct direction it will be very noisy and will be unable tocompress the refrigerant gas.A fan turns in the correct direction when it draws air from inside the unit. The units are manufactured and tested toensure that the above components have the same direction of rotation. Therefore, if one component turns in thecorrect direction, then the others should be connected correctly.Check the direction of rotation of all components on initial start-up and after every maintenance operation. In theevent of incorrect rotation direction of all components, invert two phase wires at main terminals of the electricalcabinet. In contrast, if it is found that only certain specific components are rotating in the incorrect direction, thepower feeding wires must be inverted on the individual terminals of the corresponding contactor(s) (see attachedwiring diagram).

12. If at the time of first startup the ambient temperature is high and the water temperature in the hydraulic circuit issignificantly higher than the operating value (e.g. 25-30 °C) this means that the unit is starting in overloadedconditions resulting in possible tripping of the protections. To reduce this overload, an inlet valve on the unit canbe closed gradually (but not totally!) to reduce the flow of water passing through. As the water temperature inthe hydraulic circuit approaches the working value, open the valve.

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CHAPTER 7

ELECTRONIC CONTROLLER7 . 1 U s e r i n t e r f a c e

7 . 2 F u n c t i o n o f b u t t o n s

The icon blinks during the defrost interval count. The icon is illuminated with a steady light during the defrosting phase (not used).

Compressor operating status icons, on if the corresponding compressor is ON. It blinks if the compressor is on timed switch-on.

When on they display a temperature. If turned on in programming mode they display the temperature differentials or set-point.

Blinking if there is at least one alarmBlinking if with the pump on the digital input of the pressure switch is active. Lower display.

When on they display a pressure. If turned on in programming mode they display the pressure differentials or set-point.

Clock icon (hours of operation of pumps, compressors).On in programming mode it displays the work load hours.Blinking in the functions menu it indicates the time left before the start of defrosting.

Switched on if at least one of the water pumps is running.FC (not used). AUX on if the tank auxiliary heater is on. On if the heating elements (antifreeze) are on. Heat pump operating mode icon (not used).

Not used.On if at least one condensation fan is on.

Upper display.

Chiller operating mode icon.

Pressed twice in the main window it shows the real working set-point (where applicable).Pressed for 3 seconds in the main window it changes the chiller set-point.

Pressed once in the main window it shows the chiller set-point.

Press once in programming mode it changes or confirms the value of a parameter.Pressed once in the ALrM menu it enables resetting the alarm.

Pressed once it enables switching the unit on or off in heat pump mode (not used on chiller only units).Pressed once it enables switching the unit on or off in chiller mode.

Pressed once it enables accessing the functions menu.Pressed once in programming mode it enables exiting from the parameters or from parameter editing.

Pressed once it enables displaying the temperatures/pressures in the lower/upper display. Pressed once in programming mode it enables scrolling through the parameters or increases the value of a parameter. Pressed for 1 second, in programming mode, it changes the level of access to the parameters. See “7.10.1 Access to parameters”.

Pressed once in the main window it displays the temperatures/pressures in the upper/lower display.Pressed once in programming mode it enables scrolling through the parameters or decreases the value of a parameter.


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7.2.1 Function of combined buttons

7 . 3 R e m o t e t e r m i n a l

You can connect up to two remote terminals to the instrument.It generally displays the same data as the local display. You can customize the display with dedicated parameters (see “7.18 Parameter Description-Settings”).In the absence of communication between the instrument and the remote terminal the upper display shows the message “ ” (no link).

7 . 4 P r o b e k e yThis chapter refers to the BEWIT, BEWOT, BWOT, BHP1, BAT1 and BTWOT probes. Refer to the refrigerant diagram and the wiring diagram for positioning them.A description of the probes used is given belowMCTAT 030-035-040-050-055-060-065 models:With storage tank:

Without storage tank:

7 . 5 U n i t s t a r t / s t o pThe unit can be switched on and off:

• With the keyboard (local or remote).• With the digital input configured as remote ON/OFF.• It provides access to parameter programming.

FUNCTION BUTTONS

+ To enter programming mode (pressed for 3 seconds).

+ To exit programming phase.

+ In programming mode: Pressed once in the main window it displays the “user” parameters.When pressed twice in the main window it displays the “service” parameters.

Probe code Board label Board terminals Description

BEWIT Eln PB1 Evaporator inlet water temperature probe

BEWOT Out1 PB2 Evaporator outlet water temperature probe

BCP1 CdP1 PB3 High pressure circuit transducer

BWOT EOut PB4 Unit outlet temperature probe (temperature control)

BAT1 Et PB5 Anti-freeze probe

BTWOT uSt1 PB6 Tank outlet temperature probe

Probe code Board label Board terminals Description

BEWIT Eln PB1 Evaporator inlet water temperature probe

BEWOT EOut PB2 Evaporator outlet water temperature probe (temperature control)

BCP1 CdP1 PB3 High pressure circuit transducer

BAT1 Et PB5 Anti-freeze probe

BTWOT uSt1 PB6 Tank outlet temperature probe


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NOTEIn case of a power loss, when power is restored the unit will be ON if it was ON at the time of power loss, and OFF if it wasOFF.

7.5.1 Switching on with the keyboardWith the unit OFF (standby), press and release the button to switch the unit on or off in chiller mode. With the unit

powered on, the LED is on.Stand-by mode is set each time the unit's chiller operation is turned off. In standby mode, too, the controller allows you to:

• Display the measured values.• Manage the alarm situation by displaying and signalling.

When the unit is on stand-by the control displays the label .

7.5.2 Switching on with the digital input You can turn the unit on/off with the digital input configured as remote ON/OFF.The OFF command (local or remote) always takes priority over the ON command. If the unit is turned off locally it must be turned back on locally. When the unit is turned OFF with the digital input the control displays the label . .

NOTETo start up the MCTAT unit, use the dedicated digital input.

7 . 6 S e t - p o i n t7.6.1 Display the set-point

To view the set-point, press and release the button.With the unit on stand-by the lower display will show SetC (set chiller)The upper display will show the set value.

7.6.2 Change the set-pointTo change the unit's working set-point press for at least 3 seconds and the working set-point SetC (set chiller) will be shown blinking.

The change is made by pressing buttons or .

To save the new set-point, press or wait for the time-out interval to elapse to exit programming mode.


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7 . 7 T h e “ M e n u ” b u t t o n f u n c t i o n s m e n uAccess to the Functions Menu enables the user to:

7.7.1 CrEn - Enable or disable the single circuitWith the CrEn submenu you can disable the operation of a single circuit to allow maintenance or isolate it in case of malfunctioning.Proceed as follows:


• With the or buttons select the lower display CrEn function.• Press the button. The lower display shows Cr1E, the upper display shows En.• Using the or buttons, select the label Cr1E.• Press for 3 seconds on the label Cr1E. The upper display shows En blinking.• Using the or buttons, select the label diS (circuit operation disabled) or En (circuit operation enabled).• Press the button to confirm the new value.

To exit the CrEn function and return to normal viewing, press or wait for time-out.In normal operation, if one of the circuits is put on diS the lower display shows a blinking label alternating with the value shown at that time.If the circuit is in diS the label shown by the lower display is b1dS = circuit disabled.

ATTENTION

The CrEn function is enabled even if the units are single-circuit. If you disable the only circuit present on these units themachine will stop all its chilling capacity.

7.7.2 COEn - Enable or disable the single compressorWith the COEn submenu you can disable the operation of a single compressor in the circuit to allow maintenance on it or isolate it in case of malfunctioning. The status labels of the compressors in the COEn function are:

• CO1E = operating status of compressor no. 1.• CO2E = operating status of compressor no. 2.

To enable or disable the compressors proceed as follows:


• Using the or buttons, select function COEn.• Press the lower display will show CO1E and the upper display will show En.• Using the or buttons, select the desired label on the lower display. The upper display will show En

blinking.• Press for 3 seconds on the label identifying the compressor to disable.

ALrM function Display and reset the alarms (see 7.9.1).

Display and clear the alarms log (see 7.9.26).

Upload the parameters from the unit to the flash drive (see 7.11).

Enable / disable the operation of a single circuit (see 7.7.1).

ALOG function

UPL function

CrEn function

COEn function

COSn function

Cond function

dF function

Enable / disable the operation of a single compressor (see 7.7.2).

Display and reset the number of starts for each compressor (see 7.7.3).

Display and reset the operating hours of the controlled loads (see 7.7.4).

Display the operating percentage of the proportional outputs for controlling the speed of the condensation fans (see 7.7.5).

Display the operating percentage of the proportional outputs (where applicable) (see 7.8).

Display the time remaining until the start of defrosting (heat pump units only)

uS function

Hour function

POEn function ENABLE or DISABLE the operation of a water pump using the key (see 7.7.6).


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• The upper display will show En blinking, use the or buttons to select the diS function (compressor operation disabled) or En (compressor operation enabled).

• Press to confirm the set function and move on to the next compressor.To exit the COEn function and return to normal viewing, press or wait for time-out.

7.7.3 COSn - Display and reset the number of compressor startsIn the COSn submenu you can see the number of compressor starts. The labels displayed are:

• C1S starts of compressor no. 1.• C2S starts of compressor no. 2.

The number of starts is displayed on the lower display with a resolution of 10 starts. For example, if the value 2 is displayed that compressor has 20 starts. To display the number of starts, proceed as follows:


• Using the or buttons, select function COSn.• Press . The label of the single load C1S appears on the upper display, the lower display shows the number

of starts multiplied by 10. • Using the or buttons view all the configured compressors.

To return to normal view, press or wait for time-out.

To reset the number of compressor starts, proceed as follows:


• In the COSn function, use the or buttons to select label C1S or C2S. • Press for 3 seconds on the load C1S or C2S. The lower display shows the number of starts per hour

blinking (reset in progress) then the value “0” indicating the reset. • Then the number of starts of the next compressor are displayed.

To exit the reset function and return to normal viewing, press or wait for time-out.

7.7.4 Hour - Display and reset the operating hours of the loadsIn the Hour submenu you can see the hours of operation of each single compressor and of the water pump. The labels displayed are:

• CO1H operating hours of compressor no. 1.• CO2H operating hours of compressor no. 2.• EP1H operating hours of evaporator water pump.• EP2H operating hours of second evaporator water pump.

As for the number of starts, the operating hours are displayed in the upper display with a resolution of 10 hours.To view the hours of work, proceed as follows:


• Using the or buttons, select function Hour.• Press . The label of the single compressor appears on the lower display, the upper display shows the

operating hours multiplied by 10. The icon will be on. • Using the or buttons view all the configured compressors.

To return to normal view, press or wait for time-out. To reset the hours of work, proceed as follows:


• In the Hour function, use the or buttons to select the label CO1H or CO2H or EP1H or EP2H.• Press for 3 seconds on the compressor label CO1H or CO2H or EP1H or EP2H the upper display will

show the hours of operation blinking (resetting in progress) then 0 indicating the reset and will go on to the next load.

To exit the reset function and return to normal viewing, press or wait for time-out.

7.7.5 Cond - Display percentage / Number of condensation stepsIn the functions menu you can view the percentages of work of the proportional ventilation output.Cnd1 Proportional output for condensation fan control.For viewing, proceed as follows:


• Using the or buttons, select function Cond.• Press the button. The lower display will show Cnd1, the upper display will show the percentage of work.

To return to normal view, press or wait for time-out.


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7.7.6 POEn - ENABLE or DISABLE the operation of a water pump using the keyOperation of a single pump can be disabled for servicing or to disconnect it from the circuit in the event of a malfunction.In the functions menu it is displayed with the label POEn; inside the folder it is displayed as follows:PE1E = evaporator no. 1 pump operating statusThe labels which identify the individual pumps are only displayed in the POEn function for the pumps actually present.

Access the function menu key:

• use the or keys to scroll the list and select the "POEn" function• press the key: the bottom display shows "PE1E" and the top display "En";• select the pump for disabling by pressing the or keys (labels “PE1E”, “PE2E”.. present depending on

the unit's configuration)• press the key for 3 seconds: the top display shows a flashing "En". Pressing the or keys alternates

the contents of the top display between “En” and “diS”; pressing the key confirms the selected status (En= enabled, diS= disabled)

Press the key to quit the POEn menu; it will also be shut down after a time-out.

Display status of the DISABLED water pumpDuring normal operation, if one of the pumps is disabled, a flashing label P1Ed, P2Ed, (evaporator pumps 1 and 2) appears on the bottom display, alternating with the parameter currently displayed.

7 . 8 u S - D i s p l a y t a n k r e s i s t a n c e p r o b eIn the functions menu you can view the temperature / pressure values of the probes that control the auxiliary outputs. FUNCTION uS display temperature / pressure; identification label in the uS function:

• uSt1 value measured by the auxiliary probe for circuit no. 1.• uSt2 value measured by the auxiliary probe for circuit no. 2.• To view the values of the probes. • Use the or buttons to select the uS function and press . • The lower display will show the label UST1 (if the auxiliary probe is configured for temperature) or USP1

(if the auxiliary probe is configured for pressure). The upper display will show the measured temperature / pressure value.

• Using the or buttons you can view the measured pressure value of the auxiliary output 2, if present. • To return to normal view, press or wait for time-out.

7 . 9 A l a r m sThe electronic control unit manages the display, reset, and logging of numerous alarms.

7.9.1 Display and reset alarms ( A L r M f u n c t i o n )ATTENTION

With this procedure you can reset all the alarms except for the compressor thermal cut-out alarms for which thepassword will be required: 14.

To access the functions menu, proceed as follows:


• With the or buttons select the function ALrM.• Press the button.

If there is no alarm, pressing is not enabled.• The label appears in the lower display with the alarm code, while the upper display, if the displayed alarm

is reset, shows the label rSt or the label no if the alarm condition is still present.• Pressing on the label rSt resets the alarm and moves on to the next one. If this is resettable too then

press to reset it and move on to the next one. • To scroll through all the alarms, you can press or .

To exit the ALrM function and return to normal viewing, press or wait for time-out.

With units on StbY (stand-by) and LED blinking, press scroll with or , select the ALrM function and press

the button to view the active alarm.


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7.9.2 How to mute the buzzerThe control unit includes an audible alarm warning (buzzer).The buzzer is switched off by:

• Automatic muting: the buzzer is muted when the situation that caused the alarm ceases.• Manual muting: press and release one of the buttons; the buzzer will be muted even if the alarm condition

persists.

7.9.3 General alarms l istThe alarm codes and warnings are composed of letters and numbers that identify the different types. The first letter of the alarm label identifies the type of alarm according to the rule:

• Letter A = unit alarm• Letter b = circuit alarm• Letter C = compressor alarm

The tables below describe the alarms managed by the electronic board. Some of the alarms mentioned might not be related to all the unit models.

1= If probe configured to control antifreeze - boiler and Ar10 = 0.2 = With manual reset alarm.

Block of outputs

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AP1 PB1 probe faulty alarm A I X X X(1)AP2 PB2 probe faulty alarm A I X X X(1)AP3 PB3 probe faulty alarm A I X X X(1)AP4 PB4 probe faulty alarm A I X X X(1)AP5 PB5 probe faulty alarm A I X X X(1)AP6 PB6 probe faulty alarm A I X X X(1)APE1 PB1 probe.. Pb8 probe of I/O expansion A I X X XAPE2 PB1 probe.. Pb8 probe of I/O expansion A I X X XAPE3 PB1 probe.. Pb8 probe of I/O expansion A I X X XAPE4 PB1 probe.. Pb8 probe of I/O expansion A I X X XAPE5 PB1 probe.. Pb8 probe of I/O expansion A I X X XAPE6 PB1 probe.. Pb8 probe of I/O expansion A I X X XAPE7 PB1 probe.. Pb8 probe of I/O expansion A I X X XAPE8 PB1 probe.. Pb8 probe of I/O expansion A I X X XAEFL Evaporator water pump pressure switch alarm A/M R X X(2) X XAtE1 Evaporator water pump thermal cut-out M I X(3) X X X(4)AtE2 Evaporator water pump second thermal cut-out M I X(3) X X X(4)AEE EEprom alarm M I X X XALSF Phase sequence alarm (NOT USED) A I X X X XASLA Alarm for LAN communication with I/O expansion A I X X XALc1 Phase monitor alarm A/M I X X XAEUn Evaporator inlet high temperature unloading signal A RACF1 Configuration alarm A I X X Xb(n)HP High pressure circuit pressure switch (n)

See chap. 7.9.6 “High pressure switch alarm” .A/M R X X

b(n)LP Low pressure circuit pressure switch (n) A/M R X Xb1AC Antifreeze in chiller circuit 1 A/M R X Xb1Ac Signal for antifreeze in chiller circuit 1 A/M Rb(n)hP High pressure condensation transducer circuit (n) M I Xb(n)lP Low pressure condensation - (evaporation with low pressure transducer)

transducer circuit (n)A/M R X

AEht Evaporator water inlet high temperature alarm M I X Xb1tF Ventilation thermal cut-out alarm circuit 1 M I Xb(n)rC Recovery disabling signal circuit (n) A IC(n)tr Alarm for thermal cut-out of compressor (n) with AL47 = 0 – 1 M I X


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3 = Compressors off with only No. 1 water pump configured or with No. 2 water pumps configured and both on thermal cut-out alarm. 4 = Boiler heating elements off with only No. 1 water pump configured or with No. 2 water pumps configured and both on thermal cut-out alarm (in this case the boiler heating elements are only triggered by the antifreeze setting to protect the evaporator). (n)= identifies circuit No. 1 or circuit No. 2 Key:A = automaticM = manualR = delayedI = instantaneous

7.9.4 Warnings Table

7.9.5 Faulty probe

7.9.6 High pressure switch alarm

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AEUn Signalling evaporator unloading b(n)Cu Signalling unloading temp. press. condensing circuit (n)b(n)Eu Signalling unloading low temp. evaporator circuit (n)C(n)Mn Maintenance on compressor (n)AEP1 Maintenance on water pump of evaporatorAEP2 Maintenance on second pump of evaporatorErr Simultaneous activation required for cooling and heating

in motocondensing units 0Yes Yes Yes Yes Yes Yes Yes

noL Signalling no communication between the keyboard or control of 2 remote terminals configured with the same address

Atr(n) Remote terminal alarm

Meaning of display label AP1 alarm probe PB1 - AP6 alarm probe PB6Causes activation Probe configured and converted value out of rangeReset Probe not configured or converted value within the rangeReset AutomaticIcon flashingAction Alarm relay + buzzer activated

Meaning of display label b1HP (high pressure digital input circuit 1) Causes activation With the unit ON and the circuit high pressure switch input ONReset Input disabledReset Resetting is always manualIcon blinkingAction Alarm relay + buzzer activated


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7.9.7 Low pressure switch alarm

7.9.8 High pressure

7.9.9 Low pressure

7.9.10 Anti-freeze alarmThe antifreeze alarm is automatically reset. It becomes manual reset after 3 trips per hour.When the machine is on stand-by or OFF the antifreeze alarm is signalled with reference to the thresholds of both the chiller and the heat pump.

7.9.11 Chil ler operating antifreeze alarm

Meaning of display label b1LP (low pressure digital input circuit 1)Causes activation With low pressure switch input of circuit active.

The alarm is not signalled:1. When switching on the compressor for the time AL01.2. If the time AL64 has not elapsed since activation of the digital input.

Reset Disabling inputReset Automatic - becomes manual after AL05 trips per hour (reset procedure in

functions menu).Icon blinkingAction Alarm relay + buzzer activated.

Meaning of display label b1hP (high pressure analogue input circuit 1)Causes activation The condensation control probe measures a value > setting AL09Reset The condensation control probe measures a value < setting AL09 - differential

AL10Reset Resetting is always manualIcon blinkingAction Alarm relay + buzzer activated

Meaning of display label b1lP (low pressure analogue input circuit 1)Causes activation The alarm is activated when the evaporation pressure probe measures a pressure

< setting AL03.When switching on the compressor for the time AL01 the alarm is not signalled.

Reset If the evaporation control probe measures a pressure > setting AL03 + differential AL04.

Reset Automatic - becomes manual after AL05 trips per hour (reset procedure in functions menu).

Icon blinkingAction Relay + buzzer on

Chiller OperationMeaning of display label b1AC (antifreeze alarm in chiller mode circuit 1)

b1Ac (antifreeze alarm signalling in chiller mode circuit 1) Causes activation In operation and on stand-by remote OFF if antifreeze control probe measures a

temperature < setting AL26 for at least AL28 seconds.Reset Antifreeze control probe measures a temperature > setting A26+ differential

AL27.Reset Automatic - becomes manual after AL29 trips per hour (reset procedure in

functions menu).Icon blinkingAction The compressors are switched off the alarm is signalled for label (b1AC b1Ac)

and the alarm relay + buzzer are activated


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7.9.12 Water differential pressure switch alarmEach time you switch on the water pump the water differential pressure switch alarm is ignored for the timeAL15 to allow the hydraulic system to come up to speed. In normal working conditions if the pressure switch is in alarm status for a time equal to AL17 the compressor is switched off and the label AEFL is displayed. The water pump stays on for the additional time AL16 at the end of which, if the pressure switch is still in alarm status, the pump is switched off.At this point the alarm remains on manual reset and it will be necessary to reset it manually.The parameter AL18 represents the time for which the pressure switch must not be in an alarm status in order to allow resetting.

ATTENTION

Alarm relay + buzzer activated only if the water differential pressure switch alarm is active in a normal operatingphase. Otherwise there is only a luminous warning (blinking icon).

NOTEThe alarm is always on automatic reset with the unit on standby or remote OFF (pump off).

Water differential pressure switch alarm manual reset:If the alarm is on manual reset, resetting requires entering the functions menu (reset procedure in functions menu).

7.9.13 Compressor thermal cut-out alarm

7.9.14 Fan thermal cut-out alarm

Meaning of display label AEFL (water differential pressure switch alarm).Causes activation The alarm is not detected for the time AL15 from the water pump starting.

Alarm signalled if ID active for the time AL17.Reset ID not active for the time AL18.Reset Automatic - becomes manual if ID active for the time AL16 counted from AL17

elapsing (reset procedure in functions menu).Icon Flow! blinking.Action Alarm relay + buzzer activated only if the water differential pressure switch

alarm is active in a normal operating phase.

Meaning of display label C1tr (compressor thermal cut-out alarm no. 1) -…C2tr (compressor thermal cut-out alarm no. 2).

Causes activation With digital input active.The alarm is not detected for AL19 when switching on the compressor.

Reset If ID inactiveReset Manual from ALrM menu with password prompt.Icon blinkingAction Alarm relay + buzzer activated.

Meaning of display label b1tF (condensation ventilation thermal cut-out alarm circuit 1).Causes activation With configured circuit digital input active.Reset With digital input not active.Reset Manual. (reset procedure in functions menu).Icon blinkingAction Alarm relay + buzzer activated.


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7.9.15 Signall ing condensation high pressure unloading in chil ler mode

7.9.16 Signall ing condensation high pressure recovery disabling in chil ler mode

7.9.17 Signall ing unloading from evaporator inlet water high temperature

7.9.18 Evaporator water pumping unit thermal cut-out alarm

7.9.19 Phase monitor alarm

Meaning of display label b1Cu (signalling unloading from condenser coil circuit 1)Causes activation In operation if the probe configured as condensation pressure or temperature

control measures a value > setting CO44Reset • if the condensation pressure or temperature measures a value <

CO44 - differential CO45• with unloading active, after the set time Par. CO48

Reset Automatic Icon blinkingAction Alarm relay + buzzer NOT activated

Meaning of display label b1rC (signalling recovery disabling circuit 1)Causes activation In operation if the probe configured as condensation pressure control measures

a value > setting rC06.Reset • If the condensation pressure or temperature measures a value <

setting rc06 - differential rC07.• From recovery disabling function turned on after the set time

Par. rC08.Reset AutomaticIcon blinkingAction Alarm relay + buzzer NOT activated.

Meaning of display label AEun (signalling unloading from evaporator).Causes activation operation if the evaporator water inlet temperature measured is > setting CO40

for the time set in Par. CO42.Reset • If the measured water temperature is < setting CO40 -

differential CO41.• From unloading function turned on after the set time Par. CO43.

Reset AutomaticAction Alarm relay + buzzer NOT activated.

Meaning of display label AtE1 (water pump thermal cut-out of evaporator).AtE2 (second pump thermal cut-out of evaporator).

Causes activation ID configured as water pump thermal cut-out with evaporator on.ID configured as second pump thermal cut-out with evaporator on.

Reset With ID inactive.Reset Manual. (reset procedure in functions menu).Icon blinkingAction Alarm relay + buzzer activated.

Meaning of display label ALc1Causes activation Phase monitor alarm.Reset Phase monitor not active alarm.Reset automatic - becomes manual after AL42 trips per hour (reset procedure in

functions menu). Recorded in alarms log exclusively with manual reset.Icon blinkingAction Alarm relay + buzzer activated.


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7.9.20 Compressor maintenance alarm

7.9.21 Pump maintenance alarm

7.9.22 EEPROM alarm

NOTEFor the unit configuration alarms “ACF1 to ACF9” and “AC10 to AC14”, please contact Technical Support.

7.9.23 Remote terminal alarm

7.9.24 Remote terminal alarm

Meaning of display label C1Mn (maintenance required for compressor 1).C2Mn (maintenance required for compressor 2).

Causes activation Compressor operating hours > set hourcounter setting.Reset Reset operating hours (in the functions menu, “Hour” function hold down the

“set” button for a few seconds).Reset ManualIcon blinkingAction Alarm relay + buzzer activated.

Meaning of display label AEP1 (maintenance required for evaporator water pump).AEP2 (maintenance required for second evaporator pump).

Causes activation Compressor operating hours > set hourcounter setting.Reset Reset operating hours (in the functions menu, “Hour” function hold down the

“set” button for a few seconds).Reset ManualIcon blinkingAction Alarm relay + buzzer activated.

Meaning of display label AEECauses activation Writing to EEPROM failed.Reset ------Reset ManualIcon blinkingAction Alarm relay + buzzer activated.

Meaning of display label noL (signalling no link).Causes activation Incorrect connection between the remote terminal and the controller or two

remote terminals configured as present and both with the same HW address (see state of the keyboard address assignment switch).

Reset Correct connection - two different HW addresses.Reset AutomaticIcon blinkingAction Alarm relay + buzzer activated.

Meaning of display label Atr1 / Atr2Causes activation Remote terminal configured by parameter but not electrically connected.Reset Correct connection - remote terminal declared missing by parameter.Reset AutomaticIcon blinkingAction Alarm relay + buzzer activated.


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7.9.25 Notes on alarm relay / open - collector / buzzerThe unit is equipped with a general alarm relay that groups all the alarms into a single output contact.The relay is active with the following logic:

7.9.26 Display and delete the alarm log in memory (ALOG function)The alarm code display function is active only if there are alarms.

• Enter the functions menu by pressing the button .• Select the function ALOG.• Press the button.

If there is no alarm, pressing is not enabled.• The lower display shows the label with the alarm code, while the upper display shows the label “n” with a

progressive number from 00 to 99.• Scroll through all the alarms using the or buttons.

To exit the ALOG function and return to normal viewing, press or wait for time-out.The memory has space for 99 alarms. Each alarm stored beyond this number will automatically overwrite the oldest alarm (the alarms are displayed in ascending order from the oldest to the most recent).

• To clear the alarm log enter the functions menu • With the or buttons select the lower display ALOG function, press .• Scroll through the alarm labels until you find ArSt in the lower display. The upper display shows PASS.• Press the button. Enter the password for deletion (the value of the password to reset the alarm log is 14)

press the button to confirm.• If the password is correct, the ArSt label blinks for 5 seconds to confirm deletion. After deletion,

you automatically exit the functions menu and return to normal view. • If the password is not correct, PASS is displayed again. If you do not enter the correct password, you can still

scroll through the alarms in memory with the or buttons. To return to normal view, press or wait for time-out.

7 . 1 0 P r o g r a m m i n g b y k e y b o a r dThe electronic control parameters are grouped into families and subdivided into three levels called:

1. USER (Pr1);2. SERVICE (Pr2);3. MANUFACTURER (Pr3).

The USER level (Pr1) permits access only to user parameters, the SERVICE (Pr2) / MANUFACTURER (Pr3) level permits access to the parameters related to unit configuration.Whether a particular parameter belongs to a certain level is determined at the design stage.

ATTENTION

All levels are password-protected.The USER password is 23.

ON With alarms not ceased.With alarms not reset.

OFF With no alarms.Machine powered off.


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The parameter families, identified by “Labels”, are divided as follows:

ATTENTION

The configuration parameters “CF” can only be changed with the unit on stand-by.

7.10.1 Access to parametersTo enter the parameters menu “Pr1” (user level):

1. Press the + buttons for 3 seconds. The upper display shows the label “PASS” the lower display shows thelabel “Pr1”.

2. Press , the upper display will show “0” blinking.3. To set the password use the or buttons.4. If the password is incorrect you will be prompted again. If the password is correct, press to display the

parameters. At the top of the display the first parameter “ALL” will be shown.5. To select each label press the or buttons, then press . The lower display will show the label a the code

of the first parameter it contains, its value in the upper one.

ATTENTION

Some parameters may only be viewable but not editable. If a parameter is only visible, LEDs no. 1 and no. 2 blink.

To exit programming and return to normal view, press the + buttons.

7.10.2 How to modify a parameter’s value• Enter programming.• Simultaneously press the + buttons for 3 seconds.• Select the desired parameter.• To change the value press the button.• Change the value with the or buttons.• Press to save the new value and pass on to the code of the following parameter.

LABEL ACTIONALL Displays all parametersST Displays Thermoregulation parameters onlydP Displays Display Viewing parameters onlyCF Displays Configuration parameters onlySD Displays dynamic set-point parameters only (FUNCTION NOT ACTIVE)

ESDisplays energy saving and switch-on parameters only (FUNCTION NOT ACTIVE)Displays only the parameters of the second set-point

CO Displays Compressor parameters onlyUS Displays auxiliary output parameters onlyFA Displays Fan parameters onlyAr Displays anti-freeze heater parameters onlyDF Displays defrosting parameters onlyrC Displays Recovery parameters onlyAL Displays Alarm parameters onlyPr Password

LED LED LED 2LED 3


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To exit, press + when a parameter is displayed or wait 240 seconds without pressing any button.

NOTEThe new value you have entered is saved to the memory also when you exit the parameter setting function by waiting for it totime out automatically without pressing button .

7 . 1 1 U s i n g t h e h o t - k e y ( U P L f u n c t i o n )7.11.1 Programming the board with the hot-key

With unit switched off: • Insert the flash drive.• Switch the unit on. • The data start downloading from the flash drive to the unit.

During this phase the adjustments are blocked and the lower part of the display shows the blinking message “doL”. At the end the upper display can show two messages:

• “End” if programming was successful (adjustment starts 30 s afterwards). • “Err” if programming was not successful.

In case of error the unit must be turned off and back on again to repeat the operation or to start with the normal setting (in this case the flash drive must be unplugged with the unit switched off).

7.11.2 Programming the hot-key

ATTENTION

Be careful, the hot-key saves the unit's parameters but does not programme them.

With unit switched on: • Insert the flash drive. • Enter the functions menu.• Select the function UPL on the lower display.

Press The data start downloading from the unit to the flash drive. During this phase the lower display shows the blinking message “UPL”. At the end the upper display can show two messages:

• “End” if programming was successful.• “Err” if programming was not successful.

To exit the UPL function, press the button or wait for the time-out time (15 sec).

7 . 1 2 A d j u s t i n g a n d c o n t r o l l i n g t h e u n i t7.12.1 Compressor control

The electronic control unit manages switching the compressors on and off respecting the minimum operating times.The two modes of adjustment and rotation are described below.

7.12.2 Choosing the type of compressor controlThe controller permits choosing between two types of temperature control:

• Proportional• Neutral Zone

7.12.3 Proportional controlThe proportional control for the chiller units as a reference uses the value of the set temperature (set-point) and an offset value called the differential. As the measured temperature increases the system gradually switches on the compressors. When the value of the temperature falls below the differential the compressors start progressively switching off.


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7.12.4 Graph of compressor proportional controlCompressor regulator operation graph in chiller mode.

7.12.5 Neutral zone controlIn chiller operation, if the reference temperature is > Set-point+Differential, the unit's compressors are switched on in sequence respecting the switch-on delay outside the neutral zone. If instead the reference temperature is < Set-point, the unit's compressors are switched off in sequence respecting the switch-off delay outside the neutral zone. In addition, to ensure the temperature reaches the set-point and the compressors rotate, if the reference temperature is within the neutral zone, the unit's compressor are switched on in sequence respecting the switch-on delay in the neutral zone. Still inside the neutral zone, after a programmable time, the control unit will switch off a compressor and, respecting the set rotation, switch on another. The actions in the neutral zone take place only if at least one of the unit's compressors is already active.Compressor regulator operation graph in chiller mode:

7.12.6 Compressors rotationFor the compressors to work properly over time the electronic control unit manages the switch-on rotation with different types of logic that are parameter selectable.The possible choices are:

• Fixed sequence: the first compressor to switch on is always the last one to switch off.• Rotation by hours: the compressor that will be switched on is the one, from the ones available, with the least

number of hours, while the first compressor to switch off, from the ones that are on, will be the one with the highest number of hours of operation.

• Rotation by starts: the compressor that will be switched on is the one, from the ones available, with the least number of starts, while the first compressor to switch off, from the ones that are on, will be the one with the highest number of starts.

7.12.7 Forced compressor rotationFor units that often work with partial loads, the controller provides the possibility of performing forced compressor rotation.Should a circuit have more than one compressor, but only one of these is on, after a programmable time the compressor is switched off and the available one is forced on.

7.12.8 Time l imit for switching on compressorsShould a circuit have more than one compressor, but only one of these is on, after a programmable time of operation the compressor is switched off and another one is switched on (the first free one depending on the operating hours or number of starts).

Step

2nd Step

1st Step

OFF

St07

Temperature

St01

DecreaseChilling capacity Zone

Neutral IncreaseChilling capacity

Set Set+Diff Temperature


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7 . 1 3 U n l o a d i n g f u n c t i o nThis function, when required, allows you to reduce the unit's chilling capacity by turning off a compressor (it can involve the entire unit or a single circuit and disables one or more compressors). There are the following types of unloading:

• Unloading due to high temperature: after defining an unloading differential and setting, if the temperature measured by the probe remains higher than the setting for an activation time, one compressor is switched off. If the probe temperature becomes less than or equal to the unloading setting less the differential or its maximum duration has elapsed, the unloading function is deactivated and the compressor switched back on.

• Unloading due to high pressure: after defining a set, a differential and an unloading time, if the condensation pressure measured in the circuit is equal to or greater than the set, the unloading function is turned on in the circuit then a compressor is turned off. The unloading function is deactivated only if the condensation pressure drops and remains below the unloading set for a default time or if it falls below set-diff.

7 . 1 4 F a n c o n t r o lOn MCTAT units the fans can be controlled in two ways:

• with electronic control (fan with integrated inverter)• in steps.

The selection may vary in relation to the configuration of the unit.

7.14.1 Units configured with “STEP” fansThese units are equipped with a pressure transducer located on the refrigerant compressor discharge pipeline.The electronic control, depending on the pressure detected by the transducer, intervenes on the operation of the fans according to an ON-OFF logic, i.e. supplying or shutting off power to the fans.

7.14.2 Units configured with regulated fansThe unit is equipped with inverter regulated fans, which serve to maintain condensation pressure around a set value.These units are equipped with a pressure transducer located on the refrigerant compressor discharge pipeline.For example, if the temperature of the air conveyed to the condenser decreases, the pressure transducer detects a drop in condensation pressure, which on sending the signal to the inverter causes a reduction in the fan rpm, thus decreasing the air flow through the condenser.In the same way, on increase of the temperature of the air conveyed to the condenser, with a consequent increase in condensation pressure, the inverter increases fan rotation speed gradually to increase the air flow through the condenser.

7.14.3 Fan control graphsThe following graph illustrates fan STEP activation logic as the condensation pressure varies.STEP graphic (CH):

BCP1OFF

FA11

Chiller

FA11

1st StepFA09

2nd StepFA10


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Electronic control graphic (CH)

7 . 1 5 M o d B u sSupervision allows you to monitor and intervene on some of the unit's parameters using a remote device via the RS485 port. The MODBUS communication mode for the control provides the following features: Baud Rate = 9600 bpsData Bit = 8 bitsParity = NoneStop Bit = 1Start/stop = 4 milliseconds of silence (approximately 3 characters)Minimum time-out = 500 ms For more information, please refer to the separate manual.

7 . 1 6 M o t o c o n d e n s i n g U n i tIf the TAT moto-condensing unit is controlled with digital commands, it operates as follows.On activating the coil of the relay -KAC1 (see wiring diagram) the unit is in chiller mode and a compressor is also activated, the display will show OnC. With the unit off the display will show StbY (Standby).The other compressors, if available, will be on when the specific relays are activated (see wiring diagram). Each relay will provide the enable signal for switching on a compressor.When the contact is active and the unit is shut down via the keypad, restart is again via the keypad. If the unit has been switched off with the keypad, to switch it back on with the digital input, this must be switched off and back on again.

7 . 1 7 A u t o m a t i c r e s t a r tIn case of a power loss, when power is restored the unit will be ON if it was ON at the time of power loss, and OFF if it was OFF.

7 . 1 8 P a r a m e t e r D e s c r i p t i o n - S e t t i n g sAll the programmable parameters and their levels are listed below. U= user level

ATTENTION

Ensure these instructions are observed in full to avoid incorrect operation of the unit.

7.18.1 Description of parameters

Parameter Level Description Min. Max. UM ResolutionTemperature controller

ST01 U Chiller setpoint.Enables setting the working set-point in chiller mode.

ST02 ST03 °C°F

DecInt

ST04 U Heat pump set-point.Enables setting the working set-point in heat pump mode.

ST05 ST06 °C°F

DecInt

ST07 U Operating range of adjustment steps in chiller mode. 0.10

25.045

°C°F

DecInt

SpeedFA12

BCP1

(%)

FA08

FA15

FA07

OFF

FA13 FA11

FA10FA09

Chiller


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ST08 U Operating range of adjustment steps in heat pump mode. 0.10

25.045

°C°F

DecInt

Pr1 U User password 0 999Display

Forced display presentationForced remote terminal display presentation

Display presentation on STD-BYPr1 U User password 0 999

UnitCompressorsAnalog inputsProbe offset

Digital inputsCF38 U ID9 configuration. 0 -o1 c75

Relay outputsProportional condensation outputs

Modulating outputsRemote terminal

CF54 U Configuration for remote terminal No. 1:0= Absent1= NTC probe on unit2= With no NTC probe on unit

0 2

Operating logicChiller / heat pump operation selection

CF59 U Chiller / heat pump operation selection:0= Via keypad1= Via digital input2= Via analogue input

0 2

Automatic change overUnit of measurement selection

Mains frequency selectionSerial address

CF64 U Serial address. 1 247Temperature control of compressors with different chilling capacity

Enabling compressor operationEnabling units with hybrid heat exchangers

Enabling buzzerChiller mode

Enabling I/O expansionEnabling electronic expansion valve driver

Configuring I/O expansionI/O expansion probes offsetI/O expansion digital inputsI/O expansion relay outputs

I/O expansion proportional outputsModulating outputs

Pr1 U User password 0 999Dynamic set-point

Pr1 U User password. 0 999Energy saving

Pr1 U User password 0 999Compressor control unit

Compressor

Parameter Level Description Min. Max. UM Resolution


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Partitions (FUNCTION NOT ACTIVE)Compressor starting

Rotation - balancing - temperature control of compressorsEvaporator water pump

CO19 U No. of hours for forced rotation of evaporator pumps. 0 999 10 Hours

10 Hours

Condenser water pump Maintaining loads

Pump downEvaporator unloadingCondenser unloading

Compressor liquid injection functionResource management in neutral zone functionEvaporator water low temperature unloading

Time-controlled pump downCompressor with modulating controlCompressor forced rotation function

Maintaining loadsUnit controlled capacity

Pr1 U User password 0 999Auxiliary relay circuit 1Auxiliary relay circuit 2

Proportional output 0-10V auxiliary No. 1Proportional output 0-10V auxiliary No. 2

Minimum modulating output valueModulating evaporator pump

Enabling auxiliary outputsPr1 U User password 0 999

Condensation fanOperation in chiller mode

Operation in heat pump modeHot start

3-4 Fans step (chiller mode)3-4 Fans step (heat pump mode)

Pre-ventilation in heat pump modePr1 U User password 0 999

Heating elements for antifreeze - support - boilerBoiler function

Boiler function in chiller modeBoiler function in heat pump mode

Anti-freeze alarmOperation of evaporator water pump with antifreeze alarm

Pr1 U User password 0 999Defrosting

Forced defrostingDefrost mode

Start end of defrosting via analogue inputDischarge fan operation in defrost mode

Defrosting with condensation fansHybrid exchangers

Dynamic set point in defrost modePr1 U User password 0 999

Heat recoveryPr1 U User password 0 999

Domestic hot water



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7.18.2 Parameter sett ingsThe table below shows the parameter settings for the controller according to the various configurations for the entire range of machines. Some functions might not be active or activatable on all the models (so the relevant parameters might not be visible on the controller).Where the parameter is not present in the “Value” column, please refer to the options listed on the right-hand side of the table.

7.18.3 Parameters depending on remote terminal kit

Pr1 U User password 0 999Alarms

High alarmCompressor oil alarm

Water differential pressure switch alarmCompressor thermal cut-out alarm

Pump-down alarmAntifreeze alarm in chiller mode

Antifreeze alarm in heat pump modeHigh compressor discharge temperature

Alarm relayPassword to reset alarm log - compressor thermal cut-out alarm

Compressor oil alarm managementGeneral shutdown alarm / signalling unit No. 2

High pressure alarm resetWater pump flow switch alarm condenser sideEvaporator water inlet high temperature alarm

Domestic hot water pump flow switch alarmSolar panel water pump flow switch alarm

Domestic hot water heating element thermal cut-out alarmSelecting the type of antifreeze alarm resetting

Compressor thermal cut-out alarmType of pressure switch alarm reset

Pr1 U User password 0 999

Para

met

er

Val

ue

UM

Lev

el

Fans control Version CH/HP Demand for chilling

Step

Adj

uste

d

N SN/S

SN

Via

key

pad

Via

rem

ote

ID

ID NT

C

ST01 12.0 °C UST04 45.0 °C UST07 4.0 °C UST08 2.0 °C UCF38 o3 -- UCF54 ch. 7.18.3 -- UCF59 -- U 0 1CF64 1 -- UCO19 4 10 hours U

Para

met

er

UM

Leve

l

Remote terminal kit

No

Yes

CF54 -- U 0 2


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CHAPTER 8

ADJUSTMENT AND CONTROL

8 . 1 R e f r i g e r a n t h i g h a n d l o w p r e s s u r e s w i t c h e sThe units are equipped with the following pressure switches:

1. low pressure switch (LP) This monitors refrigerant compressor suction pressure and will trip to protect the compressor if the pressure fallsto potentially hazardous values.It is of an “automatic reset” type.Alarm b1LP or b1lP (see chapter “7.9 Alarms”), generated by activation of this pressure switch, can be delayedwith respect to start-up of the compressor, to prevent temporary fluctuations in intake pressure or false alarmsfrom interfering with correct unit operation.On elapse of the time interval, tripping of the pressure switch is detected by the electronic control unit,which displays the alarm signal b1LP or b1lP (see chapter “7.9 Alarms”) blocking the compressor/s and fan/s,while the pump (if installed) remains in operation.After the alarm has tripped, if pressure on compressor intake increases and exceeds the reset point of the pressureswitch, it resets.The unit can then be restarted according to the alarm reset procedure described in Chapter 7 “Electroniccontroller”.If the cause of pressure switch activation is not eliminated, this cycle may be repeated continuously.

2. High pressure switch (HP)This monitors the refrigerant compressor discharge pressure and prevents it increasing to levels dangerous to theoperation of the compressor and people within the vicinity.It is “automatic reset” type.Its tripping will open the compressor power supply circuit and, in addition, this will be detected by the electroniccontrol unit that will display an alarm signal b1HP or b1hP (see chapter “7.9 Alarms”) and the fan/s will beactivated at maximum speed for 60 s to counter the alarm situation after which they will be turned off.When the compressor discharge pressure decreases and falls below the reset point, the pressure switch resetsautomatically.The unit can then be restarted according to the alarm reset procedure described in Chapter 7 “Electroniccontroller”.If the cause of pressure switch activation is not eliminated, this cycle may be repeated continuously.

The LP and HP pressure switches are connected to the refrigerant circuit pipes by means of SCHRAEDER valves (with needle) that prevent the refrigerant from escaping if the pressure switches are to be replaced.The TRIP and RESET values of the pressure switches depend on the type of refrigerant and are shown in the following table:MCTAT Models

COMPONENT REFRIGERANTTRIP RESET

bar °C °F bar °C °FLow pressure switch (LP)

R410A3.4 -17.8 0.0 5.0 -8.9 16

High pressure switch HP 39 61.9 143.4 30.4 51.3 124.3

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8 . 2 E l e c t r i c a l c a b i n e t f o r c e d v e n t i l a t i o nAll units are equipped with a thermostat controlled ventilation system for the electrical cabinet.The fan is controlled by a thermostat in the electrical cabinet and it starts when the temperature inside the electrical cabinet is higher than the thermostat set-point.

The set-point is 35 °C.The differential value, 10 °C, is fixed.

8 . 3 E l e c t r i c a l c a b i n e t h e a t i n g e l e m e n t ( o p t i o n a l )The unit's electrical cabinet, on request, is fitted with an electric heating element, which has the purpose of heating the electrical components inside the cabinet to safeguard them from the problems related to a lowering in the temperature.The heating element is controlled by a thermostat in the electrical cabinet and it starts when the temperature inside the electrical cabinet drops to the set-point. It switches off at the value of the set-point + differential.

The set-point is 5 °C.The differential value, 10 °C, is fixed.

8 . 4 C o m p r e s s o r i n t e g r a l p r o t e c t i o n ( P I )This protection comprises a combination of the thermo-magnetic circuit breaker and the compressor's protection.This system ensures complete protection against most of the problems that can cause burn-out of the windings.When the protection trips find and eliminate the cause, at which point the unit can be restarted by means of the ON-OFF button.

ON

OFF

Electrical cabinet fan status

Differential (Fixed)

TemperatureSet-point

Internal temperatureat the electrical cabinet

ON

OFF

Electrical cabinet heating element status

Differential (fixed)

Temperature Internal temperatureat the electrical cabinetSetpoint+Diff.of Setpoint

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CHAPTER 9

OPERATION AND MAINTENANCE9 . 1 O p e r a t i o n

NOTEThe MCTAT motocondensing units are supplied without an evaporator and installation is to be completed by the customer/installer.

ATTENTION

Before you start or operate on these units, make sure that the installer has performed all of the steps illustrated inChapter 5 “Installation”.

Operation of the unit is fully automatic.There is no need to power off the unit in the absence of a thermal load because it will switch off automatically once the preset unit outlet water temperature is reached.

9 . 2 M a i n t e n a n c e

ATTENTION

Before installing or operating these units, ensure that all personnel involved have read and understood the chapterconcerning “Safety” in this manual.

If serviced properly these units can work for many years without any trouble.

9.2.1 Access to the unit 's internal components (see attached drawings)

ATTENTION

The unit's electrical cabinet can be opened exclusively when the unit is powered off.

To access the refrigerant circuit components remove the front lower panel.To remove the front panel, use a screwdriver to undo the screws fixing it to the lateral uprights.To access the electrical cabinet components turn the main switch/disconnect switch to the OFF position “O” and open the electrical cabinet doors by opening the bolts with the key supplied with the unit.To access the rear compartment, remove the rear panel.

ATTENTION

Given the presence of sharp corners and edges in the rear compartment, service personnel must protect themselves fromaccidental contact during work inside the compartment.Caution must also be used in relation to the floor of the compartment as it may be wet and slippery.

MAINTENANCE AND OPERATING MANUALOperation and maintenance

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9.2.2 Maintenance and Inspection Schedule

ATTENTION

The above maintenance schedule is based on average operating conditions.In some installations it may be necessary to increase the frequency of maintenance.

OPERATION 1Day

1Month

6Months

1Year

Check control panel display for any alarm signals.Check that the water outlet temperature is within the specified range.Check that water inlet temperature is lower than the limit utilised for selection of the chiller.Check that the difference between the pump (if present) discharge pressure and suction pressure (measured on the pressure gauge with pump stopped) is within the prescribed range and not lower than the pump maximum flow rate value.Check that the unit's current absorption is within the data plate values.Carry out visual inspection of refrigerant circuit, looking out for any deterioration of the piping or any traces of oil which might indicate a refrigerant leak.Check the condition and security of piping connections.Check the condition and security of wiring and electrical connections.Using a spanner, check that the connections to the refrigerant compressor have not slackened.Check that the ambient air temperature is lower than the value utilised when selecting the chiller.Check that the area in which the unit is installed is well-ventilated.Check that fans are automatically controlled by the electronic control unit. Check that fan operation is not noisy.Thoroughly clean the fins of the condenser with soft brush and/or jet of clean compressed air.Check that the grilles of the dryer are free from dirt and any other obstructions.Clean condenser fins with a mild detergent.

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CHAPTER 10

TROUBLESHOOTING

PROBLEM CAUSE SYMPTOM REMEDYA

BEWOT water outlet temperature higher than prescribed value.

A1Thermal load too high.

A1.1BEWOT temperature higher than prescribed value.

Restore thermal load to within prescribed limits.

A2Ambient temperature too high.

A2.1See A1.1.

If the unit is installed in an enclosed place, reduce ambient temperature to within the prescribed limits if possible, for example by increasing room ventilation.

A3Condenser fins fouled.

A3.1See A1.1.

Clean the condenser fins.

A4Front surface of the condenser blocked.

A4.1See A1.1.

Remove the obstruction from the front surface of the compressor.

A5No refrigerant fluid in the circuit.

A5.1• See A1.1;• Low evaporation pressure;• If the circuit is equipped

with a liquid sight glass check it for the presence of a large number of air bubbles.

Call in a qualified refrigeration engineer to check for leaks and eliminate them.Have the circuit charged by a qualified refrigeration engineer.

A6Compressor protection trips.

A6.1• The head and the body of the

compressor are very hot;• The compressor stops and

attempts to restart after a short time (even few seconds).

Call in a qualified refrigeration engineer to check for leaks and eliminate them. Have the circuit charged by a qualified refrigeration engineer.


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BHigh pressure switch (HP) trip.

Alarm displayed:b1HP

B1One or more fans do not work.

B1.1• Refrigerant compressor

stops;• the display shows b1HP;• General alarm relay trip.

Repair or replace the fan.Where fitted, check the circuit breaker of the fan.Perform the alarms reset procedure to restart the unit (Chapter 7 “Electronic controller”).Check the fans speed control system.

B2Ambient air temperature too high.

B2.1• Ambient air temperature

higher than maximum permitted value;

• See B1.1.

If the unit is installed in an enclosed place, reduce ambient temperature to within the prescribed limits if possible, for example by increasing room ventilation.Perform the alarms reset procedure to restart the unit (Chapter 7 “Electronic controller”).

B3Recirculation of warm air due to incorrect installation.

B3.1• Condenser cooling air

temperature higher than the max. permitted value;

• Condenser cooling air temperature higher than maximum permitted value;

• See B1.1.

Change the position of the unit or the position of any nearby obstructions in order to prevent recirculation. Perform the alarms reset procedure to restart the unit (Chapter 7 “Electronic controller”).

B4See A3.

B4.1See B1.1.

Clean the condenser fins.Perform the alarms reset procedure to restart the unit (Chapter 7 “Electronic controller”).

B5See A4.

B5.1See B1.1.

Remove the obstruction from the front surface of the compressor.Perform the alarms reset procedure to restart the unit (Chapter 7 “Electronic controller”).

B6Thermal load too high.

B6.1• Water outlet temperature too

high;• Refrigerant compressor

stops;• General alarm relay trip.

Restore thermal load to within prescribed limits if possible. Perform the alarms reset procedure to restart the unit (Chapter 7 “Electronic controller”).

CLow pressure switch (LP) trips

Alarm displayed:b1LP

C1No refrigerant fluid in the circuit (see also A5).

C1.1• Refrigerant compressor

stops;• The display shows b1LP;• General alarm relay trip.

Call in a qualified refrigeration engineer to check for leaks and eliminate them.Have the circuit charged by a qualified refrigeration engineer.

C2Machine upline filter, if present, is fouled.

C2.1See C1.1.

Clean or renew the water inlet filter, if installed.

PROBLEM CAUSE SYMPTOM REMEDY


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DCompressor protection trips.

Alarm displayed:C1tr or C2tr

D1Thermal load too high with insufficient refrigerant charge in circuit (see also A5).

D1.1• The head and the body of the

compressor are very hot;• The compressor stops and

attempts to restart after a short time (even few seconds);

• Compressor thermal protection trips;

• Display shows code C1tr orC2tr;

• LED illuminates for general alarm icon .

Call in a qualified refrigeration engineer to check for leaks and eliminate them. Have the circuit charged by a qualified refrigeration engineer.

D2Incorrect rotation direction of scroll compressor (three-phase units only).

D2.1Refrigerant is not compressed and the unit is unable to provide cooling action.

Invert the position of two phase wires of the power supply.

EDisplay blank and all LEDs switched off with main switch P1 set to ON (I).

E1Control board fuse has blown.Power supply fluctuations or “spikes”.

E1.1Despite the presence of power on the board terminals the display remains blank and the LEDs remain off.

Change the fuse.Provide cleaner power supply to the dryer.

E2Abnormal power consumption by one or more of the control board components.

E2.1See E1.1.

Change the fuse. Provide cleaner power supply to the dryer.

FAlarm displayed:AP1, AP2 ...

F1Probe PB_ damaged.

F1.1• See problem;• General alarm relay trip.

Check that the temperature probe is correctly connected to the control board terminals and that the cable is undamaged. If necessary replace the temperature probe.

GAlarm displayed:b1AC

G1Low water outlet temperature.The set alarm value is lower than the value measured by the probe.

G1.1• See problem;• Compressor stops and then

restarts;• General alarm relay trip;• LED illuminates for general

alarm icon .

Identify and remedy the problem that caused BEWOT temperature to fall to a value below the alarm.

G2Water flow rate too low.

G2.1• See problem;• Compressor stops and then

restarts;• General alarm relay trip.

Increase the water flow rate.

HAlarmACF(n)

H1Configuration error.

H1.1Code ACF(n) flashing on display and unit shuts down.

Power off the unit and then power it on again.If this doesn’t solve the problem, contact the nearest service centre.

IAlarmAEE

I1Processor is not saving data correctly.

I1.1• Unit not working;• Code AEE flashing on

display;• LED illuminates for general

alarm icon .

Power off the unit and then power it on again.If this doesn’t solve the problem, contact the nearest service centre.

PROBLEM CAUSE SYMPTOM REMEDY

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CHAPTER 11

RISK ANALYSIS: RESIDUAL RISK

Description of risk: Effect: User instructions:1. Risk of crushing Falling of machine onto persons and/or

crushing of limbs.Use lifting equipment suited to the task in hand, to be performed by qualified personnel with reference to the labelling instructions and manual.

2. Risk of cutting and detachment caused by sheets or profiles in general.

Risk of cutting upper limbs on sharp edges caused by shearing of sheets or saw cutting of profiles.

Strictly observe all manual instructions. Chapter 3 “Safety”; Chapter 5 “Installation” and Chapter 9 “Operation and maintenance”.

3. Risk of cutting or detachment due to the finned surface of air-cooled condensers.

Risk of cutting upper limbs. Strictly observe all manual instructions. Chapter 1 “General information”; Chapter 3 “Safety” and Chapter 9 “Operation and maintenance”.

4. Risk of cutting or detachment due to fan blades.

Risk of cutting or detachment. Strictly observe all manual instructions. Chapter 1 “General information”; Chapter 3 “Safety” and Chapter 9 “Operation and maintenance”.

5. Risk of high pressure fluid ejection from pipelines and/or pressure tanks in cooling circuit due to accidental bursting.

Contact of body parts with refrigerant gas or parts of cooling circuit pipelines launched at high speed.

Strictly observe all manual instructions. Chapter 3 “Safety” and Chapter 5 “Installation”

6. Risk of high pressure fluid ejection from pipelines and/or pressure tanks in cooling circuit due to design pressure values being exceeded.

Contatto di parti del corpo con gas frigorigeno o residui di tubazione del circuito frigo lanciati ad alta velocità.

Strictly observe all manual instructions. Chapter 3 “Safety”; Chapter 5 “Installation” and Chapter 9 “Operation and maintenance”

7. Risk of high pressure fluid ejection from pipelines and/or pressure tanks in hydraulic circuit due to accidental bursting.

Contact of body parts with fluids or residual parts of hydraulic circuit pipelines launched at high speed.

Disconnect the machine from the electrical mains during interventions on the hydraulic circuit.Strictly observe all manual instructions. Chapter 3 “Safety”; Chapter 5 “Installation” and Chapter 9 “Operation and maintenance”

8. Risk of high pressure fluid ejection from pipelines and/or pressure tanks in hydraulic circuit due to design pressure values being exceeded.

Contact of body parts with fluids or residual parts of circuit pipelines launched at high speed.

Depressurise the machine during interventions on the hydraulic circuit.Strictly observe all manual instructions. Chapter 3 “Safety”; Chapter 5 “Installation” and Chapter 9 “Operation and maintenance”

9. Electrical hazards due to direct contact with live parts.

Risk of electrocution and burns. Strictly observe all manual instructions.Chapter 3 “Safety” and 5.5 “Electrical connections”

10. Electrical hazards due to indirect contact with parts that are live due to faults, in particular due to an insulation fault.

Risk of electrocution and burns. Strictly observe all manual instructions. Chapter 3 “Safety” and 5.5 “Electrical connections”

11. Electrical hazards: electrostatic phenomena.

Uncontrolled movements by victim of electrostatic discharge due to contact

Strictly observe all manual instructions. 5.5 “Electrical connections”

12. Electrical hazard: heat radiations or other phenomena, such as projection of melted particles, and chemical effects deriving from short circuits, overloads.

Risk of electrocution with live parts due to short circuits, scalding on contact with hot components due to overload.

Strictly observe all manual instructions. Chapter 3 “Safety” and 5.5 “Electrical connections”


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13. Heat-associated risk: burns and/or scalding

Scalding on contact with pipelines at temperatures over 65°C and/or freezing due to contact with surfaces at temperatures below 0°C.

Strictly observe all manual instructions. Chapter 3 “Safety”

14. Hazards generated by noise levels that may impair hearing capacity (deafness) and other physical disorders (such as loss of balance, consciousness).

Loss of hearing capacity by operator. Secure all components correctly after interventions and maintenance.

15. Hazards generated by materials or substances handled, used, produced or offloaded from the machine and by materials used to construct the machine: inhalation of refrigerant gases.

Inhalation of refrigerant gas. Strictly observe all manual instructions. Chapter 3 “Safety”

16. Hazards generated by materials or substances handled, used, produced or offloaded from the machine and materials used to construct the machine: fire or explosion.

Risk of fire or explosion. Install the system in an environment fitted with adequate fire fighting equipment. Strictly observe all manual instructions.Chapter 5 “Installation”

17. Hazards generated by failure to use personal protective equipment.

Lacerations to upper limbs during maintenance or installation.

Use adequate personal protective equipment and observe all instructions in the manual.Chapter 1 “General information”; Chapter 3 “Safety”; Chapter 5 “Installation” and Chapter 9 “Operation and maintenance”

18. Hazards generated by failure to observe principles of ergonomics during machine design, caused, for example, by: inadequate design, layout or identification of manual controls.

Hazards associated with failure to correctly identify manual controls.

Consult all sections of the manual.

19. Hazards generated by failure to observe principles of ergonomics during machine design, caused, for example, by: inadequate design, or layout/location of visual display units.

Hazards associated with failure to correctly understand visual display units.


20. Inadvertent start-up, overtravel/unexpected excess speed (or any other similar malfunction) caused by: fault or malfunction of control system.

Electrical or mechanical hazard due to incorrect settings of operating parameters or settings.

Strictly observe all manual instructions.Chapter 3 “Safety”; Chapter 9 “Operation and maintenance”; 5.5 “Electrical connections” and Chapter 5 “Installation”

21. Inadvertent start-up, overtravel/unexpected excess speed (or any other similar malfunction) caused by: fault or malfunction of control system with possibility of disabling safety devices.

Electrical hazard during interventions on machine with safety devices inhibited.

Strictly observe all manual instructions. Chapter 3 “Safety”; 5.5 “Electrical connections”; Chapter 5 “Installation” and Chapter 9 “Operation and maintenance”

22. Inadvertent start-up, overtravel/unexpected excess speed (or any other similar malfunction) caused by: fault or malfunction of control system.

Electrical hazards associated with environmental work conditions.

Strictly observe all manual instructions. Chapter 3 “Safety”; Chapter 2 “Technical data, performance and operating limits” and 5.5 “Electrical connections”

23. Inadvertent start-up, overtravel/unexpected excess speed (or any other similar malfunction) caused by: return of electric power supply after failure.

Hazards associated with inadvertent start-up of the machine when electric power supply is restored.

Strictly observe all manual instructions. Chapter 3 “Safety”; 5.5 “Electrical connections” and Chapter 6 “Starting”

Description of risk: Effect: User instructions:


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24. Inadvertent start-up, overtravel/unexpected excess speed (or any other similar malfunction) caused by external factors on the electrical equipment (EMC).

Electrical hazards associated with electric stress on internal machine components, short circuits and overloads.

Strictly observe all manual instructions.Chapter 3 “Safety”; 5.5 “Electrical connections” and Chapter 9 “Operation and maintenance”

25. Hazards caused by assembly errors. Hazards associated with machine instability caused by vibrations. Hazards on contact with operating fluids, risk of pollution due to dispersion of fluids into the environment.

Strictly observe all manual instructions. Chapter 3 “Safety”; Chapter 5 “Installation” and Chapter 6 “Starting”

26. Risk of falling or projection of objects or fluids.

Contact of body parts with metallic materials such as the fan blades or moving parts of the compressor.

Disconnect the machine from the electrical mains during interventions on the hydraulic circuit.Strictly observe all manual instructions.Chapter 3 “Safety”; Chapter 5 “Installation” and Chapter 9 “Operation and maintenance”

27. Loss of stability/upturning of machine.

Crushing of body parts. Strictly observe all manual instructions.Chapter 5 “Installation” and instructions on packaging.

28. Loss of stability/upturning of machine due to installation on unstable ground and/or vibrations generated on connection pipelines.

Crushing of body parts due to upturning of the machine, contact of body parts with water due to failure of connections to the hydraulic circuit caused by excessive vibrations.

Strictly observe all manual instructions.Chapter 5 “Installation” and Chapter 6 “Starting”

29. Hazards generated by absence of and/or position of measures/instruments influencing safety: all guards.

Hazard of contact, due to sudden ejections, with machine components and processed or used materials.

Strictly observe all manual instructions.Chapter 3 “Safety”; Chapter 5 “Installation”; Chapter 6 “Starting” and Chapter 9 “Operation and maintenance”

30. Hazards generated by absence of and/or position of measures/instruments influencing safety: graphic safety signs.

Hazard associated with the lack of or inadequate graphic instruction and warning symbols related to dangers that could not be eliminated in design.

The operator must observe all graphic safety signs on the machine and replace when worn or illegible.Strictly observe all manual instructions.Chapter 1 “General information”

31. Hazards generated by absence of and/or position of measures/instruments influencing safety: manual.

Hazards associated with incorrect preparation of the manual due to lack of and/or unclear information required to ensure operator safety and safe use of the machine.


32. Hazards generated by absence of and/or position of measures/instruments influencing safety: disconnection of power sources.

Contact with live parts, contact with high pressure fluids or gas.

Strictly observe all manual instructions. Chapter 3 “Safety” and 5.5 “Electrical connections”

33. Hazards generated by absence of and/or position of measures/instruments influencing safety: instruments and accessories for adjustments and/or maintenance in safety conditions.

Hazard of cutting, ejection of fluids or gas at high pressure, scalding, or vibrations caused by incorrect maintenance.

Strictly observe all manual instructions. Chapter 3 “Safety”; Chapter 5 “Installation”; Chapter 9 “Operation and maintenance”

Description of risk: Effect: User instructions:

Appendix


APPENDIXGENERAL CONDITIONS CHECKLIST

Start

No

Yes

Yes

Yes

Yes

No

No

Has the unit suffered transport damage?

Have the minimum installation clearances specified in this manual been observed?

Are the condensing coils free of obstructions?

General condition of unit is in compliance

Do not start the unit before repairs

Correct installation of the unit, working in compliance with the prescriptions given in the manual

Clean condensing coils

Are the fan grilles free of obstructions? Clear the fan grillesNo

Appendix


CHECKLIST FOR FIRST START-UP (ONLY MCTAT UNITS)

Start

No

Yes

No

Yes

No

No

Yes

Persons not involved in the operations must be kept clear of the area

Any alarms shown on unit display?

Do the pressure switches or the differential pressure switch for the water trip properly?

When connecting the high and low pressure gauges, check that the working pressure reading is correct?

When setting the high pressure value to approx. 14 bar, are gas leaks > 3 grams/year detected?

Start procedure terminated

Trip test:Adjust the plant water gate valves to reduce the flow rate to the evaporator

Stop the unit and find the cause of the problem

Check and/or renew the component

Stop the unit and find the cause of the problem

Stop unit and find the cause of the leak in compliance with EN 378-2

Yes

Appendix


CONTROLLER CHECK

Start

No

Yes

Yes

Yes

Yes

Yes

No

No

No

No

Power supply voltage complies with specification given in wiring diagram?

Power feeding conductors are fit for purpose (wiring diagram)?

Protective earth connection complies with statutory legislation?

Protection upline from unit is adequate?

Correct phase sequence?

Unit electrical connection is properly executed

Connect the unit to the correct power supply voltage

Replace conductors with conductors of an appropriate type

Remake the connection in compliance with statutory legislation

Replace component with an adequate protection device

Correct the sequence of phases

Appendix


OIL CHECKLIST

Start

No

Yes

Sufficient oil level in compressor?

If required, has crankcase heater been switched on at least 12 hours before start-up?

The compressor is ready to start

Check the oil sight glass where there is one.Top up as necessary

Activate crankcase preheating and wait 12 hours

No

Yes

Appendix


UNIT RUNNING CHECKLIST

Start

No

Remove all unauthorised persons from the test area

Power on the unit

Check that the display is on

Contactors and devices functioning correctly?

Check that the unit is on stand-by and LED with icon off

Start the machine using button .(For motocondensing units see the “User's Quick Guide”)

The START-UP procedure has now been completed

Check the component and renew if necessary

Yes

The On/Off operations must only be performed with

button .

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