Fujitsu CPYA080LLW Installation guide

Category
Split-system air conditioners
Type
Installation guide

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Installation manual
A CLASS ENERGY EFFICIENCY AIRCOOLED REVERSIBLE HEAT PUMPS WITH EC INVERTER AXIAL FANS,
INVERTER ROTARY COMPRESSOR, PLATE EXCHANGER AND HYDRONIC KIT
CP*A050LLW/CP*A060LLW/CP*A080LLW
PART No. 9377863553
2
3
1. GENERAL 4
1.1 DOCUMENT INFORMATION 4
1.2 ACCESSORIES 4
1.3 MACHINE IDENTIFICATION 5
1.4 INTENDED USE 5
1.5 GENERAL PRECAUTIONS 5
1.6 BASIC SAFETY RULES 6
1.7 RESIDUAL RISK 6
1.8 USER GUIDELINES 7
1.9 MACHINE DESCRIPTION 7
1.10 DIMENSIONS DRAWINGS 8
1.11 SAFETY DEVICE 9
1.12 DECOMMISSIONING AND DISPOSING 9
2. SHIPMENT 10
2.1 POSITION OF THE EQUIPMENT 10
2.2 EQUIPMENT 10
2.3 STORAGE 10
2.4 HANDLING 10
2.5 UNPACKING 11
2.6 ACCESS TO INTERNAL PARTS 11
2.7 RESTING ON THE GROUND 11
3. INSTALLATION 12
3.1 INSTALLATION LOCATION REQUIREMENTS 12
3.2 WORK FIELDS 12
3.3 UNIT POSITIONING AND FUNCTIONAL SPACES 12
4. WATER CONNECTIONS 15
4.1 CONNECTION DIAGRAM 15
4.2 POSITION OF CONNECTIONS 15
4.3 HYDRAULIC DATA 15
4.4 CONNECTION TO THE SYSTEM 16
4.5 SYSTEM FILL-UP 16
4.6 PIPING INSULATION 16
4.7 PROTRUSION LENGTH OF OUTDOOR TEMP THERMISTOR 16
5. ELECTRICAL CONNECTIONS 17
5.1 MACHINE CONNECTION 17
5.2 CONNECTIONS OF THE ACCESSORIES 17
5.3 WIRING METHOD 18
5.4 ELECTRICAL DATA 18
5.5 EXTERNAL INPUT AND OUTPUT 18
6. COMMISSIONING 19
6.1 PRELIMINARY INSPECTIONS 19
6.2 FIRST START-UP OR RESTART AFTER LONG INACTIVITY 19
6.3 SHUT-DOWN 19
6.4 FLOW RATE CALIBRATION 19
6.5 FLOW RATE BALANCE 19
7. CONTROL PANEL 20
7.1 USER INTERFACE 20
7.2 ALARMS 24
7.3 REMOTE CONTROL PANEL 25
7.4 AVP CONTROLLER 26
4
1. General
1.1 Document information
1.2 Accessories
1.3 Machine identification
1.4 Intended use
1.5 General precautions
1.6 Basic safety rules
1.7 Residual risk
1.8 User guidelines
1.9 Machine description
1.10 Dimensions drawings
1.11 Safety device
1.12 Decommissioning and disposing
Preliminary precautions
1.1 Document information
1.2 Accessories
model Item amount
CP*A050LLW Installation manual 1
D.O.C. 1
Energy label 1
CP*A060LLW Installation manual 1
D.O.C. 1
Energy label 1
EMI core 1
CP*A080LLW Installation manual 1
D.O.C. 1
Energy label 1
EMI core 1
Drain pipe 1
Drain cap 2
1.1.1 Symbols
This publication contains the following symbols:
This publication is an integral part of the equipment and therefore it should be kept with
care and should always go with the equipment also in case of its cession to another owner,
user or moving to another plant. If it is damaged or lost, request another copy from customer
service in the relevant area.
The document is reserved by law and any kind of duplication or transmitting to a third party
without our explicit consent of the manufacturing company is forbidden.
The manufacturer reserves the right to make changes to its models at any time without
prejudice to the basic features described in this manual.
The manufacturing company excludes any contractual and extra-contractual liability
for damage caused to people, animals or objects, due to installation, regulation and
maintenance errors, to improper use or non-compliance with the rules reported in
the accompanying documents, in the signposting applied on the machine, in Safety
Regulations in force in the installation place as well as in the precautions suggested by
common sense.
Inform all personnel involved in machine use about these instructions.
The manual is divided into chapters as follows:
General;
Shipment;
Installation;
Water connections;
Electrical connections:
Commissioning;
Control panel;
Maintenance.
Attached.
The preliminary precautions must be read before performing any of the following operations.
This document uses the following definitions:
Danger zones: any area inside and/or near the machine in which the presence of an
exposed person constitutes a risk to his/her own health and safety.
Exposed person: any person who is entirely or partially in a danger zone.
Operator/Maintenance Technician: the person/s assigned to operate, adjust, service, repair
or move the machine.
A Chapter
B Sequence of paragraphs
C Preliminary precautions
D Operations
Danger
Draws attention to actions that can cause serious injury if not performed
correctly.
Prohibited Draws attention to actions that impose a prohibition.
5
1.3 Machine identification
A Rating Label
The equipment can be identified from:
• Rating Label
Affixed on the machine, it shows the technical and performance data of the equipment.
The loss of the label may compromise CE compliance. If it is lost or
deteriorated, request a duplicate from Technical Support.
Tampering with, removal and deterioration of the identification plates complicate any
installation, maintenance and spare part request.
1.4 Intended use
This equipment is intended to heat or cool water (eventually added with inhibited ethylene
glycol) which circulates in a closed circuit.
Hot or cold water produced by the machine shall be used for heating-cooling applications or
industrial process.
Any other use of the machine is forbidden.
Do not use flammable products near the machine.
Do not use substances that can form explosive mixtures close to the
machine.
Do not use the machine where there are problems of environmental
impact.
The unit will be damaged if the unit is left prolonged periods at pow-
er-off state with an outside temperature of 0°C or lower.
Do not install the unit at a location exposed to salty breeze or in hot
springs where a sulfidizing gas is generated.
1.5 General precautions
Please ask professional sales shop to install this unit.
Do not attempt to install this unit by yourself to avoid the accidents such as electric shock,
fire and leakage of water.
These units must comply with their intended use in line with their performance character-
istics.
Wear suitable and accident prevention clothing and equipment during installation and/or
maintenance. The manufacturer declines any liability for non-compliance with safety and
accident prevention regulations in force.
All unit installation, connection, start-up and shut-down operations must only be
implemented by qualified and authorised personnel.
Comply with the laws in force in the country where the machine is installed, concerning
the use and disposal of the packaging, the products used for cleaning and maintenance
and for the management when the unit life cycle is complete.
Any repairs or maintenance must be performed by the technical support of the manufac-
turer or by qualified personnel, in accordance with this publication.
Preferably use original spare parts when replacing components.
If the refrigerant should leak, ventilate the room. The liquid refrigerant produces toxic gas
when exposed to a flame.
In the case of a malfunction or spill of liquid or gas refrigerant, set the main switch to off
and close the shut-off valves. Promptly call technical support or professional personnel. Do
not intervene personally on the unit.
If the outside temperature may drop below zero, there is a freezing hazard and the system
must be drained or anti-freeze must be added.
Where the outdoor temperature is 0 °C or less, set up the outdoor unit in a high place,
and do not arrange the frame of installed stand under the drain port. Because the water
dropped from the drain port repeats freezing and accumulating, and may block the drain
port.
In the area with heavy snowfall, if the intake and outlet of unit is blocked with snow, it
might become difficult to get warm and it is likely to cause of the breakdown. Please con-
struct a canopy and a pedestal or baffle board.(local configured).
This unit contains fluorinated greenhouse gas covered by the Kyoto Protocol. Maintenance
and disposal must be carried out only by qualified personnel.
A
A
CP*A050-060LLW CP*A080LLW
6
Based on CE Standard no. 842/2006 on certain fluorinated greenhouse gases, it is mandatory
to indicate the total amount of refrigerant in the installed system. This information is present in
the technical plate found in the outdoor unit.
After finishing the installation, please check no defective points in the testing operation. Then,
kindly explain to the user about the directions and maintenance according to the operation
manual.
For product modification, the product and its specification may show slight differences from
the description of this manual.
Be sure to install the unit in steady place to hold the heavy weight. Lack of stability or
imperfect installation may cause injury due to the fall of the unit.
Be sure to fix the power supply cord in connecting points of the terminal block correctly,
Imperfection of the connecting may cause overheating and a fire.
Be sure to install the wiring lid in a straight line. Imperfect wiring works may cause
overheating, a fire or electric shock at the connecting point in the terminal block.
1.6 Basic safety rules
Using products that require electricity and water require some basic safety rules to be complied
with, such as:
It is prohibited to operate the unit before having disconnecting it from the power supply by
setting the main switch to "off".
It is prohibited to modify the safety devices or the settings without authorisation and
instructions from the manufacturer of the unit.
It is prohibited to pull, detach or twist the electrical cables coming from the unit, even if it is
disconnected from the power supply.
It is strictly prohibited to touch any moving parts, interpose between them or introduce
pointed objects through the grids.
It is prohibited to use gas and water pipes to earth the unit.
It is prohibited to touch the unit when barefoot or with wet or damp parts of the body.
It is prohibited to stand on the unit, sit down on it and/or lean any type of object against it.
It is prohibited to dispose of and leave the packaging material in the reach of children as it
can be a potential source of danger.
It is prohibited for children or unassisted disabled persons to use the unit.
It is prohibited to introduce R410A in the atmosphere: R410A is a fluorinated greenhouse
gas referred to in the Kyoto Protocol with a Global Warming Potential (GWP)= 2088.
1.7 Residual risk
Description
The description of the residual risk considers the following elements:
the type of dangers those working around the machine are subject to;
a description of main risks;
who could be exposed to such risks;
what are the main safety measures adopted to reduce the risk of injury.
The guidelines for the prevention of accidents reported below, with reference to the relative areas
of residual risk, must be integrated with all the general instructions of this chapter and with the
accident prevention regulations in force in the destination country of the system.
Residual risk near the machine
Electrocution, if the electrical connection and earthing of the machine are not carried out
correctly.
Cuts or abrasions due to the presence of sharp edges.
Suction of substances in the installation site and subsequent dispersion in the environment.
Projection of any object that may fall on the fans blades.
Leakage of water (in case of a fault).
Formation of condensation water and ice in the area in front of the machine during the
heating operation of the heat pump machines.
Micro-climate alteration (during operation).
Noise emission (during operation). The sound pressure levels of the individual units are shown
in this manual.
Oils leaks (due to a fault).
Refrigerant gas leak (due to a fault).
Refrigerant gas is a greenhouse gas effect substance. Vapours are heavier than air and they
can cause suffocation by reducing oxygen available for breathing. Rapid evaporation of the
liquid can cause freezing.
Measures to be adopted if refrigerant gas leaks
• Product type:
R410A
First aid measures
• General information:
do not administer anything to an unconscious person.
• Inhalation:
move outdoors.
use oxygen or artificial respiration if needed.
do not administer adrenaline or similar drugs.
Contact with eyes:
rinse thoroughly with plenty of water for at least 15 minutes and consult a doctor.
Contact with skin:
wash immediately with plenty of water
immediately remove all contaminated clothing
Measures in the event of accidental spillage
• Personal precautions:
Move all personnel to safe areas.
Provide adequate ventilation.
Use personal protective equipment.
• Environmental precautions:
Intercept the emission.
• Cleaning methods:
Use absorbent products.
Operations with removed panels
Some of the operations and/or tests described below require the removal of the panels to access
inside the unit.
There may be hot surfaces (piping, compressor, etc.) or cold (compressor, intake separator, etc.),
sharp edges (coils fins) or moving parts (fans) even with the machine stationary.
The power supply must be disconnected before removing any panel.
Operations that require the panels to be opened must only be carried out by qualified
personnel wearing personal protective equipment.
7
1.8 User guidelines
Keep this manual in a place accessible to the operator.
Take note of the unit identification data so as to provide them to the service centre when
required (see the "Machine identification" paragraph).
It is recommended to keep track of the operations carried out on the unit, so as to facilitate any
troubleshooting.
Request the installer to be trained on:
switching on/shut-down;
shutting down for long periods;
maintenance;
what to do/not to do in case of a fault.
In case of a fault or malfunction:
immediately disable the unit without resetting the alarm;
verify the type of alarm to notify the service centre;
contact an authorised service centre;
request original spare parts.
1.9 Machine description
1.11.1 Features
Structure
Self-supporting galvanised steel frame further protected with polyester powder painting.
Panels are easily removable to facilitate the inspection and maintenance of the internal
components of the unit.
Coil protection metallic guards and stainless steel bolts
Compressor
DC Inverter Rotary, internal overheat protection and crankcase heater, if needed, mounted on
shock absorbers.
It is installed in a compartment separate from the air flow to reduce noise.
The crankcase heater is always powered when the units is in stand-by.
Inspection is possible through the front panel of the unit.
EC Inverter fans
Axial fans with low rpm and special wing profile directly coupled to high efficiency DC Brushless
motors with external rotor, propelled by INVERTER.
They are statically and dynamically balanced and complete with safety protection grid placed on
the air outlet.
Condenser
Made up of a finned coil with copper pipes and aluminium fins.
With moisture drain pan.
Evaporator
In AISI 304 stainless steel braze welded plates type, insulated with closed cell foam.
An antifreeze heater is always installed.
Electrical board
It includes: main switch with door lock device, fuses, filter for harmonic current, compressor
contact, external air sensor for climatic adjustment, DHW sensor, and external three-way valve
management.
Microprocessor
Microprocessor
For the automatic control of the following functions: water temperature regulation, antifreeze
protection, compressor timing, alarm reset, alarm management and operating LEDs, cumulative
alarm contact for remote signalling, local or remote commutation of the cooling / heating cycle,
high and low pressure control.
The unit includes serial interface.
Control logic of the Inverter Scroll compressor
It adjusts using Inverter the power supplied by the compressor as a function of the system
thermal load, the condensing pressure and the outdoor air temperature.
The control system, thanks to Inverter technology, monitors and adapts rapidly the performances
of the Inverter compressor, the pump and the fans in order to guarantee the best operating
conditions for the unit.
Thanks to the Inverter logic, units are able to operate even with low water content in the system,
thus making the use of the inertial tank superfluous.
Refrigerant circuit
The circuit, in copper tubing, includes: dryer filter, electronic expansion valves, liquid receiver,
4-ways reversing valve; pressure transducer; shut-off valves; silencer; electro valve; capillary tube;
regulation expansion valve.
Water circuit
It includes: evaporator; temperature sensor; antifreeze sensor; circulator with high efficiency DC
Brushless motor; flow switch; water gauges in suction line; expansion vessel; manual air vent;
water drain; security valve.
8
1.10 Dimensions drawings
Dimensions CP*A050-060LLW
Schema elettrico CP*A080LLW
621
330
34
60
18
20
830
373
320
892
1160
128
127
Ø12
1120
40
400
1180
40
Pitch of bolts for installation
28kg 33kg
111,3 111,3897,4
13,5
13,5
28kg 33kg
Pitch of bolts
for installation
OUT
IN
Cables entry
130
290
34
60
18
625
627
105
17
17
320
105
40
40
274
354
800
Ø12
1010
127
1050
685
1058
Cables entry
Pitch of bolts for installation
15kg
20kg
15kg
20kg
Pitch of bolts
for installation
OUT
IN
Manometer
Manometer
9
1.11 Safety device
Model CP*A050LLW CP*A060LLW CP*A080LLW
Circuit protection
Main fuse current (next to main power supply terminals) 250V 1,25A-T
Auxiliary fuse current (next to main power supply terminals) 250V 1,25A-T
Main fuse current (next to ODU power supply terminals) 250V 20A 250V 25A 250V 25A
Fuse current (ODU fiche)
250V 15A
250V 3,15A 250V 3,15A250V 10A
250V 3,15A
Fan protection Thermal protection
Intervention 100°C
+/-10°C - motor stop
Rearmament 95°C
+/-10°C - motor on
Intervention 150°C +/-15°C
- motor stop
Rearmament 120°C
+/-15°C - motor on
Compressor protection
Motor thermal protection
Intervention 108°C - motor stop
Rearmament 80°C - motor on
Delivery thermal protection
Intervention 110°C - motor stop
Rearmament after 7 minutes - motor on
High pressure protection
Heat exchanger thermal protection
Intervention 67°C - compressor stop
Rearmament 63°C - compressor on
Pressure sensor
Intervention 4,2MPa - compressor stop
Rearmament 3,0MPa - compressor on
Low pressure (cooling only) Pressure sensor
Intervention 0,12MPa - compressor stop
Rearmament 0,15MPa - compressor on
1.12 Decommissioning and disposing
This product falls within the field of application of Directive 2012/19/EU on the management of
waste electric and electronic equipment (WEEE).
These types of products may contain substances that are potentially harmful to human
health and the environment and cannot be disposed of as household waste.
When the machine needs to be replaced or dismantled it must be disposed of according to local
regulations on sorted waste, otherwise you must contact your local dealer for information on free
pick-up.
10
2. Shipment
Preliminary precautions
Complaints must be made within 8 days from receipt, late claims will not be valid.
The unit must be moved only by qualified personnel, properly equipped and with
equipment suitable to the weight and dimensions of the device, provided below. If using
a forklift, insert the forks into the relative openings of the base. Avoid dangerous situations
if using a hoist to lift the unit. When using chains and ropes, make sure they are in good
conditions, of proper capacity and approved in compliance with safety regulations in force
in the place of installation.
In all lifting operations be sure to have firmly anchored the unit to avoid tippings or
accidental falls.
During the discharge and positioning of the unit, pay attention to not make abrupt
manoeuvres.
Only remove the packaging when set in the place of installation.
Do not dispose of the parts of the packaging in the environment or leave them within reach
of children as they are potential sources of danger; dispose of the packaging according to
regulations in force in the country.
Move the unit with utmost care in order to not damage it.
During lifting and moving operations, move away from the concerning area.
2.1 Position of the equipment
2.2 Equipment
2.3 Storage
2.4 Handling
2.5 Unpacking
2.6 Access to internal parts
2.7 Resting on the ground
2.4 Handling
It is prohibited to use the pipes or other components of the machine as lifting points.
During moving it is forbidden to pass the maximum inclination consented as indicated in
the figure.
2.4.1 Lifting with forks
Insert the forks from the side;
2.1 Position of the equipment
A,B Pocket for accessories
Keep the documentation in a dry place to prevent deterioration, for at least 10 years for
future reference.
Any accessories that are not factory-fitted are supplied in separate packages, with a
relevant instruction sheet.
2.2 Equipment
Mounting positions of accessories
:
Installation manual / D.O.C. / Energy label
:
EMI core / Drain pipe / Drain cap
For details of accessories, see 1.2 Accessories
2.3 Storage
The room temperature in which the units are stored must be between -20 / +50°C.
B
A
11
2.5 Unpacking
Before positioning the unit in the right installation place, remove the protective packing.
Cut and remove the strapping which block the cardboard packing.
Remove the cardboard paying attention to not scratch the panels of the unit.
Remove the protection sack.
Remove the polystyrene parts, basement and cover.
The machine is supplied without shock absorbers. Install any shock absorbers before
resting the machine definitely on the ground.
Only remove the packaging when set in the place of installation.
Due to the different nature of packing materials (wood, nylon, polystyrene,
cardboard, etc.), it is advisable to store them separately and to deliver them to
companies specialized in waste disposal and recycling in order to safeguard the
environment.
2.6 Access to internal parts
CP*A050-060LLW CP*A080LLW
To access the electrical board:
Disassemble the indicated panels.
Before opening the electrical board, make sure to remove the voltage.
Open the electrical board doors with the dedicated screwdriver.
In reassembling the cover panels, make sure to mount the toothed washer screws to grant
earth continuity. As rule at least two screws per removable panel.
2.7 Resting on the ground
The unit must be positioned on a surface perfectly horizontal and able to withstand its
weight.
Install the unit where it will not be tilted more than 5°.
Positioning must be performed slowly and so that all support points are touching the floor.
Install the unit in a location that can withstand its weight, and where it will not topple or
fall.
12
3. Installation
Installation location requirements
Work fields
Unit positioning and functional spaces
3.1
3.2
3.3
Preliminary precautions
The location of the hydraulic, cooling and electric systems should be determined by the
system designer and must consider both the purely technical requirements as well as any
applicable local legislation and specific authorisations.
Comply with the technical clearances to guarantee proper access when performing
maintenance on the machine.
The whole area of compliance should be prohibited, except for the operators and
maintenance personnel of the machine.
The units must not be installed in the presence of flammable or explosive gases, in very
humid environments (laundries, greenhouses, etc.) or in places where there are other
machines that generate a strong source of heat.
Install the unit on a solid base that can support the weight; the unit, if installed
incompletely or on a non- adequate base, may harm people or damage objects if it
detaches from its base.
3.1 Installation location requirements
The installation place must be chosen according to that specified in standard EN 378-1 and the
requirements of standard EN 378-3. In any case, the installation site must consider the risks
associated with an accidental leak of refrigerant gas contained in the direct expansion units. Do
not install the unit near flammable materials or others that could cause a fire. Provide specific fire-
fighting measures.
3.2 Work fields
Operating ranges are indicative, in proximity of operation limits units may partialize their heating
or cooling capacity.
Check the actual capacity by using the capacity tables or the selection software.
Operating mode: cooling
Standard operation
Ta Ambient air temperature (°C)
To Outlet water temperature (°C)
Operating mode: heating
Standard operation
Ta Ambient air temperature (°C)
To Outlet water temperature (°C)
To
Ta
3.3 Unit positioning and functional spaces
The unit should be positioned far from any obstacle.
AIR
ABCDE
mm mm mm mm mm
Min 100 Min 300 Min 300 Min 300 Min 600
13
When there are obstacles behind and in front of the machine.
AIR
AB
mm mm
Min 300 Min 600
When there are obstacles behind, on one side and over the machine.
CDEF
mm mm mm mm
Min 100 Min 300 Min 300 Min 300
When there are obstacles behind and in front with several units.
AIR
AIR
AIR
GH I
mm mm mm
Min 250 Min 1000 Min 300
Installation, in addition to the indicated spaces, must enable access to the authorised personnel
for maintenance operations and must take into account the safety distances from any other equip-
ment installed near the machine.
It is prohibited to place the unit under a roof, canopy or any covering in general.
The heat pump units allow ice and condensation to form that pours on to the floor in front
of the unit. Collect and drain the condensation and defrost water to prevent the floor from
becoming slippery.
It is prohibited to place the unit inside basement windows.
AIR
14
3.3.1 Noise
During operation, the unit generates noise.
Avoid installation in reverberant environments.
Avoid placing the machine with the side of the coil in the direction where the noise level is
more critical.
STD
(ISO 3744)
Model
CP*A050LLW CP*A060LLW CP*A080LLW
Hz
dB(A) dB(A) dB(A)
63 61 69.5 59.5
125 56.5 65 57
250 47.5 53.5 56
500 48 54.5 53.5
1000 46 52 51.5
2000 39.5 45 45
4000 37 40 45
8000 38 34.5 36
To t.
63 69 69
dB(A)
The sound level values, intended as sound power, in accordance with ISO 3744, in dB(A), have
been measured in free field conditions at 1 m distance from the unit with water temperature of
35°C.
3.3.2 Windy areas (Resting on the ground)
The wind can affect the operating conditions. Minimise the effects by:
Placing the unit with the long side parallel to the direction of the main winds.
Avoid placing it with the coil perpendicular to the direction of the main wind.
3.3.3 Resting on the ground
D Rigid rubber band
H Slab of 10-15 cm
Place the unit on a perfectly level support surface.
Interpose a hard rubber band between the base of the machine and the support surface.
Verify that the support surface withstands the weight of the unit.
Provide a support slab that is proportional with the unit if resting on unstable ground.
The slab must be horizontal and able to withstand approximately 200% of the operating
weight of the machine.
In case of need it is advisable the use of rubber shock absorbers.
Lay the machine on the ground with screws and plugs appropriate to the support/
basement type.
Provide the indicated space to ensure good airflow.
If possible, do not install the unit where it will be exposed to direct sunlight.(If necessary,
install a blind that does not interfere with the airflow.)
During heating operation, drain water flows from the outdoor unit. Therefore, install the out-
door unit in a place where the drain water flow will not be obstructed.
Do not install the unit where people pass.
Install the unit in a place where it will be free from being dirty or getting wet by rain as much
as possible.
15
4. Water
connections
Preliminary precautions
Selection and installation of the system components are assigned to the installer who must
operate according to the regulations of good technical practice and governing law.
Make sure that the pipes do not contain stones, sand, rust, slag or other foreign objects that
could damage the system.
It is mandatory to install a suitable filter for the impurities in the unit inlet water.
It is mandatory to mount a flow switch for fluids which shall be dimensioned and adjusted
according to plant features.
It is mandatory to install air vent valves at the highest points of the pipes.
The water content of the system must prevent imbalance in the operation of the refrigerant
circuits.
The installation of water disconnecting switches is advised to avoid vibration transmission
to the plant.
Check the pressure drops of the equipment, system and of any accessories mounted.
4.1 Connection diagram
4.2 Position of connections
4.3 Hydraulic data
4.4 Connection to the system
4.5 System fill-up
4.6 Piping insulation
4.7 Protrusion length of outdoor temp thermistor
4.1 Connection diagram
1 UNIT
ANT Anti-vibration joint (recommended)
FTR Mesh filter (mandatory)
RI Shut-off ball valve
RIC Automatic water filling valve
SFA Automatic air vent
4.3 Hydraulic data
4.3.1 Water volume
Machine electronic control, to protect the electrical motor, limits hourly start up of the
compressor.
This operation creates oscillations of the water temperature in the draw-off point, affecting plant
efficiency.
For a proper operation it is necessary the water content complies with the following table:
Water flow
Evaporator
Model
CP*050LLW CP*060LLW CP*080LLW
Pmin l/s 0.19 0.22 0.30
Pmax l/s 0.37 0.44 0.60
V L 15 18 25
Pmin = Evaporator minimum capacity
Pmax = Evaporator maximum capacity
V = Water volume (l)
If the water volume in the circuit (V) does not reach what is indicated, installing a new inertial
storage tanks shall be required.
The machine is equipped with expansion vessel which consents a plant maximum water content
as shown below.
Plant pre-load 1bar
Water volume
max plant
Model
CP*050LLW CP*060LLW CP*080LLW
L 128 128 128
In the event that the plant water content is higher, it is necessary to include an additional external
expansion vessel as a supplement.
Some of the components in the diagram may already be included in the unit with the
hydronic kit. Those not present must be provided by the installer.
Connection pipes must have a suitable diameter and be supported so as not to impose
their weight on the unit.
4.2 Position of connections
The position of the water connections and the inlet and outlet direction is indicated by the labels
on the connections.
OUT
Unit
IN
16
4.3.2 Protection against freezing
If you do not wish to drain the system during periods when the machine is not used, the water
may freeze, or if the system must operate with temperatures less than 5°C, ethylene glycol must
be mixed with the water.
Adding glycol changes the physical characteristics of the water and the performance of the ma-
chine.
The table indicates the multiplicative factors to calculate the performance change based on the
percentage of glycol used.
% G 0 10 20 30 40 50
Tc 0 -4.5 -9.5 -15.5 -21.5 -32.5
CQ 1 0.975 0.953 0.931 0.914 0.882
CP 1 1.01 0.995 0.99 0.985 0.975
CG 1 1.01 1.04 1.08 1.14 1.20
CP 1 1.05 1.13 1.21 1.26 1.32
% G = Glycol percentage
Tc = Water freezing temperature (°C)
CQ = Cooling capacity correction factor
CP = Electrical power absorbed correction factor
CG = Correction factor of mixing flow
Cp = Pressure drops correction factor
4.4 Connection to the system
Position of hydraulic fittings
IN OUT
CP*A050-60LLW / CP*A080LLW
In these models the connections are placed outside the unit and on the rear side.
Remove the protection caps from the connections.
Connect the pipes to the connections.
Tightening torque
15 to 30 Nm (150 to 350 kgfcm)
A safety valve on the water circuit provided as standard will permit, in case of
plant serious abnormalities (i.e. fire), to discharge the system avoiding possible
explosions.
During the hydraulic connection operations, never operate with free
flames near or inside the unit.
Provide shut-off valves and anti-vibration joints on the connection pipes.
Make sure to provide a proper drain for the pressure relief valve to avoid any water coming into
contact with electrical parts.
Air vents must be provided at all high points of the system. The vents should be located at
points which are easily accessible for servicing. An automatic air purge is provided inside the
unit. Check that this air purge valve is not tightened too much so that automatic release of air
in the water circuit remains possible .
Take care that the components installed in the field piping can withstand the water pressure.
For threaded connections:
Fasten by holding a part in order to tighten the other part.
To guarantee the seal is recommended to use suitable seals (fibre seals, o-rings), teflon tape or
hemp, and sealing paste.
4.5 System fill-up
Before performing any operation, make sure the main switch is off.
Make sure that the drain valves are closed and the air vent valves are
open.
Open the shut-off valves of the water system.
• Start filling.
When starts the water outflow from the air vents, close the latter and pressure water to a
plant estimated value (max. 1 - 1,5 bar). Keep in mind that the calibration of the safety
valves is 3 bar.
When the water pressure is stable (read the manometer installed on the machine side), close
the load valve and verify the tightness of all joints.
It is advisable to periodically check the pressure in the water circuits to prevent
malfunctions.
The water circuits must always be topped-up with the pumps off.
4.6 Piping insulation
The complete water circuit, inclusive all piping, must be insulated to prevent condensation during
cooling operation and reduction of the cooling and heating capacity.
If the temperature is higher than 30°C and the humidity is higher than RH 80%,then the thickness
of the sealing materials should be at least 20 mm in order to avoid condensation on the surface of
the sealing.
Be sure to insulate the pipes in order to prevent the water being frozen.
4.7 Protrusion length of outdoor temp thermistor
Confirm that the protrusion length of outdoor temp thermistor is 15mm.
If it is not 15mm, adjust the length to 15mm.
The illustration below is an image of CP*A050-060LLW.
Outdoor temp thermistor
15 mm
17
5. Electrical
connections
Preliminary precautions
Make sure that the characteristics of the mains are adequate for the consumption indicated
on the electrical board plate and the wiring diagram, considering also any other units in
parallel operation.
Make sure that the power supply voltage corresponds to the nominal value +/- 5% with a
maximum imbalance between the phases of 2%.
Use cables with double insulation for the electrical connections.
The use of an omnipolar general-purpose circuit breaker adequately sized to protect the
power supply line is mandatory.
It is mandatory to set up an effective earthing.
It is prohibited to use gas and water pipes to earth the unit.
The manufacturer is not liable for any damage caused if the earthing is missing or failure to
comply with that indicated in the wiring diagrams.
5.1 Machine connection
5.2 Connections of the accessories
5.3 Wiring method
5.4 Electrical data
5.5 External input and output
5.1 Machine connection
E Electrical wiring inlet
5.2 Connections of the accessories
5.2.1 External consents
If you wish to enable or disable the unit remotely, connect the external consent to the contacts
listed in the wiring diagram.
Avoid placing the control cables in the same duct as the power cables. Always use a
suitable shielded cable.
The connection cables must have a minimum cross section of 1.5 mm².
5.2.2 Noise Filter connection.
In CP*A060LLW and CP*A080LLW the noise filter shall be mounted (supplied with the machine).
The filter shall be installed near electrical power connections inside the electrical panel.
For the power supply connection, follow the attached wiring diagrams.
CP*A050-060-080LLW
The equipment is equipped with holes with cable glands for the power wiring inlet.
The equipment incorporates earth connections with a sole functional purpose.
Insert the cables from the outside, guiding them towards the electrical board.
Avoid direct contact with non-insulated copper pipes and with the compressor.
It is forbidden to enter the device with electrical cables in positions not specifically required
in this booklet.
Before inserting the power supply cable to the outlet, be sure to check a proper voltage.
Be sure to use an exclusive power source with a circuit breaker.
Install the outlet within the length of power supply cord.
Do not use power supply cord extended or connected halfway.
To set up the electrical connections:
Place the main switch upstream the unit (electrical plant) on 0 (off).
Open the electrical board.
Make the connections as shown in the wiring diagram.
Use the hole for the main power cable and the hole for the cables of other external
connections.
Hold power wirings and external connection with cable ties present along the wiring path.
After completing the electrical connections lock the cables with the cable glands and close the
doors of the electrical board.
Before connecting the remote ON-OFF switch, remove the jumper from
the relative clamps.
18
5.3 Wiring method
CP*A050-060LLW
L
N
E
L
N
E
Cable clamp
Power supply
cable
Q
Cable preparation
(Unit : mm)
Power supply cable
EMI core
* for only
CP*A060LLW
Power supply
terminal
Cable clamp
120 60 10
CP*A080LLW
E
N
L
L
1050
90
N
E
(Unit : mm)
Power supply
terminal
Power supply
cable
Cable clamp
Q
Cable preparation
Power supply cable
EMI core
side view
front view
*Processing of Rubber cap for all model
When passing the power cable, make cut of 10mm horizontally and vertically in the centre of the
rubber cap.
The illustlation below is an image of CP*A080LLW.
When passing the power cable, make a cut of 10mm
horizontally and vertically in the centre of the rubber cap.
Additional cable clamp (bottom)
Top view
5.4 Electrical data
Model CP*A050LLW CP*A060LLW CP*A080LLW
Power voltage V 220-240
Power supply
Voltage V 230
Frequency Hz 50
Maximum current
Heating A 14 19 20
Main fuse ( )
Current
A202525
Blocked rotor current Heating/cooling A Not applicable (lower than operating current)
Electrical connections Power wirings mm2 3,5-4,0
Electrical wirings
Power supply 3
Wiring type H05RN-F
5.5 External input and output
Using the external input and output allows you to use the functions listed in the following table.
1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Terminal number Input or Output Function
1,2 Input Capacity requirement
3,4 Input Offset of the set temperature
5,6 Output Auxiliary heater ON/OFF
7,8 Output Error occurrence output on IF side
9,10 Output DHW 3-way valve ON/OFF
11,12 Input External thermostat ON/OFF
13,14 Input DHW ON/OFF
15,16 Input External cooling/heating instruction
External input and output terminal
19
6. Commissioning
6.1 Preliminary inspections
6.2 First start-up or restart after long inactivity
6.3 Shut-down
6.4 Flow rate calibration
6.5 Flow rate balance
Preliminary precautions
6.1 Preliminary inspections
6.1.1 Electrical
Verify the voltage on L1, L2 or L1, L2, L3 terminals is that indicated on the unit plate
(tolerance allowed) ±5% verifiable with a tester. If voltage changes occur frequently, please
contact our technical department to choose suitable protections.
Check the connecting cables connected securely.
Check pipe connection sections thermally insulated.
Check the earthing lines connected securely.
6.1.2 Hydraulic
Make sure that the water circuit has been previously cleaned: it is recommended to wash
the water circuit via by-passing the unit and then check the cleanliness of the system filter.
The machines are shipped with open vents and drains, which must be closed during
installation when filling the water circuit. Labels indicate their positions.
Make sure that the hydraulic system has been bled, thereby eliminating any residual air. The
operation must be performed by loading gradually and opening the venting devices set up by
the installer in the upper part of the system.
If you are using glycol water you can move the antifreeze set-point. The value must be equal to
the value of the freezing temperature of the fluid plus 6K.
Check no hot water socket above the regular socket.
Check the equipment and main pipe connection sections free of circulating water leaks.
6.1.3 Cooling
Check that there is no refrigerant leak, possibly using a leak detector.
6.2 First start-up or restart after long inactivity
6.2.1 Start-up
Activate the machine according to that described in the relative command section.
6.2.1.1 Checks during operation
Check that the machine does not generate abnormal noise or excessive vibrations.
Verify that the machine operates within the optimum working range.
A few minutes after the compressors are started, during the summer mode cycle, make sure
that the condensing temperature is 18±4K higher than the air temperature entering the
condenser and that the average evaporating temperature is approximately 5K lower than the
water temperature leaving the utility exchanger.
Verify that the overheating temperature of the refrigerant is between 5 and 7K. To verify:
Measure the temperature with a contact thermometer placed on the intake pipe of the
condenser.
Verify that the subcooling temperature of the refrigerant is between 4 and 8K. To verify:
Measure the temperature with a contact thermometer placed on the outlet pipe from the
condenser.
The initial start up of the chiller must be carried out by the Technical Support.
Make sure that all safety conditions have been complied with.
Make sure that the unit has been adequately fixed to the support surface.
Make sure that you have complied with the clearance area.
Make sure that the water connections have been implemented according to the instruction
manual.
Make sure that the hydraulic system is filled and vented.
Make sure that the shut-off valves of the water circuit are open.
Make sure that the electrical connections have been implemented correctly and that all
terminals are tightened.
Make sure that the earthing has been implemented correctly.
Make sure that the all the electrical connections have been tightened correctly.
6.3 Shut-down
6.3.1 Temporary shut-down
Disable the machine according to that described in the relative command section.
Avoid to remove voltage using the switch on board or the main switch of the plant.
Voltage loss do not allow the antifreeze heater operation with the consequent risk of
freezing.
The antifreeze protection function is only active if the unit is in “STAND-BY” mode. In case of
operation, the unit controls pump start-up.
To safeguard the system and the units, we recommend installing an electrical heater on the
connection pipes, or to fully empty the system.
6.3.2 shutting down for long periods;
Not using the unit for a long period of time requires the following operations to be performed:
Disable the unit in any mode of operation it may be, from the control panel.
Set the remote switch to “OFF” (if present) after having turned off the unit.
Disable the internal terminal units by setting the switch of each unit to off.
Set the main switch of the system to ‘’off.
Close the water valves.
If, during the period of inactivity the temperature drops below zero, the system must be
fully empties or topped up with antifreeze liquid.
6.4 Flow rate calibration
Once the pump has started, verify that the fluid flow rate of the utilities is within the expected
values for the unit.
To verify:
Verify the temperature difference between fluid utilities inlet and outlet when the unit works at
full capacity.
The difference in water temperature between input and output must be between 4° and 6°C:
If lower than 4°C, the water flow is too high: slightly close the shut-off valve placed on the
pump delivery, plant side, coming out of the machine.
If higher than 8°C, verify the pressure drops on water circuit.
6.5 Flow rate balance
When there are multiple units in parallel, the ΔT of the water produced by the machines turned on
must be checked.
It may occur that the units closer to the pump produce a ΔT<5°C (high flow rate), while the units
farther away may produce a ΔT>5°C (flow rate lower than nominal values).
To correct the potential flow rate offset, the shut off valves on the inlet and outlet of each machine
must be operated on.
Slightly close the valve on the units with high flow rate and make sure the shut off valves on the
units with lower flor rate are fully open.
20
7. Control Panel
7.1 User interface
7.2 Alarms
7.3 Remote control panel
7.4 AVP controller
7.1 User interface
7.1.1 Control panel
The control panel enables all machine functions to be performed, to display its operation and any
alarms which may trigger.
7.1.1 Display
From the display of the control panel it is possible to see the sizes of the values set and machine
operation may be displayed through the LEDs.
Values
A space of four digits can be seen on the display, from which you may read the numerical values
and letters corresponding to the entries of the menu and to the alarms triggered.
Alarm LED
The ALARM LED indicates that an alarm has triggered.
On: triggered alarm.
Flashing: resettable alarm.
Heating LED
The HEATING LED indicates that the unit is operating in Heat Pump mode.
On: heat pump operation.
Flashing: remote heat pump operation.
Cooling LED
The COOLING LED indicates that the unit is operating in cooling only mode.
On: cooling only operation.
Flashing: remote cooling mode only.
Stand-by LED
The STAND-BY LED indicates that the unit is in Stand-By mode.
On: the unit is in Stand-By.
Flashing: the unit has been remotely placed in Stand-By.
Defrosting LED
DEFROSTING LED indicates that the unit operates in defrosting mode.
Economy LED
The ECONOMY LED means that the economy function is on.
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Fujitsu CPYA080LLW Installation guide

Category
Split-system air conditioners
Type
Installation guide
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