ICS iC 215 User Manual

WATER CHILLERS
OPERATING AND MAINTENANCE MANUAL
iC 215 ÷ iC 780
38178800943
Original instructions in Italian language

ICS iC 215 Specifications

General

Brand	ICS
Model	iC 215
Category	Chiller
Language	English

Summary

USER'S QUICK GUIDE

Unit start/stop

Unit can be switched on/off via keypad or digital input.

Start from the keypad

Procedure for starting/stopping the unit using the keypad.

Start-up from a digital input

Procedure for starting/stopping the unit via digital input.

Setpoint

How to display and change the unit's setpoint.

Alarms display and reset

Procedure for displaying and resetting unit alarms.

CHAPTER 1 GENERAL INFORMATION

Symbols and Decals

Explains the meaning of symbols used on unit decals and diagrams.

Manual Purpose and Scope

Defines the manual's audience and intent for installation and maintenance.

CHAPTER 2 SAFETY

General Safety Precautions

General warnings and precautions for safe operation and maintenance.

User Circuit Liquids Compatibility

Information on compatibility of user circuit liquids with unit materials.

Lifting and Transport Precautions

Guidelines for safe lifting and transport of the unit.

Precautions During Operation

Safety measures to be followed during unit operation.

Maintenance Precautions

Safety measures to be followed during maintenance activities.

Refrigerant Gases

Information on the refrigerant used (R410A) and handling safety.

CHAPTER 3 TECHNICAL DATA

Data Plate Information

Lists technical data found on the unit's data plate.

Declaration of Conformity

CE declaration of conformity documents.

Unit Dimensions

Table detailing unit dimensions for various models.

Pump and Fan Characteristics

Technical specifications for pumps and fans across different models.

Sound Level Measurements

Data on sound pressure and power levels for various models.

CHAPTER 4 DESCRIPTION

Components Overview

Lists the main components of the units.

Refrigerant Circuit Details

Describes the refrigerant circuit, its components, and refrigerant type.

Compressors

Describes the SCROLL type compressors and their features.

Condenser

Describes the construction of the condenser coils.

Evaporator

Describes the evaporator type and protection features.

Tank

Describes the storage tank and its protection features.

Pump

Describes the centrifugal pumps used and their types.

Fans

Details the axial flow fans, their protection rating, and control types.

Cabinet Construction

Describes the cabinet materials and construction.

Materials in contact with the liquid

Lists materials used in contact with the cooling liquid.

Electrical Circuit Information

Refers to electrical hook-ups and diagrams.

CHAPTER 5 INSTALLATION

General Installation Precautions

Safety requirements before installation and general installation guidelines.

Unit Inspection

Procedure for checking the unit for damage after unpacking.

Location requirements

Guidelines for selecting a suitable installation location.

Freeze Protection

Methods and recommendations for protecting the unit from freezing.

Operating Limits

Specifies the operating limits for ambient and water temperatures.

Hydraulic Connections

Instructions for connecting the unit's hydraulic system.

Expansion Vessel

Information on the installation and calculation of the expansion vessel.

Electrical Connections

Guidelines and precautions for connecting the unit's electrical supply.

Phase Monitor

Function of the phase monitor for power supply supervision.

CHAPTER 6 STARTING

Pre-Start Safety Checks

Essential checks before starting the unit.

Starting Procedure

Step-by-step instructions for starting the unit.

CHAPTER 7 ELECTRONIC CONTROLLER

User Interface Description

Explanation of the controller's display and icons.

Button Functions

Description of the functions of the controller's buttons.

Remote Terminal Connection

Information on connecting and using remote terminals.

Probe Identification

Details on various probes used by the controller.

Unit Start/Stop Control

How the electronic controller manages unit start and stop.

Setpoint Adjustment

Procedures for displaying and changing the setpoint.

Dynamic Setpoint Function

Explanation of the dynamic setpoint adjustment based on ambient temperature.

Accessing Circuit Values

How to view internal circuit values.

Functions Menu Overview

List of available functions in the controller's menu.

Circuit Enable/Disable

Function to enable or disable individual refrigerant circuits.

Compressor Enable/Disable

Function to enable or disable individual compressors.

Compressor Start Count

Displaying and resetting compressor start counts.

Compressor Running Hours

Displaying and resetting compressor running hours.

Condensing Steps Display

Viewing percentage of condensing fan output.

Tank Heater Probe Display

Displaying values from tank heater probes.

Alarm Management

How to display and reset alarms.

Buzzer Muting

How to mute the audible alarm buzzer.

General Alarms List

Comprehensive list of alarms, codes, and their impact.

Probe Fault Indication

How probe faults are displayed and indicated.

High Pressure Switch Alarm

Details on the high pressure switch alarm.

Low Pressure Switch Alarm

Details on the low pressure switch alarm.

High Pressure Indication

Details on high pressure indications.

Low Pressure Indication

Details on low pressure indications.

Anti-freeze Alarm

Details on the anti-freeze alarm.

Chiller Mode Anti-freeze Alarm

Specifics of the anti-freeze alarm in chiller mode.

Water Differential Pressure Switch Alarm

Details on the water differential pressure switch alarm.

Compressors Thermal Alarm

Details on compressor thermal alarms.

Fan Thermal Alarm

Details on fan thermal alarms.

High Condensing Pressure Unloading

Indication of unloading due to high condensing pressure.

High Condensing Pressure Recovery Disabling

Indication of recovery disabling due to high condensing pressure.

Evaporator Inlet High Water Temperature

Unloading indication due to high evaporator inlet water temperature.

Evaporator Water Pump Thermal Alarm

Details on evaporator water pump thermal alarms.

Phase Monitor Alarm

Details on the phase monitor alarm.

Compressors Maintenance Alarm

Details on compressor maintenance alarms.

Pumps Maintenance Alarm

Details on pump maintenance alarms.

EEprom Alarm

Details on EEprom alarm.

Remote Terminal Alarm

Details on remote terminal communication alarms.

Alarm Relay/Buzzer Notes

Explains the logic for alarm relay and buzzer activation.

Alarms Log Display and Deletion

How to display and clear the alarms log.

Parameter Access

How to access user-level parameters.

Changing Parameter Values

Procedure for modifying parameter values.

Hot-Key Programming

Using the hot-key to program the unit.

Unit Adjustment and Control

Overview of unit adjustment and control features.

Compressor Control Methods

Describes methods for compressor control and rotation.

Proportional Control

Explanation of proportional compressor control logic.

Neutral Zone Control

Explanation of neutral zone control for compressors.

Compressor Rotation Logic

Options for managing compressor rotation based on hours or starts.

Forced Compressor Rotation

Facility for forced compressor rotation at partial loads.

Compressors Starting Time Limitation

Limits on compressor starting time to prevent rapid cycling.

Unloading Function

Function to reduce cooling capacity by stopping compressors.

Anti-freeze Heaters

Optional anti-freeze heaters for evaporator and pump protection.

Fan Control Methods

Ways fans can be controlled (ON/OFF, steps, speed).

STEP Fan Control Diagrams

Diagrams illustrating STEP control logic for fans.

Fan Speed Control Diagrams

Diagrams illustrating fan speed control logic.

Hydraulic Unit Configurations

Possible configurations for the circulator pump.

Anti-freeze Pump Management

How pumps are managed in anti-freeze mode.

ModBus Communication

Characteristics of the ModBus communication mode.

Automatic Restart

Behavior of the unit after a power loss.

Parameter Description and Settings

Overview of programmable parameters and their access levels.

CHAPTER 8 OTHER COMPONENTS

Compressor Motor Protection

Internal motor protection system using a power circuit breaker.

Refrigerant High and Low Pressure Switches

Details on LP and HP pressure switches and their functions.

Fan Pressure Switches

Information on pressure switches for fan control in ON/OFF mode.

Electronic Thermostatic Valve

Function and control of the optional electronic thermostatic valve.

Pressure Transducers

Role of pressure transducers in monitoring and control.

Level Sensor Functionality

Description of the level sensor and its alarm function.

CHAPTER 9 OPERATION AND MAINTENANCE

Unit Operation

Description of the unit's automatic operation.

Maintenance Precautions

Safety measures before performing maintenance tasks.

Accessing Unit Components

Instructions on how to open panels to access unit components.

Draining Process Water Circuit

Procedure for draining the water circuit to prevent freezing.

Maintenance Schedule

Recommended maintenance tasks and their frequency.

CHAPTER 10 TROUBLESHOOTING

High Outlet Temperature Issues

Causes and remedies for high water outlet temperature.

Low Pressure Head Issues

Causes and remedies for insufficient pump outlet pressure.

Water Differential Pressure Switch Alarms

Causes and remedies for water differential pressure switch alarms.

High Pressure Switch Trips

Causes and remedies for HP switch trips.

Compressor Protection Trips

Causes and remedies for compressor protection trips.

Low Pressure Switch Trips

Causes and remedies for LP switch trips.

Compressor Protection Trips (iC 640-780)

Causes and remedies for compressor protection trips in specific models.

Pump Thermal Cutout Issues

Causes and remedies for pump thermal cutout.

Configuration Errors

Causes and remedies for unit configuration errors.

Processor Data Saving Issues

Causes and remedies for processor data saving errors.

Low Water Outlet Temperature

Causes and remedies for low water outlet temperature.

Water Flow Rate Too Low

Causes and remedies for low water flow rate.

CHAPTER 11 RISK ANALYSIS: RESIDUAL RISK

Crushing and Cutting Risks

Hazards related to crushing, cutting, and detachment of parts.

Fluid Ejection Risks

Hazards from high-pressure fluid ejection from pipelines.

Electrical Hazards (Direct/Indirect Contact)

Risks from direct/indirect contact with live electrical parts.

Electrical Hazards (Heat/Environment/Stress)

Electrical risks from heat, environment, and component stress.

Noise Level Hazards

Risks from noise levels impacting hearing and physical well-being.

Material Handling Hazards

Risks associated with handling materials and substances, including refrigerant gas.

Ergonomics and Usability Hazards

Hazards from poor ergonomics in design or manual clarity.

Inadvertent Start-up/Overtravel Risks

Risks from unintended machine startup or excessive speed.

Electrical Hazards (Assembly/Environment/Control)

Electrical risks from assembly, environment, and control system faults.

Hazards from Absence of Safety Measures

Risks due to missing guards, instruments, or graphic signs.

Hazards from Absence of Power Disconnection

Risks from absence of power disconnection measures for safety.

Hazards from Incorrect Maintenance Procedures

Risks from incorrect procedures for adjustments and maintenance.