ICS iC 410 User Manual

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

ICS iC 410 Specifications

General

Brand	ICS
Model	iC 410
Category	Chiller
Language	English

Summary

User Quick Guide Overview

Unit Start and Stop Procedures

Procedure for switching the unit on and off locally via keypad or remotely via digital input.

Setpoint Display and Adjustment

Alarm Display and Reset Functionality

Procedure to view, reset, and manage active alarms on the unit's control panel.

Safety Guidelines and Precautions

General Safety Precautions

Essential safety rules and precautions for handling, operating, and maintaining the unit.

Lifting and Transport Safety Guidelines

Guidelines and precautions for safely lifting and transporting the unit, including weight specifications.

Installation Safety Precautions

Essential precautions to be taken before and during the unit's installation process.

Operation Safety Precautions

Safety measures to follow during the unit's operation, including electrical safety and personnel competence.

Maintenance Safety Guidelines

Safety guidelines for performing maintenance, including environmental protection and part replacement.

Refrigerant Gas Handling Safety

Information on refrigerant handling, compatibility, and safety data sheet for R410A.

Refrigerant Safety Datasheet Details

Detailed information on refrigerant hazards, first aid, fire-fighting, accidental leakage, handling, and PPE.

Installation Procedures and Requirements

Initial Unit Inspection Procedure

Installation Location Requirements

Guidelines for selecting an appropriate installation location, considering ventilation, environment, and space.

Freeze Protection Measures and Settings

Recommendations for adding antifreeze to water and details on anti-freeze settings and heaters.

Unit Operating Limits Specification

Hydraulic Connection Guidelines

Instructions for making hydraulic connections, including valve installation and filling procedures.

Electrical Connection Procedures and Safety

Guidelines for connecting the unit to the power supply, compliance with laws, and cable specifications.

Phase Monitor Functionality and Alarms

Unit Starting Procedures

Unit Starting Procedures

Step-by-step instructions for safely starting the unit and verifying correct operation.

Electronic Controller Functions

Controller User Interface Overview

Description of the controller's display, icons, and status indicators for operation modes and alarms.

Controller Keypad Button Functions

Explanation of the functions performed by each button on the electronic controller's keypad.

Controller Unit Start/Stop Procedures

Detailed procedures for starting and stopping the unit via the keypad or a digital input.

Controller Setpoint Display and Adjustment

Controller Functions Menu Navigation

Alarm Management System

Overview of the electronic controller's alarm management features, including display and reset.

Alarm Display and Reset Procedure (ALrM)

Detailed steps to display, reset, and manage alarms using the ALrM function.

General Alarm Code List and Descriptions

A comprehensive list of alarm codes, their descriptions, and affected outputs.

Alarm Indication Label Meanings

High Pressure Switch Alarm Details

HP Switch and Compressor Thermal Alarms

Low Pressure Switch Alarm Details

Anti-freeze Alarm Behavior

Water Differential Pressure Switch Alarm

Information on water differential pressure switch alarms, their cause, reset, and activation logic.

Compressor Thermal Alarm Handling

Phase Monitor Alarm Details

Alarms Log Display and Deletion (ALOG)

Keypad Parameter Programming Overview

Overview of parameter levels (User, Service, Manufacturer) and access procedures.

Accessing Parameter Menu Levels

Step-by-step guide to enter the parameter menu and navigate through parameter families.

Changing Parameter Values

Instructions on how to modify parameter values and store them using the keypad.

Unit Adjustment and Control Features

Compressor Control Logic

Description of how the controller manages compressor start/stop and minimum run times.

Compressor Control Type Selection

Anti-freeze Heater Functionality Details

Fan Control Methods Overview

Parameter Descriptions and Settings Overview

Comprehensive list and description of all programmable parameters and their access levels.

Parameter Details: Thermoregulation, Display, Remote Terminal

Detailed descriptions of parameters related to thermoregulation, display, and remote terminal configuration.

Parameter Details: Compressors, Fans, Anti-freeze

Details of parameters for compressor plant, condensing fans, and anti-freeze/water heater functions.

Parameter Details: Alarms, Heat Recovery, Hot Water

Parameter descriptions covering alarms, hybrid exchangers, heat recovery, and domestic hot water settings.

Parameter Settings by Unit Model

Tables showing parameter settings and availability based on unit model, freeze protection, and fan control.

Other Unit Components

Compressor Motor Protection System

Refrigerant High and Low Pressure Switches

Information on low and high pressure switches, their function, and trip/reset values.

Water Level Sensor Operation and Safety

Operation and Maintenance Procedures

Unit Normal Operation

Maintenance Overview and Safety Reference

Process Water Circuit Draining Procedure

Recommended Maintenance Schedule

Schedule of routine operations to check and maintain the unit's performance and safety.

Troubleshooting Common Issues

Troubleshooting: High Water Outlet Temperature

Troubleshooting steps for high water outlet temperature, including thermal load and ambient conditions.

Troubleshooting: Low Pump Outlet Pressure

Troubleshooting for low pump outlet pressure, including flow rate, thermal trip, and evaporator clogging.

Troubleshooting: Water Differential Pressure/Level Sensor Alarms

Steps to resolve alarms related to water differential pressure or level sensors, including filter and pump issues.

Troubleshooting: High Pressure Switch Alarms (iC 215-540)

Troubleshooting for high pressure switch trips, covering fan issues, ambient temp, and condenser blockage.

Troubleshooting: High Pressure/Compressor Trip Alarms (iC 640-780)

Troubleshooting for high pressure and compressor protection trips in specific models, including thermal load and refrigerant charge.

Troubleshooting: Low Pressure Switch Trip Issues

Troubleshooting steps for low pressure switch trips, including refrigerant charge and compressor rotation.

Troubleshooting: Compressor Protection Trip Alarms (iC 215-540)

Troubleshooting for compressor protection trips, including thermal load, refrigerant charge, and rotation errors.

Troubleshooting: Blank Display and No LEDs

Steps to diagnose and resolve issues where the display is blank and no LEDs are lit.

Troubleshooting: Probe Failure Alarms (AP1-AP6)

Troubleshooting: Low Water Outlet Temperature Alarms (b(n)Ac)

Troubleshooting: Pump Thermal Cutout Alarms (AtE1/AtE2)

Steps to address pump thermal cutout alarms, including grille obstruction and pump malfunction.

Troubleshooting: Configuration Error Alarms (ACFx)

Troubleshooting: EEprom Data Saving Alarms (AEE)

Risk Analysis and Safety Measures

Mechanical Hazards: Crushing and Cutting Risks

Fluid Ejection Hazards Analysis

Assessment of risks from high-pressure fluid ejection due to pipeline or tank bursting or overpressure.

Electrical Hazards and Safety Precautions

Identification of electrical hazards, including direct/indirect contact and electrostatic discharge.

Thermal, Noise, and Heat-Associated Hazards

Material Hazards and Personal Protective Equipment (PPE)

Inadvertent Start-up and Electrical Factor Hazards

Risks from inadvertent start-up, overtravel, and electrical factors like errors, power restoration, and EMC.

Stability, Falling Objects, and Connection Hazards

Absence of Safety Measures and Documentation Hazards

Safety Disconnection and Adjustment Instrument Hazards