Climma CWS Guida all'installazione

Installation, usage and

maintenance manual

CLIMMA CWS

DC INVERTER

Rev. 190124

Veco S Installation Manual –Page 2 / 20

Table of Contents

1. Introduction ................................................................................................................................................................................................................... 3

1.1. General information ......................................................................................................................................................................................... 3

1.2. System features ................................................................................................................................................................................................. 3

1.3. Installation .......................................................................................................................................................................................................... 3

1.4. Transport and handling .................................................................................................................................................................................. 4

1.5. Unpacking ........................................................................................................................................................................................................... 4

1.6. Directives ............................................................................................................................................................................................................. 4

1.7. General safety .................................................................................................................................................................................................... 4

2. Installation ...................................................................................................................................................................................................................... 5

2.1. Climma DC chiller positioning ...................................................................................................................................................................... 5

2.2. Electronic control box and display .............................................................................................................................................................. 5

2.3. Flow switch installation .................................................................................................................................................................................. 5

2.4. Grounding ........................................................................................................................................................................................................... 5

2.5. Chiller condensate ............................................................................................................................................................................................ 6

2.6. Other system components: fancoils ........................................................................................................................................................... 6

2.7. Other system components: sea water circuit ........................................................................................................................................... 6

2.8. Other system components: fresh water circuit ....................................................................................................................................... 7

2.9. Electrical connections ...................................................................................................................................................................................... 8

2.10. Installation checks ............................................................................................................................................................................................ 8

3. Operating instructions ................................................................................................................................................................................................ 9

3.1. The electrical control box ............................................................................................................................................................................... 9

3.2. The display .......................................................................................................................................................................................................... 9

3.3. Modes of operation .......................................................................................................................................................................................... 9

3.4. Climma functions ............................................................................................................................................................................................ 10

3.5. Starting the unit .............................................................................................................................................................................................. 10

3.6. Shut off procedure ......................................................................................................................................................................................... 11

3.7. Option Menu .................................................................................................................................................................................................... 11

3.7.1. User Menu ................................................................................................................................................................................................... 12

3.7.2. Input/Output .............................................................................................................................................................................................. 13

3.7.3. Language & Infos....................................................................................................................................................................................... 14

3.8. Warnings and errors ....................................................................................................................................................................................... 14

3.9. Mechanical remote control (optional) ..................................................................................................................................................... 15

3.10. Secondary digital display (optional) ......................................................................................................................................................... 15

4. Maintenance and cleaning ...................................................................................................................................................................................... 16

4.1. Basic maintenance .......................................................................................................................................................................................... 16

4.2. Extended maintenance ................................................................................................................................................................................. 16

4.3. Winterization ............................................................................................................................................ Error! Bookmark not defined.

5. Warnings, alarms and troubleshooting ............................................................................................................................................................... 17

5.1. Warnings and alarms ..................................................................................................................................................................................... 17

5.2. Basic troubleshooting ................................................................................................................................................................................... 20

Veco S Installation Manual –Page 3 / 20

1. Introduction

1.1. General information

Thank you for purchasing a Climma CWS system!

This manual will provide necessary information for the proper installation, operation, and maintenance of

your Climma system.

Climma chiller and products are designed and produced to the highest standards and they are all tested

in the factory. If your Climma system is used according to the guidelines in this manual, it will guarantee

you trouble free operation for many years.

If you require assistance, please contact one of our many authorized service centers. To find the service

center please check our website www.veco.net or write us at customerser[email protected].

WARNING

This unit should only be used for the purposes for which it was designed. The manufacturer declines all

responsibility for any damage caused by incorrect or unreasonable use, such as:

 improper use by untrained persons;

 technical modifications or operations not suited to specific models;

 use of non-original or non-specific spare parts;

1.2. System features

Following the main features of the Climma DC chillers:

 Variable Output from a Single Air-conditioning Unit. Depending on the heat load requirements,

the compressor frequency varies controlling the output capacity, to produce faster cooling and

heating, significantly improving the comfort on-board.

 Water Cooled Inverter Compressor. Climma’s water cooled inverter protects the DC brushless

compressor from excessive temperature, current overload and irregular voltage supply, allowing it

to be installed in the engine room without additional ventilation. Added to this, the electronic

control provides continuous monitoring of the compressor curve to keep the unit within safe

operating limits, eliminating also stop-start cycles.

 Eco mode. This function has been specifically developed to optimize the power consumption of

the system in three principle ways: it enables the chiller to work more efficiently with a smaller

output generator than would ideally be required; in ECO mode the power consumption is further

reduced during night operation when only a courtesy/night generator is working running and less

power is needed; ECO mode allows the air-conditioning to run while on the dock with a limited

shore power supply.

 No Start Load. By using a DC compressor with inverter the Climma compressor starts at a low

frequency requiring a fraction of the power.

 Up to 50% energy saving

A Climma centralized air-conditioning system includes different products: the Climma DC chiller, fancoils

installed in each cabins, fresh water piping that connects the chiller to the fancoils, sea water piping

bringing sea water to the chiller condenser, the fresh and the sea water pumps.

While the Climma system is running in cool mode, the Climma DC chiller is cooling the fresh water that

circulates in the fresh water circuit to the fancoils; heat is removed from the cabins through fancoils,

blowing fresh air into the cabins.

While in heat mode (reverse cycle mode), the Climma DC chiller is heating the fancoil water circuit that

brings heated water to the fancoils, allowing them to blow heated air in the cabins.

1.3. Installation

Veco S Installation Manual –Page 4 / 20

The unit must be installed by an authorized Climma service center and in compliance with the instructions

given in this manual.

1.4. Transport and handling

When loading or unloading the unit, use a fork lift equipped with forks at least 2/3 the length of the

shipping base.

Use an overhead lift if the unit is equipped with lifting eye-bolts.

Select lifting equipment suited to the weight and overall dimensions of the packaged unit or components.

Take every precaution to prevent damage, when handling the unit or components keeping in compliance

with the information given on the packaging material.

1.5. Unpacking

Remove all cardboard, wood or other materials from the wood base. Lift the unit or components by suitable

means (e.g. lift truck), remove the wood base, then set the unit or components into position.

Once all packing material has been removed, check that the unit has not been damaged in any way.

Caution: Wear protective gloves when handling any packing materials and the wood base. Dispose of all

packaging materials appropriately in accordance to local codes.

1.6. Directives

Climma DC chillers respect the following directives.

 CE

 Low voltage: 2006/95/EC

 Electromagnetic Compatibility: 2004/108/EC

 Machinery Directive: 2006/42/CE

 Veco manufacturing Quality Standards UNI EN ISO 9001:2008

1.7. General safety

Injuries or accidents caused by failure to comply with the recommendations of this manual are solely the

responsibility of the unit operator.

Basic Rules for Safe Operation:

 do not touch the unit with moist or wet hands or feet;

 never operate the unit while barefoot;

 before installation and maintenance operations, disconnect the unit from the power supply. failure

to comply may result in injury or death;

 installation and maintenance of this system can be hazardous due to system working pressure and

electrical components. Only a Climma certified service center should install and maintain the

system;

 to minimize the hazard of electrical shock and personal injury, this component must be effectively

grounded;

 during installation and maintenance follow safety codes, wear safety glasses and work gloves;

Veco S Installation Manual –Page 5 / 20

2. Installation

WARNINGS

 Failure to follow all the instructions in this manual can cause property damage, injury or death.

 Improper installation, adjustment or alteration can cause property damage, injury or death.

 Electrical connections should be performed only by a certified professional.

 Electrical and grounding connections must comply with the National Electric Code and local

electric codes. Failure to comply with this procedure can cause property damage, injury or death.

 Before connecting the unit to the electrical supply, verify that the electrical connection agrees with

the specifications on the data plate, placed on the main electrical box of the unit. Failure to comply

with this procedure can cause property damage, injury or death.

 This appliance must be connected to a grounded, metal, permanent wiring system. Failure to

comply with this procedure can cause property damage, injury or death.

2.1. Climma DC chiller positioning

The Climma DC chiller must be installed in the engine room, technical space or similar area.

Normal engine room temperatures will not affect the Climma DC chiller, since the condenser and inverter

are water cooled. Climma DC chiller does not require additional ventilation during operation.

The unit must be accessible for service.

The unit must be secured on a surface using the mounting brackets below the drain pan.

WARNINGS

The Climma DC chiller is provided with an inverter mounted on the unit (VDF - Variable Frequency Drive).

The inverter is IP20, therefore the Climma DC chiller must be installed where it would not get wet.

2.2. Electronic control box and display

The electronic control box of the Climma DC chiller is already completely connected to the chiller.

The control box has to be installed close enough to the chiller, due to the connection to the unit, and to a

flat horizontal or vertical surface.

The control box has to be installed in a location free from water, water spray and moisture and it has to be

accessible for operation and maintenance.

The standard version has the display on the control box itself, but the display can be also remote.

If the display is remote, the distance between the control box and the display has to be:

 50 meters with standard cable

 500 meters with AWG22 twisted pair cable. Note: please contact Veco if you plan to install the

display at a distance exceeding 50mt.

2.3. Flow switch installation

Flow switch has to be connected to the electronic control box and it needs to be installed in the fancoil

water circulation system.

Please refer to instruction C897 for the correct installation.

WARNING: Failure to properly install the flow switch will void the warranty on the Climma DC chiller.

2.4. Grounding

The Climma DC chiller has to be properly grounded to prevent corrosion due to stray current.

WARNING: Failure to properly ground the Climma DC chiller will void warranty. 

Veco S Installation Manual –Page 6 / 20

2.5. Chiller condensate

Every Climma DC chiller has two drains for condensate water.

At least one drain has to be properly connected to ensure the correct condensate water drainage.

Plastic condensate drain nipples are provided in a separate plastic bag to help the installation.

2.6. Other system components: fancoils

Climma fancoils have to be installed in a technical space inside or close to the cabin they have to cool/heat.

Fancoils need to be properly secured on a leveled surface in order to operate correctly and remove the

condensation. Return air flow from the fancoil has to be ensured as well as the supply air flow from the

fancoil.

WARNING

No fancoil has to be installed close to engine room area and it must be ensured that no vapor or air from

the engine room can enter in the return air flow of the fancoil.

The positioning of the fancoil display is important. The temperature sensor is mounted on the display,

therefore the display has to be mounted on an inside wall, around the mid-height of the cabin where the

air can circulate so that it can sense the correct temperature.

If a correct positioning is not possible, a remote temperature sensor can be mounted; in this case, the

sensor must be placed behind the return air grill. In this case, the display temperature sensor will be

automatically excluded.

WARNING

Do not place the temperature sensor on the supply air flow or close to return/supply grills, under the

sunlight or close to heating devices.

Ducting of the return and supply air of the fancoil has to be done properly; ducts must be short and as

straight as possible, avoiding bends greater than 90° or loops.

Supply air ducting has to be at least 1.5 meter (5’) in order to reduce fan motor noise, but it should not

exceed 6 meters in order to reduce pressure drops.

Supply and return grills must be located not too close to each other, in order to avoid the supply air to

enter directly in the return air flow. Return grill should be placed below while supply grill should be placed

over the mid-height, as high as possible in the cabin.

WARNING

Failure to proper position the supply and return grills will cause no mixing between the cooler

temperatures and the warmer temperatures.

All Climma fancoils are provided with condensate drains to remove condensation produced by the fancoil;

condensation can reach 2 liters per hour, therefore condensate drains must be properly connected and

tested during installation. Drains should be as short and as downhill as possible, with no loops and bends.

To test it, pour some water in the fancoil pan and check that all water flows out of the pan through the

drains.

2.7. Other system components: sea water circuit

The Climma DC chillers have a water cooled condenser therefore they need to be connected to sea water

to operate correctly.

The sea water circuit includes: a sea water pump sized according to the chiller capacity, a sea water intake

and outlet and a sea water strainer.

The sea water in the circuit should not exceed 0.6 m3/h every 12.000 Btu/h (2,64 GPM or 10 lt/m per 1 TON)

of chiller capacity.

Veco S Installation Manual –Page 7 / 20

Chiller rated capacity is guaranteed at 20°C (68°F) sea water temperature; the system will work in cool mode

up to 40°C (104°F) and in cool mode with a sea water temperature up to 5°C (41°F).

The sea water circuit must always have an uphill incline from the sea water inlet to the chiller condenser to

prevent the system to run properly. All hoses should be installed as straight as possible with no loops and

bends.

All metal components of the sea water circuit must be properly grounded.

SEAWATERPUMP

The sea water pump has to be properly secured on a leveled surface in order to operate correctly; Use the

special fixing kit with anti-vibration supports.

The sea water pump has to be installed below the water line in order to operate correctly.

SEAWATERINTAKE

Sea water intake has to be installed as far below the water line to ensure always that no air enters the sea

water circuit.

SEAWATERSTRAINER

Sea water strainer has to be installed between the sea water intake and the sea water pump and it must be

accessible for cleaning operations. The strainer has to be cleaned periodically.

WARNING: Sea water strainer is mandatory in the seawater circuit. Failure to install the sea water strainer

will void the warranty.

SEAWATEROUTLET

The sea water outlet has to be installed above the sea water line, but as close as possible to it to reduce

noises.

2.8. Other system components: fresh water circuit

The fresh water circuit is a closed loop bringing water from the chiller to the fancoils and then back to the

chiller again. The circuit has the following components: a fresh water pump, flow switch, manifolds, hoses,

an expansion tank and an air-bleeder; everything is sized accordingly to the fancoils number, type and

overall capacity.

Water pressure in the circuit must be between 1 and 1.5 Bar (14.5 and 22 psig).

FRESHWATERPUMP(CIRCULATIONPUMP)

The fresh water pump must be installed near the Climma DC chiller. The pump has to be installed on the

return line of the fresh water circuit, pumping water directly in the chiller and then to the fancoils.

FLOWSWITCH

Flow meter has to be installed on the fresh water circuit and it has to be accessible for maintenance.

The flow meter switch is mandatory safety equipment that will stop the system whenever the fresh water

flow stops or if it is not enough.

The flow meter switch has to be connected to the main electrical box of the unit as specified in the electrical

schematic.

Make sure that the flow meter is correctly connected to the control box. To test it, simulate a low flow

situation pressing the lever inside the cover of the switch.

MANIFOLDS

Manifolds should be installed to be accessible for maintenance. If calibrating valves are installed, they have

to be completely opened.

HOSES

The water circuit must be as simple and straight as possible, avoiding bends, loops.

Veco S Installation Manual –Page 8 / 20

EXPANSIONTANK

The expansion tank allows the water in the system to expand as it gets hot when the chiller is in heat mode

and it also acts as a cushion. The expansion tank has to be installed in the fresh water pump inlet.

AIRBLEEDER

The automatic air bleeder must be installed on the pump outlet. This will prevent that any air in the circuit

reaches the fan coils and all the legs of the circuit.

ANTIFREEZESOLUTION

The fresh water circuit needs to be filled with water (80%) and antifreeze (20%). Antifreeze will prevent

water and pipes from freezing. Antifreeze also reduces the corrosion inside the fresh water circuit.

Always check that the pressure gauge shows 1.5 Bar in the fresh water circuit.

We suggest two methods for filling the fresh water circuit with antifreeze:

 Calculate approximately the circuit capacity; Fill the circuit with water and add to it 20% of

antifreeze, using the second charging valve by gravity or using a pressure pump. Then connect the

circuit to the sanitary water circuit of the vessel, pressurize up to 1.5 Bar and start purging the air.

It is obvious that if purging will be difficult the percentage of antifreeze will decrease, as more water

will be needed to fill the circuit, therefore more antifreeze must be added to the circuit.

 Empty the circuit from the water used for leak test. Prepare an antifreeze solution of the quantity

needed to fill the circuit, made with 20% of antifreeze liquid; fill the circuit using a pressure pump.

Then proceed with purging air and topping up the pressure using the solution.

2.9. Electrical connections

The unit must be installed on a dedicated circuit with a rated thermal-magnetic circuit breaker. The circuit

breaker and electric cables (power supply) must be rated for the unit and comply with all local and national

codes.

The manufacturer will not be held responsible for damage or injuries due to improper installation.

Incorrect installation will void the Manufacturer’s warranty.

The electrical control box is already connected by Veco; to install the electrical box:

 Connect the power supply to the electrical box

 Connect the sea water pump to the electrical box

 Connect the circulation (fresh) water pump to the electrical box

Please refer to the Electrical schematics in this manual.

2.10. Installation checks

The following checks MUST be made during the initial field start-up:

 Check all wire connections.

 Check electrical input.

 Check the standard pressure in the refrigerant system.

 Check the expansion valve during operation.

Note: If the unit and/or remote condensing unit were not transported in an upright position, or has been

overturned during the installation process, allow them to stand, in an upright position, at least 4 hours

before starting the unit.

Veco S Installation Manual –Page 9 / 20

3. Operating instructions

The unit can be controlled by the main display on the electrical control box, by the remote mechanical

panel or remotely via Modbus protocol. In this chapter only the main electrical box control and remote

mechanical panel are shown.

3.1. The electrical control box

The electrical control box of the chiller Climma DC can be external, as in the DC35, DC50 and DC65, or

internal, as in the DC130.

Exampleofexternalelectricalbox.



The digital display can be mounted on the electrical box, on the unit iself, but it can also be remote.

The electrical box, or the unit in case of internal electrical box, has to be connected during the installation

to the main power supply, to the sea water pump and to the circulation pump.

The electrical box is already connected to: the inverter, the RC valve and water valve on the chiller, to the

electronic expansion valve, to the flow meter and to all the pressure and temperature sensors required by

the unit.

3.2. The display

The display has 6 buttons:

 WARNING: this will allow to access in the Warning/Error screens

 PROGRAM: this button allows to enter in the programming mode

 ESC: this button allows to exit from the current screen and go back to the previous level

 ENTER: when the cursor is on a value, the button allows to confirm the value

 UP/DOWN: these buttons allows to move between values or screens

3.3. Modes of operation

Veco S Installation Manual –Page 10 / 20

The unit has 2 possible modes:

 SUMMER: When the unit is in SUMMER mode, the system will run in cool mode as chiller, cooling

the water until a specified set-point temperature value is reached.

 WINTER: When the unit is in HEAT mode, the system will run as heat pump, heating the water until

a specified set-point temperature value is reached.

When the system is powered up it will recall the previous mode of operation.

When the system starts for the first time, it will start in OFF status, with the default mode on.

3.4. Climma functions

When the unit is working, the system can run with two different functions:

 AUTOfunction: when system is in AUTO function, the Climma Control will automatically adjust the

system power: when more power is requested, the compressor will run up to its maximum speed,

but when less power is requested, compressor will slow down.

 ECOfunction: when system is in ECO function, the Climma Control will automatically adjust the

system power, but this time the maximum power is limited to a specific ECO value, which allows

you to set a maximum power consumption, lower than the maximum system power consumption.

Example.

Chiller maximum power consumption: 4,2kW

Generator: 10kW

When you are running the generator you can set the AUTO function on. If the system will run at full power,

it will still work with no problems, even at maximum speed.

When you are docked, you cannot run the generation and you have only 4kW from the harbor, then you

can set the ECO function on. This will allow the system to run up to 50% of its overall power, this means

that the power consumption will be limited around 2kW, allowing the system to run anyway.

3.5. Starting the unit

To start the unit, turn on the main power supply from the dedicated circuit breaker.

The display will show the following screens.

Screen 1. Screen 2.

When the display shows Screen 1, and later Screen 2, there is a short time where you can change the

language from Italian to English (or the other way around).

To change the language from the current one, press ENTER. To confirm the current language press ESC.

If nothing is pressed, the system will start with the current language settings.

After the language settings, the system will go to the main screen.

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