RLC

AIR COOLED LIQUID CHILLER

INSTALLATION, COMMISSIONING,
OPERATION AND MAINTENANCE

R134a RLC-A & RLC-A R/P/D

R407C RLC-B

Part No. 035B09025-0GB GB

Subject to change without notice
ALL RIGHTS RESERVED
 Table of Contents
1 SUPPLIER INFORMATION 4 INSTALLATION
1.1 Introduction 3 4.1 Location 17

1.2 Warranty 3 4.2 External Water System 17

1.3 Safety 3 4.3 Water Connections 20

1.4 Emergency Stops/Shutdown 4 4.4 Electrical Supplies 21

1.5 About this Manual 4 4.5 Electrical Connections 22

1.6 Safety Labels 5 5 COMMISSIONING

1.7 Material Safety Data 7 5.1 Preliminary Checks 25

2 PRODUCT DESCRIPTION 5.2 Starting 25

2.1 Introduction 10 5.3 Performance Check 26

2.2 General Specification 10 5.4 Customer Handover 26

2.3 Compressors 10 6 OPERATION

2.4 Refrigerant Circuits 11 6.1 Regulation and Control Logic 27

2.5 Evaporators 11 6.2 Compressor Starting Logic 27

2.6 Air Cooled Condensers 11 6.3 Water Temperature

Regulation (IN) 28
2.7 Heat Recovery Condensers 11
6.4 Water Temperature
2.8 Power And Controls 12 Regulation (OUT) 28

2.9 Chiller Control 12 6.5 Control Panel 31

2.10 Accessories 13 6.6 Unit Starting 32

2.11 Interface Board 13 6.7 Set Point 33

2.12 Options 13 6.8 Heat Recovery Operation 33

2.13 Theory Of Operation 14 6.9 Alarm Display and Reset 33

3 TRANSPORTATION, HANDLING 6.10 Unit Shutdown 33

AND STORAGE
6.11 Electromechanical Safety
3.1 Inspection 15 Devices 33

3.2 Handling 15

3.3 Anchorage 16

3.4 Storage 16

1
7 MAINTENANCE 10 SPARE PARTS
7.1 General Requirements 35 10.1 Recommended Spares 66

7.2 Daily Maintenance 35 10.2 Recommended Compressor Oils 66

7.3 Refrigerant Charge 36 10.3 Wiring Diagrams 66

7.4 Refrigerant Circuits 36 11 DE-COMMISSIONING, DISMANTLING

AND DISPOSAL
7.5 Compressors 36
11.1 General 67
7.6 Condenser Coils 37

7.7 Condenser Fans 37

7.8 Filter Drier 37

7.9 Sight Glass 37

7.10 Thermostatic Expansion Valve 38

7.11 Evaporator 38

8 TROUBLE SHOOTING 39

9 TECHNICAL DATA
9.1 Pressure Drop Graphs 41

9.2 Safety Switch Setting 43

9.3 Operational Limits 44

9.4 Physical Data 46

9.5 Total Unit Electrical Data 49

9.6 Compressor Electrical Data 50

9.7 Fan Electrical Data 51

9.8 Sound Power Levels 52

9.9 Dimension, Weight and

Isolator Data 53

9.10 Piping and Instrumentation

Diagrams 56

9.11 General Arrangements 60

2
1 SUPPLIER INFORMATION
1.1 Introduction
RLC Series chillers are manufactured to the most
stringent design and construction standards to en-
sure high performance, reliability and adaptability to
all types of air conditioning installations. The unit is
intended for cooling water (and heating water in the
case of heat recovery chillers of those fitted with a
desuperheater) and is not suitable for purposes
other than those specified in this manual.
If the unit is used improperly, or for different purpo-
ses without the prior agreement of Itelco-Clima or
their agents, then such use would be outside the
scope and may be unsafe.
This manual contains all the information required
for correct installation and commissioning of the
unit, together with operation and maintenance in-
structions. The manual should be read thoroughly
before attempting to operate or service the unit.
With the exception of the operations detailed in this
manual, all installation, commissioning and mainte-
nance tasks must be performed by suitably trained
and qualified personnel from an Authorised Service
Centre.
The manufacturer is not liable for injury or damage
resulting from incorrect installation/commissioning
or operation, insufficient maintenance and/or failure
to follow the procedures and instructions contained
in this manual.
1.2 Warranty
The unit is supplied finished, tested and ready to
work. The unit warranty will be void if any modifica-
tion to the unit is carried out without written agree-
ment of the manufacturer.
For warranty purposes, the following conditions
must be satisfied:
The initial start of the unit must be carried out by
trained personnel from an Authorised Service
Centre.
Maintenance must be carried out by properly trai-
ned personnel.
Only genuine spare parts must be used.
All the scheduled maintenance operations detai-
led in this manual must be performed at the spe-
cified times.
Failure to satisfy any of these conditions will auto-
matically void the warranty.
1.3 Safety
The installation of the unit must be carried out
according to the Machinery Safety Directive
(CEE 98/37), to the Low Voltage Directive
(73/23/EEC), to the Electromagnetic Interferen-
ce Directive (89/336/EEC) as modified by Direc-
tive (92/31/EEC) and according to normal rules
for technical matters prescribed by the applica-
ble country regulations. Do not operate the unit
before having observed all the above.
The unit must be earthed and no instal-
lation or maintenance work should be
attempted on the electrical equipment
WARNING without first switching off and isolating
the main power supply and any control
supplies.
Failure to observance of the above safety measu-
res may result in fire or electrocution should a short-
circuit occur.
3
 The unit contains refrigerant vapour
and liquid under pressure within the
heat exchangers, compressors and pi-
WARNING pework. Release of refrigerant can be a
danger and cause injury.
Fan guards must be fitted at all times
and not removed unless the main
power supply has been isolated.
WARNING
It is the responsibility of the user to en-
sure that the unit is suitable for the con-
ditions of use and that installation and
WARNING regular maintenance is carried out by
personnel with the appropriate skills
and in accordance with this manual.
Support of the unit must be provided as
indicated in this manual, failure to pro-
vide proper support may put personnel
WARNING at risk of injury.
The unit is not designed to withstand loads
or stresses from adjacent equipment, pi-
pework and structures. Any such extra-
CAUTION neous loads or stress may cause failure or
collapse which can be a danger and cause
injury. In such cases the warranty will be
void.
The user should ensure that reasonable
care is taken by other trades to avoid da-
mage/abuseto the unit during and after in-
CAUTION stallation.
Do not discard or burn the packaging in the
environment.
CAUTION
4
1.4 Emergency Stops/Shutdown
The isolator switch on the electrical panel will shut-
down the unit, when set to the 0 (Off) position.
The unit should be restarted in accordance with the
procedure detailed in this manual.
1.5 About this Manual
For safety reasons, the instructions contained in
this manual must be followed categorically; further-
more, damage caused by misuse is not covered by
the warranty.
This manual uses the following conventions:
Warning messages alert you to a speci-
fic procedure or practice which, if not
followed correctly, could cause serious
WARNING personal injury.
Caution messages appear before proce-
dures which, if not observed, could result
in damage to the unit.
CAUTION
Notes contain particularly important com-
ments which are set off from the text.
Hints provide useful information to improve
operation efficiency
HINTS
The contents of this manual, and any other docu-
mentsupplied with the unit, are the property of Itel-
co-Clima which reserves all rights. They may not be
reproduced, in whole or in part, without the written
authorisation of Itelco-Clima.
1.6 Safety Labels
The following labels are fitted to each unit in the lo-
cations stated:

Refrigerant Identification - Outside Panel Door

TENERE SU QUESTA LINEA

GANCIO DI SOLLEVAMENTO

KEEP LIFT HOOK

ON THIS LINE
Centre of Gravity - Base Frame

Electrical Warning -
Adjacent to Isolator Switch
Unit Identification -
Inside of Outer Panel Door

5

ATTENZIONE
QUESTO COMPRESSORE RICHIEDE UN
CORRETTO SENSO DI ROTAZIONE
RISPETTARE LA CORRETTA SEQUENZA
DELLE FASI
CAUTION
THIS COMPRESSOR REQUIRES PROPER
DIRECTION OF ROTATION
CHECK PROPER ELECTRICAL PHASING
Scroll Compressor Direction of Rotation -
Compressor
Connection Identification - Adjacent to Connections
Test Certificate -
Inside of Outer Panel Door
6
881000215/B
ATTENZIONE
INSERIRE LE RESISTENZE DI RISCALDAMENTO OLIO ALMENO
12 ORE PRIMA DI OGNI AVVIAMENTO (SE PREVISTE).
PRIMA DELLA MESSA IN TENSIONE ASSICURARSI CHE LE VITI
DEI CIRCUITI ELETTRICI SIANO SERRATE COMPLETAMENTE.
WARNING
ENERGIZE THE CRANCKCASE HEATER FOR AT LEAST 12
HOURS BEFORE EACH STARTING (IF FITTED).
BEFORE TIGHTENING-UP, TO TIGHTEN ALL TERMINAL SCREWS
ESPECIALLY THOSE IN MAIN CIRCUIT.
Start up Warning -
Outside of Electrical Panel Door
Lifting Point - Base Frame
EIN - INLET
ENTRE - ENTRATA
AUS - OUTLET
SORTIE - USCITA
Earth Point - In Panel Adjacent to Connection
1.7 Material Safety Data
Refrigerant Data:
Safety Data:
Toxicity
In contact with skin
In contact with eyes
Ingested
Inhalation
Further Medical Advice
Long term exposure
Occupational exposure limits
Stability
Conditions to avoid
Hazardous reactions
Hazardous decomposition
products
R407C, R134a
Low.
Liquid splashes or spray may cause freeze burns. Unlikely to be
hazardous by skin absorption. Thaw affected areas with water.
Remove contaminated clothing carefully - may adhere to skin in
case of freeze burns. Was affected areas with plenty of warm water.
If symptoms occur (irritation or blistering) obtain medical attention.
Vapour has no effect. Liquid splashes or spray may cause freeze
burns. Immediately irrigate with eyewash solution or clean water for
at least 10 minutes. Obtain immediate medical attention.
Highly unlikely to occur - but should this occur freeze burn will occur.
Do not induce vomiting. Provided patient is conscious, wash mouth
with water and give about 250 ml (0.5 pint) to drink. Obtain immedia-
te medical attention.
R407C, R134a: High atmospheric concentrat ions may lead anae-
sthetic effect, including loss of consciousness. Very high exposures
may cause an abnormal heart rhythm and prove suddenly fatal.
At higher concentration there is a danger from asphyxiation due to
reduced oxygen content of atmosphere. Remove patient to freshair,
keep warm and at rest. Administer oxygen if necessary. Apply artifi-
cial respiration if breathing has ceased or shows signs of failing. In
event of cardiac arrest apply external cardiac massage. Obtain
immediate medical attention.
Symptomatic and supportive therapy is indicated. Cardiac sensitisa-
tion has been described which may, in the presence of circulating ca-
techolamines such as adrenalin, give rise to cardiac arrhythmias and
subsequent arrest following exposure to high concentrations.
R407C, R134a: A lifetime inhalation study in rats has shown that ex-
posure to 50,000 ppm resulted in benign tumours of the testis. This is
not considered to be of relevance to humans exposed to concentra-
tions at or below the occupational exposure limit.
R407C, R134a: Recommended limit: 1000 ppmv/v - 8 hr TWA.
R407C, R134a: Not specified.
Use in presence of naked flames, red hot surfaces and high moisture
levels.
May react violently with sodium, potassium, barium and other alkali
and alkaline earth metals. Incompatible materials: Magnesium and al-
loys containing more then 2%magnesium.
R407C, R134a: Halogen acids by thermal decomposition and hy-
drolysis.
7
 General precautions Avoid inhalation of high concentrations of vapours. Atmospheric con-
centrations should be minimised and kept as low as reasonably prac-
ticable below the occupational exposure limit. The vapour is heavier
than air and collects at low level and in confined areas. Ventilate by
extraction at lowest levels.
Respiratory protection Where doubt exists on atmospheric concentration, HSE approved
breathing apparatus should be worn. This should be self contained or
of the long breather type.

Storage Keep containers dry and in a cool place away from fire risk, direct sun-
light, and all sources of heat such as radiators. Keep at temperatures
not exceeding 45 deg C.

Protective clothing Wear overalls, impervious gloves and goggles/face protection.

Spill / Leak procedure Ensure suitable personal protective clothing and respiratory protec-
tion is worn. Provided it is safe to do so, isolate the source of the
leak. Allow small spillages to evaporate provided there is suitable
ventilation.
Large spillages: Ventilate area. Contain spillages with sand, earth or
any suitable absorbent material. Prevent liquid from entering drains,
sewers, basements and work pits since vapour may create a suffoca-
ting atmosphere.

Disposal Best to recover and recycle. If this is not possible, destruction is to be

in an approved facility whichis equipped to absorb and neutralise
acids and other toxic processing products.

Fire extinguishing data R407C. R134a: Non-flammable at atmospheric conditions.

Containers Fire exposed containers should be kept cool with water sprays. Con-
tainers may burst if overheated.
Fire fighting protective Self contained breathing apparatus and protective clothing must be
equipment worn in fire conditions.

8
Refrigerant Oil Data:

Safety Data Oil Polyester (POE)

Classification Non-hazardous
In contact with skin Minimally irritating. No first aid necessary. Exercise reasonable perso-
nal cleanliness including cleansing exposed skin areas several times
daily with soap and water. Launder soiled work clothes at least
weekly.

In contact with eyes As with most foreign materials flush with plenty of eyewash solution or
clean water.

Ingested Obtain immediate medical attention.

Inhalation Obtain immediate medical attention.

Conditions to avoid Strong oxidisers, caustic or acid solutions, excessive heat. May de-
grade some paints and rubber materials.

Respiratory protection Use in well ventilated areas.

Protective clothing Goggles or face shield should be worn. Gloves not necessary, but re-
commended, especially for prolonged exposure.

Spill / Leak procedure Wear suitable protective equipment, especially goggles. Stop source
of spill. Use absorbent materials to soak up fluid (i.e. sand, sawdust,
and commercially available materials).

Disposal Incinerate the oil and all associated wastes in a approved facility in
accordance with local laws and regulations governing oily wastes.

Fire extinguishing datra Use dry chemical, carbon dioxide or foam spraying water on hot or
burning liquid, may cause frothing or splashing.

If a leak or spill has not ignited use water spray to disperse the va-
pours and to provided protection for persons attempting to stop the
leak.

Containers Fire exposed containers should be kept cool with water sprays.

Fire fighting protective equipment Self contained breathing apparatus should be worn in fire conditions.

9
2 PRODUCT DESCRIPTION The unit is pressure tested, evacuated and finally
charged with refrigerant and includes an initial oil
2.1 Introduction charge. After assembly a full run test is performed,
with water flowing through the evaporators, to verify
The RLC range of twin refrigerant circuit water chil- that each refrigerant circuit operates correctly.
lers are designed to be located outside on the roof
of a building or at ground level. The unit base and frame is of heavy gauge galvani-
sed steel fastened with stainless steel screws and
The range includes the following models: bolts. Compressor and refrigerant circuit compo-
nents are located in an acoustically lined enclosure.
Models Description All panels are easily removed for access to compo-
nents. Galvanised steel parts are painted with
RLC-A Water chillers charged with baked-on enamel coloured white RAL 9001.
210 to 525 refrigerant R134a
2.3 Compressors
RLC-B Water chillers charged with
210 to 800 refrigerant R407C Model Compressor

RLC-A da 210 a 525 Two reciprocating compres-

The following options are available:
Option Description
/R 100% (total) heat recovery on both re-
frigerant circuits tosupply simulta-
neous chilled and warm water. During
heat recovery the refrigerant flows via
the heat recovery condensers
/P 50% (partial) heat recovery on a single
refrigerant circuit to supply simulta-
neous chilled and warm water. During
heat recovery the refrigerant flows via
the heat recovery condenser
RLC-B da 210 a 800 sors with part wind starting
RLC-A 210 to 525 and
RLC-B 210 to 800
Compressor lubrication is force-fed by a reversible
oil pump to all crankshaft and bearing surfaces th-
rough a fine mesh stainless steel oil strainer.
The compressor motors are refrigerant gas cooled,
with integral temperature-sensing solid state over-
load protection in each phase. The motor terminal
boxes are to IP-54 weather protection.

/D Heat is recovered via a desuperheater Compressor capacity control is provided by sole-

installed on the compressor discharge
line.
/Q Low noise emission, using mufflers
and continuous fan speed control
noid-actuated, capacity control valves, which are
controlled by the unit microprocessor. This method
efficiently and effectively matches low load condi-
tions as required. Gas flow is sufficient at all times
to cool the motors.

2.2 General Specification

RLC models are completely assembled with all in-
terconnecting refrigerant piping and wiring ready for
field installation.

10
2.4 Refrigerant Circuits
Two complete refrigerant circuits are supplied on
each unit. All piping is ACR copper, with brazed
joints. Refrigerant circuits include: a service valve
for refrigerant charging, suction discharge and li-
quid line isolating valves, sight glass with moisture
indicator, thermal expansion valve with external
equaliser. Solenoid valve, filter drier and differential
oil pressure switch on sizes 210 to 800. High and
low pressure switches and safety valves on sizes
300 to 800.
2.5 Evaporators
RLC-A and RLC-B models 210 upwards each have
a single steel shell and copper tube evaporator.
The dual-circuit evaporator is a direct-expansion ty-
pe, with the refrigerant in the tubes, which are for-
med in a hair-pin configuration, and chilled liquid
flowing through the baffled shell. The evaporator is
covered with flexible, closed-cell, foam insulation.
Water connection to the evaporator is via threaded
connections on models 210 to 360 and victualic ty-
pe on models 400 upwards.
All evaporators have a heating element controlled
by a thermostat for frost protection to -10C. Water
vent and drain connections are included on all eva-
porators.
The evaporator design working pressure on the wa-
ter side is 10 bar g and on the refrigerant side 25
bar g.
2.6 Air Cooled Condensers
The condenser coils are seamless copper tubes,
arranged in staggered rows, mechanically expan-
ded into corrugated aluminium fins. Integral sub-
cooling is included. The design working pressure of
the coil is 28 bar g.
The condenser fans are direct drive with aluminium
aerofoil blades. Each fan has a painted galvanised
steel protection guard.
The three phase totally enclosed fan motors are to
IP-54 weather protection and have thermocontact
protection embedded in their windings.
2.7 Heat Recovery Condensers
The heat recovery condensers are cleanable shell
and tube type with seamless high pressure shell
and external finned copper tubes rolled into tube
sheets. The condenser shell is factory insulated
with flexible closed cell insulation and has a heater
mat for antifreeze protection down to -20C.
The design working pressure is 25 bar g on the re-
frigerant side and 10 bar g on the water side.
Full heat recovery units have two heat recovery
condensers and partial heat recovery units have
one condenser. All heat recovery units are equip-
ped with cooling-heat recovery mode change-over
valve(s) and controller(s). A factory wired control
sensor, not including sensor pocket, is provided for
field installation.
11
2.8 Power And Controls
All units are equipped with a Chiller Control micro-
processor control and management system.
All controls and motor starting equipment neces-
sary for unit operation are factory wired and tested.
Power and control components are separated and
accessed via individual doors. The power section
has a door interlocked isolator. The total enclosure
is fitted with a second upward opening door. The
panel is designed to IP-54 weather protection.
The power compartment contains:
General switch.
Main isolator, compressor contactors and fuses,
fan contactors and fuses.
The control compartment contains:
Anti-frost thermostat; auxiliaries transformer, fu-
ses and relays.
The Chiller Control microcomputer keypad and
display, mounted in the control section door.
2.9 Chiller Control
The Chiller Control unit consists of an expandable
interface board and a control unit.
The expandable interface board monitors inputs
and provides control outputs as follows:
Digital inputs, such as alarms and commands.
Analog inputs, such as temperature and pressure
measurements.
Digital outputs for control relay and remote con-
trol switch operation.
12
The control unit implements the following logic:
LED and visual display of unit alarms and unit
operation.
Compressor start-up logic (part-winding and cut
out), power adjustment on 2 or 4 steps.
Display of compressor working hours and evapo-
rator temperature.
Anti-cycling and anti-start-up surge timers.
Automatic compressor lead/lag start-up sequen-
ce.
Fan cut out.
Management of set points and parametric data:
User level - The machine operator can adjust da-
ta at the keyboard with the SET, + and - keys.
Service Level - System password access for
authorised Service personnel.
The display panel has keypad type buttons identi-
fied by symbols, colour coded to Eurovent stan-
dards, and LEDs to display function status:
Green indicates Normal operation
Yellow indicates Caution
Red indicates Stop
2.10 Accessories 2.12 Options
Flow Switch Condenser Coil-fin Protection

Supplied loose for field installation by contractor.
Anti-vibration Mounts
Open spring isolator mounts with fixing down holes,
supplied loose for field installation by contractor.
Painted galvanised steel guards mounted on the
exterior of the unit.
Air Cooled Condenser Options
Copper fins or vinyl coated fins.

Improved Capacity Control Gauge Kit

Six or eight step control instead of standard four
step control for semi-hermetic compressor models.
Fan-speed Control
Maintains constant condensing temperature, during
operation in low ambient conditions.
2.11 Interface Board
Factory fitted mechanical dial gauges for suction
and discharge pressure indication of each refrigera-
tion circuit.
Extra Temperature and Pressure Sensors
To display compressor suction and discharge pres-
sures and evaporation temperature of each refrige-
ration circuit.

An optional communications interface enables the Time Programme Board

unit to be controlled and managed from a local sta-
tion via RS232 up to 500m, or via modem and a te-
lephone line.
Remote management and control can therefore be
met by integrating twith a Building Management Sy-
stem.
Factory mounted to programme set point hours per
day (Maximum of four different set points over 24
hours per day and 5 days). Also implements chiller
on/off schedule. Generally used with ice storage sy-
stems.

Nomenclature

R L C - 360 A / R / P / D

REFRIGERATOR

LARGE CAPACITY DESUPERHEATER

COOLING ONLY PARTIAL RECOVERY

COMMERCIAL USE TOTAL RECOVERY

SIZE REFRIGERANT

A = R134a
B = R407c

13
 WITH 50%
HEAT RECOVERY

CONDENSER
CONDENSER
COIL
COIL

HEAT COOLER
RECOVERY
CONDENSER

COOLER

LP VAPOUR HP LIQUID HP VAPOUR LP LIQUID LP VAPOUR HP LIQUID HP VAPOUR LP LIQUID

RLC-A & RLC-B RLC-A /P

2.13 Theory Of Operation

Cooling Mode Heat Recovery Mode

Low pressure liquid refrigerant enters the cooler
(Evaporator) and is evaporated and superheated
by the heat energy absorbed fromthe chilled water
passing through the cooler shell. Low pressure va-
pour enters the compressor where pressure and
superheat are increased. Heat is rejected via the air
cooled condenser coil and fans. The fully conden-
sed and subcooled liquid refrigerant then enters the
expansion valve where pressure reduction and
further cooling takes place before returning to the
cooler.
During heat recovery operation the refrigerant pas-
ses to the water cooled condenser instead of the air
cooled condenser. The high pressure superheated
refrigerant vapour enters the condenser shell, whe-
reheat is rejected to thewarm water in the tubes,
and is condensed. High pressure liquid refrigerant
then passes through the expansion valve, where
pressure reduction and cooling takes place, before
returning to the cooler. Excess heat is rejectedat
theair cooledcondenser.

WITH 100%
HEAT RECOVERY WITH DESUPERHEATERS
CONDENSER
COIL

CONDENSER
COILS

DESUPERHEATER DESUPERHEATER

CONDENSER
COIL

HEAT
RECOVERY HEAT COOLER
CONDENSER RECOVERY
CONDENSER

LP VAPOUR HD LIQUID HP VAPOUR LP LIQUID LP VAPOUR HP LIQUID HP VAPOUR LP LIQUID

RLC-A /R RLC-A /D
RLC-B/D (to Model 400)

14
3 TRANSPORTATION, HANDLING Insert a spreader bar or frame between the ca-
AND STORAGE bles, vertical to the units centre of gravity.

RLC series chillers are supplied fully assembled, Attach the crane hook at the units centre of gra-
(with the exception of the rubber vibration pads vity.
supplied with the unit) which are installed on site.
Units are pre-charged with refrigerant and oil in the Cable length shall be such that they do not form
correct quantity required for operation. an angle of less than 45 degrees to the horizontal
when under tension.
3.1 Inspection
Immediately upon receiving the unit, it should be in-
spected for possible damage which may have oc- International Lifting Lugs
curred during transit as goods are shipped ex-
works at purchasers risk. In addition, ensure that
all ordered components have been received.
If any damage is evident, it should be noted on the
carriers freight bill and a claim entered in accordan-
ce with the advice note instructions. If the damage
is other than superficial, immediately advise your
local Itelco-Clima representative.

Itelco-Clima accepts no responsibility for shipping

damage, even in cases where the factory has ar-
ranged for shipping.

3.2 Handling
RLC series chillers are designed to be lifted using L > Unit Width
lifting lugs and cables. A spreader bar or frame L

should be used with the cables, to avoid crushing

the unit.

Before moving the unit ensure that the installation

site is suitable to receive the unit and to support its
weight and mechanical impact.

During handling, avoid touching sharp parts (for

example coil fins).

Never move the machine on rollers or lift

the machine using a fork lift truck.

CAUTION

Proceed as follows to lift and move the machine:

Insert and secure the lifting lugs through the Care should be taken to avoid damaging
marked holes in the base frame. the side-mounted coil fins and panelling
when lifting and moving the unit to the in-
Attach the cables to the lifting lugs. CAUTION stallation site.

The sides of the unit should be protected

with stiff cardboard or plywood.

CAUTION

15
 Do not remove the protective plastic wrap-
ping and the coil protectors, which prevent
dirt, dust and other foreign matter from en-
CAUTION tering the fan grilles or damaging the exter-
nal surfaces, until the unit is ready for ope-
ration.
3.3 Anchorage
RLC Series chillers are provided with 18 mm dia-
meter holes in the base frame for retaining the
spring damper mounts if required.
It is not necessary to anchor theunit to foundations,
except in areas of high risk of earthquake, or where
the unit is located at high level on a steel mounting
frame.
16
3.4 Storage
If the unit is to be stored prior to installation, certain
precautions should be taken to prevent damage,
corrosion or deterioration:
Ensure that all openings, such as water connec-
tions, are securely capped or sealed.
Do not store where exposed to ambient air tem-
peratures exceeding 45C for R134a or 42C for
R407c units, preferably out of direct sunlight.
The finned heat exchangers should remain cove-
red to protect the fins from potential corrosion,
particularly where building work is in progress.
Store the unit in a location where minimum acti-
vity is likely to take place in order to limit the risk
of accidental damage.
Do not steamclean the unit.
Remove the keys necessary to gain access to
the control panel and deposit them with a respon-
sible person on site.
Periodic visual examination during storage is re-
commended.
4 INSTALLATION
4.1 Location
Before installing the unit, make sure
that the building structure and/or
mounting surface can support the unit
WARNING weight. Overall weights and weight di-
stribution is detailed in Section 9.
The unit has been designed for floor mounting in
outside locations. Rubber anti-vibration pads are
supplied as standard and they must be positioned
centrally, underneath each of the supporting plates.
When the unit is to be installed on the ground, a
concrete slab must be provided to ensure uniform
weight distribution.
Special mounts are not normally required. Howe-
ver, if the unit is to be installed directly above inha-
bited rooms, it is advisable to set the unit on spring
damper mounts (supplied as accessories, refer to
Section 9) to minimise the vibrations transmitted to
the structure.
The following factors must be considered when se-
lecting a location for the unit:
The units longitudinal axis should be parallel to
prevailing winds to ensure balanced air flow over
the condenser coils.
The unit should not besited downwind of boiler
flues.
The unit should not be sited downwind of sources
of grease-laden air such as extractor vents for
large kitchens. In such cases, accumulated grea-
se on the condenser fins can trap air-borne con-
taminants, thus leading to rapid soiling or clog-
ging.
The unit should not be sited in areas exposed to
heavy snowfall.
The unit should not be sited in areas exposed to
flooding or beneath downpipes, etc.
The unit should not be sited in air wells,
courtyards or other restricted spaces where noi-
se would be reverberated off the walls, or where
air expelled by fans could be channelled back to
condenser inlets.
The installation position should ensure adequate
clearances for air circulation and maintenance,
refer to Section 9 for details.
4.2 External Water System
The external water hydraulic circuit must
ensure constant water flow to the evapora-
tor under all operating or adjustment con-
CAUTION ditions.
The external water system should consist of the fol-
lowing:
A circulation pump providing sufficient output and
hydraulic head.
To ensure that repetitive starts of compressors is
avoided, which can cause damages, the primary
system water content should be no less than 10
litres per kW of cooling capacity. If the total volu-
me in primary system pipework and evaporator is
insufficient, an insulated buffer tank should be in-
stalled.
A diaphragm-type expansion tank with safety val-
ve outlet which must be visible.
The tank should be sized to accommodate
a 2% increase in total fluid volume in the
system (evaporator, lines, user circuits and
water reservoir where provided). The Ex-
pansion tank need not necessarily be insu-
lated, as water does not normally circulate
therein.
A flow switch to deactivate the unit when water is
not circulating.
The flow switch must be connected in se-
ries with external interlocks as shown on
wiring diagram in control panel.
CAUTION
17
Follow the manufacturers instructions careful-
ly when installing the flow switch.

In general, the flow switch should be installed on

the pump delivery, upstream of the unit, on a hori-
zontal pipe run of at least 10 pipe diameters from
any bend, valve or other item which could interfere
with water flow upstream or downstream of the flow
switch.

A Normally Open differential pressure switch may

be installed instead of the flow switch. The pressure
switch senses water pressure drop across the eva-
porator.

In addition:

Install air vent valves at the highest points of the

lines.

Install shutoff valves on the evaporator and heat

recovery condenser inlet and outlet water lines.

Provide suitable drainage points (with plugs,

cocks etc.) at the lowest points of the lines.

Install a valved by-pass around the evaporator.

Insulate the pipework to prevent heat loss.

A filter/strainer located on the suction side of the

evaporator or heat recovery condenser.

A water flow measuring device.

18
 FLOW SWITCH INSTALLATION

UNIT EXTERNAL WATER SYSTEM

Typical Connection Diagram

Key Standard evaporators provided on RLC units are

designed to chill mixtures of water and ethylene gly-
I Pressure gauge tapping col with a corrosion-inhibiting additive down to
GA Flexible connections 10C.
T Thermometer The amount of ethylene glycol to be added is as fol-
S Gate valves lows.
R Drain tap
F Strainer Amounts are shown as a percentage by weight of
Fl Flow switch the circuit design water content:

operation from + 5 to 0 C : 20%

Before filling the system, ensure that it is
free from foreign matter, sand, stones, rust operation from 0 to -5 C : 30%
flakes, solder, slag or other materials whi-
CAUTION ch could damage the evaporator. operation from -5 to -10 C : 40%

It is advisable to by-pass the unit when flushing out

the lines. A strainer screen must be installed
upstream of the chiller.

Water used to fill the circuit may have to be

treated to ensure that the PH value is cor-
rect.

19
Where two or more units are connected in parallel it
is recommended that the connections be made th-
rough a Reverse Return circuit (as shown below)
in order to balance the pressure drop in each unit
circuit.

Typical Parallel Hydraulic Connection

Key RLC-A 360 to 525 and RLC-B 400 to 800

A From circulating pump Connect the external water supply lines to the water
inlet and outlet fittings on the left hand side of the
B Chilled water to the system unit, when viewed from the electrical panel.
S Gate valves The unit is provided with Victaulic fittings, refer to
VG Balancing valve section 9 for diameters and locations.
E1 Evaporator, 1st unit
RLC-A Heat Recovery Models (/R and /P)
E2 Evaporator, 2nd unit
E3 Evaporator, 3rd unit A factory wired control sensor (6 mm diameter x 30
mm long) is provided for field installation.
4.3 Water connections
A sensor pocket, which is not supplied, should be
The water inlet and outlet connections must be con- installed by the contractor in the common pipework
nected correctly as shown on the labels fitted adja- leaving the condenser(s).
cent to the fittings.

RLC-A 210 to 300 and RLC-B 210 to 360

Connect the external water supply lines to

the water inlet and outlet fittings at rear of
the unit.
CAUTION

The unit is provided with threaded pipe fittings, refer

to section 9 for diameters and locations.

20
4.4 Electrical Supplies Supply and isolating devices shall be designed so
that the lines are fully independent.
Ensure that the power supply is off
before working on the electrical sy- Magnetic thermal differential breakers are recom-
stem. mended, to prevent damage due to electrical phase
WARNING loss.

Power supplies to the compressors and the fans

are through contactors controlled by the control pa-
The unit must be provided with an earth nel.
connection.
WARNING Each motor is provided with an internal thermal
overload cut-out and external fuses.

Supply cables should be routed through the cable

It is the installers responsibility to ensure entries on the unit front and enter the electrical pa-
that all external wiring complies with appli- nel through a hole at the bottom of the panel.
CAUTION cable safety regulations.

The Manufacturer is not responsible for injury

or damage of any kind resulting from failure to
observe these precautions.

The unit complies with EN 60 204-1.

The following connections are required:

One three-phase line and earth for the power cir-

cuit supply.

The electrical distribution system must be able to

supply all the unit power, refer to Section 9.

The disconnect switches and circuit breakers must

be sized to handle the unit starting current, refer to
section 9.

21
4.5 Electrical Connections
The installation of the unit on the final site must
be carried out according to the Machinery Sa-
fety directive (98/37/EC), to the Low Voltage Di-
rective (73/23/EEC), to the Electromagnetic In-
terference directive (89/336/EEC) and according
to normal rules for technical matters prescribed
by the applicable country regulations. Do not
operate the unit before having observed all the
above. Supply lines shall consist of insulated
copper conductors sized for maximum current
draw.

Terminal connections should be made in accordan-

ce with the connection diagram in this manual and
the diagram supplied with the unit.

Before connecting the supply lines, check

that the mains voltage is within the range
shown in the Electrical Data in Section 9.
CAUTION

For the 3 phase power supply, also check that the

phase unbalance does not exceed 2%. The check
is performed by measuring the difference between
the voltage of each phase pair and the average
mains voltage during operation. The maximum
measured difference (unbalance) shall not exceed
2% of the average voltage.

If the unbalance is unacceptable, the electricity

supply company must be asked to correct the fault.

Supplying the unit with a line whose unba-

lance exceeds the specified value will au-
tomatically void the warranty.
CAUTION

22
MORSETTIERA DELL'UNIT
UNIT TERMINAL BOARD MORSETTIERA
EXTERNAL ESTERNA
TERMINAL BOARD

LINE
400-3-50

FLOW SWITCH OR
EXTERNAL INTERLOCK
(24V)

INTERLOCK
(OPTIONAL) (24V)
CIRC PUMP ETC

REMOTE INDICATION
VOLTAGE ON (VF)

REMOTE ON/OFF CONTROL

(VOLT FREE CONTACT)

COMMON

(NO) GENERAL ALARM

VOLT FREE

(NC)

COMPRESSOR 1 ON
VOLT FREE

COMPRESSOR 2 ON
VOLT FREE

RLC-A e RLC-B Electrical Connections

23
 UNIT TERMINAL
MORSETTIERA BOARD
DELL'UNIT EXTERNAL TERMINAL
MORSETTIERA BOARD
ESTERNA

LINE
400-3-50

FLOW SWITCH OR
EXTERNAL INTERLOCK
(24V)

INTERLOCK
(OPTIONAL) (24V)
CIRC PUMP ETC

REMOTE INDICATION
VOLTAGE ON (VF)

REMOTE ON/OFF CONTROL

(VOLT FREE CONTACT

COMMON

(NO) GENERAL ALARM

VOLT FREE

(NC)

COMPRESSOR 1 ON
VOLT FREE

COMPRESSOR 2 ON
VOLT FREE

REMOTE ON/OFF HEAT RECOVERY

(VOLT FREE CONTACT)

RLC-A, RLC-B with Heat Recovery, Electrical Connections

24
5 COMMISSIONING
The unit must be started by trained per-
sonnel from an Authorised Service Centre.
failure to satisfy this requirement will void
CAUTION the warranty.
The operations performed by service per-
sonnel are limited to unit starting, and do
not include other work on system such as
electrical connection, water connection,
etc. All other preparatory work, including
oil pre-heating (for at least 12 hours) must
be performed by installer.
5.1 Preliminary Checks
The following operations must be performed before
starting the unit and should be performed before
service personnel arrive.
With master isolating switch off, check the supply
cable cross-section, the ground connection, the
electrical terminal clamps are tight and that all
contactors operate correctly.
Check that the voltage and phase unbalance of
the power supply is within limits, refer to Section 4.
Connect (non-energised) contacts of the flow
switch and the pump thermal overload cut-out or
other devices (where provided) to terminals 1-2
and 3-4 respectively.
Check that the external water circuit components
(pumps, user equipment, filters, expansion tank
and reservoir where provided) have been correc-
tly installed as advised by manufacturer and that
the inlet and outlet water connections are correct.
Check that the external water circuit is full and
that the fluid circulates freely with no signs of
leakage or air bubbles. If ethylene glycol antifree-
ze is used, check that the percentage concentra-
tion is correct.
Check that the pump direction of rotation is cor-
rect, and allow fluid to circulate for at least 24
hours (12 hours for each pump). Then clean the
basket filters on the pump suction.
Adjust the water system so that the flow rates are
as specified.
Check that the water quality is as specified.
Check the position of the safety and anti-icing
thermostat sensors.
Check that the oil heaters, if fitted have been
energised for at least 12 hours.
5.2 Starting
The starting sequence is as follows.
Turn on the master isolating switch (12 hours
before).
Check that the compressor oil is sufficiently warm
(minimum temperature at the oil pan exterior mu-
st be approximately 40C) and that the auxiliary
control circuit is energised.
Check that all external equipment is in running
order and that the associated control equipment
is correctly calibrated.
Start the liquid pump and check that the water
flow rate is as required.
Set the desired fluid inlet temperature on the con-
trol panel (refer to Section 6).
Start the unit (refer to Section 6).
Check the correct Scroll compressor direction of
rotation.
After around 15 minutes of operation, check that
no air bubbles are visible through the sight glass
on the fluid line.
If air bubbles are visible, the unit has lost
part of its charge through one or more
leaks. The leaks must be eliminated refer
CAUTION to Section 7.
Repeat the starting procedure after eliminating
the leaks.
Check that the oil level is correct.
MAX
MIN
25
 MAX
MIN MAX
MIN
MIN

RLC-A 210, 240, 300, 360,

400, 450, 525 RLC-B 210, 240, 300, 360

Sight Glass Sight Glass

RLC-B 400, 450, 525, 600,

700, 800

Sight Glass

5.3 Performance Check Check that the saturated evaporation and conden-
sation temperatures during operation at high and
Check the following: low pressure by connecting gauges to the schrader
valves on the high and low pressure refrigerant cir-
Evaporator manifold inlet water temperature. cuits.

Evaporator manifold outlet water temperature. High pressure side Approximately 15 to

18C above coil inlet air
Evaporator manifold outlet water flow rate. temperature
Compressor current at startup and stable opera- Low pressure side Approximately 5 to 7C
ting conditions. below chilled water ou-
tlet temperature
Fan current at startup and stable operating condi-
tions.
5.4 Customer Handover

Familiarise the user with the machine operating

instructions in Section 6.

26
6 OPERATION
RLC series chillers are equipped with a micropro-
cessor control logic and regulation management
system.
The system consists of a unit logic board and a li-
quid crystal control panel which manages the con-
trol, starting, shutdown and display functions.
6.1 Regulation and control logic
Control logic automatically manages the following
functions:
Unit alarm management and display
High pressure alarm.
When the alarmis activated, control logic locks
out the associated refrigerating circuit and opens
the compressor control chain (fail-safe mode).
Alarmis reset from the pressure switch and ma-
nually from panel.
Low pressure alarm.
When the alarmis activated, control logic locks
out the associated refrigerating circuit. Alarm
operation is delayed approximately 30 seconds
after starting (Note 1). Alarm is reset manually
from panel.
Differential oil pressure alarm.
When the alarmis activated, control logic locks
out the associated refrigerating circuit. Alarm
operation is delayed approximately 120 seconds
(Note1). Alarmis reset manually from panel.
Compressor thermal overload cut-out alarm.
When the alarmis activated, control logic locks
out the associated refrigerating circuit and opens
the compressor control chain. Alarm is reset ma-
nually from panel.
Anti-freezing alarm.
This alarm is activated when water temperature
at evaporator outlet drops below 3 C (Note 1).
Alarm is reset manually from panel.
External interlock alarm.
When the alarmis activated, control logic locks
out the unit. Reset is automatic.
Fan thermal overload cut-out alarm.
Activation of this alarm locks out the associated
circuit and fans. Alarmis triggered by fan motors.
Reset is automatic.
6.2 Compressor starting logic
Control logic automatically manages all functions
connected with compressor starting.
Anti-cycling timer delay.
Prevents compressor starting attempts from
being made in quick succession (360 seconds/6
minutes) (Note 1).
Starting delay.
Prevents compressors from starting simulta-
neously (10 seconds) (Note 1).
Part wind starting is used to reduce starting cur-
rent. Panel logic automatically manages this star-
ting mode, in which only a part of the compressor
winding is activated during starting.
Automatic compressor starting sequence change.
Used to ensure that compressors operate for the
same number of hours.
Note 1 These parameters are variable.
Changes must be carried out by Itelco-Cli-
ma authorised personnel only.
27
The water temperature can be controlled from the
inlet or the outlet.

6.3 Water Temperature Regulation (IN)

Regulation is performed via inlet water temperature
SET POINT as shown below. The band is divided
into a number of steps. G1 OFF G2 OFF G3 OFF G4 OFF G5 OFF G6 OFF G7 OFF G8 OFF
G1 ON G2 ON G3 ON G4 ON G5 ON G6 ON G7 ON G8 ON

The control regulates the output of the compressor

as a function of the system; control is in two steps, 8-step Type Regulation
four steps or optionally six or eight. Depending on
the required set point and the proportional band
(pre selected to be 5C), the controller determines Key
the number of functioning compressors and possi- 1 SET POINT Programmed set point
ble unloading. 2 Width of regulation band
(set to 5C)
The above always refers to nominal water flow with Tr Water return temperature
a dT equal to 5C. G1 - G8 Steps of unloading

6.4 Water Temperature Regulation (OUT)

Regulation is performed via outlet water temperatu-
re SET POINT as shown below:

When the temperature of the water leaving the unit

remains within the neutral zone the capacity loa-
ding of the chiller remains unchanged.
G2 OFF
G1 OFF
G2 OFF
G1 ON
G2 ON
G1 ON
When the temperature of the water leaving the unit
increases and goes outside the neutral zone the
2-Step Type Regulation controller increases the capacity loading.

When the temperature of the water leaving the unit

decreases and goes outside the neutral zone the
controller decreases the capacity loading.

BAND

ZONE NEUTRAL
G1 OFF G2 OFF G3 OFF G4 OFF
G1 ON G2 ON G3 ON G4 OFF T. WATER (OUT)
TR

4-step Type Regulation IMPOSTAZIONE

SET SET

Outlet Water Temperature Regulation

28
RLC-A, RLC-B Control Panel

29
 RLC-A R/P/D Control Panel (Heat Recovery)

30
6.5 Control panel

Key Function Key Funtion

Display Displays operating and fault Voltage indicator LED.
parameters. Indicates that unit is connected
to power supply.
SET POINT + key.
(increase temperature Anti-freezing alarm LED.
SET POINT). Indicates that water temperature
at evaporator outlet is below
SET POINT - key. safe limit.
(rreduces temperature
SET POINT). External interlock
alarm LED.
SET POINT display key.

Fan thermal overload alarm LED

Indicates that a fan thermal
Page key. overload cut-out has been
Calls data display pages. activated.
Warm weather mode start key
Circuit 1 or 2 power key and LED. and LED. Starts the unit in
(Select circuit 1 or 2). the cooling mode.
Led lights up to indicate
operating in cooling mode.
100% power level indicating
LED for circuit 1 and 2 Heat Recovery start key and
compressors. LED. Starts the unit heat recovery
mode. Led lights up to indicate
Compressor partialisation operating in recovery mode.
indicating LED for circuit
1 and 2 compressors Service mode key and LED.
(For use only by authorised
Circuit 1 or 2 high pressure alarm service personnel).
LED. Indicates that high pressure
switch for circuit 1 or 2 has been
activated.
Circuit 1 or 2 low pressure alarm
LED. Indicates that low pressure
switch for circuit 1 or 2 has been
activated.
Circuit 1 or 2 differential oil
pressure alarm LED (semi-
hermetic compressor only).
Indicates that differential oil
pressure switch for circuit 1 or 2
has been activated.
Circuit 1 or 2 compressor thermal
overload alarm LED. Indicates
tht compressor thermal
overload has been activated
for circuit 1 or 2.

31
6.6 Unit Starting Data and Temperature Display
Proceed as follows to start the unit: Display 1 (Models RLC 150 to RLC 800)

Turn the master isolating switch to the ON posi-

tion to energise unit.
In Tmp Wat
Check that LED (voltage indicator) goes on. Out Tmp Wat

The following display will appear on screen:

Evaporator inlet water temperature

Evaporator outlet water temperature

Display 2

Wait (circa 10 sec.) for this message to disappear

and check that there are no active alarm signals. Condenser Coils
Air Tmp

Prepare the two circuits for operation by pressing

the key for each circuit.
Air temperature
unit is now in stand-by and LEDs for the asso-
ciated circuits are on.

Press key to start the unit in the cooling mode.

LED will go on.

Compressor operation and power level will be indi-

cated by LEDs for each circuit.

Check that SET POINT is as desired (SET

POINT established at the factory is 8C).

If necessary, change the set point as described in

6.7.

32
 Display 3 The heat recovery function is by means of a four-
way valve in the discharge line from the compres-
sor to the condenser. The four-way valve diverts hot
refrigerant gas to the recovery condenser, when the
Hour Counter
thermostat is calling for heat.

When the leaving warm water temperature reaches

the set point of the thermostat the four-way valve di-
verts the refrigerant to the air cooled condenser and
Operating hours for compressors 1 and 2. the heat is dissipated to the ambient air. As the
warm water temperature leaving the recovery ves-
sel falls below the set point of the thermostat the
Press key to scroll displays. four-way valve diverts the refrigerant back to the
heat recovery condenser.
Alarm readouts are shown at the foot of display 3. 6.9 Alarm Display and Reset
Press page key again to return to display 1.
Alarms are indicated by the associated panel LEDs
and by messages on the liquid crystal display. The
6.7 Set point letters AL will appear in the upper right corner of
display to indicate that an alarm is active or has
To display cooling mode SET POINT: been stored in memory. To display alarm, press
page key several times until the alarm display
Press key with unit operating in cooling mode. appears.

To change SET POINT, Proceed as follows: To reset and delete memorised alarms, press page

Display SET POINT as directed above; key until the following display appears:

Press page key to move onto the digit to be

changed.

Change digit using and keys;

Press key to confirm;

Then press key to delete and reset alarms

To change SET POINT with compressors off, de-
activate the two circuits by pressing keys.
6.8 Heat Recovery Operation
The heat recovery option is activated by the heat
recovery start key on the control panel, which is illu-
minated when activated. Heat recovery operation is
controlled by a factory wired thermostat, mounted
by the installer, in the warm water flow from the heat
recovery condenser(s).
6.10 Unit Shutdown
Press warm weather mode key to stop the
unit.
Turn master isolating switch to OFF position to
de-energise the unit.
6.11 Electromechanical Safety Devices
Each refrigerating circuit on the RLC Series units is
protected by anti-freezing devices implemented by
the Chiller Control panel and a set of electrome-
chanical safety devices including a high pressure
switch, a low pressure switch and a differential oil
pressure switch (units with semi-hermetic compres-
sor only).

33
Ant-freezing device (supplied with unit) Low pressure switch

Units are provided with anti-freezing device consi-
sting of an electric heating element in contact with
the refrigerant/water heat exchanger. Heating ele-
ment is activated whenever water temperature dro-
ps below 2C, even when the unit is off. An anti-
freeze alarm stops the unit if outlet water tempera-
ture drops below 3C. During the cold season, it is
advisable to drain water circuit to prevent ice dama-
ge to lines. If this is not possible, do not cut off
power supply to the unit to ensure that the anti-free-
ze heating element will be activated if needed.
High pressure switch
Manual-reset switch opens contacts.
Automatic-reset switch opens contacts.
Circuit can be reset manually through Chiller Con-
trol panel.
Differential oil pressure switch
This instrument is provided on circuits with semi-
hermetic compressor. Switch senses pressure dif-
ferential across compressor casing and compres-
sor oil delivery.
Switch cut-in is delayed 120 seconds to allow pres-
sure to rise after compressor start-up. Circuit can
be reset manually through control panel.

Circuit can be reset manually through Chiller Con-

trol panel, after resetting device.

Alarm Displays

Compressor 1 or 2 Circuit 1 or 2 Fan * Circuit 1 or 2

Circuit 1 or 2 HIGH
Thermal Overload Thermal Overload HIGH Pressure
Pressure Switch
Cut-out Cut-out Limit Exceeded

Evap. Outlet 1 * Circuit 1 or 2 Low Evap. Outlet 2 Evap. Inlet Water

Water Low Temp. Pressure Limit Water Temp. Limit High temperature
Limit Exceeded Exceeded Exceeded Limit Exceeded

Evap. Inlet Water Circuit 1 or 2

circuit 1 or 2 LOW Compressor 1 or 2
Low Temperature Differential Oil
Pressure Switch Maintenance
Limit Exceeded Pressure Switch

Analogue Input for Temperature Set Mistake in Interface

Remote Setpoint External Interlock
Point Out of Range Managing
Out of Range

EPROM Timer Missing or * Only if optional pressure and temperature

Damaged Not Working sensors are fitted

34
7 MAINTENANCE
Never release refrigerant to the atmo-
sphere when emptying the refrigerating
circuit. Suitable retrieval equipment
WARNING must be used. If reclaimed refrigerant
cannot be re-used. It must be returned
to the manufacturer.
Never discard used compressor oil, as
it contains refrigerant in solution. Re-
turn used oil to the oil manufacturer.
WARNING The Safety Section of this manual
7.2 Daily Maintenance
The maintenance checks should be carried out in
accordance with the maintenance schedule detailed
below by a competent person. Please note, howe-
ver, that RLC series units are not generally user ser-
viceable and no attempt should be made to rectify
faults or problems found during daily checks. If in
any doubt, contact an Authorised Service Centre.
Scheduled Maintenance

Start of Season

End of Season
should be read carefully before attemp-
ting any maintenance operation on the
unit.

Monthly
Operation

Weekly
Unless otherwise indicated, the maintenance ope-

Daily
rations described below can be performed by any
properly trained maintenance technician.
Check evaporator leaving
7.1 General Requirements liquit temperature
Check heat evaporator
The RLC range has been designed to work conti-
nuously provided they are regularly maintained and
pressure drop
operated within the limitations given in this manual. Check electrical power
each unit should be maintained in accordance with consumption
the schedule by the operator/customer, backed up Check suction pressure
by regular service and maintenance visits by an and temperature
authorised Service Centre. Check discharge pressure
and temperature
It is the responsibility of the owner to provide for Check compressor
these regular maintenance requirements and/or en-
ter into a maintenance agreement with a Service
oil level
Centre to protect the operation of the unit. Check for gas bubbles
in refrigerant
If damage or a system failure occurs due to impro-
per maintenance during the warranty period, manu-
Check finned coil cleanliness
Check oil heater
facturer shall not be liable for costs incurred to re- efficiency
turn the unit to satisfactory condition. Check Remote
This maintenance section applies only to the basic
Control Unit
RLC unit and may, on individual contracts, be sup- Check low pressure
plemented by additional requirements to cover any switch
modifications or ancillary equipment as applicable. Check high pressure
switch
Check diff. oil pressure
switch
Check heat exchanger
insulation
Check clamp tightness
Check terminal screw
tightness
Clean outside surface
with soapy water
Straighten coil fins
Check density of any
circulating brine
Drain evaporator of add
antifreeze

35
7.3 Refrigerant Charge
Never introduce liquid refrigerant in the low
pressure side of circuit. Extreme care must
be taken to ensure that circuit is correctly
CAUTION charged.
An insufficient charge will lead to poor machine
performance. In extreme cases, the low pressure
switch will cut in and lock the circuit.
Excessive charge will raise the condensation pres-
sure (which in extreme cases will cause the high
pressure switch to cut in and lock the circuit) with a
consequent increase in power consumption.
Under no circumstances must the com-
pressor be used as a vacuum pump to pur-
ge circuit.
CAUTION
The refrigerant circuit must be charged whenever it
is emptied for maintenance purposes (leak repair,
compressor replacement, etc.). Charge quantities
are given in Section 9.
Before charging, the ci rcuit must be vacuum-pur-
ged and dried, reaching a minimum absolute pres-
sure of 50 Pa.
The refrigerant gas must be introduced to eliminate
vacuumand to charge the circuit to 90% of the total
required gas in liquid formthrough the appropriate
charging valve on liquid line at condenser outlet.
A refrigerant container should then be connected to
the charging valve on suction line, the container
should be held so that only gaseous phase refrige-
rant is released.
The compressor should be started and gas allowed
to flow from the refrigerant container until liquid in
the sight glass runs clear and gas temperature at
evaporator outlet has stabilised at around 5C.
36
7.4 Refrigerant Circuits
Each RLC Series unit is equipped with two fully in-
dependent refrigerating circuits. Units are equipped
with a single tube bundle evaporator with two sepa-
rate circuits on refrigerant side and a single circuit
on water side.
7.5 Compressors
Compressors are supplied with the correct quantity
of lubricant required for operation. Under normal
operating conditions, refrigerant charge and lubri-
cant will last the life of the machine. Fluid top-up is
not required as long as refrigerating circuit operates
correctly and no repair operations have been car-
ried out.
Should it be necessary to replace compressor (e.g.
as a result of winding burnout or mechanical failu-
re), contact an authorised ServiceCentre.
RLC models functioning with refrigerant
R407C and R134a employ compressors
charged with polyester oils. During com-
CAUTION pressor maintenance, or the opening of
any part of the refrigerant circuit, remem-
ber that this oil is extremely hydroscopic,
and, therefore, avoid long exposure to the
ambient air, which would require that the
complete oil charge be replaced.
7.6 Condenser Coils
Condenser coils feature copper tubes and alumi-
nium fins. Should refrigerant leakage take place as
a result of accidental impact or damage. The coils
must only be repaired or replaced by an Authorised
Service Centres.
To ensure high condenser coil serviceability and
heat exchange, the condenser surfaces must be
kept free of impurities such as leaves, fibres, in-
sects, dirt etc. Soiled condenser coils will increase
power consumption. In addition, the maximum
pressure alarm may cut in and lock out the unit.
Take care not to damage aluminium fins
during cleaning.
CAUTION
The condenser should be cleaned using compres-
sed air directed parallel to aluminium fins and in the
opposite direction to that of normal air circulation. A
vacuum cleaner may be used to clean the conden-
ser coil from outside. The coil may also be cleaned
with soapy water using a suitable spray nozzle.
7.7 Condenser Fans
Each condenser fan features a wing-profile impeller
and cylindrical nozzle. The fan motor bearings are
lubricated for life.
Ensure that fans rotate in the direction indicated by
arrowbefore starting machine following repair work
involving 3-phase disconnection (air flow up
wards).
If fan rotation is not correct, disconnect and invert
two of the three phases supplying the motor.
7.8 Filter Drier
Refrigerating circuits are provided with filter/driers.
The filter/driers are inspectable cartridge type on
models 210/800, and non-inspectable strainer type
on smaller units.
Filter/drier clogging will be indicated by bubbles in
the sight glass, or by a difference in temperature
upstream and downstreamof filter/drier.
If bubbles persist after changing cartridge, the ma-
chine has lost part of its refrigerant charge through
one or more leaks which must be identified and re-
paired.
7.9 Sight Glass
The sight glass is used to observe refrigerant flow
and moisture content. Bubbles in flow indicate that
filter/drier (where provided) is clogged, or that refri-
gerant charge is low.
A colour indicator is located inside the sight glass.
Compare the colour of the indicator with the scale
on the sight glass lock ring to determine the moistu-
re content of refrigerant. If moisture content is too
high, proceed as follows:
For machines with hermetic compressors, dischar-
ge the circuit without releasing refrigerant to the at-
mosphere. Vacuum-purge the circuit and replenish
the charge.
For machines with semi-hermetic compressors,
change the filter cartridge, operate the unit for one
day and check the moisture content again.
No further action is required if the moisture content
returns to normal. If the moisture content is still too
high, change the filter/drier again, start the unit and
operate for a further day.
37
7.10 Thermostatic Expansion Valve
RLC refrigerating circuits are provided with a ther-
mostatic expansion valve with an external equali-
ser. Valves are calibrated at the factory for a 5C
temperature rise.
To check the temperature rise:
7.11 Evaporator
Check the heat exchanger water side for cleanli-
ness at regular intervals. This may be accompli-
shed by checking water side pressure drop (refer to
Section 9) or simply by checking the fluid tempera-
tures at heat exchanger inlet and outlet and compa-
ring them with evaporation temperatures.

Read the suction pressure on the units gauge panel
or on a pressure gauge connected to charging val-
ve on suction side.
Using the pressure gauge temperature scale, de-
termine the saturated suction temperature Tsa cor-
responding to this pressure.
Determine the effective suction temperature Tse
using a contact thermometer applied to the evapo-
rator gas outlet fitting.
Temperature rise S is given by:
For effective heat exchange, the water outlet tem-
perature and the saturated evaporation temperatu-
re should differ by 5 to 7C. A larger difference indi-
cates that the heat exchanger is operating ineffi-
ciently, and is thus soiled.
If soiled, the heat exchanger must be chemically clea-
ned by authorised Itelco-Clima service personnel.
For other types of service (special maintenance,
heat exchanger replacement, etc.), contact an
authorised Service Centre.

S = Tse - Tsa

The temperature rise can be corrected using the

adjuster screw on the thermostatic expansion val-
ve. Turn the adjuster screw through a single revolu-
tion and operate the unit for five minutes. Then
check the temperature rise again and correct as ne-
cessary.

If the thermostatic expansion valve does not react

to temperature rise calibration, it is probably mal-
functioning and must be replaced. Valve replace-
ment must be performed by an authorised Service
Centre.

38
8 TROUBLE SHOOTING
The following table details possible unit faults, their probable cause and suggested remedies. For any
other problems not immediately recognisable and/or for technical assistance, call an Authorised Service
Centre.
Fault
Differential oil pressure switch
cuts on, break circuit
Unit operates continuously, but
without cooling.
Suction line freezes.
Excessive noise.
Low compressor oil level.
Probable Cause
Defective differential pressure
switch operation.
Low oil level as a result of circuit
leakage.
Start up with cold oil.
Compressor lube circuit mal-
function.
Low refrigerant charge.
Drier/filter clogged.
Loss of efficiency in one or both
circuits.
Temperature rise of thermostatic
valve out of calibration.
Vibrating lines.
Thermostatic expansion valve
hiss.
Noisy compressor.
One or more gas or oil leaks in
circuit
Mechanical damage to compres-
sor.
Faulty crankcase oil heater.
Remedy
Check switch operation, repla-
cing if necessary.
Determine location of leak and
repair.
Check oil heater operation.
Call an Authorised Centre.
Top up charge.
Replace drier/filter
Check compressor valves, repla-
cing if necessary (semi-hermetic
compressor only).
Increase setting.
Check charge.
Secure lines.
Check line retention.
Top up charge.
Check filter/drier, replacing if ne-
cessary.
Check condition of valves.
Bearings have seized; replace
compressor.
Check that compressor retaining
nuts are tight.
Identify and eliminate all leaks
Call an Authorised Service Cen-
tre
Check electrical circuit and
crankcase heater element ope-
ration, replacing any defective
components.
39
 Fault
One or both compressors not
working.
Low pressure switch cuts in,
braking circuit.
High pressure switch cuts in,
braking circuit.
Liquid line too hot.
Liquit line freezes
40
Probable Cause
Power circuit interrupted.
High pressure switch activation.
Control circuit fuse blown
Loose terminal clamps.
Power circuit thermal overload
cut-out activation.
Incorrect wiring.
Line voltage too low.
Compressor motor short-circui-
ted.
Compressor seizure
Gas leakage.
Insufficient charge.
Pressure switch failure.
High pressure switch malfunc-
tion.
Delivery valve partially closed.
Non-condensables in circuit.
Condenser fan(s) inoperative.
Insufficient charge.
Liquid line valve partially closed.
Receiver/drier clogged.
Remedy
Check power circuit for earth
leakage and shorts.
Check fuses.
Reset pressure switch from pa-
nel and re-start machine.
Identify and eliminate causes of
pressure switch activation.
Check control circuit for earth
leakage and shorts.
Change fuses.
Check clamp tightness.
Check operation of control and
safety devices.
Identify and eliminate cause of
activation.
Check control and safety device
wiring.
Check line voltage. If problem
due to system, eliminate it.
If problem is due to distribution
network, inform the electricity
supply company.
Check motor winding continuity.
Replace compressor.
Identify and eliminate leakage.
Top up charge.
Replace pressure switch.
Check switch operation, repla-
cing if necessary.
Open valve, replacing if neces-
sary.
Purge circuit.
Check wiring and motors. Repair
or replace if necessary.
Identify and eliminate causes of
charge loss and top up charge.
Check that all valves are open.
Replace cartridge.
9 TECHNICAL DATA
9.1 Pressure Drop Graphs
RLC-A & RLC-B All Models - Evaporator
PRESSURE DROP (kPa)

FLOW RATE (l/s)

41
RLC-A R/P Models Heat Recovery Condenser
PRESSURE DROP (kPa)

FLOW RATE (l/s)

Note: R Models - Pressure drop is for each Condenser

42
RLC-A /D Models - Desuperheater
PRESSURE DROP (kPa)

FLOW RATE (l/s)

Note: Pressure drop is for each Desuperheater

9.2 Safety Switch Settings

RLC-A & RLC-B All Models

Model 210 240 300 360 400 450 525 600 700 800
Low Pressure Switch bar 0,4 (0,2)(2)
High Pressure Switch bar 28 (22)(2)
TUV High Pressure Switch(1) bar 25
Oil Pressure Switch bar 0,8
Anti Freezing Thermostat C 3
Safety Valve bar None 24

Nota: 1 Also heat recovery, heat pump in the winter mode

2 RLC-A models

43
9.3 Operational Limits
RLC-B All models

210 240
Model
Min. Max. Min. Max.
Water Outlet C 6 15 6 15
Evaporator
Water Outlet Brine Outlet C -5 15 -5 15
Temperature
Temperature Spread C 3 8 3 8
Evaporator
(Water) Flow Rater Water/Brine l/s 1,5 10 2,3 10
Pressure Drop Water/Brine kPa 7,5 to 85
Maximum Pressure
bar 10
Water/Brine Side
Standard Unit C -5 to 48
Air on
Temperature Units with
Condenser C -20 to 48
Speed Control
Condenser Standard Unit Pa 0
(Air) Maximum Units with
External Speed Control Pa 0
Static
Pressure Units with High
Pa 100
Pressure Fans
Power Supply Voltage 400 V, 3 Ph, 50 Hz V 342 to 462
Recommended System Water Volume(1) l 1250 1500

300 360 400 450 525 600 700 800

Model
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
Water Outlet C 6 15 6 15 5 15 5 15 5 15 5 15 5 15 5 15
Evaporator
Water Outlet Brine Outlet C -5 15 -5 15 -5 15 -5 15 -5 15 -5 15 -5 15 -5 15
Temperature
Temperature Spread C 3 8 3 8 3 8 3 8 3 8 3 8 3 8 3 8
Evaporator
(Water) Flow Rate Water/Brine l/s 4 16 4 16 5,2 22 5,8 25 7 28 8 33 10 42 11 48
Pressure Drop Water/Brine kPa 7
Maximum Pressure
bar 10
Water/Brine Side
Standard Unit C -10 to 48 -5 to 46 -10 to 46
Air on
Temperature Unit with
Condenser C -20 to 48 -20 to 46 -20 to 46
Speed Control
Condenser Standard Unit Pa 0
(Air) Maximum Unit with
External Speed Control Pa 0
Static
Pressure Units with High
Pa 100
Pressure Fans
Power Supply Voltage 400 V, 3 Ph, 50 Hz V 342 to 462
Recommended System Water Volume(1) l 1350 1600 2050 2450 2850 3250 3900 4480

Note: 1 Table shows minimum water/brine volume of the primary water system

44
RLC-A All Models

210 240
Model
Min. Max. Min. Max.
Water Outlet C 5 15 5 15
Evaporator
Water Outlet Brine Outlet C -10 15 -10 15
Temperature
Temperature Spread C 3 8 3 8
Evaporator
(Water) Flow Rate Water/Brine l/s 2,3 10 2,3 10
Pressure Drop Water/Brine kPa 7,5 to 85
Maximum Pressure
bar 10
Water/Brine Side
Standard Unit C -5 to 48
Air on
Temperature Units with
Condenser C -20 to 48
Speed Control
Condenser Standard Unit Pa 0
(Air) Maximum Units with
External Speed Control Pa 0
Static
Pressure Units with High
Pa 100
Pressure Fans
Condenser Water Outlet C 35 to 50
RLC-A/R/P
HRC Temperature Spread C 3 to 10
Desuperheater RLC-A/D Water Outlet C 40 to 70
Power Supply Voltage 400 V, 3 Ph, 50 Hz V 342 to 462
Recommended System Water Volume(1) l 1250 1500

300 360 400 450 525

Model
Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
Water Outlet C 5 15 5 15 5 15 5 15 5 15
Evaporator
Water Outlet Brine Outlet C -10 15 -10 15 -10 15 -10 15 -10 15
Temperature
Temperature Spread C 3 8 3 8 3 8 3 8 3 8
Evaporator
(Water) Flow Rate Water/Brine l/s 4 16 4 16 4 16 4 16 4 16
Pressure Drip Water/Brine kPa 7,5 to 85
Maximum Pressure
bar 10
Water/Brine Side
Standard Unit C -10 to 48
Air on
Temperature Units with
Condenser C -20 to 48
Speed Control
Condenser Standard Unit Pa 0
(Air) Maximum Units with
External Speed Control Pa 0
Static
Pressure Units with High
Pa 100
Pressure Fans
Condenser Water Outlet C 35 to 50
RLC-A/R/P
HRC Temperature Spread C 3 to 10
Desuperheater RLC-A/D Water Outlet C 40 to 70
Power Supply Voltage 400 V, 3 Ph, 50 Hz V 342 to 462
Recommended System Water Volume(1) l 1350 1600 2050 2450 2850

Note: 1 Table shows minimum water/brine volume of the primary water system

45
9.4 Physical Data
RLC-B 210 - 240

Model 210 240

Type semi-hermetic
Circuit 1 Theoretical
m3/h 107 127
Displacement
Type semi-hermetic
Circuit 2 Theoretical
m3/h 107 127
Displacement
Compressor
Quantity 2 2
Number of Cylinders 6 6
Revs. per Minute rpm 1450 1450
Oil Charge per
dm3 7,4 7,7
Compressor
Number of Loading Stages 100/50 100/50
Quantity 1 1
Type (Direct Expansion) Shell and Tube
Number of Refrigerant Circuits 2 2
Evaporator
Water Volume per
Evaporator l 33 33
Refrigerant Volume dm 3
16,7 16,7
Face Area m2 8,3 8,3
Air Cooled
Condenser Number of Rows 2 3

Fan Diameter mm 710 710

Number 6 6
Fans
Power Input at 890 rpm kW 0,9 0,9
Air Flow Rate m3/s 24 22
Refrigerant Charge R 407C kg 2 x 15 2 x 21
Operational Weight Aluminium Fins kg 1780 1890
Shipping Weight kg 1740 1850
Copper/Copper Coils kg 344 344
Additional RLC/R kg 190 200
Weight RLC/P kg 95 100
RLC/D kg 40 50
Length mm 4040 4040
Dimensions Width mm 2040 2040
Height mm 1730 1730

Note: 1 Per condenser

46
RLC-B 300 - 800

Model 300 360 400 450 525 600 700 800

Type semi-hermetic
Circuit 1 Theoretical
m3/h 151 180 202 180 180 180 180 180
Displacement
Type semi-hermetic
Circuit 2 Theoretical
m3/h 151 180 210 243 284 324 406 464
Displacement
Compressor
Quantity 2 2 2 2 2 2 2 2
Number of Cylinders 8 8 8 6 7 8 7 8
Revs. per Minute rpm 1450 1450 1450 1450 1450 1450 1450 1450
Oil Charge per
dm3 7,7 7,7 7,5 20 20 20 20 20
Compressor
100-75 100-75 100-75 100-75 100-75 100-75
Number of Loading Steps 100-50 100-50
50-25 50-25 50-25 50-25 50-25 50-25
Quantity 1 1 1 1 1 1 1 1
Type (Direct Expansion) Shell and Tube
Evaporator Number of Refrigerant Circuits 2 2 2 2 2 2 2 2
Water Volume per Evaporator dm3 55 55 87 80 133 125 222 206
Refrigerant Volume dm3 27,4 27,4 38,9 44,8 52,9 60 80 92,3
Face Area m2 11 11 16 16 16 16 20 24,6
Air Cooled
Condenser Number of Rows 2 3 2 3 3 4 4 4

Fan Diameter mm 710 710 800 800 800 800 800 800
Number 8 8 6 6 8 8 10 12
Fans
Power Input at 890 rpm kW 0,9 0,9 1,5 1,5 1,5 1,5 1,5 1,5
Air Flow Rate m3/s 32 30 35 34 44 43 53 64
Refrigerant Charge R 407C kg 2 x 21 2 x 30 2 x 33 2 x 40 2 x 44 2 x 50 2 x 63 2 x 74
Operational Weight Aluminium Fins kg 2430 2570 4500 4800 5200 5600 6640 7050
Shipping Weight kg 2380 2520 4400 4700 5100 5500 6450 6900
Copper/Copper Coils kg 258 389 700 700 700 736 700 700
Additional RLC/R kg 250 250 600 800 800 800 660 660
Weight RLC/P kg 115 125 200 400 400 400 400 400
RLC/D kg 50 60 150 200 200 200 200 200
Length mm 5040 5040 4860 4860 4860 4860 6100 7100
Dimensions Width mm 2040 2040 2240 2240 2240 2240 2260 2260
Height mm 1730 1730 2225 2225 2225 2225 2250 2250

Note: 1 Per condenser

47
RLC-A 210 - 525

Model 210 240 300 360 400 450 525

Type semi hermetic
Circuit 1 Theoretical
m3/h 151 181 210 284 348 406 464
Displacement
Type semi hermetic
Circuit 2 Theoretical
m3/h 151 181 210 284 348 406 464
Displacement
Compressor
Quantity 2 2 2 2 2 2 2
Number of Cylinders 8 8 8 7 6 7 8
Revs. per Minute rpm 1450 1450 1450 1450 1450 1450 1450
Oil Charge per
l 7,7 7,7 7,5 23 20 20 20
Compressor
100 100 100 100 100-75 100-75 100-78
Number of Loading Stages
50 50 50 50 50-25 50-25 50-28
Quantity 1 1 1 1 1 1 1
Type (Direct Expansion) ED 135 ED 135 ED 220 ED 220 ED 310 ED 360 ED 420
Evaporator Number of Refrigerant Circuits 2 2 2 2 2 2 2
Water Volume per l 33 33 48 48 80 95 115
Evaporator
Refrigerant Volume dm3 16,7 16,7 27,4 27,4 38,9 44,8 52,9
Face Area m2 8,3 8,3 11 11 16 16 16
Air Cooled
Condenser Number of Rows 2 3 2 3 2 3 3

Fan Diameter mm 710 710 710 800 800 800 800

Number 6 6 8 6 6 6 8
Fans
Power Input at 890 rpm kW 0,9 0,9 0,9 1,5 1,5 1,5 1,5
Air Flow Rate m3/s 24 22 32 35 35 34 44
Heat RLC-A/R/P
Recovery /R 2 Condenser Type Shell and Tube
Condenser /P 1 Condenser
Water Volume(1) l 9,4 12,1 23,4 32,3
Refrigerant Volume(1) dm3
RLC-A/D Type Shell and Tube
Desuperheater
Refrigerant Volume dm3
Refrigerant Charge R 134A kg 2 x 15 2 x 21 2 x 21 2 x 30 2 x 34 2 x 40 2 x 45
Operational Weight Aluminium Fins kg 2004 2114 2430 5380 5650 5700 5880
Shipping Weight kg 1944 2064 2360 5280 5550 5600 5780
Copper/Copper Coils kg 344 344 258 389 700 700 700
Additional RLC-A/R kg 190 200 250 250 600 800 800
Weight RLC-A/P kg 95 100 115 125 200 400 400
RLC-A/D kg 40 50 50 60 150 200 200
Length mm 4040 4040 5040 4860 4860 4860 4860
Dimensions Width mm 2040 2040 2040 2240 2240 2240 2240
Height mm 1730 1730 1730 2225 2225 2225 2225

Note: 1 Per condenser

48
9.5 Total Unit Electrical Data
RLC-A All Models

Model 210 240 300 360 400 450 525

Current Nominal (1)
114 140 128 175 203 241 273
Input
(A) Maximum(2) 128 162 160 229 257 311 347
Power Nominal(1) 53 65 73 95 115 134 140
Input
(kW) Maximum(2) 65 79 89 119 145 169 194
Maximum Starting 322 387 340 424 438 569 590
Current (A)

Nota: 1 Nominal conditions 7C chilled water outlet temperature, 35C ambient temperature
2 Maximum condition at 14C chilled water outlet temperature, 45C ambient temperature
Table applicable to units with standard fans

RLC-B All Models

Model 210 240 300 360 400 450 525 600 700 800
Current Nominal(1) 116 136 158 184 205 219 261 293 361 417
Input
(A) Maximum (2)
138 160 190 218 255 267 323 373 439 503
Power Nominal(1) 59 69 82 96 113 121 144 162 199 230
Input
(kW) Maximum(2) 77 87 101 119 137 147 170 192 239 274
Maximum Starting 237 270 354 418 467 568 734 759 947 982
Current (A)

Nota: 1 Nominal conditions 7C chilled water outlet temperature, 35C ambient temperature
2 Maximum condition at 14C chilled water outlet temperature, 45C ambient temperature
Table applicable to units with standard fans

49
9.6 Compressor Electrical Data
RLC-A All Models

Power Input Power Input

Current per Current per Starting
Voltage(5) per per Fuse
Model Circuit Compressor(1) Compressor(2) Current(3)
(V) Compressor(1) Compressor(2) Size(4)
(A) (A) (A)
(kW) (kW)

210 1+2 400 24 51 30 60 250 200

240 1+2 400 30 64 37 75 300 200

300 1+2 400 32 56 41 72 252 200

360 1+2 400 43 79 55 106 301 250

400 1+2 400 53 93 68 120 301 315

450 1+2 400 61 112 80 147 405 400

525 1+2 400 70 125 91 162 405 400

Nota: 1 Nominal conditions at 7C chilled water outlet temperature, 35C ambient temperature
2 Maximum condition at 14C chilled water outlet temperature, 45C ambient temperature
3 Compressors Starting, Part Winding
4 Fuse sizes stated are maximum values, smaller sizes may be used if applicable
5 Minimum allowable supply voltage 342 Volts

RLC-B All Models

Power Input Power Input

Current per Current per Starting
Voltage(5) per per Fuse
Model Circuit Compressor(1) Compressor(2) Current(3)
(V) Compressor(1) Compressor(2) Size(4)
(A) (A) (A)
(kW) (kW)
210 1+2 400 27 52 34 63 161 200

240 1+2 400 32 62 39 74 183 200

300 1+2 400 38 70 47 87 250 250

360 1+2 400 45 84 56 101 300 250

400 1+2 400 52 94 64 119 329 250

450 1+2 400 56 101 69 125 424 315

525 1+2 400 66 119 79 150 559 400

600 1+2 400 75 135 90 175 559 400

700 1+2 400 92 166 112 205 711 500

800 1+2 400 106 191 128 234 711 500

Nota 1 Nominal conditions at 7C chilled water outlet temperature, 35C ambient temperature
2 Maximum condition at 14C chilled water outlet temperature, 45C ambient temperature
3 Compressors Starting, Part Winding
4 Fuse sizes stated are maximum values, smaller sizes may be used if applicable
5 Minimum allowable supply voltage 342 Volts

50
9.7 Fan Electrical Data
RLC-A All Models

Standard fans High Pressure Fans

Model Nominal Power Max Running Max Starting Nominal Power Max Running Max Running
(kW) Current (A) Current (A) (kW) Current (A) Current (A)
RLC-A 210-300 0,9 1,95 5,9 2,9 4,8 7,6
RLC-A 360-525 1,5 2,9 8,8 4,7 8,7 28

RLC-B All Models

Standard fans High Pressure Fans

Model Nominal Power Max Running Max Starting Nominal Power Max Running Max Running
(kW) Current (A) Current (A) (kW) Current (A) Current (A)
RLC-B 210-360 0,9 1,95 5,9 2,9 4,8 7,6
RLC-B 400-800 1,5 2,9 8,8 4,7 8,7 28

51
9.8 Sound Power Levels
RLC-A All models

Octave Band (Hz)

Model Total dB(A)
125 250 500 1000 2000 4000 8000
(1) 90 93 95 90 86 75 69 95
210
(2) 78 81 87 83 77 67 57 87
(1) 91 92 95 90 85 80 70 95
240
(2) 78 85 88 84 77 69 58 88
(1) 92 96 97 91 88 79 70 97
300
(2) 78 87 92 85 77 69 59 90
(1) 91 95 99 93 84 80 71 98
360
(2) 80 87 94 84 77 70 60 92
(1) 93 96 98 94 86 78 73 98
400
(2) 83 91 94 87 77 67 67 93
(1) 93 96 98 94 86 78 73 98
450
(2) 86 90 94 88 74 67 67 93
(1) 96 99 101 95 86 79 74 100
525
(2) 87 93 95 89 75 68 68 94

Nota: Reference data with machine operating at nominal condition 12/7C chilled water
1 > 38C ambient RLC-A (Standard Version)
2 < 25C ambient RLC-A/Q (Quiet Version)
Tolerance +/- 2 dB(A)

RLC-B All Models

Octave Band (Hz)

Model Total dB(A)
125 250 500 1000 2000 4000 8000
(1) 90 92 95 91 86 75 69 95
210
(2) 78 83 87 83 77 67 57 87
(1) 91 93 95 92 84 80 70 95
240
(2) 78 83 88 84 76 69 59 88
(1) 92 95 97 91 88 79 70 97
300
(2) 78 87 89 86 76 69 59 89
(1) 91 95 96 94 84 80 71 97
360
(2) 80 86 90 86 76 70 60 90
(1) 93 96 98 94 85 78 73 98
400
(2) 83 88 90 89 76 67 67 91
(1) 93 96 98 94 85 78 73 98
450
(2) 86 88 91 90 74 67 67 92
(1) 96 98 100 96 86 79 74 100
525
(2) 87 90 92 90 78 68 68 93
(1) 94 97 100 96 88 81 75 100
600
(2) 87 91 93 90 85 77 70 94
(1) 96 98 101 97 88 81 75 101
700
(2) 87 92 95 92 78 72 68 95
(1) 97 99 102 98 89 82 76 102
800
(2) 88 92 95 92 88 74 71 96

Nota: Reference data with machine operating at nominal condition 12/7C chilled water
1 > 38C ambient RLC-A (Standard Version)
2 < 25C ambient RLC-A/Q (Quiet Version)
Tolerance +/- 2 dB(A)

52
9.9 Dimension, Weight and Isolator Data
RLC-A All Models

RLC-A 300
RLC 210-240; 400-600

RLC-A 60-150

Compressor/
Control panel Top view

Centre of
gravity

Model 210 240 300 360 400 450 525

Dim. Dimensions (mm)
X 1550 1550 2060 1860 1880 1890 1940
Y 140 140 140 140 232 232 232
A 790 790 790 790 783 783 783
B 1468 1468 1468 2342 2342 2342 2342
C 1500 1500 1710 1277 1277 1277 1277
D 790
Z 1930 1930 1930 2090 2090 2090 2090
Overall Weight (kg)
2004 2114 2430 5380 5650 5700 5880
Pos. Weight Distribution (kg)
1 and 2 231 251 245 619 668 870 860
3 and 4 366 376 365 667 667 890 896
5 and 6 265 280 265 540 580 580 625
7 and 8 140 150 220 464 490 510 540
9 and 10 120

53
RLC-B All Models

RLC-B 300-360; 700-800

RLC-B 210-240; 400-600

RLC-B 60-150

Compressor/
Control panel Top view

Centre of
gravity

Model 210 240 300 360 400 450 525 600 700 800
Dim. Dimensionis (mm)
X 1680 1670 2060 2060 1980 1980 1970 1990 2680 3030
Y 140 140 140 140 232 232 232 232 235 235
A 790 790 790 790 783 783 783 783 1179 1179
B 1468 1468 1468 1468 2342 2342 2342 2342 1663 1850
C 1500 1500 1710 1710 1277 1277 1277 1277 1440 2160
D 790 790 1350 1500
Z 1930 1930 1930 1930 2090 2090 2090 2090 2090 2090
Overall Weight (kg)
1780 1890 2430 2570 4500 4800 5200 5600 6640 7050
Pos. Weight Distribution (kg)
1 and 2 175 195 245 260 585 636 725 776 720 800
3 and 4 310 320 365 385 762 805 832 880 830 835
5 and 6 265 280 265 280 496 515 567 631 740 770
7 and 8 140 150 220 230 407 444 476 513 555 600
9 and 10 120 130 475 520

54
 SPRING ISOLATOR TABLE KIT
SPRING ISOLATOR CODE
Standard Coil Al/Cu Standard Coil Cu/Cu
Kit Code Chiller Chiller/H Chiller Chiller/H Chiller/R Chiller
R407C R22 R134A R134A R134A R134A
462B26050-210 210
462B26050-240 240 240
462B26050-300 300 300
462B26050-360 360
462B26050-400 400
462B26050-450 450
462B26050-525 525
462B26050-600 600
462B26050-700 700
462B26050-800 800
462B26150-210 210
462B26150-360 360
462B26150-400 400
462B26150-450 450
462B26150-525 525
462B26150-600 600
462B26200-210
462B26200-240
462B26200-300
462B26200-360
462B26200-400
462B26200-450
462B26200-525
462B26200-600
462B26200-700
462B26200-800
462B26300-210 210 210
462B26300-240 240 240
462B26300-300 300
462B26300-360 360
462B26300-400 400/450
462B26300-525 525
462B26350-210 210/240
462B26350-300 300
462B26350-360 360
462B26350-400 400
462B26350-450 450
462B26350-525 525
462B26100-210
462B26100-240
462B26100-300
462B26100-360
462B26100-400
462B26100-450
462B26100-525
462B26100-600
462B26100-700
462B26100-800
462B26400-210 210
462B26400-240 240
462B26400-300 300
462B26400-360 360
462B26400-400 400/450
462B26400-525 525

55
9.10 Piping and Instrumentation Diagrams
RLC, RLC-A and RLC-B Models 210 to 240

56
RLC-A and RLC-B Models 300 to 360

57
RLC-A and RLC-B Models 400 to 450

58
RLC-A Model 525 and RLC-B Models 525 to 800

59
9.11 General Arrangements
RLC-A and RLC-B Models 210 to 240

1785

60
RLC-A and RLC-B Model 300 and RLC, RLC-B Model 360

61
RLC-A Model 360 and RLC and RLC-B Models 400 to 450

62
RLC-A Model 525 and RLC-B Models 525 to 600

63
RLC-B Model 700

64
RLC-B Model 800

65
10 SPARE PARTS
10.1 Recommended Spares
The table below lists the recommended spares for one unit for 2 years

Components Qty.
HP Switch 1
LP Switch 1
Differential Oil Pressure Switch 1
Gas Filter 2
Thermostatic Valve 1
Auxiliary Relays 2
Fan fuses 6
Compressor Fuses 6
Auxiliary Fuses 6
Compressor Contactor 1
Fan Contactor 1
Power Contactor 1
Sensor L4000 1
Sensor SS 100 1
Pressure Transducer 1
EPROM 1
Electronic Board 1
Keyboard 1
Flat Cable 1

10.2 Recommended Compressor Oils

The table below lists the recommended oil type for each unit

Versione Tipo dolio Marca

RLC 210 to 360 3GS Wiltco Suniso
RLC 400 to 800 ABC
RLC-A 210 to 240 22A Mobile Arctic
RLC-A 300 to 360 325C ICI Emkerate
RLC-A 400 to 525 685 ICI Emkerate
RLC-B 120 to 360 22A Mobile Arctic
RLC-B 400 to 800 685 ICI Emkerate

10.3 Wiring Diagrams

Wiring diagrams are fitted on control panel door.

Other requests for wiring diagrams have to be re-
quired to Service Centre.

66
11 DE-COMMISSIONIG,
DISMANTLING AND DISPOSAL
Never release refrigerant to the atmo-
sphere when emptying the refrigerating
circuits. Suitable retrieval equipment
WARNING must be used. If reclaimed refrigerant
cannot be re-used. It must be returned
to the manufacturer.
Never discard used compressor oil, as
it contains refrigerant in solution. Re-
turn used oil to the oil manufacturer.
WARNING
Unless otherwise indicated, the operations descri-
bed below can be performed by any properly trai-
ned maintenance technician.
11.1 General
Isolate all sources of electrical supply to the unit in-
cluding any control system supplies switched by the
unit. Ensure that all points of isolation are secured
in the OFF position. The supply cables may then
be disconnected and removed. For connection
points refer to Section 4.
Remove all refrigerant from each system of the unit
into a suitable container using a refrigerant reclaim
or recovery unit. This refrigerant may then be reu-
sed, if appropriate, or returned to the manufacturer
for disposal. Under NO circumstances should refri-
gerant be vented to atmosphere. Drain the refrige-
rant oil from each system into a suitable container
and dispose of according to local laws and regula-
tions governing the disposal of oily wastes. Any spilt
oil should be mopped up and similarly disposed of.
Isolate the unit heat exchanger(s) from all external
water systems and drain the heat exchanger sec-
tion( s) of the system. If no isolation valves are in-
stalled it may be necessary to drain the complete
system(s).
If glycol or similar solutions have been
used in the water system(s), or chemi-
cal additives are contained, the solu-
WARNING tion mUST be disposed of in a suitable
and safe manner. Under NO circum-
stances should any system containing
glycol or similar solutions be drained
directly into domestic waste or natural
water systems.
After draining, the water pipework can be discon-
nected and removed.
Packaged units can generally be removed in one
piece after disconnection as above. Any fixing down
bolts should be removed and then the unit should
be lifted from position using the points provided and
equipment of adequate lifting capacity.
Reference should be made to Section 4 for unit in-
stallation instructions, Section 9 for unit weights
and Section 3 for handling.
Units which cannot be removed in one piece after
disconnection as above, must be dismantled in po-
sition. special care should be taken regarding the
weight and the handling of each component. Where
possible units should be dismantled in the reverse
order of installation.
Residual refrigerant oil and glycol or si-
milar solutions may remain in some
parts of the system. These should be
WARNING mopped up and disposed of as descri-
bed above.
It is important to ensure that whilst components are
being removed the remaining parts are supported
in a safe manner.
Only use lifting equipment of adequate
capacity.
WARNING
After removal from position the unit parts may be di-
sposed of according to local laws and regulations.
67