Installation Manual - ClimateWell SolarChiller - v9 - 33 - 4 - EN

ClimateWell SolarChiller
Installation Manual
................................................................................................................................. TABLE OF CONTENTS
Thank you for choosing ClimateWell SolarChiller!
With Solar Cooling you will feel better…and so will the Environment!
Solar energy day and night

Solar powered heating and cooling both day and night. This is what makes the ClimateWell SolarChiller a unique
product and that will enable you to enjoy comfort cooling and heating without compromising the environment. For
the first time, a solar powered climate solution meets the requirements both of single family homes and
commercial buildings. We made Solar Cooling possible and profitable.
Contribution
Solar Cooling typical monthly savings for a single family home are 100-200 Euros per 100 m² of floor surface. At
the same time the owner contributes to a better world by reducing CO2 emissions by some 5.000 kilos per 100 m²
every year.
Independency
With your own energy supply system installed you achieve high Independency of changes in energy prices at the
same time as you get immediate savings thanks to the lower energy costs.
Some 25% of the world’s CO2 emissions come from heating and cooling of buildings. With ClimateWell this can
now be done using everyone’s own energy source. The Sun.
Per Olofsson
CEO ClimateWell AB
Picture of CEO?
Legal Notes
This manual contains material which is protected by copyright. All rights are reserved. No part of this manual may be reproduced, photocopied
or translated to another language without the expressed written permission of ClimateWell AB.
ClimateWell®, Solar Cooling® and Frío Solar® are registered trademarks of ClimateWell AB.
ClimateWell AB 2010-05-26
Article no: 700020
Version: v9:33.4 EN
Copyright © 2010 ClimateWell AB. All rights reserved.
1
........................................................................................................................................................INSTALLATION MANUAL
Table of Contents TM
INSTALLATION MANUAL _________________________________________________3
Important Information .............................................................................................................................. 4
Preparation ............................................................................................................................................... 5
Electrical Properties ................................................................................................................................ 5
Dimensions of the ClimateWell SolarChiller ........................................................................................... 5
Where to Place the ClimateWell SolarChiller ......................................................................................... 6
Installation Kit .......................................................................................................................................... 7
Delivery of the ClimateWell SolarChiller ................................................................................................ 8
Assembling the ClimateWell SolarChiller .............................................................................................. 9
Connecting the Plumbing Unit ................................................................................................................ 9
Connecting the External Circuits .......................................................................................................... 13
Connecting the Temperature Sensors and Load Cells ......................................................................... 14
Commissioning ..................................................................................................................................... 17
Filling the ClimateWell SolarChiller ....................................................................................................... 18
Cover Assembly .................................................................................................................................... 20
Technical Data and Specifications ....................................................................................................... 22
Troubleshooting ..................................................................................................................................... 23
Maintenance ........................................................................................................................................... 24
CE ............................................................................................................................................................ 24
Appendix ................................................................................................................................................. 25
Table of Contents ................................................................................................................................. 25
Appendix A – Bypass Specification ...................................................................................................... 25
Appendix B – Declaration of Conformity ............................................................................................... 27
Index ........................................................................................................................................................ 28
Reference ................................................................................................................................................ 29
2
INSTALLATION MANUAL........................................................................................................................................................
Installation Manual
This installation manual explains the complete installation of a ClimateWell SolarChiller and is only for advanced users.
Please observe that this manual only describes the installation of a ClimateWell SolarChiller, not the auxiliary units such
as solar panels, water heaters or fan-coils. These should be dimensioned with the assistance of ClimateWell engineers
prior to delivery of the ClimateWell SolarChiller.
! Important! Before you start installing a ClimateWell SolarChiller it is important that you read through the User Manual to
get a basic knowledge of the machine.
Fig 1. Schematic of the two barrels and the plumbing unit (without covers).
3
! Important Information
To prevent personal injury, damage to the machine or other property damages read the following information carefully
before installing a ClimateWell SolarChiller.
Installation and Safety
Only ClimateWell authorized installers are allowed to install, commission or in other ways change the machine.
ClimateWell SolarChiller should not be in a tilted position during transport. The inclination of the floor where the
machine is finally placed and installed should be less than 1% or 10 mm per meter. Exaggerated tilting could
cause irreparable damage to the machine.
Check that all the parts are included in the delivery packages and that all parts are intact before assembling and
installing the machine.
For personal safety reasons be sure to wear steel toe shoes and work gloves when handling with the barrels
and plumbing unit.
Initially the fluid in the circuits could cause corrosion, but after some time all the air in the fluid have been used
in the corrosion process and it will decrease, not producing any problems. It is important not to
change the fluid in the circuits too frequently (maximum once per year).
Never install or leave ClimateWell SolarChiller outside without protection from rain and damp.
Do not damage or otherwise modify the power supply cord.
Make sure the supply cord is properly in place.
If the supply cord is damaged, it must be replaced by the manufacturer, service agent or similarly qualified
persons in order to avoid a hazard.
4
Preparation
Electrical Properties
The ClimateWell SolarChiller needs a 230 V single –phase AC electrical connection. The average power consumption in
normal usage is 22 W. The maximum power consumption is 70 W.
i Please Note! The circuits mentioned above will depend on the application. Do not hesitate to contact any of ClimateWell’s
engineers concerning this preparation.
Dimensions of the ClimateWell SolarChiller

Total weight of ClimateWell SolarChiller is 990 kg.The plumbing unit and control system box (with cover) placed on top of
the barrels weighs 78 kg.
Fig 2. Dimensions of the ClimateWell SolarChiller.
5
Where to Place the ClimateWell SolarChiller
In order to prepare the area where ClimateWell SolarChiller shall be placed, consider the following:
 Minimum ceiling height at least 2245 mm.

 Inclination of the floor should be less than 1% or 10 mm per meter. See Fig 3.
Fig 3. Inclination of the floor.
6
Installation Kit
Below is a list of the installation equipment required for the ClimateWell SolarChiller, i.e. the tools and other parts not
included with the product delivery from ClimateWell.
The tools needed for installation are:
Standard Tools
A C
D
B
A. A 19 mm open-end wrench or an adjustable spanner to connect load cell.

B. A 10 mm wrench is necessary to steady the rod when fastening load cell in place and for fastening the plumbing
unit’s rack to the barrels.
C. A slide scale for measuring the rod when adjusting the load cell.
D. A 39 mm open-end wrench or an adjustable spanner to connect barrels to plumbing unit with corrugated piping
and to connect plumbing unit to external circuits.
Vacuum Pump
E. A vacuum pump, vacuum pump tool and a manometer are needed to vacuum pump barrel A and barrel B in the
end of the charging cycle during the commissioning of the ClimateWell SolarChiller. That procedure is explained
in the Commissioning chapter.
7
Delivery of the ClimateWell SolarChiller

ClimateWell SolarChiller is delivered by truck in three packages. It is necessary to use a fork lift to unload each of these
packages.
Package 1: Plumbing Unit with top cover (a packet of accessories are included).
Package 2: Barrel A with front cover and logotype cover.
Package 3: Barrel B with front cover.
i Please Note! Barrel A and Barrel B are discharged on delivery.
! Safety Notice! Handle the barrels with care; each barrel weighs approximately 456 kg. The plumbing unit weighs
approximately 78 kg with covers.
Fig 4. Items included in the delivery.
Remove the plastic and cardboard covers from both barrels and the plumbing unit. Place the barrels in their final position
according to the system configuration.
i Please Note! In the plumbing unit there is a small packet that includes:
Fig 5. Temperature sensors, aluminum tape and insulation tape are also included in the delivery.
The high temperatures secure aluminum tape and the insulation tapes are used for connecting the temperature sensors to
the external pipes.
8
Assembling the ClimateWell SolarChiller

When the barrels are placed in their final position, follow the steps below to assemble the barrels and to connect them to
the auxiliary units.
Fig 6. Place the barrels in their final position according to the system configuration.
Connecting the Plumbing Unit

1. Lift off the plumbing unit top cover and put it aside.
i Please Note! The covers of the barrels should not be removed.
2. Fasten and adjust the condenser so the load cell rests between the washer and the tank. Use a 19 mm
wrench or an adjustable spanner to tighten the lock nut to 52 mm and then release it counter clockwise to
50 mm according to Fig 7.
! Important! Use the 10 mm wrench to steady the rod while adjusting the nut and a slide scale to measure.
9
Fig 7. Load Cell.
! Important! The adjustment above has to be done before connecting the load cell to the control system box.
If this is not done there will be a negative current to the control system which could damage some of the hardware.
3. Remove the red protection caps on the barrels’ pipes. See Fig 8.
Fig 8. Remove protection caps.
10
4. Remove lock nuts and washers from the bolts (two on each barrel) coming out of the barrels according to Fig
9 A before placing the plumbing unit on top of the barrels.
5. Lift the plumbing unit and place it on top of the barrels with the connection pipes in the front. Place the holes in
the plumbing units’ rack according to Fig 9 B. Put back washers and lock nuts according to Fig 9 C and fasten
the plumbing unit to the barrels using a 10 mm open-end wrench or an adjustable spanner.
! Important! Be careful not to damage the load cells or the connection pipes while placing the plumbing unit.
Fig 9. Place the plumbing unit on top of the barrels.
6. Connect the plumbing unit pipes to the barrels.
1) There are a total of 8 brass sealing rings placed in the connections between the plumbing unit and
the flexible pipes from the barrels. See Fig 10.
Fig 10. Each ring is placed in the connections between the plumbing unit and the barrels.
! Important! Apply pipe sealing paste on the pipes before tightening the connections to facilitate a
leak proof installation.
2) If necessary, move the plumbing unit, and possibly also the barrels to help fit the connections. The
pipes in the plumbing unit are flexible, meaning that it is possible to push them up to facilitate the
connection.
11
Fig 11. Flexible pipes.
3) Tighten the 8 connections (4 to each barrel) between the plumbing unit and the barrels. See Fig 12.
Fig 12. Connections between the plumbing unit and the barrels.
! Important! Make sure that the pipe does not move while tightening the connection since this could
damage the connections. Make sure all connections are securely tightened.
12
Connecting the External Circuits

Connect the circuits. Fig 13 shows how the circuits should be connected. The 6 pipes are all 28 mm copper and the
clamping ring connections to the external circuits have the dimension 28 x 1.5 mm.
Fig 13. Connections to the barrels and the external circuits.
13
Connecting the Temperature Sensors and Load Cells

! Important! It is necessary for the ClimateWell SolarChiller to always have a small flow rate even if it does not need the
energy, to be able to monitor the circuit’s temperature. In installations, a bypass is mandatory in the SP circuit, but
recommended in the AC and HS circuits as well. If the external output signals from the machine to AC and HS pumps are
used, then bypasses are not needed for these circuits.
The TAC, TSP and THS shall be placed on the outside of their bypass valves. For more information see Appendix A,
Bypass Specification.
Fig 14. Temperature sensors and Load Cell connections.
Temperature sensors to connect are:
TAC Temperature sensor – Air Condition

TSP Temperature sensor – Solar Power
THS Temperature sensor – Heat Sink
Load Cells to connect are:
LCA Load Cell – Barrel A

LCB Load Cell – Barrel B
14
Connect the TAC, TSP and THS temperature sensors to the external copper pipes according to Fig 14 and 15.
Fig 15. Connect the TAC, TSP and THS temperature sensors.
1) Place the temperature sensor on the copper pipe.

2) Use the aluminium tape to fasten the sensor to the copper pipe. Make sure that the sensor is lying
tightly against the copper pipe.
3) Cover the temperature sensor connection with a piece of insulation.
Make sure that the TAC, TSP, THS temperature sensors and Load Cells are connected to the control system. See
Fig 14 and 16.
4) Open the metallic control system box in front of the plumbing unit.
5) Inside the plumbing unit, find the black cable mounted on the “From ClimateWell SolarChiller To AC”
connection pipe.
6) Lead it through the hole in the metallic control system box and connect it to the TAC port next to the
other temperature sensors.
7) Repeat for THS mounted on “To ClimateWell SolarChillerFrom HS”, and TSP mounted on “To
ClimateWell SolarChiller from SP” if necessary.
8) Inside the plumbing unit, find the black Load Cell cables from barrel A and barrel B and connect
them according to Fig 16.
15
i Please Note! Verify that all connections are made according to Fig 16.
Fig 16. Connections from the barrels and the plumbing unit to the control system hardware.
16
Commissioning
Start-up
1. Make sure that all the connections are made.
2. Start the machine by connecting the 230 V cable to a power source.
Note! After doing a restart or after a power failure please wait approximately 50 seconds for the control
system panel to power up.
3. The ClimateWell SolarChiller will start in Manual mode when started the first time.
4. Check that all sensors and valves are connected properly and that signals are received into the display
interface. Make sure that the temperatures and flow rates are reasonable.
5. Fill the ClimateWell SolarChiller (see following chapter Filling the ClimateWell SolarChiller).
6. Double check the pressure in all external piping systems is 3 bar (machine in the primary) or 1,5 bar (machine
in the secondary).
7. Verify that the flows are stable after degassing (see following chapter Filling the ClimateWell SolarChiller).
Calibration
1. Change the operation mode to Full cycles and run the machines for at least one charge and discharge cycle
per barrel.
2. Create a graph of the LC values from CWIC log data for each barrel.
3. Identify max and min values.
4. Input values under Parameters – Loadcellmin and Parameters – Loadcellmax for both barrels.
5. Change the operational mode to Normal.
6. Set the local currency and electricity price.
7. Set the fixed flow rates of the SP and HS for appropriate power and energy calculations.
Vacuum Pumping
1. Vacuum pump in the end of the charging cycle (Barrel A and B).
2. The end of the charging cycle is defined as when the difference between TC Out - TC In of the charging barrel
is less than 3 degrees and the TR In is over 90 degrees with a flow of 15 litres / minute in the condenser of the
charging barrel.
3. Connect the exhaust hose with the exhaust filter and if possible lead it to the outside of the building.
4. Connect the vacuum pump using the vacuum tool, to the charging machine’s condenser.
5. Turn on the manometer.
6. Start the vacuum pump and note that the pressure sinks to below 1,5 mbar.
7. The vacuum pump needs to be warm to be fully functional. It is recommended to let the pump run for around
one hour before opening any valves to the barrels.
8. Open the valve in the vacuum tool.
9. Note the pressure. The pressure should be 30-35 mbar.
10. Run the vacuum pump for 15 minutes.
11. Make a note of the pressure at the end of vacuum pump cycle.
12. Close the valve on the vacuum tool and shut down the pump.
13. Disconnect the vacuum plug while under pressure and check that the pressure does not rise when the
vacuum tool rod is extracted. If the pressure does not change disconnect the vacuum tool.
14. Do the same procedure for the other barrel in the end of the charging cycle.
17
Final Step
1. When all the steps above are checked, make sure the operation mode is set to “Normal” and the ClimateWell
SolarChiller will be ready to start delivering solar cooling to the building.
Filling the ClimateWell SolarChiller
Filling the ClimateWell SolarChiller by using the Control System Display User Interface
1. Set the operation mode to Filling Mode. For a more detailed description of the Display User Interface please
see the ClimateWell SolarChiller Control System Manual.
Fig 17. Filling Mode.
2. Once the external circuits are tightly connected, fill the system with non-toxic antifreeze. If the ClimateWell
SolarChiller is in the secondary solar circuit the filling overpressure could be 1-1,5 bar or if the ClimateWell
SolarChiller is in the primary solar circuit the filling overpressure should be approximately 3 bar.
! Important! Fill the system with non-toxic antifreeze to protect the system in temperatures down to at least
-5°C. For example using Propylene Glycol 1,2 L ≥ 15% concentration.
3. Get rid of the air pockets by using the air venting valves outside of the ClimateWell SolarChiller system
(external circuits).
4. The filling mode window has three different “valve” buttons: AC, HS and SP. They are red to indicate that the
valves are closed. To fill the AC circuit, push the AC button which then turns green and the two CAC and two
RAC valves open.
The HS and SP buttons are connected in similar ways; the HS button controls the four CHS and RHS valves
for both barrels and SP button opens and closes the two RSP valves.
18
Fig 18. Filling the AC circuit.
Open one circuit at a time and fill to the specific pressure. Then close it and open the next circuit. Keep on
until the pressure is stable in all three circuits.
i Please Note! The liquids should be the same in all circuits since it will be mixed in the ClimateWell
SolarChiller.
! Important! After approximately a week the air pockets should be gone. Make sure to fill the circuits if the
pressure is below 1 bar.
19
Cover Assembly
Fig 19. Front cover assembly.
Fig 20. Logotype cover assembly.
20
Fig 21. Top cover assembly.
Fig 22. The ClimateWell SolarChiller is assembled.
21
Technical Data and Specifications
ClimateWell SolarChiller
Measurements (H x W x D) mm 2038 x 1211 x 807
Weight Total (with covers) kg 990
Weight Plumbing Unit and

kg 78
Control Unit (with cover)
Weight Barrel (with cover) kg 456
Maximum Pressure in Circuits bar 10
Total Volume in Circuits liter 74,5
The Continuous Maximum Temperature °C 120
Pressure Drops
SP circuit 25l/min kPA 30

HS circuit 50l/min 38
AC circuit 25l/min 45
Average Electric Energy Consumption over a Year kWh 200
Use non-toxic antifreeze to protect the

system in temperatures down to at
Freeze Protection Liquid least -5°C. For example using
Propylene Glycol 1,2 L ≥ 15%
concentration.
Energy Storage Capacity - Cooling kWh 56 ( 28 per barrel )

*73 kWh if
combined (both
Energy Storage Capacity - Heating kWh 64 ( 32 per barrel )
charging and
discharging.
Energy for Charging (One Cycle) kWh 57 per barrel
22
Troubleshooting
If the machine should stop delivering cooling/heating, there are some simple tests to be made to make sure that the
machine behaves as it should. This is because there could be several reasons for the machine to stop deliver
cooling/heating or stop consuming energy even when the machine is functioning correctly. One example is that the
machine could be empty of energy.
PROBLEM POSSIBLE CAUSE SOLUTION

ClimateWell Has it been sunny the last couple of days? If all these criteria are met wait 30 minutes
SolarChiller does not If not the machine has probably not been able to see if things change. In the beginning
deliver cooling/heating to charge and have no energy to use for of the discharging cycle it could take up to
producing cooling/heating. 30 minutes before the barrel starts to
deliver cooling/heating. If the machine has
If it has been sunny, what is the level on the not begun delivering cooling/heating still
discharging barrel? after 30 minutes it can be necessary to
This is another measurement of the energy left perform a system restart. Push the
in the machine. If the level is less than 10 % the Power Off button in the Control system
barrel is empty. panel and then wait 30 s before
unplugging the power connection.
Reinsert the power connection to perform
the restart.
For more information about the Power Off

button please see the Control System
Manual.
If the problem remains call an authorized

installer for help, see Reference chapter.
23
Maintenance
Initially the water in the circuits could cause corrosion, but after some time all the air in the water have been
used in the corrosion process and it will decrease, not producing any problems. It is important not to
change the water in the circuits too frequently (maximum once per year).
ClimateWell SolarChiller should not be subjected to temperatures below 0°C. To avoid temperatures below 0°C
and any possible corrosion, an indoor location is recommended.
CE
ClimateWell SolarChiller is certified according to the following EC directives:
89/336/EEG Electromagnetic Compatibility (EMC)

2006/6/95/EG Low Voltage Directive (LVD).
Please see the “Declaration of Conformity” in Appendix B.
24
Appendix
Table of Contents
Appendix A. Bypass Specification

Appendix B. Declaration of Conformity
Appendix A – Bypass Specification
Working temperature, max 115°C
Demands on gaskets to resist 120°C
Pressure, max 10 bar
Type of valve Trottle valve
Flow rate < 2 l/min
Material Corrosion resistant
Useful life 15 years
Environment-friendly Recycable
Fluid Tyfocor or water
i Please Note!
In installations, a bypass is mandatory in the SP circuit, but recommended in the AC and HS circuits as well. If the
external output signals from the machine to AC and HS pumps are used, then bypasses are not needed for these circuits.
25
Placement of bypass
The bypass should be mounted between the inlet and outlet pipes in the SP or HS circuits (Fig. 1). As an
alternative to the throttle valve, a copper pipe of 2-3 mm can be soldered to the in- and outlet pipes (Fig. 2).
Fig. 1: Bypass solution with throttle valve.
Fig. 2: Bypass solution with copper pipe.
26
Appendix B – Declaration of Conformity
27
Index
A I
Appendix ..................................................................... 24 Important Information ....................................................4
Assembling the ClimateWell SolarChiller ..................... 9 Installation Kit ................................................................7
C M
CE .............................................................................. 23 Maintenance ................................................................23
Commissioning ........................................................... 17
P
Connecting the External Circuits ................................ 13
Connecting the Plumbing Unit ...................................... 9 Preparation ....................................................................5
Connecting the Temperature Sensors
and Load Cells ............................................................ 14 R
Cover Assembly.......................................................... 19 Reference ....................................................................28
D T
Delivery of the ClimateWell SolarChiller ....................... 8 Technical Data and Specifications ..............................21
Dimensions of the ClimateWell SolarChiller ................. 5 Troubleshooting ...........................................................22
E V,W
Electrical Properties ...................................................... 5 Where to Place the ClimateWell SolarChiller ................6
F
Filling the ClimateWell SolarChiller............................. 18
28
Reference
ClimateWell AB
Instrumentvägen 20
126 53 Hägersten (Stockholm)
Sweden
Tel. +46 8 794 03 70
Fax. +46 8 744 30 70
[email protected]
ClimateWell Ibérica S.A.U.

C/Insula Barataria N° 27
28034 Fuencarral (Madrid)
Spain
Tel. +34 91 372 12 55
Fax. +34 91 734 16 52
[email protected]
ClimateWell Ibérica S.A.U.

Avenida de Segovia 6,
Polígono Industrial,
C.P. 42110, Ólvega (Soria)
Spain
[email protected]
29
Due to our policy of ongoing development and improvement ClimateWell AB reserves the right to
vary configurations, dimensions, availability, etc without prior notice.
www.climatewell.com
30

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ClimateWell SolarChiller

Thank you for choosing ClimateWell SolarChiller!

Solar energy day and night

Copyright © 2010 ClimateWell AB. All rights reserved.

Installation and Safety

Do not damage or otherwise modify the power supply cord.

Make sure the supply cord is properly in place.

Dimensions of the ClimateWell SolarChiller

Fig 2. Dimensions of the ClimateWell SolarChiller.

Where to Place the ClimateWell SolarChiller

 Minimum ceiling height at least 2245 mm.

Fig 3. Inclination of the floor.

A. A 19 mm open-end wrench or an adjustable spanner to connect load cell.

Delivery of the ClimateWell SolarChiller

i Please Note! Barrel A and Barrel B are discharged on delivery.

Fig 4. Items included in the delivery.

Assembling the ClimateWell SolarChiller

Connecting the Plumbing Unit

i Please Note! The covers of the barrels should not be removed.

Fig 7. Load Cell.

Fig 8. Remove protection caps.

Fig 9. Place the plumbing unit on top of the barrels.

6. Connect the plumbing unit pipes to the barrels.

Fig 11. Flexible pipes.

Connecting the External Circuits

Fig 13. Connections to the barrels and the external circuits.

Connecting the Temperature Sensors and Load Cells

Fig 14. Temperature sensors and Load Cell connections.

Temperature sensors to connect are:

TAC Temperature sensor – Air Condition

Load Cells to connect are:

LCA Load Cell – Barrel A

1) Place the temperature sensor on the copper pipe.

Filling the ClimateWell SolarChiller

Fig 17. Filling Mode.

Fig 18. Filling the AC circuit.

Fig 19. Front cover assembly.

Fig 20. Logotype cover assembly.

Fig 21. Top cover assembly.

Fig 22. The ClimateWell SolarChiller is assembled.

Technical Data and Specifications

Weight Total (with covers) kg 990

Weight Plumbing Unit and

Weight Barrel (with cover) kg 456

Maximum Pressure in Circuits bar 10

Total Volume in Circuits liter 74,5

The Continuous Maximum Temperature °C 120

SP circuit 25l/min kPA 30

Average Electric Energy Consumption over a Year kWh 200

Use non-toxic antifreeze to protect the

Energy Storage Capacity - Cooling kWh 56 ( 28 per barrel )

Energy for Charging (One Cycle) kWh 57 per barrel

PROBLEM POSSIBLE CAUSE SOLUTION

For more information about the Power Off

If the problem remains call an authorized

89/336/EEG Electromagnetic Compatibility (EMC)

Please see the “Declaration of Conformity” in Appendix B.

Appendix A. Bypass Specification

Appendix A – Bypass Specification