Installation and maintenance manual Manuel d'installation et de maintenance Installations- und Wartungshandbuch Manuale di installazione e di manutenzione Manual de instalación y de mantenimiento WQL-WQH-WQRC 524-1604 English 154 460 kW 170 508 kW Français Deutsch Italiano Español Water Cooled Liquid Chillers - Water/Water Reverse Cycle Heat Pumps - Condenserless Units Refroidisseurs de Liquid à Condensation par l’Eau - Pompes à Chaleur Réversibles Eau/Eau Refroidisseurs de Liquid sans Condenseur
1 - FOREWORD 7 - PRODUCT DESCRIPTION 1.1 Introduction...........................................................................2 7.1 General Information.............................................................26 1.2 Warranty...............................................................................2 7.2 Body and Frame..................................................................26 1.3 Emergency stop/Normal stop................................................2 7.3 Compressors.............
11--Introdução Foreword 1.1 Introduction 1.3 Emergency stop / Normal stop Units, manufactured to state-of-the-art design and implementation standards, ensure top performance, reliability and fitness to any type of air-conditioning systems. The emergency stop of the unit can be enabled using the master switch on the control panel (move down the lever). For a normal stop, press the relevant push-buttons.
English 2 - Safety 2.1 Foreword These units must be installed in conformity with the provisions of Machinery Directive 2006/42/EC, Pressure Equipment Directive 2014/68/EU, Electromagnetic Compatibility Directive 2014/30/EU, as well as with other regulations applicable in the country of installation. If these provisions are not complied with, the unit must not be operated.
2 - Safety (continued) disassemble connections, filters, joints or other line items 2.2 Definitions OWNER: means the legal representative of the company, body or individual who owns the plant where unit has been installed; he/she has the responsibility of making sure that all the safety regulations specified in this manual are complied with, along with the national laws in force.
connections, even for limited periods of time or in an emergency n place a warning sign “do not turn on - maintenance in progress” on the external disconnecting switch n make sure that on-off remote controls are inhibited n wear suitable personal protective equipment (helmet, safety gloves, goggles and shoes etc.
2 - Safety (continued) 2.7 Safety labels Instruction for the movimentation - Outside the packaging Identification of the unit Outside, on the left -hand front column CODICE PRODOTTO NEUTRO PRODUCT CODE MODELLO MODEL 0425 MO.NO MATRICOLA SERIAL NO. ANNO DI COSTRUZIONE Manuf. Year REFR. CIRCUIT GWP 1 2 3 4 CHARGE (Kg) (tCO₂eq) PS (LATO ALTA / LATO BASSA) MIN. 5 cm bar PS (HIGH / LOW SIDE) TS (ALTA / BASSA) °C TS (HIGH / LOW) ALIM.
Electrical warning Adjacent to the master switch Grounding connection on the electrical board, adjacent to the connection ATTENZIONE ! ATTENTION ! ACHTUNG ! Prima di Enlever aprire togliere l’alimentation tensione electrique avant d’ouvrir CAUTION ! ATENCION ! Vor offnen des Disconnect Cortar la corrente antes gehauses electrical de abrir hauptschalter supply before el aparato ausschalten opening Commissioning - Outside, on the left-hand front column Read the instruction on the electrical board Fitti
2 - Safety (continued) Identification of refrigerant - Below identification of the unit Circuit drain - Outside, on the right-hand front column ATTENTION! Don’t leave the unit with water inside hydraulic circuit during winter or when it is in stand by. ATTENZIONE! Non lasciare l’unità con acqua nel circuito idraulico durante l’inverno o quando non è funzionante. ATTENTION! Ne laissez pas l’unitè avec de l’eau dans le circuit hydraulique pendant l’hiver ou quand elle ne travaille pas.
2.8 Safety regulations REFRIGERANT DATA Toxicity SAFETY DATA: R410A Low If sprayed, the refrigerant is likely to cause frost burns. If absorbed by the skin, the danger is very limited; it may cause a slight irritation, and the liquid is degreasing. Unfreeze the affected skin with water. Remove Contact with skin the contaminated clothes with great care - in the presence of frost burns, the clothes may stick to the skin. Wash with plenty of warm water the affected skin.
2 - Safety (continued) 2.8 Safety regulations (continued) REFRIGERANT DATA General precautions Respiratory system protection SAFETY DATA: R410A Do not inhale concentrated vapours. Their concentration in the atmosphere should not exceed the minimum preset values and should be maintained below the professional threshold. Being more weighty than the air, the vapour concentrates on the bottom, in narrow areas. Therefore, the exhaust system must work at low level.
2.8 Safety regulations (continued) LUBRICANT OIL DATA SAFETY DATA: POLYESTER OIL (POE) Classification Not harmful. Contact with skin May cause slight irritation. Does not require first aid measures. It is recommended to follow usual personal hygiene measures, including washing the exposed skin with soap and water several times a day. It is also recommended to wash your overalls at least once a week. Contact with eyes Wash thoroughly with a suitable solution or tap water.
3 - Transport, Handling and Storage WQL / WQH / WQRC units are supplied fully assembled and tested (except for accessories supplied loose in the units – absorbers, filter, etc.). They are ready to be installed and started on the field. Space requirements request to handling R410A units are only charged with liquid refrigerant and with oil in the quantity required for operation.
3.3 Anchoring n Minimum storage temperature is -25 °C. It is not essential to secure the unit to the foundations, unless in areas where there is a serious risk of earth-quake, or if the appliance is installed on the top of a steel frame. n Store the units in areas where minimum activity is likely to take place in order to avoid any risk of accidental damage. n Never use steam to clean the unit. 3.
4 - Installation 4.1 Positioning of the unit DANGER 4.2 Spring Isolator Installation Before installing the unit, make sure that the structure of the building and/or the supporting surface can withstand the weight of the appliance. The weights of the units are listed in Chapter 8 of this manual. n Prepare the base, that must be flat and plane. n Lift the appliance and insert shock absorbers as follows: These units have been designed for indoor installation on a solid surface.
4.3 Internal/external Water Circuit The expansion tank shall be dimensioned in such a way that it can absorb a 2% expansion of the total volume of the water in the plant (exchanger, pipelines, uses and storage tank, if available). The flow switch and the filter water, although not included in the supply, must always be fitted such as plant components. Their installation is mandatory for warranty.
4 - Installation (continued) WQL - WQH 524 / 1604 HYDRAULIC SYSTEM BASIC A 1- C 6 2 B E 5 4 8 INLET 7 5 C 8 A 1- E 6 6 2 B 3 E E OUTLET 5 4 8 INLET 7 5 C 8 COMPONENTS 1C Condenser 1E Evaporator 2 Water filter 3 Water outlet 4 Water inlet 5 Globe valve 6 Flexible pipes 7 By pass valve 8 Pressure point/drainage SAFETY/CONTROL DEVICES A Water differential pressure switch (50 mbar) B Inlet water temperature sensor C Outlet water temperature sensor D Vent valve E Thermometer Unit sid
WQL - WQH 524 / 1604 HYDRAULIC SYSTEM 1P CONDENSER 1P EVAPORATOR COMPONENTS 1C Condenser 1E Evaporator 2 Pump 3 Water filter 4 Pressure expansion tank 5 Water outlet 6 Water inlet 7 Globe valve 8 Flexible pipes 9 By pass valve 10 Pressure point/drainage SAFETY/CONTROL DEVICES A Water differential pressure switch (50 mbar) B Inlet water temperature sensor C Outlet water temperature sensor D Vent valve E Thermometer F Water safety valve (6BAR) Unit side Probes 17 English 4 - Installation (continued)
4 - Installation (continued) WQL - WQH 524 / 1604 HYDRAULIC SYSTEM 2P CONDENSER 2P EVAPORATOR D A 10 2 F 8 3 1- C B 2 E 7 6 11 INLET 9 10 7 C 11 D A 10 2 F 8 OUTLET 4 1- E 8 3 B 5 E E 7 6 2 INLET 11 9 7 10 C 11 COMPONENTS 1C Condenser 1E Evaporator 2 Pump 3 Water filter 4 Pressure expansion tank 5 Water outlet 6 Water inlet 7 Globe valve 8 Flexible pipes 9 By pass valve 10 Non-return valve 11 Pressure point/drainage SAFETY/CONTROL DEVICES A Water differential press
4.4 Water connections WARNING It is important that the appliance is grounded. The attachments at the water inlet and outlet shall be connected in compliance with the instructions which can be found on the labels in the proximity of the attachments. DANGER Connect the water lines of the plants with the attachments of the unit whose diameters and positions are shown by Chapter 8. DANGER 4.
4 - Installation (continued) 4.6 Electrical connections The maximum % value of these differences (unbalance) must not exceed 2% of the mean voltage. The unit must be installed on site according to the Machinery Directive 2006/42/EC, Electromagnetic Compatibility Directive 2014/30/EU and the usual procedures and standards applicable in the place of installation. If the unbalance is unacceptable, contact the Energy Distributor to solve this problem.
Electrical Connections * Terminals block “05A” - “05”: Condenser flow switch terminals as a standard Terminals block “06" - "07”: Condenser flow switch terminals for well water application 21 English 4 - Installation (continued)
5 - Start-Up WARNING The unit must be started for the first time by personnel suitably trained by one Authorised Service Centre. Failure to meet this requirement will immediately void the warranty. n Start the pump and check that the water flow is correct. n Set the desired fluid temperature on the control board. n Start the appliance (see Chapter 6). n Check the correct direction of rotation of compressors.
6 English 6 - Control General information Introduction This document contains the information and the operating instructions for WQL/WQH/WQRC units. Main characteristics – simple user interface with possibility to customize keys functions and to set menus visibility – parameter setting through keyboard or PC – thermoregulation → inlet/outlet water probe, according to customer need / application – 6.
6 - Control (continued) ICON / COLOR STEADY ICON 6.4 Menu structure BLINKING ICON GREY - Alarm ON - Alarm QUIT / GREY - Mode: HEATING - Antifreeze+Heat pump ON - Heating mode by remote / GREY - Mode: COOLING - Cooling mode by remote / GREY - Mode: STAND-BY - Stand-by mode by remote / GREY / / / GREY - Configurable - Configurable / GREY - Current HR - Time slots activ.
English 6 - Control (continued) 6.
7 - General Description 7 General Description 7.4 Refrigeration circuits The refrigeration circuit is provided with a thermostatic expansion valve, dehydrating cartridge filter, sight glass with a colour-change humidity indicator, HP and LP pressure switches. 7.1 Introduction The new range of water cooled chillers, includes 14 different capacities, fit for medium-sized, commercial and industrial applications.
WQL 524 - 1604 Refrigeration System COMPONENTS 1 Compressor 3 Condenser 4 Drier filter 5 Sight glass 6 Mechanical expansion valve 7 Evaporator 9 Electronic expansion valve 10 Desuperheater SAFETY / CONTROL DEVICES A High pressure switch (40.
7 - General Description (continued) 7.8 Accessories Phase Monitor Kit Water Filter It is assembled on the unit as a standard. 2”1/2 filter (524-804 units) and 4” filter (904-1604 units) is supplied loose and has to be mounted by the customer. (both evaporator and condenser side) Airway Packaging Complete wooden package for units without refrigerant and with nitrogen precharge. No refrigerant charge is shipped loose with the unit. The customer has to fill the unit through the apposite connection.
DISCHARGE LINE Condensing control kit Antivibrating supports (AVM) It is provided as an option/accessory to allow the unit managing the control of condensation, in case very cold water (from a well in example) is entering the condenser . A 0-10V signal (terminal 2-3 of the electrical box / refer to Chapt. 4) is available to manage a variable flow device (in example 2/3 ways modulating valve, inverter pump). Isolating spring suppor ts, equipped with bolts for fastening to the base.
8 - Technical Data 8.
English 8 - Technical Data (continued) 8.
8 - Technical Data (continued) WQH 524-1604 524 604 704 804 904 Number of refrigerant circuits Part load steps Power supply 1004 1104 1204 1404 1604 2 % 0-25-50-75-100 V/ph/Hz 400V/3/50Hz Startup type Direct REFRIGERANT Type / GWP Charge (1)/(2) (4) R410A / 2088 kg 9,0 / 9,0 11,4 / 11,4 13,1 / 13,1 13,9 / 13,9 17,3 / 17,3 21,8 / 21,8 24,4 / 24,4 27,5 / 27,5 30,4 / 30,4 30,4 / 30,4 tCO2eq 18,8 / 18,8 23,8 / 23,8 27,4 / 27,4 29,0 / 29,0 36,1 / 36,1 45,5 / 45,5 50,9 / 50,9 57,4 / 57,4 63,
English 8 - Technical Data (continued) Operating weight (1) kg 909 989 1187 1360 1376 1500 1598 1704 1787 1842 Operating weight (2) kg 1012 1092 1290 1463 1479 1603 1701 1807 1890 1945 1404 1604 DIMENSIONS Length mm 2250 Width mm 850 (1) / 854 (2) - 885 (1)/(3) - 1005 (2)/(3) Height mm 1845 (1) / 1880 (2) (1) STD version (2) S version (3) Only for handling (4) The refrigerant value are indicative values for standard units. The actual data are indicated on the unit label.
8 - Technical Data (continued) 8.3 Unit electrical data WQL/WQH/WQRC Rated voltage Max. absorbed power 524 604 704 804 V/ph/Hz 1004 1104 1204 1404 1604 59,0 68,2 77,1 86,4 97,4 108,4 126,2 144,0 176,0 196,0 Rated current A 64 83 86 86 101 116 133 150 158 174 Max. current FLA A 124 136 141 147 171 195 228 262 294 324 Max.
English 8 - Technical Data (continued) 8.
8 - Technical Data (continued) WQL/H/RC 1404-1604 available static pressure - internal heat exchanger (1/2P SP/E) H [kPa] 350 350 300 300 1604 1604 250 250 200 200 1404 1404 150 150 100 100 50 50 0 0 0 0 5 5 10 10 15 15 20 20 25 25 30 30 35 35 40 40 45 45 Water flow rate [l/s] H [kPa] WQL/H 1404-1604 available static pressure - external heat exchanger (1/2P SP/C) 400,0400,0 350,0350,0 300,0300,0 250,0250,0 200,0200,0 150,0150,0 100,0100,0 50,0 50,0 0,0 0,0 0 0 5 1604 1604 1404 1404 5 10 10 15 1
English 8 - Technical Data (continued) WQL/H/RC 524-1204 available static pressure - internal heat exchanger (1/2P HP/E) 350 325 300 704 275 250 225 H [kPa] 1204 1104 804 200 524 604 175 904 - 1004 150 125 100 23 24 25 26 23 24 25 26 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 50 4 75 Water flow rate [l/s] WQL/H/RC 524-1204 available static pressure - external heat exchanger (1/2P HP/C) 375 350 1104 325 300 275 604 1204 1004 225 804 200 524 704 175 90
8 - Technical Data (continued) WQL/H/RC 524-1204 - internal heat exchanger pressure drop 100 804 90 704 80 524 70 604 1004 H [kPa] 60 50 1104 904 40 1204 30 20 10 40.0 39.0 38.0 36.0 37.0 35.0 44.0 34.0 43.0 33.0 32.0 31.0 30.0 29.0 28.0 27.0 26.0 25.0 24.0 23.0 22.0 21.0 20.0 19.0 18.0 17.0 16.0 15.0 14.0 13.0 12.0 11.0 9.0 10.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.
English 8 - Technical Data (continued) WQL/H 1404-1604 - external heat exchanger pressure drop 120 100 1404 1604 H [kPa] 80 60 40 20 0 0 5 10 15 20 25 30 35 40 45 Water flow rate [l/s] 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 1404 1104 1604 904-1004 1204 604 Water flow rate [l/s] 39 4.6 4.4 4.2 4.0 3.8 3.6 3.4 3.2 3.0 2.8 2.6 2.4 2.2 2.0 1.8 704-804 1.6 1.4 1.2 1.0 0.8 0.6 0.4 0.2 524 0.
8 - Technical Data (continued) WQRC WQH WQL 8.
WQRC WQH 50 WQL WQL/WQH/WQRC 524-1604 (S) 524 604 704 804 904 1004 1104 1204 1404 1604 524 604 704 804 904 1004 1104 1204 1404 1604 524 604 704 804 904 1004 1104 1204 1404 1604 English 8 - Technical Data (continued) Weight distribution (kg) Operating Shipping P1-P4 coordinates CG coordinates P1 P2 P3 P4 weight (kg) weight (kg) a (mm) b (mm) x (mm) y (mm) 265 264 317 402 427 446 466 491 497 508 269 268 324 409 435 457 476 501 507 518 297 298 353 442 466 486 505 524 531 542 284 298 331 390 401 429 455
8 - Technical Data (continued) 804 1P SP/E : one pump / standard pressure / evaporator 1P SP/C : one pump / standard pressure / condenser 2P SP/E : two pumps / standard pressure / evaporator 2P SP/C : two pumps / standard pressure / condenser 1P HP/E : one pump / high pressure / evaporator 1P HP/C : one pump / high pressure / condenser 2P HP/E : two pumps / high pressure / evaporator 2P HP/C : two pumps / high pressure / condenser 704 604 524 WQL/WQH/WQRC Weight distribution (kg) Operating Shipping P5
1204 1P SP/E: one pump / standard pressure / evaporator 1P SP/C : one pump / standard pressure / condenser 2P SP/E : two pumps / standard pressure / evaporator 2P SP/C : two pumps / standard pressure / condenser 1P HP/E : one pump / high pressure / evaporator 1P HP/C : one pump / high pressure / condenser 2P HP/E : two pumps / high pressure / evaporator 2P HP/C : two pumps / high pressure / condenser 1104 1004 904 WQL/WQH/WQRC Weight distribution (kg) Operating Shipping P5-P8 coordinates CG coordinates
8 - Technical Data (continued) 1604 1404 WQL/WQH/WQRC Weight distribution (kg) Operating Shipping P5-P8 coordinates CG coordinates 1404-1604 (HYDRONIC OPTIONS) P5 P6 P7 P8 weight (kg) weight (kg) a (mm) b (mm) x (mm) y (mm) 1P SP/E 80 85 63 68 294 264 400 774 425 473 1PSP/E 1PSP/C 114 121 84 90 408 348 400 774 425 480 1PSP/C 84 89 66 71 310 280 400 774 425 473 2P SP/E 102 108 77 84 371 340 400 774 425 477 2PSP/E 2PSP/C 164 174 117 127 582 519 400 774 425 4
English 8 - Technical Data (continued) 8.
8 - Technical Data (continued) Dimensional drawings - WQRC 524-1604 STD Back view P Q R Side view Front view S M 2MC1 2MC2 N°4x L 29 O N 1845 G 1MC1 1050 1MC2 B INDOOR HEAT EXCHANGER H A I 254 280 1950 1100 2250 705 20 850 885 Only for movimentation 445 P4 4x 17 38 207 189 105 850 774 191 158 38 P2 P1 705 P3 1100 425 Top view INDOOR HEAT EXCHANGER NOTES GH I L M IN G Water connections Electrical power supply Main switch Control keypad/display DIMENSIONS A = 227 m
English 8 - Technical Data (continued) Dimensional drawings - WQL/WQH 524-1604 S Back view Side view Front view 854 E M N°4x 29 C F L 1880 O D OUTDOOR HEAT EXCHANGER N 1117 I A H B INDOOR HEAT EXCHANGER G 70 254 280 1950 705 850 1004 Only for movimentation 20 1100 2250 445 P4 4x 17 705 1100 445 P1 40 774 40 P2 P3 NOTES GHEF I L M N O Top view Water connections Electrical power supply Main switch Control keypad/display Desuperheater water outlet 1˝ Gas M Desuperhea
8 - Technical Data (continued) Dimensional drawings - WQRC 524-1604 S Back view Q P R Side view Front view 854 S M L N°4x 29 H 1117 B INDOOR HEAT EXCHANGER O N 1880 G A I 70 254 280 1950 705 850 20 1100 1005 445 Only for movimentation P4 4x 17 705 445 1100 P1 Top view 40 774 P2 40 2250 P3 INDOOR HEAT EXCHANGER NOTES GH I L M IN G Water connections Electrical power supply Main switch Control keypad/display DIMENSIONS A = 227 mm B = 369 mm 2 1/2” VICT - 76,1 mm A = 2
English 8 - Technical Data (continued) Dimensional drawings - WQ + IDRO 524-1604 Back view Side view N°4x Q Side view 850 29 2MC1 M 2MC2 OUTDOOR HEAT EXCHANGER L P 1MC2 INDOOR HEAT EXCHANGER 1050 1MC1 889 B D C 227 A I 70 254 280 423 50 2767 642 1100 704 400 885 Only for movimentation 250 3096 P2 8x 17 P4 P1 2P Dimensions 524 604 704 804 904 1004 1104 1204 1404 1604 A LP 410 410 410 430 450 450 450 450 490 490 1P Dimensions 524 604 704 804 904 1004 1104 1204 1404 1
8 - Technical Data (continued) Dimensional drawings - WQ + IDRO 524-1604 Back view Side view Front view 854 S OUTDOOR HEAT EXCHANGER M R Q L N°4x P 29 1649 E 1486 D B 1880 F 1117 INDOOR HEAT EXCHANGER 227 A 595 758 C 70 254 I 280 423 2767 705 1100 850 50 642 400 250 1005 Only for movimentation 40 3096 17 P4 P6 P8 P5 P7 774 P2 8x P3 40 P1 705 2P Dimensions 524 604 704 804 904 1004 1104 1204 1404 1604 A LP 410 410 410 430 450 450 450 450 490 490 1P Dimensio
8.
DANGER When the recovered refrigerant cannot be reused, return it to the manufacturer. Do not throw away the waste oil of the compressor, because it contains refrigerant in solution. DANGER The waste oil must be returned to the manufacturer.
9.3 Refrigerant charge 9.5 Condenser Do not inject refrigerant liquid into the LP side of the circuit. Be very careful, and charge the circuit properly. If the charge is insufficient, the efficiency of the unit will be lower than expected. (In the worst of cases the LP transducer may stop the unit.) Check at regular intervals that the water side of the heat exchanger is perfectly clean.
9 - Maintenance (continued) 9.8 Mechanical expansion valve 9.9 Evaporator The circuit of the unit is equipped with a mechanical expansion valve, with external equalizer Check at regular intervals that the water side of the heat exchanger is perfectly clean. To do this, measure the pressure drop, water side (see Section 8) or measure the temperature of the liquid leaving and entering the heat exchanger, and compare it to the evaporation temperature.
The table below lists the anomalies of operation of the unit, the relevant causes and the corrective measures. For anomalies of any other type or not listed, contact one of authorised Service Centre for technical assistance. Anomaly Cause Operation The unit continues to work, but without cooling Insufficient charge of refrigerant. Refill. The dehydrating filter is clogged. Replace. Ice on the suction line Wrong calibration of overheating. Excessive noise Increase overheating. Check the charge.
11 - Spare Parts 11.1 Spare part list The table below shows the list of spare parts recommended during the first two years of operation. Component Number Pump 1 Differential pressure switch 1 High pressure transducer 1 Low pressure transducer 1 Expansion valve 1 Gas filter 1 4 way valve 1 Electronic main board 1 Auxiliary circuit trasformer 1 Compressor contactor 2 Pump contactor 1 Water sensor 4 Auxiliary contact 4 Driver EEV 1 Fuses 4 11.
After draining operations, the piping of the hydraulic networks can be disconnected and disassembled. During the draining of the refrigeration circuits, do not let the refrigerant overflow in the surrounding atmosphere. DANGER Once they have been disconnected as specified, the packaged units can be disassembled in a single piece.
Systemair srl Via XXV Aprile, 29 20825 Barlassina (MB) Italy Tel. +39 0362 680 1 Fax +39 0362 680 693 www.systemair.com As part of our ongoing product improvement programme, our products are subject to change without prior notice. Non contractual photos. Dans un souci d’amélioration constante, nos produits peuvent être modifiés sans préavis. Photos non contractuelles. In dem Bemühen um ständige Verbesserung können unsere Erzeugnisse ohne vorherige Ankündigung geändert werden.
