Stulz WLA Compact Series Instructions Manual
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Stulz WLA Compact Series Instructions Manual

Stulz WLA Compact Series Instructions Manual

Air cooled water chiller
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ENGLISH EN
W L A C
M P A C T
STULZ the natural choice
Instructions
Index 04
Revision 09.2015
WLA Compact
Air cooled water chiller
230/1/50, 230/1/60
400/3/50, 460/3/60
Translated instructions

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  • Page 1 ENGLISH EN W L A C M P A C T STULZ the natural choice Instructions Index 04 Revision 09.2015 WLA Compact Air cooled water chiller 230/1/50, 230/1/60 400/3/50, 460/3/60 Translated instructions...
  • Page 2 It is the result of decades of research and design studies, with a fine search of materials and technologies to obtain an high quality chiller. The CE mark guarantees that the STULZ/Cosmotec products satisfy the requirements of the European Machinery Directive for safety.

  • Page 3: Table Of Contents

    Summary Introduction ........................5 1.1. General information......................5 1.2. Symbols used in the manual ..................5 1.3. Annexes ...........................5 Safety ..........................6 2.1. Introduction ........................6 2.2. General rules ........................6 2.3. Residual risk ........................7 2.4. Safety data ........................9 2.5. Labels ........................... 16 2.6. Intended and unintended use ..................18 Coding ...........................19 Description ........................20 4.1.
  • Page 4 12.9. Crankcase heater (code OC10HR0 ÷ OC20HR0)..................59 Accessories ........................60 Contacts ........................61 STULZ SpA reserves the right to modify the data contained in this manual without prior notice. The images and illustrations in this manual for illustrative purposes only and they do not constitute contractual ob- ligation.

  • Page 5: Introduction

    Introduction 1.1. General information The units described in this manual belong to the vapour compression refrigerator system family that use chillers of group 2, intended for water cooling. This manual contains safety operating instructions to be complied with during installation, use, and maintenance. Therefore, read and comply with the instructions contained herein. This manual is intended for the following professionals, who are considered authorised personnel: The INSTALLER must check that the handling and installation of the chiller is performed according to the occupational standards and instructions contained in this manual.

  • Page 6: Safety

    Safety 2.1. Introduction This chiller is intended for professional use according to reference directives listed in the CE declaration of conformity attached. The chiller must be installed in compliance with the following directives: • 2006/42/EC - Machinery Directive • 97/23/EC - PED Pressure equipment directive •...

  • Page 7: Residual Risk

    2.3. Residual risk During transport and installation Area Danger Risk Preventive measures Under the unit Defective lifting system of Bruises, shocks. Stay outside the danger area while the the unit, which causes the unit is being handled. fall. Close to the unit Accidental shock with Burns, formation of Stay outside the danger area while the...
  • Page 8 Area Danger Risk Preventive measures Close to the unit With unit ON: leaks in the Burns, formation of For installation inside buildings: convey refrigerant circuit; defective acid vapours in the the safety valve discharge towards safety valve or high presence of flames. specific outdoor areas.

  • Page 9: Safety Data

    Area Danger Risk Preventive measures Close to the Disconnection of the water Irritation of skin and De-pressurise the hydraulic circuit before water pipes. pipes still under pressure. eyes due to contact disconnection. Wear PPE. with ethylene glycol. Electrocution. Slipping. Electrical panel Live power supply line Electrocution.
  • Page 10 REFRIGERANT SAFETY DATA 5. FIRE-FIGHTING Specific hazards Exposure to flames may cause the container to break or explode. MEASURES Hazardous Due to thermal decomposition, the following products may Combustion Products originate: - Carbon monoxide Hydrogen fluoride - Carbonyl Fluoride Specific methods If possible, stop the product from leaking.
  • Page 11 REFRIGERANT SAFETY DATA 7. HANDLING AND Handling Only experienced and trained personnel can handle gas under STORAGE Measures pressure The product must be handled according to the good and technical practices of safety and industrial hygiene. Use only specific precautions equipment, suitable for the product, pressure and operating temperature.
  • Page 12 REFRIGERANT SAFETY DATA 8. EXPOSURE/ Suitable technical The systems under pressure must be checked periodically to PERSONAL checks verify the absence of leaks. PROTECTION CHECKS Use oxygen detectors if there asphyxiating gases are likely to be released. Make sure that the exposure is far below the occupational exposure limits.
  • Page 13 REFRIGERANT SAFETY DATA 9. PHYSICAL Physical state at 20°C I 101 .3kPa AND CHEMICAL Colour Colourless PROPERTIES Odour Ethereal The odour threshold is subjective and Odour Threshold inadequate to detect overexposure. Not applicable Molecular mass [g/moI] Melting point [°C] -101 Boiling point [°C] -26.5 Critical temperature [°C]...
  • Page 14 REFRIGERANT SAFETY DATA 11. TOXICOLOGICAL Acute toxicity This product has no known toxicological effects INFORMATION Skin corrosion/irritation No effects are known in relation to this product Serious eye damage/irritation No effects are known in relation to this product Respiratory or skin sensitization No effects are known in relation to this product Carcinogenicity No effects are known in relation to this product Mutagenicity...
  • Page 15 REFRIGERANT SAFETY DATA 14. INFORMATION ON Number UN 3159 TRANSPORT Suitable shipment Non-flammable, non-toxic gas name Class 2 (ADR, ADNR, RID); 2.2 (IATA, IMDG) Classification code 2A (ADR, ADNR, RID) Hazard identification 20 (ADR, ADNR, RID) number Label EmS Number F-C, S-V (IMDG) Marine Pollutant...

  • Page 16: Labels

    2.5. Labels Tank filling Position: close to the filling valves of the storage tank (where available). Tank discharge Position: close to the draining valves of the evaporators and storage tank (where available). Chiller hydraulic circuit inlet (chiller water return) Position: close to the hydraulic circuit inlet connection.
  • Page 17 0035 REFRIGERATORE DI LIQUIDO - LIQUID COOLER - KUHLANLAGE - REFROIDISSEUR DE LIQUIDE MODELLO - MODEL - TYP - MODELE WLA2240020000 7035 SERIE - SERIES - SERIE - SERIE N°0000000001 ORDINE - ORDER - ORDER - COMMANDER 0000000000 DATA - DATE - DATUM - DATE 29/01/14 Tensione nominale - Rated voltage - 400-460V/3/50-60Hz...

  • Page 18: Intended And Unintended Use

    The operation safety of the system is guaranteed as long as it complies with its intended use. The storage and operation limit values indicated on the data plate and stated in paragraph 5.1 must NEVER be exceeded. STULZ is not liable for damage caused by improper use. The operator is fully responsible for this risk. Unintended use The use of the chiller must ALWAYS comply with the standards in force and instructions provided in this manual.

  • Page 19: Coding

    Coding The code indicates every variant of the chiller and it is indicated on the chiller data plate (see page 17). The following table summarises all the possible code digit values. Some combinations of these values are non- available codes. 1°...

  • Page 20: Description

    The chiller is controlled from the Dixell XW05K electronic regulator (designed and produced according to STULZ specification) and from a main switch placed on the side of the electronic regulator on the chiller front panel. The electrical panel, with protection rate IP44, can be accessed from the upper part of the unit and contains all the electrical control components of the chiller already wired.
  • Page 21 1° 2° 3° 4° 5° 6° 7° 8° 9° 10° 11° 12° 13° 14° - - - - - EN//0915/WLA Compact/21...
  • Page 22 1° 2° 3° 4° 5° 6° 7° 8° 9° 10° 11° 12° 13° 14° - - - - - EN/0915/WLA Compact/22...
  • Page 23 1° 2° 3° 4° 5° 6° 7° 8° 9° 10° 11° 12° 13° 14° - - - - - EN//0915/WLA Compact/23...
  • Page 24 1° 2° 3° 4° 5° 6° 7° 8° 9° 10° 11° 12° 13° 14° - - - - - EN/0915/WLA Compact/24...

  • Page 25: Components Of The Refrigerant Circuit

    4.3. Components of the refrigerant circuit The compressor compresses the refrigerant gas and takes it at a higher temperature and pressure. By crossing the condenser, the hot gas is cooled and liquefied, thus releasing heat into the outdoor air. Pushed by the electronic thermostatic expansion valve, the liquid refrigerant loses pressure in order to start evaporating.

  • Page 26: Protection Components Of The Refrigerant Circuit

    4.5. Protection components of the refrigerant circuit Refrigerant filter A chiller filter is located in the liquid line of each refrigerant circuit. This filter holds the humidity particles in the chiller. Evaporator antifreeze protection device. The antifreeze protection device prevents the evaporator from freezing. An evaporator outlet probe placed on the water circuit measures the temperature of the cooled liquid.

  • Page 27: Components Of The Hydraulic Circuit

    4.7. Components of the hydraulic circuit Chiller The standard hydraulic circuit includes an evaporator (see paragraph 4.3), two water probes, one on the inlet and the other one on the outlet of the heat exchanger, a pressure gauge, a non-pressurised storage tank, and a pump. The refrigerated water pipes are made of polyurethane and are equipped with quick coupling connections.
  • Page 28 Electronic control The electronic control consists of a XW07K microprocessor board and a CX40 keyboard to control the devices of the chiller (compressor, fan, adjustment and safety devices, etc.). The operation software and the file with the parameters are written in EEPROM so that they remain in the memory even in case of power failure. The keyboard with 3-digit display is placed on the front side of the chiller.

  • Page 29: Technical Data

    5.1. Application limits The STULZ WLA Compact chillers have been designed to store and operate within the limits described in this paragraph. The warranty becomes void and null immediately if these limits are not complied with. Contact the manufacturer if the temperature of the fluid to be cooled is required to be outside the defined limits.

  • Page 30: Index

    CFU/ml: number of colony forming units per millilitre With LSI > 0.4 water is saturated with calcium carbonate and has a high tendency to fouling For the type of treatment to be used, contact Stulz Technical Department to evaluate the possible solutions.
  • Page 31 5.2. Technical data (1) Nominal conditions MODEL STANDARD Temperature of the fluid to be cooled at the evaporator inlet [°C] Temperature of the fluid to be cooled at the evaporator outlet [°C] Condenser outside air temperature [°C] Refrigerant (composition referred to the weight) Water 100% (2) The sound pressure level is measured according to Standard EN-ISO 9614-1, and declared at the following conditions:...
  • Page 32 WLA-WLL 12 WLA-WLL 15 Cooling capacity 1200 1500 Sound pressure level at 1 m dB(A) (1) (2) Refrigerant R134a R134a N. of refrigerant circuits Nominal power supply V/-/Hz 230/1/50 230/1/60 230/1/50 230/1/60 Maximum power consumption with standard pump 1364 1316 1157 1512 Maximum current consumption with standard pump...
  • Page 33 WLA-WLL 22 WLA-WLL 30 Cooling capacity 2200 2900 Sound pressure level at 1 m (1) (2) dB(A) Refrigerant R134a R134a N. of refrigerant circuits Nominal power supply V/-/Hz 230/1/50 230/1/60 230/1/50 230/1/60 Maximum power consumption with standard pump 1485 1830 2766 3625 Maximum current consumption with standard pump...
  • Page 34 WLA-WLL 34 WLA-WLL 44 Cooling capacity 3400 4400 Sound pressure level at 1 m dB(A) (1) (2) Refrigerant R134a R134a N. of refrigerant circuits Nominal power supply V/-/Hz 230/1/50 230/1/50 Maximum power consumption with standard pump 3600 4300 Maximum current consumption with standard pump 16.1 20.9 Inrush current with standard pump...
  • Page 35 WLA-WLL 23 WLA-WLL 30 Cooling capacity 2300 2900 Sound pressure level at 1 m (1) (2) dB(A) Refrigerant R134a R134a N. of refrigerant circuits Nominal power supply V/-/Hz 400/3/50 460/3/60 400/3/50 460/3/60 Maximum power consumption with standard pump 2174 2351 2738 3535 Maximum current consumption with standard pump...
  • Page 36 WLA-WLL 34 WLA-WLL 44 Cooling capacity 3400 4400 Sound pressure level at 1 m dB(A) (1) (2) Refrigerant R134a R134a N. of refrigerant circuits Nominal power supply V/-/Hz 400/3/50 460/3/60 400/3/50 460/3/60 Maximum power consumption with standard pump 3250 4160 3720 4730 Maximum current consumption with standard pump...
  • Page 37 Pump head Size No. 1 - WLA12 - WLA15 - WLA22 Size No. 2 - WLA23 Pompa di media pressione (60Hz) Medium pressure pump (60Hz) Pompa di media pressione (50Hz) Medium pressure pump (50Hz) Pompa standard (60Hz) Standard pump (60Hz) Pompa standard (50Hz) Standard pump (50Hz) Flow rate [l/min]...
  • Page 38 Automatic by-pass The automatic by-pass (BPA) is located on the right side of the chiller, and is accessible by removing the right panel. The factory setting of the by-pass is for operation with pumps 50 Hz. For the correct operation with a power supply frequency of 60 Hz it is necessary to change the calibration of the automatic by-pass according to the following table.

  • Page 39: Dimensional Drawings

    5.3. Dimensional drawings Size 1 Air flow Dimensions Main E l e c t r o n i c disconnection controller switch      Pressure gauge Safety label Tank filing cap Visual level Tank discharge Air filter (if available) Chiller data label...
  • Page 40 Size 2 Air flow Dimensions E l e c t r o n i c Main disconnection controller switch      Pressure gauge Tank filing cap Safety label Visual level Tank discharge Air filter (if available) Chiller data label Electrical panel Liquid supply...
  • Page 41 Minimum distance from obstacles or other chillers Distance in millimetres [mm] Size WLA 12-15-22 WLA 23-30-34-44 EN//0915/WLA Compact/41...

  • Page 42: Handling And Storage

    If the goods are not delivered ex-works, in case of damage, follow the instructions indicated on the transport document. This product must not be returned without prior authorisation of STULZ. Contact you local STULZ partner in case assistance service is required.

  • Page 43: Handling

    6.2. Handling The chiller must be lifted safely, without inclining it or resting it on its sides, with suitable equipment. The capacity of the mean must be suitable for the weight of the chiller to be lifted. The load must be balanced to prevent overturning. Do not perform sudden and/or violent manoeuvres.

  • Page 44: Installation

    Installation To install the air conditioner, comply with the Directives indicated at the beginning of chapter “2. Safety” . 7.1. Positioning Pay attention to the following factors to identify the chiller installation site. • The unit should not be positioned downstream heat sources or dirt, in relation to the wind direction. Particles of grease and dust in the air would deposit on the condenser fins, reducing the heat transmission efficiency.

  • Page 45: Hydraulic Connections

    7.2. Hydraulic connections The minimum equipment required for the external hydraulic circuit are: • Pipes with diameter equal to the diameter of the circuit connections, indicated in the hydraulic diagrams in paragraph 4.6. • Two shut-off valves to isolate the chiller from the system in correspondence of the inlet and outlet hydraulic connections.

  • Page 46: Electrical Connections

    7.3. Electrical connections Before performing any operation on electrical parts, make sure that there is no voltage. Make sure that the earthing system of the unit is efficient. • Make sure that the power supply matches with that indicated in the data plate of the chiller (voltage, phase number, frequency) and that the values are not out of the range indicated in paragraph 5.1.

  • Page 47: Commissioning Preliminary Operations

    7.4. Commissioning preliminary operations The operations to be performed before commissioning must be carried out by the installers according to their field of expertise. The commissioning preliminary operations must be performed maximum two days before commissioning. Check correct installation Make sure that the unit has been installed as described in chapter “7. Installation” . •...
  • Page 48 Filling the hydraulic circuit • With machine powered, but in OFF mode, fill the circuit completely with the filling cap. You can use the point indicated with RI in the chiller hydraulic diagram as filling point (see “4.6. Hydraulic diagrams” on page 26). For the symbols, refer to “1.2.

  • Page 49: Commissioning

    Commissioning Only support centres authorised by the manufacturer are allowed to commission the unit. For information and quotations, contact the manufacturer technical support service (see "Contacts" at the end of this paragraph). The preliminary checks described in paragraph 7.4 are not included in the commissioning operations. 8.1.

  • Page 50: Checks To Be Performed After Start Up

    8.2. Checks to be performed after start up • Make sure no alarms are displayed. • Make sure that the fan runs correctly and guarantees correct air flow to the condenser without recirculation. • Make sure that the power supply voltage remains within the limits allowed when the unit is running. •...

  • Page 51: Maintenance

    Maintenance 9.1. Warnings For maintenance operations, comply with the general safety rules described in paragraph 2.2. These operations can be carried out only by qualified personnel, as specified in paragraph 1.1. Remember that routine and special maintenance operations must be carried out by support centres authorised by the manufacturer. RISK OF EXPLOSION: avoid open flames close to refrigerant pipes when the refrigerant circuit is under pressure, regardless of the operation described in this chapter.

  • Page 52: Routine Maintenance

    9.2. Routine maintenance Periodically check the chiller and its operation. Routine maintenance must be performed according to the intervals indicated. Delays or omissions make the warranty void and null, besides reducing the efficiency of the unit. If, according to your experience, the unit requires more frequent maintenance interventions, these must be performed according to the requirements.
  • Page 53 Check the presence of leaks: it is mandatory to check the presence of refrigerant leaks according to European Standard 842/2006 (F-gas). Qualified companies and personnel (according to Reg. 303/2008) provide regular seal checks (according to Reg. 1516/2007 and Reg. 1497/2007) and store registration of the maintenance activities in a specific register containing the various checks performed.

  • Page 54: Special Maintenance

    Hydraulic circuit Water filter on chiller return: if available, check its cleanliness and wash it with water, if required. Hydraulic circuit seal: check the presence of leaks and the seal of the fittings Liquid to be cooled: top up if the level of liquid is low. Switch the unit off and follow the instructions provided in paragraph 7.4.

  • Page 55: 10. Troubleshooting

    10. Troubleshooting Refer to the general safety rules indicated in paragraph 2.2. All the operations described in this chapter must be performed only by qualified personnel according to that specified in paragraph 1.1. Problem Possible cause Recommended intervention MAIN no external consents check the presence of external consents.
  • Page 56 Problem Possible cause Recommended intervention no refrigerant gas see point vii the chiller runs incorrect thermostat configuration check and restore the original configuration continuously excessive thermal load reduce thermal load no refrigerant gas see point vii the chiller runs but presence of humidity in the refrigerant discharge, dry the circuit, replace the filter, does not cool down...

  • Page 57: Decommissioning And Disposal

    Decommissioning and disposal The chillers must be decommissioned by specialised and qualified personnel. RISK OF EXPLOSION: avoid open flames close to refrigerant pipes when the refrigerant circuit is under pressure, regardless of the operation described in this chapter. Do not approach open flames to damaged or perforated pipes, as the refrigerant gas vapours mixed with the compressor oil may catch fire and produce toxic gases.

  • Page 58: 12. Optional

    • Liquid low temperature up to -5°C, Stulz code OC10TW0 ÷ OC20TW0 • Device for ambient low temperature up to -5°C, Stulz code OC10TM0 ÷ OC20TM0 • Device for ambient low temperature up to -10°C, Stulz code OC10TL0 ÷ OC20TL0 •...

  • Page 59: Multi-Pole Connector (Code Oc10Cc0 ÷ Oc20Cc0)

    Insulation of the cold parts (pipes, evaporator, etc.) with chemically cross linked closed cell polyethylene, protected with black anti-scratch film. It allows you to reach liquid supply temperature up to -5 °C. To know the refrigerant yield difference, contact Stulz Technical Department.

  • Page 60: Device For Low Ambient Temperature Up To -10°C (Code Oc10Tl0 ÷ Oc20Tl0)

    12.4. Device for low ambient temperature up to -10°C (code OC10TL0 ÷ OC20TL0) Installation of a differential pressure switch to control the condensation fan in modulation mode. Installed as per standard on models with precision +/-1K, “WLL - Laser unit” The kit allows the extension of the ambient temperature limit of the chiller from +2.5 °C to -10°C (with water and glycol in suitable amount).

  • Page 61: 13. Accessories

    These are: • External automatic by-pass, Stulz code AC10AB0 ÷ AC20AB0 • 100µm water filter for installation on supply, Stulz code AC10FW0 ÷ AC20FW0 • “Y” water filter for installation on return, Stulz code AC10FY0 ÷ AC20FY0 • Polypropylene air filter with metal mesh, Stulz code AC10FP0 ÷ AC20FP0 •...

  • Page 62: 14. Contacts

    14. Contacts STULZ SpA has a worldwide sales and technical support network. For any request or doubt regarding STULZ SpA products, contact the local partner or branch. The list is available on www.stulz.it STULZ S.p.A. Reception Aftersales Via Torricelli, 3...

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