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Summary of Contents for Stulz Explorer WPA
- Page 1 WPA Explorer Original instructions Air cooled liquid chillers Index i01 400V / ~3 / 50Hz Issue 06.2016...
- Page 2 - take advantage of our know-how. Founded in Hamburg in 1947, today STULZ has a presence in over 140 countries. The STULZ Group has STULZ subsidiaries in 17 countries, 7 production...
- Page 3 It is the result of many years of research and design studies, as well as a fine matching of materials and technologies to obtain a high quality chiller. The CE mark guarantees that the STULZ products fulfill the requirements of the European Machinery Directive for safety.
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Page 4: Table Of Contents
5.1.1 Operating conditions:.............................. 34 5.1.2 Storage conditions: ..............................35 5.2 Chilled water quality ........................36 5.2.1 Glycol correction factors ............................36 5.3 Pressure Drops ............................36 5.4 Technical Data .............................40 5.5 Dimensional drawings ........................45 EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... - Page 5 8.5.3 Differential pressure switch ..........................73 8.6 Electric circuit ............................73 8.6.1 Powerboard ..................................73 8.7 Unit in general ............................73 Malfunction ..................74 Dismantling and disposal ..............76 CE declaration of Conformity ...............77 Subjet to change without notice © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
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Page 6: Introduction
The initial startup of the chiller has to be carried out by trained personnel authorized from STULZ. Only STULZ approved spare parts and liquids are allowed to be used. All scheduled maintenance operations described in this manual must be performed accordingly by trained and qualified personnel. -
Page 7: Safety
With equipped antifreeze option, even in the proximity of the heaters around the evaporator, the circuit of the pumps, the steel hydraulic piping and the storage tank. © STULZ S.p.A. – all rights reserved EN/06.2016/i01... - Page 8 HFC fluids causing greenhouse effect regulated by Kyoto protocol - Das Gerät erhält wie vom Kyoto-Protokoll geregelte Fluorkohlenwasserstoffe Treibhausgasen - Dispositif contenant fluides HFC à effet de serre disciplinés par le protocole de Kyoto MADE IN ITALY EN/06.2016/i01 © STULZ S.p.A. – all rights reserved...
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Page 9: Safety Instructions
INFOrMATION This cooling unit contains fluorinated greenhouse gas covered by the Kyoto protocol In these STULZ chillers the refrigerant R410A is used. Refrigerants are volatile or highly volatile fluorinated hydrocarbons which are liquefied under pressure. They are incombustible and not hazardous to health when used as intended. -
Page 10: Safety And Environmental Requirement
• In the case of acute effects, the casualty is to be brought into the fresh air as quickly as possible. • Splashes of fluorinated hydrocarbons in the eyes can be blown out or fanned out by an assis- tant. Then rinse with water. EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... - Page 11 W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S Independent conversion and manufacture of replacement parts The system may only be converted or modified after consultation with STULZ. Original replace- ment parts and replacement parts/accessories authorised by STULZ are an aid to safety.
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Page 12: Residual Risk
Wear safety gloves. Cover lower arms ture up to 70°C skin with clothing Electrical alimentation Falsely dimensioned cables or Short-circuit, fire, acid vapours Correctly design alimentation cables and protection devices protection elements. Wear protective mask EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... -
Page 13: Maintenance
CAS No. 354-33-6 (HFC-32) CE No.: 206-557-8 Information on ingredients Concentration: 50% Difluoroethane (HFC-125) CAS No. 75-10-5 CE No.: 200-839-4 Concentration: 50% WArNING Please, refer to the specific “Safety Data Sheet” of refrigerant gas © STULZ S.p.A. – all rights reserved EN/06.2016/i01... - Page 14 WARNING: Never use welding or cutting torch on or near container because product can ignite. Combustible liquid. Launder or discard soiled clothes. Avoid prolonged contact. WArNING Please, refer to the specific “Safety Data Sheet” of lubrificant oil EN/06.2016/i01 © STULZ S.p.A. – all rights reserved...
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Page 15: Transport/ Storage
• You receive the consignment papers with the delivery of the chiller • The shipment is made ex works, in case of shipment damages, please assert your claim directly towards the carrier. © STULZ S.p.A. – all rights reserved EN/06.2016/i01... -
Page 16: Storage
F-Gas regulations and EN 378. 3.3 Transport The STULZ chillers can be lifted and moved by lifting devices with ropes or belts. For this pur- pose there are openings in the base frame, through which steel tubes must be pushed. The steel tubes are supplied and already inserted in the chiller. - Page 17 W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S Spacer Rope Shakles Lifting bar with stop end © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
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Page 18: Centre Of Gravity
1240 mm 1210 mm 1880 mm 1860 mm 1860 mm 1930 mm 1980 mm 2000 mm 1910 mm 1130 mm 1140 mm 1020 mm 1140 mm 1040 mm 1020 mm 980 mm EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... - Page 19 1070 mm 1000 mm 940 mm 940 mm Five V-modules low Noise without pump, without tank WPA 180 WPA 200 1290 mm 1290 mm 3490 mm 3490 mm 950 mm 950 mm © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
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Page 20: Description
5 n°1 pump + Tank + Antifreeze heaters 6 n°2 pumps + Tank + Antifreeze heaters Heat recovery 12°digit 0 none D partial recovery (t.b.d.) total recovery (t.b.d.) Options 13°digit (change accordingly to the selected options) 14°digit EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... -
Page 21: Intended Use
Each free cooling chiller is equipped with an hydronic group that consists of one storage tank and at least one pump. low noise version With the low noise version of the Explorer WPA chillers you have the possibility to reduce the noise emissions to up to –10dB. © STULZ S.p.A. – all rights reserved EN/06.2016/i01... -
Page 22: Refrigerant Circuit
25% resp. 12.5%. The compressor contains a crankcase heater. 4.3.5 Evaporator The Explorer WPA 060 – WPA 140 is equipped with a brazed welded heat exchanger made of AISI 316 and AISI 304 stainless steel. The sizes Explorer WPA 160 – WPA 200 are supplied with a shell &... -
Page 23: Electrical Cabinet
4.3.9 C2020 A graphical touch display is connected to the STULZ C2020 and installed in the door of the electrical cabinet. It is able to show the information about the operation conditions, the status of the unit and all the alarms. It is accessible from the outside. All features are password protected. -
Page 24: Piping Diagrams
Shut-off valve Needle valve Liquid receiver Condenser Temperature transmitter Compressor Solenoid Valve Pressure transducer Sight glass Evaporator Condenser fan Safety valve with spring Refrigerant filter loading High pressure switch Electronic expansion valve EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... - Page 25 W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S Four compressors, two condensing modules © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
- Page 26 W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S Four compressors, three condensing modules EN/06.2016/i01 © STULZ S.p.A. – all rights reserved...
- Page 27 W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S Four compressors, four condensing modules © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
- Page 28 W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S Six compressors, four condensing modules EN/06.2016/i01 © STULZ S.p.A. – all rights reserved...
- Page 29 W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S Six compressors, five condensing modules © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
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Page 30: Hydraulic Diagrams
Water tank Temperature sensor Free cooling water-air Manifold exchanger Evaporator VICT Victaulic ® connections Flow switch Non-return valve Automatic release valve Three-way valve Manometer Safety valve Differential pressure switch Expansion vessel Water pump EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... -
Page 31: Standard & Low Noise Version
W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S 4.5.2 Standard & low Noise version © STULZ S.p.A. – all rights reserved EN/06.2016/i01... - Page 32 W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S Free Cooling - two V-modules (WPA 060-070) EN/06.2016/i01 © STULZ S.p.A. – all rights reserved...
- Page 33 W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S Free Cooling - three V-modules (WPA 080-090-100-110) © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
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Page 34: Technical Data
W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S 5. Technical Data 5.1 Application limits The STULZ Explorer WPA units are provided for operations within the following ranges: Type of network TT; TN-S ; TN-C-S... - Page 35 61.2 75.9 Pressure drop [kPa] 10.15 8.60 6.39 5.28 4.72 3.40 WPA120 WPA140 WPA160 WPA180 WPA200 Water flow [m³/h] 83.8 89.2 133.0 67.9 67.9 Pressure drop [kPa] 10.15 8.60 17.4 15.8 15.8 © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
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Page 36: Chilled Water Quality
INFOrMATION The following limits for the water circuit must not be exceeded DANGEr For outlet water temperatures lower or equal to +5°C and environments with temperatures lower than 0°C, use non freezing mixture approved by STULZ Minimum Maximum Feature value... - Page 37 W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S Pressure drop on the evaporator Water flow [m³/h] Free cooling: net residual head Water flow [m³/h] © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
- Page 38 W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S One pump option: net residual head Water flow [m³/h] Two pump option: net residual head Water flow [m³/h] EN/06.2016/i01 © STULZ S.p.A. – all rights reserved...
- Page 39 W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S One pump option + accumulation: net residual head Water flow [m³/h] Two pump option + accumulation: net residual head Water flow [m³/h] © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
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Page 40: Technical Data
10.4 10.4 13.7 13.7 Maximum current consumption 9.57 11.44 11.44 15.07 15.07 Additional weight of the second pump Efficiency index ESEER 4.31 4.38 4.02 4.26 4.26 IPLV 4.79 4.68 4.07 4.32 4.52 EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... - Page 41 Average sound pressure level, at 10m distance, unit in a free field on a reflective surface. Unit at full capacity. According to ISO 3744. Pumps contribution is not considered. * In case of applications with output fluid temperature below 0°C, please contact the manufacturer © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
- Page 42 Average sound pressure level, at 10m distance, unit in a free field on a reflective surface. Unit at full capacity. According to ISO 3744. Pumps contribution is not considered. * In case of applications with output fluid temperature below 0°C, please contact the manufacturer EN/06.2016/i01 © STULZ S.p.A. – all rights reserved...
- Page 43 Average sound pressure level, at 10m distance, unit in a free field on a reflective surface. Unit at full capacity. According to ISO 3744. Pumps contribution is not considered. * In case of applications with output fluid temperature below 0°C, please contact the manufacturer © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
- Page 44 Average sound pressure level, at 10m distance, unit in a free field on a reflective surface. Unit at full capacity. According to ISO 3744. Pumps contribution is not considered. * In case of applications with output fluid temperature below 0°C, please contact the manufacturer EN/06.2016/i01 © STULZ S.p.A. – all rights reserved...
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Page 45: Dimensional Drawings
500 L Victaulic ® WPA090 3" 500 L Victaulic ® WPA100 3" 500 L " Dis.F" at page 48 Victaulic ® WPA110 4" 750 L " Dis.I" at page 48 Victaulic ® © STULZ S.p.A. – all rights reserved EN/06.2016/i01... - Page 46 060 - 070 - 080 - 090 - 100 With 1or 2 pumps + tank low Noise 060 - 070 - 080 - 090 Dis.C Free Cooling 060 - 070 3140 2208 3" Victaulic EN/06.2016/i01 © STULZ S.p.A. – all rights reserved...
- Page 47 Noise 110 - 120 Dis.G 2208 4447 4" Victaulic Standard 110 - 120 - 140 With 1or 2 pumps low Noise 110 - 120 Dis.H 2208 4447 4" Victaulic 436 454 © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
- Page 48 Noise 110 - 120 Dis.F Free Cooling 2208 4447 3" Victaulic low Noise With 1or 2 pumps + tank Free Cooling 080 - 090 - 100 Dis.I 2208 4447 4" Victaulic EN/06.2016/i01 © STULZ S.p.A. – all rights reserved...
- Page 49 Without pump low Noise Dis.L 2208 5820 4" Victaulic 2200 Standard Without pump low Noise Dis.O 2208 5820 5" Victaulic 2250 Without pump Standard 180 - 200 Dis.P 2208 5820 5" Victaulic 2200 © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
- Page 50 4" Victaulic 1824 With 1or 2 pumps + tank low Noise Dis.N 5820 2208 4" Victaulic 5V-shapes modules Without pump low Noise 180 - 200 Dis.Q 2208 7130 5" Victaulic 2200 2085 EN/06.2016/i01 © STULZ S.p.A. – all rights reserved...
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Page 51: Electrical Connection Data
WPA 100 Mini fit WPA 110 Mini fit WPA 120 n.a. Mini fit WPA 140 n.a. Mini fit WPA 160 n.a. Mini fit WPA 180 n.a. Mini fit WPA 200 n.a. Mini fit © STULZ S.p.A. – all rights reserved EN/06.2016/i01... -
Page 52: Installation
• To avoid possible noise and vibration transmission the use of anti vibration mounts (option) is recommended. After installing the chiller check its horizontal alignment using a spirit level. EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... -
Page 53: Minimum Distance From Obstacles Or Other Chillers
W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S 6.1.1 Minimum distance from obstacles or other chillers 6.1.2 Distance of installation of several units 1,25 1,25 1,25 1,25 © STULZ S.p.A. – all rights reserved EN/06.2016/i01... -
Page 54: Weight On The Supports
With pump, with tank Base: WPA 110, 120, 140 low Noise: WPA 100, 110, 120 Free Cooling: WPA 080, 090, 100, 110 Without pump, without tank With pump, without tank With pump, with tank EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... - Page 55 W PA Ex P lO r E r O r I G I N A l I N ST r U C T I O N S Base: WPA 160, 180, 200 low Noise: WPA 140, 160 Without pump, without tank With pump, without tank With pump, with tank low Noise: WPA 180, 200 Without pump, without tank © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
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Page 56: Refrigerant Circuit
-5 to -10°C from -10 to -15°C from -15 to -20°C from -20 to -25°C INFOrMATION Prepare the required water/glycol mixture outside of the chilled water circuit and fill the circuit later EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... - Page 57 The discharge of the safety valve must be positioned in a proposed area so that the leaving fluid will not endanger persons. Model WPA 060 - 140 WPA 160 - 200 Drain connection of the safety valves 3/4" G male 1 1/4" G male © STULZ S.p.A. – all rights reserved EN/06.2016/i01...
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Page 58: Outside Temperature Sensor
The location of the sensor must be checked plant-specifically and if necessary be transferred out of the chiller unit. In this case the sensor cable must be correspondingly extended (max. 30 EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... -
Page 59: Chilled Water Connection
The connection piping must be connected to the chilled water lines of the chiller free of mechanical stress. INFOrMATION For the dimensions and positions of the hydraulic connections, see "5.5 Dimensional drawings" at page 45 6.7 Filling and bleeding air Open Close © STULZ S.p.A. – all rights reserved EN/06.2016/i01... -
Page 60: Electrical Connection
• Consider local regulations for the electrical wiring. WArNING Do not touch electronical components, without taking care of protective ESD measures. EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... -
Page 61: Opening The Electric Cabinet
Connect the ground cable to the base of the chiller using on the designated position iden- tified by the grounding symbol. Use screw with a minimum diameter Ø 8 mm. The cable must contain a terminal lug. © STULZ S.p.A. – all rights reserved EN/06.2016/i01... -
Page 62: Pump Control
Design the wiring between the controller and the contactor with reference to the connection diagram for the controller and the wiring between the pump and power switch according to the manufacturer's notes. EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... -
Page 63: Commisioning
• Check whether all power switches and control-circuit fuses in the electrical section of the unit are switched OFF. • Retighten all screw connections in the electric cabinet. • Verify the smooth function of the contactors. © STULZ S.p.A. – all rights reserved EN/06.2016/i01... -
Page 64: Oil Preheating
(use the contactor in the electrical cabinet) and checking if the chiller is turned off • keep the pump running for 8 hours and clean the implemented filter (recommended part of the external circuit) after this lapse of time EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... -
Page 65: Commissioning Of The Refrigerant Circuit
If the tolerances (18 K at the condenser, 7 K at the evaporator) are exceeded, there is a prob- lem of heat transmission. The probable cause is the pollution of the heat exchage surfaces. Also the superheating may be set too high. © STULZ S.p.A. – all rights reserved EN/06.2016/i01... - Page 66 According to the compressors manufacturer specifications the following preset paramenters must be kept: Value description Time Minimum runtime of compressor: 300s Minimum pause time of compressor: 300s Run time Pause Minimum cicle time of compressor: 600s Cycle time EN/06.2016/i01 © STULZ S.p.A. – all rights reserved...
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Page 67: Maintenance
Check for fugue Tightness of the refrigerant circuit Check the high pressure safety switch Check the high pressure and low pressure switch Check the pressure relief valve Sobstitute the pressure relief valve (Directive 97/23/CE) © STULZ S.p.A. – all rights reserved EN/06.2016/i01... -
Page 68: Refrigerant Circuit
• extract the nitrogen by the vacuum pump (not by the compressor!) to approximately 0 barg • fill with refrigerant gas according to name plate of the chiller for type and weight INFOrMATION R410A must be charged in a liquid state. EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... -
Page 69: Quantity
Take an oil sample, determine the humidity content and exchange the oil in case of excessive humidity content. In this case the refrigerant must be completely evacuated and recharged by new refrigerant according to the above described instruction. © STULZ S.p.A. – all rights reserved EN/06.2016/i01... -
Page 70: Exchange Of Filter Drier
If the pressure switch has tripped too early (e.g. at 4,0 bar), you can reduce the threshold by turning counterclockwise the adjustment screw on the top side of the pressure switch after having removed the adjustment lock. EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... -
Page 71: Expansion Valve
(bottom line) and not rise above the upper line during operation. Crankcase heater Check the crankcase heater function by measuring the ohmic resistance at the terminals of the © STULZ S.p.A. – all rights reserved EN/06.2016/i01... -
Page 72: Air Circuit
• Check the presence of air in the water circuit. In case bleed the circuit following the instruc- tions given in paragraph "6.7 Filling and bleeding air" at page 59 8.5.1 Tightness Check the water circuit visually for tightness. Beyond that a level indication at the storage tank, EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... -
Page 73: Evaporator
• Check also the insulation of the water piping. Condensing air humidity on cold water pipes means a loss of cooling capacity. • Check for loose parts that cause an increase in noise and vibration. © STULZ S.p.A. – all rights reserved EN/06.2016/i01... -
Page 74: Malfunction
Faulty speed control of condensing fans of circuit Faulty signal from the electronic control: contact the Stulz service centre Failure of the phase cut control modul: replace Clean the condenser/air filter (optional) - Page 75 Through the fluid level sight glass of the circuit check for Clogged filter-drier of the circuit moisture or bubbles in the refrigerant. Contact the Stulz service centre Completely open the tap Partially closed tap on the fluid line of circuit Low press.
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Page 76: Dismantling And Disposal
It is advisable to contact a specialized recycling company. Basically, the unit contains the following raw materials: aluminium (exchangers and condensers); copper (exchangers, refrigerant pipes and electric cables), galvanized steel and iron (evaporator and condensers, panels and metal frames); rubber (water pipes). EN/06.2016/i01 © STULZ S.p.A. – all rights reserved... -
Page 77: Ce Declaration Of Conformity
• CEI EN 60204-1 2006-6: Electrical Equipment of Machines • CEI EN 61000: 6-2:2006; 6-3:2007/A1:2011: Electromagnetic compatibility • UNI EN ISO 12100-1:2010: Safety of machinery - Basic concepts, general principles for design • EN 378-1:2012;-2:2012: Refrigerating system and heat pumps © STULZ S.p.A. – all rights reserved EN/06.2016/i01... - Page 78 STULZ Top Service – more than fast emergency assistance Advice Maintenance Implementation Test Center Technical Climate Customized Service-Portal For general questions about our products and services, you can reach us on weekdays from 8 – 18 at phone 0039 045 6331615.
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