SystemAir WQH Series Installation And Maintenance Manual
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SystemAir WQH Series Installation And Maintenance Manual

Water cooled liquid chillers - water/water reverse cycle heat pumps - condenserless units
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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
English
Water Cooled Liquid Chillers - Water/Water Reverse Cycle Heat Pumps - Condenserless Units
21
Refroidisseurs de Liquid à Condensation par l'Eau - Pompes à Chaleur Réversibles Eau/Eau
Refroidisseurs de Liquid sans Condenseur
193 kW
Flussigkeitsküler Wassergekühlt - Wasser/Wasser Wärmepumpen - Werdampfereinheiten
(ohn Verflüssiger)
24
Refrigeratori di Liquido Condensati ad Acqua - Pompe di Calore Acqua/Acqua - Unità Motoevaporanti
Enfriadoras de Fluido con Condensación por Agua - Bomba de Calor Agua/Agua
Modelo Condensador Remoto
211 kW
Part number / Code / Code / Codice / Código:
Supersedes / Annule et remplace / Annulliert und ersetzt / Annulla e sostituisce /
Anula y sustituye:
Notified Body / Organisme Notifié / Benannte Zertifizierungsstelle / Organismo
Notificato / Organismo Notificado N°. 1115
WQL-WQH-WQRC
Français
354455/A
Deutsch
354455/B
"
Italiano
Español
ISO 9001:2008 certified management system

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  • Page 1 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 English Français Deutsch Italiano Español Water Cooled Liquid Chillers - Water/Water Reverse Cycle Heat Pumps - Condenserless Units Refroidisseurs de Liquid à...
  • Page 2 ITALY COSTRUTTORE / MANUFACTURE - BUONE NORME DI MANUTENZIONE DEI DISPOSITIVI DI SICUREZZA MONTATI SUL GRUPPO FRIGORIFERO Gentile Cliente, Le ricordiamo alcune indicazioni circa le modalità di manutenzione dei dispositivi di sicurezza montati sul gruppo frigorifero da Lei acquistato. I dispositivi di sicurezza montati sul gruppo sono stati verificati dal COSTRUTTORE a norma di legge. È...

  • Page 3: Table Of Contents

    Table of Contents 1 - FOREWORD 7 - PRODUCT DESCRIPTION 1.1 Introduction ................2 7.1 General Information ............29 1.2 Warranty ................2 7.2 Body and Frame ..............29 1.3 Emergency stop/Normal stop ..........2 7.3 Compressors ..............29 1.4 An introduction to this manual ..........2 7.4 Refrigeration circuits ............29 2 - SAFETY 7.5 Evaporator .................29...

  • Page 4: Foreword

    1 - Introdução 1 - Foreword 1.1 Introduction 1.3 Emergency stop / Normal stop Units, manufactured to state-of-the-art design and implementation The emergency stop of the unit can be enabled using the master standards, ensure top performance, reliability and fitness to any type switch on the control panel (move down the lever).

  • Page 5: Safety

    2 - Safety 2.1 Foreword These units must be installed in conformity with the It is the User’s responsibility to ensure that provisions of Machinery Directive 2006/42/EC, Low Voltage the unit is fit for the conditions of intended use Directive 2006/95/EC, Pressure Vessels Directive 2014/68/ and that both installation and maintenance are EU, Electromagnetic Interference Directive 2004/108/EC, carried out by experienced personnel, capable...

  • Page 6: Definitions

    2 - Safety (continued) disassemble connections, filters, joints or other line items 2.2 Definitions do not use your hands to check for any pressure drops OWNER: means the legal representative of the company, body or individual who owns the plant where unit has been installed; he/she use tools in a good state of repair;...

  • Page 7: Precautions During Maintenance Operations

    2 - Safety (continued) connections, even for limited periods of time or in an emergency place a warning sign “do not turn on - maintenance in progress” on the external disconnecting switch Prevention of other residual risks make sure that on-off remote controls are inhibited make sure that the connections to the unit conform to the instructions provided in this manual and on the unit’s panelling wear suitable personal protective equipment (helmet, safety...

  • Page 8: Safety Labels

    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 MIN. 5 cm Sequence phase control on the electrical board Pump operation - Outside, on the right-hand front column Gravity centre - Base Instruction for the lifting...
  • Page 9 2 - Safety (continued) Electrical warning Grounding connection on the electrical board, Adjacent to the master switch adjacent to the connection ATTENZIONE ! ATTENTION ! Prima di Enlever aprire togliere l’alimentation tensione electrique avant d’ouvrir ACHTUNG ! CAUTION ! ATENCION ! Vor offnen des Disconnect Cortar la...
  • Page 10 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...
  • Page 11 2 - Safety (continued) 2.8 Safety regulations REFRIGERANT DATA SAFETY DATA: R410A Toxicity 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.
  • Page 12 2 - Safety (continued) 2.8 Safety regulations (continued) REFRIGERANT DATA 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 General precautions than the air, the vapour concentrates on the bottom, in narrow areas.

  • Page 13: Safety Regulations

    2 - Safety (continued) 2.8 Safety regulations (continued) LUBRICANT OIL DATA SAFETY DATA: POLYESTER OIL (POE) Classification Not harmful. 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. Contact with skin It is also recommended to wash your overalls at least once a week.

  • Page 14: Inspection

    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, Space requirements request to handling etc.). They are ready to be installed and started on the field. R410A units are only charged with liquid refrigerant and with oil in the quantity required for operation.

  • Page 15: Anchoring

    3 - Transport, Handling and Storage 3.3 Anchoring Minimum storage temperature is -25 °C. Store the units in areas where minimum activity is likely to take It is not essential to secure the unit to the foundations, unless in areas place in order to avoid any risk of accidental damage.

  • Page 16: Installation

    4 - Installation 4.1 Positioning of the unit 4.2 Spring Isolator Installation Prepare the base, that must be flat and plane. Before installing the unit, make sure that the structure of the building and/or the supporting Lift the appliance and insert shock absorbers as follows: surface can withstand the weight of the appliance.
  • Page 17 4 - Installation (continued) 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 The flow switch and the filter water, although not included in total volume of the water in the plant (exchanger, the supply, must always be fitted such as plant components.
  • Page 18 4 - Installation (continued) WQL - WQH 20/45 HYDRAULIC SYSTEM BASIC INLET OUTLET COMPONENTS SAFETY/CONTROL DEVICES 1 Plate heat exchanger Water differential pressure switch..( ) 2 Water filter Inlet water temperature sensor 3 Water outlet Outlet water temperature sensor 4 Water inlet Vent valve 5 Globe valve Thermometer...
  • Page 19 4 - Installation (continued) WQL - WQH 20/45 HYDRAULIC SYSTEM 1P CONDENSER INLET OUTLET COMPONENTS SAFETY/CONTROL DEVICES 1 Plate heat exchanger Water differential pressure switch..( ) 2 Pump Inlet water temperature sensor 3 Water filter Outlet water temperature sensor 4 Water outlet Vent valve 5 Water inlet Thermometer...
  • Page 20 4 - Installation (continued) WQL - WQH 20 / 45 HYDRAULIC SYSTEM 1P EVAPORATOR INLET OUTLET COMPONENTS SAFETY/CONTROL DEVICES 1 Plate heat exchanger Water differential pressure switch..( ) 2 Pump Inlet water temperature sensor 3 Water filter Outlet water temperature sensor 4 Pressure expansion tank Vent valve 5 Water outlet...
  • Page 21 4 - Installation (continued) WQL - WQH 50 / 190 HYDRAULIC SYSTEM BASIC 1- C INLET OUTLET 1- E INLET OUTLET COMPONENTS SAFETY/CONTROL DEVICES 1C Condenser Water differential pressure switch..( ) 1E Evaporator Inlet water temperature sensor 2 Water filter Outlet water temperature sensor 3 Water outlet Vent valve...
  • Page 22 4 - Installation (continued) WQL - WQH 50 / 190 HYDRAULIC SYSTEM 1P CONDENSER 1P EVAPORATOR 1- C INLET OUTLET 1- E INLET OUTLET COMPONENTS SAFETY/CONTROL DEVICES 1C Condenser Water differential pressure switch..( ) 1E Evaporator Inlet water temperature sensor 2 Pump Outlet water temperature sensor 3 Water filter...

  • Page 23: Internal/External Water Circuit

    4 - Installation (continued) WQL - WQH 50 / 190 HYDRAULIC SYSTEM 2P CONDENSER 2P EVAPORATOR 1- C INLET OUTLET 1- E INLET OUTLET COMPONENTS SAFETY/CONTROL DEVICES 1C Condenser Water differential pressure switch..( ) 1E Evaporator Inlet water temperature sensor 2 Pump Outlet water temperature sensor 3 Water filter...

  • Page 24: Water Connections

    4 - Installation (continued) 4.4 Water connections The attachments at the water inlet and outlet It is important that the appliance is grounded. shall be connected in compliance with the DANGER instructions which can be found on the labels in WARNING the proximity of the attachments.
  • Page 25 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 If the unbalance is unacceptable, contact the Energy Distributor to Directive (2006/42/EC), the Low Voltage Directive (2006/95/EC), solve this problem.

  • Page 26: Electrical Connections

    4 - Installation (continued) Electrical Connections...

  • Page 27: Start-Up

    5 - Start-Up Start the pump and check that the water flow is correct. The unit must be started for the first time by Set the desired fluid temperature on the control board. personnel suitably trained by one Authorised Service Centre. Failure to meet this requirement Start the appliance (see Chapter 6).

  • Page 28: Control

    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 6.2 Keypad functions –...

  • Page 29: Folder Structure

    6 - Control (continued) 4) Program define parameters, functions, password and to display ICON / COLOR STEADY ICON BLINKING ICON alarm log / RED - Alarm ON - Alarm QUIT - Antifreeze+Heat pump ON 6.4 Menu structure / GREEN - Mode: HEATING - Heating mode by remote “Program”...

  • Page 30: Alarm List

    6 - Control (continued) 6.5 Alarm list RESET Internal circuit Internal circuit Sanitary valve / Code Alarm unit description CPS status auto/man pump status pump status heater status Er00 General alarm Er01 High pressure circuit Er05 Low pressure circuit Er10 Thermal protection - compressor 1 CPS 1 Er11...

  • Page 31: General Information

    7 - General Description General Description 7.4 Refrigeration circuits The refrigeration circuit is provided with a thermostatic expansion 7.1 Introduction valve, dehydrating cartridge filter, sight glass with a colour-change The new range of water cooled chillers, includes 14 different humidity indicator, HP and LP pressure switches. capacities, fit for medium-sized residential, commercial and industrial WQH units feature also a 4-ways valve and check valves in order to applications.
  • Page 32 7 - General Description (continued) WQL 20 - 45 Refrigeration System COMPONENTS SAFETY / CONTROL DEVICES Compressor High pressure switch (42 Bar) Condenser Low pressure switch (2 Bar) Drier filter AT High pressure transducer (optional) Sight glass BT Low pressure transducer Mechanical expansion valve ST Suction temperature probe Evaporator...
  • Page 33 7 - General Description (continued) WQL 50 - 190 Refrigeration System COMPONENTS SAFETY / CONTROL DEVICES Compressor High pressure switch (40.5 Bar) Condenser Low pressure switch (2 Bar) Drier filter BT Low pressure transducer Sight glass AT High pressure transducer (optional) OIL EQUAL.

  • Page 34: Accessories

    7 - General Description (continued) 7.8 Accessories Domestic hot water kit It is provided as an accessory to allow the unit managing the control Water Filter of a 3 ways valve, in order to switch water flow from plant to boiler. 1-1/2”...
  • Page 35 7 - General Description (continued) Additional heating device kit Climatic control kit It is provided as an option/accessory to allow the unit managing the It is provided as an accessory to allow the unit managing the control control of an additional heating device (a boiler in example), in order of water temperature, according outdoor air temperature.

  • Page 36: Pressure Drops

    8 - Technical Data 8.1 Pressure drops PRESSURE DROP IN THE EVAPORATOR 20 to 45 kPa/(l/s) 17,0 16,5 15,9 15,6 11,4 7,97 Minimum flow rate 0,62 0,78 0,90 1,02 1,15 1,37 Nominal flow rate 1,00 1,25 1,45 1,63 1,83 2,19 Maximum flow rate 1,66 2,08...
  • Page 37 8 - Technical Data (continued) WQL 20-45 Number of refrigerant circuits Part load steps 0-100 0-100 0-100 0-100 0-100 0-100 Power supply V/ph/Hz 400V/3/50Hz Startup type Direct Direct Direct Direct Direct Direct REFRIGERANT Type R410A Charge COMPRESSORS Number Type Scroll Crankcase heater EVAPORATOR Number...
  • Page 38 8 - Technical Data (continued) WQH 20-45 Number of refrigerant circuits Part load steps 0-100 0-100 0-100 0-100 0-100 0-100 Power supply V/ph/Hz 400V/3/50Hz Startup type Direct Direct Direct Direct Direct Direct REFRIGERANT Type R410A Charge COMPRESSORS Number Type Scroll Crankcase heater INTERNAL HEAT EXCHANGER Number...
  • Page 39 8 - Technical Data (continued) WQRC 20-45 Number of refrigerant circuits Part load steps 0-100 0-100 0-100 0-100 0-100 0-100 Power supply V/ph/Hz 400V/3/50Hz Startup type Direct Direct Direct Direct Direct Direct REFRIGERANT Type R410A COMPRESSORS Number Type Scroll Crankcase heater EVAPORATOR Number Type...
  • Page 40 8 - Technical Data (continued) WQL 50-190 Number of refrigerant circuits Part load steps 0-50-100 0-50-100 0-50-100 0-50-100 0-50-100 0-50-100 0-50-100 0-50-100 Power supply V/ph/Hz 400V/3/50Hz Startup type Direct Direct Direct Direct Direct Direct Direct Direct REFRIGERANT Type R410A Charge 11,3 13,8 15,5...
  • Page 41 8 - Technical Data (continued) WQH 50-190 Number of refrigerant circuits Part load steps 0-50-100 0-50-100 0-50-100 0-50-100 0-50-100 0-50-100 0-50-100 0-50-100 Power supply V/ph/Hz 400V/3/50Hz Startup type Direct Direct Direct Direct Direct Direct Direct Direct REFRIGERANT Type R410A Charge 11,8 14,3 16,0...

  • Page 42: Technical Data

    8 - Technical Data (continued) WQRC 50-190 Number of refrigerant circuits Part load steps 0-50-100 0-50-100 0-50-100 0-50-100 0-50-100 0-50-100 0-50-100 0-50-100 Power supply V/ph/Hz 400V/3/50Hz Startup type Direct Direct Direct Direct Direct Direct Direct Direct REFRIGERANT Type R410A COMPRESSORS Number Type Scroll...

  • Page 43: Unit Electrical Data

    8 - Technical Data (continued) 8.3 Unit electrical data WQL/WQH/WQRC Rated voltage V/ph/Hz 400 (± 10%) / 3 / 50 Max. absorbed power 10,2 12,0 13,5 14,8 17,1 Rated current 11,8 12,9 13,9 16,0 20,7 Max. current FLA 15,0 21,0 22,0 25,0 31,0...
  • Page 44 8 - Technical Data (continued) Compressors electrical data WQL/WQH/WQRC Number Nominal power input 10,1 Max. absorbed power 10,2 12,0 13,5 14,8 17,1 Rated current 11,8 12,9 13,9 16,0 20,7 Max. current 15,0 21,0 22,0 25,0 31,0 34,0 Oil pan resistor WQL/WQH/WQRC Number Nominal power input...
  • Page 45 8 - Technical Data (continued) 8.4 Hydraulic features WQL/H/RC 20-45 available static pressure - internal heat exchanger (1P/E) 20-25-30 0.25 0.75 1.25 1.75 2.25 2.75 Water flow rate [l/s] WQL/H 20-45 available static pressure - external heat exchanger (1P/C) 20-25 35-40 0.25 0.75...
  • Page 46 8 - Technical Data (continued) WQL/H/RC 50-190 available static pressure - internal heat exchanger (1/2P SP/E) 10 10.5 11 11.5 Water flow rate [l/s] WQL/H 50-190 available static pressure - external heat exchanger (1/2P SP/C) 9.5 10 10.5 11 12.5 11.5 13 13.5 14 Water flow rate [l/s]...
  • Page 47 8 - Technical Data (continued) WQL/H/RC 50-190 available static pressure - internal heat exchanger (1/2P HP/E) 9.5 10 10.5 11 12.5 11.5 13 13.5 14 Water flow rate [l/s] WQL/H 50-190 available static pressure - external heat exchanger (1/2P HP/C) 9.5 10 10.5 11 12.5 11.5...
  • Page 48 8 - Technical Data (continued) WQL/H/RC 20/45 - internal heat exchanger pressure drop 20-25-30-35 0.75 1.25 1.75 2.25 2.75 3.25 3.75 Water flow rate [l/s] WQL/H 20/45 - external heat exchanger pressure drop 20-25-35-40 0.75 1.25 1.75 2.25 2.75 3.25 3.75 4.25 4.75...

  • Page 49: Hydraulic Features

    8 - Technical Data (continued) WQL/H 50/190 - external heat exchanger pressure drop 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 Water flow rate [l/s] WQL/H/RC 50/190 - desuperheater pressure drop Water flow rate [l/s]...

  • Page 50: Position Of Shock Adsorbers And Weight Distribution On Supports

    8 - Technical Data (continued) 8.5 Position of shock adsorbers and weight distribution on supports Weight distribution (kg) Operating P1-P4 coordinates CG coordinates Shipping WQL/WQH/WQRC 20-45 weight (kg) weight (kg) a (mm) b (mm) x (mm) y (mm) 45 STD 40 STD 35 STD 30 STD...
  • Page 51 8 - Technical Data (continued) WQL/WQH/WQRC Weight distribution (kg) Operating P1-P4 coordinates CG coordinates Shipping 50-190 weight (kg) weight (kg) a (mm) b (mm) x (mm) y (mm) (BASIC UNIT) 114 123 127 131 138 138 150 145 212 224 240 249 255 260 275 273 100...
  • Page 52 8 - Technical Data (continued) WQL/WQH/WQRC Weight distribution (kg) Operating P5-P8 coordinates CG coordinates Shipping 50-190 weight (kg) weight (kg) a (mm) b (mm) x (mm) y (mm) (HYDRONIC OPTIONS) 1P SP/E 1PSP/E 1PSP/C 1PSP/C 2P SP/E 2PSP/E 2PSP/C 2P SP/C 1P HP/E 1PHP/E 1PHP/C 1PHP/C...
  • Page 53 8 - Technical Data (continued) WQL/WQH/WQRC Weight distribution (kg) Operating P5-P8 coordinates CG coordinates Shipping 50-190 weight (kg) weight (kg) a (mm) b (mm) x (mm) y (mm) (HYDRONIC OPTIONS) 1P SP/E 1PSP/E 1PSP/C 1PSP/C 2P SP/E 2PSP/E 2PSP/C 2P SP/C 1P HP/E 1PHP/E 1PHP/C 1PHP/C...

  • Page 54: Dimensional Drawings

    8 - Technical Data (continued) 8.6 Dimensional drawings - WQL/WQH/WQRC 20-45 Side view Side view Front view Side view ø 30 Top view Control display Main switch Auxiliary lines, electrical connection Gauge kit E, F, G Internal heat exchanger connections Ø1 1/2” VIC H, I, L External heat connections Ø1 1/2”...
  • Page 55 8 - Technical Data (continued) 8.6 Dimensional drawings - WQL/WQH/WQRC 50-190 (without hydrokit) Side view Side view Front view Rear-view ø 45 1200 Lost view Control display Main switch Auxiliary lines, electrical connection Gauge kit G, H Internal heat exchanger connections Ø2 1/2” VIC (Ø76.1 MM) E, F External heat connections Ø2 1/2”...

  • Page 56: Dimensional Drawings

    8 - Technical Data (continued) 8.6 Dimensional drawings - WQL/WQH/WQRC 50-190 (with hydrokit) Side view Side view Front view Rear-view ø 45 ø 45 1200 1960 Low view * Only for WQRC - for transport Control display Main switch Auxiliary lines, electrical connection Gauge kit G, H, L Internal heat exchanger connections Ø2 1/2”...

  • Page 57: Unit Clearances

    8 - Technical Data (continued) 8.7 Unit clearances (in mm) WQL/WQH/WQRC 20-45 WQL/WQH/WQRC 50-190...

  • Page 58: Maintenance

    9 - Maintenance Carefully read the “Safety” section of this manual before carrying out any maintenance operations. Operations Do not discharge the refrigerant into the atmosphere while the refrigeration circuits Check the temperature of the leaving are being drained. Use appropriate recovery fluid equipment.

  • Page 59: Refrigerant Charge

    9 - Maintenance (continued) 9.3 Refrigerant charge 9.5 Condenser Check at regular intervals that the water side of the heat exchanger Do not inject refrigerant liquid into the LP side of the circuit. Be very is perfectly clean. To do this, measure the pressure drop, water side careful, and charge the circuit properly.

  • Page 60: Mechanical Expansion Valve

    9 - Maintenance (continued) 9.8 Mechanical expansion valve 9.9 Evaporator The circuit of the unit is equipped with a mechanical expansion valve, Check at regular intervals that the water side of the heat exchanger with external equalizer 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 The valve is factory calibrated for an overheating of 5 °C.

  • Page 61: Troubleshooting

    10 - Troubleshooting 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...

  • Page 62: Spare Parts

    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 Differential pressure switch High pressure transducer Low pressure transducer Expansion valve Gas filter 4 way valve Electronic main board Auxiliary circuit trasformer...

  • Page 63: Dismantling, Demolition And Scrapping

    12 - Dismantling, Demolition and Scrapping 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 Once they have been disconnected as specified, the packaged units the surrounding atmosphere.

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