R134a Water Cooled Chillers. WCWWXT/Y Series ( Ton)

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1 R134a Water Cooled Chillers WCWWXT/Y Series ( Ton) 1

2 INDEX Page General description 3 Versions 3 Technical features 3 Factory fitted accessories 3 Loose accessories 3 Reference conditions 3 Operating range 3 Technical data 4-5 Cooling and heating capacity 6-7 Water circuit pressure drops - Evaporator 8 Evaporator water flow limits 8 Correction factors - Evaporator 8 Evaporator fouling factors corrections 8 Water circuit pressure drops - Condenser 9 Condenser water flow limits 9 Correction factors - Condenser 9 Condenser fouling factors corrections 9 Refrigeration circuit diagram: Cooling only units Dimensions, weights and clearances Water circuit 17 Sound pressure level 18 Microprocessor control system 19 Wiring diagrams Wiring diagrams explanation 24 2

3 GENERAL DESCRIPTION The Water cooled liquid chiller units for indoor installation. The range consists of 18 models covering a cooling capacity from 260 to 2470 kw. VERSIONS: WCWW/Y WCWW/Y/SSL - cooling only - super silenced cooling only TECHNICAL FEATURES: Frame. The unit features a galvanized steel frame further protected with polyester powder painting. The frame supports the main components and allows easy acess for maintenance and other necessary operations. Compressors. Screw semihermetic with built-in oil separator, suction filter, cranckcase heater, oil sight glass, thermal protection, hot gas shut off valves. Condenser. Shell and tube type, with easily removable cast iron heads to enable acess for maintenance operations. Each refrigerant circuit is supplied with an indipendent condenser. Water connections for cooling tower operation. Evaporator. Shell and tube type, with two independent refrigerants circuits (1302-B B) or three indipendent refrigerants circuits (6603-B B) and one water circuit. Electrical board. Includes: main switch with door safety interlock; fuses, overload protection for compressors; interface relays and electrical terminals for external connections. Microprocessor for automatic control of the unit allowing continuous display of the operational status of the unit, control set and real water temperature and, in case of partial or total block of the unit, indication of security device that intervened. Refrigerant circuit. Each unit includes two (1302-B-6002-B) or three (6603-B-9003-B) independent refrigerant circuits. Produced in copper tubing, all models have the following components:electronic expansion valve, filter-drier, level and humidity indicator, pressure transducer, high and low pressure switches (with fixed setting) and safety valve. Water circuit. Includes: evaporator, temperature sensor, antifreeze sensor, air vent and water drain. LOOSE ACCESSORIES: MN - High and low pressure gauges for every refrigeration circuit. CR - Remote control panel to be inserted in the room for remote control of the unit, with the same functions as that inserted in the machine. IS - RS 485 serial interface for connection to controls and centralized supervision systems. PV3-3-ways pressostatic valve to control the condensation. AG - Rubber vibration dampers to be inserted at the bottom of the unit to dampen possible vibrations due to the type of floor where the machine is installed. AM - Spring shock absorbers to be inserted at the bottom of the unit to dampen possible vibrations due to the type of floor where the machine is installed. FL - Flow switch to prevent any water flow interruption. REFERENCE CONDITIONS All technical data, indicated on pages 4 & 5, refer to the following unit operating conditions: - Cooling: entering water temperature 12 C. leaving water temperature 7 C. condenser entering water temperature 30 C. condenser leaving water temperature 35 C. - Heating: entering water temperature 40 C. leaving water temperature 45 C. evaporator entering water temperature 10 C. - sound pressure level (DIN 45635): measured in free field conditions at 1m from the unit and at 1,5m from the ground. According to DIN Sound pressure level (ISO 3744): measured in free field conditions at 1m. As defined by ISO The power supply is 400V/3Ph/50Hz; auxiliary supply is 230V/1Ph/ 50Hz. FACTORY FITTED ACCESSORIES: IM - Magnetothermic switches instead of fuses and thermal relays. RZ - Stepless regulation of the compressors to adjust the cooling capacity to the termic load of the system. HR - Desuperheater with 20% heat recovery. HRT - Total heat recovery for 100% heat recovery. RF - Cooling circuit shut off valve on liquid line. FE - Evaporator heater with thermostatic control. SS - Soft start to reduce compressor starting current. DP - Device for the heat pump functioning. Includes: water inlet and outlet temperature sensors on the condenser to control the compressor start and stop. WM - Web Monitoring: monitoring enables remote management of the system through communication protocols, GPRS/GSM/ TCP-IP. Authorized users have access to a dashboard display that provides critical system information from which the user can measure, manage and report as necessary. CP - Potential free contacts for remote alarm and control. ORATING RANGE Evaporator inlet water temperature Evaporator outlet water temperature Evaporator water thermal difference (1) Condenser inlet water temperature Condenser outlet water temperature Condenser water thermal difference (1) Min. chilled water/glycol temperature Max. operating pressure evaporator water side Max. operating pressure condenser water side C 8 20 C 5 15 C 3 9 C C C 4 12 C - 8 kpa 1000 kpa 1000 (1) In all cases the water range will have to re-enter within the reported limits on page

4 TECHNICAL DATA MODEL Cooling: Cooling Capacity (1) Absorbed power (1) Heating: Heating capacity (1) Absorbed power (1) Compressors Refrigerant Circuits Capacity steps Evaporator: Pressure drops (1) Water connections Water volume Condenser: Water flow (1) Pressure drops (1) Water connections Water volume Compressor: Unitary absorbed power (1) Unitary absorbed current (1) Oil charge kw kw kw kw n n % l/s 12,76 15,43 17,87 20,35 23,32 27,57 31,53 35,83 42,62 kpa DN dm³ l/s 15,48 18,71 21,67 24,67 28,00 33,43 38,00 42,99 51,32 kpa DN dm³ kw 28,5 34,4 39,8 45,2 49,4 61,3 67,9 74,9 91,1 A Kg Standard version: Sound pressure level - DIN (1) db(a) Sound pressure level - ISO (1) db(a) Refrigerant charge R134a Kg Unit lenght Width Height Unit transport weight mm mm mm Kg SSL version: Sound pressure level - DIN (1) db(a) Sound pressure level - ISO (1) db(a) Refrigerant charge R134a Kg Cooling only unit lenght mm Width mm Height mm Cooling only unit transport weight Kg Total electrical consumption: Power supply Max. Current Starting current V/Ph/Hz < / 3 / > A A (1) Referential conditions on page 3. 4

5 TECHNICAL DATA MODEL Cooling: Cooling Capacity (1) Absorbed power (1) Heating: Heating capacity (1) Absorbed power (1) Compressors Refrigerant Circuits Capacity steps Evaporator: Pressure drops (1) Water connections Water volume Condenser: Water flow (1) Pressure drops (1) Water connections Water volume Compressor: Unitary absorbed power (1) Unitary absorbed current (1) Oil charge Standard version: Sound pressure level - DIN (1) Sound pressure level - ISO (1) Refrigerant charge R134a Unit lenght Width Height Unit transport weight SSL version: Sound pressure level - DIN (1) Sound pressure level - ISO (1) Refrigerant charge R134a Cooling only unit lenght Width Height Cooling only unit transport weight kw kw kw kw n n % 50,12 55,37 61,44 68,70 77,02 85,47 94,65 105,30 118,15 l/s kpa DN dm³ 60,17 66,55 73,67 82,42 92,45 102,53 113,52 126,47 142,04 l/s kpa DN dm³ kw A Kg db(a) db(a) Kg mm mm mm Kg db(a) db(a) Kg mm mm mm Kg Total electrical consumption: Power supply Max. Current Starting current < / 3 / > V/Ph/Hz A A (1) Referential conditions on page 3. 5

6 COOLING AND HEATING CAPACITY CONDENSER LEAVING WATER TEMRATURE C To( C) , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , kwf: Cooling capacity (kw). kwt: Heating capacity (kw). kwe: Power input (kw). To: Evaporator leaving water temperature ( t in./out = 5K). 6

7 COOLING AND HEATING CAPACITY CONDENSER LEAVING WATER TEMRATURE C To( C) kwf: Cooling capacity (kw). kwt: Heating capacity (kw). kwe: Power input (kw). To: Evaporator leaving water temperature ( t in./out = 5K). 7

8 WATER CIRCUIT PRESSURE DROPS: Evaporator Water flow limits 5,0 14,6 6,4 18,1 6,8 19,1 7,4 21,7 8,1 24,8 9,2 28,9 11,0 34,3 11,3 37,2 17,0 50,0 18,2 54,1 19,8 64,4 19,8 64,4 23,8 78,1 27,4 89,2 29,7 96,6 29,7 96,6 35, , ,0 8,0 9, CORRECTION FACTORS If an unit is made to operate with a glycol-water solution, the following correction factors should be applied to any calculations. Ethylene glycol percent by weight (%) Freezing point ( C) Cooling capacity corr. factor Power input corr. factor Mixture flow corr. factor Pressure drop corr. factor 0-4,5-9,5-15,5-21,5-32,5 1 0,975 0,95 0,93 0,91 0,88 1 1,01 0,995 0,990 0,985 0, ,01 1,04 1,08 1,14 1,20 1 1,05 1,13 1,21 1,26 1,32 EVAPORATOR FOULING FACTOR CORRECTIONS 0 Clean evaporator 1 1 0,44 x 10-4 (m² C/W) 0,98 0,99 0,88 x 10-4 (m² C/W) 0,96 0,99 1,76 x 10-4 (m² C/W) 0,93 0,98 f1: capacity correction factors; fp1: compressor power input correction factor; unit performances reported in the tables are given for the condition of clean exchanger (fouling factor = 0). For different fouling factors values, unit performances should be corrected with the correction factors shown above. 8

9 WATER CIRCUIT PRESSURE DROPS: Condenser Condenser Water flow limits 5,6 17,6 6,3 19,8 7,1 23,0 8,7 26,5 11,1 31,2 11,1 37,2 13,4 40,8 15,8 48,6 17,4 54,9 20,6 65,8 20,6 79,0 22,1 86,2 23,9 93,6 27, , , , , CORRECTION FACTORS If an unit is made to operate with a glycol-water solution, the following correction factors should be applied to any calculations. Ethylene glycol percent by weight (%) Freezing point ( C) Cooling capacity corr. factor Power input corr. factor Mixture flow corr. factor Pressure drop corr. factor 0-4,5-9,5-15,5-21,5-32,5 1 0,975 0,969 0,961 0,920 0, ,018 1,023 1,029 1,063 1, ,004 1,008 1,037 1,060 1, ,040 1,124 1,247 1,366 1,554 CONDENSER FOULING FACTOR CORRECTIONS 0,44 x 10-4 (m² C/W) 1 1 0,88 x 10-4 (m² C/W) 0,987 1,021 1,76 x 10-4 (m² C/W) 0,965 1,064 f1: capacity correction factors; fp1: compressor power input correction factor; unit performances reported in the tables are given for the condition of exchanger with fouling factor = 0,44 x 10-4 (m² C/W). For different fouling factors values, unit performances should be corrected with the correction factors shown above. 9

10 REFRIGERATION CIRCUIT DIAGRAM Cooling only units VDS VDS RM CA RM MHP MHP SPS P> RLL RLL SPS P> SPH P> VP SPL P< MC RC TP FD SF FD SF TP SPH P> VP SPL P< MC RC MLP VT VT T1 MLP TP VDS EW VDS TP T2 DESCRIPTION Condenser Evaporator Filter-drier Compressor High pressure guage (accessory) Low pressure guage (accessory) Crank case heater Liquid line shut-off valve (accessory) Discharge line Sight glass High pressure switch Low pressure switch Safety pressure gauges Temperature sensor Antifreeze sensor Pressure transducer Safety valve Step regulation valve (accessory) Electronic expansion valve 10

11 REFRIGERATION CIRCUIT DIAGRAM Cooling only units TP SF FD RLL VT VDS CA CA VDS CA VDS RM RM RM MHP MHP MHP SPS P> RLL RLL SPS P> SPS P> SPH P> VP RC TP TP SPH P> VP RC SPH P> VP RC SPL P< MC FD SF FD SF SPL P< MC SPL P< MC MLP VT VT T1 MLP MLP TP EW TP TP VDS T2 VDS VDS DESCRIPTION Condenser Evaporator Filter-drier Compressor High pressure guage (accessory) Low pressure guage (accessory) Crank case heater Liquid line shut-off valve (accessory) Discharge line Sight glass High pressure switch Low pressure switch Safety pressure gauges Temperature sensor Antifreeze sensor Pressure transducer Safety valve Step regulation valve (accessory) Electronic expansion valve 11

12 DIMENSIONS, CLEARANCES AND WEIGHTS WCWW/Y 1302-B-1502-B B OUT IN 25 C IN OUT A Basement Condenser connections K1 K3 K2 K4 Electrical panel side n. 2+2 Ø18 Clearance area DIMENSIONS A mm B mm C mm ORATING WEIGHT K1 Kg K2 Kg K3 Kg K4 Kg

13 DIMENSIONS, CLEARANCES AND WEIGHTS WCWW/Y 1702-B-2802-B OUT IN C IN OUT A Basement B Condenser connections K1 K3 K2 K4 Electric panel side N. 2+2 ø18 25 Clearance area DIMENSIONS A mm B mm C mm ORATING WEIGHT K1 Kg K2 Kg K3 Kg K4 Kg

14 DIMENSIONS, CLEARANCES AND WEIGHTS WCWW/Y 3002-B-4202-B C IN OUT A B Basement Condenser connections K1 K4 K5 K6 n. 6 Ø18 K2 K Electric panel side IN Clearance area OUT DIMENSIONS A mm B mm C mm ORATING WEIGHT K1 Kg K2 Kg K3 Kg K4 Kg K5 Kg K6 Kg

15 DIMENSIONS, CLEARANCES AND WEIGHTS WCWW/Y B-6002-B C 500 IN OUT A Basement B Condenser connections K1 K2 K3 K4 K5 K6 K7 K8 K9 K Electrical panel side IN Clearance area OUT 15 DIMENSIONS A mm B mm C mm ORATING WEIGHT K1 Kg K2 Kg K3 Kg K4 Kg K5 Kg K6 Kg K7 Kg K8 Kg K9 Kg K10 Kg

16 DIMENSIONS, CLEARANCES AND WEIGHTS WCWW/Y C IN OUT A B Basement Condenser connections K1 K2 K3 K4 K5 K8 K9 K10 K11 K12 K13 K K6 K Electrical panel side IN Clearance area OUT DIMENSIONS A mm B mm C mm ORATING WEIGHT K1 Kg K2 Kg K3 Kg K4 Kg K5 Kg K6 Kg K7 Kg K8 Kg K9 Kg K10 Kg K11 Kg K12 Kg K13 Kg K14 Kg

17 WATER CIRCUIT General characteristics Water circuit WCWW/Y, WCWW/Y/SSL versions. Includes: evaporator, temperature sensor, antifreeze sensor, manual air vent valve and water drain. WATER CIRCUIT DIAGRAM ST2 T FL ST1 T SFA EW SCA OUT IN DESIGNATION Evaporator Flow switch (accessory) Water drain Manual air vent valve Sensor for unit operation Antifreeze sensor 17

18 SOUND PRESSURE LEVEL The sound level values indicated in db(a) have been measured in free field conditions. The measurement is taken at 1m distance and at a height of 1,5 m with respect to the base of the machine. On the noise levels that are indicated, a tolerance of +/- 3dB(A) should be considered (according to DIN 45635). 49,0 50,0 50,0 49,5 49,0 50,0 50,0 49,0 49,0 68,0 69,0 69,0 69,5 69,0 69,5 69,5 66,5 67,0 71,0 71,0 72,0 72,5 70,5 71,5 71,0 72,5 74,0 76,5 77,0 77,5 78,0 77,0 77,5 78,0 79,5 81,0 73,0 73,5 74,0 74,0 73,5 74,5 74,0 78,5 79,5 68,5 70,0 71,0 71,5 71,0 71,5 72,0 72,5 74,5 64,5 67,0 69,0 69,5 67,5 69,0 69,5 63,5 65,0 48,0 53,0 54,0 58,5 60,5 56,0 57,5 59,5 62,5 68,0 73,0 74,0 78,5 80,5 76,0 77,5 79,5 82,5 75,0 80,0 81,0 85,5 87,5 83,0 84,5 86,5 89,5 82,0 87,0 88,0 92,0 93,5 90,0 91,5 93,0 95,5 80,0 85,0 86,0 90,5 92,5 88,0 89,5 91,5 94,5 75,0 80,0 81,0 85,5 87,5 83,0 84,5 86,5 89,5 66,5 71,5 72,5 77,0 79,0 74,5 76,0 78,0 81,0 47,0 48,0 48,5 48,0 47,5 48,0 48,5 47,5 47,5 65,5 66,0 67,0 67,0 66,5 66,5 66,5 64,0 64,5 65,5 65,5 67,0 67,5 66,5 66,5 66,5 67,0 68,0 70,5 71,0 71,0 71,0 70,5 71,0 71,0 73,0 75,0 68,0 68,5 69,0 69,5 67,5 69,0 69,5 74,5 75,0 65,5 66,0 67,0 67,5 67,5 69,0 69,0 70,0 71,0 62,5 64,5 67,0 68,0 65,5 66,5 67,0 62,0 63,5 46, ,5 55, , ,5 75, , ,5 82, , , , ,5 87, , ,5 82, ,0 66,5 67,5 72,0 74,

19 MICROPROCESSOR CONTROL SYSTEM A microprocessor controls all the functions of the unit and allows any adjustments to be made. The set-points and operating parameters are set directly into the microprocessor. This type of microprocessor enables the adjustment of up to four compressors. It has a visual alarm signal, pushbuttons for the various functions, and offers a continuous control of the system as well as saving all the data in case of a cut in the power supply. Through the display, one can input and have an indication of set values. Principal functions: indication of entering and leaving water temperature; identification and display of blocks by means of alphanumerical code; control of one or two pumps; flow switch alarm delay at start-up ; hour counter of compressors in operation; automatic changeover of compressor and pump sequence; compressors start individually and not together; frost protection; remote on-off; operation signalling; manual operation; manual reset; pump down stop; electronic card for connection to management and service systems. Alarms: high and low pressure, oil and overload on each compressor; antifreeze; flow switch. Accessories: electronic card for connection to management and service systems, remote display. 19

20 41X1: B W G B W G + T M B W G B W G + T M POWER ELECTRICAL DIAGRAM: WCWW/Y 1302-B-6002-B - Wiring diagram explanation at page 24; - Dotted lines indicate optional electrical connections or to carry out during the installation. CONTROL ELECTRICAL DIAGRAM: WCWW/Y 1302-B-6002-B - Wiring diagram explanation at page 24; - Dotted lines indicate optional electrical connections or to carry out during the installation. SB1 L3 L2 L1 ID IDCOM ID IDCOMID ID ID ID ID ID ID ID ID ID ID ID ID ID ID ID ID ID IDC ID ID COMAI AI AI AI +VDC A1 GND AI +5V AI AI AI AI AI AI AI AI AI AI FA1 TT RF L1L2L3 FA2 KA1 TQ FA3 KA1 RQ1 VQ1 KC1 KC3 RTC1 RTC2 RTC3 RTC4 RESET PI1 RESET PI A A L N 1114 L N 1114 RC1 RC2 PD PI1 PL1 P H 2 P H 1 PI2 PL2 P H 4 P H 3 PDC SL SA ONLY WP VERSION R TP 1 KP1 R TP 2 SL SA KP2 T P 1 TPL1 T P 2 SM1 TPL2 SM2 P C 1 P C 2 P C 3 R EV 1 20

21 POWER ELECTRICAL DIAGRAM: WCWW/Y 1302-B-6002-B - Wiring diagram explanation at page 24; - Dotted lines indicate optional electrical connections or to carry out during the installation. CONTROL ELECTRICAL DIAGRAM: WCWW/Y 1302-B-6002-B - Wiring diagram explanation at page 24; - Dotted lines indicate optional electrical connections or to carry out during the installation. AOAOAOAO L N AOAO C NO NC C NO G Go R120CANHCANLGND D TT 230 MB1 TT MB2 FA FA 3X3: MD1 L N MD2 L N A 1 21 A P C 4 R T 1 R E V 1 124A 1 23 A P C P C 6 S 0 V C 1 KC2 KC1 S C 2 KC3 KC6 KC5 KC4 KA1 X4: X4: VI VI ONLY WP VERSION 8 X2: 2 1 O N/OF F 4A 4 3 A LARM EMERGENCY OFF SUMMER/WINTER D2 REMOTE DISPLAY SD1 MAX 1000mt X5 2 1 SVT X5 + T M + T M VT1 T PVT SVT T PVT 2 VT ONLY WP VERSION 21

22 POWER ELECTRICAL DIAGRAM: WCWW/Y 6603-B-9003-B - Wiring diagram explanation at page 24; - Dotted lines indicate optional electrical connections or to carry out during the installation. FC1 FC2 SG KC1 RTC1 KC2 KC5 KC3 RTC3 L1 L2 L3 400V/50Hz/3Ph/ X1: X1: 9 L1 U L2 V L3 W 14 IN+ IN SSC1 RTC2 X1: X1: 17 L1 U L2 V L3 W IN+ IN SSC2 0V SC2 0V SC MC MC CONTROL ELECTRICAL DIAGRAM: WCWW/Y 6603-B-9003-B - Wiring diagram explanation at page 24; - Dotted lines indicate optional electrical connections or to carry out during the installation. 22

23 POWER ELECTRICAL DIAGRAM: WCWW/Y 6603-B-9003-B - Wiring diagram explanation at page 24; - Dotted lines indicate optional electrical connections or to carry out during the installation. L1 L2 L3 FC3 KC4 KC6 KC7 RTC5 KC8 KC9 X1: SSC3 RTC4 L1 U L2 V L3 W IN+ IN- RTC6 X1: V SC3 MC CONTROL ELECTRICAL DIAGRAM: WCWW/Y 1302-B-9003-B - Wiring diagram explanation at page 24; - Dotted lines indicate optional electrical connections or to carry out during the installation. 23

24 ELECTRICAL DIAGRAM EXPLANATION DESIGNATION DISPLAY (USER INTERFACE) REMOTE DISPLAY * AUXILIARY CIRCUIT FUSES COMPRESSOR FUSES CIRCUIT AUXILIARY CONTACTOR COMPRESSOR CONTACTOR COIL COMPRESSOR DRIVER COMPRESSOR CAPACITY STEPS FLOW SWITCH CONDENSER FLOW SWITCH HP SWITCH CIRCUIT MOTOR PROTECTION COMPRESSOR LP SWITCH CIRCUIT COMP. CRANKCASE HEATER EVAPORATOR HEATER PHASE SEQUENCE RELAY CONDENSATION REGULATOR ELECTRICAL BOARD HEATER PIS HEATER COMPRESSOR OVERLOAD RELAY PUMP OVERLOAD RELAY ANTIFREEZE SENSOR MICROPROCESSOR DISPLAY CONNECTION BOARD EXPANSION BOARD MAIN SWITCH TEMRATURE SENSOR DISCHARGE LINE SENSOR SERIAL INTERFACE * COMPRESSOR SOFT START PRESSURE TRANSDUCER LOW PRESSURE TRANSMITTER VT PRESSURE TRANSDUCER ELECTRICAL BOARD THERMOSTAT AUXILIARY TRASFORMER REVERSE CYCLE VALVE CIRCUIT ELECTRIC BOARD FAN * Accessory 24

25 U.S.A. Dallas, Texas TX P.O. Box Phone: Fax: U.A.E. Dubai P.O. Box Phone: Fax: All models, sizes, dimensions, and specifications are subject to change without prior notice. CATALOG # WCWWXT/Y-08-15

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