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Stulz Explorer WSA 160, Original Instructions Manual

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Stulz Explorer WSA 160 Original Instructions Manual Download Page 34

34

 EN/06.2016/i09   © STULZ S.p.A. – all rights reserved

WSA ExplOrEr OriginAl inStructiOnS

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EVAPORATOR

WATER OUT

WATER IN

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EVAPORATOR

WATER OUT

WATER IN

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EVAPORATOR

WATER OUT

WATER IN

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PDZAL

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EVAPORATOR

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SHELL & TUBES

EVAPORATOR

WATER OUT

WATER IN

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PDZAL

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SHELL & TUBES

EVAPORATOR

WATER OUT

WATER IN

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PDZAL

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SHELL & TUBES

EVAPORATOR

WATER OUT

WATER IN

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SHELL & TUBES

EVAPORATOR

WATER OUT

WATER IN

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PDZAL

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SHELL & TUBES

EVAPORATOR

WATER OUT

WATER IN

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PDZAL

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Standar

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Without pumps

With no.1 pump 

Or no.1 pump + no.1 inverter

With no.2 pump 

Or no.2 pump + no.1 inverter

Summary of Contents for Explorer WSA 160

Page 1: ...Index i09 Issue 06 2016 WSA Explorer Original instructions Water cooled liquid chillers 400V 3 50Hz...

Page 2: ...nd from many thousands of projects that we have implemented worldwide We have systems and solutions of all sizes and with the most diverse requirements take advantage of our know how Founded in Hambur...

Page 3: ...chiller The CE mark guarantees that the STULZ products fulfill the requirements of the European Machinery Directive for safety The level of quality is permanently checked at every phase from design to...

Page 4: ...ts 15 3 2 Storage 16 3 3 Transport 16 3 3 1 Transport protection 16 3 3 2 Centre of gravity 20 4 Description 22 4 1 Type Code 22 4 2 Intended use 23 4 3 Chiller Design 23 4 3 1 General 23 4 3 2 Versio...

Page 5: ...n 69 7 2 First Startup 69 7 2 1 Oil pre heating 70 7 2 2 Commissioning of the chilled water circuit 70 7 2 3 Commissioning of the refrigerant circuit 71 8 Maintenance 73 8 1 Safety instructions 73 8 1...

Page 6: ...e warranty is limited to free replacement and shipping of any faulty part or sub assembly which has failed due to poor quality or manufacturing errors All claims must be supported by evidence that the...

Page 7: ...owerboard Entrance of the hydraulic circuit of the chiller intet of the chiller Location next to the inlet fitting of the hydraulic circuit Exit of the hydraulic circuit of the chiller outlet of the c...

Page 8: ...s HFC effet de serre disciplin s par le protocole de Kyoto REFRIGERATORE DI LIQUIDO LIQUID COOLER KUHLANLAGE REFROIDISSEUR DE LIQUIDE SERIE SERIES SERIE SERIE DATA DATE DATUM DATE WPAR044207ZFT0 7035...

Page 9: ...ater according to the Stulz specification Observe the national regulations of the country where the unit will be installed The refrigerant circuit contains refrigerant and refrigerating plant oil obse...

Page 10: ...llation the operation and the repeated inspection Installation according to EN 378 Operation Determination of emergency measures accidents malfunctions Creation of an abbreviated instruction and notif...

Page 11: ...parts and replacement parts accessories authorised by STULZ are an aid to safety Unacceptable operating methods The operating safety of the system is only guaranteed when it is used as intended The li...

Page 12: ...frigerant piping closed stop valves defective safety valve Discharge of refrigerant under high pressure burns in case of contact to the skin formation of acid vapours with open flames Open stop valves...

Page 13: ...ocedures in reverse order 2 5 Dismantling Area Danger Risk Preventative measures Refrigerant piping Soldering off or cutting the refrigerant pipes still under pressure Discharge of refrigerant under h...

Page 14: ...Non hazardous substance Non dangerous good No special warning labels are required Does not contain any hazardous ingredients at or above regu lated thresholds The product contains no known carcinogens...

Page 15: ...be nitrogen The chiller units must always be transported upright INFORMATION The refrigerant circuit is filled with R134a refrigerant ready to use The chiller is labelled as follows STULZ Logo STULZ o...

Page 16: ...contains refrigerant gas during the storage period you also have to consider the current F Gas regulations and EN 378 3 3 Transport The STULZ chillers can be lifted and moved by lifting devices with r...

Page 17: ...17 STULZ S p A all rights reserved EN 06 2016 i09 WSA Explorer Original Instructions WSA 160 LIFTING 2473 3000 821 434 2237 2278 3893 45 0 4255 5 0 5 0 Spacer Rope Shakles Lifting plate...

Page 18: ...p A all rights reserved WSA Explorer Original Instructions LIFTING 45 0 3892 9 624 1011 2473 2237 2278 3000 5 0 5 0 4635 WSA 220 LIFTING 45 0 45 0 2440 844 2440 811 2473 2237 2278 424 3217 6959 5 0 5...

Page 19: ...2016 i09 WSA Explorer Original Instructions LIFTING 821 434 8119 2466 2237 2278 3000 864 3000 45 0 45 0 3893 100 5 0 5 0 LIFTING 45 0 45 0 3888 2473 1282 3016 3000 3016 1669 11983 2237 2278 100 5 0 5...

Page 20: ...ithout pump WSA 160 WSA 220 x 1250 mm 1240 mm y 1700 mm 1900 mm z 880 mm 870 mm F C without pump WSA 160 WSA 220 x 1250 mm 1240 mm y 1700 mm 1900 mm z 1065 mm 1053 mm Base without pump WSA 250 WSA 280...

Page 21: ...1280 mm 1240 mm 1240 mm 1210 mm y 3820 mm 3870 mm 3990 mm 4110 mm z 900 mm 890 mm 870 mm 1050 mm F C 2 pumps WSA 320 WSA 360 WSA 380 WSA 440 x 1569 mm 1520 mm 1520 mm 1483 mm y 4030 mm 4083 mm 4209 mm...

Page 22: ...kW 1 380 911 kW 1 280 630 kW 1 440 1032 kW 1 300 672 kW 1 480 1122 kW 1 1 at 50 Hz W7L35 640 1260 kW 1 2 7 digit Evaporation Temperature 1 Outlet water 15 C 2 Outlet water 15 C standard 8 digit C Ver...

Page 23: ...ers with screw compressors has a unit designation which takes the following pattern WSA _ _ _ 2 CN _ There is one more version which will be described in the following Free Cooling Version The free co...

Page 24: ...gerant will exit 4 3 4 Compressor The chiller has semi hermetic screw compressors equipped with internal capacity control The single compressor can be partializzed stepless from 25 to 100 In each unit...

Page 25: ...rature PTC to manage the set point differential pressure switch to guarantee the safety of the unit sensor for freezing temperature PTC to guarantee the safety of the unit Air Temperatures sensor for...

Page 26: ...spring loading CO M Compressor IN Water inlet PT Pressure Transducer TCE Electronic expansion valve EV Evaporator OUT Water outlet FG Refrigerant filter RU H Manual valve TT Temperature trasmitter RL...

Page 27: ...1 4 1 4 RG1 VSC1 M1 CO2 1 4 1 4 RG2 VSC2 M2 BC4 BC3 PZHH 1 PSL 1 PZHH 2 MT13 MT12 MT11 MT10 MT17 MT16 MT15 MT14 1 4 PSL 2 FG1 RU1 RL1 VSC1 TCE 1 FG2 RU2 RL2 TCE 2 VSC2 H H PT 1 PT 2 BC1 BC2 TT 1 TT 2...

Page 28: ...SC2 M2 PZHH 1 PSL 1 PZHH 2 1 4 PSL 2 BC5 BC1 BC2 BC3 BC4 TT 1 TT 2 PT 3 PT 4 SHELL TUBES EVAPORATOR WATER OUT WATER IN RE PDZAL 3 TT 4 TT 7 PT 1 PT 2 PDZAL 1 PDZAL 2 0 5 2 A S W 1 2 3 4 5 6 7 9 8 10 1...

Page 29: ...4 1 4 RG1 VSC1 M1 CO2 1 4 1 4 RG2 VSC2 M2 PZHH 1 PSL 1 PZHH 2 1 4 PSL 2 BC5 BC1 BC2 BC3 BC4 TT 1 TT 2 PT 3 PT 4 SHELL TUBES EVAPORATOR WATER OUT WATER IN RE PDZAL 3 TT 4 TT 7 PT 1 PT 2 PDZAL 1 PDZAL 2...

Page 30: ...PT 2 MT13 MT12 MT11 MT10 MT20 MT21 MT19 MT18 MT29 MT28 MT27 MT26 MT33 MT32 MT31 MT30 MT25 MT24 MT23 MT22 MT17 MT16 MT15 MT14 TT 1 TT 2 PT 3 PT 4 SHELL TUBES EVAPORATOR WATER OUT WATER IN RE PDZAL 3 T...

Page 31: ...Water inlet M Motorized valve OUT Water outlet PT Pressure Transducer RU H Manual valve EV Evaporator RE Heaters M Pump Check valve TT Temperature trasmitter Disconnectable joint PD ZAL Low pressure...

Page 32: ...10 MT17 MT16 MT15 MT14 TT 3 TT 5 SHELL TUBES EVAPORATOR WATER OUT WATER IN RE PDZAL TT 4 TT 7 M M BC1 BC2 BC3 BC4 BC5 BC6 BC7 BC8 MT12 MT11 MT10 MT16 MT15 MT14 MT24 MT23 MT22 MT20 MT19 MT18 TT 3 TT 5...

Page 33: ...1 MT20 MT19 MT18 TT 5 SHELL TUBES EVAPORATOR WATER OUT WATER IN RE PDZAL TT 4 TT 7 M M BC1 BC2 BC3 BC4 MT18 MT20 BC5 BC6 MT32 MT30 BC11 BC12 BC9 BC10 MT24 MT22 BC7 BC8 TT 3 TT 5 MT13 MT12 MT11 MT10 MT...

Page 34: ...7 SHELL TUBES EVAPORATOR WATER OUT WATER IN RE PDZAL TT 4 TT 7 M M H H M H H SHELL TUBES EVAPORATOR WATER OUT WATER IN RE PDZAL TT 4 TT 7 SHELL TUBES EVAPORATOR WATER OUT WATER IN RE PDZAL TT 4 TT 7...

Page 35: ...TN S TN C S Voltage 400 V 3ph 50Hz PE Voltage Tolerance 10 Frequency Tolerance 1 Rated ultimate short circuit breaking capacity 25 kA Temperature difference 4 8 K Max glycol content ethylenic 40 prop...

Page 36: ...SA160 44 51 48 50 6 10 10 44 WSA220 39 47 45 48 10 10 10 37 WSA250 45 52 49 51 4 10 10 43 WSA280 42 50 48 50 6 10 10 41 WSA300 39 48 46 48 8 10 10 38 WSA320 44 52 48 51 6 10 10 40 WSA360 41 50 47 49 8...

Page 37: ...conditions outside the limits specified in the nameplate 5 2 1 Glycol correction factors INFORMATION In case glycol has to be added the technical data described in this paragraph shall be adjusted ac...

Page 38: ...80 640 0 0 25 0 50 0 75 0 100 0 125 0 150 0 175 0 200 0 225 0 250 0 275 0 300 0 325 0 Water Flow m h Pressure drop kPa 90 0 100 0 110 0 120 0 130 0 140 0 150 0 160 0 170 0 180 0 WSA160 WSA220 WSA250 W...

Page 39: ...A440 W SA480 W S A 6 4 0 275 300 325 350 375 400 425 450 475 100 125 150 175 200 225 250 50 75 100 125 150 175 200 225 250 275 300 325 W SA250 W S A 2 8 0 W SA300 W SA320 W SA360 WSA380 WSA440 WSA480...

Page 40: ...W S A 4 8 0 225 250 275 300 325 350 375 400 425 450 475 500 25 50 75 100 125 150 175 200 225 50 75 100 125 150 175 200 225 250 275 300 325 W S A 4 4 0 W S A 2 5 0 W S A 2 8 0 W S A 3 0 0 W SA320 W SA3...

Page 41: ...20 111280 122250 Power Consumption W7L35 kW 16 10 16 Absorbed current W7L35 A 34 4 20 34 4 Power consumption kW 17 6 17 6 17 6 Max absorbed current A 37 8 37 8 37 8 F C Temperature of total FC C n a n...

Page 42: ...und level 10m dB A 70 5 62 6 70 5 Power Sound level dB A 98 5 90 6 98 5 HYDRAULIC Water flow m h 83 76 82 7 Pressure drops kPa 35 33 34 75 Water circuit content unit side t b d t b d t b d Coolant Liq...

Page 43: ...61 4 69 3 Power Sound level dB A 97 3 89 4 97 3 HYDRAULIC Water flow m h 97 92 97 4 Pressure drops kPa 36 31 35 56 Water circuit content unit side t b d t b d t b d Coolant Liquid Type Water max 40 gl...

Page 44: ...10m dB A 69 6 69 6 69 6 Power Sound level dB A 97 7 89 8 97 7 HYDRAULIC Water flow m h 108 101 108 2 Pressure drops kPa 38 37 38 25 Water circuit content unit side t b d t b d t b d Coolant Liquid Typ...

Page 45: ...10m dB A 69 6 69 6 69 6 Power Sound level dB A 97 7 89 8 97 7 HYDRAULIC Water flow m h 115 107 115 4 Pressure drops kPa 35 28 35 4 Water circuit content unit side t b d t b d t b d Coolant Liquid Type...

Page 46: ...10m dB A 70 6 70 6 70 6 Power Sound level dB A 98 7 90 8 98 7 HYDRAULIC Water flow m h 127 118 126 8 Pressure drops kPa 43 33 42 77 Water circuit content unit side t b d t b d t b d Coolant Liquid Typ...

Page 47: ...l 10m dB A 70 8 70 8 70 8 Power Sound level dB A 98 9 91 98 9 HYDRAULIC Water flow m h 145 134 145 Pressure drops kPa 32 28 32 24 Water circuit content unit side t b d t b d t b d Coolant Liquid Type...

Page 48: ...10m dB A 70 8 70 8 70 8 Power Sound level dB A 98 9 91 98 9 HYDRAULIC Water flow m h 156 146 156 4 Pressure drops kPa 38 36 38 07 Water circuit content unit side t b d t b d t b d Coolant Liquid Type...

Page 49: ...l 10m dB A 71 7 71 7 71 7 Power Sound level dB A 99 8 91 8 99 8 HYDRAULIC Water flow m h 177 164 177 1 Pressure drops kPa 32 42 31 99 Water circuit content unit side t b d t b d t b d Coolant Liquid T...

Page 50: ...10m dB A 72 6 72 6 72 6 Power Sound level dB A 100 7 92 8 100 7 HYDRAULIC Water flow m h 193 181 192 5 Pressure drops kPa 41 181 40 68 Water circuit content unit side t b d t b d t b d Coolant Liquid...

Page 51: ...el 10m dB A 74 74 74 Power Sound level dB A 102 94 1 102 HYDRAULIC Water flow m h 216 200 216 2 Pressure drops kPa 49 200 49 2 Water circuit content unit side t b d t b d t b d Coolant Liquid Type Wat...

Page 52: ...nsport 2 Operating 2 Standard Low Noise units without pumps Standard HT Standard HT WSA 160 2473 2278 4255 1232 1837 423 6 Victaulic 4898 4918 5092 5112 WSA 220 2473 2278 4635 1389 1837 423 6 Victauli...

Page 53: ...49 6561 WSA 280 2473 2278 6960 1321 2962 423 6 Victaulic 6285 6325 6583 6623 WSA 300 2473 2278 6960 1321 2962 423 6 Victaulic 6379 6668 6419 6708 Free Cooling without pumps WSA 250 2473 2278 6960 1321...

Page 54: ...Victaulic 9333 9393 9976 10036 WSA 360 2473 2278 8120 1425 4741 474 188 377 8 Victaulic 9618 9678 10464 10524 WSA 380 2473 2278 8880 1825 5141 474 170 377 8 Victaulic 10068 10128 10958 11018 WSA 440 2...

Page 55: ...n a 10551 n a Free Cooling without pumps WSA 480 2473 2278 11983 1698 t b d 518 t b d t b d 8 Victaulic 12045 12105 13027 13087 WSA 640 2473 2278 11983 1698 t b d 518 t b d t b d 8 Victaulic 12346 n...

Page 56: ...on on the general lock door switch and signals connector Input lug size Model General lock door Signal WSA 160 M10 Mini fit WSA 220 M10 Mini fit WSA 250 M10 Mini fit WSA 280 M10 Mini fit WSA 300 M10 M...

Page 57: ...take place and a high sun exposure is present For locations where outer influences might affect the airflow an enclosure or louvre is recom mended Please consider negative impacts on the airflow by ne...

Page 58: ...m 1 3 mm 1 3 mm 1 3 mm 1 3 mm 1 3 mm 1 35 mm 1 35 mm 1 0 mm 58 EN 06 2016 i09 STULZ S p A all rights reserved WSA Explorer Original Instructions 6 1 1 Minimum distance from obstacles or other chillers...

Page 59: ...all rights reserved EN 06 2016 i09 WSA Explorer Original Instructions 6 2 Weight on the supports WSA 220 WSA 160 P1 P2 P3 P4 Without pump without tank 24 21 27 21 P1 P2 P3 P4 Without pump without tan...

Page 60: ...reserved WSA Explorer Original Instructions WSA 320 WSA 360 WSA 440 WSA 250 WSA 280 WSA 300 P1 P2 P3 P4 P5 P6 P7 P8 Without pump without tank 11 12 11 17 16 10 13 10 P1 P2 P3 P4 P5 P6 P7 P8 Without p...

Page 61: ...61 STULZ S p A all rights reserved EN 06 2016 i09 WSA Explorer Original Instructions WSA 480 WSA 640 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 Without pump without tank 7 14 6 16 10 10 12 9 11 7...

Page 62: ...am in chapter 4 5 Hydraulic dia grams at page 31 On the evaporator side a frost protection sensor measures the temperature of the liquid and reports it to the controller in which a threshold for an an...

Page 63: ...ions The expansion tank must be dimensioned in such a way that the water circuit volume can increase by 2 without draining off liquid through the safety valve Storage tank as an accumulator for heat e...

Page 64: ...pressure drop of each unit equally high Inlet Outlet For connecting the units to the external system remove the protective hoods from the water pipes 6 5 Water connection INFORMATION To avoid any mis...

Page 65: ...ons see 5 6 Dimensional drawings at page 52 6 6 Filling and bleeding air Open the vent valves See the exact location of the vent valves in the hydraulic scheme A standard chiller provides vent valves...

Page 66: ...additional controls should be installed in the control panel According to EN 60204 the operator is responsible to install current protection devices between the supply conductors and the power supply...

Page 67: ...umentation Use a cable gland on the bottom panel to fix the cable Connect the ground cable to the base of the chiller using on the designated position identi fied by the grounding symbol Use screw wit...

Page 68: ...manual 6 10 Pump control The unit s microprocessor controls internal and external pumps as well as monitoring a pump alarm 6 10 1 System with external pump Choose a power switch and a contactor in re...

Page 69: ...the outside temperature of the refrigerant pressure In case off leak age please contact the manufacture Check compressor oil level see 8 3 9 Compressor at page 71 Check correct power connection cabli...

Page 70: ...oil pre heating time of 24 hours Below an air ambient temperature of 5 C the side of the compressor where the oil separator is located should be insulated The insulation can be removed 10 minutes aft...

Page 71: ...t gauges at the high pressure and low pressure side and verify by reading the pres sures that the saturation temperatures for evaporation low pressure side and condensation high pressure side which co...

Page 72: ...xplorer Original Instructions Compressor operation According to the compressors manufacturer specifications the following present parameters must be kept Value description Time Minimum runtime of comp...

Page 73: ...t doing any operation in the electrical cabinet Discharges of the capacitors Live electrical components are to be switched to de energized and checked to ensure that they are in the de energized state...

Page 74: ...on Check the tightness of all terminals Check the cleanliness and integrity of the contatctors Check the connections of the pressure switches Unit in general Check the absence of abnormal vibration Ch...

Page 75: ...ity companies or persons which have carried out maintenance dates and results of inspections 8 3 4 Purity To be checked sight glass filter drier Bubbles in the sight glass indicate that the charge is...

Page 76: ...the action value as there are on behalf of the C2020 electronic controller further monitoring functions via the high pressure sensor which intervenes in the compressor control high pressure management...

Page 77: ...h require inspection and mainte nance The integrated oil filter is maintenance free Pressure relief valve The pressure relief valve has a response pressure difference of 28 bar and is maintenance free...

Page 78: ...quantity of oil contained in the compressor is allowed For larger quantities contact technical support If there have been losses of oil these must be replaced by topping up oil 1 Take a clean dry tran...

Page 79: ...ing such an operation in order not to limit the exchange efficiency and increase the pressure drop on the air side Do not use chemicals these could cause corrosion at the coils 8 4 2 Condenser Fan To...

Page 80: ...less than 3 K it indicates a limited heat transmission and thus pollution Another possibility to verify this consists in the comparison of the chilled water outlet temper ature with the saturated evap...

Page 81: ...plify the search for leaks Check the pipes the compressor and the condenser for a tight seat Vibrations of pipes and circuit components can result in leaks Check also the insulation of the water pipin...

Page 82: ...e to the thermal breaker of the X fan Replace the protection device Pump X thermic X pump failure Replace the pump Failure of the power supply circuit of the X pump cables remote control switch Replac...

Page 83: ...the display Contact the Stulz service centre Low amount of fluid to be cooled Check the fluid level in the storage tank and if necessary top up Low min temperature Low flow of fluid to be cooled Check...

Page 84: ...the cooling gas into the atmosphere The cooling gas must be recovered by a qualified refrigerator technician and if not reused sent to an authorized disposal centre Even the PVE oil of the compressor...

Page 85: ...CE Electromagnetic compatibility 2006 42 CE Machinery directive 97 23 CE Directivies PED PED Category III Evaluation Module H Certificate Number 162983 2014 CE ITA ACCREDIA Unit reference normatives...

Page 86: ...aving time at the restart of the chiller The UPS is installed into the electrical cabinet of the chiller Installation INFORMATION At first start is necessary to connect two wires from the Battery to t...

Page 87: ...87 STULZ S p A all rights reserved EN 06 2016 i09 WSA Explorer Original Instructions...

Page 88: ...39 045 6331615 aftersales stulz it OTHER AREAS on www stulz com EN 06 2016 i09 STULZ S p A Subjet to change without notice Maintenance Test Center Advice Service Portal Technical Implementation Clima...

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