Modular Water-Cooled Chiller

Transcription

1 OPERATION AND INSTALLATION MANUAL Modular Water-Cooled Chiller WGZ020BM / WGZ020BS WGZ030BM / WGZ030BS Please appropriately keep this manual Please carefully read this manual before installing or using

2 Contents WGZBE1308-A00 Part No.: M Product Introduction Safety Notes Technical Parameters Unit Installation and Operation Unit Maintenance Troubleshooting

3 ! Note Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment.! Warning Pay attention to avoiding contacting the harmful sharp edges.! Warning Pay attention to avoiding contacting the compressor copper pipe when the unit is in operation to avoid any burn caused by the copper pipe delivering high-temperature refrigerant.! Warning Any movement of the unit or the power is dangerous that personal injury or death may be caused. Cut off the power supply before maintenance.! Warning Forbid installing the unit in the site where metal and electrical components easy to be corroded. Forbid installing in the vent of Ammonia equipment and toilet, the vent of operating room, and nearby sewer.! Warning Control water pump on and off by PCB controller output; otherwise the BPHE may burst due to freezing. If the unit suspends running for a long time, please cut off the power supply for pump and drain the water off from the unit by drain valve; otherwise the liquid side heat exchanger and water pipe may freeze and burst. McQuay is a registered trademark of McQuay International. All rights reserved throughout the world International McQuay reserves the right to make changes in design and construction at anytime without prior notice. 1

4 1. Product Introduction 1.1 Characteristics Overview McQuay WGZ-B Series modular water-cooled chiller is characterized in simple structure, quiet operation and long life and is able to meet the highest requirements of the user on reliability and flexibility. The unit can match with air side flexibly so that fan-coil or air handling unit in different specifications can be adopted and the quantity depends on the cooling capacity and total processing capacity of air-coil or air handling unit. With the traits of high-performance, low noise, compact structure, easy operation, safety, easy installation and maintenance and others, the unit is widely used by factories, stations, hotels, villas, offices, and other scenarios which are not sensitive to the noise both indoors and outdoors. Superior Performance WGZ-B series products use the world's leading technology and world-renowned accessories and have been strictly tested so that the stability can be ensured. Compressor has high energy efficiency ratio and low noise; the highly efficient heat exchanger ensures the full exertion of the unit's ability. There are much fewer parts than general piston type water-cooled chiller so that the unit has a much lower failure rate, more reliable operation and a longer life. WGZ-B unit adopts flexible scroll compressor that creates outstanding performance incomparable by the piston compressor. The unit operates stably with the noise 3~5dB (A) lower than the piston compressor. In addition, it has unique structural design, stronger liquid-strike capability, higher reliability, higher energy efficiency ratio, less power consumption and less operation cost. The chiller system starts compressors step by step, this can not only reduce the starting current greatly but also prevent safety risk caused by inrush current as compared with the ordinary single-compressor system. Easy Operation The unit adopts microcomputer control system and all the temperature and water flow have been set up by the manufacturer. The unit will detect and adjust water temperature automatically. Users are only required to start the ON/OFF button, and then the unit will complete all operation automatically. Easy Installation Refrigerant is factory charged in accurate amount. The user is not required for refrigerant charging. The water outlet and inlet are reserved for connecting with air side devices. Water can be supplied for operation directly as long as the system pipeline is cleared and the water quality is acceptable. Safe Operation Control Refrigeration system has high and low pressure protection and exhaust temperature protection which will protect the unit when there is abnormal operation. Meanwhile, the operation condition of all parts can be monitored automatically by the micro-controller. Refrigeration system automatic protection will work when the unit is overloaded and the unit will stop automatically when the water temperature is too low to prevent internal freezing of the water system, thereby ensuring the safe operation of the unit. Convenient Maintenance Once the abnormal trip occurs, the error code will be displayed on the controller which can help the quick problem solving. 2

5 1.2 Nomenclature WGZ 020 B M - FACE Modular water-cooled chiller E: export; domestic: default Power supply:f refer to V/3N~/50Hz Master/Slave Unit:M-Master unit S-Slave unit Design series B:B series Nominal cooling capacity(rt) Model name: WGZ modular water-cooled chiller Cooling capacity code: 020, 030 Design series: A, B, C Unit features: modular water-cooled chiller, M: master unit, S: slave unit Refrigerant code: R407C: 4; R410A: 5; R22: Default Power supply: F: V/3N~/50Hz; A: V~/50Hz Specific product description: AA, AB, AC specific description of specification Export/domestic: E: export; domestic: default 3

6 2. Safety Notes Pay special attention to the air-conditioning unit installation for the following safety problems before installation, in the installation and test operation process as well as when displacing the unit in the future: 2.1 Installation Preparations Please check the power supply condition. Power supply and installation must comply with norms and rules of the local authorities (such as the national power supply department). The fluctuation of voltage cannot exceed ± 10% of the rated voltage. Power supply lines must be separated from welding transformer which may cause greater fluctuations in voltage. The air-conditioning unit should be installed by professional staff with relevant qualification certificates. Improper installation may cause water leakage, electric shock, fire or other accidents. Please install the air-conditioning unit in accordance with the Manual. Improper installation may cause water leakage, electric shock, fire or other accidents. A dedicated circuit in line with the Electric Equipment Engineering Standard and the Indoor Electrical Wiring Norms should be set up. For ground installation, a solid cement foundation must be built in advance and take good measures for preventing typhoon, strong wind and earthquake. Prepare protective equipment and installation tools. Protective equipment, such as gloves and work clothes can prevent personal injury. 2.2 Cautions for Installation Outdoor unit must be installed firmly and solidly to avoid swing in the operation process. The electric control box should be covered firmly to prevent dust and water entering that may cause the failure or accident. If refrigerant leaks in the installation process, open doors and windows of the room for ventilation. Poisonous gas may be generated if the refrigerant contacts with flame. Preventive measures should be developed to prevent that hypoxia and asphyxia of people when the refrigerant concentration after leakage exceeds the safety limit. Pay attention to the damp-proofness of electrical parts which should be kept far away from water sources. Otherwise, electric shock, fire or other accidents may be caused. The protection devices cannot be replaced and their settings cannot be changed. Otherwise, bad performance, fire or explosion accident may be resulted. The power cord cannot be too tight. Otherwise, it may rupture so that the unit cannot be started or other accidents may be caused. Use the power cord with enough current capacity and rating power. The improper power cord may cause leakage of electricity or even a fire. Unit must be grounded correctly. Incorrect grounding may cause electric shock. Do not connect the grounding line to lightning protection devices or telephone lines. The unit must be lifted and handled by related equipment. 2.3 Cautions for Test Operation Do not touch the switch by wet hands or electric shock may be caused. Do not start the air-conditioner when the panel or protection net is removed or personal injury or damage of other items may be caused by the moving components. Do not touch refrigerant pipeline in the operation course or when the operation just stops or burns or frostbite may be caused by the pipeline which may be very hot or very cold when the air-conditioner is running. 2.4 Cautions for moving the Air-Conditioner Installation Location Contact the Company's distributor and consult to the professional maintenance service personnel. Do not charge other type of refrigerant to the units, otherwise, it will cause units failure Please refer to 4. Unit Installation and Operation for other cautions. 4

7 3. Technical Parameters 3.1 Specifications Unit Model WGZ020BM/BS WGZ030BM/BS Nominal cooling capacity kw Nominal power input kw Cooling Evaporator m 3 /h (user side) Water flow rate Condenser m 3 /h (cooling) Nominal heating capacity kw Nominal power input kw Heating Condenser m 3 /h (user side) Water flow rate Evaporator m 3 /h (heat source) EER Water pressure drop Evaporator kpa 21 Condenser kpa 17 Heat exchanger type Evaporator BPHE Condenser Shell and tube type Diameter of connection Evaporator mm Condenser mm DN80 Capacity steps Step 2 3 Compressor type Hermetic scroll compressor Throttling mode Thermal expansion valve Refrigerant Type R22 Charge amount kg 4.5x L mm Outline dimensions H mm W mm Net weight kg Transport weight kg Operation weight kg Note: Nominal cooling capacity test condition: user side outlet water temperature: 7, flow coefficient: 0.172[m 3 /(h*kw)]; cold water side inlet temperature: 30, flow coefficient: 0.215[m 3 /(h*kw)] Nominal heating capacity test condition: user side outlet water temperature: 45, flow coefficient: 0.172[m 3 /(h*kw)]; heat source side inlet water temperature: 15, flow coefficient: 0.134[m 3 /(h*kw)]; The switchover between cooling mode and heating mode is achieved by the valve of the external water system. The factory does not provide; Evaporator and condenser water pressure drop does not include the resistance of any external water pipes and parts; The basic unit modules of the combined unit are WGZ020BM/BS and WGZ030BM/BS. The same or different modules combination is allowed. Specification parameters are subject to change along with the products improvement without notice. 5

8 3.2 Unit Performance Parameters Performance parameters of WGZ020BM/BS under various conditions Cooling mode Heating mode Condenser inlet water temperature Condenser inlet water temperature Evaporator outlet water temperature Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) Evaporator outlet water temperature Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw)

9 Performance parameters of WGZ030BM/BS under various conditions Cooling mode Heating mode Condenser inlet water temperature Condenser inlet water temperature Evaporator outlet water temperature Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) * * * * Evaporator outlet water temperature Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power Capacity Power (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw) (kw)

10 3.3 Operation Range CONDENSOR WATER INLET TEMPERATURE CONDENSOR WATER INLET TEMPERATURE EVAPORATOR WATER OUTLET TEMPERATURE EVAPORATOR WATER OUTLET TEMPERATURE COOLING MODE HEATING MODE Note: 1. In order to ensure the operation efficiency, it is suggested to control the cooling water temperature lower than 35 ºC in the cooling mode. 2. Strict test has been given to the unit in the factory so that the safe operation of the unit in the operation range can be guaranteed. 3. Please refer to 3.2 Unit Performance Parameters for the unit performance parameters under various conditions. 4. The operation range and performance parameters change are not applicable for low -temperature unit with antifreeze. 5. The operation range is the unit standard operation range. The unit can operate beyond the range for a short time, or the unit will be alarm. Working Conditions Item Description Power supply voltage Rated voltage ±10% Power supply frequency Rated frequency ±1% Variations between phases Rated voltage ±2% Air quality Must not contain solute that can corrode copper, aluminum or iron. Flow rate of chilled water m/s Pressure of chilled water < 0.7Mpa Must not contain solute that can corrode copper, iron, or welding material. Quality of chilled water For details on the water quality requirements, please refer to 4.6 Water Quality Requirements. Installation site Take anti-snow and ventilation measures as required. Ambient temp. Refer to the figure above. Relative humidity <90% 8

11 3.4 Schematic Diagrams WGZ020BM/BS Low-pressure switch Discharge Temperature Protector Discharge Temperature Protector Compressor Compressor Low-pressure switch Inlet Outlet BPHE Evaporator High-pressure Switch High-pressure Switch Shell&Tube Condenser Outlet Inlet Thermo Expansion Valve Thermo Expansion Valve WGZ030BM/BS Low-pressure switch Discharge Temperature Protector High-pressure Switch Discharge Temperature Protector High-pressure Switch Compressor Compressor Compressor Oil Equalizer Low-pressure switch Inlet Outlet BPHE Evaporator Shell&Tube Condenser Outlet Inlet Thermo Expansion Valve Thermo Expansion Valve 9

12 3.5 Water Pressure Drop Modular Water-Cooled Chiller EVAPORATOR/CONDENSER WATER PRESSURE DROP CURVE WGZ020B Evaporator Pressure drop (kpa) WGZ020B Condenser WGZ030B Evaporator WGZ030B Condenser Flowrate (m 3 /h) 10

13 3.6 Outline Dimensions Modular Water-Cooled Chiller Outline dimensions of WGZ020BM / WGZ020BS Unit: mm Evaporator Inlet R2" Access Valve ,5 397 Evaporator Outlet R2" Condenser Outlet Rc2" Condenser Inlet Rc2" Mounting Hole 8-R Outline dimensions of WGZ030BM / WGZ030BS Unit: mm Evaporator Inlet R2" Access Valve Evaporator Outlet R2" Condenser Outlet Rc2" Condenser Inlet Rc2" Mounting Hole 8-R

14 Modular combination unit outline dimensions Unit: mm L=(630+5) N

15 The combination examples in table below are only for common models: Master Unit Slave Unit 1 Slave Unit 2 Slave Unit 3 Slave Unit 4 Slave Unit 5 Slave Unit 6 Slave Unit 7 Slave Unit 8 Slave Unit 9 Combination model 020BM WGZ020B 030BM WGZ030B 020BM 020BS WGZ040B 030BM 020BS WGZ050B 030BM 030BS WGZ060B 030BM 020BS 020BS WGZ070B 030BM 030BS 020BS WGZ080B 030BM 030BS 030BS WGZ090B 030BM 030BS 020BS 020BS WGZ100B 030BM 030BS 030BS 020BS WGZ110B 030BM 030BS 030BS 030BS WGZ120B 030BM 030BS 030BS 020BS 020BS WGZ130B 030BM 030BS 030BS 030BS 020BS WGZ140B 030BM 030BS 030BS 030BS 030BS WGZ150B 030BM 030BS 030BS 030BS 020BS 020BS WGZ160B 030BM 030BS 030BS 030BS 030BS 020BS WGZ170B 030BM 030BS 030BS 030BS 030BS 030BS WGZ180B 030BM 030BS 030BS 030BS 030BS 020BS 020BS WGZ190B 030BM 030BS 030BS 030BS 030BS 030BS 020BS WGZ200B 030BM 030BS 030BS 030BS 030BS 030BS 030BS WGZ210B 030BM 030BS 030BS 030BS 030BS 030BS 020BS 020BS WGZ220B 030BM 030BS 030BS 030BS 030BS 030BS 030BS 020BS WGZ230B 030BM 030BS 030BS 030BS 030BS 030BS 030BS 030BS WGZ240B 030BM 030BS 030BS 030BS 030BS 030BS 030BS 020BS 020BS WGZ250B 030BM 030BS 030BS 030BS 030BS 030BS 030BS 030BS 020BS WGZ260B 030BM 030BS 030BS 030BS 030BS 030BS 030BS 030BS 030BS WGZ270B 030BM 030BS 030BS 030BS 030BS 030BS 030BS 030BS 020BS 020BS WGZ280B 030BM 030BS 030BS 030BS 030BS 030BS 030BS 030BS 030BS 020BS WGZ290B 030BM 030BS 030BS 030BS 030BS 030BS 030BS 030BS 030BS 030BS WGZ300B Note: 1. The outline dimensions of the master unit and the slave units are the same; 2. N refers to unit quantity, N

16 3.7Electrical Parameters and Wiring Requirements Unit Model Nominal cooling power (kw) Operating current (A) Nominal heating power (kw) Operating current (A) Main power cord Neutral line Grounding line Crosssectional area (mm 2 ) pcs Crosssectional area (mm 2 ) pcs Crosssectional area (mm 2 ) WGZ020B WGZ030B WGZ040B WGZ050B WGZ060B WGZ070B WGZ080B WGZ090B WGZ100B WGZ110B WGZ120B WGZ130B WGZ140B WGZ150B WGZ160B WGZ170B WGZ180B WGZ190B WGZ200B pcs 14

17 4. Unit Installation and Operation Modular Water-Cooled Chiller! Warning The unit installation and maintenance should be carried out by McQuay service staff or experienced person. Pay attention to the electric distribution security! 4.1 Unit Inspection When the unit is received: 1 Check whether the unit is injured during the transport process. If yes, make record on the delivery note and ask the supplier representative to inspect in written form. The hidden damage should be reported within 15 days. 2 Check the packing list to verify that all parts are delivered. Any shortage should be noted on the packing list immediately. 4.2 Unit Handling Handle gently to avoid injury to the unit or components. The regular tool is forklift or roller and forceful drag is in any case forbidden. Pay attention to the following issues when handling: Do not collide with other objects in the moving process, the tilt angle should not exceed 15 degrees, and touch down the ground gently. Do not take copper pipe connector or water pipe connector as the working point of the handling, or connector deformation or damage may be caused. Please properly protect the painting on the metal surface. Rust may occur on the shell once it is scratched by sharp objects. The end cap of the connector can be removed only before connecting pipeline. Do not use the attached packaging lace to carry, move or handle the unit. The lace may break and accident or risk may be caused. Handle the plastic bag properly and avoid children touching the machine. Before the unit is installed, do not remove the cushion block at the bottom of the unit. Use pad when lifting or handling the unit by lifting equipment to avoid injury. It is proposed to handle the unit by lifting. Use reliable lifting rope and support the unit at four points as shown in the diagram below. Do not support the lifting by two points which will lead to instability and falling of the unit. Lifting cord 2 pcs(>6m) Protection pad 15

18 4.3 Installation Location In order to achieve the best performance of the unit, the installation location should meet the following conditions: Since the unit vibration is very small, it can be installed on concrete ground directly without foundation. Reserved installation place 1 Reserved installation place 2 If the engine room is on the floor, the floor should be able to bear the operation weight of the chiller. Ensure sufficient water system installation and maintenance space around the unit. For the modules combination, keep at least 5mm space between units. 16

19 >1000 mm >1800 mm >1500 mm >1500 mm >2000 mm Minimun gap between modular 5 mm 4.4 Unit Installation The installation location should be strong enough to bear the unit weight and the vibration in operation. Do not install at the place with much dirt, grease, large salt content or large amount of sulfide gas. Do not install the outdoor unit at the place where inflammable gas may exit. The leakage and accumulation of inflammable gas around the unit may lead to explosion. Do not install the outdoor unit at the place which is easy to be attacked by strong wind or typhoon directly. If conditions permit, set up auxiliary facilities to prevent rain, snow and direct sunlight. It is proposed to install 20mm rubber cushion on the floor for vibration reduction (as shown in the diagram below) Rubber cushion quantity Rubber cushion specification 4 pcs mm 17

20 Refer to the following design diagram for the installation foundation: Foundation Bolt M12x220 Note: 1. The foundation is the concrete structure with the concrete and soil ratio: cement: sand: gravel= 1:2:4 and place 10 pieces of φ10mm strengthened reinforcing steel bar at the interval of 300mm. 2. Level the foundation surface by sand slurry and chamfer the edges. 3. When the foundation is constructed on the concrete floor, gravel cannot be used, but dabbing treatment should be given to the surface. 4. Since there is no drainage connection at the bottom of the unit, the drainage pipe should be connect to the place that drainage is allowed and keep at least 1:50 slope so that a little condensing water inside the unit can be drained timely. 5. When the unit is installed on the roof, please carefully check the building strength and take safe drainage measures. 6. Size A should be determined according to the installation location at the filed. 7. Fix each unit by four M12x220 foundation bolts. 8. Add 20mm rubber bumper on the foundation for vibration reduction. 9. N refers to the number of the unit module. 18

21 T T T T T 4.5 Water System Design Modular Water-Cooled Chiller All water system design should be carried out by personnel familiar with the local building and safety related laws and regulations and with rich water system installation experience. The typical cooling water system diagram below is for reference: Cooling Water System Flow Chart Air vent Cooling tower... Feed water Full Drain Pressure bypass valve Cooling pump WGZ-B WGZ-B Drain T Feed water WGZ-B WGZ-B WGZ-B WGZ-B WGZ-B WGZ-B chilling water pump Gate valve Pressure gauge PI valve Butterfly valve Check valve Thermometer Pump Electric butterfly valve Flexible joint Electric 2WV Ball valve Brass Y strainer Pressure bypass valve Note: Before start the unit, clean the water system and ensure that pipes are clean without contaminants. For details of the cleaning method, please refer to 5.3 Water Treatment 19

22 The switchover between water-cooled chilled water and water-source hot water modes can be achieved by the opening and closing of valves in the water system to meet the annual demand for cooling or heating. The switchover schematic diagrams of the cooling and heating systems are shown below: 20

23 4.6 Water Quality Management Modular Water-Cooled Chiller Water circulating system at the chilled water side of the unit: Water circulating system at the chilled water side of the unit:! Note Too much oil, salt and acid substances in the chilled water system will lead to unit performance reduction. Please supply required qualified water. The closed water circulation system is recommended. The circulating water inside the system cannot contact other substances in the atmosphere, which can effectively guarantee the water quality, stabilize the pressure and reduce the oxidation and corrosion degree of the pipeline and equipment greatly. The water system must be preliminary softening treatment, aimed to protect plate exchanger from scaling. In addition, the unsoften water may be scaled on the pipeline, leading to increase the water resistance, then the water flow and water pump will be impacted. The requirements on water quality for the water system are as follows: Items Reference items Item Recommended Tendencies value Corrosion Scaling ph (25 C) Conductivity (25 C) µs/cm < 800 Cl - mg (Cl - )/L < SO 4 mg (SO 2-4 )/L < 200 Acid consumption (ph = 4.8) mg (CaCO 3 )/L < 100 Total hardness mg (CaCO 3 )/L < 200 Fe mg (Fe)/L < 1.0 S 2- mg (S 2- )/L 0 NH + mg (NH + )/L < 1.0 SiO 2 mg (SiO 2 )/L < 50 Note: represents factors that may cause corrosion or scaling. Circulation pump selection principles and standards: 1 Water flow total rated water flow of all the outdoor units Pump Head: For the closed circulation: head (frictional resistance of the water system+ local resistance of the water system+ unit water pressure drop) 1.1 For the open circulation: head (hydrostatic pressure of the water system+ frictional resistance of the water system + local resistance of the water system+ unit water pressure drop) 1.1 When several units are equipped with only one water pump, take the loop with the biggest resistance, usually the farthest unit loop. 21

24 Minimum water volume requirements for the unit operation! Note Frequent alarm and stop will be caused if actual operation volume of the water system is less than the required minimum volume in operation. No. Model Inlet Water Setting Temperature Min. Water Volume Vmin(l) 1 WGZ020B 2 WGZ030B Water system volume in the process of operation includes the volume of main water pipes, water storage tank and the air side of the normally open two-way valve. If the actual volume V of the water system in the process of operation is less than Vmin, please install a (Vmin-V) L water storage tank in the water system. This table is calculated subject to 5 unit anti -freezing temperature and the minimum volume will change along with different anti-freezing temperatures. This table is only applicable to the minimum volume selection of the conventional unit water system and is not applicable to the water system of low-temperature unit that is added with antifreeze. The unit minimum volume in the table is calculated subject to the rated water flow of the unit. 22

25 The calculation of frictional resistance and local resistance can refer to the circulating pipe frictional resistance parameters table. Circulating pipe frictional resistance parameters table Water pipe frictional resistance Hf=L*Rf, L: pipe length; Rf: unit frictional resistance. See the data below: Velocity v Pipe diameter DN15 DN20 DN25 DN32 DN40 DN50 DN80 DN100 DN125 DN150 DN200 DN250 DN300 Internal diameter *4 159* *6 273*7 325*8 Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R

26 Velocity v Note: Modular Water-Cooled Chiller Pipe diameter DN15 DN20 DN25 DN32 DN40 DN50 DN80 DN100 DN125 DN150 DN200 DN250 DN300 Internal diameter *4 159* *6 273*7 325*8 Q R R Q R R Q R R Q R R Q R R Q R R Q R R Q R R v: water velocity (m/s), Q: water flow (m³/s), R2: unit frictional resistance when the relative roughness is 0.2mm (mmh 2O/m), R5: unit frictional resistance when the relative roughness is 0.5mm (mmh 2O/m) Water system local resistance design parameters table Name Ball (check) valve Angle valve Gate valve Model Local resistance coefficient ζ Full open,< DN Full open,>dn Full open,< DN Full open,>dn Full open,< DN Full open,>dn Check valve degrees bend Curvature radius 2r 0.26 Curvature radius >2r 0.20 Three-way 3.0 Three-way 1.8 Three-way 1.5 Three-way 0.68 Expansion flare D/d=2/ Narrowing flare D/d=2/

27 4.7 Water Pipe Connection! Note In order to ensure the correct installation and safe operation, the unit should be installed by professional installation company or experienced personnel. The pipeline installation should comply with the principle of minimizing the number of bends and reducing the height of pipes as far as possible to reduce the pressure loss. It is also required to pay attention to that: All water pipes should be well fixed to avoid any stress transferred by the water pipes and pressure brought by the water system to affect the unit. Use damper to reduce the noise and vibration transferring to the building. Taker proper measures to maintain pressure of the water system (such as the installation of expansion water holder). Take insulation and moisture proofing measures on the chilled water pipeline to prevent cooling capacity loss and the formation of condensing water. In order to ensure water quality, a water filter more than 20 mesh should be installed on the water inlet pipe of the evaporator.! Note A water filter more than 20 mesh should be installed at the inlet of the evaporator, or the unit performance will be affected by the entered impurities or dirt! When connecting pipes at site, pay attention to connecting inlet and outlet pipes correctly in the light of marks on the unit. The air vent should be set up as the highest point of the chilled water system. After completion of the chilled water system connection, fill the system full of water, open the discharge valve to eliminate air in the chilled water completely, and then close the valve. Make sure that the cleaning of indoor pipelines should be carried out with by-pass unit. The leakage test should be qualified. If the water quality is poor or the pipes are dirty, clean the filter after 30 minutes of water pump operation. Install drainage valve at the lowest point of the pipeline. It is recommended to add wash-out valve at the inlet and outlet pipe to facilitate the regular maintenance on the heat exchanger. Install a water flow switch on the chilled water pipeline to ensure the safety operation of the unit. When installing the water flow switch, pay attention that: Keep the direction of arrow on the water flow switch consistent with the water flow direction in the pipeline. There should be straight pipe at least 5 times of the pipe diameter before and after the water flow switch and there is no valve or other water flow limiting device on this pipe. Discharge water inside the unit in winter when the unit is not used, or the unit may be frozen.! Note Discharge water inside the unit in winter when the unit is not used, or the unit may be frozen! 25

28 Water flow switch Water discharge sketch map for internal water discharge in winter 4.8 Electrical Connection! Warning Power supply connection is so dangerous that may cause injury or death. It should be handled by professionals!! Warning A breaker device shall be installed at power supply input port, it shall have at least 3mm contact separation. The breaker device shall have short circuit and ground fault protection function. The breaker device shall be provided and installed by user. The unit should be grounded well. Do not connect the grounding line to the gas pipes, water pipes or telephone lines. Improper grounding will lead to electric shock accident. The leakage circuit breaker should be equipped. Do not install the unit in the flammable and explosive environment. A circuit-breaker with sufficient capacity should be installed at the power incoming line. The circuit-breaker should at least have 3mm clearance between open contacts. If there is fuse on the circuit-breaker, mark the model and rated value of the fuse. Check and make sure that the unit power line meets the requirements before installation. Please see 3.7 Electrical Parameters and Wiring Requirement for the wiring requirements. You can see the circuit diagram inside the electronic control box. The main power lines connection between different modules should refer to diagrams below: 26

29 L1 L2 L3 N BREAKER BREAKER BREAKER R S T N R S T N R S T N Master Unit Slave Unit1 Slave Unit5 For the modules combining installation, pay attention to the shielding of communication lines among units to avoid interference. It is recommended to use the STP (shielded twisted pair) as diagram below: A: Conductor (twisted tin plated copper wires with cross sectional area at least 0.5mm 2 or 20AWG) B: Insulator C: Shielding layer (twisting or weaving tin plated copper wires with the shielding rate at least 95%) D: Outer sheath (PVC) Note: 1. Select network connection wire with compact shielding layer and small twisting pitch as far as possible. 2. Refer to UL2547 or UL2791 wire standard. STP (shielded twisted pair) The communication wirings between master and slave units should be connected as below diagram: Master/slave unit communication lines connection diagram Master unit Slave unit Slave unit n-1 Slave unit n Power adapter AC:220V~/50Hz Wired controller 27

30 Unit DIP setting DIP switches for capacity, address and slave quantity setting are shown on the air-conditioner controller. Capacity DIP has been set up before delivery and cannot be changed. MODEL 020BM(MASTER) 020BS(SLAVE) S1.1 ON ON 030BM(MASTER) ON 030BS(SLAVE) ON S1.2 OFF OFF S1.3 S1.4 OFF OFF S2.1 ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF S2.2 OFF OFF S2.3 OFF OFF S3.1 OFF OFF S3.2 OFF OFF S3.3 OFF OFF S3.4 OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF ON Address DIP and slave quantity must be set up in accordance with the specific situation after installation. The user should record the address DIP and the corresponding installation location in an important file which should be kept properly for future maintenance reference. S1 DIP Setting S2~S4 (Model setting) Without remote switch Standard cooling only unit With remote switch Cooling only unit with heat recovery Standard heat pump unit Quantity of slave units (see details in table below) Heat pump unit with heat recovery Hot water heater unit Slave unit quantity DIP Zero (that is, there is only a main unit used as the single unit) set of slave unit sets of slave unit sets of slave unit sets of slave unit sets of slave unit sets of slave unit sets of slave unit sets of slave unit sets of slave unit sets of slave unit sets of slave unit sets of slave unit sets of slave unit sets of slave unit sets of slave unit

31 S2 DIP Setting Modular Water-Cooled Chiller Normal Fixed water 0 Slave unit 0 0 temperature water volume system system Address DIP (see details below table) 1 Main unit 1 Variable water volume system 1 Low temperature water system Address DIP # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # Note: The maximum slave unit address is # 15 29

32 S3 DIP Setting 1 Modular Water-Cooled Chiller 2 Mode Priority(active under summer auto mode) 3 4 S3.3~S3.4 models DIP 0 Factory-set state 0 Air conditioning first 0 0 WGZ020B 1 On-line test state 1 Hot water first 0 1 WGZ030B 4.9 Test Run Pay attention to the following issues before the test operation: Clean the water system before test operation. If circulating water is required, water treatment should be given. Check and make sure that the phase sequence of the wiring is correct, or the phase sequence protector will work. If all are checked to be correct, press ON/OFF on the wired controller to start the unit. WGZ-B modular water-cooled chiller has the automatic failure alarm function. When error occurs during unit operation, corresponding code will be displayed on the controller and the wired controller when there s a failure, corresponding error code will display on the controller and PCB. (For detailed information, please refer to 6. Trouble shooting ) Make sure that the working conditions do not exceed the rated working range. (For detailed information, please refer to 3.3 Operation Range ) 5. Unit Maintenance! Note The power must be cut off to stop the operation before maintenance! 5.1 Maintenance The unit maintenance should be carried out by personnel who have received professional refrigeration training. Before the restart of the unit, check and analyze the unit safety control parts. Convenient maintenance has been fully considered in the design so that it can be carried out easily after remove the maintenance panel. Under normal circumstances, it is only required to inspect the plate heat exchange and the shell and tube condenser regularly (monthly or quarterly depending on the actual situation). If the water quality is poor, the plate and the shell-and-coil should be cleaned by professional personnel frequently to ensure efficient operation and enough cooling capacity. 5.2 Care Regular inspection should be carried out in the operation process to ensure the unit performance. This is also the best way to avoid unit stop and other waste. The regular inspection includes the following contents: 30