WAT E R S O U R C E H E AT P U M P S

Transcription

1 WAT E R S O U R C E H E AT P U M P S - 小 Water To Water 3 in 1 Units High Efficiency E Vintage Sizes 024~142 Installation Operation and Maintenance Instructions Important: These instructions are for the use of specially trained personnel, experienced in the installation of this equipment and related systems. Some states require licensing of installation and service personnel. Unqualified individuals should not attempt to interpret these instructions or install this equipment. Read instructions carefully before unpacking, installing and operating unit. Inspection: This heat pump has been factory inspected; however, we recommend you check the carton and inspect the unit for concealed shipping damage. Note any transit damage on all copies of the bill of lading. Purchasers must file transit damage claims promptly with the freight company. Handling: Always move the unit with care and in the horizontal position as shipped on pallet. Moving the heat pump on its side or dropping it may damage internal parts. Storage: Store in a clean, dry and protected area. Location: Install units indoors in an area that provides for maintenance access. Mammoth is committed to a policy of continuous product improvements, and thus reserves the right to change specifications and design without notice. WL Version:

2 Contents 1.Unit specification Unit data Unit installation. 5 4.Maintenance 8 5.Electrical Start and Operation

3 Unit specification 1. 3 in 1 water source/geothermal heat pump Geothermal(water source) heat pump technology is using the low temperature & low position heat energy constituted by solar and geothermal energy which absorbed from shallow surface water source (ground water, river, lake, sea) and soil, taking heat pump principle, realizing the heat transferring from low position to high by using little electricity input. Mammoth 3 in 1 geothermal (water source) heat pump can achieve the multipurpose for cooling, heating, and domestic hot water. Mammoth 3 in 1 geothermal (water source) heat pump can replace heating boiler (or central heating) and AC system, compared with traditional AC, it has the remarkable characters and excellency as below. 1) Various optional sizes; 2) Suitable for water loop and geothermal application; 3) Cooling, heating and hot water three-in-one function, fully accurate intelligent water temperature controlling technology; 4) Powerful domestic hot water function (cycle heating): a. Using heat recovery technology, the unit working in cooling mode and simultaneously free enjoying domestic hot water which can reach 55 ; b. When cooling and heating is not required, unit can heat domestic hot water independently, and the temperature can reach 55 ; c. Much cheaper when heat domestic hot water during night as the electricity can be low price; d. Hot water will be available at any moment if install central cycling hot water system; 5) Use environmental friendly refrigerant R410A, high Energy Efficiency Ratio(EER); 序号符号名称及规格建议安装位置序号符号名称及规格建议安装位置 6) Unit can work together with AHU, fan coil system and floor 1 heating; 防震软管 6 三通 7) Unit has the unique sound attenuation technology, 温度计 floor type 2 installation is suitable for 7 indoor ( 随机附件 and ) some special occasions. 压力表 3 8 水泵 2. Unit Description: 3 in 1 water source heat pump is one kind 4 of water 截止阀 cooled unit which can offer cooling, 9 冷却塔 heating and domestic hot water. The load side is 三通 connected 5 with 水过滤器 terminal unit which 10 work 水量调节阀 with chilled/hot water and the source side is connected with heat discharge or absorption equipments (boiler, cooling tower or geothermal system), and the heat recovery side is connected with user's domestic hot water system. Every unit can effectively work when the source entering water temperature range is Every unit is fully run tested in factory. 3. Unit Structure: Unit cabinet is made of high quality steel, and is coated. It is easy to exam and repair compressor and electric components by the side and top access panel. Use fiberglass insulation to prevent condensation and minimize the noise level. All the pipe fittings are screwed conduit and locate at the same unit side, easy for installation and repairing. The controller box is available to maintenance through an openable and closeable repairing door. (See picture 1 and 2) Picture 1: Unit structure Picture 2: Unit External Connection Picture 3 2

4 Unit Specification 4. System designation: Good quality hermetic rotary & scroll compressor with high efficiency, small vibration and low noise, assuring long time stable operation(see picture 3). The plate of BPHE is made of high intensity stainless steel with good heat transfer efficiency, low liquid resorted, and assures unit oil returning, frequent flowage makes less scale formation and less cleaning. The safety protection consists high/low refrigerant pressure protection switch, provide protection for unit refrigerant system when work under lack of gas or extremely low temperature. Temperature sensor on water loop system to prevent plate exchanger damage when work under low water flow or low water temperature. 5. Electrical box: all electric components are installed in control box. Maintenance can be easily performed by opening the access door. 6. Domestic water system: Quickly and stably provide high quality domestic hot water for your better life. 7. Housing life: 3 in 1 unit can provide not only cooling and heating, but also for floor heating and conveniently hot water for washing machine and dishwasher. Furthermore, it can be connected with solar water heater, to realize energy saving in different seasons.(see picture 4) 8. Nomenclature Model: M S R No.1: MSR represent Mammoth Water Source Heat Pump; No. 2: Unit code; 9. Characteristic Code W H E No.1: W represents water to water unit; No.2 : H represents water loop,l represents ground loop; No.3: Design vintage 10. Unit parameter: Please refer to the latest catalog issued by Mammoth, the real using result might be a little different to the designed data, essentially, rectify it according to real application and Mammoth catalog; the result can be treated as the real performance under this conditions. Mammoth is committed to a policy of continuous product improvements, and thus reserves the right to change specifications and design without notice. Picture 4 3

5 Unit Data 1. Electrical Data Table 1 Model Power Compressor Total Current RLA (A) LRA (A) (A) Min./Max.Voltage (V) Breaker Max. Size(A) MSR V~/50HZ /253 25A MSR V/3N~/50HZ /420 15A MSR V/3N~/50HZ /420 25A MSR V/3N~/50HZ /420 25A MSR V/3N~/50HZ /420 50A MSR V/3N~/50HZ /420 62A MSR V/3N~/50HZ /420 62A MSR V/3N~/50HZ /420 62A 2. Operation Limits Table 2 Water loop Ground loop Load Side Temperature Range Source Entering Water Temp. Range Cooling Heating Hot water Cooling Heating Hot water Entering water 12~ 30 Entering water 15~ 50 Max. Leaving water 55 Entering water 12~ 30 Entering water 15~ 50 Max. Leaving water 55 20~40 15~30 10~32 10~40-4~25 7~32 1, Under cooling mode, if the source entering water temperature is lower than 20, use flow by-pass valve to reduce water flow and to keep the leaving water temperature higher than 25. And load side should not long time work at extra high water temperature, it may cause carbonation of compressor lubricate oil, and finally compressor may not work normally. 2, When the leaving source water temperature is lower than 2,please add antifreeze into the water system to avoid unit frozen and broken. 3, When domestic hot water temperature is required to be 55, the source entering water temperature should not be lower than 7 under the rated water flow in order to keep the unit under reliable operation. 4, The temperature range of above mentioned inlet and outlet water is under rated water flow. 5, If the ambient temperature is too low to operate the unit, and if unit is going to be stopped for long period, pump out all the water inside the unit by water-draining flange or open back access panel and release the water from the valve which locate at the bottom of pump to avoid plate exchanger and water pipes frozen. 6, The evaporating and condensing pressure for unit long-lasting working must be in the normal operation range as below. 4

6 Unit installation 1. Safety warning Please read the "Safety Warning" carefully to ensure correct installation before installing. The described warning items are divided into "Warning" and "Notice", the serious events, such as death or seriously hurt may caused by wrong installation, will be listed on the warning screen. However, it might cause accidents as well if people do not follow the items listed on notice. Therefore, please follow he instructions strictly as it is for safety issue. 2. Unit removing and installation 1) Removing: a) Before removing unit, please ensure there will be suitable installation equipments and tools at the location, and also make sure the location can afford the weight of unit and accessories. b) Remove unit horizontally, do not remove at side plate. Avoid random removing as it may cause unit broken. c) Lift up unit at the positions where indicated on the lifting labels if it is wooden package, and if it s not wooden package, hang up at the shackles by tightwire and one beam support from unit bottom. Check the balance before lifting up, the crane arm should be long enough to avoid touching all other objects, the crane must reach the unit weight requirement. d) It is better to keep horizon when remove unit, and the incline degree should be less than 15, truck or crane would be the suitable option. e) If can not lift up the unit vertically, tumble it horizontally. First lift up unit for certain height by jack, then put rolling wood wheel under the support, and take it out after reach the position. Put shockproof flexible gasket between bottom leg and foundation, adjust horizontally and fasten bottom leg screws. 2) Installation a) Unit should be installed at the undistorted rigid foundation or concrete foundation; the surface should be evenly and can afford the unit operating weight. The installation incline should be less than 5, if more than 5, adjust it and start unit after one hour. b) If unit installed on the ground, it should be placed on the rubber shockproof gaskets. The support should be offered by installation company and left enough space around unit for maintenance. See picture 5 for the minimum installation space. c) Suitable raceways or some other treatment are required around the foundation for pumping system water out during unit seasonal stopped or maintenance. d) Unit is not suitable for high humidity, rot and explosive environment. If unit or cooling tower is installed in low temp and opening environment, Mammoth will not be responsible for anti-freezing protection. The foundation should be away from sunlight or other directly heat radiation. 5 警告 空调器的主电源开关应设在儿童不能触及的位置, 防止儿童玩 弄主电源开关发生危险 在雷雨天气, 请断开主开关, 否则闪电可能使机组受损 机组长时间不用或用户离开空调器房间时间较长时, 请断开主 电源开关, 否则可能会发生意外 切勿使用液体清洗剂 液化清洁剂及腐蚀性清洁剂擦拭机组或 往机组身上洒水或其他液体, 否则会损坏机身塑料件, 严重时 可能会发生电击 在设置及移装空调器时, 制冷循环系统内除了规定的制冷剂 (R22) 以外不要让空气等混入 如有空气等混入则制冷循环 系统会产生异常高压而有引起破裂, 人身伤害等事故 请予接地, 接地线请勿连接到煤气管 自来水管 避雷针或电 话的接线上 接地不当, 有可能引起触电等事故 Warning Please read installation instructions carefully before installing and serving the unit. It may cause seriously hurt or death accident or unit broken and/or performance decline if disobey of it. e) If unit installed in the room, add one rubber shockproof gasket with the length of 10-20mm between support and foundation for anti shocking. f) The required materials and tools: flexible connections, flexible shockproof gasket, lifting equipment, lifting beam, sling, jack, tumbling stow wood, gasket wheel and tommy bar etc. Picture 5 Unit Installation Space!!

7 Unit Installation 3. Water pipe connection(see picture 6) Water pipe can be connected after unit complete installation and adjustment, and pay attention on below items: g) The installation and temperature preservation of water pipe system should be designed and guided by qualified personnel, and obey the relevant installation criterion. h) The inlet and outlet water pipe should be connected according to unit labels. i) Water pipe system shall firstly install flexible shockproof connection, water filter, draining valve, stop valve and flow switch etc. (see picture 6) and then connected with cooling tower or geothermal water loop. j) Water pipe shall be connected with the pump with correct water flow and head to ensure the steady water supply. Pump shall be installed on the inlet water pipe of heat exchanger. If pump absorb water from evaporator directly, it may reduce the unit performance. k) Water filter should be installed at the inlet water pipe, and be closer to inlet/outlet water connection that can avoid the chipping in the pipe between heat exchanger and filter to enter into plate exchanger and to make it broken. l) System Water should be treated according to the quality, because the dust, dirt and grease etc. in water will adhere on the surface of exchanger to reduce the performance, and also they may increase the condensing pressure, reduce the water flow and make mechanical damage to exchanger plate. See page 8, table 3 for requirement of source water quality. a) Except flexible connections installed between pump and unit, pump and water pipes, a separate support shall be installed between water pipes and pump to avoid unit bearing pressure. For the pipes crossing wall or floor, it is necessary to take some measures to keep pipe vibration be away from building. b) Water pipe should be cleaned before connecting with unit. c) In cooling water system, user should ensure the lowest outlet source water temperature is not less than 2 whatever the load or external temperature is changing or not. If less than 2, please add freezestat in proportion into water system to protect unit. Add a water 3-way valve to adjust water flow of condenser.(for installation, see picture 6) d) The inlet and outlet of heat recovery will be in high temperature, so the heat endurance of connection materials must be higher than 100, good heat preservation for the pipes and accessories is going to protect body and avoid other harms. e) Suitable flow switch must be installed at source and load side to protect heat exchanger when no flow in short time operation. f) Motorized check valves are suggested to be installed at inlet and outlet hot water ends (more than 100 ), connected with pump, and fix air release pressure valve on it to protect water tank from high temperature if no use for long time. Note: Do not connect pipes with unit before cleaning Picture 6: Water pipe connection 6

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9 Maintenance 1. Startup Install the unit, connect water pipes and power supply, check all inner wire connection and outer controlling facilities, then start the unit. 2. Water filter Heat pump absolutely can not work without filter(by others). Filter shall be cleaned in every six months, and clean it frequently if in dirty and junky environment. Unit will have low efficient performance if the filter is dirty and congested. 3. Compressor Mammoth heat pump units have diversified protection switches which can protect units refrigerant system. When refrigerant pressure ascend or descend speedy, the protection elements will stop the compressor automatically. 4. Field flexible rubber connection There should be one pair of weaved flexible stainless steel hose installed at inlet and outlet water pipes. Two suitable wrenches are required when tightening, one is putting on fitting of grooved tube, the other one is putting on fitting of hexagonal pipe. Wrench should not clip on the hose or hose cover. Hose can not be tight, torsion or knot. Before pressurize to water system, check hose and pipe fittings carefully to ensure no slit, attrition, torsion, knot and hose can not touch with sharp surface and edge 保养和维护 angle. There should be one ball valve installed on every hose for adjusting and stopping water flow, balancing water system. 5. Water pipe system 1) When flushing water loop, the unit should be disconnected 警告 or separated by valves. 2) Every 190 liters water should be mixed with 0.45KG sodium phosphate. 3) Venting the accumulated air in pipes. Using assist heater to keep water temperature at 43, and keep liquid circulating for about 8 hours. 4) Pump out all water in system. And can be recleaned if required. 5) After flushing water system and pumping water out, charge fresh water into the loop and keep water PH value. be around ) Connect the unit with water loop. 7) Ensure air vented out in water loop and water flow of every unit reach the rated value! Warning Disconnect electric power supply to heat pump before removing cabinet access panel In the serious condition of humidity and torridity, the life span and operational security of all electronic elements would be reduced. Mammoth would not be responsible for all the damage caused due to the incorrect application. 1. Unit is suitable for the environment where the relative humidity is less than 70%, and be sure there is good rain and sunlight proof cover. 2. If the relative humidity is higher than 70%, please advice Mammoth prior to placing an order for comments. 3. Anytime, if the temperature is below 0, antifreeze treatment must be used. Pump out water from system when unit doesn't work or add antifreeze if possible. 6. Source water quality Source water quality must reach following requirements (Table3): Inspection Items Unit Requirements Inspection items PH No. NTU 10 Turbidity degree μs/cm 1600 Electrical conductivity(25 ) mg/l 250 C1-(count with C1-) mg/l 1 Total iron content(count with Fe) mg/l 300 Calcium hardness(count with CaCO3) mg/l 0.1 Dissolved oxygen mg/l 200 Total alkalinity(count with CaCO3) mg/l 1 Phosphate(count with P) mg/l 0.5 There should be water filter installed before source water entering into the heat exchanger. The filter needs to be cleaned frequently to ensure no plant coring, domestic garbage, mud and mortar etc. entering into heat exchanger. It may bring on performance descended, heat exchanger broken and some other damage to unit if these objects entered. If happened, Mammoth would not be responsible for it. 8

10 Electrical Picture 7: Single phase wiring! Warning To avoid seriously electric shock accident, disconnect the power supply before maintain the controller! And maintenance must be performed by qualified technical personnel. 1. Unit power supply Electric power cable should be through a suitable air switch. Fuse's capacity, minimum loop current and defined voltage are mentioned on nameplate or manual instructions. If there is assistant electrical heater, it's power supply must be separated with the unit. The wiring of water source heat pump is divided into two sections: user power supply coming line and controlling line. There are two identifications on terminal block of user s power supply. 1)L,N,E type terminal is used for coming single phase, L terminal connected with live line, N terminal connected with neutral line, and E terminal connected with earth line.(see picture 7) 2)R,S,T,N type terminal is used for 3-phase five wires power supply, R terminal connected with A phase of the 3 phases, S terminal connected with B phase of the 3 phases, T terminal connected with C phase, N terminal connected with neutral wire of the 3 phases, and earth wire connected with mental plate of electronic controlling box.(see picture 8) 3)Electricity wires in this manual is for standard unit, user can see the attached circuit label for detailed connection contents, and be safe-keeping for maintenance. 2. Unit controlling wire Controlling wire was connected with relay on main PCB directly, and it's load capacity was affected by the relay(relay's load capacity normally is less than 2.5A), so controlling wire is made of good quality copper core wire with the cross section of 0.5mm2~1.0mm2. If load with high power, take relay's output as the driving source. 3 in 1 water source heat pump has the output connection of source water pump, and the pump can be linked with unit, and available for water flow inspection connection. User should install water flow switch according to the relevant instruction labels, and connect with water flow inspection input connection in control box. If this connection is not closed, unit will alarm and can t be started. Ö» ú Model Í ¼7 µ Ï àµ çô ½ øï ßÊ ¾Ò âí ¼ Picture 8:Three phase wiring Ö» ú Í ¼8 È ýï ൠçô ½ øï ßÊ ¾Ò âí ¼ Terminal µ Ï àµ çô ½ øï ß Ó Ã» ½ øï ß 220V «/50HZ È ýï ൠçô ½ øï ß Ó Ã» ½ ÓÏ ß 380V/3N «/50HZ Cross section area of user power input wire shall be not less than showed in table 4. Conductor cross section area (mm2) MSR 024 L,N,E 2.5 MSR 036 R,S,T,N 2.5 MSR 052 R,S,T,N 2.5 MSR 072 R,S,T,N 2.5 MSR 086 R,S,T,N 4 MSR 100 R,S,T,N 4 MSR 120 R,S,T,N 4 MSR 142 R,S,T,N 6 Wires inside unit are completed with good insulation before leaving factory; any user s wire connection should not make any inner 9modifications

11 Start and Operation 1. Preparation before start Please read the attached installation manual instructions carefully before installation, adjustment, operation and maintenance. The first time adjustment must be guided by our engineer. Check the wire connection is loosen or not, fasten it if loosen. Check system pressure to see if any leakage. Ensure correct phase & voltage meets unit power supply requirements. Check the temperature sensor installation position & connection and make sure there is no problem. Start source pump and make sure the right rotation direction. Water flow complies with nameplate data Ensure no damage on all components before start unit, ensure voltage and frequency of power supply and water system is normal. Power supply should be executed as below 1) Allowable voltage range:360~415v(gb12325 indicate rating voltage to be ±7% ) 2) Allowable frequency range: be within ±2%(GB/T15945) 3) Unbalance tolerance of 3 phase voltage: be within ±2%(GB12326 indicates 2.5%; GB/T15543 indicates 2%) 4) Unbalance tolerance of 3 phase current: be within ±5% If above preparation is completed and without error, then can press start button to enter start operation; Meanwhile, pay attention to unit operation status, and result should meet above requirements. 2. Error analysis When unit has error, solve the field error according to below analysis, if the error is not included in the table, please consult with Mammoth After-sale services department. Error type Possible reason Trouble shooting 1.Unit can not be Power supply cut off Check main switch and main power supply started No controlling voltage Check controlling transformer Compressor self-protection Wait for recovery or check compressor Compressor electronic Check unit high and low pressure etc. 2.Big compressor noise 3. Compressor can not start after resetting error 4.Compressor overload 5. Compressor inner protection protection Too low voltage Voltage in ±10% of showing on compressor nameplate Power supply phase problem Check connection wire Contactor error Check connection and program time-delay No load requirement Load Program is time delaying Wait for a few minutes. Main power supply not available Supply main power Too high compressor operation Check motor insulation resistance, check current work condition Too much water in refrigerant Remove system water, start unit after system, abnormal motor rectified motor insulation insulation overheat compressor coil Check unit working condition after Too high discharging measurement temperature Contactor failure Inner protection modular connection wire failure Check the connection, and renew or reconnect. 10

12 6. Power protection 7.Suction pressure too low 8. Discharge pressure too high Power protector in electric box failure Check power voltage, phase order, phase protector reset Insufficient Evaporator liquid 在 Check superheat degree normal or not, supply check liquid accumulation Lack of refrigerant, or leakage Check unit filling information, leaking position and rectify Evaporator water side scale When in fully load and standard water flow, formation actual temperature difference is 1 more than standard's, it may be caused by scale formation. Please clean it. Insufficient evaporating side Check water flow, if too small, check water flow Condenser water side scale formation Insufficient condensing water flow relevant water pump, valve and filter etc. When in fully load and standard water flow, actual temperature difference is 1 more than standard's, it may be caused by scale formation. Please clean it. Check water flow, if too small, check relevant water pump, valve and filter etc 9.Discharging temperature too low 10.Discharging temperature too high 11. Refrigerant side high pressure switch protection 12. Refrigerant side low pressure switch protection 13.Other error Too much refrigerant charging or non condensable gas Small suction side superheat Non condensable gas exist Large suction side superheat Compressor lacks of lubricating oil Less refrigerant Non condensable gas exist in system(such as Nitrogen) The water is not released in pipes and heat exchanger when non start in winter Water pipes partial blocked Failure of anti freeze protection and low pressure protection Pump is off when refrigerant charging Overhigh pressure Pressure switch broken Connection wire failure Overlow pressure Pressure switch broken Connection wire fault Analyzed by Mammoth After-sale service personnel Release extra refrigerant. Remove non condensable gas Adjust suction superheat(reduce charging or adjust throttle device) Vacuumize and refill Adjust suction side superheat(adjust throttle facilities or refrigerant charging) Supply the oil Find out the reason(less filling, leakage),fill refrigerant Discharge it Remove out water in system Install 40 grill filter and periodically maintain it Check unit protection setting, anti freeze switch and sensor Pump must be running when filling refrigerant Check water temperature and pressure is over rated value or not Change pressure switch Check connection wire Check water temperature and pressure is less than rated value or not Change pressure switch Check connection wire Solved by Mammoth After-sale service personnel 11

13 Switch on/off frequency: Restart unit 10 minutes later after stopped The start times should less than 6 times in one hour. Unit must work at least 5 minutes every time. Suction pressure is decreased and discharge pressure is raised after start; otherwise stop unit immediately. Suction side superheat : 5~15K Discharge temperature Discharge temperature low limit value is 60,for reference only. Discharge temperature should be 30K higher than condensing temperature Check following data regularly if unit working for a long period Unit working parameters(such as: 3 phase voltage, unit current, suction and discharge temperature, load and source water side temperature, high/low pressure etc.) Check lead connection and fastening Switch off Press Switch off key to stop unit, and keep two side pumps working approximate for 15 minutes (When water pump is connected with main unit, water pump will stop automatically according to the procedure) Good antifreeze and antirust treatment to unit water loop system if stopped for a long period. 12

14 Commissioning Form Company name Tel. Fax Company address Nameplate data Unit name Refrigerant /charging Rated cooling capacity Cooling power input Cooling current Unit model Rated heating capacity Heating power input Heating current Operating data Source entering water temperature, Source leaving water temperature, Water flow m 3 /h; Load entering water temperature, Load leaving water temperature, Water flow m 3 /h; Heat recovery entering water temperature, Heat recovery leaving water temperature,water flow m 3 /h; Discharge pressure kpa, Suction pressure kpa Discharge temperature, Suction temperature Superheat, Supercool Working current A, Voltage V Note Service man: 13 Commissioning date: