McQuay WMC Product manual

Product Manual
KPMWC00905-10EN
Date: May 2010
Supersedes:
--
Oil Free Centrifugal Chiller
with Magnetic Bearings
WMC
XE (High Efficiency) 100S ÷ 300D
Cooling Capacity from 317 to 1048 kW
Refrigerant: R-134a
McQuay is participating in the Eurovent Certification Programme.
Product are as listed in the Eurovent Directory of Certified Products
and on the web site www. eurovent-certification. com
Index
Features and advantages ................................................................................................................................................. 3
Next Generation Centrifugal ........................................................................................................................................... 3
Benefit Summary ............................................................................................................................................................ 3
Code requirements – Safety and observant of laws/directives ....................................................................................... 3
Certifications................................................................................................................................................................... 3
Versions ......................................................................................................................................................................... 4
Noise Configuration ........................................................................................................................................................ 4
General characteristics..................................................................................................................................................... 5
Cabinet and structure ..................................................................................................................................................... 5
Frictionless Centrifugal compressor with magnetic bearings.......................................................................................... 5
Ecological HFC 134a refrigerant..................................................................................................................................... 8
Evaporator ...................................................................................................................................................................... 8
Condenser ...................................................................................................................................................................... 8
Electronic expansion valve ............................................................................................................................................. 8
Refrigerant Circuit........................................................................................................................................................... 8
Electrical control panel ................................................................................................................................................... 8
Controller features and benefits ................................................................................................................................... 10
Connection to BMS....................................................................................................................................................... 11
Standard accessories (supplied on basic unit) ............................................................................................................. 11
Options (on request)..................................................................................................................................................... 11
Nomenclature .................................................................................................................................................................. 13
Specifications WMC XE-ST ............................................................................................................................................ 14
Sound Levels................................................................................................................................................................... 15
Operating limits............................................................................................................................................................... 16
Dimensions WMC XE-ST ................................................................................................................................................ 17
Installation notes............................................................................................................................................................. 19
Warning ........................................................................................................................................................................ 19
Handling ....................................................................................................................................................................... 19
Location........................................................................................................................................................................ 19
Space requirements ..................................................................................................................................................... 20
Technical Specification for Oil Free Centrifugal Water Cooled Chiller ...................................................................... 21
GENERAL .................................................................................................................................................................... 21
REFRIGERANT............................................................................................................................................................ 21
PERFORMANCE.......................................................................................................................................................... 21
UNIT DESCRIPTION.................................................................................................................................................... 21
NOISE LEVEL AND VIBRATIONS ............................................................................................................................... 21
DIMENSIONS............................................................................................................................................................... 21
CHILLER COMPONENTS............................................................................................................................................ 22
KPMWC00905-10EN - page 2/24
Features and advantages
Next Generation Centrifugal
The industry’s next generation of centrifugal chillers is here today with WMC chillers. The new technology begins with
centrifugal compressors utilizing frictionless magnetic bearings for oil-free operation, integral variable-frequency drives,
and high-speed direct drive technology. The high efficiency compressor is matched with highly efficient heat exchangers
to make an impressive chiller. The control system is based on MicroTech II® family to provide the optimum chiller control
system.
Benefit Summary
-
Breakthrough energy efficiency, especially at part load conditions, resulting in great energy savings.
-
Increased reliability This frictionless magnetic bearing design needs no oil management system, resulting in
increased reliability and reduced maintenance. With no oil to coat the heat transfer surfaces, a gain in heat
exchanger efficiency can also be realized.
-
Compact design and light weight The compressor weight of 120 kg is less than 20% of the weight of
competitive compressors and approximately 50% smaller, this allows a compact unit design thus making this
series the perfect choice for retrofit projects
-
Low noise level The WMC chiller is one of the quietest in its size range: this eliminates the need for expensive
sound attenuation accessories and makes the unit ideal for every sound sensitive environments such as schools,
performance halls, museums, etc.
-
Extremely low vibration levels As a result of the high-speed design, the compressor vibration levels are
extremely low, minimizing vibration that could be transmitted to the structure.
-
Smart refrigerant choice The compressor is optimized for HFC 134a, the positive pressure refrigerant with no
phase-out schedule and no ozone depletion.
-
Smart controls Onboard digital electronics provide smart controls. The compressor is totally self-correction and
incorporates a system of sophisticated self-diagnostics, monitoring and controls.
In the event of a power failure, the compressor motor acts as a generator, providing power for the bearing control
system during coast down. It also has a system to gently de-levitate the shaft.
-
Easy integration with BMS The unit controller can be connected to BMS (Building Management System) based
on the most common protocols as LONWORKS®, BACnet®, or Modbus®
-
Extensive option list A wide portfolio of options is available to meet different requirements
Code requirements – Safety and observant of laws/directives
All WMC units are designed and manufactured in accordance with applicable selections of the following:
Construction of pressure vessel
Machinery Directive
Low Voltage
Electromagnetic Compatibility
Electrical & Safety codes
Manufacturing Quality Stds
97/23/EC (PED)
2006/42/EC
2006/95/EC
2004/108/EC
EN 60204–1 / EN 60335-2-40
UNI – EN ISO 9001:2004
Certifications
All units manufactured are CE marked, complying with European directives in force, concerning manufacturing and
safety. On request units can be produced complying with laws in force in non European countries (ASME, GOST, etc.),
and with other applications, such as naval (RINA, etc.).
KPMWC00905-10EN - page 3/24
Versions
WMC is available in high efficiency version:
XE: High Efficiency
6 sizes to cover a range from 317 up to 1048 kW (Cooling Capacity), with EER up to 6.00 and
ESEER up to 9.60.
The EER (Energy Efficiency Ratio) is the ratio of the Cooling Capacity to the Power Input of the
unit. The Power Input includes: the power input for operation of the compressor, the power input
of all control and safety devices.
The ESEER (European Seasonal Energy Efficiency Ratio) is a weighed formula enabling to take
into account the variation of EER with the load rate and the variation of water inlet condenser
temperature.
ESEER = A x EER100% + B x EER75% + C x EER50% + D x EER25%
Coefficient
Condenser water inlet temperature (°C)
Noise Configuration
WMC is available in standard noise level configuration:
ST: Standard Noise
KPMWC00905-10EN - page 4/24
A
0.03 (3%)
30
B
0.33 (33%)
26
C
0.41 (41%)
22
D
0.23 (23%)
18
General characteristics
Cabinet and structure
The cabinet is made of galvanized steel sheet and painted to provide a high resistance to corrosion. Colour Ivory White
(Munsell code 5Y7.5/1) (±RAL7044).
Frictionless Centrifugal compressor with magnetic bearings
The frictionless Centrifugal compressor with magnetic bearings and integrated VFD is an innovative compressor that
allows great unit efficiency and reliability.
The compressor’s one moving part (rotor shaft and impellers) is directly put in rotation by the permanent magnet direct
drive motor and kept levitated by a digitally controlled magnetic bearing system; the speed of rotation reduces as the
condensing temperature and/or cooling load reduces. Movable inlet guide vanes, activated by step motor, redirect gas
flow into the first stage impeller during low loads, after the compressor has reached minimum speed.
2 stage centrifugal
compressor
Inverter speed
control
Pressure and
temperature sensors
Permanent Magnet
Direct Drive Motor
Inlet Guide
Vanes
Motor and
bearing control
(the electronics)
Fig.1
Motor
Variable Speed Permanent Magnet Direct Drive Motor (Fig.2), also known as ‘brushless’, is a synchronous motor,
refrigerant cooled and fully protected with thermistors.
Permanent magnets (Fig.3), placed onto the rotor, generate the magnetic flux that is necessary to provide torque.
VFD (Variable Frequency Drive) is required to adjust, depending on the load, the speed of rotation that normally is
between 18,000 and 48,000rpm.
Fig.2
Fig.3
KPMWC00905-10EN - page 5/24
Magnetic bearing system
Fig.4
Fig.5
Fig.6
1.
The rotor shaft’s position is held by front and rear electro-magnetic cushions;
2.
The shafts position is monitored with 10 sensors that send a signal to a digital controller which then sends a
command to the 5 separate pulse width modulators (PWM), for a proper shaft repositioning;
3.
In case of power failure, within 0.5 micro-seconds, the motor acts as a generator for the magnetic bearings and
the compressor comes gradually to a complete stop; the rotor de-levitates normally unto backup bearings.
Onboard capacitors have enough power to fully support the bearing system during the coast down.
The friction losses and the oil management hardware and controls associated with conventional oil-lubricated bearings
are now totally eliminated.
There is no need for oil pumps, oil reservoirs, controls, starter, piping, heaters, oil coolers, oil filters, water regulating
valves or oil relief valves that are needed to maintain oil quality. These devices can be a source of problems in traditional
chillers, and removing them significantly increases unit reliability and reduces the maintenance.
Modern magnetic bearing technology along with the integrated VFD (variable-speed drive) enables outstanding energy
efficiency, especially at partial loads, where significant gains can be realized.
The improvements in terms of efficiency and annual energy cost is maximised when there are long periods of part load
operation.
Also the inrush current is strongly reduced thanks to the use of VFD, resulting in an advantageous down-sizing of
electrical protection devices.
KPMWC00905-10EN - page 6/24
Electronics
Inbuilt sophisticated electronics (Fig.7 and 8) guarantee self-diagnostics on Motor, bearings, compressor, expansion
valve, performance, events, faults,…and allow the exchange and visibility of data with the chiller controller.
VFD
Shaft position
control
Magnetic
bearing PWM
Fig. 7
Line reactor
Rectifier
DC-link capacitors
Motor
IGBT
Supply
3 Phases
380-480V
50-60HZ
Controller
DC-DC converter
Compressor controller
PWM output
Power - Motor
Power - Generator
Control
Magnetic
bearings
Fig. 8
KPMWC00905-10EN - page 7/24
Ecological HFC 134a refrigerant
The compressors have been designed to operate with R-134a, ecological refrigerant with zero ODP (Ozone Depletion
Potential) and very low GWP (Global Warming Potential) that means low TEWI (Total Equivalent Warming Impact).
Evaporator
Flooded shell-and-tube evaporator operating with refrigerant in shell and water in tubes. Replaceable water tubes are
fabricated from integral finned copper and mechanically bonded to steel tube sheets. The evaporator is PED designed,
constructed, inspected and stamped. Water side working pressure is designed for 10,5 bar. Vessels include 1” NPT
spring loaded pressure relief valves. Shell and non-connection water heads are insulated with 3/4” thick closed cell
insulation. Standard configuration on water connection side is 2 passes. The evaporator water outlet connections are
provided with Victaulic Kit (as standard).
Condenser
Flooded Shell-and-tube type operating with refrigerant in shell and water in tubes. Replaceable water tubes are
fabricated from integral finned copper and mechanically bonded to steel tube sheets. Condenser is designed to conform
PED. Water side working pressure is designed for 10.5 bar. Standard configuration on water connections side is 2
passes. The condenser water outlet connections are provided with Victaulic Kit (as standard).
Electronic expansion valve
The unit is equipped with the most advanced electronic expansion valves to achieve precise control of refrigerant mass
flow. As today’s system requires improved energy efficiency, tighter temperature control, wider range of operating
conditions, the application of electronic expansion valves becomes mandatory. Electronic expansion valves possess
unique features: short opening and closing time, high resolution, positive shut-off function to eliminate use of additional
solenoid valve, continuous modulation of mass flow without stress in the refrigerant circuit and corrosion resistance
stainless steel body.
Electronic Expansion Valves are typically working with lower ΔP between high and low pressure side, than a thermostatic
expansion valve. The electronic expansion valve allows the system to work with within a wide operating range without
any refrigerant flow problems and with perfect chilled water leaving temperature control.
Refrigerant Circuit
Each unit has 1 refrigerant circuit including:
•
1 or 2 Compressors
•
Electronic expansion valve
•
Evaporator
•
1 or 2 ( 1/compressor) safety valve on suction side
•
Manometers on evaporator and condenser
•
Condenser
•
Safety valves on evaporator and condenser
•
Water pressure differential switch on evaporator and condenser
Electrical control panel
Power and control are located in two sections of the main panel that is manufactured to ensure protection against all
weather conditions. The electrical panel is IP54 and (when opening the doors) internally protected with Plexiglas panel
against possible accidental contact with electrical components (IP20). The main panel is fitted with a main switch
interlocked door.
Power Section
The power section includes circuit breaker, compressors inverters, control circuit transformer.
KPMWC00905-10EN - page 8/24
MicroTech II controller
The control system of the chiller consists of two major components: the operator interface panel and the unit control
panel.
The touch screen panel is on an adjustable arm so that it can be
positioned comfortably for the operator.
The operator interface panel has a Super VGA touch-screen, utilizing
graphics to provide clear and concise information on the chiller status,
alarms, trends, and setpoint adjustment. Should the touch-screen
become inoperable, the unit and compressor controllers will continue
uninterrupted operation of the chiller.
Fig.8
The control panel contains a USB port for downloading the unit’s fault history, major parameter trends, and the unit
operating manual that is stored in the microprocessor. These design features built into this control system optimize ease
of operation, reliability, and efficient operation.
The unit’s control panel is featured with the controller, which is responsible for functions involving the single compressors
and the entire unit (controlling the electronic expansion valve, for instance) and is the interface point for devices and
signals external to the unit.
EXV Board
Field Wiring Knockouts EXV Board
Terminal Board TB UTB1 For Field
Wiring Connections Field Wiring
Knockouts EXV Board
On/Off
Switches
UNIT
COMP #1
COMP #2
Controller
OITS PC
Universal
Communica
tion Module
Comp #1 I/O
Comp #2 I/O
Fig. 9
KPMWC00905-10EN - page 9/24
Controller features and benefits
FEATURE
BENEFIT
Easy integration into Building Management System
Designer can select any BAS supplier using standard
open protocols and know the MicroTech II control will
interface with it.
Easy to read, adjustable, Super VGA colour touch
screen operator interface
Operators can observe chiller operation at a glance and
easily select various data screens and change setpoints
Historic trend data-downloadable
Water temperatures, refrigerant pressures, and motor
load plots can provide valuable information for energy
conservation
Precise ± 0.2 °F chilled water control
Provides stability in chilled water system
Proactive pre-shutdown correction of “unusual
conditions” allows chiller to stay li
Activates alarm and modifies chiller operation to provide
maximum possible cooling
Automatic control of chilled water and condenser
water pumps
Integrated lead/lag and automatic engagement of
backup pump
Controls up to four stages of tower fans and
modulation of tower fan and/or bypass valve
Optimum integrated, efficient, control of cooling tower
water based on system conditions
Twenty-five previous alarm descriptions are stored in
memory
Invaluable asset in trouble shooting
Operating and maintenance manuals plus unit parts
lists stored in memory
Information instantly available (downloadable) for the life
of the unit.
Multiple language capability
Great asset for world-wide applications
Reliable, economic use of any chiller depends largely on an easy operator interface. That’s why operation simplicity was
one of the main considerations in the development of the MicroTech II controller. The operator’s interface with the chiller
is through a compact Super VGA color monitor with touch-screen capability. The operator can clearly see the entire
chiller graphically displayed with the key operating parameters viewable on the screen. Pressing a single on-screen
button will access the set screens where setpoints can be reviewed and changed, if necessary. Other screens, such as
alarm history, are easily accessed through touch screen buttons.
By constantly monitoring chiller status, the MicroTech II controller will automatically take proactive measures to relieve
abnormal conditions or shut the unit down if a fault occurs. For example, if a problem occurs in the cooling tower and
discharge pressure starts to rise, the controller will automatically hold the load point and activate an alarm signal. A
further rise in pressure will initiate compressor unloading in an effort to maintain the setpoint pressure and stay online. If
the pressure continues to rise, the unit will shut off at the cutout pressure setting.
The MicroTech II controller's memory retains a record of faults and the time/date stamp. The controller's memory (no
batteries required) can retain and display the cause of the current fault and the last twenty-five fault conditions. This
method for retaining the fault is extremely useful for trouble shooting and maintaining an accurate record of unit
performance and history. The controller features a two-level password security system to provide protection against
unauthorized use.
The Home Screen shown in Figure 8 is usually used as the primary viewing screen. It provides real time data on unit
status, water temperatures, chilled water set point and motor amp draw
Many standard features have been incorporated into MicroTech II control in order to maintain the operating economy of
WMC chillers. In addition to replacing normal relay logic circuits, the controller's energy saving capabilities are enhanced
with the following features:
•
Direct control of water pumps. Optically isolated, digital output relays provide automatic lead-lag of the
evaporator and condenser pumps, permitting pump operation only when required.
•
User-programmable compressor soft loading. Prevents excessive power draw during pull down from high
unoccupied chilled water temperature conditions.
KPMWC00905-10EN - page 10/24
•
Chilled-water reset. Accomplished directly on the unit by resetting the leaving water temperature based on the
return water temperature. A remote 4-20 ma or 1-5 VDC BAS signal can also be used to reset the leaving
water. Raising the chilled water setpoint during periods of light loads dramatically reduces electrical
consumption.
•
Demand limit control. Maximum motor current draw can be set on the panel, or can be adjusted from a remote
4-20 ma or 1-5 VDC BAS signal. This feature controls maximum demand charges during high usage periods.
•
Condenser water temperature control. Capable of four stages of tower fan control plus an optional analog
control of either a three-way tower-bypass valve or variable speed tower-fan motor. Stages are controlled from
condenserwater temperature. The three-way valve can be controlled to a different water temperature or track
the current tower stage. This allows optimum chilled water plant performance based upon specific job
requirements.
•
Plotting Historic Trends. Past operation of the chiller can be plotted as trend lines and even downloaded to
spread sheets for evaluation - a valuable tool for optimizing efficiency.
Connection to BMS
The controller can be connected to BMS (Building Management System) based on the most common protocols as
LONWORKS®, BACnet®, or Modbus®; this is possible through serial cards (not included).
Standard accessories (supplied on basic unit)
Evaporator - 2 passes configuration
Evaporator Victaulic kit – Hydraulic joint with gasket for an easy and quick water connection.
Evaporator water side design pressure 10 bar
20mm evaporator insulation
Condenser – 2 passes configuration
Condenser Victaulic kit – Hydraulic joint with gasket for an easy and quick water connection.
Condenser water side design pressure 10 bar
Electronic expansion valve
High pressure side manometers on evaporator and condneser
Water pressure differential switch on evaporator and condenser - Factory mounted, differential switch is available to
detect evaporator and condenser loss of flow.
Inverter compressor starter – For low inrush current and reduced starting torque.
Double pressure relief valve with diverter
Current limit – To limit maximum absorbed current of the unit whenever is required
Hour run meter
General fault contactor
Set-point reset – The leaving water temperature set-point can be overwritten with the following options: 4-20mA from
external source (by user); outside ambient temperature; evaporator water temperature Δt.
Demand limit – User can limit the load of the unit by 4-20mA signal or by network system
Alarm from external device – Microprocessor is able to receive an alarm signal from an external device (pump etc…).
User can decide if this alarm signal will stop or not the unit.
Options (on request)
Evaporator 1/3 passes – availability of these configurations must be checked on the selection software
Evaporator flange kit - Evaporator flanged connections (150 psig) are available instead of the standard victaulic
connections
Evaporator double flange kit
KPMWC00905-10EN - page 11/24
Evaporator marine water box - Evaporator can be furnished with marine water boxes with victaulic or flanged
connections (on request). To save time and work marine water boxes cover can be easily removed to clean internal
tubes without the disconnection of water pipes.
Evaporator water side design pressure 21 bar
Condenser 1/3 passes - availability of these configurations must be checked on the selection software
Condenser flange kit - Condenser flanged connections (150 psi) are available instead of the standard victaulic
connections
Condenser double flange kit
Condenser marine water box - Evaporator can be furnished with marine water boxes with victaulic or flanged
connections (on request). To save time and work marine water boxes cover can be easily removed to clean internal
tubes without the disconnection of water pipes.
Condenser water side design pressure 21 bar
20mm condenser insulation
Cu-Ni 90-10 condenser tubes - To work with sea water the heat exchangers are fitted with Cu-Ni tubes and special
protection inside the end covers.
Evaporator/Condenser Flow switch – Supplied separately to be wired and installed on the evaporator water piping (by
the customer).
Suction line shut off valve – Installed on the suction port of the compressor to facilitate maintenance operation.
Energy Meter – This device allows to measure the energy absorbed by the chiller during its life. It is installed inside the
control box mounted on a DIN rail and show on a digital display: Line-to-Line Voltage, Phase and Average Current,
Active and Reactive Power, Active Energy, Frequency.
Rubber type antivibration mounts – Supplied separately, these are positioned under the base of the unit during
installation. Ideal to reduce the vibrations when the unit is floor mounted.
Sound proof system - - Made of sheet metal and internally insulated, the cabinet is "integral kind" ( around the whole
chiller, not only around the compressors ) to reach the best performance in noise reduction.
Witness test – Every unit is always tested at the test bench prior to the shipment. On request, a second test can be
carried out, at customer’s presence, in accordance with the procedures indicated on the test form. (Not available for units
with glycol mixtures).
Acoustic test
KPMWC00905-10EN - page 12/24
Nomenclature
WMC
-A
XE
100
S
ST
Machine type
WMC
= Oil Free Centrifugal Chiller
Model series
Letter A,B,…: major modification
Efficiency level
XE
= Standard Efficiency
Unit size
100 ÷ 300
Always 3-digit code
Number of compressors
S=1
D=2
Noise configuration
ST
= Standard Noise
KPMWC00905-10EN - page 13/24
Specifications WMC XE-ST
Version XE - ST
TECHNICAL SPECIFICATIONS
Cooling Capacity (1) (2)
Capacity control
Unit power input (1) (2)
MIN - MAX
Type
at MIN capacity
at MAX capacity
Cooling
Cooling
kW
--kW
kW
--------mm
mm
mm
kg
kg
--l/s
kPa
Cooling
Cooling
--l/s
kPa
EER up to (1)
ESEERup to (1)
Casing
Colour
Material
Dimensions
Unit
Unit
Operating Weight
Type
Nominal water flow rate (3)
Nominal Water pressure drop (3)
Insulation material
Type
Nominal water flow rate (3)
Nominal Water pressure drop (3)
Insulation material
Weight
Evaporator
Condenser
Compressor
Sound level
Refrigerant circuit
Piping connections
Safety devices
Height
Width
Length
Type
Quantity
Sound Power
Sound Pressure (4)
Refrigerant type
Refrigerant charge
N. of circuits
Evaporator water inlet/outlet
Condenser water inlet/outlet
100S
114-317
21.6
65.9
5.40
8.60
27.7
85.7
5.40
8.60
1823
1276
3254
2360
2520
1823
1276
3254
2416
2634
15.1
30
20.5
31
Cooling
Cooling
150S
200D
250D
18.3
24
24.6
25
33.1
21.6
27.7
104
132
171
6.00
5.40
5.50
9.40
8.80
8.60
Ivory White
Galvanized and painted steel sheet
1823
1276
3419
2546
2812
1755
1790
3441
3709
4074
300D
172-1048
33.1
206
5.90
9.60
1748
1853
3289
4095
4548
1794
1904
3401
4765
5330
24.9
30.3
40.9
23
18
21
Closed cell
Flooded Shell&Tube (2 passes)
50.1
11
Flooded Shell&Tube (2 passes)
29.9
36.7
28
24
Closed cell
49.1
25
59.9
29
Oil free Centrifugal compressor with magnetic bearings
--No.
dB(A)
dB(A)
--kg.
No.
mm
mm
125S
128-429
172-521
114-635
128-856
Variable speed centrifugal compressor
1
89.0
70.9
R-134a
210
1
168.3
168.3
1
90.1
72.0
R-134a
190
1
168.3
168.3
1
91.2
73.0
R-134a
180
1
219.1
168.3
2
92.4
73.8
R-134a
220
1
219.1
219.1
2
93.6
75.1
R-134a
300
1
219.1
219.1
2
94.6
75.9
R-134a
300
1
273.0
219.1
Low suction and high discharge pressure
Surge high motor temperature
Low motor current
Starter fault
Sensor fault
Evaporator - Condenser water flow loss
Notes (1)
Oil free Centrifugal chiller provide different Cooling capacity, Power input, EER, etc (at fixed evaporator and condenser water conditions)
depending on the compressor speed of rotation;figures in the table are based on following standard conditions:evaporator 12/7°C; condenser
30/35°C. EER and ESEER reported in the table represent the maximum at these conditions and at a specific speed. A dedicated selection
tool (WMC Selection Software) is available to select the units and calculate the performance at specific working conditions
Notes (2)
For dual compressor units the minimum capacity is related to the condition with only one compressor running
Nominal water flow rate and Pressure drop values are related to maximum cooling capacity at standard conditions; values at specific working
conditions can be calculated by the WMC selection software
Sound pressure related to maximum cooling capacity at standard conditions, according to ISO3744 at 1m and free field semi spherical
conditions
Notes (3)
Notes (4)
ELECTRICAL SPECIFICATIONS
Power Supply
Version XE - ST
Phase
Frequency
Voltage
Voltage Tolerance
Minimum
Maximum
Maximum starting current
Nominal running current
Maximum running current
Maximum current for wires sizing
Phase
Voltage
Unit
Compressor
Voltage Tolerance
Maximum running current
Starting method
Minimum
Maximum
--Hz
V
%
%
A
A
A
A
No.
V
%
%
A
---
100S
125S
150S
200D
250D
300D
3
50
400
-10%
+10%
135
104
135
149
3
400
-10%
+10%
135
3
50
400
-10%
+10%
213
142
210
231
3
400
-10%
+10%
210
3
50
400
-10%
+10%
176
168
176
194
3
400
-10%
+10%
176
3
50
400
-10%
+10%
270
207
270
297
3
400
-10%
+10%
135+135
3
50
400
-10%
+10%
420
285
420
462
3
400
-10%
+10%
210+210
3
50
400
-10%
+10%
352
335
352
385
3
400
-10%
+10%
176+176
VFD
Allowed voltage tolerance ± 10%. Voltage unbalance between phases must be within ± 3%.
Maximum starting current: starting current of biggest compressor + current of the compressor at 75% maximum load
Notes
Nominal current in cooling mode is referred to the following conditions: evaporator 12/7°C; condenser 30/35°C
Maximum running current is based on max compressor absorbed current in its envelope
Maximum unit current for wires sizing is based on minimum allowed voltage
Maximum current for wires sizing: compressors full load ampere x 1,1.
KPMWC00905-10EN - page 14/24
Sound Levels
WMC XE-ST
Unit size
Sound pressure level at 1 m from the unit in semispheric free field (rif. 2 x 10-5 Pa)
Power
63 Hz
125 Hz
250 Hz
500 Hz
1000 Hz
2000 Hz
4000 Hz
8000 Hz
dB(A)
dB(A)
100S
38.7
50.1
55.6
58.8
64.5
62.7
63.6
66.6
70.9
89.0
125S
39.2
50.6
57.0
59.8
66.0
63.5
64.7
67.9
150S
39.7
51.7
57.7
61.1
66.8
64.6
66.1
68.5
200D
41.7
53.0
58.6
61.8
67.4
65.8
66.4
69.6
250D
42.2
53.6
60.0
62.9
69.1
66.4
67.9
71.0
300D
42.7
54.9
60.7
63.9
69.8
67.5
69.1
71.3
72.0
73.0
73.8
75.1
75.9
90.1
91.2
92.4
93.6
94.6
Figures in the table are related to standard working conditions (evaporator water 12/7°C and condenser water 30/35°C) and maximum
cooling capacity
Sound pressure level correction for different distances
Unit size
Distance
1m
5m
10m
15m
20m
25m
50m
100S
0.0
-8.7
-13.7
-16.9
-19.2
-21.1
-26.9
125S
0.0
-8.7
-13.8
-17.0
-19.3
-21.1
-26.9
150S
0.0
-8.7
-13.7
-16.9
-19.2
-21.0
-26.8
200D
0.0
-8.4
-13.4
-16.6
-18.9
-20.7
-26.5
250D
0.0
-8.5
-13.5
-16.6
-18.9
-20.7
-26.5
300D
0.0
-8.4
-13.4
-16.5
-18.8
-20.6
-26.4
Reduction to be applied to standard sound levels
KPMWC00905-10EN - page 15/24
Operating limits
WMC XE-ST
50
45
Condenser Leaving Water Temp. (°C)
40
35
30
25
20
15
Operation with Glycol
(below 4°C Evap LWT)
10
5
0
0
2
4
6
8
10
12
14
Evaporator Leaving Water Temp. (°C)
Above diagram is indicative: for the operating limits of the specific models please refer to the WMC selection
software.
Notes:
The operation with Glycol influences the unit performance: the WMC selection software is able to adjust the calculations keeping this
into account
KPMWC00905-10EN - page 16/24
16
Dimensions WMC XE-ST
Legend
1 - Electrical Panel
2 - Power Connection Slot
3 - Compressor
4 - Evaporator Water Inlet
5 - Evaporator Water Outlet
6 - Condenser Water Inlet
7 - Condenser Water Outlet
WMC
100S
125S
150S
A
B
C
D
1276
1276
1276
3254
3254
3419
1822
1822
1822
1518
1518
1518
E
(1)
334
334
334
F
(2)
334
334
487
Dimensions
G
H
496
496
496
286
286
286
I
L
M
N
O
515
515
515
319
319
319
495
495
496
286
286
284
176
176
177
(1)
Condenser hydraulic connections
Evaporator hydraulic connections
Note: the above drawing refers to size 150S
(2)
KPMWC00905-10EN - page 17/24
Legend
1 - Electrical Panel
2 - Power Connection Slot
3 - Compressor
4 - Evaporator Water Inlet
5 - Evaporator Water Outlet
6 - Condenser Water Inlet
7 - Condenser Water Outlet
WMC
200D
250D
300D
A
B
C
1790
1853
1904
3441
3289
3401
1755
1748
1794
(1)
Condenser hydraulic connections
Evaporator hydraulic connections
Note: the above drawing refers to size 300D
(2)
KPMWC00905-10EN - page 18/24
D
(1)
487
334
334
E
(2)
334
334
411
Dimensions
F
G
546
546
598
284
360
360
H
I
L
M
N
542
496
474
319
383
383
522
585
609
360
360
413
203
203
227
Installation notes
Warning
Installation and maintenance of the unit must to be performed only by qualified personnel who have knowledge with local
codes and regulations, and experience with this type of equipment. Must be avoided the unit installation in places that
could be considered dangerous for all the maintenance operations.
Handling
Care should be taken to avoid bumping and/or jolting during unloading from the lorry and moving the unit. Do not push or
pull the machine from any part other than the base frame. Secure the machine inside the lorry to prevent it from moving
and causing damage to the panels and to the base frame. Do not allow any part of the unit to fall during transportation or
unloading, as this could cause serious damage.
All units of the series are supplied with lifting points marked in yellow. Only these points may be used for lifting the unit,
as shown in the following figure (the picture is indicative, so lifting tools are not supplied)
Location
All units are designed for indoor installations. The machine must be installed on a robust and perfectly level foundation;
should the machine be installed on balconies or roofs, it might be necessary to use weight distribution beams.
For installation on the ground, a strong cement base that is at least 250 mm wider and longer than the machine must be
prepared. Also, this base must be strong enough to support the weight of the machine as stated in the technical
specifications.
If the machine is installed in places that are easily accessible to people and animals, it is advisable to install protection
gratings for the compressor section.
To ensure the best possible performance on the installation site, the following precautions and instructions must be
followed:
• Make sure to provide a strong and solid foundation to reduce noise and vibration as much as possible.
KPMWC00905-10EN - page 19/24
• The water in the system must be particularly clean and all traces of oil or rust must be removed. A mechanical water
filter must be installed on the machine’s inlet piping.
Space requirements
Every side of the machine must be accessible for all post-installation maintenance activities.
In particular, service clearance has to be provided at one end of the unit for possible removal of evaporator and/or
condenser tubes. Evaporator and condenser tubes are rolled into the tube sheets to permit replacement if necessary; the
length of the vessel must be allowed at one end (doors or removable wall sections can be utilized). Keep a free space to
allow the opening of electrical panel doors. Minimum clearance at all sides, including the top, is (1 meter); local
regulation may require larger clearance.
The above recommended information are representative of general installation. A specific evaluation should be done by
contractor depending on the case.
KPMWC00905-10EN - page 20/24
Technical Specification for Oil Free Centrifugal Water Cooled
Chiller
GENERAL
The Oil free Centrifugal water cooled chiller will be designed and manufactured in accordance with following European
directives:
Construction of pressure vessel
Machinery Directive
Low Voltage
Electromagnetic Compatibility
Electrical & Safety codes
Manufacturing Quality Stds
97/23/EC (PED)
2006/42/EC
2006/95/EC
2004/108/EC
EN 60204–1 / EN 60335-2-40
UNI – EN ISO 9001:2004
The unit will be tested at full load in the factory at the nominal working conditions and water temperatures. Before
shipment a full test will be held to avoid any losses.
Chiller will be delivered to the job site completely assembled and charged with right refrigerant.
Comply with the manufacturer instructions for rigging and handling equipment.
The unit will be able to start up and operate as standard at full load and condenser entering fluid temperature from .… °C
to .… °C with an evaporator leaving fluid temperature between …. °C and ….. °C
REFRIGERANT
Only HFC 134a will be accepted.
PERFORMANCE
3
Number of Oil free Centrifugal water cooled chiller: ...............
3
Cooling capacity for single Oil free Centrifugal water cooled chiller: ............... kW
3
Power input for single Oil free Centrifugal water cooled chiller in cooling mode: ............... kW
3
Flooded Shell & tube evaporator entering water temperature in cooling mode: ............... °C
3
Flooded Shell & tube evaporator leaving water temperature in cooling mode: ............... °C
3
Flooded Shell & tube evaporator water flow: ............... l/s
3
Flooded Shell & tube condenser entering water temperature in cooling mode: ............... °C
3
Flooded Shell & tube condenser leaving water temperature in cooling mode: ............... °C
3
Flooded Shell & tube evaporator water flow: ............... l/s
3
Operating voltage range should be 400V ±10%, 3ph, 50Hz, voltage unbalance maximum 3%, without neutral
conductor and shall only have one power connection point.
UNIT DESCRIPTION
Chiller shall include as standard not less than: one refrigerant circuit, Oil free Centrifugal water cooled compressors (with
integrated VFD), electronic expansion device (EEXV), flooded shell & tube heat exchangers, R134a refrigerant, control
system and all components necessary for safe and stable unit operation.
Chiller will be factory assembled, protected by an epoxy paint.
NOISE LEVEL AND VIBRATIONS
Sound pressure level at 1 meter distance in free field, semispheric conditions, shall not exceed ………dB(A). The sound
pressure levels must be rated in accordance to ISO 3744.
DIMENSIONS
Unit dimensions shall not exceed following indications:
3
unit length ............... mm
3
unit width ............... mm
3
unit height ............... mm
KPMWC00905-10EN - page 21/24
CHILLER COMPONENTS
Compressors
1.
The unit shall utilize magnetic bearing, oil-free, semi-hermetic centrifugal compressors. The compressor drive
train shall be capable of coming to a controlled, safe stop in the event of a power failure.
2.
The motor shall be of the semi-hermetic type, of sufficient size to efficiently fulfill compressor horsepower
requirements. It shall be liquid refrigerant cooled with internal thermal sensing devices in the stator windings. The
motor shall be compatible with variable frequency drive operation.
3.
The chiller shall be equipped with an integrated Variable Frequency Drive (VFD) to automatically regulate
compressor speed in response to cooling load and the compressor pressure lift requirement. Movable inlet guide
vanes and variable compressor speed, shall provide unloading. The chiller controls shall coordinate compressor
speed and guide vane position to optimize chiller efficiency.
4.
Each compressor circuit shall be equipped with a line reactor to help protect against incoming power surges and
help reduce harmonic distortion.
Evaporator
Water side working pressure is designed for 10,5 bar. Vessels include 1” NPT spring loaded pressure relief valves. Shell
and non-connection water heads are insulated with 3/4” thick closed cell insulation. Standard configuration on water
connection side is 2 passes.
9
The units will be equipped with a flooded shell-and-tube evaporator operating with refrigerant in shell and water
in tubes. Replaceable water tubes are fabricated from integral finned copper and mechanically bonded to steel
tube sheets.
9
The evaporator will have 1 circuit and standard configuration on water connection side is 2 passes.
9
The water connections shall be VICTAULIC type connections as standard to ensure quick mechanical
disconnection between the unit and the hydronic network.
9
Evaporator is manufactured in accordance to PED approval.
Condenser
9
Condenser will be flooded shell-and-tube operating with refrigerant in shell and water in tubes. Replaceable
water tubes are fabricated from integral finned copper and mechanically bonded to steel tube sheets.
9
The units will have one condenser on the refrigerant circuit
9
Standard configuration on water connection side is 2 passes.
9
The water connections shall be VICTAULIC type connections as standard
9
Condenser is manufactured in accordance to PED approval.
Refrigerant circuit
9
9
The unit must have one refrigerant circuit.
Each circuit shall include as standard: electronic expansion device piloted by unit’s microprocessor control,
sight glass with moisture indicator and insulated suction line.
Control panel
1.
The unit shall have a microprocessor-based control system consisting of a 15-inch VGA touch-screen operator
interface and a unit controller.
2.
The touch-screen shall display the unit operating parameters, accept setpoint changes (multi-level password
protected) and be capable of resetting faults and alarms. The following parameters shall be displayed on the
home screen and also as trend curves on the trend screen:
• Entering and leaving chilled water temperatures
• Entering and leaving condenser water temperatures
• Evaporator saturated refrigerant pressure
• Condenser saturated refrigerant pressure
• Percent of 100% speed (per compressor)
• % of rated load amps for entire unit
3.
In addition to the trended items above, all other important real-time operating parameters shall also be shown on
the touch-screen. These items shall be displayed on a chiller graphic showing each component. At a minimum,
the following critical areas must be monitored:
• Compressor actual speed, maximum speed, percent speed
• Evaporator water in and out temperatures, refrigerant pressure and temperature
• Condenser water in and out temperatures, refrigerant pressure and temperature
KPMWC00905-10EN - page 22/24
• Liquid line temperature
• Chilled water setpoint
• Compressor and unit state and input and output digital and analog values
4.
A fault history shall be displayed using an easy to decipher, color coded set of messages that are date and time
stamped. The alarm history shall be downloadable from the unit's USB port. An operating and maintenance
manual specific for the unit shall be viewable on the screen.
5.
All setpoints shall be viewable and changeable (multi-level password protected) on the touch screen and include
setpoint description and range of set values.
6.
Automatic corrective action to reduce unnecessary cycling shall be accomplished through preemptive control of
low evaporator or high discharge pressure conditions to keep the unit operating through abnormal transient
conditions.
7.
Optionally, the factory mounted controller(s) shall support operation on a BACnet®, Modbus® or LONWORKS®
network via one of the data link / physical layers listed below as specified by the successful Building Automation
System (BAS) supplier.
• Modbus
• BACnet MS/TP master (Clause 9)
• BACnet IP
• BACnet ISO 8802-3, (Ethernet)
• LonTalk® FTT-10A. The unit controller shall be LONMARK ® certified.
8.
The information communicated between the BAS and the factory mounted unit controllers shall include the
reading and writing of data to allow unit monitoring, control and alarm notification as specified in the unit
sequence of operation and the unit points list.
9.
For chillers communicating over a LONMARK network, the corresponding LONMARK eXternal Interface File (XIF)
shall be provided with the chiller submittal data.
10.
All communication from the chiller unit controller as specified in the points list shall be via standard BACnet
objects. Proprietary BACnet objects shall not be allowed. BACnet communications shall conform to the BACnet
protocol. A BACnet Protocol Implementation Conformance Statement (PICS) shall be provided along with the unit
submittal.
9
Field power connection, control interlock terminals, and unit control system should be centrally located in an
electric panel (IP 54). Power and starting controls should be separate from safety and operating controls in
different compartments of the same panel.
9
Operating and safety controls should include energy saving control; emergency stop switch; high and low
pressure cut-out switch (for each refrigerant circuit); anti-freeze thermostat; cut-out switch for each compressor.
9
All of the information regarding the unit will be reported on a display and with the internal built-in calendar and
clock that will switch the unit ON/OFF during day time all year long.
9
The following features and functions shall be included:
- leaving water temperature reset by controlling the water temperature Δt, by a remote 4-20mA DC signal
or by controlling the external ambient temperature;
- soft load function to prevent the system from operating at full load during the chilled fluid pulldown period;
- password protection of critical parameters of control;
- start-to-start and stop-to-start timers to provide minimum compressor off-time with maximum motor
protection;
- communication capability with a PC or remote monitoring;
- discharge pressure control through intelligent cycling of condenser fans;
- lead-lag selection by manual or automatically by circuit run hours;
- double set point for unit version;
- scheduling via internal time clock to allow programming of a yearly start-stop schedule accommodating
weekends and holidays.
Optional High Level Communications Interface
Chiller must be able to communicate to BMS (Building Management System) based on the most common protocols as:
•
ModbusRTU
•
LonWorks, now also based on the international 8040 Standard Chiller Profile and LonMark Technology
•
BacNet BTP certifief over IP and MS/TP (class 4) (Native)
•
Ethernet TCP/IP.
KPMWC00905-10EN - page 23/24