Systemair WQL 20-190, WQH 20-190, WQRC 20-190 User Manual

Chiller

WQL/WQH/WQRC 20-190

Water Cooled Water Chillers Cooling Only,
Heat Pump and Condenserless Versions
Engineering Data Manual

21 to 193 kW

24 to 212 kW

Key point

14 sizes from 20 kW up to 190 kW

R410A refrigerant circuit with single or tandem Scroll compressors

2 different frames/configurations : 1 compressor/1 circuit up to 45 kW and

2 compressors/1 circuit from 50 kW to 190 kW

Reduced refrigerant charge (less than 10 kg per circuit for units up to size

90 kW)

New electronic controller with auto-adaptive function to reduce water

content in the piping system

WQL-WQH-WQRC 20-190

|

3

Condensing pressure control available as option for well application

Wide range of hydrokit for "Plug and Play" units

DHW (Domestic Hot Water) function available on the controller with 3-way

valve available as accessory

Victaulic joints for all internal water piping connections

Desuperheater heat exchanger available as option (50-190 sizes)

Sizes from 20 kW to 45 kW

with factory mounted hydrokit

Sizes from 50 kW to 190 kW

with factory mounted hydrokit

Sizes from 50 kW to 190 kW

without hydrokit

|

4

WQL-WQH-WQRC 20-190

Specifications

General

WQL/WQH/WQRC are new water to water units equipped with Scroll

compressors, optimized to work with R410A refrigerant.

3 different versions are available :

Cooling only units WQL

Heat pump units WQH

Remote condenser units WQRC

2 different acoustic options are available :

Standard (STD) : units are supplied with compressors box to reduce

noise emissions

Super Low Noise (S) : units are supplied with compressors box and

additional insulation panels on the cabinet in order to furtherly reduce
noise impact

WQL/WQH/WQRC units are available in totally 14 sizes (20, 25, 30, 35, 40,

45, 50, 60, 75, 90, 120, 150, 170, 190), ranging from 20 to 190 kW in
cooling operation and from 25 to 210 kW in heating operation.

WQL/WQH/WQRC units are available on two different structural frames

(F1 for 20-45 sizes, F2 for 50-190 sizes). Each unit is equipped with single
refrigerant circuit, single hermetic scroll compressor for F1 sizes, and two
hermetic scroll compressors (tandem) for F2 sizes.

Evaporators and condensers are brazed plate heat exchanger type.

Heat pump units (WQH) are equipped with reversible valve, thus allowing to
reverse cycle on refrigerant side and not on water side.

Remote condenser units (WQRC) are not equipped with condenser heat
exchangers, but equipped with stop valves on discharge and liquid lines in
order to allow connection to remote condensers.

Cabinet and structure

Cabinet and structure are made of galvanized steel. All galvanized steel
components are individually painted by a special painting process before
assemblying of the unit. This painting system performs a homogeneous
protection to the corrosion. The painting is a polyester powder based type,
coloured in RAL 9001. The units are suitable for indoor installation.

Refrigerant circuit

Refrigerant circuit is equipped with one or two hermetic scroll compressors
(depending on the frame), sight glass, filter-drier and mechanical expansion
valve (electronic expansion valve is available as an option).

Heat pump units (WQH) refrigerant circuit is also provided with 4-way
reversing valve and check valves system in order to always run liquid line in
the same direction (both in cooling and in heating mode).

Remote condenser units (WQRC) refrigerant circuit is supplied without
condenser and it is provided with liquid receiver, stop valves both on
discharge and liquid lines, solenoid valve on liquid line.

The functional diagram of each circuit is shown in section "Refrigerant flow
diagram".

Compressors

Compressors are hermetic scroll type fitted with an electronic control device
ensuring protection of compressors against :

Overheating

Overloading

Reversal rotation

Phase loss

All compressors have direct-on-line starting and are mounted on rubber
vibration isolators in order to minimize noise and vibration transmission.

Evaporators and condensers

Evaporator and condenser heat exchangers are brazed stainless steel plate
type. They are insulated with a 10 mm thick closed cell polyethylene foam
material and provide with Victaulic connections.

Electrical board

Electric equipment is built in compliance with CE standards. Easy accessible
in front of the unit - through an access panel fixed with screws - the equipment
is complete with :

Door lock main isolating switch

Compressor contactors and fuses

Compressor overload protection (optional only on F2 units)

Automatic circuit breaker switches (Standard on F1 units, optional on F2

units)

Phase sequence control

Clamps for remote start/stop switch

Clamps for remote summer/winter switch

Clamps for external flow switches (both exchangers)

Clamps for remote double set-point

Clamps for external interlock

Clamps for remote general alarm

Connection clamps to remote keyboard (optional)

Clamps for evaporator/condenser pump relay control (optional)

Clamps for boiler relay control (optional)

Clamps for dynamic set-point compensation (4-20 mA, 0-1 V, 0-5 V,

0-10 V)

Clamps for DHW 3-way valve (accessory)

Clamps for outdoor air temperature probe (accessory)

Electronic control SBW655

Soft-starter (optional)

Power factor correction capacitors (optional)

0-10 V clamps for condensing control (optional)

Control

A new optimized control is supplied on all the units with a simple user
interface (possibility to customize keys functions and to set menus visibility).

In addition to standard features as water temperature control (with possibility
to choose LWT/EWT probe), the control can also manage following functions :

DHW control with anti-legionella function daily and weekly activated

Dynamic set point (4-20 mA, 0-1V, 0-5V, 0-10V)

Double set point

OAT compensation

Boiler/Electrical heater integration

Condensing control

Auto adaptative function to reduce the water content of the plant

Managing of DHW 3-way valve (accessory)

Advanced pump management (both primary circuit and source side)

Remote keyboard (accessory) with possibility to connect (up to 100 m

distance) without any serial interface

WQL-WQH-WQRC 20-190

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5

Safety

Each unit is equipped with following electrical / refrigerant / hydraulic safety
devices :

Door lock main isolating switch

Phase monitor control

High pressure switch with manual reset

Discharge safety valve

Low pressure switch with automatic / manual reset

Anti-freeze probe (leaving water temperature)

Differential pressure switch (source / plant side)

Standards

WQL/WQH/WQRC are built in compliance with following standards :

Machinery Directive : 2006/42/EC

Low Voltage Directive : 2006/95/EC

Electromagnetic Compatibility Directive : 2014/30/EU

Pressure Equipment Directive : 2014/68/EU

And following harmonized European standards :

Safety of machinery - Basic concepts, general principles for design: UNI

EN ISO 12100-1 / 2

Safety of machinery - Safety Distances To Prevent Hazard Zones Being

Reached By Upper And Lower Limbs : EN ISO 13857

Safety of machinery - Electrical equipment of machines : EN 60204-1

Low-voltage switchgear and controlgear assemblies : EN 60439-1

Electromagnetic compatibility (EMC) - Immunity for industrial

environments : IEC EN 61000-6-2

Electromagnetic compatibility (EMC) - Emission standard for residential,

commercial and light-industrial environments : IEC EN 61000-6-3

Factory installed options

ModBus protocol kit for BMS

Compressor soft starter

Power factor correction capacitors

Electronic expansion valve

Compressor overload protection (only for F2 units)

Automatic circuit breaker (only for F2 units)

Condensing control kit

Electric heater wiring kit

Additional heating device wiring kit

Mechanical gauges kit

Compressor jacket

On board hydrokit (1P/both exchangers/SP for F1 units, 1P/2P/both

exchangers/SP-HP for F2 units)

Desuperheater (only for F2 units)

Field installed accessories

Remote ON-OFF

Remote keyboard panel

Sequencer up to 4 units

Condensing control kit

Water temperature sensor for DHW tank

Outdoor air sensor for weather compensation

Electric heater wiring kit

Additional heating device wiring kit

Pressostatic water valve for well application (only for F1 units)

Compressor jacket

Refrigerating systems and heat pumps. Safety and environmental

requirements : EN 378-1 / 2

Metallic products - Types of inspection documents : EN 10204

Copper and copper alloys. Seamless, round copper tubes for air

conditioning and refrigeration : BS EN 12735-1 / 2

Pressure equipment for refrigerating systems and heat pumps. General

requirements : BS EN 14276-1 / 2

Refrigerating systems and heat pumps - Pressure relief devices and their

associated piping - Methods for calculation : BS EN 13136

Metallic industrial piping : BS EN 13480-3

Flow switch

Pressure switch

Victaulic to threaded pipe connection

3-way valve for DHW production

Spring type anti-vibration mounts (only for F2 units)

Water filter

Valves IN/OUT (only for F1 units)

|

1

VALVE (OPTIONAL)

6

WQL-WQH-WQRC 20-190

Refrigerant Flow Diagram - WQL 20 to 45

AT

A

2 6

C

F

E

S

S

43

SM

MECHANICAL EXPANSION

VALVE (STANDARD)

B

5

D

G

H

S

UNIT

CONTROL

SUCTION LINE

ST BT

EXV

CONTROL

COMPONENTS

1 Compressor

2 Condenser

3 Drier filter

4 Sight glass

5 Mechanical expansion valve

6 Evaporator

7 Electronic expansion valve

3 4 7

ELECTRONIC EXPANSION

SAFETY / CONTROL DEVICES

A High pressure switch (42 bar)

B Low pressure switch (2 bar)

AT High pressure transducer (optional)

BT Low pressure transducer

C Water differential pressure switch

D Water differential pressure switch

E Outlet water temperature sensor

F Inlet water temperature sensor

G Inlet water temperature sensor

H Outlet water temperature sensor

S 5/16" Shrader connection (service only)

ST Suction temperature probe

Pipe connection with Shrader valve

Refrigerant Flow Diagram - WQL 50 to 190

VALVE (OPTIONAL)

WQL-WQH-WQRC 20-190

|

7

8

I

AT

2 6

C

F

E

S

1

S S

A

OIL EQUAL.

43

MECHANICAL EXPANSION

VALVE (STANDARD)

B

D

G

H

5

S

UNIT

CONTROL

SUCTION LINE

ST BT

EXV

CONTROL

COMPONENTS

1 Compressors

2 Condenser

3 Drier filter

4 Sight glass

5 Mechanical expansion valve

6 Evaporator

7 Electronic expansion valve

8 Desuperheater

3 4 7

ELECTRONIC EXPANSION

SAFETY / CONTROL DEVICES

A High pressure switch (40.5 bar)

B Low pressure switch (2 bar)

AT High pressure transducer (optional)

BT Low pressure transducer

C Water differential pressure switch

D Water differential pressure switch

E Outlet water temperature sensor

F Inlet water temperature sensor

G Inlet water temperature sensor

H Outlet water temperature sensor

I PED pressure valve (45 bar)

S 5/16" Shrader connection (service only)

Pipe connection with Shrader valve

|

2

VALVE (OPTIONAL)

8

WQL-WQH-WQRC 20-190

Refrigerant Flow Diagram - WQH 20 to 45

AT

3

C

F

E

S

ON

4

S

A

5

MECHANICAL EXPANSION

1

6

VALVE (STANDARD)

S

B

7

D

G

H

88

8

S

8

ST

BT

EEV

CONTROL

UNIT

CONTROL

COMPONENTS

1 Compressor

2 4-way valve

3 Condenser

4 Drier filter

5 Sight glass

6 Mechanical expansion valve

7 Evaporator

8 Check valve

9 Electronic expansion valve

4

ELECTRONICAL EXPANSION

SAFETY / CONTROL DEVICES

A High pressure switch (42 bar)

B Low pressure switch (2 bar)

AT High pressure transducer (optional)

BT Low pressure transducer

C Water differential pressure switch

D Water differential pressure switch

E Outlet water temperature sensor

F Inlet water temperature sensor

G Inlet water temperature sensor

H Outlet water temperature sensor

S 5/16" Shrader connection (service only)

Pipe connection with Shrader valve

5

9

Refrigerant Flow Diagram - WQH 50 to 190

VALVE (OPTIONAL)

2

10

I

AT

1

S

A

OIL EQUAL.

|

WQL-WQH-WQRC 20-190

S

B

9

3

C

F

E

S

ON

7

D

G

H

88

8

4

5

MECHANICAL EXPANSION

6

VALVE (STANDARD)

S

8

ST

BT

EEV

CONTROL

4

5

ELECTRONICAL EXPANSION

9

UNIT

CONTROL

COMPONENTS

1 Compressors

2 4-way valve

3 Condenser

4 Drier filter

5 Sight glass

6 Mechanical expansion valve

7 Evaporator

8 Check valve

9 Electronic expansion valve

10 Desuperheater

SAFETY / CONTROL DEVICES

A High pressure switch (40.5 bar)

B Low pressure switch (2 bar)

AT High pressure transducer (optional)

BT Low pressure transducer

C Water differential pressure switch

D Water differential pressure switch

E Outlet water temperature sensor

F Inlet water temperature sensor

G Inlet water temperature sensor

H Outlet water temperature sensor

I PED pressure relief valve (45 bar)

S 5/16" Shrader connection (service only)

Pipe connection with Shrader valve

|

ELECTRONIC EXPANSION

VALVE (OPTIONAL)

10

WQL-WQH-WQRC 20-190

Refrigerant Flow Diagram - WQRC 20 to 45

2

3

AT

4

5

S

A

6

1

7

MECHANICAL EXPANSION

VALVE (STANDARD)

BS

9

8

S

D

UNIT

CONTROL

G

H

SUCTION LINE

ST

BT

EXV

CONTROL

COMPONENTS

1 Compressor

2 Globe valve

3 Globe valve

4 Liquid receiver

5 Solenoid valve

6 Drier filter

7 Sight glass

8 Mechanical expansion valve

9 Evaporator

10 Electronic expansion valve

SAFETY / CONTROL DEVICES

A High pressure switch (42 bar)

B Low pressure switch (2 bar)

AT High pressure transducer (optional)

BT Low pressure transducer

D Water differential pressure switch

G Inlet water temperature sensor

H Outlet water temperature sensor

S 5/16" Shrader connection (service only)

ST Suction temperature probe

Pipe connection with Shrader valve

6

7

10

Refrigerant Flow Diagram - WQRC 50 to 190

VALVE (OPTIONAL)

WQL-WQH-WQRC 20-190

|

11

S

1

OIL EQUAL.

6

B

7

MECHANICAL EXPANSION

8

VALVE (STANDARD)

S

9

S

D

UNIT

CONTROL

G

H

SUCTION LINE

ST

BT

EXV

CONTROL

I

2

3

AT

4

A

5

COMPONENTS

1 Compressors

2 Globe valve

3 Globe valve

4 Liquid receiver

5 Solenoid valve

6 Drier filter

7 Sight glass

8 Mechanical expansion valve

9 Evaporator

10 Electronic expansion valve

SAFETY / CONTROL DEVICES

A High pressure switch (40.5 bar)

B Low pressure switch (2 bar)

AT High pressure transducer (optional)

BT Low pressure transducer

D Water differential pressure switch

G Inlet water temperature sensor

H Outlet water temperature sensor

I PED pressure valve (45 bar)

S 5/16" Shrader connection (service only)

ST Suction temperature probe

Pipe connection with Shrader valve

6

7

ELECTRONIC EXPANSION

10

|

OUTLET

OUTLET

12

WQL-WQH-WQRC 20-190

Hydraulic Circuit Diagram - WQL/WQH 20 to 45

Hydraulic system basic

D

A

B

C

1

2

8

8

6

7

6

5

E

4

INLET

5

E

3

COMPONENTS

1 Plate heat exchanger
2 Water filter
3 Water outlet
4 Water inlet
5 Globe valve
6 Flexible pipes
7 By-pass valve
8 Pressure point/drainage

SAFETY / CONTROL DEVICES

A Water differential pressure switch
B Inlet water temperature sensor
C Outlet water temperature sensor
D Vent valve
E Thermometer

Hydraulic system 1P condenser

A

B

C

1

Unit side
Probes

D

2

3

9

9

7

8

7

6

E

5

INLET

6

E

4

COMPONENTS

1 Plate heat exchanger
2 Pump
3 Water filter
4 Water outlet
5 Water inlet
6 Globe valve
7 Flexible pipes
8 By-pass valve
9 Pressure point/drainage

SAFETY / CONTROL DEVICES

A Water differential pressure switch
B Inlet water temperature sensor
C Outlet water temperature sensor
D Vent valve
E Thermometer

Unit side
Probes

Hydraulic Circuit Diagram - WQL/WQH 20 to 45 (continued)

OUTLET

Hydraulic system 1P evaporator

D

WQL-WQH-WQRC 20-190

|

13

A

B

C

COMPONENTS

1 Plate heat exchanger
2 Pump
3 Water filter
4 Pressure expansion tank
5 Water outlet
6 Water inlet
7 Globe valve
8 Flexible pipes
9 By-pass valve

10 Pressure point/drainage

1

2

4

SAFETY / CONTROL DEVICES

A Water differential pressure switch
B Inlet water temperature sensor
C Outlet water temperature sensor
D Vent valve
E Thermometer

Unit side
Probes

3

10

10

8

9

8

7

E

6

INLET

7

E

5

|

OUTLET

OUTLET

14

WQL-WQH-WQRC 20-190

Hydraulic Circuit Diagram - WQL/WQH 50 to 190

Hydraulic system basic

A

B

C

1- C

2

8

8

6

7

6

5

E

4

INLET

5

3

E

OUTLET

A

B

C

COMPONENTS

1C Condenser
1E Evaporator

2 Water filter
3 Water outlet
4 Water inlet
5 Globe valve
6 Flexible pipes

1- E

SAFETY / CONTROL DEVICES

A Water differential pressure switch
B Inlet water temperature sensor
C Outlet water temperature sensor
D Vent valve
E Thermometer

Unit side

Probes
7 By-pass valve
8 Pressure point/drainage

Hydraulic system 1P condenser and 1P evaporator

D

1- C

D

1- E

COMPONENTS

1C Condenser
1E Evaporator

2 Pump
3 Water filter
4 Pressure expansion tank
5 Water outlet
6 Water inlet
7 Globe valve
8 Flexible pipes
9 By-pass valve

10 Pressure point/drainage

SAFETY / CONTROL DEVICES

A Water differential pressure switch
B Inlet water temperature sensor
C Outlet water temperature sensor
D Vent valve
E Thermometer

Unit side
Probes

A

B

C

A

B

C

2

8

8

2

4

2

3

10

10

3

10

10

6

7

6

8

9

8

8

9

8

5

E

4

INLET

5

E

E

E

E

E

3

7

6

INLET

7

5

7

6

INLET

7

5

OUTLET

Hydraulic Circuit Diagram - WQL/WQH 50 to 190 (continued)

OUTLET

OUTLET

Hydraulic system 2P condenser and 2P evaporator

WQL-WQH-WQRC 20-190

|

15

2

D

A

B

C

A

B

C

1- C

D

1- E

10

2

10

2

10

2

10

F

3

11

11

F

4

3

11

11

8

9

8

8

9

8

7

E

6

INLET

7

E

E

E

5

7

6

INLET

7

5

COMPONENTS

1C Condenser
1E Evaporator

2 Pump
3 Water filter
4 Pressure expansion tank
5 Water outlet
6 Water inlet
7 Globe valve
8 Flexible pipes
9 By-pass valve

10 Non-return valve
11 Pressure point/drainage

SAFETY / CONTROL DEVICES

A Water differential pressure switch
B Inlet water temperature sensor
C Outlet water temperature sensor
D Vent valve
E Thermometer
F Water safety valve (6 bar)

Unit side

Probes

|

20

25

30

35

40

45

50

55

60

-10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20

-10 -8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20

25

30

35

40

45

50

55

60

16

WQL-WQH-WQRC 20-190

Operating Limits

WQL/WQH 20 - 190

Chilled
liquid

Leaving water
temperature

Maximum operating pressure bar 6

Heated
liquid

Leaving water
temperature

Maximum operating pressure bar 6

Power supply voltage 400 V, 3 ph, 50 Hz (+/- 10%)

Note : Maximum % glycol (ethylenic or propilenic) : 40%.

Water °C +5 to +18
Brine °C -8 / +5 (with glycol and electronic expansion valve); +5/+18 (standard application)
ΔT water °K 3 to 8

Water °C +25 to +55
ΔT water °K 3 to 15

Water

+

Water

Glycol

Condenser leaving water temperature (°C)Condensing temperature (°C)

Evaporator leaving water temperature (°C)

WQRC 20 - 190

Chilled
liquid

Leaving water
temperature

Maximum operating pressure bar 6
Condensing temperature °C +30 to +58
Power supply voltage 400 V, 3 ph, 50 Hz (+/- 10%)

Note : Maximum % glycol (ethylenic or propilenic) : 40%.

Water °C +5 to +18
Brine °C -8 / +5 (with glycol and electronic expansion valve); +5/+18 (standard application)
Temperature spread °K 3 to 8

Water

+

Glycol

Evaporator leaving water temperature (°C)

Water

Correction Factors

Unit capacity, absorbed power, brine flow rate, brine pressure drop, have to be corrected according to following formula :

Corrected unit capacity

x K

i

E,P

c

E,P

i

Q

CORRECTED/GLYCOL

= Q

NOMINAL

x Kc x K

where :

= capacity corrective factor according to LWT (ΔT = 5 [K])  refer to Table 1

K

c

E

= capacity corrective factor according to glycol percentage (ETHYLENE GLYCOL)  refer to Table 2

K

c

P

= capacity corrective factor according to glycol percentage (PROPYLENE GLYCOL)  refer to Table 4

K

c

Corrected unit absorbed power

P

CORRECTED/GLYCOL

where :

= absorbed power corrective factor according to LWT (ΔT = 5 [K])  refer to Table 1

K

i

E

= absorbed power corrective factor according to glycol percentage (ETHYLENE GLYCOL)  refer to Table 2

K

i

P

= absorbed power corrective factor according to glycol percentage (PROPYLENE GLYCOL)  refer to Table 4

K

i

= P

NOMINAL

x K

WQL-WQH-WQRC 20-190

|

17

Corrected brine flow rate

G

CORRECTED/GLYCOL

where :

G

RE-CALCULATED

E

= flow rate corrective factor according to glycol percentage (ETHYLENE GLYCOL)  refer to Table 2

K

f

K

f

= flow rate according to P

P

= flow rate corrective factor according to glycol percentage (PROPYLENE GLYCOL)  refer to Table 4

CORRECTED/GLYCOL

(P

CORRECTED/GLYCOL

= G

RE-CALCULATED

x 860 / ΔT / 3600)

x K

Corrected brine pressure drop

∆P

CORRECTED/GLYCOL

where :

∆P

RE-CALCULATED

E

= pressure drop corrective factor according to glycol percentage (ETHYLENE GLYCOL)  refer to Table 2

K

p

P

K

p

Table 1

Leaving water

temperature

[LWT] (°C)

(ΔT=5 [K])

= pressure drop according to G

CORRECTED/GLYCOL

= pressure drop corrective factor according to glycol percentage (PROPYLENE GLYCOL)  refer to Table 5

K

c

7 1.000 1.000
4 0.887 0.940
2 0.816 0.900
0 0.748 0.865

-2 0.685 0.826

-4 0.624 0.788

-6 0.568 0.753

-8 0.513 0.718

-10 0.461 0.683

K

i

Table 2

Ethylene Glycol Percentage % 0 10 20 30 35 40

Freezing point (1) °C 0 -4 -10 -17 -21 -25

Minimum leaving water temperature allowed °C 6 2 -2 -6 -8 -8

Capacity corrective factor (2)

Absorbed power corrective factor (2)

Flow rate corrective factor

Pressure drop corrective factor (3)

(1) ASHRAE Handbook Fundamentals.
(2) Valid for LWT=7 °C. If LWT < 7°C consider K
(3) Valid for LWT > 5 °C. If LWT < 5 °C then refer to Table 3.

(K

BPHE

x (G

= ∆P

RE-CALCULATED

CORRECTED/GLYCOL

)2)

x K

E,P

f

E,P

p

E

K

1 0.995 0.985 0.970 0.963 0.955

c

E

K

1 0.998 0.995 0.985 0.983 0.980

i

E

K

1 1.015 1.050 1.085 1.123 1.160

f

E

K

1 1.070 1.160 1.235 1.283 1.330

p

c

x K

E

and Ki x K

c

E

.

i