Aircold WLA Compact 230/1/50 Setup guide

WLACompact
Translation of original instructions
Air cooled water chiller
230/1/50, 230/1/60
400/3/50, 460/3/60
Index i04
Revision 10.2021
LIQUID CHILLER
www.aircold.dk
[email protected]
tlf.: [phone]

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COSMOTEC HISTORY
Cosmotec was founded in 1989. In 2001, Cosmotec joined Stulz GmbH, which has its
headquarters in Hamburg. In 2004, Cosmotec SpA changed its name to Stulz SpA.
Stulz SpA immediately became a major producer of air conditioning and cooling in the
industrial and ICT markets. Innovation, exibility and respect for the environment are
the primary quality factors behind the ISO9001 certication.
The most important corporate goals are a range of tailor-made solutions, high stock
levels, a resulting high delivery capacity and a service tailored to customer needs.
A high degree of customer satisfaction is due to the fast order processing and a deliv-
ery capability within a few days.
Foundation of
COSMOTEC srl
Expansion of
production site
COSMOTEC
become part of
STULZ
Expansion of
production site
New chillers range
TECHNO
New expansion of
production site
2
COSMOTEC S.p.A.
via Torricelli, 3
37067 Valeggio Sul Mincio
Verona - Italy
2016
2010
2006
2001
1989
1994

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WLA Compact – High quality liq-
uid chiller made in Italy
Dear Customer,
Thank you for purchasing a Cosmotec chiller.
It is the result of many years of research and design studies, as well as a ne matching of materi-
als and technologies to obtain a high quality chiller.
The CE mark guarantees that the Cosmotec products fulll the requirements of the European
Machinery Directive for safety.
The level of quality is permanently checked at every phase, from design to production and
makes Cosmotec products synonymous of SAFETY, QUALITY and RELIABILITY.
For any questions or requests concerning products by Stulz SpA, please contact our Aftersales
at:
telephone [phone]
fax [phone]
email [email protected]
Or visit our website for more information about our products and services:
www.cosmotec.it
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Summary
1.Introduction.................................................................................................................................................. 6
1.1.Introduction................................................................................................................................... 6;
1.2.Warranty.......................................................................................................................................... 6;
1.3.Annex.................................................................................................................................................. 6
2.Safety.................................................................................................................................................................7
2.1.Symbols used in the manual..........................................................................................7;
2.2.Labels.................................................................................................................................................7;
2.3.Safety instructions.................................................................................................................. 9;
2.4.Handling refrigerants........................................................................................................... 9;
2.5.Safety and environmental requirement ............................................................10
3.Residual risk............................................................................................................................................... 11
3.1.Refrigerant safety data.......................................................................................................12
4.Moving and storage........................................................................................................................... 15
4.1.Receipt............................................................................................................................................ 15;
4.2.Handling........................................................................................................................................16;
4.3.Removing of the packaging........................................................................................16;
4.4.Storage ...........................................................................................................................................16
5.Description..................................................................................................................................................17
5.1.Coding............................................................................................................................................. 17;
5.2.Intended and unintended use................................................................................... 18;
5.3.Layout of the components, principle and mode operation............18;
5.4.Components of the refrigerant circuit................................................................19;
5.5.Safety components of the refrigerant circuit.............................................. 20;
5.6.Protection components of the refrigerant circuit................................... 20;
5.7.Components of the hydraulic circuit.................................................................. 20;
5.8.Air circuit........................................................................................................................................21;
5.9.Protection and control electric components................................................21;
5.10.Hydro-cooling circuits....................................................................................................23
6.Technical data........................................................................................................................................26
6.1.Application limits...................................................................................................................26;
6.2.Features of primary fluid................................................................................................27;
6.3.Technical data.........................................................................................................................28;
6.4.Available pressure...............................................................................................................34;
6.5.Pressure losses......................................................................................................................35;
6.6.Calibration of automatic bypass............................................................................ 36;
6.7.Dimensional drawings.......................................................................................................37
7.Installation ..................................................................................................................................................39
7.1.Positioning .................................................................................................................................. 39;
7.2.Hydraulic connections.................................................................................................... 40;
7.3.Electrical connections..................................................................................................... 40;
7.4.Commissioning preliminary operations..............................................................41
8.Commissioning......................................................................................................................................43
8.1.Start up...........................................................................................................................................43;
8.2.Checks to be performed after start up..............................................................44;
8.3.Deactivation ...............................................................................................................................44
9.Maintenance ............................................................................................................................................45
9.1.Warnings ......................................................................................................................................45;
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Soggetto a modifiche senza preavviso
9.2.Routine maintenance........................................................................................................45;
9.3.Extraordinary maintenance......................................................................................... 48
10.Troubleshooting............................................................................................................................... 49;
11.Decommissioning and disposal of the unit............................................................... 50;
12.Options........................................................................................................................................................52
12.1.Multi-pole connector.......................................................................................................53;
12.2.Device for low ambient temperature up to -5°C ...................................53;
12.3.Device for low ambient temperature up to -10°C..................................54;
12.4.Temperature tracking with differential thermostat..............................54;
12.5.Tank electric level with pump stop function .............................................54;
12.6.50/60 Hz medium pressure pump....................................................................54;
12.7.Pre-heating resistance...................................................................................................55;
12.8.Under-beam kit ....................................................................................................................55
13.Connection diagrams.................................................................................................................... 56
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1. Introduction
1.1. Introduction
These operating instructions contain basic information which is to be complied with for installation,
operation and maintenance. They must therefore be read and complied with by the tter and the
responsible trained sta/operators before assembly and commissioning.
All procedures detailed in the manual, including tasks for installation, commissioning and
maintenance must only be performed by suitable trained and qualied personnel. They must be
permanently available at the place where the system is used.
The manufacturer will not be liable for any injury or damage caused by incorrect installation,
commissioning, operation or maintenance resulting from a failure to follow the procedures and
instructions detailed in the manual.
INFORMATION
An informative document on the REACH Regulation is available. Please view it on web site
https://www.cosmotec.it/certicazioni.
1.2. Warranty
The warranty is limited to free replacement and shipping of any faulty part, or sub-assembly which
has failed due to poor quality or manufacturing errors. All claims must be supported by evidence
that the failure has occurred within the warranty period, and that the chiller has been operated
within the designed parameters specied.
All warranty claims must specify the model and serial number of the chiller. This information is
printed on the name plate, tted on the door from the electrical cabinet.
The warranty will be invalid in case of any modication on the chiller which is not written approved
from Cosmotec.
To claim any warranty purpose the following conditions need to be satised:
The initial startup of the chiller has to be carried out by trained personnel authorized from Cosmotec.
Only Cosmotec approved spare parts and liquids are allowed to be used.
All scheduled maintenance operations described in this manual must be performed accordingly
by trained and qualied personnel.
Not fullling at least one these conditions will automatically void the warranty.
1.3. Annex
The following annexes are an integral part of this manual.
•Manual part 2: consisting of water-refrigeration diagram, electrical diagram, and CE declaration
of conformity;
•Electronic control manual (user version);
•Accessory manuals (if presents).
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2. Safety
2.1. Symbols used in the manual
DANGER Risk of death or injury to the operator
WARNING Risk of damage to the unit
INFORMATION Important information, use note
ESD CAUTION Risk of damage to electronic components
2.2. Labels
Tank lling
Position: close to the lling valves of the storage tank (where
available).
Tank discharge
Position: close to the draining valves of the evaporators and storage
tank (where available).
Chiller hydraulic circuit inlet (chiller water return)
Position: close to the hydraulic circuit inlet connection.
Chiller hydraulic circuit outlet (chiller water supply)
Position: close to the hydraulic circuit outlet connection.
Hot components
Position: close to condenser inlet/outlet pipes (under the protection
guard) and on the compressor support. With antifreeze option, they
can be found close to the heaters around the evaporator, at the
pump volute, steel hydraulic pipes and in the storage tank.
High voltage
Position: close to electric components and in the electrical panel.
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Direction of rotation of motors.
Location: near the fans and the pumps.
Label recalling the instruction manual.
Location: on the side of the powerboard.
The chiller is identied by the nameplate shown on
the side. The identication nameplate also shows
the serial number of the unit, it is important to know
the label as it is essential to get assistance or any
information concerning the unit described in this
manual.
Location: under the power board.
88
400-460V/3/50-60 Hz
--- bar
85 °C
--- / --- A
----- kW (W15L32)
45 °C
--- kg
R134a
--- kg
Tensione nominale - Rated voltage -
Nennspannung - Tension nominale
PS HP (Max pressione ammissibile HP - Max allowable pressure
HP - Max zulässiger Druck HP - Pression maximum admise HP)
TS MAX (Refrigerante - Refrigerant - Kaltemittel - Refrigerant)
Avviamento/marcia - Starting/run current -
Anlaufstrom/Nennstrom - Démarrage/marche
Resa nom. - Cooling cap. - Kalteleistung -
Puissance nominale
Potenza Assorbita - Input power - Leistungsaufnahme -
Puissance absorbée
TSS (Max temp. Di stoccaggio - Max Storage temp. - Max
Lagertemperatur - Temp. Max d'emmagasinage)
Carica gas - Filling capacity - Fullmenge - Charge de gaz
Refrigerante tipo - Refrigerant type - Kaltemittel - Refrigerant type
Peso - Weight - Gewicht - Poids
----- kW (W15L32)
Contiene gas fluorurati ad effetto serra disciplinati dal protocollo di Kyoto - Device
containing HFC fluids causing greenhouse effect regulated by Kyoto protocol - Das Gerät
erhält wie vom Kyoto-Protokoll geregelte Fluorkohlenwasserstoffe Treibhausgasen -
Dispositif contenant fluides HFC à effet de serre disciplinés par le protocole de Kyoto
REFRIGERATORE DI LIQUIDO - LIQUID COOLER -
KUHLANLAGE - REFROIDISSEUR DE LIQUIDE
SERIE - SERIES - SERIE - SERIE
DATA - DATE - DATUM - DATE
WLA13B1A061A080 7035
N°0000458674
-- /-- /----
MODELLO - MODEL - TYP - MODELE
MADE IN ITALY
ORDINE - ORDER - ORDER - COMMANDER 2130006329
-10 °C
TS MIN (Refrigerante - Refrigerant - Kaltemittel - Refrigerant)
--- bar
PS LP (Max pressione ammissibile LP - Max allowable pressure
LP - Max zulässiger Druck LP - Pression maximum admise LP)
I
CAT PED
Modulo valutazione - Evaluation Module - Bewertungsverfahren -
Procédure d'évaluation A1
0035

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2.3. Safety instructions
INFORMATION
This cooling unit contains uorinated greenhouse gas covered by the Kyoto protocol.
In these Cosmotec chillers the refrigerant R134A is used. Refrigerants are volatile or highly volatile
uorinated hydrocarbons which are liqueed under pressure. They are incombustible and not
hazardous to health when used as intended.
DANGER
•Works have to be carried out by competent sta only.
•Observance of the regulations for accident prevention.
•Stay out of danger when lifting and setting o the unit.
•Secure the unit to avoid the risk of overturning.
•Safety devices may not be bypassed.
•Respect the corresponding EN- and IEC standards for the electrical connection of the unit
and observe the conditions of the power supply companies.
•Switch o the voltage from the unit when working on it.
•The unit must be earthed.
WARNING
•The unit may only be used to cool water according to the Cosmotec specication.
•Observe the national regulations of the country where the unit will be installed.
•The refrigerant circuit contains refrigerant and refrigerating plant oil, observe professional
disposal for maintenance and when setting the unit out of service.
•Cooling water additives have an acidic eect on skin and eyes, wear safety glasses and safety
gloves.
•Observe personal protective equipment when working on the refrigerant circuit.
INFORMATION
•Respect material compatibility in the whole hydraulic circuit.
•The male triangular wrench is to be placed in a visible location in the immediate vicinity of
the unit.
2.4. Handling refrigerants
According to EN 378, refrigerants are divided in groups in respect of health and safety.
•Adherence to the regulations by law and guide-lines.
•Execution only by competent sta.
•Responsibility for correct disposal of refrigerant and system parts is incumbent on the operator.
•Refrigerants have a narcotic eect when inhaled in high concentrations.
•The room is to be evacuated immediately if high concentrations of refrigerant suddenly occur.
The room may only be entered again after adequate ventilation.
•If unavoidable work is required in the presence of a high concentration of refrigerant, breathing
apparatus must be worn. This does not mean simple lter masks. Comply with breathing
protection data sheet.
•Safety glasses and safety gloves are to be worn.
•Do not eat, drink or smoke at work.
•Liquid refrigerant must not get onto the skin (risk of burns).
•Only use in well ventilated areas.
•Do not inhale refrigerant vapours.
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•Warn against intentional misuse.
•It is absolutely essential to comply with the rst aid measures if accidents occur.
•Refrigerants containing FCs contribute to the global warming and with this to climate changes.
The FCs must therefore be disposed of in accordance with the regulations, i.e. only by companies
specially qualied and licensed as recognised disposal companies for refrigerants.
2.5. Safety and environmental requirement
The following requirements relate to the operation of refrigerating plants within the European
Community.
•The used components must correspond to the pressure equipment guide-line 2014/68/EC and
EN 378 part 1-4.
•Independent of the design, the equipment and inspection before the delivery, also the operator
of such plants has duties according to EN 378 and national regulations.
•This concerns the installation, the operation and the repeated inspection:
•Installation: according to EN 378
•Operation: Determination of emergency measures (accidents, malfunctions)
Creation of an abbreviated instruction and notication (template page)
1. A unit protocol must be kept.
2. To be stored in the proximity of the unit
3. Access for competent sta in case of repairs and repeated inspection must be ensured.
•Repeated inspection: according to EN 378. The operator is responsible for the execution.
The operator must ensure that all maintenance, inspection and assembly work is carried out
by authorised and qualied specialist sta who have made an in-depth study of the operating
instructions. It is absolutely essential to comply with the procedure for shutting down the system
described in the operating instructions. Before maintenance work, the unit must be switched o
at the main switch and a warning sign displayed to prevent unintentional switching-on.
First aid measures
•If health problems occur during or after handling uorinated hydrocarbons, a doctor is to be
consulted immediately.
•The doctor is to be informed that the work involved the use of uorinated hydrocarbons.
•In the case of acute eects, the casualty is to be brought into the fresh air as quickly as possible.
•Splashes of uorinated hydrocarbons in the eyes can be blown out or fanned out by an assistant.
Then rinse with water.
Independent conversion and manufacture of replacement parts
The system may only be converted or modied after consultation with Cosmotec. Original
replacement parts and replacement parts/accessories authorised by Cosmotec are an aid to
safety.
Unacceptable operating methods
The operating safety of the system is only guaranteed when it is used as intended. The limit values
stipulated in the technical data must not be exceeded under any circumstances.
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3. Residual risk
During transport and installation
Area Danger Risk Preventative measures
Under
the unit
Defective lifting system of the
unit, which causes its fall.
Contusions,
trauma.
Keep away from the danger area while handling the
unit.
Near the
unit
Accidental shock with damage
to the refrigerant circuit and leak
of high pressure refrigerant.
Bruises,
formation of
acid vapours.
Keep away from the danger area while handling the
unit. Wear PPE.
Near the
unit
Unstable or unsuitable unit
support that causes its overturn.
Contusions,
trauma.
Make sure the unit support is adequate to its weight, is
stable and levelled. Wear PPE.
Electrical
box
Connection cables under
voltage.
Electroshock Make sure to disconnect the power supply from the
distribution panel.. Remain electrically insulated from
the ground. Wear PPE.
During start-up and operation
Area Danger Risk Preventative measures
Near the unit Suction and following expulsion of
objects, dust, and substances from the
fans in the installation site.
Contusions, trauma. Clean the installation area.
Wear PPE.
In contact with
the unit
Non-compliant electrical connection
and missing earth connection.
Electroshock. Remain electrically insulated
from the ground. Wear PPE.
Near water
pipes
Closed shut-o valves; leaks from the
hydraulic pipes. Consequent leaking of
water and additives.
Irritation of skin and
eyes due to contact
with ethylene glycol.
Irritation of the skin
and breathing system
due to glycol vapours.
Electrocution, slipping.
Open the shut-o valves of the
hydraulic circuit. Wear PPE.
Near water
pipes
Condensate formation in the presence
of the dew point with leaks of the not
insulated pipes.
Electroshock, slipping. Wear PPE.
Near the unit With unit ON: Losses in the refrigerant
circuit; defective safety valve and high
pressure switch; re; shut-o valves
in the refrigerant circuit closed after
maintenance; defect on the gas charge
line. Consequent explosive breakage of
the refrigerant circuit.
Bruises, formation of
acid vapours with open
ames..
Wear PPE. In case of re, wear
re-ghting masks.
Near the unit
(Electrical box,
supply cables)
Short-circuit; incorrect sizing of the
cables or of the main switch.
Electroshock, re,
formation of acid
vapours.
Check the xing of the terminal
cables; select the power supply
cables and main switch. Wear
PPE. In case of re, wear re-
ghting masks.
Near the unit Noise emission. Injury of the hearing
system.
Wear PPE.
During maintenance
Area Danger Risk Preventative measures
Near the unit Losses in the refrigerant circuit;
defective safety valve and high
pressure switch; re; defect on
the gas charge line. Consequent
explosive breakage of the
refrigerant circuit.
Bruises,
formation of
acid vapours
with open
ames.
Wear PPE. In case of re, wear re-
ghting masks.
Components of the
unit: compressor,
delivery pipes,
condenser
Contact with hot surfaces. Bruises. Avoid the contact. Wear PPE.
Condenser Contact with sharp surfaces (ns). Cuts,
abrasions.
Wear PPE.
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Area Danger Risk Preventative measures
Electrical box Live power supply line even if the
switch on board the unit is OFF.
Electroshock Make sure to disconnect the power
supply from the distribution panel.
Make sure that the main switch is not
reactivated during maintenance.
During dismantling
Area Danger Risk Preventative measures
Near the
unit
Losses in the refrigerant circuit;
defective refrigerant recovery
system. Consequent explosive
breakage of the refrigerant circuit.
Bruises, formation
of acid vapours with
open ames..
Wear PPE.
Near the
unit
Oil leaks during recovery. Oil contact wit skin
or eyes
Wear PPE.
Near
water
pipes
Unscrewing the water pipes still
under pressure.
Irritation of skin and
eyes due to contact
with ethylene
glycol.. Electro-
shock. Slipping
De-pressurise the hydraulic circuit before
disconnection. Wear PPE.
Electrical
box
Live power supply line even if the
switch on board the unit is OFF.
Electroshock. Make sure to disconnect the power
supply from the distribution panel.
Make sure that the main switch is not
reactivated during maintenance.
3.1. Refrigerant safety data
Refrigerant safety data
1. Identication of
the substance/
preparation
Identication of the preparation STAR COLD 134a
Recommended uses Refrigerant
2. Composition
/ information on
the ingredients
Tetrauoroethane (C2H2F4) N° CAS: 811-97-2
N° CE: 212-377-0
Concentration: 100%
3. Identication of
the hazards
Possible Hazards Not dangerous according to Directive 1999/45/EC. Consequences on the
environment: not readily biodegradable. Physical and chemical hazards: thermal
decomposition in toxic and corrosive products.
4. Fire-ghting
measures
Inhalation Move the victim to a non-contaminated area wearing breathing equipment. Keep
the patient warm and at rest. Call a doctor. Apply articial respiration if breathing has
stopped.
Contact with skin In case of frostbite, spray with water for at least 15 minutes. Apply a sterile gauze.
And obtain medical assistance.
Contact with eyes Immediately wash the eyes with water for at least 15 minutes.
Ingestion Ingestion is not considered a potential route of exposure.
Protection for rst-aiders Wear suitable respiratory equipment in case of interventions in saturated atmosphere.
Notes for the doctor Do not administer catecholamines (due to the cardiac eects of the product)
5. Fire-ghting
measures
Suitable extinguishing medium Adopt extinguishing measures in re area.
Special risks from the
substance or mixture
The product is not ammable in ambient pressure and temperature. Any mixtures,
under pressure with air, can be ammable. At high temperature: There is thermal
decomposition into toxic and corrosive products as hydrouoric acid and carbon
oxides.
Advice for re-ghters
Cool containers/tanks with spraying water. Provide a rapid container evacuation
system. In case of re nearby, keep away containers exposed to re. In case of re,
wear a self-contained breathing apparatus and a complete protection suit against
chemical agents.
6. Accidental
release measures
Individual measures Try to stop the leakage. Evacuate the area. Ensure suitable ventilation. Use the
respiratory equipment to access the involved area unless atmosphere is proved
to be unbreathable. Avoid accessing sewers, basements, or any place where its
accumulation could be dangerous.
Environmental precautions. Try to stop the leakage.
Methods and materials for
containment and recovery
Ventilate the area.
1212

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7. Handling and
storage
Precaution for safe handling
Storage and handling dispositions applied for the following products: under
pressure gas and liqueed gas. Provide adequate ventilation and extraction near
equipment. Provide showers, eye fountains. Provide nearby points of water delivery.
Well ventilate cisterns and tanks, before intervening inside. Prohibit sources of
ignition and the contact with hot surfaces. DON’T SMOKE. Avoid the contact with
skin, eyes and inhalation of vapours. Don’t drink and don’t eat during use. Clean
hand after manipulation. Remove contaminating clothing and protective clothing
before entering food catering areas.
Condition for secure storage,
including any incompatibilities
Keep in a fresh and well ventilated place. Keep away from free ames, hot surfaces
and ignition sources. Don’t smoke. Protect full containers from heat sources to
avoid over pressures. Protect from lights. Avoid direct lights.
Storage temperature <45°C
Incompatible products Alkaline hydroxides. Alkaline earth metals. Strong oxidizing agents. Finely divided
metals.
Packaging material Recommended: Ordinary steel, stainless steel.
To avoid: alloy containing more than 2% magnesium. Plastic materials.
Storage conditions Keep in a fresh, dry and well ventilated place. The temperature cannot be higher
than 50°C. Maintain the valves well closed.
Suitable packaging Storage in original cylinder. Protect from contaminations.
8 . Exposure/
personal
protection
checks
Exposition Norurane = 13936 mg/m3 in case of inhalation for workers.
Norurane = 2476 mg/m3 in case of inhalation for consumers.
General protection measures Ensure an adequate air change and/or aspiration in working environments
Protection for respiratory tracts In case of not enough ventilation, use a suitable air breathing apparatus.
Hand protections Leather glove
Eyes/face protection Protection glasses with side-shields
Skin/body protection Wear protection suit (cotton) that covers legs and arms.
Ambient Should not be released into the environment.
9. Physical
and chemical
properties
Aspect Physical state (20°C): gaseous; Physical state: liqueed gas; Colour: without colour
Odour Slightly similar to air
Fusion interval / point -108 °C
Boiling interval / point -26 °C
Flammability (solids,gas)
Non-ammable substance. Vapour pressure: 0,574 MPa a 20 °C.
Vapour density: 4,24 kg/m3. Density: 1,206 kg/m3 a 25°C, 1,102 kg/m3 a 50°C, 996
kg/m3. Relative density (Water): 1,21 a 20°C, 1,1 a 50°C
Solubility in water 1 g/l a 25 °C
Auto-ignition temperature 743 °C a 1 bar
Decomposition temperature >370 °C
Other information Henry constant: 155E+03 PA.m3/mol. Molecular weight: 102 g/mol
Critical pressure: 4,07 MPa. Critical temperature: 101 °C
10. Stability and
reactivity
Chemical stability and
reactivity
Stable at ambient temperature. The product, in presence of air, can create a
ammable mix, under certain conditions of temperature and pressure.
Conditions to be avoided Keep far from eat sources and other causes of re. Avoid the contact with ames
and incandescent metallic surfaces.
Incompatible materials Alkaline hydroxides. Alkaline earth metals. Strong oxidizing agents. Finely divided
metals.
Thermal decomposition Decomposition temperature: > 370 °C
Hazardous decomposition
products
At high temperature there is the thermal decomposition into toxic and harmful
products: Gaseous hydrogen uoride and carbon oxides.
11. Toxicological
information
Inhalation
Reduced harm for inhalation. As the others volatile aliphatic halogenated compounds,
trough vapours accumulation and/or inhalation of huge quantities, the substance
can cause: loss of consciousness and heart disease, aggravated by stress and lack
of oxygen: mortal risk.
Local eects Possible frostbite for liqueed gas sketches on skin and eyes.
Respiratory or skin sensitization No genotoxic eects.
Carcinogenicity No carcinogenic or mutagen eects in animal experiments.
Toxicity for reproduction No toxicity to reproduction. No toxic eects for developing foetus, at no toxic
concentration for mothers.
Specic target organ toxicity Studies of long inhalation on animals didn’t highlighted any chronic toxic eect.
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WLA COMPACT - TRANSLATION OF ORIGINAL INSTRUCTIONSWLA COMPACT - TRANSLATION OF ORIGINAL INSTRUCTIONS
12. Ecological
information
Acute toxicity Low harmful for shes. Low harmful for alga.
Persistence and degradability Not readily biodegradable
Potential for bioaccumulation Considered to be not bioaccumulative
13. Considera-
tions on disposal Waste disposal methods Elimination of the product, recycle or incinerate. According to local and national
Norms.
14. Transport
information
UN number 3159
Suitable shipment name LIQUIFIED GAS N.O.S. (Tetrauoroetano)
Transport danger class 2 (ADR) - 2 (ADN) - 2.2 (IATA_Cargo) - 2.2 (IATA - Passenger) - 2.2 (IMDG)
ImS code F-C, S-V
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4. Moving and storage
4.1. Receipt
To ensure product quality and reliability, all the chillers are checked and tested before delivery.
The standard packaging consists of:
•Bubble wrap around the sides and roof of the unit;
•Some plastic air bag strips around the unit.
•Specic pallet for transporting the chiller
WARNING
Standard packaging is not suitable for sea or air freight
The packaging is equipped with an
adhesive providing the following
information:
•COSMOTEC logo
•COSMOTEC production order number
•Unit code
•Unit serial number
•TSS: maximum storage temperature
Other labels of this type can be positioned
on the packaging to identify the accessories
included in the unit packaging.
Upon reception of the goods, immediately inspect the unit.
•Make sure that the goods have been transported in the correct position. Write any unsuitable
shipment on the transport document.
•Check the presence of all the items indicated in the transport document and also check the
integrity of the conditioner upon reception.
•Make sure that there are no external damage and, if any, write them on the transport document
in the presence of the carrier.
Hidden damage, to be veried after having removed the packaging, must be signalled to the
carrier within the times and methods indicated in the transport document.
With goods delivered ex-works, the carrier is liable for any damage caused during transport.
If the goods are not delivered ex-works, in case of damage, follow the instructions indicated on
the transport document.
This product must not be returned without prior authorisation of COSMOTEC. Contact you local
COSMOTEC partner in case assistance service is required.
INFORMATION
•Due to the pre-lled refrigerant, the unit is marked as transport of dangerous goods.
•The refrigerant is non-toxic and non-ammable.
•For special shipping indication, please contact the corresponding sales department.
•Special transport regulations must be checked country specically.
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WLA COMPACT - TRANSLATION OF ORIGINAL INSTRUCTIONSWLA COMPACT - TRANSLATION OF ORIGINAL INSTRUCTIONS
4.2. Handling
WARNING
The chiller must be lifted safely, without inclining it or resting it on its sides, with suitable
equipment.
The capacity of the mean must be suitable for the weight of the chiller to be lifted.
The load must be balanced to prevent overturning.
Do not perform sudden and/or violent manoeuvres.
Do not overlap other objects on the chiller.
Handling with forklift truck:
- Chiller on pallet Handling with eyebolts
4.3. Removing of the packaging
Once the chiller is placed on the ground, remove the packaging without damaging the unit
The packaging must be disposed of in compliance with Regulation in the place of disposal. For
more information see chapter “11. Decommissioning and disposal of the unit”.
4.4. Storage
If you put the unit into intermediate storage before the installation, the following measures have
to be carried out:
•Make sure that the hydraulic connections are provided with closing caps supplied in series with
the unit;
•Do not expose the unit to direct sunlight;
•Store the unit in its original packaging.
The chiller are packaging with standard packaging (unless dierent agreements). The packaging:
•It doesn’t protect the chiller from rain and adverse weather conditions;
•It’s not suitable for sea freight;
•It’s not suitable for air freight.
The ambient conditions for storage are shown in paragraph 6.1.
1616
B
C
D
E
F
G
345678910
A
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WLA COMPACT - TRANSLATION OF ORIGINAL INSTRUCTIONS
5. Description
5.1. Coding
The type code represents the variant of
your chiller unit and can be found on the
nameplate located on the inner side of
the electric cabinet. You can decode the
type code by the following table.
INFORMATION
Please be aware that not every
combination of these values is
possible.
Liquid Chiller
L
W
A
3°digit
0
2
4°digit
5°digit
6°digit
Cooling Capacity
02 1,4 kW 08 3,2 kW
03 1,6 kW 10 4,1 kW
05 2,5 kW 13 5,1 kW
A
7°digit
Pump conguration
AExchanger
BExchanger + Standard pressure pump P3
CExchanger + Medium pressure pump P5
8°digit
0
Hydraulic conguration
0Standard - without tank
1Tank
9°digit
10°digit
Power supply
00 230/1/50 (only for WLA10-13)
20 230/1/50-60
61 400/3/50- 460/3/60 (only for
WLA05-08-10-13)
A
11°digit
Electrical options
AStandard
BMulti-pole connector (Power + alarm signal)
CDierential control with external probe
DMulti-pole connector (Power + alarm signal) +
Dierential control with external probe
14°digit
8
Refrigerant
8R134a
2°digit
1°digit
Hydraulic option with tank
ANo option
B Electrical level stop pump
CUnder-beam
DPre-heating in the pump + Electrical level stop
pump
EUnder-beam + Electrical level stop pump
FUnder-beam + Pre-heating in the pump + Elec-
trical level stop pump
A
0
Regulation of condensing pressure
0Standard
1On-O system for low ambient T version -5°C
2Modulating system for low ambient T version
-10°C
3Modulating system + Hot gas bypass for LASER
version
0
0
12°digit
13°digit
0
Frame
0Standard
1Stainless steel
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WLA COMPACT - TRANSLATION OF ORIGINAL INSTRUCTIONSWLA COMPACT - TRANSLATION OF ORIGINAL INSTRUCTIONS
5.2. Intended and unintended use
Intended use
The chiller is designed to cool liquids in an industrial environment, protected from heat sources,
according to limits and indications of technical label.
The unit is designed to be used in room with supervised and/or authorized access category (see
tab. 4 EN 378-1:2016). Consequently, on informed personnel can stay near the unit; it’s considered
that, in case of re, the personal is aware of the intrinsic risk of the unit.
The operation safety of the system is guaranteed as long as it complies with its intended use. The
storage and operation limit values indicated on the data plate and stated in paragraph 6.1 must
never be exceeded.
COSMOTEC is not liable for damage caused by improper use. The operator is fully responsible for
this risk.
Unintended use
The use of the chiller must always comply with the standards in force and instructions provided
in this manual.
Moreover, its use is prohibited in the event it is installed:
•Incorrectly;
•On mobile parts or on oscillating, inclined (not levelled) supports or on supports that transmit
vibrations;
•In areas with high heat radiation;
•In areas with strong magnetic elds;
•In areas with open ames;
•In areas featuring explosive atmospheres;
•In the presence of ammable products;
•In areas with risk of explosion;
•In areas with saline atmosphere;
•In areas with aggressive atmospheres;
•In areas excessively dusty;
•In the presence of materials that may obstruct the air circuit after being deposited or suctioned
by the chiller.
Moreover, its use is prohibited after any modication or transformation applied but not approved
by COSMOTEC, including the use of non-original spare parts.
5.3. Layout of the components, principle and mode operation
Only chiller
The chillers described in this manual consist of:
•Hermetic refrigerant circuit, lled with R134a refrigerant. The refrigerant circuit includes a rotary
vane compressor, condenser, an electronic thermostatic valve, and stainless steel evaporator as
brazed plate heat exchanger;
•Hydraulic circuit;
•Condensation module consisting of a condenser and a fan.
The chiller is controlled from the Dixell XW07K electronic regulator (designed and produced
according to COSMOTEC specication) and from a main switch placed on the side of the electronic
regulator on the chiller front panel. The electrical panel, with protection rate IP40, can be accessed
from the upper part of the unit and contains all the electrical control components of the chiller
already wired. The holes for the passage of power supply cables are located on the rear side of
the unit and are provided with cable gland sheaths.
The compressor is xed to the base and it is found in the left rear side of the chiller (accessible by
removing the left side panel).
The condenser, with intake fan integrated, is located in the left side of the chiller and it can be
accessed from the left panel and from the front side, prior removal of the specic panels.
The evaporator as brazed plate heat exchanger is placed at the centre of the unit and it can be
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WLA COMPACT - TRANSLATION OF ORIGINAL INSTRUCTIONS
accessed by removing the front panel.
The condenser cooling air is suctioned from the front side and discharged on the rear by means
of the specic grid in the closing panels.
The inlet and outlet water ttings are located on the rear right, whereas additional hydronic
components (circulation pump and storage tank) are found on the chiller right side.
5.4. Components of the refrigerant circuit
The compressor compresses the refrigerant gas, bring it to higher temperature and pressure.
Through the condenser, the hot gas is cooled and liqueed, releasing hot to the external air.
Pushed through the electronic expansion thermostatic valve, the liquid refrigerant lose pressure
and its prepares for the evaporation. This takes place in the evaporator, where the refrigerant
absorbs the heat of the warm water or of the mixture to the treated, which is therefore cooled.
5.4.1 Compressor
According to the cooling capacity, compressor type changes: see below the table with relation
between size and compressor type. The compressor has thermal protection from overload.
Size Compressor
WLA02 Alternative piston
WLA03 Alternative piston
WLA05 Rotary vane
WLA08 Rotary vane
WLA10 Scroll
WLA13 Scroll
5.4.2 Condenser
The condenser is copper-aluminium type, with copper pipes and aluminium ns. The chiller
cannot be use in environments with aggressive atmosphere.
On request there is the possibility to have the exchanger with cataphoresis treatment, tested
to resist with salt mist > 1000h. Other particular treatments for aggressive environments can be
evaluated on request.
5.4.3 Fan
Installed in the rear side of the condenser, it’s non-ductable suction type. The fan, with metallic
blades, it has metallic protection grid.
5.4.4 Evaporator
Plate condensers are used, made in stainless steel AISI 316 and brazed AISI 304.
WARNING
The liquid to be cooled must be conform to the prescriptions reported in paragraph 6.1.
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WLA COMPACT - TRANSLATION OF ORIGINAL INSTRUCTIONSWLA COMPACT - TRANSLATION OF ORIGINAL INSTRUCTIONS
5.4.5 Expansion valve
It’s mechanical type, based on pressure and temperature in base exiting from the evaporator
(compressor suction), adapts the refrigerant capacity to the evaporator. The adjustments for the
correct working are made by the manufacturer and cannot be altered afterwards.
5.5. Safety components of the refrigerant circuit
5.5.1 High pressure switch
A high pressure switch is installed on the refrigerant circuit and it triggers when the pressure inside
the refrigerant circuit exceeds 25 barg. The circuit compressor is deactivated and an alarm signal
appears on the electronic controller display. The alarm conditions stops when the pressure drops
below 17 barg.
5.6. Protection components of the refrigerant circuit
5.6.1 Refrigerant lter
A chiller lter is located in the liquid line of each refrigerant circuit. This lter holds the humidity
particles in the chiller.
5.6.2 Evaporator antifreeze protection device
The antifreeze protection device prevents the evaporator from freezing.
An evaporator outlet probe placed on the water circuit measures the temperature of the cooled
liquid. If this reaches values equal to or lower than the alarm threshold, the control disables the
cooling mode.
5.7. Components of the hydraulic circuit
5.7.1 Chiller
The standard hydraulic circuit includes an evaporator, two water probes, one on the inlet and the
other one on the outlet of the heat exchanger, a pressure gauge, a non-pressurised storage tank,
a pump and a protection ow switch.
The refrigerated water pipes are made of polyurethane and are equipped with quick coupling
connections. The chiller can be supplied in the following versions:
•Evaporator + Tank + centrifugal pump with standard prevalence.
•Evaporator + centrifugal pump with standard prevalence.
•Only evaporator, standard version.
Moreover, the following options are available and can be installed inside the chiller:
•Medium head centrifugal pumps.
•Non-ferrous crankcase and anti-freeze heater
5.7.2 Low temperature uid up to -5°C
Optional. For more information, please refer to paragraph 12.2.
2020