MAXA R407C User manual

MODULAR AIR COOLED LIQUID CHILLERS AND HEATPUMPS
WITH AXIAL FANS AND SCROLL COMPRESSORS FROM 30 kW
TO 520 kW.
AIR CONDITIONING
R407C
A21
TECHNICAL MANUAL
Serie/Series/Serie/Série Emissione/Edition/Au-
sgabeIssue
CD 30÷520 05.07
Catalogo/Catalogue/Katalog/Brochure Sostituisce/Superseedes
Ersetzt/Remplace
MTE0112560020
02.07

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CONTENTS
Modular Air-cooled Chiller System
1- Modular air-cooled Chiller System
1. Summarization ..........................................................................5
2. Nomenclature ............................................................................6
3. Outlook view..............................................................................6
4. System principle figure ..............................................................7
5. Specification ..............................................................................11
6. Sound pressure level.................................................................15
7. Digital scroll compressor ...........................................................19
8. The capacity control of the new modular chiller.........................21
9. Advantages of digital scroll compressor ....................................23
10. Features ....................................................................................30
11. Unit installation ..........................................................................32
12. Water system installation...........................................................35
13. Debugging .................................................................................39
14. Maintenance..............................................................................43
15. Troubles and solutions...............................................................46
16. Wiring diagram (main unit) ........................................................47
17. Wiring diagram (auxiliary unit) ...................................................49
18. Wiring & communication diagram..............................................50
19. Installation system figure ...........................................................51

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2- Electric control
1. Outlook view .............................................................................51
2. parts descriptions......................................................................52
3. Failure & protections codes ......................................................57
3- Wire controller
1. Outlook view .............................................................................59
2. Pattern & buttons description....................................................60
3. Basic operating conditions ........................................................62
4. Function description..................................................................63

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Air-cooled heat-pump module unit
1.Summarization
Maxa Commercial Digital scroll air-cooled heat-pump module unit is designed and produced on
the basement of sufficiently absorbing the top technology in AC areas, adopting self-control
components with high quality made by world famous producers. Moreover, after optimizing, unit can
run more efficiently and more stably. One 60kW module consists of two 30kW units, and several
modules can be formed into a digital scroll air-cooled heat-pump module unit by connecting each
module’s inlet & outlet pipeline in series. The whole unit consists of 1-8 modules (or 2-16 units) and
the max capacity is 480kW(520kW).
Maxa Commercial Digital scroll air-cooled heat-pump module unit can be used widely in civil
construction of AC engineering and industrial engineering, such as hotel, villa, restaurant, hospital,
factory, etc. It is a wise choice for areas where water is insufficient or there are strict limits on noise
level and surroundings.
Relevant noun description:
 Unitüüone independent outdoor unit, including two entire refrigeration system and one
electric controller.
 Main controller üüevery electric control system of unit can accomplish the following functions
independently: Mode input; Data collection; Output interface control; Failure alarm analyzing.
 Digital scroll air-cooled heat-pump module unitüüa unit consists of one or more(1÷8) than one
modules (2÷16 units).
 Wire Controllerüüthe interface between the module and human, it can receive the operation
command and sent them to main controller, meanwhile receive the running state data and
display them.

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2. Nomenclature
3. View of 30kW module (composed by just one basic unit)
Cooling capacity (kw)
A: Auxiliary unit
M: Main unit
Digital
Chiller
C D – M 30

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View of 65kW module (composed by two basic unit)
4. Principle of system
Basic unit “Main and Auxiliary” from 30kW of cooling capacity is equipped with two independent
refrigerant circuits, with two compressors (1 digital, 1 fixed), just one plate heat exchanger and just
one control main board.
Basic unit “Main” from 65kw is the melt of two basic units of 30kW, so it is composed by 4
independent refrigerant circuits, 4 compressors (1 digital, 3 fixed), 2 plate heat exchanger and 2
control main boards.
Basic unit “Auxiliary” from 65kw is the melt of two basic units of 30kW, so it is composed by 4
independent refrigerant circuits, 4 fixed compressors, 2 plate heat exchanger and 2 control main
boards.

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Numbers of modules can be assembled together into a large unit by connecting each own inlet &
outlet pipeline in series; can be connected together modules from 30kW and from 65kW of cooling
capacity until 16 units and 520kW of cooling capacity; here below you can see the connection
principle:
Two modules 30kW connected in series

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Two modules 65kW connected in series
Two modules, one of 65kW and one of 30kW connected in series

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To correctly operate the unit and ensure normal and safe running when the outdoor Temp is
under 0°C in winter, the following should be noticed:
 If the unit will not be used for a long time, please drain water away to prevent the plate heat-
exchanger from freezing.
 If it is used frequently, it is absolutely forbidden to switch off the power, because the unit has
auto anti-freeze function. Moreover, in order to protect the plate heat-exchanger from freezing
in case the unit stops at night, and it must add some anti-freeze mixture to water system such
as glycol or propylene glycol.
 Water flow switch should be installed correctly; otherwise, the unit may be damaged. What’s
more, the water flow switch should be Queryed periodically if it is work normally.
 If malfunctions occur, it is absolutely forbidden to turn on the unit before the problems are
solved. At the same time, please drain water away to prevent the plate heat-exchanger from
freezing.

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5. Specification
CD
Model 30 65 95 130 160 195 225 260
KW 65 95 130 160 195 225 260 240
Cooling
Capacity *1000 kcal/h 55.9 81.7 111.8 137.6 167.7 193.5 223.6 206.4
KW 69 101 138 170 207 239 276 256
Heating
capacity *1000 kcal/h 59.34 86.86 118.68 146.2 178.02 205.54 237.36 220.2
Cooling input kW 10 21.5 31.5 43 53 64.5 74.5 86
Heating input kW 9.8 21 30.8 42 51.8 63 72.8 84
Power 380V 3N50Hz
Control type Wire control
Safety protection device High/low-pressure switch, anti-frost switch, water-flow switch, over-load
protection, and power phases sequence protection.
30kW master+65kW master+
65 kW auxiliary modules 1+0+0 0+1+0 1+0+1 0+1+1 1+0+2 0+1+2 1+0+3 0+1+3
Compressor input kW 9 18.5 27.5 37 46 55.5 64.5 74
Refrigerant R407C
Refrigerant kg 4.5*2 4.5*4 4.5*6 4.5*8 4.5*10 4.5*12 4.5*14 4.5*16
Water flow volume
m3/h 1.45 3.11 4.56 6.62 7.67 9.33 10.78 12.44
Water resistance
loss kPa 29.4
Waterside
heat-exchanger Welding, stainless steel, plate heat exchanger
Max. Pressure
MPa 1.0
Water system
Water inlet/outlet
pipeline diameter 133mm
Type Fin coil
Air flow volume
*103m3/h 12 24 36 48 60 72 84 96
Air side
heat
exchanger Fan motor input
kW 0.7*1 0.7*2 0.7*3 0.7*4 0.7*5 0.7*6 0.7*7 0.7*8
L mm 1514 2492 2492 2492 2492 2492 2492 2492
W mm 850 2300 3450 4600 5750 6900 8050 9200
Dimension
(mm)
H mm 1820
30kW master 1620x1034x2041
65kW master 2612x1034x2041
Packaging
dimension
(mm) 65 kw auxiliary 2612x1034x2041
Total weight kg 440 700 1140 1400 1840 2100 2540 2800
Optional auxiliary heater kW 7.5 15 22.5 30 37.5 45 52.6 60

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CD
Model 290 325 355 390 420 455 485 520
KW 325 355 390 420 455 485 520 240
Cooling
Capacity *1000 kcal/h 279.5 305.3 335.4 361.2 391.3 417.1 447.2 206.4
KW 345 377 414 446 483 515 552 256
Heating
capacity *1000 kcal/h 296.7 324.22 356.04 383.56 415.38 442.9 474.72 220.2
Cooling input kW 96 107.5 117.5 129 139 150.5 160.5 172
Heating input kW 93.8 105 114.8 126 135.8 147 156.8 168
Power 380V 3N50Hz
Control type Wire control
Safety protection device High/low-pressure switch, anti-frost switch, water-flow switch, over-load
protection, and power phases sequence protection.
30kW master+65kW master+
65 kW auxiliary modules 1+0+4 0+1+4 1+0+5 0+1+5 1+0+6 0+1+6 1+0+7 0+1+7
Compressor input kW 83 92.5 101.5 111 120 129.5 138.5 148
Refrigerant R407C
Refrigerant kg 4.5*16 4.5*20 4.5*22 4.5*24 4.5*26 4.5*28 4.5*30 4.5*32
Water flow volume
m3/h 13.89 15.56 17 18.67 20.11 21.78 23.22 24.89
Water resistance
loss kPa 29.4
Waterside
heat-exchanger Welding, stainless steel, plate heat exchanger
Max. Pressure
MPa 1.0
Water system
Water inlet/outlet
pipeline diameter 133mm
Type Fin coil
Air flow volume
*103m3/h 108 120 132 144 156 168 180 192
Air side
heat
exchanger Fan motor input
kW 0.7*9 0.7*10 0.7*11 0.7*12 0.7*13 0.7*14 0.7*15 0.7*16
L mm 2492 2492 2492 2492 2492 2492 2492 2492
W mm 6650 6650 8100 8100 9550 9550 11000 11000
Dimension
(mm)
H mm 1820
30kW master 1620x1034x2041
65kW master 2612x1034x2041
Packaging
dimension
(mm) 65 kw auxiliary 2612x1034x2041
Total weight kg 3240 3500 3940 4200 4640 4900 5340 5600
Optional auxiliary heater kW 67.5 75 82.5 90 97.5 105 112.5 120

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3. surrounding Temp. of unit work is shown as follows웛
Name Cooling operation Heating operation
Water-outlet temperature 7°C ÷ 12°C 45°C ÷ 50°C
Air-side heat-exchanger
Air-inlet temperature 17°C ÷ 43°C -10°C ÷ 21°C
6. Sound pressure level
Note: Sound pressure level is measured on each side at 1500mm distance and 1660mm height.
This drawing shows the testing way of single module. When there are some module units combined,
the testing points on the side will be the center on the side of combined unit system.
Air outlet
Center D
Center ACenter B
Center C

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Noise specification(30KW & 65KW)
Noise dB(A)
Capacity
range (kW) Center A Center B Center C Center D Surface average noise
30     
65     
CD 30 Octave bandwidth analysis
Octave band center frequency
Sound pressure level [dB(A)]
Audibility limits of
continuous white
sound
Center A Center B
Octave band center frequency Hz]
Sound pressure level [dB(A)]
Audibility limits of
continuous white
sound
Octave band center frequency Hz]
Sound pressure level [dB(A)]
Audibility limits of
continuous white
sound
Octave band center frequency [Hz]
Sound pressure level [dB(A)]
Audibility limits of
continuous white
sound
Center C Center D

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CD 65 Octave bandwidth analysis
Octave band center frequency [Hz]
Sound pressure level [dB(A)]
Audibility limits of
continuous white
sound
CD30 Average sound pressure level on surface
Octave band center frequency [Hz]
Sound pressure level [dB(A)]
Audibility limits of
continuous white
sound
Center A
Octave band center frequency [Hz]
Sound pressure level [dB(A)]
Audibility limits of
continuous white
sound
Center B

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







Center C Center D
Octave band center frequency [Hz]
Sound pressure level [dB(A)]
Audibility limits of
continuous white
sound
Octave band center frequency [Hz]
Sound pressure level [dB(A)]
Audibility limits of
continuous white
sound
CD65 Average sound pressure level on surface
Octave band center frequency [Hz]
Sound pressure level [dB(A)]
Audibility limits of
continuous white
sound

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7. Digital scroll compressor
Digital scroll compressor is made up of following components: fixed vortex plate, movable vortex
plate, motor, suction and discharge pipeǃPWM(Pulse Width
Modulation) solenoid valve and so on. It differs from ordinary
scroll compressor: the compressor utilizes the axial flexible
sealed technology and PWM solenoid valve to precisely adjust
the axial moving range of the stator scroll plate. And there is an
additional connecting bypass at the suction inlet connected with
the middle pressure bore at the floating sealed point of axial
stator. When PWM solenoid valve is turned on, the pressure in
middle pressure bore is released. The pressure in compress
bore is higher than on the stator. The stator axis of the
compressor will move upward a little. So the unload is achieved.
When the solenoid is turned off, the stator is pressed down. Then the seal and upload is achieved.
The compressor plate can adjust the ratio of on and off freely to achieve the output of “0-1”, that is
Digital Scroll Compressor.
7.1 Flexible
The stator and rotor can move axially and radial in certain space and can separate under normal
condition.
7.2 Axial flexible sealed
There is about 1mm space for stator to move axially. Normally, under the action of gas pressure
(discharge pressure and middle pressure of compressor chamber), the stator and rotator can
combine tightly and form the sealing surface.
7.3 Pulse width modulate (PWM)
During half period of output voltage, the output voltage wave is divided into some pulse waves. Due
to the average output voltage and pulse duty ratio (pulse width dividing the pulse period is duty ratio)
is direct ratio, when modulating the frequency, not change the pulse width but change the pulse duty
ratio, thus realize variable frequency and variable voltage.

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7.4 Principle of Digital Scroll Compressor
The fixed vortex plate on the top is allowed to move upwards about 1
mm during the operation of the Digital Scroll. Lifting the top vortex
plate ensures that there is no pumping through the vortex plate, and
there is no mass flow through the compressor. This is the period of
zero capacity for the compressor. This state is called the “Unloading
State” of the compressor. The “Loading State” is the normal state
when the scrolls are operating normally like a standard scroll and the capacity is 100%. It is
important to point out that there is no bypass of gas in this operation. The principle of achieving
modulation is by alternately lifting and engaging the top vortex plate. A cycle time consists of a
“Loading State” time and “Unloading State” time. The duration of these 2 time segment determine
the capacity modulation of the compressor.
Example: the total capacity is 10HP, cycle time is 20 seconds. If the output power is 5HP(50%of
total capacity),the compressor modulation is(10 sec. h100%+10sec. h0%)/20sec.=50%. The
loading state time is 10 seconds and the unloading state time is 10 second. If the output power is
2HP( 20%of total capacity),the compressor modulation is 20%, the state time is 4 sec. and the

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unloading state time is 16 sec.the rest can be deduced by analogy. The following is schematic
diagram when output capacity is respectively 10%, 50% and 100%.
8. The capacity control of the new modular chiller
(1) Capacity adjustment of the system.
Only the main unit can control the capacity output according to the temperature of total output
water (Ts).
1. Cooling capacity adjustment
Please preset Ts (Ts=7ˈ8ˈ9ˈ10ˈ11ˈ12ć). Ts is 7ćin default.
At first, the main unit will calculate¥1 (¥1=Ts-7), then adjust the capacity output
according to T˄T=5ˈ6ˈ7ć˅+¥1(T means the real temperature of total outlet water). The
detail of cooling capacity adjustment is as following chart:
OFF
Ts
Cooling capacity adustment
2. Heating capacity adjustment
Please preset Ts (Ts=45ˈ46ˈ47ˈ48ˈ49ˈ50ć), Ts is 45ćin default.˗At first, the main
T
Regolazione della potenza di raffreddamento

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unit will calculate¥2 =Ts-45ˈthen adjust the capacity output according T˄T=44ˈ45ˈ46ˈ
47ˈ48ć˅+¥2 (T means the real temperature of total outlet water). The detail of heating
capacity adjustment is as following chart:
For example˖If the system have 11 sets of units, when T reduce to 45ćin HEATING mode,
the system will operate on 80%. So the actual operation units are 9 sets. (11*80%=8.8,adopts
9), and the main unit will stop two units which address is highest.
(2) Capacity adjustment of every one unit
Heating capacity adjustment
Temperature of heat exchanger
Cooling adjustment capacity in ON/OFF mode
Temperature of plate heat exchanger
Heating adjustment capacity in ON/OFF mode