MDV HM/II-65S User manual

MCAC-ATSM-2014-11 Hydraulic Module 50Hz
1
Content
1 Introduction......................................................................................................................................................................2
2 Feature.............................................................................................................................................................................2
3 External appearance......................................................................................................................................................3
4 Nomenclature..................................................................................................................................................................3
5 Products list .....................................................................................................................................................................4
6 Application range.............................................................................................................................................................4
7 Specifications...................................................................................................................................................................4
8 Dimensions......................................................................................................................................................................5
9 Wiring Diagram................................................................................................................................................................6
10 Exploded views.............................................................................................................................................................7
11 Selection.......................................................................................................................................................................11
12 Key components configuration parameter..............................................................................................................11
13 Trouble shooting .........................................................................................................................................................12
14 Installation....................................................................................................................................................................13
Manufacture reserves the right to discontinue, or change at any time, specifications or designs without notices and without
incurring obligations.

Hydraulic Module 50Hz MCAC-ATSM-2014-11
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1 Introduction
The series hydraulic module is designed for air-cooled scroll chiller unit, it built-in two pumps, one is backup. The water pump can
be automatic switching under failure (malfunction shifting). It is the use of the hydraulic module integration solutions, is a
completely prefabricated sets strict monitoring of products, with a pump, valve, automatic replenishment, safety components,
bypass components, drain dirty sewage and control system, etc. For water cycle, constant pressure to supply water for all water
media transportation, for industrial, commercial and residential buildings, it is the best choice for water distribution system.
Capacity range:
Applies to air-cooled scroll chiller from 65&130kW.
2 Feature
2.1 Backup function
It built-in two pumps, one is backup. It can be automatically switched between two pumps in failure.
2.2 High-class main components
It adopts dustproof and waterproof designed for main components. For the pipe, it adopts brass, stainless steel or metal with
special coating and anti-rust treatment.
2.3 Intelligent control, energy security
The control cabinet can achieve linkage control with any formal air-condition mainframe through active or passive junction.
2.4 Easy installation and maintenance
The unit can be installed indoor or outdoor, suit for different customer’s requirement. There are screw connecting and flange
connecting, convenient for connecting.
2.5 Save the installation space and cost.
Integrated design, covering area is small. Intelligent control, it saves energy more than 30% than traditional. For air-cooled
scroll chiller, it’s no need expansion tank.
2.6 Fixed pressure replenishing water valve
It consists of reducing valve, stop valve and check valve. The automatic replenishment valve consists reduced pressure and
stable pressure device, the pressure value can be automatically adjusted and kept, which according to pressure gauge and the
replenishment valve scale, when the system pressure is low, it will be automatically open to filling water, automatically close
when the pressure up to setting value, avoid to damage system device cause of high pressure.
Maximum pressure of inlet water：10 bar
The pressure adjustment range：0.5～4 bar
Water flow signal output
Alarm signal output
To W1/W2 PORT of air cooled
scroll chiller
Hydraulic
Module
Power input
380V 3Ph~50Hz
Pump signal input
Signal from P1/P2 port of
air cooled scroll chiller

MCAC-ATSM-2014-11 Hydraulic Module 50Hz
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Setting pressure in plant：1.5 bar
2.7 More safety
The motor safety class is IP24, insulation class is F.
3 External appearance
4 Nomenclature
HM / VII –65 S
Power Supply
S: 380V, 50Hz, 3Ph
D: 220V, 60Hz, 3Ph
Rated cooling capacity (kW)
Water pump quantity
I: one pump
II: two pumps
Special function code
V: inverter pump
Omit for fixed speed pump
Hydraulic module

Hydraulic Module 50Hz MCAC-ATSM-2014-11
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5 Products list
Model
Water flow(m3/h)
Head(m)
Cooling capacity(kW)
Power supply
HM/II-65S
11
16
65
380V/3Ph/50Hz
HM/II-130S
22
17
130
6 Application range
Content
Running range
Running media
Water, Glycol
The fluid medium temp.
-20˚C～100˚C
Ambient temp.
-15˚C～46˚C
Power supply
380V/3Ph/50Hz
Voltage rating tolerance
±10%
Three-phase voltage imbalance
±2.25%
Power supply frequency
±2%
Three-phase current imbalance
±5%
7 Specifications
Content
Unit
HM/II-65S
HM/II-130S
Recommended cooling capacity
corresponding to the range selection
kW
65
130
Water flow
m3/h
11
22
Pump Head
m
16
17
Water pressure loss
KPa
16
17
Water tank volume
L
150
260
Pipe diameter (inlet & outlet)
mm
DN65
DN65
inch
2-1/2”
2-1/2”
Power supply
V/Ph/Hz
380V/3Ph /50Hz
380V/3Ph /50Hz
Unit rated input power
KW
2.2
4
Net size (L*W*H)
mm
1615×990×965
1705×1120×1050
Packing Size (L*W*H)
mm
1640×1026×1120
1721×1160×1225
Net weight
kg
290
400
Operation Weight
kg
310
420
Area
㎡
1.6 ㎡
1.9 ㎡

MCAC-ATSM-2014-11 Hydraulic Module 50Hz
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8 Dimensions
Unit: mm
HM/II-65S
HM/II-130S

Hydraulic Module 50Hz MCAC-ATSM-2014-11
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9 Wiring Diagram
HM/II-65S
HM/II-130S

MCAC-ATSM-2014-11 Hydraulic Module 50Hz
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10 Exploded views
HM/II-65S

Hydraulic Module 50Hz MCAC-ATSM-2014-11
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No.
Part Name
Qty
No.
Part Name
Qty
1
Middle support board
1
19
Base welded parts
1
2
Rear panel
2
20
Column II
1
3
Middle column
2
21
Handle
6
4
The welded parts of top cover
1
22
Front panel II
1
5
Column I
3
23
Soft rubber joint
2
6
Y-shape filter
1
24
Front panel I
1
7
Outlet water pipe ass'y of water tank
1
25
Outlet water pipe ass'y of water pump
2
8
Pumping rod type brass gate valves
2
26
Safety valve
1
9
Water pump return pipe ass'y
1
27
Support ass'y of total outlet water pipe
1
10
Outdoor unit electric control box ass'y
1
28
Support ass'y of expansion tank
1
10.1
Welded parts of electric control box
1
29
Water baffle II
1
10.2
Outdoor main control board ass'y
1
30
Connection pipe of expansion tank
1
10.3
AC contactor
2
31
Right side board
1
10.4
Transformer
1
32
Expansion tank
1
10.5
Seven Terminal Block
1
33
Inlet water pipe ass'y of water tank
1
10.6
Wire joint
1
34
Check valve
2
10.7
Terminal block
1
35
Welded parts of water tank
1
11
Left side board
1
36
Exhaust valve
2
12
Cover of electric control box
1
37
Target flow-volume controller
1
13
Pressure difference by-pass valve
1
38
Water charge valve
1
14
Water baffle I
1
39
Snap ring ass'y
2
15
Welded part of electric control box support
2
40
Total outlet water pipe ass'y
1
16
The belt of expansion tank
1
41
Compressor electric heater
1
17
Soft rubber joint
2
43
Cover of inlet/outlet pipe
1
18
Water pump
2

MCAC-ATSM-2014-11 Hydraulic Module 50Hz
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HM/II-130S

Hydraulic Module 50Hz MCAC-ATSM-2014-11
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No.
Part Name
Qty
No.
Part Name
Qty
1
Middle support board
1
19
Base welded parts
1
2
Rear panel
2
20
Column II
1
3
Middle column
2
21
Handle
6
4
The welded parts of top cover
1
22
Front panel II
1
5
Column I
3
23
Soft rubber joint
2
6
Y-shape filter
1
24
Front panel I
1
7
Outlet water pipe ass'y of water tank
1
25
Outlet water pipe ass'y of water pump
2
8
Pumping rod type brass gate valves
2
26
Safety valve
1
9
Water pump return pipe ass'y
1
27
Support ass'y of total outlet water pipe
1
10
Outdoor unit electric control box ass'y
1
28
Support ass'y of expansion tank
1
10.1
Welded parts of electric control box
1
29
Water baffle II
1
10.2
Outdoor main control board ass'y
1
30
Connection pipe of expansion tank
1
10.3
AC contactor
2
31
Right side board
1
10.4
Transformer
1
32
Expansion tank
1
10.5
Seven Terminal Block
1
33
Inlet water pipe ass'y of water tank
1
10.6
Wire joint
1
34
Check valve
2
10.7
Terminal block
1
35
Welded parts of water tank
1
11
Left side board
1
36
Exhaust valve
2
12
Cover of electric control box
1
37
Connection wires of water flow switch
1
13
Pressure difference by-pass valve
1
38
Water charge valve
1
14
Water baffle I
1
39
Snap ring ass'y
2
15
Welded part of electric control box support
2
40
Total outlet water pipe ass'y
1
16
The belt of expansion tank
1
41
Electrical heater of compressor
1
17
Soft rubber joint
2
42
Compressor electric heater
1
18
Water pump
2
43
Cover of inlet/outlet pipe
1

MCAC-ATSM-2014-11 Hydraulic Module 50Hz
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11 Selection
To confirm the hydraulic module, must be according to:
1. Air-cooled scroll chiller capacity.
2. Designed water volume.
3. Pump head.
Power supply: 380V/3Ph/50Hz
Hydraulic model
Water flow(m3/h)
Head(m)
Cooling capacity(kW)
Recommend combination capacity of air
cooled scroll chiller(kW)
HM/II-65S
11
16
65
25(30/35)+25(30/35)
55/60/65/70
HM/II-130S
22
17
130
25(30/35)+25(30/35)+25(30/35)+25(30/35)
25(30/35)+25(30/35)+55(60/65/70)
55(60/65/70)+55(60/65/70)
120/130
Note:
1. The hydraulic module is special matching to air-cooled scroll chiller.
2. Please make sure how many water system is need, each water system match the outdoor unit combined quantity and type.
3. Each water system design of pump head, please refer to flow-head curve.
12 Key components configuration parameter
No.
Name
Connection dimension
Parameter
1
Fixed pressure
replenishment valve
1/2'
Working pressure max.10bar；setting pressure：0.5-4bar；
setting pressure in plant：1.5bar
2
Automatic air valve
3/8'
Working pressure max.10bar；working temp. max.110℃
3
Safety valve
1/2'
Setting working pressure 6bar；working temp. range：-10℃～
+110℃
4
Water flow switch
R1'
Working pressure 10bar；working temp. max.100℃
5
Pressure by-pass valve
R1-1/4'
Working pressure 10bar；working temp. range：0～100℃；
setting pressure range:0.5～3bar
6
Expansion tank
G3/4'
Volume：12L
7
Pump
/
Power input:2.2kW(for 65kW)
Power input:4kW(for 130KW)
8
Filter with flange(iron)
/
Mesh:16
Flow-head curve (HM/II-65S)
Flow(m3/h)
Flow-head curve (HM/II-130S)
Flow(m3/h)
Head(m)
Head(m)

Hydraulic Module 50Hz MCAC-ATSM-2014-11
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13 Trouble shooting
Name
Phenomenon
Possible reasons
Solutions
Phase sequence
failure
The alarm signal output.
a. Phase sequence failure.
b. Lake phase.
a.Exchange two wires of them.
b.Check whether the circuit is loose,
please connect it again if yes.
The pump
overloading
protection
The power supply is normal,
linkage and manual didn’t start
pump.
The pump overloading
protection.
After cut off power supply, replace the
heating relay (press blue button),
restart power supply.
Passive interlock
connect to the
active interlock by
mistake
The pump didn’t run.
Linkage wire connecting is
wrong.
To make good connecting after
confirm the linkage signal type.
Contactor abnormal
noise.
Contactor makes abnormal
noise after close.
a. The contactor inside entered
dirty or quality problem.
b.The coil voltage is low.
c. Bad contacting for circuit.
a.Replace contactor.
b.Check the voltage is normal or not.
c.Wiring again to good connecting.
The contactor is
broken.
Power supply and circuit are
normal, can’t start it by linkage
and manual, the coil voltage is
normal.
Cut off power supply, press on
contactor by hand, the
contactor is broken if don’t
press down.
Replace contactor.
Relay failure.
Normally start pump by
manual, active start-up failure,
corresponding light is not on.
Relay failure.
Replace relay.
Water flow failure
The air cooled scroll chiller has
error signal output.
a.The system lack water.
b.The water flow switch
selection wrong.
c.Air in system.
a.Check the replenishment pressure
is normal or not.
b.Reset the switch type of main unit
flow or exchange flow switch.
d.Exhaust enough.
Pump with large
noise
The pump makes large noise
in running.
a.Pump reversal.
b.Dirty in system or pump lock
running.
c.Return water pressure is low.
d.Air in system.
e.Return air inlet bad seal.
a.Correctly adjudge the running
direction of pump by pressure gauge
and adjusting.
b.Clean Y type filter,(The Y type filter
must be installed, otherwise the
dirty enter into pump so that the pump
is broken, must be clean it after the
first time running )
c.Check whether the replenishment
water system is normal.
d.Correctly install exhausting valve
(make it on the top point of system),
exhaust enough.
e.Check whether the joint has smaller
hole in pipeline, and fully seal.

MCAC-ATSM-2014-11 Hydraulic Module 50Hz
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14Installation
14.1Dimension selection of pipe
Model
Unit
Water
inlet/outlet
Expansion
tank
Pressure
by-pass valve
Fixed pressure
replenishment valve
Safety
valve
Automatic air
valve
HM/II-65S
mm
DN65
/
/
/
/
/
Inch
2-1/4'
G3/4'
R1-1/4'
1/2'
1/2'
3/8'
HM/II-130S
mm
DN65
/
/
/
/
/
Inch
2-1/2'
G3/4'
R1-1/4'
1/2'
1/2'
3/8'
14.2 Installation introduction and key points:
1. Water quality requirement: pay attention to the problem of used water, scale and sundries will bring great impact to the normal
operation of the system. At the beginning of the system operation, the filtering net inside the Y-shape filter should be washed from
time to time.
2. When connect pipe (include flexible pipe), please lock module pipe orifice and water pipe joint respectively in order to avoid the
module set water pipe be damaged by large torque, result in water pipe cracking and leakage.
3. In order to improve the efficiency of water system, must proceeding pipeline air exhaust, can install vent valve at the top of
pipeline system.
4.The following is the connection schematic of air cooled scroll chiller water system.
9
4
5
1
6
DN65
DN65
DN15
DN32
F
Auxiliary electric heater
unit
unit
Terminal
Terminal
Two-way valve
Terminal
Three-way valve
2
3
2
789
10
11
No.
Name
No.
Name
No.
Name
1
Water flow switch
5
Y-shape filter
9
Check valve
2
Automatic discharge valve
6
Water storage tank
10
Pressure relief valve
3
Water replenishment valve
7
Circulating pump
11
Pressure by-pass valve
4
Expansion tank
8
Flexible joint
The above view is the situation of installing the hydraulic module in the front of the module unit, then can directly use this unit;

Hydraulic Module 50Hz MCAC-ATSM-2014-11
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4
5
6
DN65
DN65
DN15
DN32
F
unit
Auxiliary electric heater
Terminal
Two-way valve
Three-way valve
unit
21
3
2
78
10
9
11
Terminal
Terminal
No.
Name
No.
Name
No.
Name
1
Water flow switch
5
Y-shape filter
9
Check valve
2
Automatic discharge valve
6
Water storage tank
10
Pressure relief valve
3
Water replenishment valve
7
Circulating pump
11
Pressure by-pass valve
4
Expansion tank
8
Flexible joint
The above view is the situation of installing the hydraulic module in the back of the module unit, it must change the by-pass valve
of pressure difference to the position displays in the figure.
5. If the module operates at lower temperature environment or don’t use it for a long time, please add ethylene glycol and propyl
alcohol mixture into water system to avoid freeze off, or drain off the water.
14.3 Installation introduction and key points:
(1) Operation instruction:
○
1 .Position：
It can be laid out flexibly in the basement, roof, garage and outdoor module room. It can also be placed in the open air. It has
unique waterproof casing design, which is specially designed for the layout of outdoor equipment group.
○
2 .Foundation：
Installation foundation.
The central drainage device to be needed when the hydraulic module is installed indoor.

MCAC-ATSM-2014-11 Hydraulic Module 50Hz
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417
854
780417
HM/II-65S
HM/II-130S
○
3 .Hoisting emplacement：
If set on rooftop，hydraulic module will set a supporting point at the bottom，which can undertake hoisting carrying capability. If set
indoor, it only needs to configure a trailer, drag it to indoor location specified. Please provide sizes and weights of each type of
hydraulic module, convenient to hoist and make a hole in place. Please keep the body in good packaging before installation.
Please take care of handling, guarantee the body which is vertical and have a slope less than 15 °. Please avoid hitting other
objects when installing, and put it placidly to avoid sliding.
○
4 .Pipe installation:
Provide pipe installation schematic drawing, and the name of connection orifice should be shown at the position of waterpower
module orifice, convenient to connect system pipeline to adopt flange interface.
○
5 .Pressure testing:
The module has a strict strength and leak testing before leaving factory. The proposal testing pressure does not exceed 0.6 MPa.
After finished installation, it will be tested for system and fully pipeline together, the safety valve will be not closed.
○
6 . Trial run:
Electric principle diagram will be provided, there are observation failure indicators in the electric control cabinets, understand
module and system operating conditions by visual observation. Please clean well the pipeline, and before trial run, turn on the
drainage valve for filtering component of the module and check pipeline cleaning status.
○
7. Acceptance:

Hydraulic Module 50Hz MCAC-ATSM-2014-11
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Make sure the linkage with the main unit device is normal, confirm the action of flow switch, confirm the operation status of pump,
confirm the visual value on the hydraulic module dial is normal or not, and confirm whether the phase sequence protection,
water-lacking protection, overload protection and other functions are normal.
(2). Special attention:
(1). Pay more attention to protect the units which is safe, as can as keep moving and placing smoothly, confirm equipment is not
damaged.
(2). Electric mounting must be done with the supervision of qualified electrician. Electrical installation and wiring must meet the
relevant standards.
(3). The power wire of units and signal wire must be separated，it can’t parallel to the wiring, otherwise it will not make the units
working normal.
(4). When installation and using process, should notice electric shock.
14.4 Transfer and installation site
(1). Before the transport, please make sure if the lifting equipment is reliable enough and please do not use poor lifting
equipment.
(2) Please use correct transfer route before transfer to prevent the external structure damaged in transfer.
(3) Please don’t tear down the packing of the hydraulic scroll before arriving installation position. Don’t scratch the units if it must
be dismantled. Lifting should be done as the packing direction and added two guard plates, in case of damage or deformation.
(4) When suspension module to moving, please use the flexible sling in order to avoid damage and scratch.
(5) Please carry the products together with external package. If it has to be opened, please use protecting templates or cardboard
to protect module.
(6) For safety, please move slowly when using chain pulleys to lift and transfer.
(7) Please don’t touch such objects as the wall, column, door, lamps and so on to avoid damage to the module.
(8) When moving on the ground, please use roller to doing traction assignments, and ensure that there is at least four rollers to
work together.
(9). While modules are in handling or moving, please try to remain horizontal and never tilt the product above 15o.
(10).The unit can be installed on the rooftop, the balcony or outside the yard .It should be noticed whether the bearing surface is
sufficient strength to withstand the weight when the unit operates. The field intensity must be strong enough, not easy to cause
resonance and noise.
(11).The unit should not be installed in the occasion filled with dust, pollutants, corrosive gas and humidity.
(12). In the occasion for unit installations, enough space must be kept for cooling and convenient to installation and maintenance
person to pass through.
(13).Keep the ambient temperature surrounding the units between 0 ~ 40℃, never more than RH75 %. Please keep sufficient
ventilation and less dust.
14.5 Power supply

MCAC-ATSM-2014-11 Hydraulic Module 50Hz
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(1). Power supply of the unit must be connected (switching-on) strictly on the basis of electric requirements. Please don’t share
power lines with other appliances.
(2). Please ensure that the unit is reliably grounded, prevent leakage accidents when installing.
(3). Operating power supply
◆Allow voltage range: rated voltage ±10%
◆Allow frequency range：Rated frequency ±2%
◆Allow three-phase voltage unbalance：±2.25%
◆Allow three current imbalance: ±5%
(4). Power supply of unit distribution (the distribution of the unit) must be connected strictly on the basis of Hydraulic module
circuit diagram in order to ensure proper operation.
User connecting: 1, 2, 3, 4, all of others are wired in plant (Please refer to the wiring diagram on page 9).
(5). Electric parameter of the unit nameplates is the quantitative value under standard running conditions. The selection of
miniature circuit breaker, AC contactor, wiring capacity and so on has been considered while the module is operating under the
harsh conditions.
(6). System control consists of electric control cabinet, temperature sensor, flow switch and so on.
(7). Control box can realize linkage and connected controlling through active contact, passive contact and any kind of central
air-conditioner main unit. What’s more, it can control the operation of corresponding pump and fan by receiving operation signal.
14.6 Starting- up the first time
(1)Preparation
○
1 Check the status of all valves.
○
2 Check whether the water is full.
○
3 Check all wiring is correct.
(2). Starting-up and checking
◆Switch on general power supply.
◆Check whether the units' phase sequence is correct.
1
2
3
5
6
7
8
9
10
4
No.
Content
1,2,3,4
Power input
5,6
Pump ON/OFF signal input
7,8
Water flow ON/OFF signal output
9,10
Alarm ON/OFF signal output

Hydraulic Module 50Hz MCAC-ATSM-2014-11
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Attention!
Frequently start-up would impact the lifespan of unit. Strongly recommend: When the units started up, don’t frequently start or
stop the units. Don’t dump directly if it's out of necessary.
14.7 Commissioning
(1). Check whether the unit is well earthed.
(2). Check whether the air-conditioning and earth source recycle system are filled with water, whether the pipeline is emptied, the
replenishing water valve is on or not.
(3). Check whether all valves of pipeline are on correct status.
(4). Check whether the voltage of power supply is correct.
(5). Check whether the main pressure gauge is normal.
(6). Check whether the terminal equipment operate normally.
(7). Start up the water pump and confirm its running direction firstly. Check whether the water flow switch is normal. Check the
replenishing water source and turn on the exhausting valve to empty air in pipeline.
(8). After finished checking water pump and water system, start to the running testing. Before starting the unit, please check
whether the power supply is normal. After that, please record the temperature and pressure from all points pipeline.
14.8 Safety in use
(1). Should close down immediately, dump, checkup and repair, if find following conditions:
A. Electrical machine current exceed 10% or above of rated current for a long time.
B. Machine set automatic stop and cannot automatic recovery operation.
C. Machine set start difficulty or cannot start.
(2). When machine set leave factory, paste different label at relevant position, please follow close to the line of rated regulations.
(3). Strictly prohibit operate each switch frequently.
(4). Main circuit power supply not be allowed break at the period of machine set normal use.
14.9 Maintenance
(1). All the devices have passed strict test in the company and they are in the best working state, so users need not adjust it
again.
(2). After 24hours' test run, you must clean the filter at water inlet end of water pump.
(3). Please do not operate each switch too frequently.
(4). Please cut off the power supply of device if you will not use it for a long time.
(5). When the device is running in winner, please pay special attention to the information below: If the temperature is below or
equal to 0℃, you shall check the thermal insulation effect of water pipes periodically and please do not cut off the power supply of
device. If you will not use the device for a long time in winner, please empty all of the water or the pipes may burst.