Stulz WSA Explorer User manual

Index i09
Issue 01.2019
WSA Explorer
Original instructions
Water cooled liquid chillers
400V / ~3 / 50Hz

2EN/01.2019/i09 © STULZ S.p.A. – all rights reserved
WSA EXPLORER ORIGINAL INSTRUCTIONS
ABOUT STULZ
Since it was founded in 1947, the STULZ company has
evolved into one of the world’s leading system suppliers of
air-conditioning technology.
Since 1974 the group has seen continual international
expansion of its air conditioning technology business, spe-
cialising in A/C for data centres and telecommunications
installations.
STULZ has ten production plants (2 in Germany, Italy,
the USA, Great Britain, Spain, 2 in China, Brazil and India)
and twenty subsidiaries (in Germany, France, Italy, Great
Britain, Belgium, Brazil, the Netherlands, New Zealand,
Mexico, Austria, Poland, Spain, Singapore, China, India,
Indonesia, South Africa, Sweden, Australia and the USA).
The company also co-operates with sales and service
partners in over 140 other countries, and therefore boasts
an international network of air-conditioning specialists.
STULZ S.p.A.
via Torricelli, 3
37067 Valeggio Sul Mincio
Verona - Italy

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WSA EXPLORER ORIGINAL INSTRUCTIONS
WSA Explorer – High quality liquid
chiller made in Italy
Dear Customer,
Thank you for purchasing a STULZ chiller.
It is the result of many years of research and design studies, as well as a fine matching of materials
and technologies to obtain a high quality chiller.
The CE mark guarantees that the STULZ products fulfil 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
STULZ 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.stulz.it

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WSA EXPLORER ORIGINAL INSTRUCTIONS
Table of Contents
1. Introduction.................................................................................................. 8
1.1 Introduction.............................................................................................................................. 8
1.2 Warranty.................................................................................................................................... 8
1.3 Safety......................................................................................................................................... 9
1.3.1 Symbols used in the manual ....................................................................................................................9
1.3.2 Labels..............................................................................................................................................................9
1.3.3 Safety Instructions ...................................................................................................................................11
1.3.4 Handling refrigerants.............................................................................................................................. 11
1.3.5 Safety and environmental requirement............................................................................................. 12
2. Residual risk ............................................................................................... 13
2.1 Transport and installation ................................................................................................. 13
2.2 Start-up .................................................................................................................................. 13
2.3 Operation............................................................................................................................... 13
2.4 Maintenance ......................................................................................................................... 14
2.5 Dismantling ........................................................................................................................... 14
2.6 Safety Data............................................................................................................................ 14
3. Transport/ Storage.................................................................................... 16
3.1 Delivery of units ................................................................................................................... 16
3.2 Storage................................................................................................................................... 17
3.3 Transport................................................................................................................................ 17
3.3.1 Transport protection ...............................................................................................................................17
3.3.2 Centre of gravity........................................................................................................................................21
4. Description................................................................................................. 23
4.1 Type Code.............................................................................................................................. 23
4.2 Intended use......................................................................................................................... 24
4.3 Chiller Design ....................................................................................................................... 24
4.3.1 General......................................................................................................................................................... 24
4.3.2 Versions .......................................................................................................................................................24
4.3.3 Refrigerant Circuit....................................................................................................................................24
4.3.4 Compressor................................................................................................................................................25
4.3.5 Evaporator ..................................................................................................................................................25
4.3.6 Condenser ..................................................................................................................................................25
4.3.7 Electrical Cabinet ..................................................................................................................................... 26
4.3.8 Sensors........................................................................................................................................................26
4.3.9 SEC.blue...................................................................................................................................................... 26
4.4 Piping diagrams................................................................................................................... 27
4.4.1 Legend.........................................................................................................................................................27
4.5 Hydraulic diagrams............................................................................................................. 32
4.5.1 Legend.........................................................................................................................................................32
5. Technical Data ........................................................................................... 36
5.1 Application limits ................................................................................................................ 36
5.1.1 Storage conditions .................................................................................................................................. 36
5.1.2 Operating conditions...............................................................................................................................36
5.2 Chilled water quality ........................................................................................................... 38

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WSA EXPLORER ORIGINAL INSTRUCTIONS
5.2.1 Glycol correction factors........................................................................................................................ 38
5.3 Pressure Drops.................................................................................................................... 39
5.4 Head pressure available ................................................................................................... 40
5.5 Technical Data...................................................................................................................... 42
5.6 Dimensional drawings ....................................................................................................... 53
5.7 Electrical connection data ............................................................................................... 57
6. Installation.................................................................................................. 58
6.1 Positioning............................................................................................................................. 58
6.1.1 Minimum distance from obstacles or other chillers ...................................................................... 59
6.2 Weight on the supports..................................................................................................... 60
6.3 Refrigerant circuit ............................................................................................................... 63
6.4 External water circuit ......................................................................................................... 63
6.5 Water connection................................................................................................................ 65
6.6 Filling and bleeding air....................................................................................................... 66
6.7 Electrical connection ......................................................................................................... 67
6.8 Opening the electric cabinet ........................................................................................... 67
6.9 Position of the electrical connections.......................................................................... 68
6.9.1 Backup battery for E.E.V. .......................................................................................................................69
6.10 Pump control ..................................................................................................................... 69
6.10.1 System with external pump................................................................................................................69
7. Commissioning .......................................................................................... 70
7.1 Preparation............................................................................................................................ 70
7.2 First Startup.......................................................................................................................... 70
7.2.1 Oil pre-heating .......................................................................................................................................... 71
7.2.2 Commissioning of the chilled water circuit.......................................................................................71
7.2.3 Commissioning of the refrigerant circuit ..........................................................................................72
8. Maintenance............................................................................................... 74
8.1 Safety instructions.............................................................................................................. 74
8.1.1 Warning notes............................................................................................................................................74
8.2 Maintenance intervals ....................................................................................................... 75
8.3 Refrigerant Circuit .............................................................................................................. 75
8.3.1 Refrigerant charge...................................................................................................................................75
8.3.2 Quantity........................................................................................................................................................76
8.3.3 Tightness of refrigerant circuit............................................................................................................. 76
8.3.4 Purity............................................................................................................................................................. 76
8.3.5 Exchange of filter drier............................................................................................................................77
8.3.6 HP switch ....................................................................................................................................................77
8.3.7 LP switch.....................................................................................................................................................77
8.3.8 Safety valve.................................................................................................................................................77
8.3.9 Expansion valve......................................................................................................................................... 78
8.3.10 Compressor............................................................................................................................................. 78
8.4 Air circuit................................................................................................................................. 80

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WSA EXPLORER ORIGINAL INSTRUCTIONS
8.4.1 Condenser ..................................................................................................................................................80
8.4.2 Condenser Fan..........................................................................................................................................80
8.4.3 Filter.............................................................................................................................................................. 80
8.5 Evaporator circuit................................................................................................................ 80
8.5.1 Tightness..................................................................................................................................................... 81
8.5.2 Evaporator ..................................................................................................................................................81
8.5.3 Differential pressure switch.................................................................................................................. 81
8.5.4 Flow switch.................................................................................................................................................81
8.6 Electric circuit....................................................................................................................... 81
8.6.1 Powerboard................................................................................................................................................82
8.7 Unit in general ...................................................................................................................... 82
9. Malfunction ................................................................................................ 83
10. Dismantling and disposal.......................................................................... 85
11. Options ....................................................................................................... 86
11.1 Quick Start (with UPS).................................................................................................... 86
11.2 Automatic Transfer Switch (Double power line) ..................................................... 87
11.2.1 Turn on the unit....................................................................................................................................... 87
11.2.2 Turn off the unit.......................................................................................................................................88
11.2.3 Maintenance mode.............................................................................................88
11.3 AxiTop diffusor................................................................................................................... 90
11.3.1 Safety.........................................................................................................................................................90
11.3.2 Material .....................................................................................................................................................90
11.3.3 Installation................................................................................................................................................91
11.3.4 Maintenance............................................................................................................................................92
11.4 Refrigerant R513A.......................................................................................................... 93
11.5 Power factor correction capacitor.............................................................................. 94
11.6 Energy meter ...........................................................................................................................

7© STULZ S.p.A. – all rights reservedEN/01.2019/i09
WSA EXPLORER ORIGINAL INSTRUCTIONS
Subjet to change without notice

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WSA EXPLORER ORIGINAL INSTRUCTIONS
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 fitter and the
responsible trained staff/operators before assembly and commissioning. All procedures detailed
in the manual, including tasks for installation, commissioning and maintenance must only be per-
formed by suitable trained and qualified 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, com-
missioning, operation or maintenance resulting from a failure to follow the procedures and instruc-
tions detailed in the manual.
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 specified.
All warranty claims must specify the model and serial number of the chiller. This information is print-
ed on the name plate, fitted on the door from the electrical cabinet.
The warranty will be invalid in case of any modification on the chiller which is not written approved
from STULZ.
To claim any warranty purpose the following conditions need to be satisfied:
The initial startup of the chiller has to be carried out by trained personnel authorized from STULZ.
Only STULZ 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 qualified personnel.
Not fulfilling at least one these conditions will automatically void the warranty.

9© STULZ S.p.A. – all rights reservedEN/01.2019/i09
WSA EXPLORER ORIGINAL INSTRUCTIONS
1.3 Safety
1.3.1 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
1.3.2 Labels
Label recalling the instruction manual.
Location: on the side of the powerboard.
Entrance of the hydraulic circuit of
the chiller (inlet of the chiller).
Location: next to the inlet fitting of
the hydraulic circuit.
Exit of the hydraulic circuit of the
chiller (outlet of the chiller).
Location: next to the outlet fitting of
the hydraulic circuit.
Evaporator drain.
Location: next to the taps to empty
the evaporators.
Hot surface.
Location: in the proximity of the input / output pipes of condensers (under the pro-
tective casing) and on the compressors. With equipped antifreeze option, even in
the proximity of the heaters around the evaporator and the steel hydraulic piping.
Lifting point.
Location: near the lifting points on the base frame of the unit.

400/3/50 V
45 bar
85 °C
239/150,5 A
195 kW (W15L35)
45 °C
C1=16,5 - C2=16,5 kg
R410A
1900 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
89,6 kW (W25L45)
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
WPAR044207ZFT0 7035
N°0000408788
07/11/12
MODELLO - MODEL - TYP - MODELE
MADE IN ITALY
ORDINE - ORDER - ORDER - COMMANDER 2120002673
- 1 0 °C
TS MIN (Refrigerante - Refrigerant - Kaltemittel - Refrigerant)
26 bar
PS LP (Max pressione ammissibile LP - Max allowable pressure
LP - Max zulässiger Druck LP - Pression maximum admise LP)
II
CAT PED
Modulo valutazione - Evaluation Module - Bewertungsverfahren -
Procédure d'évaluation A1
0496
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WSA EXPLORER ORIGINAL INSTRUCTIONS
Discharge of the safety valves of the chiller.
Location: in the proximity of the refrigerant discharges of the safety valves.
Symbol Description
CE Units built in accord to the EC directives
0496 Reference number of the Technical File notified to
Approval Authority
EAC Units comply with EurAsian Conformity directives
Double Power
Supply
Double power supply (only if this option is present)
Rated Voltage Voltage - Phases - Frequency of the power supply
F.L.A. Maximum Absorbed current ofthe Main Power Supply
considering the toughest condition at the operating limit
of the unit
Auxiliary Power
Supply
Voltage - Phases - Frequency of the auxiliary power
supply
F.L.A. (Auxiliary
Power Supply)
Maximum Absorbed current of the Auxiliary power supply
considering the toughest condition at the operating limit
of the unit
Cooling Cap. Rated Cooling Capacitywith watertemperature 12 - 30°C
Refrigerant Type Refrigerant type used
Kg Refrigerant gas charge
Min/Max temp.
Storage
Maximum and minimum storage temperature (unit not
powered)
PS HP/PS LP Maximum working pressure permitted on the high pres-
sure side and minimum working pressure permitted on
the low pressure side.
TS Max. / TS Min. Maximum and minimum temperature reached by the
operating components of the refrigerant circuit
CAT PED Category complying with the Pressure Equipment
Directives
Evaluation
module
Conformity evaluation module according to the Pressure
Equipment Directives
Weight Unladen mass of the unit (without packing, but with the
refrigerant charge
CO2 Eq. Tons of Equivalent CO2 according to the FGas directives
(517/2014)
According to
Kyoto Protocol
According to Kyoto Protocol
Empty Space Empty for additional refrigerant charge added on the
installation site
Connecting hole for external earthing.
Location: on the base frame, close to properly designed holes.
The chiller is identified by the nameplate shown on the left.
The identification 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: on the side of the powerboard.