WATER COOLED CHILLER

WSW Techno

2

70 years

3000 employees

50000 m²

400.000.000 €

120 Countries

6 production sites

20 Subsidiaries

137 Partners

1 Group

5 Brands

Headquarters

Subsidiary companies

Production

Partners

Cosmotec Premises

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120 Countries

20 Subsidiaries

137 Partners

Data Centre Comfort

TelecommunicationsIndustrial CoolingSpecialists in:

4

134R

a

St d

Versions

Indoor installation WSW Techno is designed to be used on any indoor installation. The electrical panel, with IP54 protection, guarantees an adequate security for electric and electronic components. The different options allow a further extension of the operating limits both at low and high temperatures of condensing water, to allow the correct operation with either dry coolers water (hight temperature), tower water (middle temperature) or well water (low temperature).

Gas R134aAll units of the WSW Techno range use refrigerant gas R134a, which ensures an higher cooling capacity with low footprint of the machine.The R134a assures a very low environmental impact, no impact on the ozone and a greenhouse gas coefficient lower than the usual refrigerants.

StandardThe Techno range expands the series of high efficiency chillers for industrial, IT and comfort applications, made by COSMOTEC.WSW are water condensed chillers for indoor installation, specifically designed to have high performance with small footprint.Efficency, strength and reliability at COSMOTEC levels.

Low NoiseWSW Techno is an highly silenced unit, thanks to the adoption of acoustic insulations, specifically designed and placed in the compressor compartment (ISO 3744).Available for all sizes of WSW Techno.

All versions have:

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Applications

Comfort

Air ambient temperature: -20°C / +45°C Water inlet temperature: +12°C / +22°C Water outlet temperature: +7°C / +18°C

Air ambient temperature: -20°C / +45°C Water inlet temperature: +0°C / +30°C Water outlet temperature: -5°C / +25°C

Air ambient temperature: -20°C / +45°C Water inlet temperature: +12°C / +20°C Water outlet temperature: +7°C / +15°C

Data Centre & Telecommunications

Process Cooling & Industrial Applications

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DimensionsDimensions

230 ÷ 430 kW (1) 460 ÷ 1530 kW (1)

1 compressor

Min MaxHeight 1880 mm 1970 mm

Lenght 1340 mm 1871 mm

Depth 3010 mm 4416 mm

Weight 2615 ÷ 3820 kg

(1) Condenser side: Water inlet temperature: +30°C Water outlet temperature: +35°CEvaporator side: Water inlet temperature: +12°C Water outlet temperature: +7°C

2 compressors

Min MaxHeight 1970 mm 2232 mm

Lenght 1871 mm 1931 mm

Depth 4558 mm 5390 mm

Weight 3785 ÷ 7800 kg

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Options

SoftstartDevice for reducing mechanical stress during compressor start-up. The device partialises the starting current of the compressors by reducing the stress on the power supply line and preserving the compressors’ components.

Automatic transfer switchThree-phase switch without neutral, with automatic or manual control (by key). Functions dedicated to network/backup unit installation, with checking function for the switching capability verify and backup unit test. Voltage and frequency control. Switch installed inside the electrical panel. Auxiliary contacts to report the line switching.

Magnetotermic switch (A.C.B.)The magnetothermic switches guarantee an high protection against inrush current, which can damage the downstream component. Thanks to the magnetothermic switch after the intervention it’s possible to restart the chiller without replace the components.

Energy meterMeter to control the electric energy required by the chiller. LCD display to visualize current values, voltage, instant values of the 3 phases, average and maximum historical values. It is possible to remote the data through ModBus RTU.This component is installed inside the electrical panel.

Power factor corrections capacitorsthe power factor correction capacitors can take back to a 0.95 cosφ the phase displacement, which can be caused by magnetic fields. The capacitors are managed by C2020 electronic control.

Flow switchComponent that verifies the flow of the fluid in the circuit. Installed on the return pipe to the chiller. The flow switch is electrically connected to the C2020 control and reports the absence of fluid circulation, preventing damage to the hydraulic components.

Antifreeze heatersElectric heaters controlled by C2020 prevent the icing of the fluid inside the hydraulic circuit. In case of particularly harsh work conditions the use of a correct amount of ethylene or propylene glycol is suggested.

Supply without refrigerant gasIt is possible to ship the chillers without the hazardous refrigerant gas, in case of particular conditions of shipment. In these cases the gas is substitute by nitrogen. the refrigerant charges are reported on the nameplate.

ContainerizationPut the chiller into the Container

Rubber Anti-vibration mountSupports specifically designed to bear the chiller weight and eliminate transmission of the vibrations to the underlying structure during operation.

Water filterThe metallic filters prevent the evaporator or condenser clogging caused by the dust in the water. The filters are installed at the evaporator or condenser inlet through Victaulic® connections.

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no.1no.2

Screw Compressor

Semi-hermetic ScrewThe heart of the COSMOTEC Techno range are the semi-hermetic screw compressors, specifically designed for air cooled refrigerant circuits. These compressors are able to compressing all the ecological refrigerant gases used by COSMOTEC. State of the art compressors, able to achieve high compression ratios with reduced consumption.Thanks to the compressor double screw system the gas is continuously compressed, allowing to maintain the rotation inertia of the compressor motor, avoiding overloads, electrical consumption peaks, reducing mechanical stresses, which are the primary cause of the reduction in the product life.

Sliding ValvesThrough a partialisation slide valve, regulated according to a 0-10 input, is possible to change continuously the refrigerant R134a compression, partialising the cooling capacity supplied.The correct compressor cooling is guaranteed by the refrigerant gas, which, in intake, flows through the rotor windings, maintaining the temperature within the limits provided by the supplier.

StartingA range of compressors with part-winding (WSW080-250, except WSW140) or star-delta (WSW140, WSW265-560) start-ups are available, depending on the size of the chiller. In both cases to limit the locked rotor current and reduce the stress of the component, the compressor is started with a load of 25%, increased up to 100% after the achievement of the total motor torque.

Two CompressorsThe screw compressors can reach a high cooling capacity with just 1 or 2 compressors installed, while maintaining an high efficiency at partial loads.

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Condenser

Shell & TubeThe Shell & tube condenser coils are made in carbon steel and inner pipes in copper.Externally fully treated with epoxy powders with same colour of the chiller (Standard Colour: RAL 7035, orange peel). Victaulic® hydraulic connections for a quick installation. The small dimension of the copper internal pipes maximizes the heat exchange from the refrigerant to water.

Double PassageThe double passage hydraulic circuit guarantees reduced dimensions with equal heat exchange. Furthermore supply and return lines are on the same side, simplifying the installation.An internal baffle force the flow to maximize the heat exchange.

Water flow:

Carbon steel case

Copper pipe

Double passage

Indipendent circuits

Victaulic® Connections

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Expansion valve

The evaporation of the refrigerant gas into the cooling circuits is guaranteed by latest generation electronic thermostatic valves. Together with appropriate pressure switches, temperature probes and the electronic controller C2020 the valves optimize the thermal exchange into the evaporator, preserving the upstream and downstream components from high temperatures or icing.The operating and calibration logic of the electronic thermostatic valves lies in the electronic controller C2020.

Quick start up with super heater control in order to achieve the full cooling capacity in less time

Wider working range operating limit increased compared to the mechanical expansion valve

Optimization of the exchange surface thanks to the correct evaporation of the liquid in each conditions

Compressor protected against the back liquid with pressure switch and probe installed on the lower line guarantees the complete transition to gas of the refrigerant before the inlet in the compressor

Humidity and liquid sightglass incorporated to check the status of the refrigerant

Safety capacitor for shut-down in case of failure of power supply, allows the complete closure of the valve to avoid the return of the liquid into the evaporator

Indipendent for each cooling circuit properly managed by electronic controller C2020

FEATURES

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Evaporator

Shell & TubeThe Shell and tube evaporator is composed by: small inner tubes made by copper, separation baffles for a better heat exchange refrigerant-fluid, outer casing carbon steel coated with suitable thermal insulation, in order to assure the entire range of operation of the chiller.Double cooling circuit and mono circuit water side, disposed in countercurrent flow to maximize the heat exchange between the refrigerant and the fluid, while keeping pressure losses very low on both circuits.Victaulic® water connections for quick installation of the chiller.

Two Refrigerant circuits (pipes) to maximize the heat exchange from the water to the gas

One Hydraulic circuits (casing) with very low pressure drop

Fully Insulated with adequate thickness with a special glass fibre, resistant to the atmospheric agents and U.V., and to reduce the yield loss

Differential Pressure Switch as standard, to check the flow through the evaporator and to guarantee its safety against icing, and stops the chiller functions in case of alarms

Victaulic® Connections for a quick installation

Carbon Steel outer casing + Copper pipes

FEATURES

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Structure

Standard Colour: RAL 7035, orange peel

Right side

Rear side

The main constructional elements of the chiller, like condensers, evaporator and compressors, also act as structure.Condensers and evaporator, specifically dimensioned, support the weight of the entire chiller even during handling. Pre-installed eye-bolts allow the lifting of the chiller by a crane. Predefined holes in the support structure allow the installation of anti-vibration mounts.

Full metal structure to ensure the resistant of the structure also during the movement operations

Epoxy powder for all the metal structure

Corrosion resistant parts guarantee for all the fixing small parts

Indoor installation

Lifting hook to safety handling the chiller

Predefined Anti vibranting Holes to correct install the anti vibranting kit

FEATURES

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Electrical Panel

Electric panel with big dimensions to allow installation of all options designed, installed in the front side of the chiller.Double or triple door, ventilated, equipped with external power switch and display to manage the chiller operating.Three-phase power supply 400V/50Hz or 460V/60Hz, secondary supply at 230V with internal transformer. The safety of the motors is guarantee by fuses and thermal protector.The inlet of the wires is from the top of the cabinet, through specific removable panels

Components and realization in accordance with CEI EN 60335-2-40, CEI EN 61000-6-1/2/3/4 standards and EMC2004/108/CE regulation.

Degree of protection IP54 for outdoor installation

Big dimensions to include all the available options

Double or Triple Door

Display with transparent protection panel, to manage the chiller

General Lock Door to guarantee the safety of the user

FEATURES

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Movements

HandlingThe WSW chillers can be handled with cranes or ropes and sling lifting. The chiller is equipped with specific eyebolts, purposely designed to handle all the weight of the chiller.

ContainerizationWSW can be put in 20 or 40 feet container. To do this is necessary a pallet under the chiller.COSMOTEC suggest the use of case or cage to protect the components.

ForkliftOnly with a special pallet under the chiller is possible to handle and move the WSW with a forklift

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Display Touch

The user interface to the electronic controller C2020 is a 7” colour touch screen display, with synoptic useful menus. All the chiller’s data, warnings and alarms will be shown on the display.The menus are available in many languages: Italian, German, English, French, Russian, Spanish.

7” tft-lCd graphical color display

Resistive Touch Screen

LED backlight

800 x 480 px resolution

Operating limits from -20 up to +60°C

Buzzer

4 diagnostic LEDs on pannel

Frontal protection IP66 for outdoor installation

Example of the synoptics menus:

Language

Alarms

Circuit n°2

Circuit n°1

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The “mind” of the COSMOTEC Techno Screw chiller is the C2020 electronic control, developed by COSMOTEC to achieve the best performance from every component. In the Techno range with screw compressors have been implemented new functions in order to obtain the best management of the new components. Memory and calculation speed are increased, allowing a better and faster control of all the components and preserving the durability of the units. The numerous functions and parameters are summarized in a few simple steps and screens, which allow the user to easily keep under control the chiller correct operation. A 7” liquid crystal display with touch screen acts as an interface between the user and the chiller. The display reports all the information on: operation status, working time, alarm history and alarm signals. Furthermore it allows to start, stop and modify the chiller operation.

C2020 Electronic Control

C 2020 Electronic Controller is equipped with the following pre-loaded functions :

• Sequencing = to connect through a specific line more chillers and manage the components as a unique chiller

• Emergency Cooling = to activate the chillers in the same line, in case the active chiller cannot make up for the overload of the user.

• Redundancy = activates alternatively the chillers and guarantees the service continuity in case of fault of a chiller.

• ModBus RTU = to manage remotely the chiller through standard interfaces

• COSMOTEC Protocol = to connect the chiller to the COSMOTEC supervision components

• Unloading = guarantees the chiller partialised operation even at high temperatures

• Antifreeze

C 2020 Electronic Controller manages :

• Compressors = start, switching off and slide valve partialisation, within the limits provided by the supplier

• Electronic Thermostatic Valves = partialises the refrigerant evaporation to obtain the requested power with the lesser electrical consumption

• Fluid side pumps (not included) = the electronic control manages the redundancy in case of installation of 2 pumps, in order to maintain the working time of the pumps as similar as possible.

• Condensing valve (not included) = partialising the 2-ways valves, to regulate the condensation.

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Low Noise

In the WSW Techno the noise can be made by the compressors. It’s possible to reduce the noise level (about -10 dB) selecting the Low Noise Version of WSW Techno.

The noise is reduced with the following solutions:

Acoustic InsulationIn WSW Techno a textile fibre of polyester vane cover each compressors.The vanes are made by metal sheet powdered in the same colour of the chiller. The vane allow the complete access to the compressors electrical box.

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WSW Techno chillers is developed to cover an entire range of applications (from process industry to data centers). The Techno units are designed for a high energy class (Class A or B) or to work in extreme environmental conditions. They also come in very precise configurations with temperature controls dedicated to the application.

In almost all applications, the thermal load and ambient temperature conditions are highly variable. WSW Techno units closely match all environmental and load conditions, achieving a high seasonal efficiency (ESEER) – even higher than 5. High ESEER values lead to significant energy savings.

EER - ESEER - IPLV

IPLV = 0.01 x EER100% + 0.42 x EER75% + 0.45 x EER50% + 0.12 x EER25%

Iplv: Integrated Part Load ValueThe Integrated Part Load Value (IPLV) is a performance characteristic developed by the Air-Conditioning, Heating and Refrigeration Institute (AHRI). It is most commonly used to describe the performance of a chiller capable of capacity modulation. Unlike an EER (Energy Efficiency Ratio) or COP (coefficient of performance), which describes the efficiency at full load conditions, the IPLV is derived from the equipment efficiency while operating at various capacities.

Eseer: European Seasonal Energy Efficiency RatioThe seasonal energy efficiency index is a parameter that indicates the seasonal efficiency of an air conditioner or a refrigerator group. The parameter is defined by the Eurovent Certification Company.

ESEER = 0.03 x EER100% + 0.33 x EER75% + 0.41 x EER50% + 0.23 x EER25%

Eer: Energy Efficiency RatioThe Energy Efficiency Ratio (EER) of a particular cooling device is the ratio of output cooling energy to input electrical energy at a given operating point. EER is generally calculated using a 35°C outside air temperature and an inlet water temperature at 12 °C, outlet water temperature at 7°C.

EER = Cooling CapacityW7L35 / Power consuptionW7L35

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Quality

Maximum ReliabilityThe WSW Techno units are designed to guarantee the integrity during the transport both on road and in container, thanks to their sturdiness and flexibility. The components assembly is realized to ensure the maximum reliability and accessibility during the maintenance.The double refrigerant circuit with semi-hermetic screw compressors guarantees the best performance at different loads, paying particular attention to intensive uses (h24/365) and providing extra durability.

COSMOTEC QualityAll the chillers are designed and produced in compliance with:

- UNI EN ISO 9001: Quality Management System, - UNI EN ISO 14001: Environmental Management - 2006/42/EC: Machinery Directive - 2006/95/EEC: Low Voltage Directive - 2004/108/EEC: EMC Directive - 97/23/EC: Pressure Equipment Directive - EN 378-1, 2, 3, 4: Refrigerating systems and heat pumps - EN ISO 12100 -1, 2: Safety of machinery - EN ISO 13857: Safety of machinery - Safety distances - EN 60204 -1: Safety of machinery - Electrical equipment - EN 61000-6-2: Immunity for industrial environments - EN 61000-6-4: Emission standard for industrial environments

In all phases of design and production the compliance with these standards and directives are checked by an independent quality management.

Component and TestThe components installed in the COSMOTEC Techno are from well-know manufacturers, and sampling con-trolled at the arrival of the shipment by the Quality department.The finished chiller undergoes a function and leak tests, including:

- Visual inspection of the correct assembly - Leakage test with detector of the cooling circuits - Leakage test of hydraulic circuit - Programming and setting the electronic controller C2020. - Control of the calibration of sensors and probes - Functional test and alarm check - Unit labeling, documents and complementary material

The certificate is included with the documentation pack.

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RE

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1

SHEL

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PZH

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PSL

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TT 1

PT 3 TCE 1

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PT 1

PZH

H2

PSL

2

TT 2

PT 4

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2

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2

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SHELL & TUBES EVAPORATOR

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M2

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WAT

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TT 7 TT 4

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Refrigeration CircuitLegend

SYMBOL DESCRIPTION

refrigerant circuit

water circuit

signal line

lift check valve

disconnectable joint

Msemihermetic screew compressor

Shell and tube heat exchanger

vessel

H manual valve disconnectable

filter

TCE electronic expansion valve

TT temperature transmitter

PZHH safety pressure cut out

PD-ZAL 0

differential pressure switch

Mmotorized valve

disconnectable check valve

safety check valve

RE anti freeze heater

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STULZ S.p.A. Via E. Torricelli, 3 37067 Valeggio s/Mincio (VR)Tel. +39 045 6331600 Fax +39 045 6331635 info@stulz.it - www.cosmotec.it