Model: FWS 20/30/40/50/60 MCC4

WATER COOLED MODULAR CHILLER

Chiller ProductsFCH07-2013/4

Contents

 

Page 1  

    

Product Nomenclature .............................................................................2  

Features................................................................................................3  

Engineering Specifications .......................................................................4  

General Data.................................................................................4  

Operating Range............................................................................6  

System Schematic Diagram.............................................................7  

Controller Features and Algorithm ....................................................8  

Sound Data ......................................................................................... 13  

Sound Pressure Level ................................................................... 13  

Equipment Selection ............................................................................ 14  

Dimensions ..........................................................................................21  

Wiring Diagrams ................................................................................... 22  

Installation .......................................................................................... 27  

Servicing and Maintenance .................................................................... 32  

Troubleshooting .................................................................................... 33  

Exploded View and Parts List ..................................................................34                            

© 2012 FRIMEC-INTERNATIONAL. All rights reserved.

Product Nomenclature

 

Page 2  

 

 Water-Cooled Modular Chiller

 

    

FWS 20 M C C 4              

4 R410A  

     

C Cooling Only       

C Product Generation  

    

M Modular Type     

20 Unit Size.  

    

FWS Water-Cooled Modular Chiller

Features

 

Page 3  

 

 Simple Installation

 

    

Safety Protection         

 Easy Maintenance

       

Flexibility & Energy Saving

 

     

High Efficiency

Compact and small footprint design of modular chillers minimizes the space needed for installation. The modular design reduces the cost of transportation and allows expansion of capacity when the needs arise in future, thus, reduce the initial investment.  The modular chillers have built in protections for all sub-system, i.e. refrigerant system, electrical system and water system. Various overload protection devices, phase protector, temperature sensor, pressure switch, flow switch, etc., have been installed to protect the system if it experiences any failure of components or abnormal external factors. With these safety measures, the system is able to deliver high performance and at the same time ensure safe operation at all time.  Wired LCD controller equipped with various operating mode, timer setting, temperatures display and self-diagnosis by error code. Through the precise and intelligent control algorithm, the load will be distributed evenly to all the modular chillers, thus greatly reduce the commissioning and troubleshooting time and prolong the service life of the compressors.  Various combinations of modular chillers provide great flexibility of matching the exact load demand of applications. Up to 4 units of modular chillers can be combined to provide the necessary capacity and allow future expansion through easy add-on features. Besides, the modular system is able to adhere to different load profile precisely and deliver highest performance at all load condition.  FWS series come with high efficiency dry expansion type shell and tube heat exchanger. The inner grooved copper tubes are accurately expanded and mechanically bonded to the end plates to produce a high performance heat exchanger.

Engineering Specifications

 

Page 4  

 

 

General Data - FWS – MCC4 Series (R410A)

Model FWS 20MCC4 30MCC4 40MCC4 50MCC4 60MCC4

Combination FWS 20 x 1 30 x 1 40 x 1 50 x 1 60 x 1

Nominal Cooling Capacity kW 70.2 107.2 146.4 186.7 230.0

RT 20.0 30.5 41.6 53.1 65.4

Nominal Input Power kW 14.8 22.6 30.6 39.2 48.3

Maximum Operating Current A 60 90 106 132 162

Minimum Power Distribution kW 21.9 32.8 42.8 54.5 67.7

Power Source V/Ph/Hz 380/3/50

Operation Control LCD Wired Micro-Computer

Compressor Type Hermetic Scroll

Quantity 2 3 2 2 2

Stage of Capacity Control 0-100% 2 0-100% 3 0-100% 2 0-100% 2 0-100% 2

Refrigerant

Type R410A

Number of Refrigerant Circuit 1 2 2 2 2

Expansion Device TXV

Charging Mass kg 14.0 17.0 22.0 28.0 36.0

Condenser

Type

Water Flow Rate m³/h 14.6 22.3 30.4 38.7 47.7

gpm 64.2 98.1 133.8 170.3 209.9

Water Pressure Drop kPa 10 14 22 27 33

ft.wg 3.3 4.7 7.3 9.0 11.0

Water Pipe DN DN65 DN65 DN80 DN80 DN100

Evaporator

Type Direct Expansion Shell and Tube

Water Flow Rate m³/h 12.1 18.4 25.1 32.0 39.5

gpm 53.2 81.0 110.4 140.8 173.8

Water Pressure Drop kPa 19 25 33 39 46

ft.wg 6.3 8.3 11.0 13.0 15.3

Water Pipe DN DN65 DN65 DN80 DN80 DN100

   Length mm 1940 1940 2320 2320 2320

   Width mm 540 590 740 740 740

Dimension Height mm 1400 1480 1720 1720 1720

Unit Weight kg 600 780 1150 1210 1270

Operation Weight kg 620 810 1190 1250 1320

 Note: 1. Products are tested in accordance to GB/T19409-2003. 2. Cooling capacity is based on 12°C entering and 7°C leaving chilled water temperature; 30°C entering and 35°C leaving cooling water

temperature. 3. Power supply is 380V/50Hz with allowable voltage fluctuation of ±10% 4. The manufacturer reserves the rights to make changes to the above specifications without prior notice.

Operating Range

 

Page 5  

Ente

rin

g c

oolin

g w

ater

tem

per

atu

re,

°C

  

  

Cooling   

FWS – MCC4                             

Leaving chilled water temperature,°C  

 

 

 

 

 

 

 

 

Page 6  

  

Controller Features and Algorithm  

 LCD Control Panel Operation Guide

  

1 2 3                

4              

5  

(1) Temperature display area (3) Clock display area (5) Error code display area

(2) Timer display area (4) Mode display area

  The control panel is a multi-color backlight LCD display. The LCD control panel supports the following functions:

 

a) Mode – Cooling b) Chilled water temperature display c) Real time display d) ON/OFF timer e) Operation status display f) Multi-color backlight g) Alarm and error code display h) Battery backup i) Key lock function j) Multiple operating parameters setting

 

Page 7  

 

Control Parameters Setting Menus By pressing the “MENU” button, the control panel will toggle through the list of as following:

a) Temperature Setting b) Time/Date Setting c) ON Timer Setting d) OFF Timer Setting

 Press “ENTER” button to exit from the Control Parameters Setting Menu. Detail steps of setting the menus are as following:

 a) Mode Setting

Under main interface, press < > and <MENU> simultaneously for 3 seconds to enter. Clock display area will show “0----“to indicate that password required to enter this setting. Set “1111” as password via navigation key and press <ENTER> to enter. Temperature display area will flash and showing the current mode setting. Press < > or < > to toggle through the modes. At the end of setting, press <ENTER> to exit.

 Note: Please DO NOT change mode of operation when unit is operating.

 b) Temperature Setting Menu

Press <MENU> button from under main interface to enter. Temperature display area will flash and showing the current temperature setting. Press < > (increase temperature) or < > (decrease temperature) to change the temperature setting. At the end of setting, press <ENTER> to exit.

 The temperature range is from 8°C to 25°C in COOL mode (default 12°C) and from 32°C to 50°C in HEAT mode (default 40°C).

Note: The temperature setting is based on Entering Water Temperature.

c) Time/Date Setting Menu Under main interface, press “MENU” button two times to enter. Clock display will flash to show the current time setting. Press < > (increase) or < > (decrease) to set time in minutes and hold for more than 3 seconds to set time in hours. Press < > or < > to toggle through the day of week. At the end of setting, press <ENTER> to exit.

 d) ON Timer Setting Menu

Under main interface, press <MENU> button three times to enter. Clock display and ON Timer symbols will flash to show the current ON timer setting. If the clock display shows “--:--“represents ON Timer for that particular day has not been activated. The ON Timer can be activated by pressing < > or < >. After the ON Timer being activated, the timer setting can be changed by pressing < > (increase) or < > (decrease) to set timer in minutes and hold for more than 3 seconds to set timer in hours. Press < > or < > to toggle through the day of week. Press <INFO> to disable ON Timer and at the end of setting, press <ENTER> to exit.

 Under the main interface, if ON Timer is activated, the Timer Clock symbol will be visible. If there is un-executed ON Timer for the day, the Timer Clock symbol and “ON” symbol will be displayed.

 

Page 8  

 

e) OFF Timer Setting Menu Under main interface, press <MENU> button four times to enter. Clock display and OFF Timer symbols will flash to show the current OFF timer setting. If the clock display shows “--:--“represents OFF Timer for that particular day has not been activated. The OFF Timer can be activated by pressing < > or < >. After the OFF Timer being activated, the timer setting can be changed by pressing < > (increase) or < > (decrease) to set timer in minutes and hold for more than 3 seconds to set timer in hours. Press < > or < > to toggle through the day of week. Press <INFO> to disable OFF Timer and at the end of setting, press <ENTER> to exit.

 Under the main interface, if OFF Timer is activated, the Timer Clock symbol will be visible. If there is un-executed OFF Timer for the day, the Timer Clock symbol and “OFF” symbol will be displayed.

 

f) Key-Lock Function Under the main interface, pressing <MENU> and <ENTER> buttons simultaneously for 3 seconds, control panel will display the symbol of a lock to indicated that the panel is being locked. When the panel is locked, only ON/OFF button is operational. To cancel the Key-Lock function, press <MENU> and <ENTER> buttons simultaneously for 3 seconds.

 

g) Operating Status Under main interface, pressing <INFO> button will enter Operating Status section. Press < > or < > to navigate through the parameters and press <ENTER> to exit.

 Temperature display area

Clock display area Description

C0 DIP switch status for main board

Hexadecimal, representing bit 7 - bit 0 of DIP switch

C1 Entering chilled water temperature

Correspond to AI04 temperature in main board #1

C2 Ambient temperature in main board #1

Correspond to AI01 temperature

C3 #1 Evaporator leaving water temperature

Correspond to AI02 temperature in main board #1

C4 #1 Condenser leaving water temperature

Correspond to AI03 temperature in main board #1

C5 #2 Evaporator leaving water temperature

Correspond to AI02 temperature main board #2

C6 #2 Condenser leaving water temperature

Correspond to AI03 temperature in main board #2

C7 #3 Evaporator leaving water temperature

Correspond to AI02 temperature in main board #3

C8 #3 Condenser leaving water temperature

Correspond to AI03 temperature in main board #3

C9 #4 Evaporator leaving water temperature

Correspond to AI02 temperature in main board #4

CA #4 Condenser leaving water temperature

Correspond to AI03 temperature in main board #4

 

Page 9  

 

h) Communication Under normal condition, indicator “COM” will flash and showing that signal is transferring Between wired controller and PCB.

 i) Water Pump

Indicator “PUMP” will ON when chilled water pump is operating.  j) Compressor

During normal operating condition, wired controller will show the compressor status via indicator . ON means 2 compressors is running while flash means only 1 compressor is running in a circuit 1 , 2 , 3 and 4 means circuit #1, #2, #3 and #4. “Error Code Display Area” will show the module address.

 k) Antifreeze (In HEAT mode only)

When ambient temperature and water temperature is too low during standby mode, Indicator “COOL” will flash to show unit is under antifreeze protection.

 l) Remote ON/OFF

When Remote ON/OFF contact is closed, the system will stop and wired controller will show “rOFF”. Manual reset is required to start the system again.

 m) Error Codes Display

When the unit is facing operational problem, the “Error codes display area” will display error codes to indicate the problem detected the interpretation of the codes are as following:

 

Page 10  

 

Error Code   

Description  

Remark Module

#1 #2 #3 #4

1 25 49 73 Water flow error (Evaporator) All modules stop (manual reset)

2 26 50 74 Water flow error (Condenser) All modules stop (manual reset)

3 27 51 75 Power failure All modules stop (manual reset)

4 28 52 76 Evaporator LWT too low Relevant module stop (auto reset)

5 29 53 77 Condenser LWT too low Relevant module stop (auto reset)

6 30 54 78 Condenser LWT too high Relevant module stop (auto reset)

7 31 55 79 Ambient temperature sensor error Antifreeze protection deactivate

8 32 56 80 Evaporator LWT sensor error Relevant module stop (auto reset)

9 33 57 81 Condenser LWT sensor error Relevant module stop (auto reset)

10 34 58 82 Chiller EWT sensor error All modules stop (auto reset)

11 35 59 83 Circuit #1 low pressure Comp #1 and #2 stop (manual reset)

12 36 60 84 Circuit #1 high pressure Comp #1 and #2 stop (manual reset)

13 37 61 85 Compressor #1 overload Comp #1 stop (manual reset)

14 38 62 86 Compressor #2 overload Comp #2 stop (manual reset)

15 39 63 87 Circuit #2 low pressure Comp #3 and #4 stop (manual reset)

16 40 64 88 Circuit #2 high pressure Comp #3 and #4 stop (manual reset)

17 41 65 89 Compressor #3 overload Comp #3 stop (manual reset)

18 42 66 90 Compressor #4 overload Comp #4 stop (manual reset)

19 43 67 91 Circuit #3 low pressure Comp #5 and #6 stop (manual reset)

20 44 68 92 Circuit #3 high pressure Comp #5 and #6 stop (manual reset)

21 45 69 93 Compressor #5 overload Comp #5 stop (manual reset)

22 46 70 94 Compressor #6 overload Comp #6 stop (manual reset)

23 47 71 95 Mode setting error* All modules stop (manual reset)

24 48 72 96 Chiller LWT sensor error* All modules stop (auto reset)  

Note: 1. Auto reset type – System will recover after particular alarm contact is closed. 2. Manual reset type – Error can be reset by i) restart the unit OR ii) press < > and <MENU> simultaneously for

3 seconds.

 

Page 11  

1m

1m

 

 

Sound Data  Sound Pressure Test Setup

         

1m 1m  

Microphone  

        

Test standard: JB/T 4330 – 1999   

Sound Pressure Level   Model

1/1 Octave Sound Pressure Level (dB, ref 20µPa) Overall (dBA)

Noise Criteria 125 Hz 250 Hz 500 Hz 1 kHz 2 kHz 4 kHz 8 kHz

FWS20 47 48 61 62 64 62 49 69 65 FWS30 48 49 63 64 66 64 51 71 66 FWS40 50 51 64 65 67 65 52 72 67 FWS50 51 52 65 66 68 66 53 73 68 FWS60 51 52 66 67 69 67 54 74 79

 

 

Sound Power Level   

Model 1/1 Octave Sound Power Level (dB, ref 1pW) Overall

(dBA) 125 Hz 250 Hz 500 Hz 1 kHz 2 kHz 4 kHz 8 kHz FWS20 54 55 68 70 73 70 56 77 FWS30 55 56 70 72 75 72 58 79 FWS40 57 58 71 73 76 73 59 80 FWS50 58 59 72 74 77 74 60 81 FWS60 58 59 73 75 78 75 61 82

 

Page 12  

 

 

Equipment Selection  

 

Selection Procedures To rate the performance of the chiller at different conditions, the System Performance Table which provided in the following pages should be referred to. The performance data is based on entering cooling water temperature and leaving chilled water temperature. To select a modular chiller, the following information is request:  1. Cooling or Heating load 2. Leaving water temperature. 3. Entering water temperature 4. Water flow rate.

 

 Knowing the chiller capacity, the leaving water temperature and either the entering water Temperature or water flow rate, unknowns can be determine by following formula:

 

 Chilled water flow rate: Cooling water flow rate:

  

. 3.6 x Q V =

4.18 x T

 (1)

 

. 3.6 x (Q+P) V =

4.18 x T

 (2)

 

W. here, V = Water Flow Rate, m³/h Q = Cooling/Heating load, kW

T = Water temperature difference, ˚C P = Input power, kW

 

 By knowing the above data, the suitable unit can be selected though System Performance table. The Water pressure drop can be found in the System Pressure Drop chart.  Example: System load = 270 kW cooling capacity. Entering water temperature 12ºC and leaving chilled water temperature is 7ºC. Entering cooling water temperature 25 ºC. Model: R410A and Cooling Only.  1. Calculate cooling capacity in tons of refrigeration:

 

 Cooling capacity, (TR) = 270 kW / 3.616 = 76.8 tons of refrigeration.

 

 From a cursory calculation, a model 80 tons of refrigeration, FWS80MCC4, is selected. FWS series basically are combinations of single modules, to achieve cooling capacity. For R410A, there are 5 single modules which is FWS20MCC4, FWS30MCC4. FWS40MCC4, FWS50MCC4, & FWS60MCC4. Table below shows the model and related combinations.

 

Page 13  

 

Model Quantity of module

FWS20 FWS30 FWS40 FWS50 FWS60 FWS20 1 - - - - FWS30 - 1 - - - FWS40 - - 1 - - FWS50 - - - 1 - FWS60 - - - - 1 FWS70 - 1 1 - - FWS80 - - 2 - - FWS90 - - 1 1 - FWS100 - - - 2 - FWS110 - - - 1 1 FWS120 - - - - 2  FWS80MCC2 is consisting FWS40MCC4 (2 module).  2. Determine the chiller performance based on designed parameters. Read the “Total CF”

(Cooling capacity correction factor) and “Power” (Power input correction factor) of a single module at the specified water temperature and entering cooling water temperature.

 FWS40MCC4: Capacity = 1.045 x 146.4 kW = 153.0 kW Power input = 0.916 x 30.6 kW = 28.0  Chiller capacity =153.0 x 2 = 306.0 kW Total power input = 28.0 x 2 = 56.0 kW

Cooling 

Model

Leaving Chilled Water Temp (°C)

Entering Cooling Water Temperature (°C)

20 25 30 35

Total CF Power CF Total CF Power CF Total CF Power CF Total CF Power CF

(kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW)

FWS - MCC4

5 0.943 0.816 0.907 0.895 0.864 0.979 0.821 1.073

6 1.048 0.833 1.006 0.920 0.962 0.993 0.916 1.089

7 1.088 0.838 1.045 0.916 1 1 0.952 1.093

8 1.126 0.843 1.084 0.921 1.037 1.005 0.988 1.099

9 1.168 0.846 1.122 0.926 1.074 1.011 1.023 1.104

10 1.206 0.840 1.160 0.931 1.120 1.017 1.060 1.120   

Note: Total CF = Total Capacity Correction Factor;

Power CF = Power Input Correction Factor

 

Page 14  

 

3. To determine the water flow rate via Formula (1) and (2):  FWS40MCC4  

. 3.6 x (153.0) Chilled water flow rate, V = = 26.4 m³/h

4.18 x 5  

. 3.6 x (153.0+28.0) Cooling water flow rate, V = = 31.2 m³/h

4.18 x 5  

 

  

     

 

Page 15  

  

System Performance Table   

Cooling 

Model

Leaving Chilled Water Temp (°C)

Entering Cooling Water Temperature (°C)

20 25 30 35

Total CF Power CF Total CF Power CF Total CF Power CF Total CF Power CF

(kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW)

FWS - MCC4

5 0.943 0.816 0.907 0.895 0.864 0.979 0.821 1.073

6 1.048 0.833 1.006 0.920 0.962 0.993 0.916 1.089

7 1.088 0.838 1.045 0.916 1 1 0.952 1.093

8 1.126 0.843 1.084 0.921 1.037 1.005 0.988 1.099

9 1.168 0.846 1.122 0.926 1.074 1.011 1.023 1.104

10 1.206 0.840 1.160 0.931 1.120 1.017 1.060 1.120

Note: Total CF = Total Capacity Correction Factor; Power CF = Power Input Correction Factor

 

Page 16  

Dimensions      

FWS20MCC4 

 

FWS30MCC4 

 

 

Page 17  

Pre

ssu

re D

rop

, (k

Pa)

 

  

 

Dimensions      

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FWS40/50/60MCC4 

 

Dimension (mm) 

A B C D E F G H I J K L M

FWS20CC4 1900 590 1400 1580 400 500 172 287 55 193 268 792 1360

FWS30CC4 1900 620 1482 1580 400 500 172 287 55 193 268 792 1360

FWS40/50/60CC4 2221 740 1720 1932 500 600 140 342 80 170 240 1000 1440

 

DUCTED AIR COOLED

©2013 FRIMEC International

A member of the TICA Group

Models: FSD 100/125/150/200/250/300A

Direct Expansion ProductsAir-CooledFDXA05-2010