Models: FWSD040.1B1C2 – 225.1B1C2 FWSD170.2B1C2 – 450.2B1C2

WATER COOLED SCREW CHILLER

Chiller ProductsFCH04-2009

©2009 FRIMEC International www.frimec-international.com

A member of the TICA Group

Page 1

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

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

Engineering Specifications ................................................................ 5

General Data .......................................................................... 5

Operating Range ..................................................................... 9

System Schematic Diagram .................................................... 10

Controller Features and Algorithm ........................................... 11

Sound Data .................................................................................. 22

Sound Pressure Level ............................................................ 23

Equipment Selection ..................................................................... 25

Heat Recovery Specification ................................................... 25

Capacity Correction Factor ..................................................... 26

Water Volume....................................................................... 26

IPLV .................................................................................... 27

Evaporator Pressure Drop ...................................................... 28

Condenser Pressure Drop ....................................................... 29

Dimensions ................................................................................... 31

Wiring Diagrams ............................................................................ 33

Installation ................................................................................... 41

Servicing and Maintenance ............................................................. 49

Troubleshooting ............................................................................. 50

Exploded View and Parts List ........................................................... 52

Contents

© 2009 FRIMEC-INTERNATIONAL. All rights reserved.

Page 2

Product Nomenclature

Water Cooled Screw Chiller

FWSD 045 1 B1

B1 Product generation.

1 Compressor nos.

C Cooling only.R With heat recovery

C 2.

Water Cooled Screw Chiller.

045 Capacity.

2 R22

Page 3

FWSD is equipped with twin screws compressor manufactured by reputable compressor makers who are well known for producing high efficiency and reliable compressors. The total numbers of moving parts in the screw compressor is only 1/10 of those in the reciprocating compressor and with only 20% of the vibration of reciprocating compressor; thus, increase the reliability of the compressor.

Heat exchanger is of dry expansion type shell and tube evaporator whereby the inner grooved copper tubes are accurately expanded and mechanically bonded to the end plates producing superior heat transfer properties. In addition, coupled with high efficiency screw compressor, the system is able to deliver optimum performance at all loading condition.

With partial load ability, the system is able to adhere to different load profile precisely and deliver the highest performance at all time. User can choose from Step (25%-50%-75%-100%) or Step-less capacity control to suite different application needs.

With wide range of products, ranging from 160 ~ 1656kW, the system is able to provide solution for various applications and installations.

The chiller system has built in protections for all system, i.e. refrigerant system, electrical system and water system. The system is equipped with various overload protection devices, phase protector, temperature and pressure transducers, expansion valves, etc 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.

With the PLC control system, user is able to start the operation of the chiller system with “One touch operation”. The operation of the chiller system is automatically and precisely controlled by the PLC control system. With the touch screen panel installed as the main interface, changing of settings and parameters has never been easier before.

The refrigerant system comes with multiple service valves and stop valves at strategic locations to ease maintenance and troubleshooting process. Besides, the system also comes with filter drier (with replaceable drier core), solenoid valves, sight glass and thermal expansion valves which enhance the serviceability of the system.

Reliable

High Efficiency

Energy Saving

Flexibility

Safety

Easy Maintenance

Features

Advance Control System

Page 4

Heat Recovery (Optional)

With the capability of heat recovery, the system is able to offer heat reclaim and at the same time increased system performance. The reclaimed heat can be used for domestic or industrial hot water or heating application. The following is a typical layout of a heat recovery system:

Hot waterExpansion tank

Stop valve Stop valveStrainerVibration isolator

Vibration isolator

Hot water pump

Back pressure control valve

Make up water valve

Hot water tank

Stop valve Stop valve

StrainerVibration isolator

Vibration isolator

Heat recoverywater pump

Stop valve

Control valveScrew compressor

Hea

t rec

over

y

Chilled water IN

Chilled water OUT Evap

orat

or

Expansion valve

Sight glass

Filter drier

Cond

ense

r

Control valve

Stop valve

Vibration isolator

Vibration isolator

Condenseing pressure regulator

Cooling water pump

Stop valveStrainer

Cooling tower

Page 5

Engineering SpecificationsGeneral Data

Note:1. Products are designed and tested in accordance to GB/T 18430.12. 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.

Model 040.1 045.1 055.1 060.1 075.1 085.1 100.1

kW 145.9 157.9 191.9 213.4 257.4 305.3 358.5

kW 35.4 38.2 45.7 50.3 60.6 72.1 83.6

A 61 65 78 86 109 129 145

A 292 319 276 369 369 521 291

A 86 91 111 121 147 179 205

V/Ph/Hz

%

Water Pipe Diameter DN 80 80 80 80 100 100 125

Water Flow Rate m3/h 31.2 33.7 40.9 45.3 54.7 64.9 76.0

Water Pipe Diameter DN 80 80 80 80 100 100 125

Water Flow Rate m3/h 25.1 27.2 33.0 36.7 44.3 52.5 61.6

Amount kg 40 40 55 55 55 65 65

Amount litre 6×1 6×1 7×1 7×1 10×1 10×1 14×1

Length mm 2965 2965 2965 2965 2995 2995 3100

Width mm 705 705 705 705 880 880 880

Height mm 1516 1516 1516 1516 1825 1825 1825

kg 1380 1395 1645 1660 1900 2180 2505

kg 1495 1507 1812 1821 2051 2391 2748

Dimension

Weight

Operating Weight

Polyurethane

Semi-hermetic Twin Screws

1

Shell and Tube

Refrigerant

Type

Circuit

Control

Lubrication Oil

Type SUNISO 5GS

Evaporator

Type

Quantity

Temperature Control

Quantity

Condenser

Type

Quantity

Nominal Input Power

Operation Control

Power Source

Starting Method

Capacity Control

Insulation Material

CompressorType

Nominal Running Current

Lock Rotor Ampere

Maximum Operating Current

Cooling Capacity

FWSD-B1C2

380 / 3 / 50

PLC Control with Touch Screen Panel

Y - Δ

100-75-50-25-0

1

Dry Type Shell and Tube

1

Temperature Sensor at Chilled Water Outlet

R22

1

TXV

Page 6

General Data

Note:1. Products are designed and tested in accordance to GB/T 18430.12. 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.

Model 115.1 130.1 145.1 160.1 175.1 225.1

kW 403.3 452.4 508.5 560.7 619.0 788.9

kW 93.2 104.4 117.4 129.4 143.0 177.3

A 156 172 200 217 238 303

A 373 394 477 572 572 785

A 221 242 279 305 337 534

V/Ph/Hz

%

Water Pipe Diameter DN 125 125 150 150 150 150

Water Flow Rate m3/h 85.4 95.7 107.6 118.7 131.0 166.1

Water Pipe Diameter DN 125 125 150 150 150 150

Water Flow Rate m3/h 69.4 77.8 87.4 96.4 106.4 135.7

Amount kg 80 90 90 105 150 200

Amount litre 14×1 16×1 19×1 19×1 20×1 28×1

Length mm 3100 3250 3250 3250 3450 3500

Width mm 946 946 946 946 1130 1130

Height mm 1825 1930 1930 1930 2300 2300

kg 2575 2640 2995 3180 3295 3585

kg 2882 2938 3319 3497 3687 4015

Dimension

Weight

Operating Weight

Refrigerant

Type

Circuit

Control

Lubrication Oil

Type SUNISO 5GS

Evaporator

Type

Quantity

Temperature Control

Quantity

Condenser

Type

Quantity

Nominal Input Power

Operation Control

Power Source

Starting Method

Capacity Control

Insulation Material

CompressorType

Nominal Running Current

Lock Rotor Ampere

Maximum Operating Current

Cooling Capacity

FWSD-B1C2

380 / 3 / 50

PLC Control with Touch Screen Panel

Y - Δ

100-75-50-25-0

Polyurethane

Semi-hermetic Twin Screws

1

Shell and Tube

1

Dry Type Shell and Tube

1

Temperature Sensor at Chilled Water Outlet

R22

1

TXV

Page 7

General Data

Note:1. Products are designed and tested in accordance to GB/T 18430.12. 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.

Model 175.2 190.2 205.2 215.2 230.2 245.2 260.2 275.2

kW 610.6 663.8 717.0 761.8 806.6 855.7 904.8 960.9

kW 144.2 155.7 167.2 176.8 186.4 197.6 208.8 221.8

A 257 274 290 301 312 328 343 371

A 700 726 496 578 594 615 636 719

A 358 384 410 426 442 463 484 521

V/Ph/Hz

%

Water Pipe Diameter DN 100 100 100 100 100 125 125 125

Water Flow Rate m3/h 129.8 140.9 152.0 161.4 170.8 181.1 191.5 203.4

Water Pipe Diameter DN 150 150 200 200 200 200 200 200

Water Flow Rate m3/h 105.0 114.1 123.3 131.0 138.7 147.1 155.6 165.2

Amount kg 65×2 65+70 70×2 70+90 90×2 90+95 95×2 95+105

Amount litre 10×2 10+14 14×2 14×2 14×2 14+16 16×2 16+19

Length mm 4000 4000 4000 4000 4000 4100 4100 4250

Width mm 1316 1316 1316 1316 1316 1366 1366 1366

Height mm 2000 2000 2000 2000 2000 2200 2200 2200

kg 3680 3920 4110 4190 4220 4360 4400 4770

kg 4101 4396 4574 4645 4713 4894 4976 5389

Temperature Sensor at Chilled Water Outlet

R22

2

TXV

Y - Δ

100-87.5-75-62.5-50-37.5-25-12.5-0

Polyurethane

Semi-hermetic Twin Screws

380 / 3 / 50

PLC Control with Touch Screen Panel

Dry Type Shell and Tube

1

2

Shell and Tube

2

Weight

Operating Weight

Lubrication Oil

Type

Dimension

SUNISO 5GS

Refrigerant

Type

Circuit

Control

Evaporator

Type

Quantity

Temperature Control

Condenser

Type

Quantity

Insulation Material

CompressorType

Quantity

Starting Method

Capacity Control

Nominal Input Power

Nominal Running Current

Lock Rotor Ampere

Maximum Operating Current

Power Source

Operation Control

FWSD-B1C2

Cooling Capacity

Page 8

General Data

Note:1. Products are designed and tested in accordance to GB/T 18430.12. 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.

Model 290.2 305.2 320.2 335.2 350.2 420.2 450.2

kW 1017.0 1069.2 1121.4 1179.7 1238.0 1477.8 1577.8

kW 234.8 246.8 258.8 272.4 286.0 334.0 354.6

A 398 416 433 455 476 570 606

A 756 851 877 909 909 1241 1319

A 558 584 610 642 674 996 1068

V/Ph/Hz

%

Water Pipe Diameter DN 125 125 125 125 150 150 150

Water Flow Rate m3/h 215.3 226.3 237.3 249.7 262.1 311.6 332.3

Water Pipe Diameter DN 200 200 200 200 200 200 200

Water Flow Rate m3/h 174.9 183.9 192.8 202.9 212.9 254.1 271.3

Amount kg 105×2 125+105 125×2 125+160 160×2 200×2 200×2

Amount litre 19×2 19×2 19×2 19+20 20×2 28×2 28×2

Length mm 4250 4250 4250 4250 4250 4650 4650

Width mm 1366 1366 1500 1500 1500 1650 1650

Height mm 2200 2200 2300 2300 2300 2450 2450

kg 5140 5330 5520 5910 5980 6520 6620

kg 5807 5990 6173 6661 6710 7323 7626

Temperature Sensor at Chilled Water Outlet

R22

2

TXV

Y - Δ

100-87.5-75-62.5-50-37.5-25-12.5-0

Polyurethane

Semi-hermetic Twin Screws

380 / 3 / 50

PLC Control with Touch Screen Panel

Dry Type Shell and Tube

1

2

Shell and Tube

2

Weight

Operating Weight

Lubrication Oil

Type

Dimension

SUNISO 5GS

Refrigerant

Type

Circuit

Control

Evaporator

Type

Quantity

Temperature Control

Condenser

Type

Quantity

Insulation Material

CompressorType

Quantity

Starting Method

Capacity Control

Nominal Input Power

Nominal Running Current

Lock Rotor Ampere

Maximum Operating Current

Power Source

Operation Control

FWSD-B1C2

Cooling Capacity

Page 9

Operating Range

Standard conditions:

Note: Values shown in table are values taken under Standard Condition. The actual values may be difference due to different operating conditions.

Recommended operating range:

Operating Values Range of fluctuation

High pressure (MPa) 1.4 ±0.2

Low pressure (MPa) 0.42 ±0.05

Discharge temperature (°C) 65 ±10

Suction temperature (°C) 5 ±3

Liquid line temperature (°C) 32 ±3

Cooling

Standard ConditionInitial operating range (Start-up)

Continuous operating range

Cooling water leaving temperature (°C) 35

Chilled water leaving temperature (°C) 7 16 ~ 25 4 ~16

21 ~ 45

Compressor capacity control:

Single system:

SV1 SV2 SV3

Start-up (25) � � �

50 � � �

75 � � �

100 � � �

Stop � � �

Capacity (%)Status of Valve

Twin system:

SV1 SV2 SV3 Motor Capacity (%) SV1 SV2 SV3 Motor Capacity (%)

Start-Up � � � � 25 � � � � 0

25 � � � � 50 � � � � 0

37.5 � � � � 75 � � � � 0

50 � � � � 100 � � � � 0

62.5 � � � � 75 � � � � 50

75 � � � � 75 � � � � 75

87.5 � � � � 100 � � � � 75

100 � � � � 100 � � � � 100

Stop � � � � 0 � � � � 0

Note:

� denotes de-energized

2. Capacity valve designation for different brand of compressor might be different

Capacity (%)Compressor NO.1 Compressor NO.2

1. � denotes energized