Uploaded by pierremagdi

BCWC Installation Manual

advertisement
Installation Manual
Aquaflair™ Modulating Water-cooled Chillers
Uniflair™ BCWC
Models
400V/3ph/50Hz, 300–1250 kW
990-9935-001
[email protected]
Publication Date: August 2016
Schneider Electric IT Corporation Legal Disclaimer
The information presented in this manual is not warranted by the Schneider Electric IT Corporation to be
authoritative, error free, or complete. This publication is not meant to be a substitute for a detailed operational
and site specific development plan. Therefore, Schneider Electric IT Corporation assumes no liability for
damages, violations of codes, improper installation, system failures, or any other problems that could arise
based on the use of this Publication.
The information contained in this Publication is provided as is and has been prepared solely for the purpose of
evaluating data center design and construction. This Publication has been compiled in good faith by Schneider
Electric IT Corporation. However, no representation is made or warranty given, either express or implied, as to
the completeness or accuracy of the information this Publication contains.
IN NO EVENT SHALL SCHNEIDER ELECTRIC IT CORPORATION, OR ANY PARENT, AFFILIATE OR
SUBSIDIARY COMPANY OF SCHNEIDER ELECTRIC IT CORPORATION OR THEIR RESPECTIVE
OFFICERS, DIRECTORS, OR EMPLOYEES BE LIABLE FOR ANY DIRECT, INDIRECT, CONSEQUENTIAL,
PUNITIVE, SPECIAL, OR INCIDENTAL DAMAGES (INCLUDING, WITHOUT LIMITATION, DAMAGES FOR
LOSS OF BUSINESS, CONTRACT, REVENUE, DATA, INFORMATION, OR BUSINESS INTERRUPTION)
RESULTING FROM, ARISING OUT, OR IN CONNECTION WITH THE USE OF, OR INABILITY TO USE THIS
PUBLICATION OR THE CONTENT, EVEN IF SCHNEIDER ELECTRIC IT CORPORATION HAS BEEN
EXPRESSLY ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. SCHNEIDER ELECTRIC IT
CORPORATION RESERVES THE RIGHT TO MAKE CHANGES OR UPDATES WITH RESPECT TO OR IN
THE CONTENT OF THE PUBLICATION OR THE FORMAT THEREOF AT ANY TIME WITHOUT NOTICE.
Copyright, intellectual, and all other proprietary rights in the content (including but not limited to software, audio,
video, text, and photographs) rests with Schneider Electric IT Corporation or its licensors. All rights in the
content not expressly granted herein are reserved. No rights of any kind are licensed or assigned or shall
otherwise pass to persons accessing this information.
This Publication shall not be for resale in whole or in part.
Table of Contents
Safety................................................................................. 1
Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Considerations While Installing This Equipment . . . . . . . . . . . . . 2
General Information ...........................................................4
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Save these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross-reference symbol used in this manual . . . . . . . . . . . . . .
Documentation included with the unit . . . . . . . . . . . . . . . . . . . .
Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
4
4
Inspecting the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspecting for missing components . . . . . . . . . . . . . . . . . . . . . . 5
Filing a claim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Equipment Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Waste Electrical and Electronic Equipment (WEEE) disposal . 5
................................................. 5
Storing the Chiller Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical components (control panels, motors, etc.) . . . . . . . . 5
Moving the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview............................................................................ 7
Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Total and Partial Heat Recovery (ETO) . . . . . . . . . . . . . . . . . . . . . . . . 10
Component Identification .................................................11
Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Uniflair BCWC Installation Manual
i
Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Dimensions and Weights .................................................14
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BCWC0320A
BCWC0630A
BCWC0950A
BCWC1250A
......................................
......................................
......................................
......................................
15
15
16
16
Unit Installation ................................................................17
Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic circuit preparation . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic Connections .....................................................18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Water Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lateral connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Corrosion resistance of the exchangers . . . . . . . . . . . . . . . . . 21
Filling the Water Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cooling and Hydraulic Circuit Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Water circuit capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum working hydraulic pressure . . . . . . . . . . . . . . . . . . .
Content of refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydronic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator pressure drop . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser pressure drop . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Correction factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
23
23
24
26
26
27
Electrical Connections .....................................................28
Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ii
Uniflair BCWC Installation Manual
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Component data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Complete unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Accessories .....................................................................34
Anti-vibration Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Serial Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Uniflair BCWC Installation Manual
iii
Safety
Important Safety Information
Read the instructions carefully to become familiar with the equipment before trying to install, operate, service,
or maintain it. The following special messages may appear throughout this manual or on the equipment to warn
of potential hazards or to call attention to information that clarifies or simplifies a procedure.
The addition of this symbol to a Danger or Warning safety label indicates that an electrical hazard
exists which will result in personal injury if the instructions are not followed.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, can result in death
or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor
or moderate injury.
NOTICE
NOTICE addresses practices not related to physical injury including certain environmental
hazards, potential damage or loss of data.
Uniflair BCWC Installation Manual
1
Safety Considerations While Installing This Equipment
Read and adhere to the following important safety considerations when working with this unit.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe electrical work
practices. See NFPA 70E or CSA Z462.
• This equipment must be installed and serviced by qualified personnel only.
• Turn off all power supplying this equipment before working on or inside the equipment.
• Always use a properly rated voltage sensing device to confirm power is off.
• Replace all devices, doors, and covers before turning on power to this equipment.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD TO PERSONNEL
To avoid any risk of injury, any work to be carried out on or around the compressor and
magnetic check valve should be done with personnel that do not have pacemakers fitted.
Failure to follow these instructions will result in death or serious injury.
WARNING
VIOLATION OF SAFETY STANDARDS
Removal of or tampering with safety devices is a violation of safety standards and will
void all warranties.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
WARNING
PERSONAL PROTECTIVE EQUIPMENT REQUIRED
During installation, authorized personnel must wear approved personal protective
equipment (PPE).
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
2
Uniflair BCWC Installation Manual
WARNING
HAZARD FROM MOVING PARTS
Keep hands, clothing, and jewelry away from moving parts. Check the equipment for
foreign objects before closing the doors and starting the equipment.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
CAUTION
DAMAGE TO EQUIPMENT OR PERSONNEL
• The equipment is heavy. For safety purposes, adequate personnel must be present
when moving this equipment.
• The load must always be solidly anchored to the bearing element of the lifting equipment
and means of transport.
• No one should be near the suspended load, nor in the working area of the crane, forklift,
truck, or any other lifting equipment or means of transport.
Failure to follow these instructions can result in moderate injury or equipment
damage.
Uniflair BCWC Installation Manual
3
General Information
Overview
Save these instructions
This manual contains important instructions that must be followed during the installation of this equipment.
Cross-reference symbol used in this manual
See another section of this document or another document for more information on this subject.
Documentation included with the unit
Every Aquaflair™ chiller is delivered with the following documentation enclosed:
• Uniflair BCWC Operation and Maintenance Manual
• Uniflair BCWC Installation Manual
• Drawing of refrigerant and hydraulic circuits of the unit
• Electrical diagrams
• List of spare parts
• EC declaration with the list of directives and European standards to which the unit complies
• Conditions of Warranty
Compliance
This unit underwent the risk analysis in compliance with Machinery Directive 2006/42/EC. The technical
solutions implemented during the design phase are described in the unit technical documentation. The
appliance was built to operate safely in the areas of application for which it was designed, provided its
installation, commissioning and maintenance are performed in compliance with the instructions provided in this
manual and on the labels affixed to the unit.
In compliance with European Community Directive 94/9/EC, these units must not be used in potentially
explosive atmospheres. In any case, always abide strictly by the applicable laws in force in the place of
installation of the system.
Pressurized equipment: This appliance is subject to European Community Directive 97/23/EC concerning
Pressurized Equipment. Any and all work performed on the pressure circuit must be expressly authorized by
Schneider Electric and personnel must be approved by Schneider Electric. If any one of the following
components: compressors, liquid tanks, safety valves, cooling pressure switches needs to be replaced,
immediate notification of the serial number of the new device and of the replaced device must be sent to
Schneider Electric, otherwise Schneider Electric will not guarantee the entire appliance.
Should it be necessary to replace any welded joint on site, Schneider Electric must be notified immediately of
which joint needs repairing and the name of the technician performing the repair work must be notified.
4
Uniflair BCWC Installation Manual
Inspecting the Equipment
Your Aquaflair™ chiller has been tested and inspected for quality assurance before shipment from Schneider
Electric. Carefully inspect both the exterior and interior of the equipment immediately upon receipt to ensure
that the equipment has not been damaged during transit.
Verify that all parts ordered were received as specified and that the equipment is the correct type, size, and
voltage.
Inspecting for missing components
All shipped loose components are identified by part number and description on the bill of lading. Ensure each
item is present before accepting delivery of the unit.
Filing a claim
If damage has occurred, or if shipped loose parts are missing, report it immediately to the delivering carrier and
note the problem on the receiving copy of the bill of lading. Failure to do so will result in replacement parts and
repairs being billed to the customer.
NOTE: In case of shipping damage, do not operate the equipment. Keep all packaging for inspection by the
shipping company and contact Schneider Electric.
Equipment Disposal
Waste Electrical and Electronic Equipment (WEEE) disposal
Schneider Electric products comply with international directives on the Restriction of
Hazardous Substances (RoHS) in electronic and electrical equipment and the disposal of
Waste Electrical and Electronic Equipment (WEEE). Dispose of any waste electronic or
electrical equipment with the appropriate recycling center. Contact Schneider Electric for
assistance.
Storing the Chiller Before Installation
If storing the chiller for a period of time, the following procedures must be followed:
• The storage area must be dry (<85% R.H.) and protected against minimum storage temperatures –15°C
(5°F) and extreme storage temperatures 50°C (122°F).
• The chiller should remain in its original packaging if stored for long periods of time.
Electrical components (control panels, motors, etc.)
NOTICE
EQUIPMENT DAMAGE
Store the chiller in an area that is protected from adverse conditions.
Failure to follow these instructions can result in equipment damage.
Electrical equipment and components should not be stored or left in an outdoor environment. Electrical
equipment and components should not be stored or left in a wet or damp environment. Components sealed in
plastic shrink-wrap are not exempt from this requirement. Moisture may collect inside the plastic, resulting in
corrosion of the cabinet, the electronic components, and/or copper bus bars.
Humidity absorbers should be installed inside each electrical and electronic components cabinet to protect
against corrosion. Openings in cabinets should be taped closed to minimize air infiltration during the storage
period.
Uniflair BCWC Installation Manual
5
A vapor-type corrosion inhibitor must be installed in the following equipment and components:
• Power panel
• Control panel
• Any optional electric enclosures
• Inside the motor terminal box on semi-hermetic compressors
Protection spray should be applied to components in the motor terminal box. The spray should also be applied
to all exposed areas of concern.
Moving the Equipment
The recommended tools for moving the equipment while it is still on the pallet include the following:
CRANE
SLING
na5025a
In order to allow for simple movement, the units are equipped with eye bolts for connection to lifting straps.
EYE BOLTS
6
Uniflair BCWC Installation Manual
Overview
Model Nomenclature
B C W C 1250 A
IDENTIFYING PREFIX
COMPRESSORS
C = CENTRIFUGAL
HEAT REJECTION TYPE
W = DIRECT EXPANSION, WATER COOLED
CHILLER TYPE
C = CHILLER
POWER SUPPLY VOLTAGE
A = 400V/3Ph/50Hz
Uniflair BCWC Installation Manual
na5666a
MODEL NUMBER
7
Main Components
0320A
Model
0630A
Power Supply
400 V/ 3 ph/50 Hz
Circuits (Number)
Compressors
1
Number
1
2
Type
3
1
Type
Flooded
Number
Condenser
4
Inverter centrifugal, oil-free, magnetic bearing
Number
Evaporator
1203A
0950A
1
Type
Shell and tube
Nameplate
The chiller nameplate is located in the electrical panel and provides the following information:
• Unit model
• Serial number
• Voltage, number of phases, and mains power frequency for the main and secondary circuits
• Absorbed current and power
• OA (operating amps), FLA (full-load amps), and LRA (locked rotor amps)
• Setting values of the safety devices
• Type and quantity of refrigerant (in kg) of each circuit
IMPORTANT: Make sure the unit power supply is the same as the power supply listed on the nameplate.
TENS.
400V/3Ph/50Hz
AUX. 230/24-12
NO. TENS. OA
(/1)
na5932a
8
TOTAL (kW)
MOD.
E
(/1)
(/1)
(*)
O
E
L
COMPRESSOR 1 (CIRC. 1)
COMPRESSOR 2 (CIRC. 1)
MP
XA
Y
L
N
VOLT
FLA LRA kW TOT
SERIAL No.
rev. B
AP1-AP2
STOP: 45,0 bar;
MAN. RESET.
BP1-BP2
STOP: 1,5 bar; DIFF: 1,0 bar
VSA1-VSA2 SAFETY VALVE OPEN AT: 1,5 bar
R314a
FACTORY CHARGE:
FACTORY CHARGE:
kg./CIRC.1
kg./CIRC.1
Icu=15kA (CEI EN 60947-2)
(*) nominal absorbed power
BCWC__________
Uniflair BCWC Installation Manual
Operation Limits
The operating conditions of chillers are strictly related to the compressor limits with the operating conditions
ensured by the heat exchangers.
In order to ensure continuous operation, the chiller control board forces the reduction of the condensing
pressure in extreme external conditions by means of a reduction in cooling capacity (unloading procedure).
This must be considered by means of the load distribution between the chillers on site.
Usually the redundancy level requires one or more units in stand-by. With this solution, all the cooling resources
are working at part-load conditions with important advantages if compared to a traditional logic.
Chiller models equipped with the required compressor to provide chilled water temperatures lower than 3°C
(37.4°F)(ETO) must be filled with antifreeze mixtures suitable to operate at the designated water temperatures
(see “Correction factors” on page 27).
BCWC OPERATION LIMITS
CONDENSER INLET WATER TEMPERATURE [°C]
50
45
40
35
30
25
20
15
10
5
0
1
2
3
4
5
6
7
8
9
10 11 12
13 14 15
16 17 18 19
EVAPORATOR OUTLET FLUID (WATER/GLYCOL) TEMPERATURE [°C]
Uniflair BCWC Installation Manual
20 21
na5003a
0
9
Total and Partial Heat Recovery (ETO)
In the BCWC range, it is possible to supply the unit fitted with heat recovery (ETO). This is carried out by
replacing the 2-step shell and tube condenser with a 4-step condenser.
Total and partial heat recovery is achieved as illustrated in the following diagram; if hot water needs to be
produced, the water should flow through the dedicated exchanger.
B
C
A
INe
E
OUTe
na5012b
D
Item
Description
A
B
C
D
E
INe
Compressor
Inlet/Outlet Recovery and Condensation
Condenser
Electronic Expansion Valve
Flooded Evaporator
Evaporator Water Inlet
OUTe
10
Evaporator Water Outlet
Uniflair BCWC Installation Manual
Component Identification
na5699a
Main Components
Item Description

Compressors

Electrical panel

Display interface

Electrical connections (behind electrical panel)

Evaporator

Condenser

Filter drier

Expansion valve

Water connections (user side) for condenser (inlet)

Water connections (user side) for condenser (outlet)

Water connections (user side) for chilled water (outlet)

Water connections (user side) for chilled water (inlet)
NOTE: Model BCWC0950 shown.
Uniflair BCWC Installation Manual
11
Component Access
Compressors
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Turn off all power supplying this equipment before working on the equipment. All electrical
work must be performed by qualified personnel. Practice Lockout/Tagout procedures. Do
not wear jewelry when working with electrical equipment.
Failure to follow these instructions will result in death or serious injury.
DANGER
HAZARD OF ELECTRIC SHOCK
Removing top cover will expose you to a high voltage hazard of up to 860 VDC. Wait at
least ten minutes to allow the DC capacitors to discharge and ensure there is no mains
input voltage present before removing it.
Failure to follow these instructions will result in death or serious injury.
CAUTION
BURN HAZARD
During regular unit operation, the cooling circuit delivery pipes and related parts get very
hot and, therefore, potentially hazardous.
Failure to follow these instructions can result in moderate injury or equipment
damage.
IMPORTANT: Using an appropriately rated voltage meter, check the DC bus bars for DC voltage level. If the
voltage is above 5 VDC, wait five minutes and recheck until the voltage is below 5 VDC.
With the guards removed, the compressors and the cooling circuit delivery pipes are within reach.
12
Uniflair BCWC Installation Manual
Electrical panel
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Turn off all power supplying this equipment before working on the equipment. All electrical
work must be performed by qualified personnel. Practice Lockout/Tagout procedures. Do
not wear jewelry when working with electrical equipment.
Failure to follow these instructions will result in death or serious injury.
NOTICE
EQUIPMENT DAMAGE
Before removing the panel, you must set the master switch to “0” to prevent the
compressors from reaching the High Pressure Alarm level.
Failure to follow these instructions can result in equipment damage.
For access to the electrical panel, turn the master switch to “0,” turn the latches 1/4 turn, and lift using the grip.
This procedure enables you to open the panel that is hinged on the top of the electrical panel.
Uniflair BCWC Installation Manual
13
Dimensions and Weights
Dimensions
Compressor
0320A
0630A
950A
1203A
(in.)*
2028 (79.8)
2130 (83.9)
1924 (75.7)
1924 (75.7)
Length - mm (in.)
2640 (103.9)
2940 (115.8)
3294 (139.7)
4591(180.8)
Width - mm (in.)
1061 (41.8)
1022 (40.2)
1544 (60.8)
1505 (59.3)
2.8 (9.2)
3.0 (9.8)
5.1 (16.7)
6.9 (22.6)
3752 (8271.7)
5760 (12698.6)
Model
Height - mm
Footprint - m2 (ft2)
* Height is measure without the addition of anti-vibration supports.
Weights
Weight* - kg (lbs)
Basic Version
1585 (3494.3)
2814 (6203.8)
* Data refers to a unit with refrigerant charge and empty hydraulic circuit
14
Uniflair BCWC Installation Manual
Service Access
The following diagrams show the minimum recommended distances to be left for clearance around the unit for
correct operation and service access.
• Place on a stable and even base, balanced in order to ensure the proper compressor operation.
• Pipeworks and electrical connections have to be easily reachable.
• Safeguard the access and operating area provided for unit controls.
• Before connecting services, make sure that the equipment is installed and entirely level.
BCWC0320A
800 mm
(31.5 in.)
600mm
(23.6 in.)
na5024a
1000 mm
(39.4 in.)
1200 mm
(47.2 in.)
BCWC0630A
800 mm
(31.5 in.)
600mm
(23.6 in.)
na5027a
1000 mm
(39.4 in.)
1200 mm
(47.2 in.)
Uniflair BCWC Installation Manual
15
BCWC0950A
800 mm
(31.5 in.)
600mm
(23.6 in.)
1000 mm
(39.4 in.)
na5028a
1600 mm
(63.0 in.)
BCWC1250A
800 mm
(31.5 in.)
1000 mm
(39.4 in.)
na5029a
1000 mm
(39.4 in.)
1600 mm
(63.0 in.)
16
Uniflair BCWC Installation Manual
Unit Installation
Preparing for Installation
Hydraulic circuit preparation
NOTE: The unit is charged with nitrogen and shipped with caps to prevent humidity inside the unit.
1. Check to make sure caps are present.
2. Check inside pressure and ensure that it is approximately 0.5 bar.
Installation
CAUTION
DAMAGE TO EQUIPMENT OR PERSONNEL
• The load must always be solidly anchored to the bearing element of the lifting equipment
and means of transport.
• No one should be near the suspended load, nor in the working area of the crane, forklift,
truck, or any other lifting equipment or means of transport.
Failure to follow these instructions can result in moderate injury or equipment
damage.
NOTICE
EQUIPMENT DAMAGE
Check that the load capacity of the floor is sufficient to support the weight of the unit.
Failure to follow these instructions can result in equipment damage.
NOTICE
EQUIPMENT DAMAGE
The unit should not be placed on its side or upside down.
Failure to follow these instructions can result in equipment damage.
Uniflair BCWC Installation Manual
17
1. Move the unit as close as possible to the installation site before removing the packaging.
2. Check the drawings enclosed with the unit or the installation drawings included in the unit
documentation.
3. Place the unit on a solid and flat surface.
NOTE: Provide a rigid installation base that will not become deformed, or a concrete foundation with
sufficient mass to support the operating weight (i.e., including all system piping and full load of
refrigerant, oil, and water).
4. Once positioned, level the unit with the aid of a spirit level using the adjustable support feet and, where
necessary, with shims. The slope must not exceed 5 mm (.2 in.).
18
Uniflair BCWC Installation Manual
Hydraulic Connections
Installation
NOTICE
EQUIPMENT DAMAGE
• The heads of the unit exchangers have not been designed to support loads and stress
caused by water pipework.
• During installation the water inlet and outlet pipes should be fixed in such a way that
dilation and/or weight and/or stress are not placed on the heads of the unit evaporator
and condenser.
Failure to follow these instructions can result in equipment damage.
NOTICE
EQUIPMENT DAMAGE
Check the direction of water flow. The unit is equipped with labels
clearly stating the inlet/outlet water connections of the evaporator,
condenser, and heat recovery, if present.
Failure to follow these instructions can result in equipment
damage.
1. Check that the section of chilled water pipe and the heat recovery installed by the client are adequate.
An inadequate water flow significantly reduces the cooling capacity of the unit.
2. Check that the section of condensing water pipe is adequate. An inadequate water flow significantly
reduces the cooling capacity of the unit.
3. Check the water intake/output directions. There are labels next to the intake and output connections.
4. Connect the chiller using flexible couplings to stop the transmission of vibrations. Fit shut-off valves so
that the unit can be isolated from the water circuit.
5. Insulate the chilled water pipes to stop the formation of condensation on the external surface.
6. Install a metal filter in the section of pipe next to the unit intake to prevent pieces of welding or flakes of
rust entering the heat exchanger.
7. Provide a discharge well near the output connection in case the unit needs to be emptied.
Uniflair BCWC Installation Manual
19
Water Filter
NOTICE
EQUIPMENT DAMAGE RISK
To prevent problems, the filter needs to be positioned at the unit inlet.
Failure to follow these instructions can result in equipment damage.
To prevent residue and metallic burrs from seriously damaging the refrigeration components, install a metallic
water filter in the refrigerant inlet pipe. A typical suggested mesh is 22.86 or 25 according to the French
number.
The following are suggested water filter features:
• French number 25
• Mesh 22.9
• Nit 45
Wire Diameter (mm)
Mesh Opening (mm)
Open Area (%)
0.24
0.87
61.3
na5782a
GR
GR
20
UNIT
Filling unit
Flexible coupling
Water filter
Balancing
valve
Non return
valve
Automatic air
valve
Pressure
gauge
Motorized
valve
Uniflair BCWC Installation Manual
Connections
NOTICE
EQUIPMENT DAMAGE
Check the direction of water flow. The unit is equipped with
labels clearly stating the inlet/outlet water connections of the
evaporator, condenser, and heat recovery, if present.
Failure to follow these instructions can result in equipment
damage.
Lateral connections
Basic versions for BCWC units are provided with the evaporator and condenser only and therefore the water
connections are inside the chiller.
Table of Correspondence between Different Types of Hydraulic Connections
Threaded Connections GAS (BSP)
Flexible (Victaulic) Joints
Flanged Connections
Male
Female
Ext. Ø Pipe to Be Welded (mm)
DN
1 in.
1 1/4 in.
1 1/2 in.
2 in.
2 1/2 in.
3 in.
4 in.
5 in.
6 in.
8 in.
1 in.
1 1/4 in.
1 1/2 in.
2 in.
2 1/2 in.
3 in.
4 in.
5 in.
6 in.
8 in.
OD 33.7
OD 42.4
OD 48.3
OD 60.3
OD 76.1
OD 88.9
OD 114.3
OD 139.7
OD 168.3
OD 219.1
DN 25
DN 32
DN 40
DN 50
DN 65
DN 80
DN 100
DN 125
DN 150
DN 200
Hydraulic Connections
Model
Evaporator Hydraulic Connections
Type
Condenser Hydraulic Connections
Type
0320A
0630A
0950A
1203A
4 in.
5 in.
6 in.
6 in.
UNI ISO 7/1-R 3
Pipe threading
4 in.
5 in.
Victaulic
6 in.
Victaulic
NOTE: Use the rolled stub pipe (optional) supplied with the unit or directly connect the unit using rolled pipes
and Victaulic® type couplings for the hydraulic connections to be welded, making sure that the seals are
properly inserted and secured.
Uniflair BCWC Installation Manual
21
Corrosion resistance of the exchangers
The table below provides a summary of the substances that could create corrosion problems. Water conditions
must adhere to these values; however, no guarantees can be deduced from this table due to the complex and
various chemical reactions involved in each particular situation.
Shell and Tube/Flooded Heat Exchangers
Substance
pH-value
Chloride CI–
Free Chlorine CI2
Sulphate SO4–
Free Carbon Dioxide CO2
HCO3– / SO4– –
Nitrate
Hydrogen Sulphide H2S
Oxygen O2
Ammonium NH4+
Phosphate PO43–
Iron and Manganese Fe3+ / Mn++
Depositable (organic) substances
Hardness
Approximate Concentration Area (mg/l)
Compatibility with Standard Heat
Exchanger
7 ÷ 9 (Value)
<3
3 ÷ 50
< 0.5
< 50
50 ÷ 100
<5
5 ÷ 50
OK
*
*
OK
OK
*
OK
*
> 1 (Value)
< 100
< 0.05
< 0.1
0.1 ÷ 2
<2
2 ÷ 20
<2
< 0.5
0 (Value)
4 ÷ 8.5 dH
OK
OK
OK
OK
*
OK
*
OK
OK
**
OK
*Corrosion problems could arise, especially when several factors are evaluated together.
**Corrosion problems could arise when they are present in certain situations.
NOTE: Data does not consider the effects of any bio-pollution present in the water.
NOTE: Nominal performance data calculated with a fouling factor of 0.00 m2°C/kW.
22
Uniflair BCWC Installation Manual
Filling the Water Circuit
NOTICE
EQUIPMENT DAMAGE RISK
If winter shut-down is planned, it is important to empty the hydraulic circuit and add the
necessary amount of glycol to the water still inside the unit.
Failure to follow these instructions can result in equipment damage.
NOTE: Before filling the water circuit, it has to be flushed. During the flushing operation, the evaporator must be
disconnected from the main water plant and its ends should be left closed with the caps originally provided from
the factory. This will prevent any external debris from entering the water circuit.
After connecting the unit to the user system, it can be filled and the air in the pipes can be bled using valves
installed by the installer.
The water and glycol mixture can be cooled down to –15°C (5°F) provided that the water inside the circuit
contains sufficient antifreeze to prevent freezing inside the evaporator.
Minimum Fluid Temperature
with Unit in Operation
Freezing Temperature
Percentage of Ethylene
Glycol by Weight
Uniflair BCWC Installation Manual
5.0°C
(41°F)
0°C
(32.0°F)
3.0°C
(37.4°F)
–4.4°C
(24.1°F)
–5.0°C
(23.0°F)
–9.6°C
(14.7°F)
–10.0°C
(14.0°F)
–16.1°C
(3.0°F)
–18.0°C
(–0.4°F)
–24.5°C
(–12.1°F)
–28.0°C
(–18.4°F)
–35.5°C
(31.9°F)
0%
10%
20%
30%
40%
50%
23
Cooling and Hydraulic Circuit Data
Water circuit capacity
The table below shows the capacity (liters) of the water circuit in the basic chiller units.
NOTE: Quantities may vary slightly due to adjustments made during end-of-line testing.
NOTE: Quantities may vary depending on unit configuration.
BCWC
0320A
0630A
0950A
1203A
Evaporator (l)
65
178
205
350
Condenser (l)
43
73
120
168
Model
Maximum working hydraulic pressure
BCWC
Model
0320A
0630A
Maximum Working Pressure (barg)
0950A
1203A
10
Content of refrigerant
NOTE: Quantities may vary slightly due to adjustments made during end-of-line testing.
NOTE: Quantities may vary depending on unit configuration.
BCWC
Model
R134a Refrigerant - kg (lbs)
24
0320A
0630A
0950A
1203A
80 (176.4)
230 (507.1)
215 (474.0)
350 (771.6)
Uniflair BCWC Installation Manual
Hydronic connections
na5030b
BCWC0320A
Item Description




Evaporator out
Evaporator in
Condenser in
Condenser out
na5031a
BCWC0630A
Item Description




Uniflair BCWC Installation Manual
Evaporator out
Evaporator in
Condenser in
Condenser out
25
na5032a
BCWC0950A
Item Description




Evaporator out
Condenser in
Evaporator in
Condenser out
na5034a
BCWC1250A
Item Description




26
Condenser out
Evaporator out
Evaporator in
Condenser in
Uniflair BCWC Installation Manual
Evaporator pressure drop
140
100
1250
80
60
0320
40
0950
0630
20
na5067a
PRESSURE DROP [kPa]
120
0
0
50
100
150
200
250
300
350
3
WATER FLOW (m h)
NOTE: Data refers to 0% glycol.
Condenser pressure drop
160
PRESSURE DROP [kPa]
140
0630
120
0950
100
80
1250
60
0320
40
na5068a
20
0
0
50
100
150
200
250
300
350
400
450
3
WATER FLOW (m h)
NOTE: Data refers to 0% glycol.
Uniflair BCWC Installation Manual
27
Correction factors
5.0°C
(41°F)
0°C
(32.0°F)
3.0°C
(37.4°F)
–4.4°C
(24.1°F)
–5.0°C
(23.0°F)
–9.6°C
(14.7°F)
Percentage of Ethylene Glycol by Weight (%)
0
10
20
30
40*
50*
Correction Factors (%)
0
10
20
30
40
50
Cooling Capacity (R0)
1
0.985
0.98
0.97
0.96
0.95
Compressor Power Consumption (P0)
1
0.995
0.99
0.98
0.98
0.97
Volumetric Flow Rate (L0)
1
1.02
1.05
1.08
1.10
1.14
Evaporator (C0)
1
1.10
1.25
1.40
1.60
1.7
Correction Factors (%)
0
10
20
30
40
50
Minimum Fluid Temperature with Unit Operating
Freezing Temperature
–10.0°C –18.0°C
(14.0°F) (–0.4°F)
–16.1°C –24.5°C
(3.0°F) (–12.1°F)
–28.0°C
(–18.4°F)
–35.5°C
(31.9°F)
Adjusted cooling capacity = Nominal cooling capacity × R0
Adjusted compressor power consumption = Nominal absorbed power × P0
Adjusted volumetric flow rate = Nominal volumetric flow rate × L0
Adjusted evaporator pressure drop, water side = Evaporator pressure drop × C0
* Glycol mixtures with concentrations higher than 30% must be managed on request.
NOTE: Adjustments are measured with the same evaporator inlet and outlet temperatures 12/7ºC.
28
Uniflair BCWC Installation Manual
Electrical Connections
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe electrical work
practices. See NFPA 70E or CSA Z462.
• This equipment must be installed and serviced by qualified personnel only.
• Turn off all power supplying this equipment before working on or inside the equipment.
• Always use a properly rated voltage sensing device to confirm power is off.
• Replace all devices, doors, and covers before turning on power to this equipment.
Failure to follow these instructions will result in death or serious injury.
Connection
Remove the reinforcement plate on the bottom of the unit. The IP42 protection rating must be ensured by using
adequate cable glands/girdle clamps and/or junction boxes.
Connect the cables inside the switchboard by removing the protective Plexiglas® installed to protect the poles
of the disconnecting switch and by securing the lead-in wires of the cables on the specific terminals.
Ensure correct connection by referencing the wiring diagram supplied with the unit.
Particular attention must be paid to the following:
• The supply cables must be protected upstream from short circuits and current overloads by a suitable
device which conforms to the current standards in force.
• The section of cable needs to be adjusted to the setting of the protection system upstream and must take
into account the temperature, the type of installation, the number of cables placed in parallel and their
type of insulation. Refer to the relative tables supplied by the current standards.
• It is of vital importance that connection to the equipment ground is carried out carefully, using a suitable
section and quality of cable (refer to the current standards).
• It is important that the protection cable runs parallel and near the supply cable.
• For sizing the supply line for the unit, it is necessary to take into consideration the total value of the FLA,
FLI, and LRA, as shown in the electrical data tables.
Uniflair BCWC Installation Manual
29
Power Supply
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe electrical work
practices. See NFPA 70E or CSA Z462.
• This equipment must be installed and serviced by qualified personnel only.
• Turn off all power supplying this equipment before working on or inside the equipment.
• Always use a properly rated voltage sensing device to confirm power is off.
• Replace all devices, doors, and covers before turning on power to this equipment.
Failure to follow these instructions will result in death or serious injury.
NOTICE
EQUIPMENT DAMAGE RISK
The power supply cable is not supplied by Schneider Electric and must be properly sized
by the installer.
Failure to follow these instructions can result in equipment damage.
Installation
1. Open the door of the main electric panel located on the front of the unit, above the compressor
compartment.
2. Make sure that the mains voltage corresponds to the voltage on the data plate of the unit (voltage,
number, and frequency of phases).
30
Uniflair BCWC Installation Manual
3. Insert the feeding cable through the flange indicated in the diagram.
On the base of the electrical panel, there are inlets to allow access to the following:
– Supply cable: This will be connected to the terminals of the general cut-off switch.
na5937a
– Signal cables: These will be connected to the terminals of the microprocessor board.
SUPPLY CABLE INLET BCWC0320
na5936a
SUPPLY CABLE INLET BCWC0650/0950/1250 (MODEL BCWC0650 SHOWN)
NOTE: The section of the power supply cable must be chosen according to its length and type of
laying, the maximum current absorbed by the chiller and in such a way as to not cause an excessive
drop in voltage (the supply voltage must be ±10% of the nominal value) in accordance with the
Standard Electromagnetic Compatibility (EMC):
• CEI EN 61000-4-11:2006-02
• EN 61000-4-11:2004-08
• IEC 61000-4-11:2004-03
Uniflair BCWC Installation Manual
31
4. Make sure no electrical components are live then connect the three power supply phases to the main
switch terminals.
5. Check the housing of the wires and their respective terminals before fastening the screws.
32
Uniflair BCWC Installation Manual
Electrical Data
As a general guide, refer to the Application Note, Chiller Plants - Best design practices.
• Power supply
– The power supply for all units is 400V/3ph/50Hz. Versions with different power supplies can be
provided on request.
– The separate power supply (if present) is 230V/1ph/50Hz. This optional version is based on a
separate power connection for the following devices:
• Unit control board
• Compressors
– FLI: Full Load Input Power - The maximum absorbed power of the unit [kW]
– FLA: Full Load Amperage - The maximum absorbed current [A]
– LRA: Locked Rotor Amperage - The current of the locked rotor
– ST: Type of start-up
• Chiller Unit
– SC: Inrush current of the unit [A], i.e., the sum of the currents to charge the capacitors of each
compressor.
– FLI: Full Load Input Power - The maximum absorbed power of the unit [kW]
– FLA: Full Load Amperage - This is the absorbed current at max operating parameters over an
extended period of time, i.e., the sum of the FLA values of each compressor fitted in the unit (from
one to four). This is the maximum steady current value actually necessary to size cabling, safety
devices, etc.
NOTE: For BCWC units, this value can be used for sizing the protection devices.
– COSφ: Cosφ is the cosine of the φ angle of displacement between the current and the voltage in an
electrical system with alternate current. In a purely resistive system (which is also called ohmic),
there is no displacement; therefore, cosφ = 1. In a real inductive system, or rather one with resistive
components, the displacement angle is between 0 and φ/2 (delayed displacement). In a system with
capacitive components, the displacement is between 0 and -φ/2 (advance displacement). In both
cases, the value of cosφ decreases by one until it theoretically reaches zero. The cosφ is also
defined as a power factor equal to the relationship between the active power (P) and the apparent
power (S). A cosφ of one means that the apparent power corresponds to the active power and there
is no reactive power. Since reactive power is not desired, neither is a cosφ of less than one.
S
90º
ĭ
na4917a
Q
P
Uniflair BCWC Installation Manual
33
Component data
Compressor
Model
0320A
0630A
FLI (kW)
85
FLA (A)
135
ST
0950A
1203A
Soft start
FLI: Full Load Input Power, the maximum absorbed power of the unit [kW]
FLA: Full Load Amperage, the maximum absorbed current [A]
ST: Type of start-up
Complete unit
Model
0320A
0630A
0950A
1203A
SC (A)
5
10
15
20
FLI (kW)
85
170
255
340
FLA (A)
135
270
405
540
COSφ
0.92
SC: Inrush current of the unit [A], i.e. the sum of the currents to charge the capacitors of each compressors.
FLI: Full Load Input Power, the maximum absorbed power of the unit [kW]
FLA: Full Load Amperage. This is the absorbed current at maximum operating parameters over an extended period of time, i.e., the sum
of the FLA values of each compressor fitted in the unit (from one to four). This is the maximum steady current value actually necessary to
size cabling, safety devices, etc.
COSφ: The cosine of the φ angle of displacement between the current and the voltage in an electrical system with alternate current.
34
Uniflair BCWC Installation Manual
Accessories
Anti-vibration Supports
General
To reduce vibration, BCWC units can be supplied with neoprene anti-vibration supports.
The anti-vibration support is composed of the following:
• Height-adjustable steel bell with leveling screw
• Vulcanized steel plate with rubber base
4000
3000
2000
na5006a
1000
0
0
1
2
3
DEFLECTION (mm)
4
5
na5015a
VERTICAL STATIC LOAD (daN)
• Hardness: 70°shA
Installation
WARNING
HEAVY EQUIPMENT
Use at least two people when handling and installing this equipment.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
1. Lift the unit.
Refer to the lifting drawing supplied with the unit documentation.
Uniflair BCWC Installation Manual
35
na5994a
2. Install the anti-vibration supports A-B-C-D-S-T as shown in the installation drawing supplied with unit
documentation.
EXAMPLE ARRANGEMENT OF
ANTI-VIBRATION SUPPORTS
A
B
C
D
S
T
3. Rest the unit on the supports.
4. Check for any deformations in the anti-vibration supports.
5. If necessary, use a jack to lift the unit until it is high enough for the rubber to be readjusted.
6. Reposition the unit.
36
Uniflair BCWC Installation Manual
Serial Cards
Installation
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Turn off all power supplying this equipment before working on the equipment. All electrical
work must be performed by qualified personnel. Practice Lockout/Tagout procedures. Do
not wear jewelry when working with electrical equipment.
Failure to follow these instructions will result in death or serious injury.
NOTICE
STATIC ELECTRICITY HAZARD
Circuit boards contained within this unit are sensitive to static electricity. Use one or more
electrostatic-discharge device while handling the boards.
Failure to follow these instructions can result in equipment damage.
1. Disconnect the power.
na4553a
2. Using a screwdriver, remove the plastic hatch from the controller.
na4499a
3. Using cutting nippers, remove the pre-cut plastic hatch.
4. Insert the optional card into the corresponding connector and ensure the card is firmly placed on both
plastic supports on the pCO controller case.
5. Close the cover using a screwdriver to fit the outside card terminal to the cover.
Worldwide Customer Support
Customer support for this or any other product is available at no charge in any of the following ways:
• Visit the Schneider Electric Web site to access documents in the Schneider Electric Knowledge Base
and to submit customer support requests.
– www.schneider-electric.com (Corporate Headquarters)
Connect to localized Schneider Electric Web sites for specific countries, each of which provides
customer support information.
– www.schneider-electric.com/support/
Global support searching Schneider Electric Knowledge Base and using e-support.
• Contact the Schneider Electric Customer Support Center by telephone or e-mail.
– Local, country-specific centers: go to www.schneider-electric.com > Support > Operations
around the world for contact information.
For information on how to obtain local customer support, contact the representative or other distributors
from whom you purchased your product.
As standards, specifications, and designs change from time to time, please ask for confirmation of the information given in this publication.
© 2016 Schneider Electric. All Rights Reserved.
Uniflair and the Schneider Electric logo are trademarks owned by Schneider Electric Industries SAS S.A.S., or its affiliated companies. All other
trademarks are the property of their respective owners.
990-9935-001
[email protected]
8/2016
Download
Related flashcards
105 mm artillery

48 Cards

Machine pistols

37 Cards

76 mm artillery

47 Cards

Create flashcards