Instruction manual

BCWC
Water-cooled water chillers
with “oil-free” centrifugal compressors
R134a (300-1250kW)
Version : 1.1
Date : November 2007
Language : English
 GB

Version: 1.1 Date: November 2007

UNIFLAIR SpA policy is one of continuous technological innovation and the Company therefore reserves the right to amend any data
herein without prior notice.

2 Version 1.1 – November 2007

 INDEX
IMPORTANT WARNINGS 4

SYMBOLS USED 5
SAFETY 5

Documentation included with the unit 6

General description 7
Basic unit 8
Versions and available accessories 9
Electrical and EC data plate 10
Main features 11
Operating limits 13
Main components 14
Dimensions and weights 23

INSTALLATION GUIDE
Transport and handling 24
Receiving and storing the unit 25
Handling 25
Positioning the unit – operation space 26
Hydraulic connections 28
Electrical connections 29

TECHNICAL DATA 32
Performance 32
Electrical data 33
Sound pressure levels 34
Evaporator pressure drops 35
Condenser pressure drops 36
Refrigeration-hydraulic diagram 37
Overall dimensions 45
Lifting diagrams 49

This unit has been subjected to risk analysis under EC Directive 98/37/CEE (89/392/CEE). The
technical solutions implemented during the design phase are described in the unit’s technical file.

This machine is subjected to the European Community Directive 97/23/EEC regarding Pressure
Equipment. Any intervention on the pressure circuit must be authorized by Uniflair, and the
personnel must be approved by Uniflair. If any of the following components: compressors, liquid
receivers, safety valves, refrigerant pressure switches are to be replaced, Uniflair must be
immediately informed of the serial number of the new and of the replaced devices, otherwise Uniflair
shall not guarantee the integrity of the equipment.
Additionally, if any soldered join needs to be repaired on site, Uniflair must be immediately informed
of which join and of the name of the engineer.

The unit has been built to operate without risks for the aim in which it has been designed provided
that the installation, operation and maintenance are carried out according to the
instructions contained in this manual and on the labels which can be found on the unit
itself.

Warnings in this manual which are particularly important for user safety are shown by the danger
symbol.
If these instructions are NOT complied with, the warranty shall be void.
Version 1.1 – November 2007 3
 IMPORTANT WARNINGS

This unit contains refrigerant gas circuits, chilled water under pressure, live electrical components,
hot surfaces, sharp edges (the fins on the coils) and rotating devices such as the fans.
All service and maintenance operations which require access to the inside of the unit while
it is in operation must be performed by qualified and experienced personnel who are aware
of the necessary precautions.

Before accessing the inside of the unit, disconnect it from the electrical power supply.

In any case, all safety legislation regarding the installation location must be followed.
In the event of fire, water and other conductive substances must not be used to put out the fire
near live electrical components. This warning must be displayed on notices in the unit installation
location.

If refrigerants used come into contact with fire they decompose, forming acids and other irritants.
The smell of these substances, even at concentrations below danger levels, gives enough
warning to allow evacuation of the area at risk.

Make sure that the mains supply to the unit is the same as that shown on the data plate.

This unit is designed to cool/heat fluid such as water and anti-freeze mixtures. If another
mixture is used, it can cause corrosion and deterioration.

This unit is not suitable for operation in aggressive environments.

Drain all the water from the system before the winter to avoid freezing.
In periods in which the temperature may fall below 0°C, empty the unit in order to prevent serious
damage caused by the formation of ice.
This precaution is not necessary if the unit is charged with an appropriate anti-freeze
mixture.

If the unit is fitted with an optional heating cable, it must be turned off without cutting the electrical
power supply.

Install a mechanical filter in the section of tubing near the intake of the unit to prevent the heat
exchanger being blocked with pieces of welding or flakes of oxidised metal from the water mains.

In compliance with Community directive 94/9/CE these units are not to be used in potentially
explosive environments.

R134a  GWP = 1100

4 Version 1.1 – November 2007

 SYMBOLS USED

SYMBOL MEANING SYMBOL MEANING

DANGER HOT SURFACE – DANGER OF
BURNING

IMPORTANT WARNING HIGH VOLTAGE – ELECTRICAL

RISK

SAFETY
The new range of BCWC units features state-of-the-art technology ensuring maximum reliability, safety, quiet
operation and respect for the environment.

1) RELIABILITY: Trouble-free operation of Uniflair precision chillers is ensured by rigorous production

process controls under ISO 9001-certified quality procedures:
quality control of components;
pressure testing of refrigerant and water circuits;
testing of current absorption and IEC safety testing;
calibration and testing of instruments and safety devices;
final testing of unit under operating conditions.

2) ACTIVE SAFETY: UNIFLAIR safety and control systems have a supervision and prevention function
with:
automatic blocking of components in dangerous conditions;
indication of function status;
reading and continuous display of circulating fluid temperature;
management of compressor start-ups to reduce excessive switching on and off;
alarm signal in the event of a refrigerant leak;
indication of anomalous function conditions and / or alarms;
compressor crankcase heater activation when the compressor is switched off;
anti-freeze protection to prevent freezing of the evaporator.

3) PASSIVE SAFETY: The essential functions of these units are protected against anomalous function
conditions and potential damage by:
high and low pressure switches on the refrigerant circuit (HP with manual re-set);
safety valve on the high and low pressure refrigerant line;
compressor motor electrical protection;
water circuit safety;
compressor oil circuit safety.

4) PERSONAL SAFETY. The design and wiring of all UNIFLAIR chillers and heat pump is conforms to
IEC electro-technical standards. Electrical panels have auxiliary 24V circuits and are equipped with:
general switch and door lock switch;
automatic circuit-breaker switches.

Version 1.1 – November 2007 5

 DOCUMENTATION INCLUDED WITH THE UNIT

Each unit is delivered complete with the following documentation:

Machine and microprocessor control instruction manuals
Unit installation diagrams
Diagrams of the refrigerant and hydraulic circuits of the unit
Electrical diagrams
List of spare parts
CE declaration with list of European directives and norms to which the unit conforms
Warranty Conditions
R134a safety data sheet

6 Version 1.1 – November 2007

 GENERAL DESCRIPTION

B.C.W.C.
Aquaflair
A new generation of chillers

Uniflair has always implemented the most recent and innovative technical solutions for its products in order
to create technologically advanced units which offer concrete advantages.

Technology is only advanced if it offers technological advantages which are competitive without
compromising reliability.

As a supplier of solutions for mission critical systems for industrial processes or highly technological
environments, Uniflair units must feature uncompromised reliability.
At the same time, given the extended operating periods over the course of a year, effective energy saving
strategies must also be applied.

For this reason BCWC (Big Centrifugal Water Chiller): units have been designed and developed: water-
cooled units which are equipped with centrifugal compressors with “oil-free” magnetic bearings and a flooded
evaporator.

Flooded evaporator is a consolidated technology and “oil-free” centrifugal compressors have been available
for a few years, but only after carrying out protracted and in-depth studies has Uniflair decided to develop
these units.

By combining the concept of “oil-free” units and “flooded evaporator”, it has been possible to develop a unit
which features:
Unequalled energy saving
Extremely low noise
Complete absence of vibrations
Less weight than that of units with a similar capacity

Version 1.1 – November 2007 7

BASIC VERSION

Between one and four “oil-free” centrifugal compressors with magnetic bearings equipped with:
- Integrated thermal protection
- Protection and control of the axis rotation position
- Synchronised brushless DC motor
- Integrated control system
- Speed control with inverter
- Soft start start up
- Phase sequence control
- Pre-rotation valve
- Temperature and pressure sensors
- 2 stages of centrifugal compressors
- Anti-vibration supports
Single refrigerant circuit conforming to EC standards (PED 97/23/CE directive) in copper piping including:
dehydrator filter, liquid sight glass, electronic expansion valve controlled by means of a level sensor,
discharge and suction compressor shut off valves, pressure switches, transducer and high and low pressure
gauges
By-pass line for start-up without load and other compressor actions
Shell & tube flooded evaporator with integrated de-mister to prevent droplets forming: the exchanger is
insulated with closet cell expanded neopropane
Differential water flow pressure switch for the evaporator and condenser
Shell & tube condenser
Electrical panel conforming to EC standards (73/23/CE and EMC 89/336/CE directives) equipped with
- EMC filter with harmonic protection
- Maximum internal temperature control
- General shut-off switch
- Fuses on the compressors
- Remote control
Line reactance for each compressor to stabilize the voltage
Phase sequence control and minimum / maximum voltage and power supply
UPC3m microprocessor control system including:
- Continuous control of the cooling capacity by means of an inverter and an IGV (Inlet Guide Vane)
- PGD local user terminal with external display
- Outlet chilled water temperature control
- Integrated LAN card for local area network connection of more than one chiller
- Clock card
The control system:
- External pump group management for the evaporator
- Modification of the set-point by an external 0-10V signal
- Management of a double set-point with contact selection
- General alarm contact and 2 addressable alarms
- ON-OFF remote control
- Interface with the main communication protocols: Modbus, Bacnet, Lonworks, Trend, Metasys, TCP/IP
and SNMP.

8 Version 1.1 – November 2007

VERSIONS AND AVAILABLE OPTIONS
Versions

Basic version
1
Version with sea water condensers
recovery
Heat

1
Partial / total heat recovery
adaptor

RS485
Serial

LON FTT10
TCP/IP
Accessories

Remote user terminal

Victaulic pipe joints
Neoprene anti-vibration supports

1
On request
Version 1.1 – November 2007 9
 DATA PLATE

DATA PLATE
The chiller data plate is in the electrical panel and OA value (operating current at nominal
gives the following information: conditions), FLA (full load current) and LRA
Model of the unit; (Locked rotor current);
Serial number; Safety device settings;
Number of phases and power supply Refrigerant type and charge (in kg) for
frequency for primary and auxiliary each circuit.
circuits;
Current and absorbed power;

“CE” ELECTRICAL DATA PLATE

UNIFLAIR S.p.A
Viale della Tecnica 2
35026 Conselve (Padova) ITALY 1115

Mod. Serial.No. Year

Electrical board:…………………….
Power supply:………………………. Consumpt. (Amp.)………………………….
Voltage supply:……………………….. Consumt. (Amp.)………………………….
Inter. power. Watt………………………………………….

Refrigerant type…………………………… Load (kg)………………………………….

PS - high side (barG): ……………… TS max. - low side (°C): …………………
TS min. (°C):………………………………..
-10

10 Version 1.1 – November 2007

 MAIN FEATURES

LEADING-EDGE TECHNOLOGY COMPRESSORS: CENTRIFUGAL COMPRESSORS WITH MAGNETIC

BEARINGS

A new generation of centrifugal chillers is available with the BCWC models from the UNIFLAIR AQUAFLAIR
BCWC
series.
The new technology is based on the use of centrifugal compressors with “oil free” magnetic bearings
integrated with frequency control (inverter) which enables extremely high fan rotation speeds to be reached
(40000 rotations/min) and to ensure efficient control at various loads. The integrated soft starter allows
gradual start-up with low inrush currents. The absence of oil allows several compressors to be installed in
parallel on a single circuit. High efficiency of the compressor is supported by high efficiency from the flooded
evaporator.
The control system is based on an UpCO3m system which communicates with the control inside the
compressor which manages the chiller.
Four water-cooled models, with nominal cooling capacities ranging from 320 to 1250kW, are available in the
chillers series.

REDUCED OPERATING COSTS

Improved performance at full load

Even if many chillers feature good performance at full load, the BCWC has a COP at full load of
4.8 and 5 kWf/kwa (according to ARI standard). Typical values for chillers with screw compressors are a
COP between 4.5 and 4.7 kwf/kwa.

Optimum performance at partial loads

In the majority of operating states the chiller does not operate at nominal load, but at lower loads.
The best system to evaluate energetic performance is therefore that which takes into consideration the load
during the entire operating period.
One of these evaluation systems is the IPLV (Integral Partial Load Value) according to ARI 550/590 which
considers the load weighted as in the following table.

Load Weight Condenser water T in Evaporator water T out

% % °C °C
100 1 29.4 6.7
75 42 23.9 6.7
50 45 18.3 6.7
25 12 18.3 6.7

With a inlet water temperature of 7°C, the BCWC has an IPLV value of between 9.5 and 10
kwf/kwa while the typical values of the chillers with screw compressors have an IPLV value of between 5.5
and 6.5.
This creates a potential energy saving of up to 45%.

Low maintenance costs

Since the system operates without oil, it doesn’t need the usual oil changes or filter replacements typical of a
system using oil.
Maintenance of the bearings and lubrification of the system in general is not necessary.

Version 1.1 – November 2007 11

REDUCED ENVIRONMENTAL IMPACT

Low noise level

Addressing issues connected to noise pollution is an important consideration when designing chillers in order
to safeguard the environment and its inhabitants from any type of disturbance which may cause irritation or
have a negative impact on wellbeing.
BCWC units feature noise power levels which are extremely low, both in their absolute values and above all
at different frequencies.
In fact, thanks to the lack of friction and the continuous compression, the frequency spectrum is without
dominant frequencies and their consequent effect on the noise perceived.

R134a Refrigerant
BCWC units use the environmentally friendly refrigerant gas R134a. It is “environmentally friendly” in the
2
sense that it does not harm the ozone layer and contributes minimally to global warming (the TEWI index
value is very low, less than 10% of that of R407C).

Almost complete lack of vibrations

Despite the high rotation speed, the vibration level of the compressors is extremely low and therefore the
vibrations which are transmitted to the structure are minimal and consequently lead to a reduction in damage
to the refrigerant line.

INCREASED RELIABILITY

Oil related problems are eradicated

The magnetic bearings operate in a toroidal magnetic field. In this way, the risk of damage caused by a lack
of oil is avoided, as is a loss of efficiency due to fouling of the exchangers.

Two or more compressors per circuit

Due to the lack of oil, it is possible to use a single refrigerant circuit with more than one compressor in
parallel.
In fact, if one compressor breaks down, it isn’t necessary to stop all of the circuit and remove the refrigerant
to avoid oil cracking in the cycle; only the compressor which has broken down needs to be isolated and
replaced.

EASE OF INSTALLATION AND MAINTENANCE

All models are fitted with a general door interlock switch: this allows direct connection to the mains power
supply without the need for an external switch; short circuit protection fuses, should, however, be fitted in
order to protect the power supply line.
The units are assembled and fully tested in the factory, making installation simply a question of connection
to the electrical power supply and water circuits.

Particular attention has been paid to planning the position of the components to allow easy access for
ordinary and supplementary maintenance.

Moreover, the sue of the single component R134a means that in the event of a leak, only a simple top up
rather than complete replacement is needed.
In the case of non azeotropic mixed refrigerants, loss of part of the fluid leads to the complete recharging of
the refrigerant circuit, and the declared efficiency will not necessarily be maintained.

2
TEWI (Total Equivalent Warming Impact): parameter concerning refrigerant emissions during the life cycle of the unit and indirect
emissions of CO2 for energy production.

12 Version 1.1 – November 2007

 OPERATING LIMITS

50

45
Condenser inlet water temperature [°C]

40

35

30

25

20

15

10

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Evaporator outlet fluid (water/glycol) temperature [°C]

Nominal power supply tolerance R0 400V +/- 10%

Maximum working pressure of hydraulic circuit P0 10 barg
Storage conditions C0 tra – 20°C e + 45°C

USE OF ETHELYNE GLYCOL

If anti-freeze mixtures are being used, some of the unit’s specifications given in the table (capacity, water flow,
pressure drops) will change.

Minimum fluid temperature 5.0 °C 3.0 °C -5.0 °C -10.0 °C -18.0 °C -28.0°C

Freezing temperature 0 °C -4.4 °C -9.6 °C -16.1 °C -24.5 °C -35.5 °C
Percentage of ethylene glycol by weight 0% 10% 20% 30% 40% 50%
Correction factors
Cooling capacity R0 1 1.02 1.01 1.01 1.01 1.00
Compressor power absorption P0 1 1.02 1.05 1.02 1.02 1.02
Water side pressure drops
C0 1 1.10 1.25 1.51 1.76 2.05
Corrected cooling capacity (**) = Nominal cooling capacity x R0.
Corrected compressor absorbed power (**): Nominal absorbed power x P0.
Corrected water side evaporator power drop (**): Evaporator pressure drop x C0.
(**) with the same evaporator inlet and outlet temperatures.

Version 1.1 – November 2007 13

 MAIN COMPONENTS

MAIN COMPONENTS

The units is built to conform to the 73/23/CEE directive and to its relative standards.
The panel has a general door interlock switch and is housed in an appropriate compartment protected by a panel
fastened with fast screws.

The maximum internal temperature of the electrical panel is controlled by a thermostat, and is maintained
within parameters which ensure that the panel is protected by the ventilation of external air.

Main features:

Conforming to EC standards (73/23/EC and EMC 89/336/EC directives)

General shut off switch
IP42 protection grade
24V auxiliary for the main board
230V auxiliary for the compressor contactors
Fuse protection for each compressor against short-circuits
Compressor contactors
1 voltage-free contact for remote signalling of general alarms
Contact for external pump group start-up
EMC filter with harmonic protection
Maximum internal temperature control

14 Version 1.1 – November 2007

COMPRESSORS
Centrifugal compressors offer, in general, optimum fluid dynamic efficiency.
Unlike with traditional centrifugal compressors, it is possible to vary the rotation speed (by means of an
inverter) which allows better efficiency at partial loads and acts efficiently with the centrifugal compression.

2 centrifugal compression
stages
Speed controller
with inverter

Temperature and
pressure
sensors

Synchronised
brushless DC
motor
Pre-rotation
valve

Motor control
and magnetic bearings

Gas compression

The refrigerant enters form the suction slow pressure and low temperature side and is heated.
It passes therefore through a valve which has adjustable fins (IGV) which is usually used in centrifugal
compressors to regulate the capacity.
The gas is subjected to the first compression by the first stage impeller.
The centrifugal forces produced by the rotation of the first impeller increases speed and pressure.
The gas is directed at high speed by means of a di-swirl vane to the impeller of the second compression
stage and is discharged through the volute. (The speed decreases in the volute and the pressure increases).
From here the high pressure gas at a high temperature exits from the discharge exhaust.

Version 1.1 – November 2007 15

 Pre-rotation blade (IGV : Inlet Guide Vane)

The IGV system is built from an angles pre-rotation blade with variable opening and is activated by a
motor which is controlled by the central microprocessor control.
The IGV system routes the refrigerant to the entrance of the fist compression stage by pre-rotating in the
same direction as the impeller rotation.
The opening angle can move from 0 to 110°. At maximum load the angle is 110° and the gas flow is
routed at a tangent to the blades of the first stage impeller.
The reduction in the cooling capacity is made by decreasing the rotation speed by means of the
inverter and by modifying the opening angle of the IGV.
By modifying the opening angle, the inclination of the refrigerant flow changes in respect to the blade of
the impeller.
To reduce the cooling capacity, the opening angle is modified to increase the inclination of the refrigerant
flow in respect to the blade of the impeller.
In this way, the gas speed component which is tangent to the blade decreases while the orthogonal
component increases.
Consequently, the maximum flow decreases, as does the cooling capacity; whereas the increase of the
orthogonal component decreases the variation in momentum between the outlet and inlet of the impeller
with a consequent decrease in the absorbed power.

Regulation of the compressor capacity by means of an inverter and IGV

A traditional centrifugal compressor is regulated with only IGV: introducing counter-rotation of the
refrigerant limits the cooling capacity.
The valve, however, generates pressure drops in the suction side limiting the total efficiency of the
compressor.

The best system for controlling the capacity is that of adapting the required load to that which is available
and this is possible with a system which has an inverter. Such a solution enables the impeller rotation
speed to be varied according to the capacity required.
Thanks to the magnetic bearings, the speed which can be reached is extremely high: the range is, in fact,
between 18000 and 40000 rpm.
Regulation by means of the inverter allows the capacity to be controlled from 100% and from 20%; the
control limits depend on the condensation conditions and by the number of compressors operating on the
same circuit: the IGV intervenes in sequence with the inverter for regulation with reduced loads (less than
20%) and with high condensing temperatures.

16 Version 1.1 – November 2007

Magnetic bearings

The motor shaft and the impellers levitate during rotation in a

Magnetic toroidal field generated by the magnetic bearings.
Two radial and one axial bearings are used.
Sensors monitor in real time the exact position of the shaft
and signal it to the control system.
If there is a misalignment compared to the correct position,
The shaft rotation is immediately changed and maintained
in a central position.
When the rotor is not connected to the power supply it is
supported by magnetic bearings which are made from
carbon and are designed for extended operating times.

In the diagram which is shown below, the position of the

components is shown and, in particular, the bearings and
the sensors.

The motor
This is a 140hp motor which has the size of an induction motor of 1 hp
Operates at high speed (15000-40000 rpm)
Low in rush current (2 ampere)
Cooling system: refrigerant
Thermistor protection

Version 1.1 – November 2007 17

Cooling the motor
The cooling of the motor is carried out by the refrigerant flow. The refrigerant enters the compressor and
cools both the electronic and mechanical components in order to achieve maximum efficiency and, at the
same time, maintain safety conditions.
The refrigerant which is sub cooled by the condenser enters the compressor through two solenoid valves
and two orifice plates which are placed in series.
The orifice plates cause the expansion and lowering of the gas temperature. Both of the solenoid valves are
driven according to the temperature detected by sensors placed on the inverter (called IGBT) and in the
cavity of the motor. When the temperature reaches a pre-determined value, one of the solenoid valves
opens, if the temperature still increases, the second solenoid valve will open.
The refrigerant is routed from the orifice plates to the cooling plate of the IGBT and then onto the rectifier
(which converts the AC line to DC).
The refrigerant then passes through the grooves which are around the stator of the motor and at this stage it
is completely vaporized.

The gas is therefore channelled towards the suction section, cooling the rotor and then the impellers of the
compressor.

18 Version 1.1 – November 2007

Integrated control system

This diagram shows the system for controlling and monitoring the compressors.

The main components are:

EMI/EMC filter: a filter for minimizing harmonics at high frequencies. Such a filter is mandatory in
order to satisfy EC directives.
Line reactor : reactance not included in the compressor which is necessary to improve the cosphi
to more than 0.95
Motor drive : which is composed of:
o Half controlled rectifier: converts the AC line to DC
o DC link capacitors: condensers placed in series with the rectifier which act
as a store of energy and as a filter ensuring a stable DC power supply
o IGBT: an inverter which converts the DC line into 3 AC phases, the
frequencies and voltage of which are controlled by PWM signals of the
Bearing – Motor-Compressor Controller.
Soft –Start Controller: limits the inrush currents by means of the SCR (silicon-controlled rectifiers)
Bearing-Motor-Compressor Controller (BMCC): this module is the central processor of the
compressor where there is the control hardware and software.
Backplane I/O: this module transfers information between the BMCC and the other
components of the compressor.
Bearing PWM amplifier: an amplifier which supplies power to the actuators of the radial and axial
magnetic bearings.
Serial driver: transforms the signal from the BMCC to control the IGV and the solenoid valves to
cool the motor and the external expansion valves.
DC-DC converters: coverts the high DC voltage (480-700 v) to low DC 250V voltage to power the
magnetic bearings and supply 24v of power to the Backplane board.

Version 1.1 – November 2007 19

Soft Start
Soft start activates the start-up of the compressor by reducing the starting current.
The starting current, which is significantly higher than the nominal current, may damage the electrical and
electromagnetic components and create disturbance on the electrical line.
When the compressor is not connected to the power supply, the condensers (DC link capacitors) are not
charged. When the compressor is powered, the input current increases to a value which results in the
condensers almost short-circuiting while they charge.
In the two graphs shown below, the curves with and without soft start are compared.
Without soft start the starting current on the DC line is extremely high when the compressor is switched on.
When the condensers are charged, the current goes down to a normal level.

20 Version 1.1 – November 2007

CONDENSER

The units are equipped with one shell & tube condenser
with two water-side and one refrigerant-side passages.

Made from copper piping and built in such a way as to

ensure high efficiency for the entire life span of the
exchanger: in fact, the tube is fitted with a special spiral
which stops incrustation forming

The units can also be supplied on request with special

condensers which are suitable for operation with sea water
(Cu/Ni tubes).

EVAPORATOR

BCWC units are fitted with a flooded evaporator, 1 gas

circuit shell side and 4 water passages inside the tubes
which are able to operate with a delta t (outlet water t –
evaporating t) between 1 and 2°C with low pressure drops
and overheating of 1-2°C.
It is built from a section of evaporator where evaporation
occurs (pool boiling) and from the separation section where
the droplets separate.
The exchanger is covered completely in closed cell
expanded polyurethane to prevent the formation of
condensation and to limit heat losses. Moreover, this
material is UV resistant.

ANTI-VIBRATION SUPPORTS

To reduce vibration, BCWC units can be supplied with neopropene anti-vibration supports.

4000
Vertical static load [daN]

3000

2000

1000

0
0 1 2 3 4 5
Deflection [mm]

Version 1.1 – November 2007 21

 ACCESSIBILITY TO THE MAIN COMPONENTS

COMPRESSORS

Direct access to the compressors.

WARNING: HOT SURFACE, BURN HAZARD. With the guards removed, the
compressors and the cooling circuit’s delivery pipes are within reach. During the
unit’s regular operation these parts get very hot and therefore are potentially
hazardous.

WARNING: When performing maintenance, ALWAYS set the master switch

IG to “0

ELECTRICAL PANEL

For access to the electrical panel, turn the handle of master switch IG to “0”, turn the latches a ¼ turn and
lift using the grip.
This procedure enables you to open the panel which is hinged on the top of the electrical panel.
.

ATTENZIONE
PRIMA DI QUALSIASI INTERVENTO LEGGERE ATTENTAMENTE IL LIBRETTO DI ISTRUZIONI.
APPARECCHIO IN TENSIONE : PRIMA DI INTERVENIRE SU QUALSIASI PARTE ELETTRICA
TOGLIERE TENSIONE ALL’APPARECCHIO.

WARNING
BEFORE ANY OPERATIONS ON THIS UNIT READ THE INSTRUCTION MANUAL CAREFULLY.
THIS EQUIPMENT CONTAINS COMPONENTS AT MAINS VOLTAGE : DISCONNECT POWER
BEFORE ANY OPERATION ON ELECTRICAL COMPONENTS.

ACTHUNG
VOR ALLEN ARBEITEN AN DIESEM GERÄT IST DIE BEDIENUNGSANLEITUNG GENAU STUDIEREN.
DIESES GERÄT ENTHÄLT BUTEILE, DIE UNTER SPANNUNG STEHEN SOWIE SICH DREHENDE
VENTILATOREN: VOR ARBEITEN IM GERÄT IST DIE NETZZULEITUNG ABZUSCHALTEN.

ATTENTION
LIRE ATTENTIVEMENT LE MANUEL D’INSTRUCTIONS AVANT TUOTE INTERVENTION.
CET EQUIPEMENT UTILISE DES COMPOSANTS ÉLECTRIQUE SOUS TENSION.
COUPER L'ALIMENTATION AU DISJONCTEUR AVANT TOOTE INTERVENTION SUR
LES COMPOSANTS ELECTRIQUES.

ATENCION
ANTES DE CUALQUIER INTERVENCIÓN LEER ATENTAMENTE EL MANUAL DE INSTRUCCIONES.
APARATO BAJO TENSIÓN. ANTES DE INTERVENIR SOBRE CUALQUIER PARTE ELÈTRICA
QUITAR TENSION AL APPARATO.

WARNING: Before removing the panel, you must set the master switch to “0” to prevent
the compressors, reaching HIGH PRESSURE ALARM level.
.

22 Version 1.1 – November 2007

BCWC – DIMENSIONS AND WEIGHTS

BCWC 0320A 0630A 0950A 1250A

Dimensions

Height mm 2028 2130 1924 1924

Length mm 2640 2940 3294 4591

Width mm 1061 1022 1544 1505

2
Footprint m 2,8 3,0 5,1 6,9

Water content Lt 105 251 325 518

(1)
Weights

Basic version Kg 1585 2814 3752 5760

(1) Data refer to a unit charged with refrigerant and with an empty hydraulic circuit

TOTAL AND PARTIAL HEAT RECOVERY

In the BCWC range it is possible (on request) to supply the unit fitted with heat recovery.
This is carried out by replacing the shell & tube condenser with 2 steps with one with 4 steps.
This option enables the heat which would otherwise be dispersed outside the condenser, is used to obtain
hot water which is typically used for sanitary purposes.
Total and partial heat recovery is achieved as illustrated in the following diagram, if hot water needs to be
produced, the water should be made to flow through the dedicated exchanger.

B C DN
54

INe E
OUTe
RUS
F12
2

Version 1.1 – November 2007 23

Compressor A

Inlet / outlet heat recovery and condensation B

Condenser / recuperator C

Electronic expansion valve D

Flooded evaporator E

Evaporator water inlet INe

Evaporator water outlet OUTe

INSTALLATION GUIDE
TRANSPORT AND HANDLING

The symbols on the packaging conform to the ISO7000 standard and are explained below.

SYMBOL MEANING SYMBOL MEANING

FRAGILE: handle with care. THIS SIDE UP shows the
orientation of the unit.

PROTECT AGAINST TEMPERATURE LIMITS: the unit

MOISTURE: the packaged unit must not be stored outside these
must be stored in a dry place. limits.

CENTRE OF GRAVITY: shows NO HOOKS: do not use hooks to

the centre of gravity of the lift the packed unit.
packaged unit.

KEEP AWAY FROM HEAT: the DO NOT STACK.

unit must be kept away from heat
sources.

Move the unit as near to the installation site as possible before removing packaging.
The unit must be lifted using equipment and procedures illustrated in the drawings in the last section of this
manual.

WARNING: check the drawing attached to the unit or the installation drawings printed on the last few
pages of this manual.

Unit dimensions are given in the technical data tables and installation drawings included with the unit.

24 Version 1.1 – November 2007

 RICEIVING AND STORING THE UNIT
Each unit leaves the factory in perfect condition. Therefore please check the unit very carefully on delivery
and notify the transport company immediately and in writing of any damage.

Check that the load capacity of the floor is sufficient to support the weight of the unit.

The unit must be set on a solid, level surface. Once positioned, level the unit with the aid of a suitable spirit
level using the adjustable feet and, where necessary, shims: the gradient should not exceed 0.5 degrees
under any circumstances.

Warning: the unit must not be turned on its side or upside down.

HANDLING
In order to allow for simple movement, the units are equipped with eyebolts for connection to the lifting straps
(for detail please see the movement diagrams shown at the end of this document).

Version 1.1 – November 2007 25

 POSITIONING THE UNIT – OPERATING SPACE
INSTALLATION NOTE
OPERATING SPACE

In the figures below, the minimum advised distances both for correct operation of the unit and for
accessibility to the internal components for standard maintenance are shown.

BCWC0320A

800mm

1000mm 600mm

1200mm

BCWC0630A

800mm

600mm 1000mm

1200mm

BCWC0950A
26 Version 1.1 – November 2007
 800mm

600mm 1000mm

1600mm

BCWC1250A

800mm

1000mm 1000mm

1600mm

Version 1.1 – November 2007 27

UNIT LAYOUT
The last section of the manual features diagrams for each unit, summarizing:
Weight distribution
Overall dimensions

HYDRAULIC CONNECTIONS
(see also the enclosed installation drawings and hydraulic diagram)

1) CHECK that the section of chilled water pipe and the heat pump 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 as
shown in the diagram below. (The drawing of the connection at the side shows the Victaulic connection
option for the evaporator).

INGRESSO - INLET
EINGANG - ENTREE

Iev ENTRADA

USCITA - OUTLET
AUSGANG - SORTIE
Uev SALIDA

4) CONNECT the chiller using flexible tubes 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.

WIRING
(consult wiring diagram)

28 Version 1.1 – November 2007

Before performing any work on electrical parts, make sure they are not connected
to the power supply.
In order for accidents to be prevented and for the chiller to provide good, lasting,
unaltered service, it is that essential wiring is carried out correctly, in a professional
manner and in accordance with the regulations in force.

GENERAL INSTRUCTIONS
CONNECTION TO SUPPLY MAINS
In order to maintain the IP42 protection grade, it is necessary to use cable glands / girdle
clamps and/or suitable junction boxes.
The cable connections must be carried out by removing the plexiglass placed on the poles of the
isolating switch and by fixing the wire terminals of the cables on the relevant holes provided for this
purpose.
After the wiring process has been carried out it is advisable to restore the protection.
It is vital that the phases are connected correctly in the position indicated on the wiring diagram
which is supplied with the unit, since if they are connected in any other way, the unit will not
work.

Particular attention must be paid to the following:

Wiring must be carried out by qualified technicians.
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 in force.
It is of vital importance that connection to the equipotent ground is carried out carefully,
using a suitable section and quality of cable (Refer to the current standards in force).
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 which are shown in the electrical data tables.

PROCEDURE DESCRIPTION
1) OPEN the door of the master electrical panel which is located on the front of the unit above the
compressor compartment;

2) MAKE SURE that the mains voltage matches the voltage given on the data plate of the unit (voltage,
number and frequency of the phases)

3) INTRODUCE the feeding cable through the flange indicated in the position in the diagram.

On the base of the electrical panel there are holes which allow the following to enter:
a. Supply cable, which will be connected to the terminals of the general cut off switch
b. Signal cables which will be connected to the terminals of the microprocessor board.

The supply cable is not supplied by Uniflair S.p.A, and must be correctly sized by the installer.
The supply cable section must be chosen according to its length and the type of installation, depending
on the maximum absorbed current of 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).
Connection of the supply cable must be supported by a suitable inlet flange.

BCWC 0320

Version 1.1 – November 2007 29

 Supply cable
inlet for
electrical panel

BCWC 0650

Supply cable
inlet for
electrical panel

BCWC 0950

30 Version 1.1 – November 2007

 Supply cable inlet
for
electrical panel

BCWC 1250A

Supply cable
inlet for
electrical panel

4) CONNECT the three power phases to the terminals of the general cut off switch after having checked that
no part of the electrical panel is connected to the power supply.
Check the housing of the wires and their respective terminals and fix the screws.

TECHNICAL DATA and PERFORMANCE

Version 1.1 – November 2007 31
Model 0320A 0630A 0950A 1250A

Power supply 400 / 3 / 50

Nr circuits / Nr compressors 1/1 1/2 1/3 ¼

Compressor type Centrifugal

Nr / type evaporators / Nr
refrigerant circuits 1 / Flooded / 1

Nr / type condensers / Nr
1 / Shell & Tube / 2 steps water side
water stops
Evaporator hydraulic
3” (BSP) DN100 (Victaulic) DN125 (Victaulic) DN150 (Victaulic)
connections
Condenser hydraulic
3” (BSP) DN100 (Victaulic) DN125 (Victaulic) DN125 (Victaulic)
connections

0320A 0630A 0950A 1250A

(1)
Cooling capacity kW 320 630 950 1250

(1)
Absorbed power kW 61 123 182 235

(1)
E.E.R. 5,22 5,12 5,2 5,31

(2)
I.P.L.V. 9,96 9,80 9,92 9,87

(3)
E.S.E.E.R. 9,61 8,90 9,57 9,53

(1)
Evaporator water flow l/h 55130 108532 163658 215340

(1)
Evaporator pressure drop kPa 63 52 64 28

Condenser thermal capacity

(1) kW 381 753 1132 1485

(1)
Condenser water flow l/h 66084 130538 196305 257418

(1)
Condenser pressure drop kPa 30 60 53 28

(1) Data refer to nominal conditions: Evaporator water temperature in/out: 12 / 7 °C; Condenser water temperature in/out: 30/35°C;
condenser fouling co-efficient: 0,000043m2°C/W; fouling co-efficient co-efficient: 0,000043m2°C/W; R134a refrigerant
(2) Integrated Partial Load Value: based on ARI conditions
(3) European Seasonal Energy Efficiency Ratio

ELECTRICAL DATA
If the electrical data refer to the following nominal conditions (OP and OA) they are shown in the tables on
the previous pages.
32 Version 1.1 – November 2007
The electrical data are as follows:

OP: Operating Power: the absorbed power at nominal conditions [kW]

OA: Operating Amperage: the electrical absorption at nominal conditions [A]
FLI: Full Load Input Power: maximum absorbed power [kW]
FLA: Full Load Amperage: maximum absorbed current [A]
LRA: Locked Rotor Amperage: the rotor current is blocked [A]
ST: Type of start-up
SC: Inrush current of the unit, the inrush current of a single compressor [A]

Compressor
OP OA FLI FLA LRA ST
0320A 59 90 95 135 145 Soft start
0630A 61 94 96 135 145 Soft start
0950A 61 93 97 135 145 Soft start
1250A 60 92 94 135 145 Soft start

Complete unit
OP OA SC FLI FLA LRA

0320A 59 90 <2 95 135 145

0630A 123 187 <75 192 270 213
0950A 184 279 <140 288 405 280
1250A 240 368 <205 376 540 348

Version 1.1 – November 2007 33

NOISE PRESSURE LEVEL
The SOUND PRESSURE levels shown are measured with the unit operating at full load, in free field with a
directional factor of Q=2, at a distance of 1m from the unit according to IS03744-3746.

The SOUND PRESSURE LEVELS are shown in the tables below (measured with BRÜEL & KJǼR class 1
sound-level meter mod. 2260) for each octave band frequency, measured with units operating at full load, in
free field with a directional factor of Q=2, at a distance of 1m from the unit according to ISO 3744.-ISO3746
The SOUND POWER LEVELS are for each octave band frequency in compliance with ISO3744-ISO3746.

The tolerance on the data is +/- 1.5 dB.

NB: the data supplied refers to units operating according to the factory settings.

SOUND PRESSURE LEVEL

Model Lp
63Hz 125Hz 250Hz 500Hz 1000Hz 2000Hz 4000Hz 8000Hz
[dB(A)]
0320A 22.1 40.3 47.6 55.4 59.6 63.2 61.5 57.3 67.3
0630A 25.1 43.3 50.6 58.4 62.6 66.2 64.5 60.3 70.3
0950A 26.9 45.1 52.4 60.2 64.4 68.0 66.3 62.1 72.1
1250A 28.1 46.3 53.6 61.4 65.6 69.2 67.5 63.3 73.3

SOUND POWER LEVEL

Model Lw
63Hz 125Hz 250Hz 500Hz 1000Hz 2000Hz 4000Hz 8000Hz
Model [dB(A)]
0320A 39.8 58.0 65.3 73.1 77.3 80.9 79.2 75.0 85.0
0630A 43.3 61.5 68.8 76.6 80.8 84.4 82.7 78.5 88.5
0950A 45.3 63.5 70.8 78.6 82.8 86.4 84.7 80.5 90.5
1250A 47.7 65.9 73.2 81.0 85.2 88.8 87.1 82.9 92.9

34 Version 1.1 – November 2007

 EVAPORATOR PRESSURE DROP (water side)

N.B. Data refer to water with 0% glycol

pressure drop evaporator

100,0

0
320

630

950

125
pressure drop kpa

10,0
10,0 100,0 1000,0
w ater flow m 3/h

CORRECTION FACTORS of the pressure drop according to the ethylene glycol content

Fluid
% Ethylene glycol
temperature
[°C] 0 10 20 30 40 50
- 10 1 1.09 1.21 1.34 1.46 1.58
-5 1 1.08 1.19 1.30 1.41 1.52
0 1 1.07 1.16 1.25 1.35 1.44
5 1 1.06 1.13 1.20 1.27 1.34
10 1 1.05 1.10 1.14 1.17 1.21

Version 1.1 – November 2007 35

 CONDENSER PRESSURE DROP (water side)

N.B. Data refer to water with 0% glycol

pressure drop condenser

100,0

1250
950
630
320
pressure drop kpa

10,0
10 100 1000
w ater flow m 3/h

CORRECTION FACTORS of the pressure drop according to the ethylene glycol content

Fluid
% Ethylene glycol
temperature
[°C] 0 10 20 30 40 50
- 10 1 1.09 1.21 1.34 1.46 1.58
-5 1 1.08 1.19 1.30 1.41 1.52
0 1 1.07 1.16 1.25 1.35 1.44
5 1 1.06 1.13 1.20 1.27 1.34
10 1 1.05 1.10 1.14 1.17 1.21

36 Version 1.1 – November 2007

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UNIFLAIR S.p.A.
Legal and Aministrative Headquarters: Viale della Tecnica
2, 35026
Conselve (PD) Italy
Tel +39 049 5388211 Fax +39 049 5388212 - uniflair.com
[email protected]
P.IVA 02160760282 C.C.I.A.A. di PD R.E.A. 212586 del
21/04/1988 - R.I.N. 02160760282 M. PD004505

Share capital € 19.550.000 fully paid up

06MM131@00B0110

Version 1.1 – November 2007