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BW10 020-090
Water-Sourced Heat Pumps
with or without Integrated
Hydronic Modules
Nominal cooling capacity 24-95 kW
Nominal heating capacity 30-116 kW
Installation, operation and maintenance instructions
VMGFT102
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CONTENTS
1 INTRODUCTION ................................................................................................................................................................... 4
1.1 - Installation safety considerations ............................................................................................................................................................................4
1.2 - Equipment and components under pressure .....................................................................................................................................................5
1.3 - Maintenance safety considerations ........................................................................................................................................................................5
1.4 - Repair safety considerations ......................................................................................................................................................................................6
2 PRELIMINARY CHECKS ........................................................................................................................................................7
2.1 - Check equipment received ........................................................................................................................................................................................7
2.2 - Moving and siting the unit .........................................................................................................................................................................................7
3 DIMENSIONS, CLEARANCES ...............................................................................................................................................9
3.1 - BW10 020-045 - standard unit...................................................................................................................................................................................9
3.2 - BW10 020-045 - unit with top connections (option 274) ................................................................................................................................9
3.3 - BW10 020-045 - unit with evaporator hydronic module (option 116) .................................................................................................... 10
3.4 - BW10 020-045 - unit with condenser hydronic module (option 270) ..................................................................................................... 10
3.5 - BW10 020-045 - unit with evaporator/condenser hydronic modules (options 116 + 270) ............................................................. 10
3.6 - BW10 020-045 - unit with hydronic module and top connections (options 116 + 274 - 270 + 274 - 116 + 270 + 274) .......11
3.7 - BW10 020-045 - stackable unit (option 273) ..................................................................................................................................................... 11
3.8 - BW10 050-090 - standard unit................................................................................................................................................................................12
3.9 - BW10 050-090 - unit with top connections (option 274) ............................................................................................................................. 12
3.10 - BW10 050-090 - unit with evaporator hydronic module (option 116) ..................................................................................................13
3.11 - BW10 050-090 - unit with condenser hydronic module (option 270) ...................................................................................................13
3.12 - BW10 050-090 - unit with evaporator/condenser hydronic modules (options 116 + 270) ...........................................................13
3.13 - BW10 050-090 - unit with hydronic module and top connections (options 116 + 274 - 270 + 274 - 116 + 270 + 274) ..... 14
3.14 - BW10 050-090 - stackable unit (option 273) ..................................................................................................................................................14
4 PHYSICAL AND ELECTRICAL DATA BW10 ........................................................................................................................15
4.1 - Physical data BW10 ....................................................................................................................................................................................................15
4.3 - Physical data BW10 units with hydronic module ...........................................................................................................................................16
4.4 - Electrical data BW10 .................................................................................................................................................................................................16
4.5 - Short-circuit stability current (TN system*) - standard unit (with main disconnect switch) ........................................................... 16
4.6 - Electrical data, optional hydronic module .........................................................................................................................................................17
4.7 - Compressor usage and electrical data table .....................................................................................................................................................18
5 APPLICATION DATA ...........................................................................................................................................................18
5.1 - Operating limits ...........................................................................................................................................................................................................18
5.2 - Operating range BW10 .............................................................................................................................................................................................19
5.4 - Minimum chilled water flow ................................................................................................................................................................................... 19
5.5 - Maximum chilled water flow ..................................................................................................................................................................................19
5.6 - Variable flow .................................................................................................................................................................................................................19
5.7 - Water flow rate ............................................................................................................................................................................................................. 19
5.8 - Minimum water volume ........................................................................................................................................................................................... 19
5.9 - Maximum water loop volume (evaporator and condenser side) ..............................................................................................................20
5.10 - Expansion tank .......................................................................................................................................................................................................... 20
5.11 - Protection against cavitation (option 116) ..................................................................................................................................................... 20
5.12 - Plate heat exchanger pressure drop (includes internal piping) ..............................................................................................................21
6 ELECTRICAL CONNECTION ...............................................................................................................................................22
6.1 - Electrical connections, control box BW10 .........................................................................................................................................................22
6.2 - Power supply ................................................................................................................................................................................................................ 22
6.3 - Voltage phase imbalance (%) ................................................................................................................................................................................. 22
6.4 - Recommended wire sections ................................................................................................................................................................................. 22
7 WATER CONNECTIONS ......................................................................................................................................................23
7.1 - Operating precautions ..............................................................................................................................................................................................23
7.2 - Water connections ...................................................................................................................................................................................................... 24
7.3 - Frost protection ........................................................................................................................................................................................................... 24
7.4 - Flow switch (units without hydronic module) .................................................................................................................................................24
8 NOMINAL WATER FLOW CONTROL WITH FIXEDSPEED PUMP ....................................................................................25
8.1 - General ...........................................................................................................................................................................................................................25
8.2 - Water flow control procedure ............................................................................................................................................................................... 25
9 NOMINAL WATER FLOW CONTROL WITH VARIABLESPEED PUMP ..................................................................................27
9.1 - Pump flow/pressure curve ...................................................................................................................................................................................... 27
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The illustrations in this document are for illustrative purposes only and not part of any offer for sale or contract.
9.2 - Available static system pressure (fixed or variable-speed high-pressure pumps, units with hydronic module) .....................27
9.3 - Available static system pressure (fixed or variable-speed low-pressure pumps, units with hydronic module) .....................................28
9.4 - Available static pressure for pumps only (units with hydronic modules) ..............................................................................................29
10 BW10 UNIT OPERATION WITH SPECIFIC HEATING CONTROL OPTION 153 ..............................................................31
10.1 - Operating principle .................................................................................................................................................................................................31
11 STARTUP ..........................................................................................................................................................................31
11.1 - Preliminary checks ...................................................................................................................................................................................................31
11.2 - Actual start-up ........................................................................................................................................................................................................... 31
11.3 - Operation of two units in master/slave mode (option 58) ........................................................................................................................32
12.4 - Parallel or serial connection of two BW10 units ............................................................................................................................................ 32
12 MAJOR SYSTEM COMPONENTS AND OPERATION DATA ..............................................................................................32
12.1 - Compressors ..............................................................................................................................................................................................................32
12.2 - Lubricant .....................................................................................................................................................................................................................32
12.3 - Evaporators and condensers ................................................................................................................................................................................32
12.4 - Electronic expansion valve (EXV) ....................................................................................................................................................................... 33
12.5 - Refrigerant ..................................................................................................................................................................................................................33
12.6 - High-pressure switch and high-pressure sensor ..........................................................................................................................................33
12.7 - High and low-pressure side safety valves ........................................................................................................................................................33
12.8 - Moisture indicator .................................................................................................................................................................................................... 33
12.9 - Filter drier in the refrigerant circuit ....................................................................................................................................................................34
12.10 - Fixed-speed pump.................................................................................................................................................................................................34
12.11 - Variable-speed pump ........................................................................................................................................................................................... 34
12.12 - Evaporator and condenser pump suction filter ..........................................................................................................................................34
12.13 - Connection sleeves ...............................................................................................................................................................................................34
12.14 - Option 272: High-temperature water production with glycol solution ...............................................................................................34
13 OPTIONS ...........................................................................................................................................................................35
14 MAINTENANCE .................................................................................................................................................................36
14.1 - Soldering and welding ...........................................................................................................................................................................................36
14.2 - General unit maintenance ....................................................................................................................................................................................36
14.3 - Refrigerant undercharge .......................................................................................................................................................................................36
14.4 - Refrigerant guidelines ...........................................................................................................................................................................................36
14.5 - Leak detection ........................................................................................................................................................................................................... 37
14.6 - Evacuation .................................................................................................................................................................................................................37
14.7 - Recharging liquid refrigerant ...............................................................................................................................................................................37
14.8 - Characteristics of R-410A .......................................................................................................................................................................................37
14.9 - Electrical maintenance ...........................................................................................................................................................................................38
14.10 - Tightening torques for the main electrical connections .........................................................................................................................38
14.11 - Tightening torques for the main bolts and screws .................................................................................................................................... 38
14.12 - Compressors ............................................................................................................................................................................................................ 38
14.13 - Evaporator and condenser maintenance ......................................................................................................................................................38
14.14 - Corrosion check ...................................................................................................................................................................................................... 38
15 MAINTENANCE PROGRAM .............................................................................................................................................39
15.1 - Maintenance schedule ...........................................................................................................................................................................................39
15.2 - Description of the maintenance operations ..................................................................................................................................................39
16 STARTUP CKECKLIST FOR BW10 UNITS USE FOR JOB FILE .....................................................................................40
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1 INTRODUCTION
Prior to the initial start-up of the BW10 unit, the people
involved in the on-site installation, start-up, operation and
maintenance of this unit should be thoroughly familiar with
these instructions and the specic project data for the
installation site.
The BW10 liquid units are designed to provide a very high level
of safety during installation, start-up, operation and
maintenance. They will provide safe and reliable service when
operated within their application range.
This manual provides the necessary information to fami-liarize
yourself with the control system before performing start-up
procedures. The procedures in this manual are arranged in the
sequence required for machine installation, start-up, operation
and maintenance.
Be sure you understand and follow the procedures and safety
precautions contained in the instructions supplied with the
machine, as well as those listed in this guide.
To nd out, if these products comply with European directives
(machine safety, low voltage, electromagnetic compatibility,
equipment under pressure etc.) check the declarations of
conformity for these products.
1.1 - Installation safety considerations
After the unit has been received, when it is ready to be installed
or reinstalled, and before it is started up, it must be inspected for
damage. Check that the refrigerant circuit(s) is (are) intact,
especially that no components or pipes have shifted (e.g.
following a shock). If in doubt, carry out a leak tightness check
and verify with the manufacturer that the circuit integrity has
not been impaired. If damage is detected upon receipt,
immediately le a claim with the shipping company.
Do not remove the skid or the packaging until the unit is in
its nal position. These units can be moved with a fork lift
truck, as long as the forks are positioned in the right place
and direction on the unit.
The units can also be lifted with slings, using only the
designated lifting points marked on the unit.
These units are not designed to be lifted from above. Use
slings with the correct capacity, and always follow the lifting
instructions on the certied drawings supplied with the unit.
Safety is only guaranteed, if these instructions are carefully
followed. If this is not the case, there is a risk of material
deterioration and injuries to personnel.
DO NOT COVER ANY PROTECTION DEVICES.
This applies to fuse plugs and safety valves (if used) in the
refrigerant or heat transfer medium circuits. Check if the
original protection plugs are still present at the valve outlets.
These plugs are generally made of plastic and should not be
used. If they are still present, please remove them. Install
devices at the valve outlets or drain piping that prevent the
penetration of foreign bodies (dust, building debris, etc.) and
atmospheric agents (water can form rust or ice). These
devices, as well as the drain piping, must not impair operation
and not lead to a pressure drop that is higher than 10% of the
control pressure.
Classication and control
In accordance with the Pressure Equipment Directive and
national usage monitoring regulations in the European
Union the protection devices for these machines are classied
as follows:
Safety
accessory*
Damage limitation accessory**
in case of an external fire
Refrigerant side
High-pressure switch x
External relief valve*** x
Rupture disk x
Fuse plug x
Heat transfer fluid side
External relief valve**** x x
* Classified for protection in normal service situations.
** Classified for protection in abnormal service situations.
*** The instantaneous over-pressure limited to 10% of the operating pressure does
not apply to this abnormal service situation. The control pressure can be higher
than the service pressure. In this case either the design temperature or the highpressure switch ensures that the service pressure is not exceeded in normal service
situations.
**** The classification of these safety valves must be made by the personnel that
completes the whole hydronic installation.
Do not remove these valves and fuses, even if the re risk is
under control for a particular installation. There is no
guarantee that the accessories are re-installed if the installation is changed or for transport with a gas charge.
All factory-installed safety valves are lead-sealed to prevent
any calibration change. If the safety valves are installed on a
reversing valve (change-over), this is equipped with a safety
valve on each of the two outlets. Only one of the two safety
valves is in operation, the other one is isolated. Never leave the
reversing valve in the intermediate position, i.e. with both ways
open (locate the control element in the stop position). If a
safety stop is removed for checking or replacement please
ensure that there is always an active safety stop on each of the
reversing valves installed in the unit.
The external safety valves must always be connected to drain
pipes for units installed in a closed room. Refer to the
installation regulations, for example those of European
standard EN 378 and EN 13136.
These pipes must be installed in a way that ensures that
people and property are not exposed to refrigerant leaks. As
the uids can be diffused in the air, ensure that the outlet is
far away from any building air intake, or that they are
discharged in a quantity that is appropriate for a suitably
absorbing environment.
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Periodic check of the safety valves: See paragraph 1.3 “Maintenance safety considerations”.
Provide a drain in the drain pipe, close to each safety valve, to
avoid an accumulation of condensate or rain water.
All precautions concerning handling of refrigerant must be
observed in accordance with local regulations.
Ensure good ventilation, as accumulation of refrigerant in an
enclosed space can displace oxygen and cause asphyxia-tion or
explosions.
Inhalation of high concentrations of vapour is harmful and
may cause heart irregularities, unconsciousness, or death.
Vapour is heavier than air and reduces the amount of oxygen
available for breathing. These products cause eye and skin
irritation. Decomposition products are hazardous.
1.2 - Equipment and components under pressure
We recommend that you consult your appropriate national trade
association or the owner of the equipment or compo-nents
under pressure (declaration, re-qualication, retesting, etc.). The
characteristics of this equipment/these components are given on
the nameplate or in the required documenta-tion, supplied with
the products.
Do not introduce signicant static or dynamic pressure with
regard to the operating pressures used during operation or
for tests in the refrigerant circuit or in the heat exchange
circuits.
1.3 - Maintenance safety considerations
Engineers working on the electric or refrigeration compo-nents
must be authorized, trained and fully qualied to do so.
All refrigerant circuit repairs must be carried out by a trained
person, fully qualied to work on these units. He must have
been trained and be familiar with the equipment and the
installation. All welding operations must be carried out by
qualied specialists.
Any manipulation (opening or closing) of a shut-off valve
must be carried out by a qualied and authorised engineer.
These procedures must be carried out with the unit shut
down.
Any intervention on the refrigerant circuit, including
changing of drier blocks, is only permitted after the complete
removal of the refrigerant charge. For these units transfer of
the refrigerant charge from the high or low-pressure side is
not possible, nor permitted.
During any handling, maintenance and service operations
the engineers working on the unit must be equipped with
safety gloves, glasses, shoes and protective clothing.
Never work on a unit that is still energised.
Never work on any of the electrical components, until the
general power supply to the unit has been cut using the
disconnect switch in the control box.
If any maintenance operations are carried out on the unit, lock
the power supply circuit in the open position ahead of the
machine.
If the work is interrupted, always ensure that all circuits are
still deenergized before resuming the work.
ATTENTION: Even if the compressor motors have been
switched off, the power circuit remains energized, unless the
unit or circuit disconnect switch is open. Refer to the wiring
diagram for further details.
Attach appropriate safety labels.
Operating checks:
IMPORTANT INFORMATION REGARDING THE
REFRIGERANT USED:
• This product contains uorinated greenhouse gas
covered by the Kyoto protocol.
Refrigerant type: R-410A
Global Warming Potential (GWP): 1975
Periodic inspections for refrigerant leaks may be
required depending on European or local legislation.
Please contact your local dealer for more information.
• During the life-time of the system, inspection and tests
must be carried out in accordance with national
regulations.
The information on operating inspections given in annex C
of standard EN378-2 can be used if no similar criteria exist
in the national regulations.
Protection device checks:
• If no national regulations exist, check the protection
devices on site in accordance with standard EN378: once
a year for the high-pressure switches, every ve years for
external safety valves.
• The detailed description of the high-pressure switch test
method is given in the service manual for the unit.
At least once a year thoroughly inspect the protection devices
(valves, pressure switches). If the machine operates in a
corrosive environment, inspect the protection devices more
frequently.
Regularly carry out leak tests and immediately repair any
leaks.
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1.4 - Repair safety considerations
All installation parts must be maintained by the personnel in
charge, in order to avoid material deterioration and injuries to
people. Faults and leaks must be repaired immediately. The
authorized technician must have the responsibility to repair the
fault immediately. After each repair of the unit, check the
operation of the protection devices and create a report of the
parameter operation at 100%.
Comply with the regulations and recommendations in unit and
HVAC installation safety standards, such as: EN 378, ISO 5149,
etc.
If a leak occurs or if the refrigerant becomes polluted (e.g. by a
short circuit in a motor or BPHE frost) remove the complete
charge using a recovery unit and store the refrigerant in mobile
containers.
Repair the leak detected and recharge the circuit with the total
R-410A charge, as indicated on the unit name plate. Do not top
up the refrigerant charge. Only charge liquid refrigerant
R-410A at the liquid line.
Ensure that you are using the correct refrigerant type before
recharging the unit.
Charging any refrigerant other than the original charge type
(R-410A) will impair machine operation and can even destroy
the compressors. The compressors operating with this
refrigerant type are lubricated with a synthetic polyol-ester oil.
Never use air or a gas containing oxygen during leak tests to
purge lines or to pressurise a machine. Pressurised air
mixtures or gases containing oxygen can be the cause of an
explosion. Oxygen reacts violently with oil and grease.
Only use dry nitrogen for leak tests, possibly with an
appropriate tracer gas.
If the recommendations above are not observed, this can have
serious or even fatal consequences and damage the
installation.
Never exceed the specied maximum operating pressures.
Verify the allowable maximum high- and low-side test
pressures by checking the instructions in this manual and the
pressures given on the unit name plate.
Do not unweld or amecut the refrigerant lines or any
refrigerant circuit component until all refrigerant (liquid and
vapour) as well as the oil have been removed from unit.
Traces of vapour should be displaced with dry nitrogen.
Refrigerant in contact with an open ame produces toxic
gases.
The necessary protection equipment must be available, and
appropriate re extinguishers for the system and the
refrigerant type used must be within easy reach.
Do not siphon refrigerant.
Avoid spilling liquid refrigerant on skin or splashing it into
the eyes. Use safety goggles and safety gloves. Wash any spills
from the skin with soap and water. If liquid refrigerant enters
the eyes, immediately and abundantly ush the eyes with
water and consult a doctor.
Never apply an open ame or live steam to a refrigerant
container. Dangerous overpressure can result. If it is
necessary to heat refrigerant, use only warm water.
During refrigerant removal and storage operations follow
applicable regulations. These regulations, permitting conditioning and recovery of halogenated hydrocarbons under
optimum quality conditions for the products and optimum
safety conditions for people, property and the environment are
described in standard NF E29-795.
Any refrigerant transfer and recovery operations must be
carried out using a transfer unit. 3/8” SAE connectors on the
liquid, suction and discharge lines are available for all units for
connection to the transfer station. The units must never be
modied to add refrigerant and oil charging, removal and
purging devices. All these devices are provided with the units.
Please refer to the certied dimensional drawings for the units.
Do not re-use disposable (non-returnable) cylinders or
attempt to rell them. It is dangerous and illegal. When
cylinders are empty, evacuate the remaining gas pressure,
and move the cylinders to a place designated for their
recovery. Do not incinerate.
Do not attempt to remove refrigerant circuit components or
ttings, while the machine is under pressure or while it is
running. Be sure pressure is at 0 kPa and that the unit has
been shut down and de-energised before removing
components or opening a circuit. If the refrigerant circuit is
open to carry out a repair, all circuit openings must be
plugged, if the repair takes longer than 30 minutes. This
prevents humidity from contaminating the circuit, especially the
oil. If the work is expected to take longer, charge the circuit
with nitrogen.
Do not attempt to repair or recondition any safety devices when
corrosion or build-up of foreign material (rust, dirt, scale,
etc.) is found within the valve body or mechanism. If
necessary, replace the device. Do not install safety valves in
series or backwards.
ATTENTION: No part of the unit must be used as a walk-way,
rack or support. The refrigerant lines can break under the
weight and release refrigerant, causing personal injury.
Do not climb on a machine. Use a platform, or staging to
work at higher levels.
Use mechanical lifting equipment (crane, hoist, winch, etc.) to
lift or move heavy components. For lighter components, use
lifting equipment when there is a risk of slipping or losing
your balance.
Use only original replacement parts for any repair or compo-nent
replacement. Consult the list of replacement parts that
corresponds to the specication of the original equipment.
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Do not drain water circuits containing industrial brines,
without informing the technical service department at the
installation site or a competent body rst.
Close the entering and leaving water shutoff valves and purge
the unit water circuit, before working on the compo-nents
in
stalled on the circuit (screen lter, pump, water ow switch,
etc.).
Periodically inspect all valves, ttings and pipes of the
refrigerant and hydronic circuits to ensure that they do not
show any corrosion or any signs of leaks.
It is recommended to wear ear defenders, when working near
the unit and the unit is in operation.
2 PRELIMINARY CHECKS
2.1 - Check equipment received
• Inspect the unit for damage or missing parts. If damage is
detected, or if shipment is incomplete, immediately le a
claim with the shipping company.
• Compare the name plate data with the order. The name plate
is attached in two places to the unit:
- on one of the unit sides on the outside,
- on the control box door on the inside.
• The unit name plate must include the following
information:
- Version number
- Model number
- CE marking
- Serial number
- Year of manufacture and test date
- Refrigerant used and refrigerant class
- Refrigerant charge per circuit
- Containment uid to be used
- PS: Min./max. allowable pressure (high and low
pressure side)
- TS: Min./max. allowable temperature (high and low
pressure side)
- Pressure switch cut-out pressure
- Unit leak test pressure
- Voltage, frequency, number of phases
- Maximum current drawn
- Maximum power input
- Unit net weight
• Conrm that the options ordered for on-site installation have
been supplied, are complete and undamaged.
• Do not keep the BW10 units outside where they are exposed
to the weather, as the sensitive control mechanism and the
electronic modules may be damaged.
The unit must be checked periodically during its whole
operating life to ensure that no shocks (handling accessories,
tools etc.) have damaged it. If necessary, the damaged parts
must be repaired or replaced. See chapter “Maintenance”.
The machine must be installed in a place that is not
accessible to the public or protected against access by nonauthorised persons.
2.2 - Moving and siting the unit
2.2.1 - Moving
See chapter 1.1 - “Installation safety considerations”.
2.2.2 - Siting the unit
Always refer to the chapter “Dimensions and clearances” to
conrm that there is adequate space for all connections and
service operations. For the centre of gravity coordinates, the
position of the unit mounting holes, and the weight
distribution points, refer to the certied dimensional drawing
supplied with the unit.
Typical applications of these units are in refrigeration
systems, and they do not require earthquake resistance.
Earthquake resistance has not been veried.
In case of extra-high units the machine environment must
permit easy access for maintenance operations.
CAUTION: Only use slings at the designated lifting points
which are marked on the unit.
Before siting the unit check that:
• the permitted loading at the site is adequate or that
appropriate strenghtening measures have been taken.
• the unit is installed level on an even surface (maximum
tolerance is 1.5 mm in both axes).
• there is adequate space above the unit for air ow and to
ensure access to the components.
• the number of support points is adequate and that they are
in the right places.
• the location is not subject to ooding.
• No material or object that can be affected by condensate
(even a small amount) must be left under the machine or
in the water ow direction.
CAUTION: Before lifting the unit, check that all casing
panels are securely xed in place. Lift and set down the unit
with great care. Tilting and jarring can damage the unit and
impair unit operation.
ATTENTION: Stacked units must not be moved.
If BW10 units are hoisted with rigging, it is neces-sary to
protect the unit frame (side and rear panels and front doors)
against accidental crushing. Use struts or lifting beams to
spread the slings above the unit. Do not tilt a unit more than
15°, or 5° for units with the stacking option (No. 273). Always
follow the instructions on the handling notice attached to the
unit.
If a unit includes a hydronic module (options 116 or 270), the
hydronic module and pump piping must be installed in a way
that does not submit it to any strain. The hydronic module
pipes must be tted so that the pump does not support the
weight of the pipes.
Never push or lever on any of the enclosure panels (panels,
uprights, front access doors) of the unit. Only the base of the
unit frame is designed to withstand such stresses.
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Checks before system start-up
Before the start-up of the refrigeration system, the complete
installation, including the refrigeration system must be veried
against the installation drawings, dimensional drawings, system
piping and instrumentation diagrams and the wiring diagrams.
For these checks national regulations must be followed. If the
national regulation does not specify any details, refer to
standard EN 378-2 as follows:
External visual installation checks:
• Compare the complete installation with the refrigera-tion
system and power circuit diagrams.
• Check that all components comply with the design
specications.
• Check that all protection documents and equipment
provided by the manufacturer (dimensional drawings, P&ID,
declarations etc.) to comply with the regulations are present.
• Verify that the environmental safety and protection and
devices and arrangements provided by the manufacturer to
comply with the regulations are in place.
• Verify that all documents for pressure containers, certi-cates,
name plates, les, instruction manuals provided by the
manufacturer to comply with the regulations are present.
• Verify the free passage of access and safety routes.
• Check that ventilation in the plant room is adequate.
• Check that refrigerant detectors are present.
• Verify the instructions and directives to prevent the
deliberate removal of refrigerant gases that are harmful to
the environment.
• Verify the installation of connections.
• Verify the supports and xing elements (materials, routing
and connection).
• Verify the quality of welds and other joints.
• Check the protection against mechanical damage.
• Check the protection against heat.
• Check the protection of moving parts.
• Verify the accessibility for maintenance or repair and to
check the piping.
• Verify the status of the valves.
• Verify the quality of the thermal insulation and of the
vapour barriers.
• Ensure that the position of the condensate drain piping
allows draining and that the connections are correct for the
water used.
• Avoid common routing of the customer power wiring and
other machine wiring, especially for longer runs (> 200
mm).
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3 DIMENSIONS, CLEARANCES
3.1 - BW10 020-045 - standard unit
Legend:
All dimensions are in mm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
Control box
Water inlet
Water outlet
Power wiring connection
161 237
153 470
160 237
153 470
1058
900
700700
1044
600
625
901
700
2
2
1
1
4
4
4
4
5
3
3
3.2 - BW10 020-045 - unit with top connections (option 274)
901
938
86
105
104
105
143
1044
600
700
900
700
700
700
2
1
4
4
4
4
4
Only for option 70F
NOTE: Non-contractual drawings. Refer to the certified dimensional drawings available
on request, when designing an installation.
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3.3 - BW10 020-045 - unit with evaporator hydronic module (option 116)
3.4 - BW10 020-045 - unit with condenser hydronic module (option 270)
3.5 - BW10 020-045 - unit with evaporator/condenser hydronic modules (options 116 + 270)
700
900
700
153
153
161 237
470
868
1044
1058
1463
704
600
625
700
379
4
4
4
4
5
2
2
1
1
3
3
398
153
161
623
1021
142 237
2
2
1
1
398
153 470
398
161
142
623
2
2
1
1
Legend:
All dimensions are in mm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
Control box
Water inlet
Water outlet
Power wiring connection
Only for option 70F
NOTE: Non-contractual drawings. Refer to the certified
dimensional drawings available on request, when designing
an installation.
Page 11
11
3.6 - BW10 020-045 - unit with hydronic module and top connections (options 116 + 274 - 270 + 274 - 116 + 270 + 274)
900
700700
143
86
237 221
86
167
167
1044
1463
1500
700
700
2
2
1
1
4
4
4
4
4
3.7 - BW10 020-045 - stackable unit (option 273)
NOTE: The water and electrical connections are identical to those of the standard unit.
1014
1014
1058
600
1841
900
700700
700
4
4
4
4
Legend:
All dimensions are in mm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
Control box
Water inlet
Water outlet
Power wiring connection
NOTE: Non-contractual drawings. Refer to the certified dimensional drawings available
on request, when designing an installation.
Page 12
12
3.8 - BW10 050-090 - standard unit
3.9 - BW10 050-090 - unit with top connections (option 274)
900
700
700
253 310
201
204
456
450
252 310
451
1474
1489
901
905
880
700
2
2
1
1
4
4
4
4
5
3
3
700
900
700
253 142 168
142
80
1474
901
938
880
700
700
2
1
4
4
4
4
4
Legend:
All dimensions are in mm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
Control box
Water inlet
Water outlet
Power wiring connection
Only for option 70F
NOTE: Non-contractual drawings. Refer to the certified dimensional drawings available
on request, when designing an installation.
Page 13
13
900
700700
657
1021
307
252
558
204
704
1474
1488
1463
905
700
880
253
2
2
1
1
4
4
4
4
5
3
3
657
1021
559
252
277
204
2
2
1
1
657
1021
559
252
277
204
282
2
2
1
1
3.10 - BW10 050-090 - unit with evaporator hydronic module (option 116)
3.11 - BW10 050-090 - unit with condenser hydronic module (option 270)
3.12 - BW10 050-090 - unit with evaporator/condenser hydronic modules (options 116 + 270)
Legend:
All dimensions are in mm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
Control box
Water inlet
Water outlet
Power wiring connection
Only for option 70F
NOTE: Non-contractual drawings. Refer to the
certified dimensional drawings available on request,
when designing an installation.
Page 14
14
900
700
700
700
1463
1500
1474
80
172
278 282
80172
700
2
2
1
1
4
4
4
4
4
1841
1014
1489
1014
700
900
700
880
700
4
4
4
4
3.13 - BW10 050-090 - unit with hydronic module and top connections (options 116 + 274 - 270 + 274 - 116 + 270 + 274)
3.14 - BW10 050-090 - stackable unit (option 273)
NOTE: The water and electrical connections are identical to those of the standard unit.
Legend:
All dimensions are in mm.
Evaporator
Condenser
Safety valve
Clearances required for maintenance (see note)
Control box
Water inlet
Water outlet
Power wiring connection
NOTE: Non-contractual drawings. Refer to the certified dimensional drawings available
on request, when designing an installation.
Page 15
15
4 PHYSICAL AND ELECTRICAL DATA BW10
4.1 - Physical data BW10
BW10 020 025 030 035 040 045 050 060 070 080 090
Sound levels*
Sound power level 10
-12
W, standard unit dB(A) 67.0 68.5 69.0 69.3 70.0 70.1 71.5 72.0 72.0 73.0 73.4
Operating weight kg 186 195 195 203 208 215 375 382 394 405 431
Compressors Hermetic scroll 48.3 r/s
Quantity 1 1 1 1 1 1 2 2 2 2 2
Number of capacity steps 1 1 1 1 1 1 2 2 2 2 2
Minimum capacity % 100 100 100 100 100 100 50 50 50 50 50
Dimensions
Width mm 600 600 600 600 600 600 880 880 880 880 880
Length mm 1044 1044 1044 1044 1044 1044 1477 1477 1477 1477 1477
Height mm 901 901 901 901 901 901 901 901 901 901 901
Refrigerant** R-410A
Charge, standard unit kg 3.5 3.7 3.7 3.8 3.9 4.6 7.6 8.1 8.5 9.1 11.5
Charge, unit with option 272 kg 2.7 2.8 2.8 2.9 2.9 3.9 7.2 7.6 7.9 8.4 10.5
Oil 160SZ
Charge per compressor l 3 3.3 3.3 3.3 3.3 3.6 3.3 3.3 3.3 3.3 3.6
Evaporator Direct-expansion plate heat exchanger
Water volume l 3.3 3.6 3.6 4.2 4.6 5.0 8.4 9.2 9.6 10.4 12.5
Water connections Victaulic
Inlet/outlet in 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2 2 2
Max. water-side operating pressure without
hydronic module
kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Condenser Plate heat exchanger
Net water volume l 3.3 3.6 3.6 4.2 4.6 5.0 8.4 9.2 9.6 10.4 12.5
Water connections Victaulic
Inlet/outlet in 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2 2 2
Max. water-side operating pressure without
hydronic module
kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
* In accordance with ISO 9614-1, measured in a free field. The sound levels only apply to units without options.
** Weight shown is a guideline only. To find out the unit refrigerant charge, please refer to the unit nameplate
Page 16
16
4.4 - Electrical data BW10
BW10 020 025 030 035 040 045 050 060 070 080 090
Power circuit
Nominal voltage V-ph-Hz 400-3-50
Voltage range V 360-440
Control circuit supply 24 V, via internal transformer
Maximum start-up current draw (Un)*
Standard unit A 98 142 142 147 158 197 164 166 175 189 233
Unit with electronic starter option A 53.9 78.1 78.1 80.9 86.9 108.4 100.1 102.1 108.9 117.9 144.4
Unit power factor at maximum capacity** 0.83 0.82 0.84 0.83 0.82 0.84 0.82 0.82 0.83 0.82 0.84
Maximum operating power input** kW 9.7 11.4 12.7 14.6 16.5 18.6 22.8 25.4 29.2 33 37.2
Nominal unit operating current draw*** A 10.5 13.2 13.8 15.6 16.2 20.2 26.4 27.6 31.2 32.4 40.4
Maximum operating current draw (Un)**** A 16.1 19.6 21.1 24.4 26.7 30.9 39.2 42.2 48.8 53.4 61.8
Maximum operating current draw (Un-10%) † A 19 22 24 28 31 36 44 48 56 62 72
Customer-side unit power reserve Customer reserve at the 24 V control power circuit
Short-circuit stability and protection See table below "Short-circuit stability current"
* Maximum instantaneous start-up current at operating limit values (maximum operating current of the smallest compressor(s) + fan current + locked rotor current of the largest
compressor).
** Power input, compressors and fans, at the unit operating limits (saturated suction temperature 10°C, saturated condensing temperature 65°C) and nominal voltage of 400 V
(data given on the unit nameplate).
*** Standardised Eurovent conditions: evaporator entering/leaving water temperature 12°C/7°C, outside air temperature 35°C.
**** Maximum unit operating current at maximum unit power input and 400 V (values given on the unit nameplate).
† Maximum unit operating current at maximum unit power input and 360 V.
4.5 - Short-circuit stability current (TN system*) - standard unit (with main disconnect switch)
BW10 020 025 030 035 040 045 050 060 070 080 090
Value without upstream protection
Short-term current at 1 s - Icw - kA rms 3 3 3 3 3 3 3 3 3 3 3
Admissible peak current - Ipk - kA pk 6 6 6 6 6 6 6 6 6 6 6
Value with upstream protection (circuit breaker)
Conditional short-circuit current Icc - kA rms 40 40 40 40 40 40 40 40 40 40 40
Schneider circuit breaker - Compact series NSX 100N
Reference number** LV429795
* Earthing system type
** If another current limitation protection system is used, its time-current and thermal constraint (I²t) trip characteristics must be at least equivalent to those of the recommended
Schneider circuit breaker. Contact your nearest Danfoss office.
The short-circuit stability current values above are in accordance with the TN system.
4.3 - Physical data BW10 units with hydronic module
BW10 (option 116J/270J) 020 025 030 035 040 045 050 060 070 080 090
Operating weight* kg 305 313 313 321 327 334 513 521 533 544 574
Height** mm 1463 1463 1463 1463 1463 1463 1463 1463 1463 1463 1463
Hydronic module
Maximum operating pressure kPa 300 300 300 300 300 300 300 300 300 300 300
Water filter (max. removed particle diameter) mm 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2
Expansion tank capacity*** l 8 8 8 8 8 8 12 12 12 12 12
Water connections in 1.5 1.5 1.5 1.5 1.5 1.5 2 2 2 2 2
* Weight shown is a guideline only. .
** The length and width dimensions are the same as for the standard unit.
*** When delivered, the standard pre-inflation of the tanks is not necessary the optimal value for the system. To permit changing the water volume, change the inflation pressure to
a pressure that is close to the static head of the system. Fill the system with water (purging the air) to a pressure value that is 10 to 20 kPa higher than the pressure in the tank.
Page 17
17
4.6 - Electrical data, optional hydronic module
The pumps that are factory-installed in these units have
motors with efciency class IE2. The additional electrical data
required* is as follows:
Motors of xed-speed hydronic module pumps, BW10 (options 116F and 270F)
No.** Description*** BW10 - options 116F and 270F (low-pressure pumps)
20 25 30 35 40 45 50 60 70 80 90
1 Nominal efficiency at full load and nominal voltage % 80 80 80 80 80 80 80 80 80 80 82
1 Nominal efficiency at 75% rated load and nominal voltage % 78 78 78 78 78 78 78 78 78 78 82
1 Nominal efficiency at 50% rated load and nominal voltage % 75 75 75 75 75 75 75 75 75 75 80
2 Efficiency level IE2
3 Year of manufacture This information varies depending on the manufacturer and model at the time of
incorporation. Please refer to the motor name plates.
4 Manufacturer's name and trademark, commercial registration
number and place of manufacturer
5 Product's model number
6 Number of motor poles 2 2 2 2 2 2 2 2 2 2 2
7-1 Rated shaft power output at full load and nominal voltage (400 V) kW 0.66 0.66 0.66 0.66 0.66 0.66 0.66 0.87 0.87 0.87 1.26
7-2 Maximum power input (400 V)**** kW 0.83 0.83 0.83 0.83 0.83 0.83 0.83 1.2 1.2 1.2 1.5
8 Rated input frequency Hz 50
9-1 Rated voltage V 3 x 400
9-2 Maximum current drawn (400 V)† A 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.3 2.3 2.3 3.1
10 Rated speed r/s 48.2 48.2 48.2 48.2 48.2 48.2 48.2 47.3 47.3 47.3 48.2
rpm 2890 2890 2890 2890 2890 2890 2890 2838 2838 2838 2892
11 Product disassembly, recycling or disposal at end of life Disassembly using standard tools. Disposal and recycling using an appropriate company.
12 Operating conditions for which the motor is specifically designed
I - Altitudes above sea level m < 1000††
II - Ambient air temperature °C < 40
IV - Maximum air temperature Please refer to the operating conditions given in this manual or in the specific conditions in
the selection programs.
V - Potentially explosive atmospheres Non-ATEX environment
Motors of variable-speed hydronic module pumps, BW10 (options 116J and 270J)
No.** Description*** BW10 - options 116J and 270J (high-pressure pumps)
20 25 30 35 40 45 50 60 70 80 90
1 Nominal efficiency at full load and nominal voltage % 82 82 82 82 82 82 82 82 82 82 82
1 Nominal efficiency at 75% rated load and nominal voltage % 82 82 82 82 82 82 82 82 82 82 82
1 Nominal efficiency at 50% rated load and nominal voltage % 80 80 80 80 80 80 79 79 79 79 79
2 Efficiency level IE2
3 Year of manufacture This information varies depending on the manufacturer and model at the time of
incorporation. Please refer to the motor name plates.
4 Manufacturer's name and trademark, commercial registration
number and place of manufacturer
5 Product's model number
6 Number of motor poles 2 2 2 2 2 2 2 2 2 2 2
7-1 Rated shaft power output at full load and nominal voltage (400 V) kW 1.26 1.26 1.26 1.26 1.26 1.26 1.90 1.90 1.90 1.90 1.90
7-2 Maximum power input (400 V)**** kW 1.50 1.50 1.50 1.50 1.50 1.50 2.30 2.30 2.30 2.30 2.30
8 Rated input frequency Hz 50
9-1 Rated voltage V 3 x 400
9-2 Maximum current drawn (400 V)† A 3.1 3.1 3.1 3.1 3.1 3.1 4.3 4.3 4.3 4.3 4.3
10 Rated speed r/s 48.2 48.2 48.2 48.2 48.2 48.2 47.7 47.7 47.7 47.7 47.7
rpm 2892 2892 2892 2892 2892 2892 2863 2862 2862 2862 2862
11 Product disassembly, recycling or disposal at end of life Disassembly using standard tools. Disposal and recycling using an appropriate company.
12 Operating conditions for which the motor is specifically designed
I - Altitudes above sea level m < 1000††
II - Ambient air temperature °C < 40
IV - Maximum air temperature Please refer to the operating conditions given in this manual or in the specific conditions in
the selection programs.
V - Potentially explosive atmospheres Non-ATEX environment
* Required by regulation 640/2009 with regard to the application of directive 2005/32/EC on the eco-design requirements for electric motors
** Item number imposed by regulation 640/2009, annex I2b.
*** Description given by regulation 640/2009, annex I2b.
**** To obtain the maximum power input for a unit with hydronic module add the maximum unit power input from the electrical data table to the pump power input.
† To obtain the maximum unit operating current draw for a unit with hydronic module add the maximum unit current draw from the electrical data table to the pump current
draw.
†† Above 1000 m, a degradation of 3% for each 500 m should be taken into consideration.
Page 18
18
4.7 - Compressor usage and electrical data table
Compressor Reference I Nom I Max
(Un)
I Max
(Un - 10%)
LRA* LRA** Circ. BW10
020 025 030 040 045 060 070 080 090 110 120
SH090 00PSG001549100 10.5 16.1 19 98 53.9 A 1
SH105 00PSG001549200 13.2 19.6 22 142 78.1 A 1 2
SH120 00PSG001549300 13.8 21.1 24 142 78.1 A 1 2
SH140 00PSG001549400 15.6 24.4 28 147 80.9 A 1 2
SH161 00PSG001549500 16.2 26.7 31 158 86.9 A 1 2
SH184 00PSG001549600 20.2 30.9 36 197 108.4 A 1 2
Legend
I Nom Nominal current draw (A) at standard Eurovent conditions see definition of conditions under nominal unit current draw)
I Max Maximum operating current, A
LRA* Locked rotor current at nominal voltage, A
LRA** Locked rotor current with electronic starter at nominal voltage, A
Electrical data notes and operating conditions:
• BW10unitshaveasinglepowerconnectionpoint,locatedimmediatelyupstream
of the main disconnect switch.
• Thecontrolboxincludesthefollowingstandardfeatures:
- a main disconnect switch,
- the starter and motor protection devices for each compressor and the pumps
- the control devices
• Fieldconnections:
All connections to the system and the electrical installations must be in full
accordance with all applicable local codes.
• TheBW10unitsaredesignedandbuilttoensureconformancewiththesecodes.
The recommendations of European standard EN 60204-1 (machine safety electrical machine components - part 1: general regulations - corresponds to IEC
60204-1) are specifically taken into account, when designing the electrical unit
equipment.
NOTES:
• GenerallytherecommendationsofIEC60364areacceptedascompliancewiththe
requirements of the installation directives. Conformance with EN 60204-1 is the
best means of ensuring compliance with the Machines Directive § 1.5.1.
• AnnexBofEN60204-1describestheelectricalcharacteristicsusedforthe
operation of the machines.
1. The operating conditions for the units are specified below:
Environment* - Environment as classified in IEC 60364 § 3:
- ambient temperature range: +5°C to +40°C, class AA4
- humidity range (non-condensing)*:
- 50% relative humidity at 40°C
- 90% relative humidity at 20°C
- altitude: ≤ 2000 m (see note for table 4.6 - Electrical data, hydronic module)
- indoor installation*
- presence of water: class AD2 (possibility of water droplets)
- presence of hard solids, class 4S2 (no significant dust present)
- presence of corrosive and polluting substances, class 4C2 (negligible)
- vibration and shock, class AG2, AH2
- competence of personnel, class BA4* (trained personnel - IEC 60364)
2. Power supply frequency variation: ± 2 Hz.
3. The neutral (N) conductor must not be connected directly to the unit (if necessary
use a transformer).
4. Over-current protection of the power supply conductors is not provided with the
unit.
5. The factory-installed disconnect switch(es)/circuit breaker(s) is (are) of a type
suitable for power interruption in accordance with EN 60947.
6. The units are designed for simplified connection on TN(s) networks (IEC 60364).
For IT networks provide a local earth and consult competent local organisations to
complete the electrical installation.
7. Derived currents: If protection by monitoring of derived currents is necessary to
ensure the safety of the installation, the control of the cut-out value must take the
presence of leak currents into consideration that result from the use of frequency
converters in the unit. A value of at least 150 mA is recommended to control
differential protection devices.
NOTE: If particular aspects of an actual installation do not conform to the
conditions described above, or if there are other conditions which should be
considered, always contact your local Danfoss representative.
* The protection level of the control boxes required to conform to this class is IPX1B
(according to reference document IEC 60529). All BW10 units fulfil this protection
condition.
Units equipped with front casing panel meet class IP23. If the casing panel has
been removed, access to energised components is protected to level IPXXB.
5 APPLICATION DATA
5.1 - Operating limits
BW10 Minimum Maximum
Evaporator
Entering water temperature at start-up °C 7.5* 27
Leaving water temperature during operation °C 5** 20
Entering/leaving water temperature difference K 2.5 7
Condenser
Entering water temperature at start-up °C 15*** 60****
Leaving water temperature during operation °C 20 65
Entering/leaving water temperature difference K 2.5 18
* For entering water temperatures below 7.5°C at start-up, contact Danfoss.
** If the leaving water temperature is below 5°C, a frost protection solution must
be used. Please refer to option 6 for evaporator leaving water low-temperature
applications (< 5°C).
*** For applications with a condenser entering air temperature below 15°C the use of
a three-way valve is recommended. This three-way valve can be controlled by the
0-10 V analogue output of the control system.
**** For a water flow rate that corresponds to a maximum water-side temperature
difference of 5 K.
BW10 + option 272 (geothermal application) Minimum Maximum
Evaporator
Entering water temperature at start-up °C -2.5* 25
Leaving water temperature during operation °C -5* 20
Entering/leaving water temperature difference K 2.5 5
Condenser
Entering water temperature at start-up °C 15** 60***
Leaving water temperature during operation °C 20 65
Entering/leaving water temperature difference K 2.5 18
* A frost protection solution must be used.
** For applications with a condenser entering air temperature below 15°C the use of
a three-way valve is recommended. This three-way valve can be controlled by the
0-10 V analogue output of the control system.
*** For a water flow rate that corresponds to a maximum water-side temperature
difference of 5 K.
Page 19
19
5.2 - Operating range BW10
Condenser leaving water temperature, °C
Evaporator leaving water temperature, °C
15
20
25
30
35
40
45
50
55
60
65
-8 -6 -4 -2 0 2 4 6 8 10 12 14 16 18 20
StandardOption 272
BW10 standard unit
BW10 unit with option 272 (brine to water)
5.4 - Minimum chilled water flow
If the system water ow rate is lower than the minimum water
ow rate, recirculation of the evaporator ow may occur. The
temperature of the mixture leaving the evaporator must never be
less than 2.5 K lower than the chilled water entering
temperature.
5.5 - Maximum chilled water flow
The maximum chilled water ow is limited by the maximum
permitted pressure drop in the evaporator. It is provided in the
tables in chapter 5.7. If the ow exceeds the maximum value,
two solutions are possible:
• Modify the ow rate with a control valve.
• Bypass the evaporator to obtain a highter temperature
difference with a lower evaporator ow rate.
5.6 - Variable flow
A pump with variable ow can be used in these units. The units
maintain a constant leaving water temperature under all ow
conditions. For this to happen, the minimum ow rate must be
higher than the minimum ow given in the table of permissible
ow rates and must not vary by more than 10% per minute.
If the ow rate changes more rapidly, the system should
contain a minimum of 6.5 litres of water per kW instead of the
values below.
5.7 - Water flow rate
5.7.1 - Standard BW10
BW10 Evaporator water flow rate, l/s
Minimum* Minimum** Maximum*** Maximum****
Low
pressure
High
pressure
Low
pressure
High
pressure
020 1.1 0.9 0.4 3.1 3.6 3.8
025 1.0 1.0 0.4 3.3 3.8 4.1
030 1.0 1.0 0.5 3.3 3.8 4.1
035 1.1 1.1 0.6 3.6 4.2 4.7
040 1.1 1.1 0.6 3.8 4.4 5.0
045 1.2 1.1 0.8 4.0 4.6 5.4
050 1.6 1.4 0.8 5.4 7.8 9.2
060 1.5 1.5 1.0 6.1 8.0 9.9
070 1.6 1.5 1.1 6.2 8.1 10.3
080 1.6 1.5 1.3 6.3 8.3 10.9
090 2.0 1.6 1.5 7.8 8.7 12.5
* Minimum flow rate for an available pressure of 10 kPa (unit with hydronic module)
** Minimum flow rate for a water temperature difference of 10 K (unit without
hydronic module)
*** Maximum flow rate for an available pressure of 20 kPa (unit with low-pressure
hydronic module) or 50 kPa (unit with high-pressure hydronic module)
**** Maximum flow rate for a pressure drop of 100 kPa in the plate heat exchanger (unit
without hydronic module)
BW10 Condenser water flow rate, l/s
Minimum* Maximum** Maximum***
Low pressure Low pressure High pressure
020 0.3 3.1 3.5 3.8
025 0.3 3.3 3.8 4.1
030 0.3 3.3 3.8 4.1
035 0.4 3.5 4.1 4.7
040 0.4 3.7 4.3 5.0
045 0.4 3.9 4.5 5.4
050 0.4 4.8 6.8 7.0
060 0.5 5.5 7.0 7.5
070 0.5 5.6 7.2 7.8
080 0.6 5.8 7.4 8.2
090 0.6 7.2 7.9 9.3
* Minimum flow rate for a water temperature difference of 18 K (unit with or without
hydronic module)
** Maximum flow rate for an available pressure of 20 kPa (unit with low-pressure
hydronic module) or 50 kPa (unit with high-pressure hydronic module)
*** Maximum flow rate for a pressure drop of 100 kPa in the plate heat exchanger (unit
without hydronic module)
5.7.2 - BW10 with option 272
BW10 Minimum evaporator water flow rate - option 272*, l/s
Minimum** Minimum***
Low pressure High pressure
020 0.5 0.6 0.3
025 0.6 0.6 0.3
030 0.7 0.7 0.3
035 0.8 0.8 0.4
040 0.8 0.8 0.4
045 0.9 1.0 0.5
050 0.8 0.9 0.5
060 1.0 1.0 0.5
070 1.0 1.1 0.6
080 1.1 1.2 0.7
090 1.1 1.4 0.7
* Option 272: Condenser side high-temperature water production, with glycol
solution, evaporator side
** Minimum flow rate for a maximum permitted temperature difference at the
minimum leaving water temperature (unit with hydronic module)
*** Minimum flow rate for a water temperature difference of 5 K (unit without hydronic
module)
5.8 - Minimum water volume
Whichever the system, the water loop minimum capacity is
given by the formula:
Capacity = Cap (kW) x N Liters
Where Cap is the nominal system cooling capacity (kW) at the
nominal operating conditions of the installation.
This volume is necessary for stable operation and accurate
temperature control.
Application N
BW10 2.5
ATTENTION: Minimum water volume required between the
unit and possible customer-supplied valves to the outside of
the unit.
Industrial process applications
Certain industrial processes may require high leaving water
stability. In these cases the values above must be increased.
Page 20
20
Bad
Bad
Good
Good
It may be necessary to add a buffer water tank to the circuit in order to achieve the required volume. The tank must itself be
internally bafed in order to ensure proper mixing of the liquid (water or brine). Refer to the examples below.
5.9 - Maximum water loop volume (evaporator and
condenser side)
Units with hydronic module incorporate an expansion tank
sized for the maximum water loop volume.
The table below gives the maximum water loop volume (in
litres) for pure water or ethylene glycol with various concentrations.
BW10 020-045 060-090
Static pressure kPa 100 200 300 100 200 300
bar 1 2 3 1 2 3
Pure water l 220 450 75 340 225 115
10% ethylene glycol l 165 110 53 255 170 85
20% ethylene glycol l 100 70 35 150 100 50
35% ethylene glycol l 85 55 30 130 85 45
5.10 - Expansion tank
The expansion tank is supplied with a pressure of 1 bar relative
(±20%). The maximum operating pressure for the tank is 3 bar.
5.11 - Protection against cavitation (option 116)
To ensure the durability of the pumps in the integrated hydronic
modules, the control algorithm of the BW10 units incorporates
anti-cavitation protection.
It is therefore necessary to ensure a minimum pump entering
pressure of 60 kPa (0.6 bar) during operation and at shut-down.
A pressure below 60 kPa will prohibit unit start-up or cause an
alarm with the unit shutting down.
In order to obtain sufcient pressure, it is recommended:
• to pressurise the hydronic circuit between 100 kPa and
300 kPa (1 and 3 bar) maximum on the suction side of the
pump,
• to clean the hydronic circuit before charging water,
• to regularly clean the screen lter.
Page 21
21
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
0.0 0.5 1.0 1.5 2.0 2 .5 3.0 3.5 4.0 4.5 5.0 5 .5 6.0 6 .5 7.0 7 .5 8.0
0.0 0.5 1.0 1.5 2.0 2 .5 3.0 3.5 4.0 4.5 5.0 5 .5 6.0 6 .5 7.0 7 .5 8.0
-10
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
0 1 2 3 4 5 6 7 8 9 10 11 12 1 3 14 1 5 16
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
0 1 2 3 4 5 6 7 8 9 10 11 12 1 3
5.12 - Plate heat exchanger pressure drop (includes internal piping)
Evaporator - standard unit without hydronic module
BW10 020-045 BW10 050-090
1 BW10 020
2 BW10 025 to BW10 030
3 BW10 035
4 BW10 040
5 BW10 045
6 BW10 050
7 BW10 060
8 BW10 070
9 BW10 080
10 BW10 090
Condenser - standard unit without hydronic module
BW10 020-045
1 BW10 020
2 BW10 025 to BW10 030
3 BW10 035
4 BW10 040
5 BW10 045
6 BW10 050
7 BW10 060
8 BW10 070
9 BW10 080
10 BW10 090
BW10 050-090
Pressure drop, kPa
Water flow rate, l/s
Pressure drop, kPa
Water flow rate, l/s
Pressure drop, kPa
Water flow rate, l/s
Pressure drop, kPa
Water flow rate, l/s
Page 22
22
Legend
1 Main disconnect switch
PE Earth connection
S Power supply cable section (see table “Recommended wire sections”).
NOTES:
The BW10 020-090 units have only one power connection
point located at the main disconnect switch.
Before connecting electric power cables, it is imperative to
check the correct order of the 3 phases (L1 - L2 - L3).
Non-certied drawings.
Refer to the certied dimensional drawings.
Before connecting the unit check that the phase order in the
customer control box is the same as shown in the customer
wiring diagrams.
6 ELECTRICAL CONNECTION
6.1 - Electrical connections, control box BW10
18
18
79
26
S
1
1
PE
6.2 - Power supply
The power supply must conform to the specication on the unit
nameplate. The supply voltage must be within the range
specied in the electrical data table. For connections refer to
the wiring diagrams.
WARNING: Operation of the unit with an incorrect supply
voltage or excessive phase imbalance constitutes abuse which
will invalidate the Danfoss warranty. If the phase imbalance
exceeds 2% for voltage, or 10% for current, contact your
local electricity supply at once and ensure that the unit is not
switched on until corrective measures have been taken.
6.3 - Voltage phase imbalance (%)
100 x max. deviation from average voltage
Average voltage
Example:
On a 400 V - 3 ph - 50 Hz supply, the individual phase voltages
were measured to be:
AB = 406 V ; BC = 399; AC = 394 V
Average voltage = (406 + 399 + 394)/3 = 1199/3
= 399.7 say 400 V
Calculate the maximum deviation from the 400 V average:
(AB) = 406 - 400 = 6
(BC) = 400 - 399 = 1
(CA) = 400 - 394 = 6
The maximum deviation from the average is 6 V. The greatest
percentage deviation is: 100 x 6/400 = 1.5 %
This is less than the permissible 2% and is therefore acceptable.
6.4 - Recommended wire sections
Wire sizing is the responsibility of the installer, and depends on
the characteristics and regulations applicable to each
installation site. The following is only to be used as a guide-line,
and does not make Danfoss in any way liable. After wire sizing
has been completed, using the certied dimensional drawing,
the installer must ensure easy connection and dene any
modications necessary on site.
The connections provided as standard for the eld-supplied
power entry cables to the general disconnect/isolator switch are
designed for the number and type of wires, listed in the table
below.
The calculations are based on the maximum machine current (see
electrical data tables). For the design the following
standardised installation methods are used, in accordance with
IEC 60364, table 52C:
• For units installed inside the building:
No.13: perforated horizontal cable conduit, and No. 41:
closed conduit.
Motor
Motor
Page 23
23
The calculation is based on PVC or XLPE insulated cables
with copper or aluminium core. A maximum ambient
temperature of 40°C has been taken into account. The given
wire length limits the voltage drop to < 5%.
IMPORTANT: Before connection of the main power cables (L1
- L2 - L3) on the terminal block, it is imperative to check the
correct order of the 3 phases before proceeding to the
connection on then terminal block or the main disconnect/
isolator switch.
6.4.2 - On-site control wiring
Selection of minimum and maximum wire sections for connection to BW10 units
BW10 Max. connectable
section*
Calculation favourable case:
Suspended aerial lines (standardised routing No. 17)
PVC insulated cable
Calculation unfavourable case:
Conductors in conduits or multi-conductor cables in closed conduit
(standardised routing No. 41)
PVC insulated cable, if possible
Section Section** Max. length for
voltage drop <5%
Cable type Section** Max. length for voltage drop
<5%
Cable type***
mm² (per phase) mm² (per phase) m mm² (per phase) m
20 1 x 35 1 x 2.5 60 PVC Cu 1 x 4 100 PVC Cu
25 1 x 35 1 x 2.5 60 PVC Cu 1 x 4 100 PVC Cu
30 1 x 35 1 x 4 80 PVC Cu 1 x 6 120 PVC Cu
35 1 x 35 1 x 4 80 PVC Cu 1 x 6 120 PVC Cu
40 1 x 35 1 x 6 100 PVC Cu 1 x 10 150 PVC Cu
45 1 x 35 1 x 6 100 PVC Cu 1 x 10 150 PVC Cu
50 1 x 35 1 x 10 120 PVC Cu 1 x 16 180 PVC Cu
60 1 x 35 1 x 10 120 PVC Cu 1 x 16 180 PVC Cu
70 1 x 35 1 x 16 140 PVC Cu 1 x 25 205 PVC Cu
80 1 x 35 1 x 16 140 PVC Cu 1 x 25 205 PVC Cu
90 1 x 35 1 x 25 170 PVC Cu 1 x 35 225 PVC Cu
6.4.1 - Field control wiring
Refer to the BW10 Control manual and the certied wiring
diagram supplied with the unit for the eld control wiring of
the following features:
• Remote on/off switch
• Remote heat/cool switch
• Demand limit external switch 1
• Remote dual set point
• Alarm report
• Pump control - unit without hydronic module.
• Relief boiler or electric heater
• Valve control (refer to the description of options 153 and 154
in the BW10 Control manual)
7 WATER CONNECTIONS
For size and position of the heat exchanger water inlet and
outlet connections refer to the certied dimensional drawings
supplied with the unit. The water pipes must not transmit any
radial or axial force to the heat exchangers nor any vibration.
The water supply must be analysed and appropriate ltering,
treatment, control devices, isolation and bleed valves and
circuits built in, to prevent corrosion, fouling and deteriora-tion
of the pump ttings. Consult either a water treatment specialist
or appropriate literature on the subject.
7.1 - Operating precautions
The water circuit should be designed to have the least number
of elbows and horizontal pipe runs at different levels. Below the
main points to be checked for the connection:
• Comply with the water inlet and outlet connections shown
on the unit.
• Install manual or automatic air purge valves at all high
points in the circuit(s).
• Use a pressure reducer to maintain pressure in the
circuit(s) and install a safety valve as well as an expan-sion
tank. Units with hydronic module include the safety valve
and expansion tank.
• Install drain connections at all low points to allow the
whole circuit to be drained.
• Install stop valves, close to the entering and leaving water
connections.
• Use exible connections to reduce the transmission of
vibrations.
• If the insulation provided is not sufcient, insulate the
cold-water piping, after testing for leaks, both to reduce
heat loss and to prevent condensation.
• Cover the insulation with a vapour barrier. If the external
water piping to the unit is in an area where the ambient
temperature can fall below 0°C, it should be insulated and
an electric heater should be installed on the piping.
NOTE: For units without hydronic module a screen lter
must be installed as close as possible to the heat exchanger and
in a position that is easily accessible for removal and
cleaning. Units with a hydronic module are equipped with this
lter.
The mesh size of the lter must be 1.2 mm. If this lter is not
installed, the plate heat exchanger can quickly become
contaminated at the rst start-up, as it takes on the lter
function, and correct unit operation is affected (reduced
water ow due to increased pressure drop).
Before the system start-up verify that the water circuits are
connected to the appropriate heat exchangers (e.g. no reversal
between evaporator and condenser).
Page 24
24
7.2 - Water connections
The diagrams on the following page illustrate a typical
hydronic installation. When the hydronic circuit is lled, use
the air vents to evacuate any residual air pockets.
7.3 - Frost protection
The units are designed to be installed under cover at outside
temperatures between +5°C and +40°C. Therefore they do not
include anti-freeze protection, as standard.
If the water piping is in an area where the ambient tempera-ture
can fall below 0°C it is recommended to install a trace heater
on the piping and to add an antifreeze solution to protect the
unit and the water piping to a temperature of 10 K below the
lowest temperature likely to be reached at the installation site.
Use only antifreeze solutions, approved for heat exchanger
duty. If the system is not protected by an antifreeze solution and
will not be used during the freezing weather conditions,
draining of the cooler and outdoor piping is mandatory.
Damage due to freezing is not covered by the warranty.
IMPORTANT: Depending on the climatic conditions in your
area you must:
• Add ethylene glycol with an adequate concentration to
protect the installation up to a temperature of 10 K below
the lowest temperature likely to occur at the installation
site.
• If the unit is not used for an extended period, it is
recommended to drain it, and as a safety precaution add
ethylene glycol to the heat exchanger, using the heat
exchanger water entering purge valve connection.
• At the start of the next season, rell the unit with water
and add an inhibitor.
• For the installation of auxiliary equipment, the installer
must comply with basic regulations, especially for
minimum and maximum ow rates, which must be
between the values listed in the operating limit table
(application data).
• To avoid corrosion by differential aeration, the complete
heat exchange circuit must be charged with nitrogen, if
it is drained for longer than one month. If the heat
exchange uid does not comply with Danfoss
recommendations, the circuit must immediately be lled
with nitrogen.
7.4 - Flow switch (units without hydronic module)
IMPORTANT: On BW10 units, the unit water ow switch
must be energised, and the chilled water pump interlock must
be connected. Failure to follow this instruc-tion will void the
Danfoss guarantee.
The ow switch is supplied, installed on the evaporator leaving
water pipe and preset at the factory to cut out when there is
insufcient water ow.
Terminals 34 and 35 are provided for eld installation of the
chilled water pump interlock (auxiliary contact for pump
operation to be wired on site).
Do not introduce any signicant static or dynamic pressure into
the heat exchange circuit (with regard to the design operating
pressures).
Before any start-up verify that the heat exchange uid is
compatible with the materials and the water circuit coating.
In case additives or other uids than those recommended by
Danfoss are used, ensure that the uids are not considered as a gas,
and that they belong to class 2, as dened in directive 97/23/
EC.
Danfoss recommendations on heat exchange uids:
• No NH4+ ammonium ions in the water, they are very
detrimental for copper. This is one of the most important
factors for the operating life of copper piping. A con-tent
of several tenths of mg/l will badly corrode the copper
over time (the plate heat exchangers used for these units
have brazed copper joints).
• Cl- Chloride ions are detrimental for copper with a risk of
perforations by corrosion by puncture. If possible keep
below 10 mg/l.
• SO
4
2-
sulphate ions can cause perforating corrosion, if
their content is above 30 mg/l.
• No uoride ions (<0.1 mg/l).
• No Fe2+ and Fe3+ ions with non negligible levels of
dis-solved oxygen must be present. Dissolved iron < 5 mg/l
with dissolved oxygen < 5 mg/l.
• Dissolved silicon: silicon is an acid element of water and
can also lead to corrosion risks. Content < 1mg/l.
• Water hardness: > 0.5 mmol/l. Values between 1 and 2.5
can be recommended. This will facilitate scale deposit that
can limit corrosion of copper. Values that are too high can
cause piping blockage over time. A total alkalimetric titre
(TAC) below 100 is desirable.
• Dissolved oxygen: Any sudden change in water oxygena-tion
conditions must be avoided. It is as detrimental to
deoxygenate the water by mixing it with inert gas as it is
to over-oxygenate it by mixing it with pure oxygen. The
disturbance of the oxygenation conditions encourages
destabilisation of copper hydroxides and enlargement of
particles.
• Specic resistance – electric conductivity: the higher the
specic resistance, the slower the corrosion tendency.
Values above 30 Ohm·m are desirable. A neutral
environment favours maximum specic resistance values.
For electric conductivity values in the order of 20-60
mS/m can be recommended.
• pH: Ideal case pH neutral at 20-25°C
7 < pH < 8
If the water circuit must be emptied for longer than one month,
the complete circuit must be placed under nitrogen charge to
avoid any risk of corrosion by differential aeration.
ATTENTION: Filling, completing and draining the water
circuit charge must be done by qualied personnel, using the air
purges and materials that are suitable for the products.
Charging and removing heat exchange uids should be done
with devices that must be included on the water circuit by the
installer. Never use the unit heat exchangers to add heat
exchange uid.
Page 25
25
Typical water piping diagram, BW10 units with hydronic modules
Components of unit and hydronic module
1 Victaulic screen filter
2 Expansion tank
3 Safety valve
4 Water pump
5 Air vent
6 Water drain valve
7/8 Entering/leaving pressure sensor
9/10 Entering/leaving temperature probe
12 Flow switch BW10 option 272 (sizes 020-045 only)
13 Compressor
14 Evaporator
15 Condenser
16 Expansion device
NOTE: Units without hydronic
module include a ow switch.
2
6
15
10
9
8
5
1
3
4
7
6
14
9
8
5
1
2
4
PT
PT
TT
TT
PT
PT TT
13
16
TT
12
3
7
10
6
6
Unit water inlet
Condenser water loop
Unit water outlet
Unit water inlet
Unit water outlet
Evaporator water loop
8 NOMINAL WATER FLOW CONTROL WITH FIXED
SPEED PUMP
8.1 - General
The water circulation pumps of the BW10 units have been
sized to allow the hydronic modules to cover all possible
congurations based on the specic installation conditions, i.e.
for various temperature differences between the entering and the
leaving water (∆T) at full load, which can vary between 2.5 and
7 K for evaporators and 3 and 18 K for condensers.
This required difference between the entering and leaving water
temperature determines the nominal system ow rate. It is above
all absolutely necessary to know the nominal system ow rate
to allow its control via a manual valve.
Manual control valves for the unit are not supplied and must be
installed upstream and downstream of the evaporator and
condenser water loops to ensure correct ow control.
With the pressure loss generated by the control valve in the
hydronic system, the valve is able to impose the system
pressure/ow curve on the pump pressure/ow curve, to obtain
the desired operating point (see example).
The pressure drop reading in the plate heat exchanger is used to
control and adjust the nominal system ow rate. The pressure
drop is measured with the pressure sensors connected to the
heat exchanger water inlet and outlet.
Use this specication for the unit selection to know the system
operating conditions and to deduce the nominal air ow as well
as the plate heat exchanger pressure drop at the specied
conditions. If this information is not available at the system
start-up, contact the technical service department responsible for
the installation to get it.
These characteristics can be obtained from the technical
literature using the unit performance tables or the Electronic
Catalogue selection program for all conditions.
8.2 - Water flow control procedure
As the total system pressure drop is not known exactly at the
start-up, the water ow rate must be adjusted with the control
valve to obtain the specic ow rate for this application.
Proceed as follows:
Open the valve fully.
Start-up the pump using the forced start command (refer to the
controls manual) and let the pump run for two conse-cutive
hours to clean the hydronic circuit of the system (presence of
solid contaminants).
Read the hydronic module pressure drop by taking the
difference of the readings at the machine connected to the
hydronic module inlet and outlet. Compare this value after two
hours of operation.
Page 26
26
Legend
O Open
F Closed
Water inlet
Water outlet
Pressure gauge
If the pressure drop has increased, this indicates that the screen
lter must be removed and cleaned, as the hydronic circuit
contains solid particles. In this case close the shutoff valves at
the water inlet and outlet and remove the screen lter after
emptying the hydronic section of the unit.
Renew, if necessary, to ensure that the lter is not conta-
minated.
When the circuit is cleaned, read the pressures at the unit (entering
water pressure - leaving water pressure), expressed in kPa to nd
out the plate heat exchanger pressure drop.
Compare the value obtained with the theoretical selection
value. If the pressure drop measured is higher than the value
specied this means that the ow rate in the plate heat
exchanger (and thus in the system) is too high. The pump
supplies an excessive ow rate based on the global pres-sure
drop of the application. In this case close the control valve one
turn and read the new pressure difference.
Entering water pressure reading
Leaving water pressure reading
O
F
F
O
F
F
Example: Unit with a given nominal flow rate of 4.8 l/s
Water flow rate, l/s
Legend
1 Unit pump curve
2 Plate heat exchanger pressure drop (to be measured with the pressure gauge
installed at the water inlet and outlet)
3 Installation pressure drop with control valve wide open
4 Installation pressure drop after valve control to obtain the specified flow rate
Pressure drop, kPa
1
2
3
4
0
25
50
75
100
125
150
175
200
2
4
6 8 10
Proceed by successively closing the control valve until you
obtain the specic pressure drop that corresponds to the
nominal ow rate at the required unit operating point.
• If the system has an excessive pressure drop in relation to
the available static pressure provided by the pump, the
resulting water ow rate will de reduced and the difference
between entering and leaving water tempe-rature of the
hydronic module will be increased.
To reduce the hydronic system pressure drops, it is necessary:
• to reduce the individual pressure drops as much as
possible (bends, level changes, accessories, etc.)
• to use a correctly sized piping diameter.
• to avoid hydronic system extensions, wherever possible.
Page 27
27
9 NOMINAL WATER FLOW CONTROL WITH VARIABLE
SPEED PUMP
9.1 - Pump flow/pressure curve
BW10 units with variable-speed hydronic module include a
water pump that automatically adjusts the ow to maintain a
constant pressure or constant temperature difference.
No control is required at start-up, but the control mode must be
selected at the unit interface (refer to the BW10 Control
manual).
50
60
70
80
90
100
110
120
130
140
150
160
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
50
70
90
110
130
150
170
190
210
0 1 2 3 4 5 6 7 8 9
50
60
70
80
90
100
110
120
130
140
150
160
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5
50
70
90
110
130
150
170
190
210
0 1 2 3 4 5 6 7 8
Condenser
9.2 - Available static system pressure (fixed or variable-speed high-pressure pumps, units with hydronic module)
Evaporator
1 BW10 020
2 BW10 025 to BW10 030
3 BW10 035
4 BW10 040
5 BW10 045
6 BW10 050
7 BW10 060
8 BW10 070
9 BW10 080
10 BW10 090
1 BW10 020
2 BW10 025 to BW10 030
3 BW10 035
4 BW10 040
5 BW10 045
6 BW10 050
7 BW10 060
8 BW10 070
9 BW10 080
10 BW10 090
BW10 020-045
BW10 050-090
BW10 020-045
BW10 050-090
Pressure head, kPa
Water flow rate, l/s
Pressure head, kPa
Water flow rate, l/s
Pressure head, kPa
Water flow rate, l/s
Pressure head, kPa
Water flow rate, l/s
Page 28
28
20
30
40
50
60
70
80
90
100
110
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
0 1 2 3 4 5 6 7 8
20
30
40
50
60
70
80
90
100
110
0.0 0.5 1.0 1.5 2.0 2.,5 3.0 3.5 4.0
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
0 1 2 3 4 5 6 7 8
9.3 - Available static system pressure (fixed or variable-speed low-pressure pumps, units with hydronic module)
Evaporator
1 BW10 020
2 BW10 025 to BW10 030
3 BW10 035
4 BW10 040
5 BW10 045
6 BW10 050
7 BW10 060
8 BW10 070
9 BW10 080
10 BW10 090
1 BW10 020
2 BW10 025 to BW10 030
3 BW10 035
4 BW10 040
5 BW10 045
6 BW10 050
7 BW10 060
8 BW10 070
9 BW10 080
10 BW10 090
BW10 020-045 BW10 050-090
Pressure head, kPa
Water flow rate, l/s
Pressure head, kPa
Water flow rate, l/s
Pressure head, kPa
Water flow rate, l/s
Water flow rate, l/s
Pressure head, kPa
Condenser
BW10 020-045
BW10 050-090
Page 29
29
9.4 - Available static pressure for pumps only (units with
hydronic modules)
9.4.1 - Fixed-speed pump
Low-pressure pumps BW10
(options 116F - 270F)
9.4.2 - Variable-speed pump
High-pressure pumps BW10
(options 116J - 270J)
Pressure head, kPa
Water flow rate, l/s
1 BW10 020-050
2 BW10 060-080
3 BW10 090
0
20
40
60
80
100
120
140
160
180
200
220
0 1 2 3 4 5 6 7 8 9 10 11 1 2
1
2
3
0
20
40
60
80
100
120
140
160
180
200
220
4
5
0 1 2 3 4 5 6 7 8 9 10 11 1 2
4 BW10 020-045
5 BW10 050-090
Pressure head, kPa
Water flow rate, l/s
Page 30
30
Page 31
31
R S V
CH
4
J7
CH
1
--
R S V
--
J2
--
CH13
CH
3
J4
CH
2
--
-- G +
12
STATUS
--
T
P
V
CH13
J3
CH
12
J1
24VAC
--
SIO
J9
SIO
CH
11
--
11
CH
10
--
J5
T
P
V
CH14
3 2 1
--
3 2 1
CH
8
--
-- G +
CH
7
--
J6
CH14
CH
6
--
J8
CH
5
CH
9
• Connector J2: Discrete outputs CH 1 to 4 for electric
heating stages 1 to 4.
• Connector J3: Discrete output CH 6 for for the control of a
directional on/off three-way valve.
• Connector J6: Analogue inputs CH 11 for outside
temperature sensors.
• Connector J6: Analogue inputs CH 12 for information on
domestic hot-water requirements.
• Connector J7: Analogue inputs CH 13 for information on
domestic hot-water requirements.
• Connector J8: Analogue inputs CH 14 for information on
summer operation only (domestic hot-water only).
To apply the different congurations required, refer to the
instructions in the BW10 Control manual.
11 STARTUP
11.1 - Preliminary checks
• Never be tempted to start the unit without reading fully,
and understanding, the operating instructions and without
having carried out the following pre-start checks:
• Check the chilled water circulation pump operation with
the Quick Test function.
• Check the air handling units and all other equipment
connected to the evaporator. Refer to the manufacturer’s
instructions.
• Check the condensing loop water circulation pump
operation with the Quick Test function.
• For units without hydronic module, the water pump
overheat protection devices must be connected in series
with the pump contactor power supply.
• Ensure that there are no refrigerant leaks.
• Conrm that all pipe securing bands are tight.
• Conrm the the electrical connections are secure.
• Avoid a long common power wiring connection run inside
the unit close to the control or signal wiring.
• Observe the clearances on each unit side to facilitate
maintenance.
• The unit wiring for all options offered is not insulated. The
insulation only protects against running condensa-tion.
• To ensure that no condensate can run under the unit, a
condensate pan must be added under the unit that collects
100% of the condensate.
• If work is required in a control box or on the compressor
wiring, the phase order must be veried with a quick test
(refer to the BW10 Control manual. The compressors
cannot support prolonged operation (>30 seconds) with
reversed phases.
• Ensure that the last refrigerant charge made by the service
team corresponds with the charge given on the name plate
- otherwise the operating ranges and the unit efciency
will be impaired. The required tolerance for the charge is
±2%.
• Before start-up ensure that the unit is level (1.5 mm/m).
ATTENTION: Use of units in an open loop is forbidden.
11.2 - Actual start-up
IMPORTANT
• Commissioning and start-up of the unit must be
supervised by a qualied refrigeration engineer.
• Start-up and operating tests must be carried out with a
thermal load applied and water circulating in the
evaporator and condenser.
• All set-point adjustments and control tests must be
carried out before the unit is started up.
Ensure that all safety devices are operational, especially that
the high pressure switches are switched on and that the
alarms are acknowledged.
10 BW10 UNIT OPERATION WITH SPECIFIC HEATING
CONTROL OPTION 153
10.1 - Operating principle
BW10 units are specially designed to optimise the operation of
heating installations that require hot-water production for a
traditional heating system and domestic hot-water production.
The control system of the BW10 units includes algorithms that
permit constant automatic optimisation of:
• control of a directional on/off three-way valve based on
the heating or domestic hot water requirements,
• control of the electric heating stages allowing relief of the
heating loop,
• hot-water setpoint reset (heating application) based on the
air temperature,
• priority control between heating application and entre
domestic hot-water application.
NOTE: The installer is responsible for ensuring that the
installation complies with the applicable legislation in terms
of electrical and thermal safety.
10.2 - Auxiliary electronic board (AUX1) - analogue and
digital inputs and outputs
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12 MAJOR SYSTEM COMPONENTS AND OPERATION
DATA
12.1 - Compressors
BW10 units use hermetic scroll compressors. The only
refrigerant permitted for these compressors is R-410A.
The compressors are not certied for mobile applications or use
in explosive environments.
For more information contact the Danfoss service team for
maintenance instructions.
IMPORTANT: All compressor and system pressure tests must
be carried out by qualied personnel, taking the greatest care
with potential dangers resulting from the pressures used, and
respecting the maximum operating pressure limit on the high
and low-pressure side, shown on the unit and compressor
name plates.
• Maximum operating pressure, low-pressure side: 2820
kPa (28.2 bar)
• Maximum operating pressure, high-pressure side: 4870
kPa (48.7 bar).
Any modication or alteration such as soldering on the
compressor shell may invalidate the right to use the equip-ment.
Units using these compressors are installed in areas where the
temperature must be between 5°C minimum and 40°C
maximum. The temperature around the compressors must not
exceed 50°C during unit shutdown cycles.
Shock absorbers are installed under the compressor feet.
12.2 - Lubricant
The compressors have the following factory lubricant charge:
polyolester oil (reference: POE 160SZ). Contact Danfoss to
order the oil. This lubricant must not be mixed with other
lubricant types.
Before start-up and after normal unit operation check that the
oil level is visible.
If an additional oil quantity is required to compensate the initial
low level in the compressors, top up the charge, using only the
permitted lubricant shown on the compressor name plate:
polyolester oil (ref: POE 160SZ).
12.3 - Evaporators and condensers
The evaporators and condensers are single-circuit plate heat
exchangers. They are tested and stamped for a maximum
operating pressure of 4870 kPa, 2820 kPa on the refrigerant side
and 1000 kPa on the water side.
The heat exchanger sizing for the whole range ensures a
saturated evaporating temperature of 4.5°C and a conden-sing
temperature of around 38°C with actual subcooling of around 4
K at the condenser leaving side, based on nominal Eurovent
conditions.
11.3 - Operation of two units in master/slave mode
(option 58)
The control of a master/slave assembly is in the entering water
piping (system return). All parameters, required for the master/
slave function must be congured using the Service
Conguration menu.
All remote controls of the master/slave assembly (start/stop, set
point, load shedding etc.) are controlled by the unit congured
as master and must only be applied to the master unit.
IMPORTANT: To permit master/slave operation both units
must be equipped with option 58.
Depending on the installation and control type, each unit can
control its own water pump.
12.4 - Parallel or serial connection of two BW10 units
Entering water control for a hydronic kit
Legend
1 Master unit
2 Slave unit
Additional CCN board (one per unit, with connection via communication bus)
Control boxes of the master and slave units
Water inlet (for customers with both units)
Water outlet (for customers with both units)
Water pumps for each unit (included as standard for units with hydronic module)
Additional sensors for leaving water control, to be connected to channel 1 of the
slave boards of each master and slave unit
CCN communication bus
Connection of two additional sensors
1
2
1
2
Leaving water control
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33
The evaporators and condensers are single-circuit for all units.
The water connections between the heat exchangers and the
piping of the hydronic modules have quick-connect Victaulic
couplings to facilitate pump disassembly, if required.
A drain with a 1/4 turn valve is included in the leaving water of
all heat exchangers.
The evaporators have 19 mm thick polyurethane foam thermal
insulation. For option 86 (condenser insulation), the condensers
also have 19 mm thick polyurethane foam thermal insulation.
The products that may be added for thermal insulation of the
containers during the water piping connection procedure must
be chemically neutral in relation to the materials and coatings
to which they are applied.
NOTES: Monitoring during operation, re-qualication,
re-testing and re-testing dispensation:
• Follow the regulations on monitoring pressurised
equipment.
• It is normally required that the user or operator sets up
and maintains a monitoring and maintenance le.
• If there are no regulations or to complement them follow
the control programmes of EN 378.
• If they exist follow local professional recommenda-tions.
• Regularly inspect the condition of the coating (paint) to
detect blistering resulting from corrosion. To do this,
check a non-insulated section of the container or the
rust formation at the insulation joints.
• Regularly check for possible presence of impurities (e.g.
silicon grains) in the heat exchange uids. These
impurities maybe the cause of the wear or corrosion by
puncture.
• Filter the heat exchange uid check and carry out
internal inspections as described in EN 378-2, annex C.
• In case of re-testing take the possible maximum pressure
difference of 25 bar into consideration.
• The reports of periodical checks by the user or operator
must be included in the supervision and maintenance
le.
Repair
Any repair or modication of the plate heat exchangers is
forbidden.
Only the replacement of the complete heat exchanger by an
original heat exchanger supplied by the manufacturer is
permitted. The replacement must be carried out by a qualied
technician.
• The heat exchanger replacement must be shown on the
monitoring and maintenance le.
Recycling
The plate heat exchanger is 100% recyclable. After use it
contains refrigerant vapours and oil residue.
Operating life
This unit is designed for:
• prolonged storage of 15 years under nitrogen charge with
a temperature difference of 20 K per day.
• 900000 cycles (start-ups) with a maximum difference of 6
K between two neighbouring points in the container, based
on 12 start-ups per hour over 15 years at a usage rate of
57%.
12.4 - Electronic expansion valve (EXV)
The EXV is equipped with a stepper motor (2625 + 160 /- 0
steps) that is controlled via the EXV board.
12.5 - Refrigerant
BW10 units operate exclusively with R-410A.
12.6 - High-pressure switch and high-pressure sensor
BW10 units are equipped with an automatically reset safety
pressure switch on the liquid line. Refer to the controls manual
for the alarm acknowledgements.
It is strictly forbidden to modify the unit refrigerant circuit. The
pressure switch is specic to the BW10 units - do not
interchange it with other units. The pressure switch tap does not
include a Schrader valve.
High-pressure switch High-pressure sensor
The high-pressure sensor is however equipped with a Schrader
valve. It is specic to these units and must not be replaced with
one from other Danfoss units.
12.7 - High and low-pressure side safety valves
The units are equipped with safety valves in accordance with
the European directive 97/23/CE. These safety valves are
calibrated and sized in accordance with the original high and
low-pressure side equipment.
12.8 - Moisture indicator
Located in the liquid line, permits control of the unit charge, as
well as the presence of moisture in the circuit. Bubbles in the
sight glass indicate an insufciant charge or the presence of
non-condensibles. If moisture is present, the colour of the
indicator paper in the sight glass changes.
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34
12.9 - Filter drier in the refrigerant circuit
The lter keeps the circuit clean and moisture-free. The
moisture indicator shows when it is necessary to change the
lter cartridges. A temperature difference between the lter
drier inlet and outlet indicates a contamination of the
cartridges.
12.10 - Fixed-speed pump
This pump is factory-installed as standard to guarantee the
nominal ow in the water loop.
This is a xed-speed pump with available system pressure. See
the pump ow/pressure curve.
The nominal system ow rate must be adjusted with a manual
control valve supplied by the customer (see chapter on the
control of the nominal system pressure).
The maximum permitted concentration of the glycol additives
(ethylene glycol or propylene glycol) is 35%.
The maximum pump suction pressure is limited to 300 kPa (3
bar) due to the valve installed on the entering water piping.
The use of any other glycol type additives must be approved by
Danfoss.
12.11 - Variable-speed pump
This pump is factory-installed. It is a variable-speed pump with
available system pressure. See the pump ow/pressure curve.
The system ow rate is automatically adjusted via the
frequency converter built into the pump, based on the heat
rejection load on the drycooler.
The maximum permitted concentration of the glycol additives
is 35%.
The maximum pump suction pressure is limited to 300 kPa (3
bar) due to the valve installed on the entering water piping.
The use of any other glycol type additives must be approved by
Danfoss.
All pumps are protected by a suction lter. This is easily
removable to recover solid particles. It protects the pump and
the plate heat exchanger against solid particles with a size
exceeding 1,2 mm. Before the unit start-up it is important to
turn the evaporator and condenser pump to decontaminate the
water loops of any solid pollution.
A specic pump start-up function in the Quick Test menu is
available for this task.
12.13 - Connection sleeves
Filter positions in the unit
12.12 - Evaporator and condenser pump suction filter
Position of the water connection sleeves in the unit
12.14 - Option 272: High-temperature water production
with glycol solution
ATTENTION: The temperature sensor positioned in the
discharge for option 272 is specic to this unit and must not
be interchanged with another temperature sensor. For
replacement please contact the Danfoss service team.
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35
13 OPTIONS
Options No. Description Advantages Use
Soft starter 25 Electronic compressor starter Reduced compressor start-up current BW10 020-090
Twinning 58 Unit equipped with an additional field-installed
leaving water temperature sensor, allowing master/
slave operation of two units connected in parallel.
Optimised operation of two units connected
in parallel with operating time equalisation
BW10 020-090
External disconnect handle 70F The handle of the electrical disconnect switch is on
the outside of the unit
Quick access to the unit disconnect switch BW10 020-090
Condenser insulation 86 Thermal condenser insulation Optimisation for heating applications BW10 020-090
Low-pressure single-pump hydronic module,
evaporator side
116F See hydronic module chapter Easy and fast installation BW10 020-090
High-pressure single-pump hydronic module,
evaporator side
116J See hydronic module chapter Easy and fast installation, reduced power
consumption of the water circulation pump.
BW10 020-090
JBus gateway 148B Two-directional communications board, complies
with JBus protocol
Easy connection by communication bus to a
building management system
BW10 020-090
BacNet gateway 148C Two-directional communications board, complies
with BacNet protocol
Easy connection by communication bus to a
building management system
BW10 020-090
LON gateway 148D Two-directional communications board, complies
with LON protocol
Easy connection by communication bus to a
building management system
BW10 020-090
Specific single-source heating control 153 Control board factory-installed on the unit, control
using weather compensation, control of supplementary electric heater (4 stages) or boiler, needle valve
for domestic hot-water production with
programmable time schedule.
Permits easy control of a basic heating
system
BW10 020-090
Specific cooling control 154 Control box to be installed on the drycooler for
communication with the unit via a bus.
Permits the use of an energy-efficient
plug-and-play system
Control of multi-source heating system 157 Additional control box for remote installation to
control the various heating system components
Allows control of pre-configured heating
systems
BW10 020-090
Low sound level (-3 dB(A) compared to standard
unit)
257 Compressor sound insulation BW10 020-090
Evaporator screw connection sleeves 264 Evaporator inlet/outlet screw connection sleeves Allows unit connection to a screw connector BW10 020-090
Screw water connection between the customer
condenser and the unit
265 Condenser inlet/outlet screw connection sleeves Allows unit connection to a screw connector BW10 020-090
Welded evaporator connection sleeves 266 Welded evaporator inlet/outlet connection sleeves Allows welding of customer connections to
the unit
BW10 020-090
Welded water connection between the customer
condenser and the unit
267 Welded condenser inlet/outlet connection sleeves Allows welding of customer connections to
the unit
BW10 020-090
Low-pressure single-pump hydronic module,
condenser side
270F See hydronic module chapter Easy and fast installation BW10 020-090
High-pressure hydronic module with single
variabe-speed pump, condenser side
270J See hydronic module chapter Easy and fast installation, reduced power
consumption of the water circulation pump.
BW10 020-090
High-temperature water production, condenser
side, with glycol solution on the evaporator side
272 Condenser side water production up to 65°C, with
glycol solution on the evaporator side to -5°C
Geothermal application and domestic
hot-water production
BW10 020-090
Unit stackable for operation 273 Unit stackable for operation Reduced footprint size BW10 020-090
Customer water connection at the top of the unit 274 Customer water connection at the top of the unit Reduced footprint size BW10 020-090
Remote user interface 275 User interface for remote installation Remote control of the unit and its operating
parameters
BW10 020-090
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14 MAINTENANCE
During the unit operating life the service checks and tests must
be carried out in accordance with applicable national
regulations.
If there are no similar criteria in local regulations, the
information on checks during operation in annex C of standard
EN 378-2 can be used.
External visual checks: annex A and B of standard EN378-2.
Corrosion checks: annex D of standard EN 378-2. These
controls must be carried out:
• After an intervention that is likely to affect the resis-tance
or a change in use or change of high-pressure refrigerant,
or after a shut down of more than two years. Components
that do not comply, must be changed. Test pressures above
the respective component design pressure must not be
applied (annex B and D).
• After repair or signicant modications or signicant
system or component extension (annex B).
• After re-installation at another site (annexes A, B and D).
• After repair following a refrigerant leak (annex D). The
frequency of refrigerant leak detection can vary from once
per year for systems with less than 1% leak rate per year
to once a day for systems with a leak rate of 35% per year
or more. The frequency is in proportion with the leak rate.
NOTE: High leak rates are not acceptable. The necessary
steps must be taken to eliminate any leak detected.
NOTE 2: Fixed refrigerant detectors are not leak detectors, as
they cannot locate the leak.
14.1 - Soldering and welding
Component, piping and connection soldering and welding
operations must be carried out using the correct procedures and
by qualied operators. Pressurised containers must not be
subjected to shocks, nor to large temperature variations during
maintenance and repair operations.
Any technician attending the machine for any purpose must be
fully qualied to work on refrigerant and electrical circuits.
WARNING: Before doing any work on the machine ensure
that the power is switched off. If a refrigerant circuit is
opened, it must be evacuated, recharged and tested for leaks.
Before any operation on a refrigerant circuit, it is necessary
to remove the complete refrigerant charge from the unit with
a refrigerant charge recovery unit.
All removal and refrigerant draining operations must be
carried out by a qualied technician and with the correct
material for the unit. Any inappropriate handling can lead to
uncontrolled uid or pressure leaks.
If an oil draining or recovery operation becomes necessary, the
uid transfer must be made using mobile containers.
14.2 - General unit maintenance
• Keep the unit itself and the space around it clean and free
of obstructions. Remove all rubbish such as packing
materials, as soon as the installation is completed.
• Regularly clean the exposed pipework to remove all dust
and dirt. This makes detection of water leaks easier, and
they can be repaired before more serious faults develop.
• Conrm that all screwed and bolted connections and joints
are secure.
• Secure connections prevent leaks and vibration from
developing.
• Check that all foam insulation joints on the heat exchanger
piping are in good condition.
14.3 - Refrigerant undercharge
If there is not enough refrigerant in the system, this is indicated
by gas bubbles in the moisture sight glass.
If the undercharge is signicant, large bubbles appear in the
moisture sight glass, and the suction pressure drops. The
compressor suction superheat is also high. The machine must be
recharged after the leak has been repaired.
Find the leak and completely drain the system with a
refrigerant recovery unit. Carry out the repair, leak test and
then recharge the system.
IMPORTANT: After the leak has been repaired, the circuit
must be tested, without exceeding the maximum low-side
operating pressure shown on the unit name plate.
The refrigerant must always be recharged in the liquid phase into
the liquid line. The refrigerant cylinder must always contain at
least 10% of its initial charge. For the refrigerant quantity per
circuit, refer to the data on the unit name plate.
During applications with option 272 (brine to water) and with
positive evaporation, bubbles will appear in the sight-glass.
This is normal, when the charge is optimised for improved
efciency in brine applications.
14.4 - Refrigerant guidelines
Refrigeration installations must be inspected and maintained
regularly and rigorously by specialists. Their activities must be
overseen and checked by properly trained people. To minimise
discharge to the atmosphere, refrigerants and lubricating oil
must be transferred using methods which reduce leaks and
losses to a minimum.
• Leaks must be repaired immediately.
• If the residual pressure is too low to make the transfer
alone, a purpose-built refrigerant recovery unit must be
used.
• Compressor lubricating oil contains refrigerant. Any oil
drained from a system during maintenance must therefore
be handled and stored accordingly.
• Refrigerant under pressure must never be discharged to
the atmosphere.
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37
14.5 - Leak detection
Never use oxygen or dry air, as this would cause a risk of re
or explosion.
• Carry out a leak detection test on the whole system using
the following methods: pressure test using dehydrated
nitrogen or a mixture of nitrogen and refrigerant used for
the system, helium leak test.
• Connect the compressor to the system by opening the
valves.
• The duration of the test must be sufcient to guaran-tee
the absence of very small leaks in the circuit.
• Use specic tools, designed for leak detection.
• The low-pressure side test pressure must not exceed
pressure Ps indicated on the compressor and unit name
plates.
• If there is a leak, repair it and carry out the leak detec-tion
test again.
14.6 - Evacuation
To evacuate the system, observe the following recommen-
dations:
Connect the vacuum pump to the high (HP) and low-pressure
(LP) side for evacuation of the complete circuit.
All units are equipped with valves with 3/8” SAE connec-tions
on the suction, discharge and liquid lines, permitting the
connection of large-diameter exible pipes limiting the
pressure drops for the evacuation.
1. The vacuum level achieved must be 0.67 mbar (500 µm
Hg).
2. Wait 30 minutes.
3. If the pressure increases rapidly, the system ist not leaktight. Localise and repair the leaks.
Restart the evacuation procedure and repeat steps 1, 2 etc.
4. If the pressure increeases slowly, this indicates that
moisture is present inside the system. Break the vacuum
with nitrogen and restart the evacuation procedure (steps
1, 2 etc.).
5. Repeat the evacuation procedure (steps 1, 2); a vacuum
level of 0.67 mbar (500 µm Hg) must be achieved and
maintained for four hours.
This vacuum level must be measured at one of the system
connections and not at the vacuum pump pressure gauge.
ATTENTION: Do not use a megohmmeter and do not place
any stress on the compressor motor when the system has been
evacuated. There is a risk of internal short circuits between the
motor windings.
Do not use additives for leak detection. Do not use CFCs/
HCFCs as tracer uids for leak detection.
14.7 - Recharging liquid refrigerant
CAUTION: The units are charged with liquid R-410A
refrigerant.
With high-pressure R-410A refrigerant the unit operating pressure
is above 4000 kPa (40 bar), the pressure at 35°C air temperature
is 50% higher than for R-22. Special equipment must be used
when working on the refrigerant circuit (pressure gauge, charge
transfer, etc.).
All checks must be pressure tests, and the appropriate
pressure/temperature ratio table must be used to determine the
corresponding saturated temperatures (saturated bubble point
curve or saturated dew point curve).
Leak detection is especially important for units charged with
refrigerant R-410A. Depending on whether the leak occurs in
the liquid or in the vapour phase, the proportion of the
different components in the remaining liquid is not the same.
NOTE: Regularly carry out leak checks and immediately
repair any leak found.
14.8 - Characteristics of R-410A
Saturated temperatures (°C) based on the relative pressure (in kPa)
Saturated
temperature, °C
Relative
pressure, kPa
Saturated
temperature, °C
Relative
pressure, kPa
-20 297 25 1552
-19 312 26 1596
-18 328 27 1641
-17 345 28 1687
-16 361 29 1734
-15 379 30 1781
-14 397 31 1830
-13 415 32 1880
-12 434 33 1930
-11 453 34 1981
-10 473 35 2034
-9 493 36 2087
-8 514 37 2142
-7 535 38 2197
-6 557 39 2253
-5 579 40 2311
-4 602 41 2369
-3 626 42 2429
-2 650 43 2490
-1 674 44 2551
0 700 45 2614
1 726 46 2678
2 752 47 2744
3 779 48 2810
4 807 49 2878
5 835 50 2947
6 864 51 3017
7 894 52 3088
8 924 53 3161
9 956 54 3234
10 987 55 3310
11 1020 56 3386
12 1053 57 3464
13 1087 58 3543
14 1121 59 3624
15 1156 60 3706
16 1192 61 3789
17 1229 62 3874
18 1267 63 3961
19 1305 64 4049
20 1344 65 4138
21 1384 66 4229
22 1425 67 4322
23 1467 68 4416
24 1509 69 4512
70 4610
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14.9 - Electrical maintenance
When working on the unit comply with all safety precau-tions
described in section 1.3.
It is strongly recommended to change the unit fuses every
15000 operating hours or every three years.
It is recommended to verify that all electrical connections are
tight:
• after the unit has been received at the moment of
installation and before the rst start-up,
• one month after the rst start-up,when the electrical
components have reached their nominal operating
temperatures,
• then regularly once a year.
14.10 - Tightening torques for the main electrical
connections
Component Designation in
the unit
Value (Nm)
Screw (PE) customer connection M8 PE 14.5
Screw on switch inlet zones
Switch - MG 28904 QS_ 8
Tunnel terminal screw, compressor contactor
Contactor LC1D12B7 KM* 1.7
Contactor LC1D18B7 KM* 1.7
Contactor LC1D25B7 KM* 2.5
Tunnel terminal screw, compressor circuit breaker
Circuit breaker 25507 QM* 3.6
Circuit breaker 25508 QM* 3.6
Circuit breaker 25509 QM* 3.6
Tunnel terminal screw, control power transformer
Transformer - ABL6TS16B TC 0.6
Compressor earth terminal in the power wiring control box
M6 Gnd 5.5
Compressor earth connection
M8 Gnd 2.83
Tunnel terminal screw, pump disconnect switch
Disconnect switch GV2ME08 QM_ 1.7
Disconnect switch GV2ME10 QM_ 1.7
Tunnel terminal screw, pump contactor
Contactor LC1K0610B7 KM 0.8 to 1.3
Contactor LC1K09004B7 KM 0.8 to 1.3
Contactor LC1K0910B7 KM 0.8 to 1.3
Contactor LC1K0901B7 KM 0.8 to 1.3
Variable-frequency switch ATV21 GS 1.3
14.11 - Tightening torques for the main bolts and screws
Screw type Used for Torque (Nm)
M8 nut BPHE* fixing 15
M10 nut Compressor mounting 30
Oil nut Oil equalisation line 90
Taptite screw M6 Panel fixing 7
H M6 screw Stauff clamps 10
* BPHE = Brazed plate heat exchanger
14.12 - Compressors
The compressors do not require any specic maintenance.
Nevertheless the preventive system maintenance operations
prevent specic compressor problems. The following periodic
preventive maintenance checks are strongly recommended:
• Check the operating conditions (evaporating tempera-ture,
condensing temperature, discharge temperature, heat
exchanger temperature difference, superheat, subcooling).
These operating parameters must always be within the
compressor operating range.
• Check that the safety devices are all operational and
correctly controlled.
• Check oil level and quality. If there is a colour change in the
sight glass, check the oil quality. This may include an
acidity test, moisture control, a spectrometric analysis etc
• Check the leak tightness of the refrigerant circuit.
• Check the compressor motor power input, as well as the
voltage imbalance between phases.
• Check the tightening of all electrical connections.
• Ensure that the compressor is clean and runs correctly;
verify that there is no rust on the compressor shell and no
corrosion or oxydation at the electrical connections and the
piping.
ATTENTION: The compressor and piping surface temperatures can in certain cases exceed 100°C and cause burns.
Particular caution is required during maintenance operations. At the same time, when the compressor is in operation, the
surface temperatures can also be very cold (down to -15°C for
units with a low leaving water temperature), and can cause
frost burns.
14.13 - Evaporator and condenser maintenance
There is no particular maintenance necessary on the plate heat
exchanger. Check:
• that the insulating foam has not become detached or
damaged during work on the units,
• that the entering and leaving water temperature sensors
are well connected
• the cleanliness on the water heat exchanger side (no signs
of leaks).
• that the periodic inspections required by local regu-lations
have been carried out.
14.14 - Corrosion check
All metallic parts of the unit (chassis, casing panels, control
boxes, heat exchangers etc.) are protected against corrosion by a
coating of powder or liquid paint. To prevent the risk of
blistering corrosion that can appear when moisture penetrates
under the protective coatings, it is necessary to carry out
periodic checks of the coating (paint) condition.
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15 MAINTENANCE PROGRAM
All maintenance operations must be carried out by technicians
who have been trained on Danfoss products, observing all
Danfoss quality and safety standards.
15.1 - Maintenance schedule
Regular maintenance is indispensable to optimise equip-ment
operating life and reliability. Maintenance operations must be
carried out in accordance with the schedules below:
Service Frequency
A Weekly
B Monthly
C Annually
D Special cases
If the equipment does not operate normally during maintenance operations, refer to the chapter on diagnostics and
breakdowns of the BW10 Control manual).
IMPORTANT: Before each equipment maintenance
operation please ensure that:
• the unit is in the OFF position
• it is impossible for the unit to restart automatically
during maintenance.
15.2 - Description of the maintenance operations
The equipment is supplied with polyolester oil (POE). Use only
Danfoss-approved oil.
Service A
Full-load operating test
Verify the following values:
• compressor high-pressure side discharge pressure
• compressor low-pressure side suction pressure
• charge visible in the sight glass
• temperature difference between the heat exchanger water
entering and leaving temperature.
Verify the alarm status
Service B
Carry out the operations listed under Service A.
Refrigerant circuit
• Full-load operating test. In addition to the operations
described under Service A, check the following values:
- compressor discharge pressure
- compressor oil level
- actual liquid subcooling
- overheating at the expansion device
• Verify the charge status by checking the colour indicator
of the sight glass. If the colour has turned to yellow,
change the charge and replace the lter drier cartridges
after carrying out a leak test of the circuit.
Electrical checks
• Check the tightening of the electric connections,
contactors, disconnect switch and transformer.
• Check the phase direction upstream of the unit and in the
customer’s electrical data table.
• Check the status of the contactors and fuses.
• Carry out a quick test (refer to the BW10 Control manual).
Mechanical checks
• Verify the correct operation of the evaporator and
condenser pumps with the Quick Test function.
• Verify the correct operation of cooling fans, speed
converter and condensing pumps.
Water circuit checks
• Check the leak-tightness of the circuit.
Service C
Carry out the operations listed under Service B.
Refrigerant circuit
• Check the leak-tightness of the circuit and ensure that
there is no piping damage.
• Carry out an oil contamination test. If acid, water or
metallic particles are present, replace the oil in the circuit.
• Verify the tightening of the thermostatic mechanism of the
expansion device.
• Full-load operating test. In addition to the checks carried out
under Service B, validate the value between leaving water
and the saturated evaporating temperature.
• Check the operation of the high-pressure switch(es).
Replace them if there is a fault.
• Check the fouling of the lter drier (by checking the
temperature difference in the copper piping). Replace it if
necessary.
Electrical checks
• Check the status and insulation of the electrical cables.
• Check the phase/earth insulation of the compressors and
pumps.
• Check the compressor and pump winding status.
Mechanical checks
• Check that no water has penetrated into the control box.
• Clean the lter of the air inlet grille and if necessary
replace the lter.
Water circuit checks
• Clean the water lter.
• Purge the circuit with air.
• Verify the correct operation of the water ow switch.
• Check the status of the thermal piping insulation.
• Check the water ow by checking the heat exchanger
pressure difference (using a pressure gauge).
• Check the concentration of the anti-freeze protection
solution (ethylene glycol or polyethylene glycol).
• Check the heat transfer uid staus or the water quality.
• Check the steel pipe corrosion.
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16 STARTUP CKECKLIST FOR BW10 UNITS USE FOR JOB FILE
Preliminary information
Job name: ................................................................................................................................................................................................
Location: .................................................................................................................................................................................................
Installing contractor: ...............................................................................................................................................................................
Distributor: ..............................................................................................................................................................................................
Start-up preformed by: ............................................................................................................................................................................
Compressors
Model: ............................................................................................. Serial No. .....................................................................................
Compressors
1. Model No. . ................................................................................. 2. Model No. ...............................................................................
Serial No. .................................................................................... Serial No. ................................................................................
Motor No. ................................................................................... Motor No. ...............................................................................
Evaporator
Model No. ....................................................................................... Manufactured by ........................................................................
Serial No. ........................................................................................ Date .............................................................................................
Condensers
Model No. ....................................................................................... Manufactured by ........................................................................
Serial No. ........................................................................................ Date .............................................................................................
Additional air handling units and accessories .........................................................................................................................................
.................................................................................................................................................................................................................
Preliminary equipment check
Is there any shipping damage ? ....................................................... If so, where ? ...............................................................................
.................................................................................................................................................................................................................
Will this damage prevent unit start-up ? .................................................................................................................................................
Unit is level in its installation
Power supply agrees with the unit nameplate
Electrical circuit wiring has been sized and installed properly
Unit ground wire has been connected
Electrical circuit protection has been sized and installed properly
All terminals are tight
All cables and thermistors have been inspected for crossed wires
All plug assemblies are tight
Check air handling systems
All air handlers are operating
All chilled water valves are open
All uid piping is connected properly
All air has been vented from the system
Chilled water pump (CWP) is operating with the correct rotation. CWP amperage: Rated: ......................... Actual............
Unit start-up
CWP starter has been properly interlocked with the unit
Oil level is correct
All discharge and liquid valves are open
Unit has been leak checked (including ttings)
Locate, repair, and report any refrigerant leaks
.................................................................................................................................................................................................................
.................................................................................................................................................................................................................
.................................................................................................................................................................................................................
Check voltage imbalance: AB .................... AC ................. BC ..................
Average voltage = ..................................... (see installation instructions)
Maximum deviation = ............................... (see installation instructions)
Voltage imbalance = .................................. (see installation instructions) ...
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Voltage imbalance is less than 2%
WARNING: Do not start unit if voltage imbalance is greater than 2%. Contact local power company for assistance.
All incoming power voltage is within rated voltage range
Check cooler water loop
Water loop volume = ................................. (litres)
Calculated volume = ................................. (litres)
Proper loop volume established
Proper loop corrosion inhibitor included ................litres of ...........................
Proper loop freeze protection included (if required) .........................litres of ..............................
Piping includes electric heater tape, if exposed to the outside
Inlet piping to cooler includes a 20 mesh strainer with a mesh size of 1.2 mm (unit without pump)
Check pressure drop across the evaporator
Entering evaporator = ............................... (kPa)
Leaving evaporator = ................................ (kPa)
(Leaving - entering) = ............................... (kPa)
WARNING: Plot cooler pressure drop on performance data chart (in product data literature) to determine total liters per
second (l/s) and nd unit’s minimum ow rate.
Total l/s = ..................................................
l/s / nominal kW = .....................................
Total l/s is greater than unit’s minimum ow rate
Total l/s meets job specied requirement of ............................................(l/s)
Perform TEST function (indicate positive result):
WARNING: Once power is supplied to the unit, check the display for any alarms, such as phase reversal. Follow the TEST
function instructions in the Controls and Troubleshooting literature (follow the procedure in the Controls IOM).
Be sure that all service valves are open, before beginning the compressor test section.
To start the unit
WARNING: Be sure that all service valves are open, and all pumps are on before attempting to start this machine. Once all
checks have been made, move the switch to “LOCAL” or “REMOTE” from “OFF”.
Unit starts and operates properly
Temperatures and pressures
WARNING: Once the machine has been operating for a while and the temperatures and pressures have stabilized, record the
following:
Evaporator EWT ............................................................................. Ambient temperature ...................................................................
Evaporator LWT ............................................................................. Condenser EWT ..........................................................................
Condenser LWT ..........................................................................
Suction pressure .............................................................................. Discharge pressure ......................................................................
Suction temperature ........................................................................ Discharge temperature .................................................................
Liquid line temperature ...................................................................
Compressor oil pressure A1* .......................................................... Compressor oil pressure A2* ......................................................
* if installed
NOTES:
.................................................................................................................................................................................................................
.................................................................................................................................................................................................................
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VMGFT102
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