Uniflair Aquaflair 00182, Aquaflair 00302, Aquaflair 00403, Aquaflair 00504, Aquaflair 00152 Instruction Manual

Versione: 1.4 - Data: 01.12.2000

Pag.: 48 - File: A-B-C-Ara14en

ARA

AIR-COOLED WATER CHILLERS

00182 - 00202 - 00232 - 00252 - 00302 - 00403 - 00504

AIR-COOLED HEAT PUMPS

00182 - 00202 - 00232 - 00252 - 00302 - 00403 - 00504

FREE COOLING CHILLERS

00182 - 00202 - 00232 - 00252 - 00302

ULTRA-LOW NOISE LEVEL FREE COOLING CHILLERS

00152 - 00182 - 00202 - 00232 - 00252 - 00302

INSTRUCTION MANUAL

© UNIFLAIR 2000.

GB

A - D - L

H - P - Q

E

M

2

UNIFLAIR ITALIA S.r.l.

Via dell’Industria, 10

35020 BRUGINE (Padova) Italy

Tel. [phone]

Fax. [phone]

Internet: www.UNIFLAIR.com

E-Mail: [e-mail]

Release:

1.4

Date:

01 - 12 – 2000

Checked by:

3

CONTENTS

WARNINGS Page. 4
SYMBOLS USED 5
SAFETY 5

GENERAL DESCRIPTION 6

Documentation included with the unit 6
Available versions and accessories 7
Data plate 8
General description and intended use of the unit 8
Access to main components 10
Description of the main components of the unit 12
Free cooling System - Free cooling 14
Recovery of condensation heat 15

INSTALLATION 16

Transport and handling 16

Receiving and storing the unit 17

Positioning the unit – working space 18
Water connections 19
Low-temperature operation with anti-freeze mixture 20
Guide to sizing of the expansion tank 21
Electrical connections 22
Remote control, local networks and supervision systems 24
Check list for start-up and testing 27

PROGRAMMING AND REGULATION 29

Microprocessor control 29

Introduction 29

Basic control 29

Advanced mP20 control 29
Regulation of cooling capacity 31
Setting the safety devices 32

TECHNICAL DATA 33

Current absorption – Cooling only versions and Heat Pumps 33
Current absorption – Free cooling version 34
Current absorption – Ultra-Quiet free cooling version 35
Dimensions and weights 36
ARA Basic version (cooling only) - Models 00182 - 00232 37
ARA Heat pump - Models 00182 - 00232 37
ARA Ultra low-noise version - Models 00182 - 00232 37
ARA Basic version (cooling only) - Models 00252 - 00504 38
ARA Heat pump - Models 00252 - 00504 38
ARA Ultra low-noise version - Models 00252 - 00504 38
ARA Free cooling version - Models 00182 - 00232 39
ARA Free cooling Low Noise Level - Models 00152 - 00232 39
ARA Free cooling version - Models 00252 - 00302 40
ARA Free cooling Low Noise level - Models 00252 - 00302 40

PROBLEM SOLVING 41

Guide to problem solving 41
Bleeding the water circuit 44
Refrigerant charge 44
Maintenance and cleaning 46
Changing the air filter 46

APPENDIX

Instruction manual for ARA microprocessor controls

4

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

This equipment is manufactured to function safely for the purposes for which it was designed as long as the

installation, operation and maintenance are carried out according to the instructions in this manual
and on the labels attached to the unit.

Warnings in this manual which are particularly important for user safety are shown by this danger symbol.

IMPORTANT WARNINGS

This unit contains refrigerant gas circuits, chilled water under pressure, live electrical components, hot
surfaces, sharp edges (the fins on the coils) and rotating devices such as the fans.

All service and maintenance operations which require access to the inside of the unit while it is in
operation must be performed by qualified and experienced personnel who are aware of the necessary
precautions.

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

In any case, all safety legislation of the installation location must be followed.

In the event of fire water and other conductive substances must not be used to put out the fire near live
electrical components. This warning must be displayed on notices in the unit installation location.

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

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

Drain all water from the system before the winter season to avoid freezing.

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

Free cooling chillers must be loaded with anti-freeze.

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

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

5

SYMBOLS USED

SYMBOL MEANING SYMBOL MEANING

DANGER MOVING COMPONENTS

IMPORTANT WARNING HOT SURFACES – DANGER OF

BURNING

HIGH VOLTAGE – ELECTRICAL

RISK

SHARP EDGES

SAFETY

The new range of UNIFLAIR ARA water chillers and heat pumps features state-of-the-art technology to give
maximum reliability, safety, quietness of operation and respect for the environment.

1) RELIABILITY: Trouble-free operation of Uniflair precision chillers is ensured by rigorous production
process controls under ISO 9001-certified quality procedures:

• quality control of components;

• pressure testing of refrigerant and water circuits;

• testing of current absorption and IEC safety testing;

• calibration and testing of instruments and safety devices;

• final testing of unit under operating conditions

2) ACTIVE SAFETY: UNIFLAIR safety and control systems have a supervision and prevention function
with:

• automatic blocking of components in dangerous conditions;

• indication of function status; reading and continuous display of circulating fluid temperature;

• management of compressor start-ups to reduce excessive switching on and off

• compressor start timing to reduce total unit start-up current

• indication of anomalous function conditions and/or alarms.

3) PASSIVE SAFETY: The essential functions of UNIFLAIR chillers are protected against anomalous
function conditions and potential damage with:

• high and low pressostats on the refrigerant circuit (HP with manual re-set)

• safety valve on the high pressure refrigerant line

• anti-freeze protection to prevent freezing of the evaporator, pump and tank

• compressor motor electrical protection

• standard differential flow gauge

• water circuit safety (with optional pump group)

• compressor crankcase heater (standard on free-cooling and heat pump versions).

4) PERSONAL SAFETY. The design and cabling of all UNIFLAIR chillers conforms to IEC electro­technical norms. Electrical panels have auxiliary 24V circuits and are equipped with:

• general switch and door lock switch;

• automatic circuit-breaker switches;

• double protection panel on fan compartment.

The fans are protected by an external metal grille which conforms to applicable safety norms.

6

GENERAL DESCRIPTION

DOCUMENTATION INCLUDED WITH THE UNIT

Every ARA chiller is delivered complete with the following documentation:

• ARA and microprocessor control instruction manuals

• Unit installation diagrams

• Diagrams of the refrigerant and hydraulic circuits of the unit

• Electrical diagrams

• List of spare parts

• CE declaration with list of European directives and norms to which the unit conforms

• Guarantee Conditions.

7

AVAILABLE VERSIONS AND ACCESSORIES

Models

ARA00152 (only M versions), ARA00182, ARA00202, ARA00232, ARA00252,
ARA00302, ARA00403 (not supplied for E and M versions), ARA00504 (not

supplied for E and M versions)

Configurations A : Basic version: mechanical cooling with on-off condensation control

D : Basic version with modulating condensation control
L : Ultra low-noise version with modulating condensation control
H : Heat pump with on-off condensation control
P : Heat pump with modulating condensation control
Q : Ultra low-noise heat pump with modulating condensation control
E : Free cooling version with modulating condensation control
M: Ultra low-noise free cooling version with modulating condensation control

Pump group

Group with 1 type A pump (0.9 kW)
Group with 2 type A pumps (0.9 kW)
Group with 1 type B pump (1.1 kW)
Group with 2 type B pumps (1.1 kW)
Group with 1 type C pump (1.85 kW)
Group with 2 type C pumps (1.85 kW)

Reservoir tank

(only with pump group)

Tank type “A” (210 litres)
Tank type “B” (300 litres)
Tank type “C” (500 litres)

Heat recovery

Partial heat recovery (with modulating condensation control as standard - not supplied
for heat pump versions)

Power supply

400V/3ph+N/50Hz

Electrical accessories

Power phase correction capacitors

Control

Basic control (not available on free-cooling versions)
Basic control with remote terminal (not available on free-cooling versions)
mP20 control without user terminal (not available on heat pumps)
mP20 control with local user terminal (not available on heat pumps)
mP20 control with remote user terminal (not available on heat pumps)

Serial connections

LAN (with mP20 control)
RS485 serial output (with basic control)
RS485 serial output (with mP20 control)
RS422 serial output + LAN (with mP20 control)
RS485 serial output + LAN (with mP20 control)

Refrigerant

R22
R407C
R134a

Norms

ISPESL (Italian)
TÜV (German)

Refrigerant Accessories

Anti-freeze heater on evaporator (not supplied for Free cooling versions)
Anti-freeze heater on pumps (not supplied for Free cooling versions)
Anti-freeze heater on tank (not supplied for Free cooling versions)
High/Low pressure manometers

Pressure sensors

Low pressure sensor (with mP20 control only)
High pressure sensor

Options

Rubber anti-vibration feet
Coil protection grilles
Metal filters for free cooling coil.

8

DATA PLATE

The chiller data plate is in the electrical panel and gives the following information:

• Model of the unit

• Serial number

• Voltage, number of phases and power supply frequency for primary and auxiliary circuits

• Current and power absorbed

• OA (Operating current), FLA (Full load current) and LRA (Locked rotor current)

• Safety device settings

• Refrigerant type and charge in kg for each circuit.

MODEL SERIAL No.

POWER SUPPLY VOLTAGE

CURRENT

OA FLA LRA KW TOTALI

SAFETY DEVICE SETTINGS

REFRIGERANT

GENERAL DESCRIPTION AND INTENDED USE

Air-cooled and water-cooled ARA air-cooled liquid chillers and heat pumps are designed for outdoor
installation in comfort and industrial applications. The chilled water produced can be sent to fan coils or room
air conditioning units or can be used for industrial process cooling.

Units fitted with the mP20 microprocessor control can be connected in parallel on a single water circuit
thanks to the possibility to connect the microprocessor control boards in a local network. The cooling capacity
of the system can therefore be altered at any time.

FUNCTION LIMITS

In free cooling and heat pump versions or in applications which require the production of chilled water in
winter as well as summer, an anti-freeze mixture (water and ethylene glycol) must be used (see “Low­temperature operation with anti-freeze mixture”). The standard cooling-only unit can operate at air

temperatures up to +46°C.

EASE OF INSTALLATION AND MAINTENANCE

The compact dimensions and reduced weight of these chillers facilitates installation even where space is
limited. All models are fitted with a main switch to enable direct connection to the mains power supply without
the need for an external switch; short-circuit protection fuses should be fitted however.
All units are assembled and fully tested in the factory, making installation simply a question of connection to
the electrical power supply and water circuits. An important feature of the design is the positioning of
components to allow easy access for service and maintenance.

9

RESISTANCE TO THE ELEMENTS

Uniflair chillers boast excellent corrosion resistance and are built to withstand the harshest of conditions. The
structure is in galvanised steel sheet painter with polyester powder; all external fastenings are in stainless
steel.

LOW NOISE LEVELS

Even the basic units have very low noise levels thanks to large exchange surfaces and low fan running
speeds. For special applications where near-silent operation is required there are ultra-low noise versions
available; these units have vibration dampers on the compressor output, sound insulation on the compressor
housing and modulating fan speed control.

10

ACCESS TO MAIN COMPONENTS

COMPRESSOR HOUSING

To access the compressor housing, remove the 8 fixing screws

1

and lift panel

A

using the two front

handles

B

. Removing panel A gives access to the compressor housing, the microprocessor control user

terminal and to the optional high and low pressure manometers..

A

C

1

3

4

B

2

5

IG

DANGER – HOT SURFACES! RISK OF BURNING. When panel

A

has been removed the compressor and
refrigerant tubes are exposed – during normal unit operation these components are very hot and can cause
burns.

IMPORTANT: Removing panel

A

does not stop the unit and the power supply to the compressors is not

interrupted. For service and maintenance, the main switch IG must be turned off (position ‘O’).

ELECTRICAL PANEL

To access the electrical panel move the main switch

IG

to position “O” and turn the two screws

4

1/4 turn.

This enables panel

C

, hinged at the base of the electrical panel to be opened.

11

PUMP GROUP

To access the optional pump group and the free cooling pump remove the six fixing screws

6

and remove

panel

D

using front handle E. To avoid contact with the fan blades there is a further steel protection panel

F

, fixed with screws.

D

6

7

E

IMPORTANT: Before removing panel

D

switch off the unit by moving main switch IG to position ‘O’ to make

sure that there is no power supply to the compressors and circulation pumps.

ATTENZIONE

PRIMA DI QUALSIASI INTERVENTO LEGGERE ATTENTAMENTE IL LIBRETTO DI ISTRUZIONI.
APPARECCHIO IN TENSIONE E CON ORGANI ROTA NTI: PRIMA DI INTERVENIRE SU QUALSIASI
PARTE ELETTRICA OPPURE SUL VENTILATORE/I TO GLIERE TENSIONE ALL’APPARECCHIO.

WARNING

BEFORE ANY OPERATI ONS ON THIS UNIT READ T HE INSTRUCTION MANUAL CAREF ULLY.
THIS EQUIPMENT CONTAINS COMPONENTS AT MAINS VOLTAGE AS WELL AS ROTATING FANS:
DISCONNECT POWER BEFORE ANY OPERATION ON ELECTRICAL COMPONENTS OR FANS.

ACTHUNG

VOR ALLEN ARBEITEN AN DIESEM GERÄT IST DIE BEDIE NUNGSANLEITUNG GENAU STUDIEREN.
DIESES GERÄT ENTHÄLT BUTEILE, DIE UNTER SPANNUNG ST EHEN SOWIE SICH DREHENDE
VENTILATOREN: VOR ARBEITEN IM GERÄT IST DIE NETZZULEITUNG ABZUSCHALTEN.

ATTENTION

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

ATENCION

ANTES DE CUALQUIER INTERV ENCIÓN LEER ATENTAMENT E EL MANUAL DE INSTRUCCIONES.
APARATO BAJO TENSIÓN Y CON COMPONENTES ROTANTES. ANTES DE INTERVENIR SOBRE
CUALQUIER PARTE ELÈTRICA O SOBRE EL VENTILADOR/ES QUITAR TENSION AL APPARATO.

12

DESCRIPTION OF MAIN COMPONENTS

STRUCTURE

These units are normally installed outdoors, often on the roof of a building. For this reason the structure of the
unit is made entirely in galvanised steel, painted with corrosion-resistant polyester powder. All external
fastenings are in stainless steel.
The panels can be easily removed to facilitate maintenance and all internal components can be accessed via
two sides of the unit.

COMPRESSORS

Ultra-reliable rotating SCROLL compressors from a leading
manufacturer are used (in tandem on models 00403 and

00504). All ARA units have two independent refrigerant
circuits, ensuring at least 50% capacity in the unlikely event
of a fault in one of the circuits.
The microprocessor control manages the switching on and
off of the compressors in order to ensure effective control
of unit capacity; capacity steps depend on the type of
control fitted; in the case of the mP20 control the steps are:

0 - 45 - 100% on models 00182 and 00232
0 - 50 - 100% on models 00202, 00252 and 00302
0 - 45 - 70 - 100% on model 00403
0 - 25 - 50 - 75 - 100% on model 00504

These units are available in versions for use with HCFC­R22 and HFC-R407C (environment-friendly) refrigerants.
Units for operation with R134a are available on special
order from UNIFLAIR ITALIA Srl.
In order to prevent the refrigerant fluid diluting the oil and
creating foam when the unit is started all free cooling or
heat pump ARA models are fitted with oil heaters which
switch on automatically when the compressor stops.
Each compressor is fitted on rubber mountings to reduce
vibration transmission.

FANS

The sickle-blade axial fans are directly connected to external rotor motors which can be fitted with voltage
modulation speed control. The metal support grille conforms to all the main safety standards. The motors
have class F insulation and IP44 protection under DIN VDE 0470 section 1/11.92 and EN 60529.
Modulating condensation temperature control is available with fan speed regulation. This control is standard
with certain unit configurations (ultra low-noise versions, free cooling versions, partial heat recovery).

EVAPORATOR

The brazed plate heat exchangers are in AISI 316 stainless steel. The exchanger is fully lined with closed-cell
expanded polyurethane to prevent the formation of condensation and to limit heat loss. Given the internal
volume and operating pressure, the evaporator does not need ISPESL or TÜV homologation under the
standards for pressurised containers.

13

CHILLED WATER PUMP GROUP (optional)

The pump group for the circulation of chilled water is available in
different configurations:

- one pump (type “A”, “B” or “C”);

- two pumps (one in stand-by);

- one pump plus reservoir tank;

- two pumps (one in stand-by) plus reservoir tank.
The pumps, with 2-pole motors (2900 rpm), are fitted with the related
connections, collectors and electrical panel (located in the main
electrical panel housing). The pump panel controls rotation of operation
between the two pumps on the basis of run time or alarms. The
electrical panel contains the run hour counter for each pump and red
LED alarm indicators.
Pump body, flange and impeller are AISI 304 stainless steel, insulation
is class F and protection is to IP55. The materials used ensure correct
pump operation with liquid temperatures from -10°C to +85°C.

CIRCULATING PUMPS

ARA 00152 00182 00202 00232 00252 00302 00403 00504

Solo freddo n.a.

A - B - C B – C C

Cooling onl

y

Pompa di calore n.a.

A - B - C B – C C

Heat pump

Free cooling

A - B – C B – C

n.a. n.a.

Free cooling

Free cooling silenziato

A - B – C B – C

n.a. n.a.

Low noise - Free cooling

n.a. = Non disponibile

n.a. = Not available

RESERVOIR TANK

ARA 00152 00182 00202 00232 00252 00302 00403 00504

Solo freddo n.a.

A A – B A - B - C

Cooling onl

y

Pompa di calore n.a.

A A – B A - B - C

Heat pump

Free cooling

A A – B

n.a. n.a.

Free cooling

Free cooling silenziato

A A – B A - B - C

n.a. n.a.

Low noise - Free cooling

n.a. = Non disponibile

n.a. = Not available

FINNED COILS

In air-cooled versions the condenser consists of coils with aluminium fins and copper tubes mechanically
expanded to obtain an optimum metallic contact and maximum exchange efficiency. The coil has a very large
surface area for operation with high ambient temperatures and has an integrated super-cooling circuit.
If there are harsh conditions in the installation environment, various treatments are available for the
exchanger: pre-painted aluminium, copper-copper protection and cataforesis aluminium treatment;
cataforesis provides the best compromise between cost and performance.

14

FREE COOLING

During normal chiller functioning, the water consumed is treated in the brazed plate heat exchanger. When
the external air temperature drops to such a level as to allow water pre-cooling, the control activates a
recirculation pump which sends the water to a finned pipe coil, mounted in front of the condenser.
For the correct power supply of the thermostatic valve it is necessary to maintain the condensation pressure
sufficiently high. For this reason, in the event of combined functioning of free cooling and mechanical cooling
with the compressors, the speed of the fans is reduced (regulation of the standard speed of all ARA models
with free cooling).

CONDENSATOR

COIL

FREE COOLING

COIL

FANS

AIR FLOW

Positioning of the Free Cooling Coil.

Since water passes through the free cooling coils, chillers must be loaded with antifreeze, or

guarantee conditions may be effected.

15

RECOVERY OF CONDENSATION HEAT

Recovery of heat from de-superheating and condensation of the refrigerant leaving the compressor enables
the production of hot water. Without heat recovery this heat is dissipated in the environment via the finned
condenser coils.
The diagram below shows the partial heat recovery circuit. The cooling and hydraulic circuit diagrams are
included with all ARA units with heat recovery.

Heat Recovery Diagram

SAC

PE

VE

D

C

CA

MV

Refrigerant Circuit

(Inside unit)

M

VS

Water Circuit

(Not supplied by Uniflair)

VS

A

VM

In order to ensure the correct functioning of the chillers avoid that the heat recovery plate exchanger D is
powered by water which is too cold. For this reason use of a three way valve VM is strongly advised yet
remains the responsibility of the installer (see diagram).
Heat recovery uses plate heat exchangers located on the output line before the air-cooled condensers and
supplied with water from the user system. Condensation control, as described above, is included in units with
heat recovery.

INSTALL a metal filter on the piping at the unit intake to stop the heat exchanger getting blocked by flakes of
welding or rust.

VM

motoriste 3-way valve

VS

water safety valve

VE

expansion tank

PE

circulation pump

SAC

reservoir tank

MV

fan

CA

finned condenser coil

C

compressor

D

heat recovery plate

exchanger

VSA

safety valve