Uniflair Aquaflair 00182 User 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

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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:

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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

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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.

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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 electro-
technical 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.

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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.

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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.

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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 “Low-
temperature 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.

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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.

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ACCESS TO MAIN COMPONENTS
COMPRESSOR HOUSING
To access the compressor housing, remove the 8 fixing screws 1and lift panel Ausing the two front
handles B. Removing panel Agives 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
5IG
DANGER – HOT SURFACES! RISK OF BURNING. When panel Ahas 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 Adoes 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 41/4 turn.
This enables panel C, hinged at the base of the electrical panel to be opened.