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Summary of Contents for Danfoss BW05
- Page 1 BW05 Brine Water Heat Pump with Integrated Hydronic Modules Nominal cooling capacity 20-310 kW 50 Hz Installation, operation and maintenance instructions...
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Page 2: Table Of Contents
3 DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION ....................8 3.1 - BW05 020-045 - unit without hydronic module (standard) .................................8 3.2 - BW05 020-045 - unit with hydronic module (option) and/or unit with option 116E (Victaulic water connection at the top) ..............................................8 3.3 - BW05 060-150 - unit with or without hydronic module ................................9... - Page 3 14.2 - Description of the maintenance operations ....................................35 15 START UP CHECKLIST FOR BW05 BRINE WATER HEAT PUMP USE FOR JOB FILE ..........37 The cover photograph is for illustrative purposes only and is not part of any offer for sale or contract.
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Page 4: Introduction
In certain cases the safety stops are installed on ball valves. These valves are factory-supplied lead-sealed in the open Prior to the initial start-up of the BW05 units, the people position. This system permits isolating and removing the involved in the on-site installation, start-up, operation and safety stop for checking and replacing. -
Page 5: Maintenance Safety Considerations
five years for external overpressure devices (safety welding operations must be carried out by qualified globe valves). • Check the “BW05 control” manual for a detailed specialists. explanation of the high-pressure switch test method. Any manipulation (opening or closing) of a shut-off valve must be carried out by a qualified and authorised engineer. -
Page 6: Preliminary Checks
• Do not keep the BW05 units outside where they are exposed ATTENTION: No part of the unit must be used as a walkway, rack or support. The refrigerant lines can break under the to the weather, as the sensitive control mechanism and the weight and release refrigerant, causing personal injury. -
Page 7: Moving And Siting The Unit
Check the protection against mechanical damage. with great care. Tilting and jarring can damage the unit and • Check the protection against heat. impair unit operation. • Check the protection of moving parts. If BW05 units are hoisted with rigging, it is necessary to • Verify the accessibility for maintenance or repair and to protect the unit frame (side and rear panels and front check the piping. • Verify the status of the valves. doors) against accidental crushing while a unit is being •... -
Page 8: Dimensions, Clearances, Weight Distribution
3 DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION 3.1 - BW05 020-045 - unit without hydronic module (standard) 3.2 - BW05 020-045 - unit with hydronic module (option) and/or unit with option 116E (Victaulic water connection at the top) 1204 BW05 020-030 BW05 040-045 1-1/4”... -
Page 9: Bw05 060-150 - Unit With Or Without Hydronic Module
3.3 - BW05 060-150 - unit with or without hydronic module 2004 Legend: NOTE: Non-contractual drawings. All dimensions are in mm. Refer to the certified dimensional drawings. Water inlet For the positioning of the fixing points, weight distribution Water outlet and centre of gravity coordinates, also refer to the certified... -
Page 10: Bw05 160-300 - Unit Without Hydronic Module (Standard)
3.4 - BW05 160-300 - unit without hydronic module (standard) 2300 1100 2013 3.5 - BW05 160-300 - unit with hydronic module (option) 2950 1100 Legend: NOTE: Non-contractual drawings. All dimensions are in mm. Refer to the certified dimensional drawings. -
Page 11: Physical And Electrical Data
Single or twin-head composite centrifugal pump, as per option used (48.3 r/s) Power input kW 1.0 Expansion tank volume, evaporator loop Field water connections Victaulic† (BW05 025-045 without hydronic module: threaded gas connections) Standard connection diameter in 2 3 OD 3 OD 3 OD 3 OD 3 Welded connection diameter mm 60.3 60.3... -
Page 12: Electrical Data
Maximum current draw 11.6 11.6 11.6 11.6 Notes The water pump power input values given are for guidance only. BW05 units have an evaporator and a condenser pump. • To obtain the maximum unit power input for a unit with hydronic kit add the evaporator (*) and condenser pump (***) power input to the maximum power input of the unit without hydronic module, given in the top table. • To obtain the maximum unit current draw for a unit with hydronic kit add the evaporator (**) and condenser pump current (†) draw to the maximum current draw of the unit without hydronic module, given in the top table. -
Page 13: Compressor Usage And Electrical Data Table
The operating environment for the BW05 brine water heat pump is specified below: The protection level of the control boxes required to conform to this class is Environment* - Environment as classified in IEC 60364 §... -
Page 14: Application Data
20°C a three-way valve is required to allow operation, while At start-up/during operation (minimum) (note 5) maintaining the correct condensing temperature. For BW05 units equipped with a hydronic module the minimum entering water During operation (maximum) (note 4) temperature is -15°C. -
Page 15: Variable Flow Evaporator
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 Air conditioning BW05 020-045 BW05 060-300 VUGFB102... -
Page 16: Evaporator And Condenser Pressure Drop Curves
5.11 - Evaporator and condenser pressure drop curves 10000 1000 Water flow rate, l/s Legend BW05 020 BW05 110 BW05 025-030 10 BW05 120 BW05 040 11 BW05 135 BW05 045 12 BW05 150 BW05 060 13 BW05 160-185 BW05 070... -
Page 17: Electrical Connection
6 ELECTRICAL CONNECTION Control box BW05 060-150 6.1 - Electrical connections BW05 units Control box BW05 020-045 PE (M8) 39 39 PE (M8) Control box BW05 160-300 PE (M12) Legend 181.5 Main disconnect switch PE Earth connection Power supply cable section (see table “Recommended wire sections”). -
Page 18: Power Supply
The following is only to be used as a guideline, and does not make Danfoss in any way liable. After wire sizing has been completed, using the certified dimensional drawing, the installer must ensure easy connection and define any modifications necessary on site. - Page 19 6.4.2 - Selection table of minimum and maximum wire sections for connection to BW05 units 400 V-3 ph-50 Hz BW05 Minimum wire Maximum wire section (mm Wire type L (m) section (mm Wire type L (m) 1x 6 XLPE Cu...
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Page 20: Water Connections
7 WATER CONNECTIONS Before any start-up verify that the heat exchange fluid is compatible with the materials and the water circuit coating. For size and position of the heat exchanger water inlet and outlet connections refer to the certified dimensional drawings In case additives or other fluids than those recommended are supplied with the unit. -
Page 21: Water Connections
Failure to follow this instruction will 7.3 - Frost protection void the guarantee. The BW05 units are designed to be installed under cover at The flow switch is supplied, installed on the evaporator outside temperatures between +5°C and +40°C. Therefore entering water pipe and preset at the factory to cut out when they do not include anti-freeze protection, as standard. - Page 22 Typical evaporator hydronic circuit piping diagram BW05 020-300 Legend Installation components Components of unit and hydronic module 11 Air vent 12 Thermometer sleeve Victaulic screen filter 13 Flexible connection Expansion tank 14 Shut-off valve Safety valve 15 Pressure gauge Water pump...
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Page 23: Nominal Evaporator Water Flow Control
8 NOMINAL EVAPORATOR WATER FLOW CONTROL Entering water pressure reading The water circulation pumps of the BW05 units have been sized to allow the hydronic modules to cover all pos-sible configurations based on the specific installation con-ditions, i.e. for various temperature differences between the entering and the leaving water ( T) at full load, which can vary between 3 and 10 K. -
Page 24: Evaporator Pump Flow/Pressure Curve
Pump curve and water flow control as a function of the system pressure drops Example: Unit at Eurovent conditions of 4.8 l/s Water flow rate, l/s Legend BW05 060-090 BW05 110-185 BW05 210-300 Water flow rate, l/s Legend Unit pump curve... -
Page 25: Available Static System Pressure (Evaporator Side)
8.3 - Available static system pressure (evaporator side) 9 CONDENSER WATER FLOW RATE Single pump The BW05 units with hydronic module are equipped with a variable-speed water pump, automatically adjusting the flow rate to maintain the lowest condensing pressure possible. No control is necessary at the start-up. -
Page 26: Available Static System Pressure (Condenser Side)
10 BW05 UNIT OPERATION WITH A DRYCOOLER Single pump 10.1 - Operating principle The BW05 units have been specially designed to optimise the operation of systems, using drycoolers as heat rejection system. With a variable-speed condenser water pump integrated into the BW05, the complexity of traditional systems, using a three-way valve has been eliminated. -
Page 27: Configuration Of The Number Of Fan Stages And The Automatic Changeover Of The Fan Stages
4 and 6-stage configuration (min. 2 - max. 8) microprocessor board of the BW05 are used for the overall system control. The control system optimises system operation to obtain the... -
Page 28: Start Up
Refer to the manufacturer’ s dedicated water pump outputs). instructions. • Check the condensing loop water circulation pump BW05 020 to 300 (standard configuration: return water operation with the Quick Test function. control) • For units without hydronic module, the water pump overheat protection devices must be connected in series with the pump contactor power supply. -
Page 29: Major System Components And Operation Data
The evaporators and condensers are single-circuit for sizes ment. BW05 020 to 150 and interlaced dual-circuit for sizes BW05 160 to 300. BW05 units using these compressors are installed in areas where the temperature must be between 5°C minimum and... -
Page 30: Thermostatic Expansion Device
BW05 020 to 070 and modular the products originally supplied. devices for sizes BW05 080 to 300. They are factory-set to maintain between 5 and 6 K superheat in all operating NOTES: Monitoring during operation, re-qualification,... -
Page 31: Fixed-Speed Cold Water Loop Pump (Evaporator Side)
BW05 020 to 150 units (plastic pump body) and system or component extension (annex B). • After re-installation at another site (annexes A, B and D). 16 bar for the model used for BW05 160 to 300 units (cast • After repair following a refrigerant leak (annex D). The iron pump body). frequency of refrigerant leak detection can vary from once 12.11 - Variable-speed hot water loop pump (condenser... -
Page 32: General Unit Maintenance
WARNING: To ensure proper operation of BW05 units there 13.2 - General unit maintenance must be at least 12 K of subcooling as the liquid refrigerant • Keep the unit itself and the space around it clean and free enters the expansion valve. of obstructions. Remove all rubbish such as packing The BW05 units use refrigerant. For your information, we materials, as soon as the installation is completed. -
Page 33: Leak Detection
13.5 - Leak detection 13.7 - Recharging liquid refrigerant CAUTION: BW05 units are charged with liquid HFC-407C Never use oxygen or dry air, as this would cause a risk of fire or explosion. refrigerant. • Carry out a leak detection test on the whole system using the following methods: pressure test using dehydrated This non-azeotropic refrigerant blend consists of 23% R-32,... -
Page 34: Compressors
Characteristics of R-407C Saturated bubble Saturated dew Saturated bubble Saturated dew Saturated bubble Saturated dew (relative) point temp., °C point temp., °C (relative) point temp., °C point temp., °C (relative) point temp., °C point temp., °C -28.55 -21.72 10.5 23.74 29.35 47.81 52.55... -
Page 35: Maintenance Program
If the equipment does not operate normally during main- tenance operations, please refer to the paragraph on dia- there is no piping damage. • Carry out an oil contamination test. If acid, water or gnostics and breakdowns of the ‘ BW05’ controls manual. metallic particles are present, replace the oil in the circuit. IMPORTANT: Before each equipment maintenance • Verify the tightening of the thermostatic mechanism of the operation please ensure that: expansion device. - Page 36 15 START UP CHECKLIST FOR BW05 BRINE WATER HEAT PUMP USE FOR JOB FILE Preliminary information Job name: ........................................................Location: ........................................................Installing contractor:....................................................Distributor: ........................................................Start-up preformed by: ..................................................Compressors Model: ............................Serial No..........................Compressors Circuit A Circuit B 1. Model No........................1. Model No........................
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Page 37: Start Up Checklist For Bw05 Brine Water Heat Pump Use For Job File
Check cooler water loop Water loop volume = ..........(litres) Calculated volume = ..........(litres) 3.5 liters/nominal kW capacity for air conditioning (units BW05 020-045) 2.5 liters/nominal kW capacity for air conditioning (units BW05 060-300) Proper loop volume established Proper loop corrosion inhibitor included ......litres of ........ - Page 38 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.
- Page 39 VUGFB102...
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