Blue Box KAPPA V SR, Installation, Operating And Maintenance Manual

Page 1: ...101070B02 Issue 02 03 Replaces 06 02 KAPPA V SR 635 1065 kW 0062 Installation operating and maintenance manual Water chillers Air water Axial fans and self contained screw compressors ISO 9001 Cert n...

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Page 3: ...ING 10 3 SAFETY PRECAUTIONS 12 3 1 DEFINITION OF DANGER ZONE 12 3 2 SAFETY PRESCRIPTIONS 12 MECHANICAL HAZARDS 13 THERMAL HAZARDS 14 NOISE RELATED HAZARDS 14 ELECTRICAL HAZARDS 14 REFRIGERANT SAFETY D...

Page 4: ...ump management ST units only 42 5 2 5 Compressor start up 42 5 2 6 Chiller mode operation 42 5 2 7 Heat pump mode operation 42 5 2 8 Evaporator low temperature chilled water protection 42 5 2 9 Evapor...

Page 5: ...ak test 51 8 3 2 High vacuum and dehydration of the refrigerant circuit 51 8 3 3 Refrigerant charge 52 8 4 ENVIRONMENTAL CONSIDERATIONS 52 9 TROUBLESHOOTING 53 10 DECOMMISSIONING THE UNIT 62 REFRIGERA...

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Page 7: ...cell expanded material Each evaporator is equipped with a low water temperature probe for freeze protection REFRIGERANT CIRCUIT Comprising compressor discharge shut off valve liquid valve charge conne...

Page 8: ...ons ST 1PS with 1 pump and a tank ST 2P with 2 pumps without a tank ST S with tank without pumps ST 1P with 1 pump without a tank ACCESSORY VERSIONS KAPPA V SR DC unit with heat recovery condenser In...

Page 9: ...ched between each other from the keypad or using a digital input The type of selection must be specified at the time of order In all cases the thermostatic valves switch automatically on the basis of...

Page 10: ...o idraulico Max Hydraultic circuit pressure Max Druck im Hydraul Kreislauf Pression maxi circuit hydraulique Data di produzione Manufacturing date Erstellungsdatum Date de fabrication Press massima ci...

Page 11: ...wer cooling kW 224 1 248 1 269 3 291 Absorbed power heating kW 217 3 240 7 261 2 282 2 Capacity steps 0 25 50 75 100 0 25 50 75 100 0 25 50 75 100 0 25 50 75 100 Condenser cooling fans type Total air...

Page 12: ...ling kW 312 7 330 4 348 1 372 2 Absorbed power heating kW 303 1 320 3 337 5 361 Capacity steps 0 25 50 75 100 0 25 50 75 100 0 25 50 75 100 0 16 7 33 5 50 66 7 83 3 100 Condenser cooling fans type Tot...

Page 13: ...W 1 x 11 0 1 x 11 0 1 x 15 0 1 x 15 0 Pump motor nominal absorbed power A 1 x 23 0 1 x 23 0 1 x 30 0 1 x 30 0 Power supply V Ph Hz Control power supply V Ph Hz Control board supply V Ph Hz Condenser f...

Page 14: ...8 190 9 240 9 240 Width mm 2 390 2 390 2 390 2 390 Heigth mm 2 432 2 432 2 432 2 432 Shipping weight kg 6 416 6 626 7 882 8 027 MODEL KAPPA V SR 88 2 93 2 100 2 106 3 Pump section Evaporator water fl...

Page 15: ...77 4 75 8 75 6 78 0 75 6 66 9 56 0 81 5 93 2 73 9 77 9 76 4 76 2 78 5 76 1 67 4 56 3 82 0 100 2 73 9 77 9 76 4 76 0 78 3 76 2 67 6 56 5 82 0 106 3 73 9 77 9 76 4 78 5 78 1 76 3 67 8 56 7 82 0 Octave b...

Page 16: ...trictly follow the rules described in this manual to conform to all the items detailed on the unit labels and take any necessary precaution Pressure in refrigerant circuits and danger from electrical...

Page 17: ...11 Figure 1 1 2 Caution ensure that the method of lifting does not allow the unit to slip from chains and slings or turn over or slide from lifting devices 1 Side panel protection not supplied 2 Lifti...

Page 18: ...g rules at all times All work on the unit must be performed by qualified personnel Before working on the unit ensure that designated personnel are conversant with the documentation supplied Always ens...

Page 19: ...tallation and maintenance manual specifies that maintenance operations should be carried out exclusively by qualified personnel and provides indications of the protective equipment to be used Normal o...

Page 20: ...ssure from the machine Operating mode Analysed risk or hazard Solution adopted Normal operating regime Maintenance Burns caused by high temperatures Most of the pipelines that could cause burns when t...

Page 21: ...physician after significant exposure Do not give adrenaline or similar drugs Ingestion Do not induce vomiting without medical advice Call a physician immediately Do not give drugs from adrenaline eph...

Page 22: ...thane 1000 ppm TWA AIHA 9 1 Stability Stable at normal conditions No decomposition if stored and applied as directed Decomposition starting from 250 C 9 2 Conditions to avoid Do not expose to temperat...

Page 23: ...use air recirculation at the condenser coil type of support surface to limit the risk of overheating do not install the unit on a dark coloured surface e g bitumen roofing membranes and compounds poss...

Page 24: ...structure it is recommended that a layer of rigid rubber sheeting is placed between the base of the unit and the supporting surface If a higher level of vibration damping is required use anti vibratio...

Page 25: ...required for satisfactory operation of the unit is as follows refer to figure 4 coils side minimum distance 0 75 meters top no impediments that obstruct the air discharge electrical panel side 1 meter...

Page 26: ...r 45 60 70 ShA which identifies the hardness of the rubber isolator The dimensional drawing enclosed in the machine shows the unit footprint with the position and weight of each isolator Rubber metal...

Page 27: ...The following devices should be located on the piping system Isolating regulating valves temperature gauges or thermometer pockets pressure gauges or binder points required for servicing operations S...

Page 28: ...1 Pump 2 Expansion tank 3 Relief valve 4 Check valve 5 Ball valve 6 Tank 7 Water pressure gauge 8 Thermometer 9 Water filter 10 Bleed valve 11 Flexible connection 12 Circuit filling unit 13 Water dra...

Page 29: ...Blue Box 23 HYDRAULIC CIRCUIT DIAGRAM VERSION KAPPA V SR ST 2PS...

Page 30: ...action is low it is advisable to verify that the water volume equals or exceeds the following ratio 24 QCOMPTOT M N where M system water content kg QCOMPTOT unit cooling capacity kW N number of capac...

Page 31: ...1 Disconnect bolts and open the joint 2 Move the gasket on the heat exchanger connection towards the shell 3 Weld the counter connection to the hydraulic circuit pipe 4 Line up the connection and the...

Page 32: ...uperheaters the connections for the relative hydraulic circuit are steel tubes with male threads The water inlet and outlet must be connected in the positions indicated as labelled on the unit see fig...

Page 33: ...ular operation once the water has reached the desired temperature If faults occur on the recovery condenser the microprocessor controller restarts the fans The calibration values of the thermostat and...

Page 34: ...ves are fitted on the high pressure side and low pressure side of the refrigerant circuit The valves must be vented to outdoors through a vent pipe The vent pipe must be sized no smaller than the reli...

Page 35: ...sequent risk of compressor breakdown The maximum water temperature at the condenser outlet must not be higher than 47 C In the event of higher temperatures the safety devices will trip causing the uni...

Page 36: ...e required chilled water temperature See table 1 TABLE 1 FREEZING POINT FOR WATER ANTIFREEZE MIXTURES If ambient temperatures lower than the freezing point of water can be expected antifreeze mixtures...

Page 37: ...erature kit 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 0 5 10 15 20 25 30 35 40 45 50 55 Pompa di calore Heat pump Riscaldamento Heating Raffreddamento Cooling Con dispositivi opzionali per basse te...

Page 38: ...r temperature rise for all versions must be between 3 C min and 8 C max 40 20 20 30 50 60 70 80 90 100 40 30 10 65 2 73 2 80 2 50 60 84 2 88 2 93 2 100 2 106 3 25 35 55 45 Portata acqua l s Water Flow...

Page 39: ...L KAPPA V SR ST 2PS PREVALENZA UTILE 0 50 100 150 200 250 300 350 400 450 500 20 30 40 50 60 Portata acqua l s Water flow Prevalenza utile kPa Available pressure 65 2 73 2 80 2 84 2 88 2 93 2 100 2 10...

Page 40: ...Blue Box 34 ELECTRICAL PANEL LAY OUT MODELS 65 2 100 2...

Page 41: ...Blue Box 35 ELECTRICAL PANEL LAY OUT MODEL 106 3 Remote electric panel Option ST version See sheet 2...

Page 42: ...ORRECT COMPR 1 FU42 FUSES CAPAC POW FACT CORRECT COMPR 2 FU46 FUSES CAPAC POW FACT CORRECT PUMPS FU50 FUSES AUX TRANSFORMER FU51 AUX CIRCUIT FUSES FU52 FUSE CONTROL FU56 PHASE SEQ RELAY FUSES KA1 VOLT...

Page 43: ...nsformer located inside the electrical panel The control circuit is protected by fuses Electrical cable anchorage anchor the electrical power cables with fixing systems able to withstand pulling and t...

Page 44: ...or start stop times safety devices and other auxiliary functions such as condensation control in cooling mode evaporation control in heat pump mode free cooling heat recovery and other functions descr...

Page 45: ...ning menu Maintenance key press this key to access the maintenance menus Print key this key is currently not used I O key pressing this key opens the menus containing the status of the digital inputs...

Page 46: ...key press this key to switch from Stand by to ON or vice versa Alarm key this key serves to mute the alarm buzzer display any active alarms and reset them in certain cases Arrow key the arrow keys all...

Page 47: ...s calibration delays can be programmed by means of the various menus Refer to the specific manual for the pCO2 controller 5 2 2 Unit in stand by mode The unit is in stand by mode when it is supplied w...

Page 48: ...started the trip is retarded if it occurs within the time programmed for the compressor stop If the unit trips due to the opening of the flow switch input the relative alarm is displayed Starting and...

Page 49: ...be restarted only after a minimum idle time or after a minimum time interval between two consecutive starts has elapsed The consecutive starting of two compressors or the consecutive starting of one c...

Page 50: ...t caused the alarm to trip plus the differential value It is possible to program the number of permissible conse cutive compressor starts before the unit shuts down in safety status 5 2 13 Low ambient...

Page 51: ...preset time limit the defrost cycle is forcibly terminated as though the defrost end signal were present The controller restarts the fans and when the pressure lowers again to the preset value it reve...

Page 52: ...re enabled the display will show the message UNIT ON After having performed the above procedures the unit will start automatically after a delay of approximately 5 minutes assuming that the enabling s...

Page 53: ...arning do not use the machine main power switch to stop the unit this switch must be used to disconnect the electrical supply when no current is flowing on the circuit i e only when the unit is in OFF...

Page 54: ...air temperature Also check that the evaporating temperature equivalent to the pressure read on the pressure gauge is 5 C lower than the evaporator outlet temperature Check that refrigerant liquid sup...

Page 55: ...and personal injury TABLE 2 CALIBRATION OF CONTROL EQUIPMENT TABLE 3 CALIBRATION OF SAFETY DEVICES Chiller heat pump CAPACITY STEPS CONTROL ELEMENT SET POINT DIFFERENTIAL Service calibration summer C...

Page 56: ...charge monthly Check that there is no oil leakage from the compressor monthly Check that there is no water leakage in the hydraulic system monthly If the unit is to be stopped for a long period the h...

Page 57: ...on of the refrigerant circuit To generate a high vacuum in the refrigerant circuit use a high vacuum pump able to reach 0 1 mbar of absolute pressure with a flow rate of 10 m3 h With this type of pump...

Page 58: ...line A unit that was originally factory charged with R407C cannot be charged with R22 and vice versa 8 4 ENVIRONMENTAL CONSIDERATIONS Laws governing the use of substances detrimental to the ozone laye...

Page 59: ...accordance with easily identifiable symptoms In relation to possible corrective action adopt the maximum attention in the operations you intend to perform as overconfidence coupled with insufficient...

Page 60: ...phase wires of the power supply line when the unit is powered up again both the green and yellow LEDs should light Relay KA5 with green and yellow LEDs off Check fuses FU56 If fuses are OK replace ph...

Page 61: ...motor faulty Check and replace if necessary F No compressor running Display On unit ON with alarm Fans protection Fan thermal protection intervention Check insulation between windings and from winding...

Page 62: ...n motor faulty Check and replace if necessary Insufficient water flow to evaporator Check hydraulic circuit Incorrect setting of defrost set point Check and correct setting if necessary I No compresso...

Page 63: ...ing Display On unit ON with alarm Power supply voltage not stable Check power supply voltage if not correct contact the electricity company No power to Control circuits Fuses FU51 burnt out Check caus...

Page 64: ...FU56 and replace if necessary Incorrect Phase Sequence and phase sequence relay with green and orange LEDs Off One of the three phases is not present Check connection of each phase Q No compressor run...

Page 65: ...ir S One or more compressors switched Insufficient refrigerant charge due to leak in circuit Call service organisation off Display On with alarm Low Pressure Compressors Thermostatic valve faulty Call...

Page 66: ...Compressors specified by alarm require maintenance Call service for scheduled maintenance W All compressors running Display On with alarm Unit Maintenance Unit maintenance required Call service for s...

Page 67: ...es Modify in accordance with values of paragraph Calibration of control equipment Compressor faulty Check replace if necessary Z Anomalous noise from system Compressor noisy Contact service organisati...

Page 68: ...collection centre also the compressor lubrication oil must be recovered and sent to a collection centre the structure and components if unusable must be stripped down and separated according to the ma...

Page 69: ...Blue Box 63 KAPPA V SR REFRIGERANT CIRCUIT...

Page 70: ...Blue Box 64 KAPPA V SR HP REFRIGERANT CIRCUIT...

Page 71: ...Blue Box 65 KAPPA V SR DC REFRIGERANT CIRCUIT...

Page 72: ...Blue Box 66 KAPPA V SR KAPPA V SR HP Models 65 2 73 2 OVERALL DIMENSIONS WEIGHTS AND HYDRAULIC CONNECTIONS...

Page 73: ...Blue Box 67 KAPPA V SR KAPPA V SR HP FOOTPRINT Models 65 2 73 2 OVERALL DIMENSIONS WEIGHTS AND HYDRAULIC CONNECTIONS...

Page 74: ...Blue Box 68 KAPPA V SR KAPPA V SR HP Models 80 2 88 2 OVERALL DIMENSIONS WEIGHTS AND HYDRAULIC CONNECTIONS...

Page 75: ...Blue Box 69 KAPPA V SR KAPPA V SR HP FOOTPRINT Models 80 2 88 2 OVERALL DIMENSIONS WEIGHTS AND HYDRAULIC CONNECTIONS...

Page 76: ...Blue Box 70 KAPPA V SR KAPPA V SR HP Models 93 2 100 2 OVERALL DIMENSIONS WEIGHTS AND HYDRAULIC CONNECTIONS...

Page 77: ...Blue Box 71 KAPPA V SR KAPPA V SR HP FOOTPRINT Models 93 2 100 2 OVERALL DIMENSIONS WEIGHTS AND HYDRAULIC CONNECTIONS...

Page 78: ...Blue Box 72 KAPPA V SR KAPPA V SR HP Model 106 3 OVERALL DIMENSIONS WEIGHTS AND HYDRAULIC CONNECTIONS...

Page 79: ...Blue Box 73 KAPPA V SR KAPPA V SR HP FOOTPRINT Model 106 3 OVERALL DIMENSIONS WEIGHTS AND HYDRAULIC CONNECTIONS...

Page 80: ...Blue Box 74...

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Page 82: ...ttei 20 35028 Piove di Sacco PD Italy Tel 39 049 9716300 Fax 39 049 9704105 Manual 101070B02 Issue 02 03 Replaces 05 02 All data in this manual is subject to change without prior notice BLUE BOX srl i...