Swegon BlueBox Kappa Sky, Instructions For Installation, Use And Maintenance Manual

Page 1: ...Kappa Sky EN 16 02 2021 Installation use and maintenance manual...

Page 2: ...n Machi nery Safety Directive The quality level is constantly monitored and therefore our products are synonymous with Safety Quality and Reliability Changes considered necessary for product improveme...

Page 3: ...esuperheater DS option 16 2 2 8 Condensate drain only for heat pump units 17 2 2 9 Refrigerant leak detector 18 2 3 Noise 19 2 4 Residual risks 19 2 5 Safety information on the refrigerant fluid 20 2...

Page 4: ...ng 32 6 3 2 Anti vibration mounts 33 6 3 3 Noise attenuation 34 6 3 4 Minimum distances 34 6 4 Hydraulic connections 35 6 5 Electrical connections 37 7 Commissioning 38 7 1 Preliminary operations 38 7...

Page 5: ...3 8 1 Adjustments 63 8 2 External cleaning 64 8 2 1 Cleaning traditional finned coils in Cu Al 64 8 2 2 Cleaning the microchannel coils 65 8 2 3 Cleaning e coated microchannel coils 66 8 3 Internal cl...

Page 6: ...eclaration of conformity that is an integral part of the manual 1 2 Description 1 2 1 Symbols A description of the main symbols used in this manual and on the labels affixed to the unit is given below...

Page 7: ...wn on the labels affixed to the unit the following illustrations are shown only as an example The Manufacturer adopts a continuous development policy and in this perspective reserves the right to make...

Page 8: ...f 16 April 2014 on fluorinated greenhouse gases and repealing Regulation EC No 842 2006 Text with EEA relevance Access to the unit requires that the closing panels where fitted are removed On no accou...

Page 9: ...ct to special con trol regulations provided for by law and must therefore be disposed of as indicated above Particular care should be taken during maintenance operations in order to reduce refrigerant...

Page 10: ...immediate vicinity be careful to avoid touching any components of the unit without suitable protection do not work in the discharge trajectory of the safety valves if the units are positioned in unpro...

Page 11: ...0 f Langelier index 0 4 0 4 pH 7 5 8 5 Electrical conductivity 10 500 S cm Organic elements Hydrogen carbonate HCO3 70 300 ppm Sulphates SO42 50 ppm Hydrogen carbonate Sulphates HCO3 SO42 1 Chlorides...

Page 12: ...temperature C unless specified this is 2 5 C Water density 1000 kg p Specific heat of water 4 186 kJ kg C Fm Q factor experimental factor different from 1 for some types of unit K1 Experimental multi...

Page 13: ...o water circulation Check the terminals provided for the flow switch in the wiring diagram of the unit Use a 2 x 1 mm cable or at most a 2 x 1 5 mm cable with diameter between 6 and 9 mm suitable for...

Page 14: ...uthorised personnel or by the manufacturer The glycol percentage by weight is determined based on the desired temperature of the chilled water see table Minimum ambient temperature or liquid outlet te...

Page 15: ...ed temperature If an anomaly occurs at the recovery condenser the microprocessor control will restart the fans It is essential for the water to come in at the connection indicated in the dimensional d...

Page 16: ...n at the connection indicated in the dimensional diagram and with the relevant label on the unit The desuperheater in reversible units can be used both in cooling and in heating mode Units set up for...

Page 17: ...oil with a condensate col lection tank with drain holes The units are supplied with two drain fittings for each condensing evaporating coil These drain fittings can be adjusted freely and can be conne...

Page 18: ...s at least once a year Check your local regulations on calibration and the testing requirements The alarm contact opens for 5 seconds any time power is cut out and then restored to the sensor Set a su...

Page 19: ...ot reasonably be eliminated or sufficiently reduced through design The presence of an operator is not required for normal operation of the unit The change from the OFF state to the ON state and vice v...

Page 20: ...ocal and or European regulations 2 5 1 Hazards and health consequences If accidentally released rapid evaporation of the liquid can cause freezing In case of contact with the liquid defrost the variou...

Page 21: ...in which it is carried out 3 2 Transport The unit is sent from the factory using suitable vehicles with correct locking in order to prevent any possibility of movement whilst in transit by road that m...

Page 22: ...f the unit must not be used as lifting points Make sure the machinery and lifting ropes are of suitable size and capacity and strictly follow their operating instructions Use only equipment that is in...

Page 23: ...the screws to a torque of 200 Nm Fig 5 Handling the unit with lifting brackets 3 4 Storage There are no special requirements if the unit has to be stored temporarily before installation Since these un...

Page 24: ...an be put on the market in any country More specifically they are allowed to be put on the market in member countries of the European Union hereinafter EU Putting the units on the market in the EU ent...

Page 25: ...required by Regulation 2013 813 2 Where provided for by Regulation 2013 811 applies to heat pumps with Pdesign 70kW 4 1 5 Efficiency parameters required for conformity To avoid ambiguity this chapter...

Page 26: ...temperature LWT cooling C Conformity Notes 1 Comfort cooling only 18 SEER sc LT 1 2 Comfort cooling only 18 SEER sc MT 3 Process cooling only 2 LWT 12 SEPR HT 4 Process cooling only 12 none 5 Process...

Page 27: ...mits stated in the Technical Catalogue will cause the unit to stop 5 2 Unintended use The unit must not be used in an explosive atmosphere in a flammable atmosphere in extremely dusty environments in...

Page 28: ...e vapour compression refrigeration cycle characterized by 4 phases com pression condensation throttling and evaporation This cycle produces heat transfer from a fluid at lower temperature to a fluid a...

Page 29: ...ting status can be carried out easily For the other operations refer to the manual of the control that is an integral part of the documentation of the unit The reference for the following instructions...

Page 30: ...and is present inside each unit It is essential to refer to this document if you are unsure about anything or need further explanations regarding the auxiliary electrical connections and power connec...

Page 31: ...y for maintenance or repair operations load bearing capacity of the support surface ventilation of the air cooled condenser orientation and exposure to solar radiation Keep the condensing coil out of...

Page 32: ...s accessory In the event of installation on roofs or intermediate floors the unit and pipes must be isolated from the walls and ceilings The units should not be positioned near private offices bedroom...

Page 33: ...he base of the unit The anti vibration mount is fixed to the base through the two holes on the flange The flange of the anti vibration mount bears a number 45 60 70 ShA that identifies the hardness of...

Page 34: ...f the unit does not affect its correct installation or its correct operation That is why it is necessary to avoid restricting the service spaces and installing covers that create recirculation between...

Page 35: ...n the exchanger inlet pipe to protect the exchanger from slag or impurities in the pipes Air valves to be placed in the highest parts of the hydraulic circuit to allow the non condensable gases to be...

Page 36: ...evant label on the unit If it does not there would be a risk of the evaporator being frozen since the antifreeze probe control would be thwarted The hydraulic circuit must be made in such a way as to...

Page 37: ...lance between phases must always be less than 2 If this does not occur contact our technical department to choose suitable protection devices Make sure the power line is correctly connected with a cl...

Page 38: ...ng the water filling valve When water begins to come out through the air valves close them and continue filling until the pressure value envisaged for the system is reached The unit should only be sta...

Page 39: ...olute as shown in the image Fig 9 Bleeding the pump Before starting the unit check that all the closing panels of the unit are in place and secured with fixing screws 7 1 1 Checking the pre charge of...

Page 40: ...e expansion coefficient of water pVE pre charge pressure of the expansion vessel barg pVS calibration pressure of the safety valve barg If the actual volume of the system is higher than this maximum v...

Page 41: ...revent damage to the hydraulic seals For units equipped with pump unit check that the pumps controlled with direct starting are rotating in the correct direction 7 2 2 Start Start the unit by acting o...

Page 42: ...liquid sight glass The continuous passage of bubbles can indicate there is insuffi cient refrigerant and it needs to be topped up In this case check that the subcooling value is at least 5 C But the p...

Page 43: ...ed in the water coil For free cooling units with decoupling exchanger FC NG where the head losses do not change only one value is set Do not set the water flow rate outside the operating limits allowe...

Page 44: ...and when it is not The operator has to repeat the manual procedure to find the pump operating speed with the free cooling valve open and then closed For free cooling units with decoupling exchanger F...

Page 45: ...must be paid to the construction arrangements of the system 7 3 2 2 System type 1 The pump in the unit is also used for circulating water in the system A sample diagram is shown below Vmin U2 U1 Un Y2...

Page 46: ...cal catalogue 7 3 2 2 System type 2 This system consists of a primary and a secondary circuit and it is also fitted with a hydraulic circuit breaker to make up for any difference in flow rate between...

Page 47: ...t button click the arrow down button to select the Flowzer function and then press Enter to confirm Press the SET button and access the screen where the setpoint difference value is set up Press ENTER...

Page 48: ...lp reduce the capacity of the buffer tank To this purpose the 3 way valves should be fitted on the furthest user points The bypass pipe must be of the same diameter as the connections of the unit 7 3...

Page 49: ...here the unit can be installed Vmin U2 U1 Un Y2V Y2V Y3V VP A2 UL UE BT2 BT1 Pex BP41 The abbreviations present in the diagram indicate A2 cooling unit controller BT1 unit input temperature sensor BT2...

Page 50: ...load varies If the demand from the system is reduced the pressure difference increases and the controller offsets it by reducing the pump speed which results in energy consumption saving The controlle...

Page 51: ...reen where the setpoint difference value is set up use the arrow buttons to move and select the parameter to be edited Press ENTER to enable the edit window Use the arrow buttons to set the new value...

Page 52: ...o set a pressure difference for operation in cooling mode and a pressure difference for operation in heating mode which helps the unit adapt to seasonal requirements This function requires the install...

Page 53: ...is means that the water flow rate calculated by the system is higher than the required rated flow as a result of which the Pp setpoint must be reduced until the Pex parameter falls within the value ra...

Page 54: ...Checking the minimum flow rate Progressively close all the user points and check that the pump speed slows progressively If the pump speed fails to be reduced the reason could be an excessive number...

Page 55: ...P BTWB VPP A2 UL UE BT2 BT1 Pex BP41 The abbreviations present in the diagram indicate A2 cooling unit controller BT1 unit input temperature sensor BT2 unit output temperature sensor EU heat exchanger...

Page 56: ...lant operating conditions with a flow rate lower than 50 of the rated flow rate of the refrigerant unit the primary circuit water will go through the bypass For correct operation of the unit even when...

Page 57: ...m original instructions Letter L appears in the first screen of the Flowzer menu to indicate that the value Pex is lower than the setpoint stored in parameter PA22 If the value Pex is higher than the...

Page 58: ...ople The control and safety equipment is calibrated and tested in the factory before the unit is shipped However after the unit has been started the safety devices must be checked only the high and lo...

Page 59: ...of water through the unit In this case it is necessary to check for closed or partially closed shut off devices in the hydraulic circuit and check the characteristics of the pumps and that they are wo...

Page 60: ...he cause that trigge red it The unit does not start the display is off the control is powered correctly The unit is switched off from the di splay and the display is disconnected or not working Restor...

Page 61: ...ilure of the protective devices to operate Check that the high pressure switches are working and if necessary replace them The valve must be replaced Opening of the valve due to overtem perature Repla...

Page 62: ...e control the pump must always be kept running When the temporary stop is carried out in this way all that needs to be done to restart the unit is to set the control to ON 7 8 Stop for long periods of...

Page 63: ...nutes before working on the electrical parts of the unit Circuits supplied from external sources made with orange cable can remain live even after the power sup ply to the unit has been turned off Wor...

Page 64: ...d in coastal or industrial areas or in areas where there are aggressive chemicals in the air periodic rinsing with clean water is considerably beneficial and helps counter corrosive effects Never clea...

Page 65: ...vacuum cleaner clean the surface using a high pressure water cleaner and evenly and steadily spray the coil from the bottom upwards keeping the jet at an angle never more than 45 to the surface never...

Page 66: ...the jet at an angle never more than 45 to the surface never exceed a jet pressure of 50 bar and always use a diffuser nozzle that is large enough 25 30 keep the diffuser nozzle at least 300 mm away fr...

Page 67: ...the unit always clean the electrical control panel of any work remnants and extraneous components Restore the safety devices and protective devices that had to be removed in order to carry out the wo...

Page 68: ...e equipment in accordance with the instructions in the safety data sheets for the chemical products used Also all technical and organisational measures for waste water treatment must be applied in acc...

Page 69: ...Monthly Check the crankcase heaters of the compressors Monthly Clean the metal filters in the hydraulic pipes Monthly Clean the finned coil by following the instructions in the External cleaning sect...

Page 70: ...store the charge of refrigerant gas In the case of small oil leaks clean the dirty parts with absorbent cloths otherwise recover the leaked oil with absorbent sheets In any case the material used must...

Page 71: ...ocal regulations The owner can return EEE to the dealer at the end of its life when purchasing equivalent new equipment This EEE may contain hazardous substances such as refrigerant gases lubricating...

Page 72: ...72 We reserve the right to make changes without any prior notice Translation from original instructions Page intentionally blank...

Page 73: ...73 We reserve the right to make changes without any prior notice Translation from original instructions Page intentionally blank...

Page 74: ...74 We reserve the right to make changes without any prior notice Translation from original instructions Page intentionally blank...

Page 75: ...75 We reserve the right to make changes without any prior notice Translation from original instructions Page intentionally blank...

Page 76: ...UM 0000 Kappa Sky EN 16 02 2021 rev02...