Swegon BlueBox Zeta Rev Series, Installation, Use And Maintenance Manual

Page 1: ...Zeta Rev EN 19 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: ...at recuperator DC option 15 2 2 9 Hydraulic connection to the desuperheater DS option 16 2 2 10 Condensate drain only for heat pump units 17 2 2 11 Refrigerant leak detector 18 2 3 Noise 19 2 4 Residu...

Page 4: ...ion of temperature sensor 40 6 6 Electrical connections 41 6 7 Refrigeration connections 42 6 7 1 Piping implementation 42 6 7 2 LE version unit installed at a higher level than the remote exchanger 4...

Page 5: ...71 7 5 Checks during operation 72 7 6 Alarms and malfunctions 73 7 6 1 General troubleshooting 73 7 7 Temporary stop 75 7 8 Stop for long periods of time 75 8 Maintenance 76 8 1 Adjustments 76 8 2 Ex...

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: ...ng on the type of compressor With some terms grouped together the formula can be rewritten as follows If the carrying fluid consists of mixtures of water glycol ethylene or propylene the density and s...

Page 13: ...table for installation Lock the cable in place with cable ties in the section between the flow switch and the inlet to the electrical control panel Refer to the instructions provided with the flow swi...

Page 14: ...temperature or liquid outlet temperature C 0 5 10 15 20 25 30 35 40 Freezing point C 5 10 15 20 25 30 35 40 45 Antifreeze by weight Ethylene glycol 6 22 30 36 41 46 50 53 56 Propylene glycol 15 25 33...

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: ...drain only for heat pump units As an accessory all heat pump version units can have a condensate drip tray with drain holes at the base of each conden sing evaporating coil If the supplied holes are...

Page 18: ...r 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 suitable delay in the warning mess...

Page 19: ...e unit The change from the OFF state to the ON state and vice versa of the unit can be carried out remotely or through the display without having to enter areas at risk Access restriction is part of c...

Page 20: ...zards and health consequences If accidentally released rapid evaporation of the liquid can cause freezing In case of contact with the liquid defrost the various part with water remove clothing careful...

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: ...uring unloading and positioning of the unit great care must be taken to prevent sudden or violent manoeuvres and the components of the unit must not be used as lifting points Make sure the machinery a...

Page 23: ...th the unit If the unit is shipped in rigid packaging this precaution is not necessary Fig 6 Lifting with crane If anti vibration mounts are installed under the base of the unit this must be done with...

Page 24: ...ents if the unit has to be stored temporarily before installation Since these units are intended for outdoor installation they withstand normal atmospheric conditions without problem The unit must be...

Page 25: ...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 26: ...quired 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 id...

Page 27: ...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 28: ...de the operating limits 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 dus...

Page 29: ...ansfer from a fluid at lower temperature to a fluid at higher temperature which is the opposite of what happens naturally In our specific case these units consist of one or more refrigerant circuits t...

Page 30: ...al input opened When Stby is show on the display to switch on the unit in cooling mode you must press button or in units that also work in heating mode press button To switch off the unit from the key...

Page 31: ...button for units in cooling only mode or with the third press for units in heat pump mode the lower display will show Setr that corresponds to the real operating set point and its upper part will sho...

Page 32: ...d finally press for more than 2 seconds the button that will become for operation in heating mode Press the button again on the main screen to restart the unit 5 7 2 3 Changing from heating to cooling...

Page 33: ...radiation Keep the condensing coil out of direct sunlight as far as possible direction of prevailing winds Do not position the unit in a such way that prevailing winds can cause air recirculation at...

Page 34: ...etter isolation is required it is advisable to use the anti vibration mounts available as accessory In the event of installation on roofs or intermediate floors the unit and pipes must be isolated fro...

Page 35: ...mount consists of an upper metal bell in which there is a screw for fixing it to the base of the unit The anti vibration mount is fixed to the base through the two holes on the flange The flange of t...

Page 36: ...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 37: ...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 38: ...levant 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 39: ...strated in the hydraulic diagram of the corresponding operating logic Two G sleeves out of supply scope are required for pressure sensor installation Install the sleeves vertically and in a position w...

Page 40: ...ntal damage The length of the sleeve to be used depends on the pipe diameter h Fig 16 Installation of pockets Fit the pocket in position and check that distance h ranges between 1 4 and 3 4 the pipe d...

Page 41: ...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 42: ...raight as possible making sure the following basic rules are complied with use the fewest number of bends possible preferably as wide as possible make a slight slope in the suction line 1 in the horiz...

Page 43: ...14 4 35 22 35 22 35 22 16 4 35 28 35 28 42 28 18 4 42 28 42 28 42 28 20 4 42 28 42 28 42 28 24 4 42 28 42 28 42 28 The above mentioned diameters were chosen in order to optimise the performance of th...

Page 44: ...the compressor when the unit is not running In the horizontal sections of the suction line G it is advisable to have a slope of at least 1 to facilitate oil return to the compressor 6 7 4 LE HP versio...

Page 45: ...hons on the vertical sections of the suction delivery line G to facilitate oil return to the compressor The height h must be less than 4 metres The horizontal sections of the suction delivery line G m...

Page 46: ...the vacuum has been obtained charge the system through the charging port 5 16 SAE placed on the liquid line Per form charging in liquid form The tables below show the estimated refrigerant charges fo...

Page 47: ...ed can at most be 10 of the total oil charge present in the refrigerant circuit of the unit The amount of oil put in the refrigerant circuit at the factory is shown in Technical Catalogue for the unit...

Page 48: ...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 49: ...olute as shown in the image Fig 17 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 50: ...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 51: ...nstructions given in the documentation for the remote exchanger 7 1 4 Preliminary operations for the Free Cooling No Glycol circuit The units are dispatched from the factory with the free cooling circ...

Page 52: ...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 53: ...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 54: ...er 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 allowed in the Tech...

Page 55: ...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 56: ...keypad present on the inverter Parameters must be entered on the inverter display to set up the desired water flow rate The inverter installed in the unit is already factory preset for the required t...

Page 57: ...s and confirm with Select using the arrow buttons select group 28 and confirm with Select using the arrow buttons select parameter 28 26 and confirm with Edit Use the arrow buttons to set the desired...

Page 58: ...must be paid to the construction arrangements of the system 7 3 2 3 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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 66: ...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 67: ...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 68: ...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 69: ...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 70: ...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 71: ...after the unit has been started the safety devices must be checked only the high and low pressure switches The checks must be carried out as described in the Periodic checks chapter The calibration v...

Page 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 clean...

Page 78: ...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 79: ...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 80: ...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 81: ...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 82: ...where present is working cor rectly 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 instru...

Page 83: ...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 84: ...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 85: ...85 We reserve the right to make changes without any prior notice Translation from original instructions Page intentionally blank...

Page 86: ...86 We reserve the right to make changes without any prior notice Translation from original instructions Page intentionally blank...

Page 87: ...87 We reserve the right to make changes without any prior notice Translation from original instructions Page intentionally blank...

Page 88: ...UM 0000 Zeta Rev EN 19 02 2021 rev07...