Datasheet | Western Airconditioning Zeta Echos/HP Technical data

ZETA 2002

38 - 266 kW

Installation, operating, and maintenance manual

Manual 101010B02

Issue 11.02

Replaces 04.02

Water chillers Air/water self-contained

0062

Axial fans and scroll compressors

ISO 9001 - Cert. n. 0201

CONTENTS Page

ZETA 2002 - water chiller ......................................................................................................... 1

UNIT FRAME ............................................................................................................ 1

COMPRESSORS ........................................................................................................ 1

CONDENSER ............................................................................................................ 1

CONDENSER FANS ................................................................................................... 1

EVAPORATOR .......................................................................................................... 1

REFRIGERANT CIRCUIT ............................................................................................. 1

ELECTRICAL PANEL .................................................................................................. 1

CONTROLS AND SAFETY DEVICES ............................................................................ 2

TESTING .................................................................................................................. 2

ZETA UNIT VERSIONS .............................................................................................................. 2

ZETA 2002 /HP: reverse cycle heat pump ................................................................... 2

ZETA 2002 LE: condensing unit. ................................................................................ 2

ZETA 2002 LE /HP: heat pump condensing unit .......................................................... 2

HYDRAULIC MODULE OPTIONS ............................................................................................... 3

ZETA 2002 /ST 2PS : ZETA 2002 /ST 2PS : unit with storage tank and pumps .............................. 3

ACCESSORY VERSIONS ........................................................................................................... 3

ZETA 2002 /DS: unit with desuperheaters ................................................................... 3

ZETA 2002 /LN: low noise unit .................................................................................. 3

ZETA 2002 /SLN: extra low noise unit ........................................................................ 3

REFRIGERANT CIRCUIT ACCESSORIES: ..................................................................................... 4

- Step type condensing pressure contro ...................................................................... 4

- Condensing pressure control by means of fan speed regulator .................................. 4

- Dual set-point ........................................................................................................ 4

- Pressure gauges ..................................................................................................... 4

- Liquid receivers ..................................................................................................... 4

- Compressor suction and discharge valves ................................................................. 4

- Liquid line solenoid valve ........................................................................................ 4

HYDRAULIC CIRCUIT ACCESSORIES ......................................................................................... 4

- Leaving water temperature control .......................................................................... 4

- Anti-freeze heater .................................................................................................. 4

- Water side relief valve (version ST only). .................................................................. 4

ELECTRICAL ACCESSORIES ...................................................................................................... 4

- Serial interface ....................................................................................................... 4

- Power factor correction cos φ ≥ 0.9 .......................................................................... 4

- Single voltage-free contacts for machine status signals .............................................. 4

- Set-point variable ................................................................................................... 4

- Remote user terminal panel .................................................................................... 4

VARIOUS ACCESSORIES ........................................................................................................... 5

- Rubber antivibration mountings ............................................................................... 5

- Spring-type antivibration mounts .............................................................................. 5

- Timber packing crate .............................................................................................. 5

- Pallet/skid for shipment in a container ...................................................................... 5

- Mesh coil guard with metallic filter .......................................................................... 5

- Anticorrosion treatment of coils for use in aggressive environments ............................ 5

- Non-standard RAL paint colours ............................................................................... 5

Blue Box

3.3

4.

4.1

1.

2.

2.1

2.2

2.3

SERIES ............................................................................................................................... 6

TECHNICAL DATA - R22 ........................................................................................... 7

TECHNICAL DATA - ELECTRICAL SPECIFICATIONS AND COMPONENTS R22 .......... 11

TECHNICAL DATA - ZETA 2002 /ST 2PS - R22 ........................................................... 13

TECHNICAL DATA - R407C ..................................................................................... 14

TECHNICAL DATA - ELECTRICAL SPECIFICATIONS AND COMPONENTS R407C ..... 18

TECHNICAL DATA - ZETA 2002 /ST 2PS - R407C ...................................................... 20

SOUND POWER AND PRESSURE LEVELS ................................................................... 21

FIELD OF APPLICATION............................................................................................ 23

3.

3.1

3.2

INTRODUCTION ...................................................................................................... 23

INSPECTION, TRANSPORT, SITE HANDLING .............................................................. 23

INSPECTION ........................................................................................................... 23

LIFTING AND SITE HANDLING .................................................................................. 23

UNPACKING ........................................................................................................... 24

SAFETY PRECAUTIONS ............................................................................................ 25

DEFINITION OF DANGER ZONE ................................................................................. 25

SAFETY PRESCRIPTIONS .......................................................................................... 25

MECHANICAL HAZARDS .................................................................................... 26

THERMAL HAZARDS ........................................................................................... 27

NOISE-RELATED HAZARDS .................................................................................. 28

ELECTRICAL HAZARDS ....................................................................................... 28

R407C REFRIGERANT SAFETY SHEETS .................................................................. 29

R22 REFRIGERANT SAFETY SHEETS ....................................................................... 31

POSITIONING .......................................................................................................... 33

INSTALLATION ........................................................................................................ 34

INSTALLATION CLEARANCES .................................................................................. 34

4.4

4.5

4.6

4.7

4.8

4.9

4.9.1

4.9.2

4.9.3

4.10

4.11

4.12

4.13

4.14

4.2

4.2.1

4.2.2

4.3

ANTI-VIBRATION ISOLATORS (option) ....................................................................... 35

Rubber Anti-Vibration Isolators ............................................................................. 35

Spring Anti-Vibration Isolators .............................................................................. 35

WATER PIPING CONNECTIONS ................................................................................ 36

RECOMMENDED HYDRAULIC CIRCUIT DIAGRAM FOR ZETA 2002 UNITS .............. 37

RECOMMENDED HYDR. CIRCUIT DIAGR. FOR MODELS ZETA 2002 / ST 2PS ......... 38

HYDRAULIC CIRCUIT DIAGRAM VERSION ST /2PS ................................................ 39

EVAPORATOR WATER PIPE CONNECTIONS .............................................................. 40

WATER FLOW SWITCH INSTALLATION INSTRUCTIONS (models 3.2 to 13.2) .............. 41

DESUPERHEATER HYDRAULIC CONNECTION (optional) ............................................ 43

ZETA 2002/DC HEAT RECOVERY EXCHANGER HYDRAULIC CONNECTIONS .............. 43

DIAGRAM WITH 3-WAY VALVE ........................................................................... 43

DIAGRAM WITH CONDENSING PRESSURE CONTROL VALVE ................................. 44

PRESSURE RELIEF VALVES ........................................................................................ 44

CONNECTIONS FOR VERSION /LE (MOTOCONDENSING UNIT) .................................. 45

Procedures to follow when sizing refrigerant lines .................................................. 45

Evaporating section at lower level than condensing section .................................... 45

Evaporating section positioned higher than the condensing unit section ................... 46

TABLE 1 - EXTERNAL PIPE DIAMENTERS FOR /LE VERSIONS ................................. 46

WATER FLOW RATE TO EVAPORATOR ...................................................................... 47

CHILLER WATER TEMPERATURE (SUMMER CYCLE) .................................................. 47

HOT WATER TEMPERATURE (WINTER CYCLE) .......................................................... 47

AMBIENT TEMPERATURE ........................................................................................ 47

FAN SPEED CONTROL (OPTIONAL) ........................................................................... 47

Blue Box

4.15

4.16

4.16.1

4.16.2

4.16.3

4.16.4

4.16.5

4.17

4.17.1

4.17.2

5.

5.1

6.1.7

6.1.8

6.1.9

6.1.10

6.1.11

6.2

6.3

6.3.1

6.3.2

6.4

6

6.1

6.1.1

6.1.2

6.1.3

6.1.4

6.1.5

6.1.6

7.

8.2.4

8.2.5

8.2.7

8.2.8

8.2.9

8.2.10

8.2.11

8.2.12

8

8.1

8.1.1

8.1.2

8.2

8.2.1

8.2.2

8.2.3

OPERATION WITH LOW TEMPERATURE CHILLED WATER AT EVAPORATOR ............... 48

TABLE 2 - FREEZING POINT FOR WATER-ANTIFREEZE MIXTURES ........................... 48

OPERATING LIMITS - R22 refrigerant .................................................................... 49

OPERATING LIMITS - R407C refrigerant ................................................................ 51

EVAPORATOR PRESSURE DROP ........................................................................... 53

PUMPS AVAILABLE PRESSURE - MODEL ZETA 2002 /ST 2PS ................................ 54

ELECTRICAL CONNECTIONS .................................................................................... 55

General ........................................................................................................... 55

Power supply to crankcase heaters ....................................................................... 56

Potential free contacts ......................................................................................... 56

Flow switch electrical connections ........................................................................ 56

Circulating pump electrical connections ................................................................ 56

MICROPROCESSOR CONTROLLERS ........................................................................... 56

Microprocessor controller for /LE and HP/LE versions .............................................. 57

RS485 serial interface (optional) ........................................................................... 57

ELECTRICAL PANEL LAY OUT .................................................................................. 58

START-UP ........................................................................................................... 60

PRELIMINARY CHECKS ............................................................................................ 60

UNITS WITH µCHILLER MICROPROCESSOR (models from 3.2 to 13.2) ......................... 61

INTRODUCTION ...................................................................................................... 61

Display ........................................................................................................... 61

Machine status information .................................................................................. 61

Keypad ........................................................................................................... 61

Controls and display screens ................................................................................ 62

Muting the BUZZER ............................................................................................. 62

ALARMS reset .................................................................................................... 62

Activation/deactivation of COOLING operation (Summer mode) ............................. 63

Activation/deactivation of HEATING mode (winter mode) ...................................... 63

Switching off the machine (stand by) .................................................................... 63

Inlet water temperature control ............................................................................ 64

Defrosting (heat pump mode only) ....................................................................... 64

STARTING THE UNIT ............................................................................................... 66

STOPPING THE UNIT ............................................................................................... 66

Temporary stop ................................................................................................... 66

Seasonal stop ..................................................................................................... 67

EMERGENCY STOP ................................................................................................. 67

TROUBLESHOOTING ................................................................................................ 67

UNIT WITH pCO 2 MICROPROCESSOR (models from 14.4 to 26.4) ............................... 75

INTRODUCTION ...................................................................................................... 75

Display ........................................................................................................... 75

Keypad ........................................................................................................... 75

OPERATING DESCRIPTION ....................................................................................... 77

Introduction ........................................................................................................ 77

Unit in stand-by mode ......................................................................................... 77

Enabling the unit ................................................................................................. 77

Pumps management (ST units only) ...................................................................... 77

Compressor start up ............................................................................................ 77

Heat pump mode operation ................................................................................. 78

Evaporator low temperature chilled water protection ............................................. 78

No-frost heater installed on the evaporator (optional) ............................................. 78

Compressor operation ......................................................................................... 78

Compressors management .................................................................................. 79

High and low pressure alarms .............................................................................. 79

Blue Box

12.

12.1

12.2

12.3

12.3.1

12.3.2

12.3.3

12.4

13.

9.

10.

10.1

10.1.1

11.

11.1

8.2.13

8.2.14

8.2.15

8.2.16

8.2.17

8.2.18

8.3

8.4

8.4.1

8.4.2

8.5

Low ambient temp. kit (option - condensing control with fan speed regulator) ......... 79

Changeover from chiller to heat pump and vice versa ............................................ 79

Defrosting (heat pump mode operation only) ........................................................ 80

Total heat recovery (option) ................................................................................. 80

Dual set-point (option) ......................................................................................... 81

Operation leaving water temperature control (option) ............................................ 81

STARTING THE UNIT ............................................................................................... 82

STOPPING THE UNIT ............................................................................................... 82

Temporary stop ................................................................................................... 82

Seasonal stop ..................................................................................................... 82

EMERGENCY STOP ................................................................................................. 83

TROUBLESHOOTING ................................................................................................ 83

CHECKS DURING OPERATION .................................................................................. 91

INTRODUCTION ...................................................................................................... 91

Checking the refrigerant charge ........................................................................... 91

CALIBRATION OF CONTROL EQUIPMENT .................................................................. 92

INTRODUCTION ...................................................................................................... 92

TABLE 3 - CALIBRATION OF CONTROL EQUIPMENT .............................................. 92

TABLE 4 - CALIBRATION OF SAFETY DEVICES ....................................................... 90

MAINTENANCE AND PERIODIC CHECKS ................................................................. 93

WARNINGS ........................................................................................................... 93

INTRODUCTION ...................................................................................................... 93

REPAIRING THE REFRIGERANT CIRCUIT .................................................................... 94

Leak test ........................................................................................................... 94

High vacuum and dehydration of the refrigerant circuit .......................................... 94

Refrigerant charge ............................................................................................... 95

ENVIRONMENTAL CONSIDERATIONS ....................................................................... 95

DECOMMISSIONING THE UNIT ................................................................................ 96

REFRIGERANT CIRCUIT ........................................................................................ 97

OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CIRCUIT CONNECTIONS ....... 109

Blue Box

ZETA 2002 - water chiller

Air-cooled liquid chillers with hermetic scroll compressors and plate type evaporator, suitable for outdoor installations.

The unit has a refrigerant circuit for each pair of compressors.

UNIT FRAME

Self supporting frame with removable panels, internally coated with expanded polyurethane sound-absorbing material; constructed from galvanized sheet steel with RAL 5014 powder paint baked at 180°C to provide a durable weatherproof finish. Threaded fasteners in stainless steel.

COMPRESSORS

Hermetic scroll type with orbital motion, connected in tandem and equipped with oil level sight glass, Klixon internal thermal protection and oil equalisation line.

The compressors are housed in a sound insulated compartment and separated from the air flow; access is provided by removable panels which allow maintenance work to be performed in safety even when the unit is in operation.

CONDENSER

Composed of a high efficiency coil manufactured from copper tubes and aluminium fins.

The finned coil is protected by a metal grille which is installed as standard.

CONDENSER FANS

Axial fans directly coupled to 6 pole motors with internal Klixon overload protection.

Motor protection category is IP 54. The fan is equipped with a safety grille to UNI EN 294.

EVAPORATOR

Brazed plate type in 316 AISI stainless steel. Thermal insulation of evaporator is provided by closed cell expanded material. Each evaporator is equipped with a low water temperature probe for freeze protection and each unit is equipped as standard with a mechanical flow switch.

REFRIGERANT CIRCUIT

Comprising: liquid valve, charge connection, liquid sight-glass, filter/dryer, thermostatic expansion valve with external pressure equalisation, high and low pressure switches for 2-compressor models.

For 4-compressor models high and low pressure values and relative condensation and evaporation temperatures are measured by pressure transducers that relay the signals to the controller so that they can be read directly on the display. The high pressure side of the circuit is equipped with high pressure switches and relief valves.

ELECTRICAL PANEL

The electrical panel includes:

- main switch

- thermal magnetic circuit-breakers for fans and (if present) pumps; compressor fuses for the power circuit

- compressor contactors

- fan contactors

- pump contactors (ST version)

The microprocessor controls the following functions on all units:

- water temperature regulation

- freeze protection

- compressor time intervals

- compressor start sequence and automatic lead/lag selection

- alarm reset

- common alarm contact for remote signalling

- operating and alarm indicator LEDs

Blue Box - 1

LCD display of the following information:

- water inlet and outlet temperature

- programmed temperature set-point and differential

- alarms description

- compressor hours run meter for 4 compressor units:

- number of starts of the unit and the compressors

- high and low pressure values and relative condensation and evaporation temperature values.

Electrical power supply [V/f/Hz]: 400/3~/50 ±5%

CONTROLS AND SAFETY DEVICES

- chilled water temperature probe (at evaporator inlet)

- freeze protection probe at the outlet of each evaporator

- safety high pressure switch with manual reset

- low pressure switch (with manual reset controlled by the control)

- high pressure relief valve

- compressor over-temperature protection

- fan over-temperature protection

- mechanical flow switch, supplied as standard on all units, as kit for units 3.2 to 13.2 and factory installed for units 14.4 to 26.4.

TESTING

The units are subjected to a dry run in the factory and supplied complete with oil and refrigerant.

ZETA UNIT VERSIONS

ZETA 2002 /HP: reverse cycle heat pump

The heat pump version operates as a air cooled chiller in summer and a air to water heat pump in winter by reversing the refrigerant flow to suit the required operating mode.

- Refrigerant circuit:

4-way reversing valve, liquid receiver, second thermostatic valve.

- Electrical panel:

Microprocessor enabled for summer/winter changeover and automatic defrosting.

ZETA 2002 LE: condensing unit.

The basic ZETA 2002 model is not equipped with an evaporator or thermostatic valve.

Also the four compressor models are not supplied with a microprocessor controller. Liquid receivers can be supplied as an accessory. The solenoid valve on the liquid line is supplied as standard.

ZETA 2002 LE /HP: heat pump condensing unit.

The basic ZETA 2002/HP model is not equipped with an evaporator, a thermostatic valve and four compressor models are not supplied with a microprocessor controller. Liquid receivers can be supplied as an accessory. The solenoid valve on the liquid line is supplied as standard.

Blue Box - 2

HYDRAULIC MODULE OPTIONS

ZETA 2002 /ST 2PS : unit with storage tank and pumps.

In addition to the components of version ZETA 2002, this unit includes: insulated storage tank; run and standby circulating pumps, with automatic changeover for four compressor models and manual changeover for two compressor models;

Also provided are an expansion tank, check valves and gate valves.

Version ST is available in the following additional four configurations:

- ST 1PS : with 1 pump and tank;

- ST 2P : with 2 pumps and no tank;

- ST S : with tank and no pumps;

- ST 1P : with 1 pump and no tank.

ACCESSORY VERSIONS

ZETA 2002 /DC: unit with heat recovery condenser.

Not available for HP versions.

This accessory is available for the following models: 3.2-13.2 “1p-2p” 18.4-26.4”s”.

In addition to the components of version ZETA 2002, this unit includes a 100% heat recovery condenser for the production of hot water, a recovery water temperature control thermostat, and a recovery circuit safety pressure switch.

ZETA 2002 /DS: unit with desuperheaters

The brazed plate type desuperheater is arranged in series with the condensing coil. It is available for the following models: from 3.2 to 13.2 with “1p-2p” and from 14.4 to 26.4 “1p-2p-1ps-2ps-s”.

It is also available in the HP configuration. In this case the installation must be fitted with a shut-off valve on the water recovery circuit, to be closed during heat pump mode operation as described in the manual.

ZETA 2002 /LN: low noise unit

In addition to the components of version ZETA 2002, this unit includes: galvanised sheet steel compressor compartment with full sound insulation using expanded polyurethane sound absorption material and expanded polyurethane with an intermediate layer of high acoustic impedance material applied to the sides of the compartment.

ZETA 2002 /SLN: extra low noise unit

In addition to the components of version LN, this unit is designed to operate with a slower fan speed to further reduce noise levels.

Blue Box - 3

REFRIGERANT CIRCUIT ACCESSORIES:

- Step type condensing pressure control

(ambient air minimum temperature 0 °C).

The control is managed in On/Off mode by the microprocessor by means of the pressure transducers.

Available for models 18.4 to 26.4 only.

- Condensing pressure control by fan speed regulator

(ambient air minimum temperature -20 °C).

Fan speed is regulated in accordance with the condensation pressure read by the pressure transducers.

Available for all models.

- Dual set-point.

With double thermostatic valves + solenoid valves. In units with two compressors the set-point must be modified manually on the controller. For four compressor units two set-points can be programmed and switched between them from the keypad or using a digital input. The type of selection must be specified at the time of the order. In all cases the thermostatic valves switch automatically on the basis of the water temperature.

- Pressure gauges.

Available for all models. Note however that on 4-compressor units the suction and discharge pressure values are read by transducers that relay the results to the controller display.

- Liquid receivers

(standard on versions /HP and /HP/LE)

- Compressor suction and discharge valves

- Liquid line solenoid valve

.

HYDRAULIC CIRCUIT ACCESSORIES

- Leaving water temperature control.

Available only on 4-compressor models (not HP versions).

- Anti-freeze heater

- Water side relief valve (version ST only).

The value is set at 6 bar, corresponding to the maximum permissible working pressure.

ELECTRICAL ACCESSORIES

- Serial interface:

- 2-compressor units are equipped with RS485 type serial interface with Carel protocol.

- 4-compressor units are equipped with RS485 type serial interface with Modbus protocol; the following optional protocols are available on request: Carel; Echelon in version RS485 or in version FTT10

- Power factor correction cos φ ≥ 0.9 at nominal operating conditions

- Single voltage-free contacts for machine status signals

- Set-point variable in a range of 3 °C with remote signal (0-1V, 0-10V, 0-4mA, 0-20mA).

Available only for models from 16.4 to 26.4

- Remote user terminal panel (in addition to the standard terminal)

Blue Box - 4

VARIOUS ACCESSORIES

- Rubber anti-vibration mountings.

Available for all models in the series

- Spring type anti-vibration mounts.

Available for models 18.4 to 26.4

- Timber crate packing

- Pallet/skid for container shipment

- Mesh coil guard with metallic filter.

Standard equipment on models from 14.4 to 26.4.

- Anti-corrosion treatment of coils for use in aggressive environments

- Non-standard RAL paint colours

Blue Box - 5

SERIES

The ZETA 2002 series of water cooled chillers and heat pumps, are available in various sizes with capacities from

38 to 266 kW.

Model designations consist of two numbers:

Shows the model

ZETA 2002 14.4

number of compressors

The model, serial number, characteristics, power supply, etc. are shown by means of decals on the unit.

Modello/Model

Modell/Modèle

Via Enrico Mattei, 20

35028 Piove di Sacco (PD)

ITALY

Tel. +039.049.9716300

0062

Matricola/Serial number

(BBOX) Matrikel/Matricule

Tensione-Fasi-Frequenza

Voltage-Phasses-Frequency

Spannung-Phasses-Frequenz

Tension-Phasses-Fréquence

Tensione circuiti ausiliari

Auxiliary circuit voltage

Steuerspannung

Tension circuits auxiliares

Corrente massima assorbita

Max absorbed current

Maximalstromverbrauch

Courant maxi absorbée

A

Tipo refrigerante

Refrigerant type

Kältemittel Typ

Type de refrigerant

Corrente massima di spunto

Max starting current

Max. Anlaufstrom

Courant maxi démarrage

IP quadro elettrico

IP electrical board

IP E-Schrank

IP tableau electrique

A

Numero circuiti refrigerante

Refrigerant circuit number

Anzahl des Kältemittelkreislaufes

Numero circuits refrigerant

Press. massima circuito refriger.

Max. Refrigerant circuit pressure

Max. Druck Kältekreislauf

Pression maxi circuit refrigerant kPa bar

Press. massima circuito idraulico

Max. Hydraultic circuit pressure

Max. Druck im Hydraul. Kreislauf

Pression maxi circuit hydraulique

Data di produzione

Manufacturing date

Erstellungsdatum

Date de fabrication kPa bar

Carica refrigerante per circuito(kg)/Refrigerant charge per circuit (kg)

/ Kältemittelfüllung Kreislauf (kg)/ Charge de refigerant chaque circuit (kg)

C1 C2 C3 C4



ITALY

Tel. +039.049.9716300

MODELLO - MODELE - MODEL - TYP

MATRICOLA - MATRICULE - SERIAL NO. - SERIENUMMER

0062

REFRIGERANTE - REFRIGERANT - KÄLTEMITTEL - REFRIGERANT

MODELLO

MATRICOLA



ITALY

Tel. +039.049.9716300

REFRIGERANTE

MODELLO - MODELE - MODEL - TYP

ESECUZIONE SECONDO

NORMATIVE

SCHEMA FRIGORIFERO

DISEGNO MECCANICO

0062

MODELLO MODELE

MODEL -TYP

MATRICOLA - MATRICULE

SERIAL NO. - SERIENUMMER

Buono di Produzione Buono di Produzione

Blue Box - 6

TECHNICAL DATA

R22 refrigerant

MODEL ZETA 2002

Cooling (*)

Nominal capacity

Evaporator water flow

Evaporator pressure drop

Heating (**)

Nominal capacity

Condenser water flow

Condenser pressure drop

Compressors

Quantity

Refrigerant circuits

Absorbed power cooling (*)

Absorbed power heating (**)

Capacity steps

Condenser cooling fans

Total air flow

Fan motor power

Nominal revolution speed

Electric motor supply

Refrigerant charge

Chiller version

Heat pump version

Oil

Oil charge

Oil producer

Oil type

Evaporator

Heat exchanger water volume

Max operating pressure water side

Dimension and weight

Length

Width

Heigth

Shipping weight l type l bar mm mm mm kg kW l/s l/h kPa kW l/s l/h kPa type n n kW kW

% type m

3

/s m 3 /h n x kW

RPM

V/Ph/Hz kg kg

3.2

38,4

1,835

6.607

59,1

38,4

1,833

6.600

59

2

1

12

12,8

0/50/100

4,472

16.100

2 x 0,6

1 x 14,5

1 x 15

2 x 3,3

4,6

2.233

1.043

1.740

594

4.2

5.2

47,1

2,251

8.105

59,2

52,9

2,528

9.102

46,9

46,9

2,239

8.061

58,6

53,2

2,540

9.146

47,3 scroll

2

1

14,3

15,4

0/50/100

2

1

16,5

16,9

0/50/100 axial

4,472

16.100

2 x 0,6

860

230/~/50

4,472

16.100

2 x 0,6

1 x 14,5

1 x 15

1 x 14,5

1 x 15

1 x 19,5

1 x 22

2 x 3,3

Maneurop

2 x 3,8

160 P plate

5,7 7,4

30

2.233

1.043

1.740

604

2.233

1.043

1.740

625

1 x 4 + 1 x 3,8

8,4

2.233

1.043

1.740

672

6.2

61,6

2,943

10.596

51,5

60,8

2,907

10.466

50,3

2

1

18,7

19,5

0/50/100

4,528

16.300

2 x 0,6

(*) ambient air temperature 35°C; evaporator entering/leaving water temperature 12-7 °C;.

(**) ambient air temperature 8°C DB, 70%RH; condenser entering/leaving water temperature 40-45 °C.

Blue Box - 7

TECHNICAL DATA

R22 refrigerant

MODEL ZETA 2002

Cooling (*)

Nominal capacity



Heating (**)

Nominal capacity



Compressors

Quantity




Capacity steps


Total air flow

Fan motor power




Chiller version

Heat pump version

Oil

Oil charge

Oil producer

Oil type

Evaporator




Length

Width

Heigth

Shipping weight type l bar mm mm mm kg kW l/s l/h kPa kW kW

% type m 3 /s m 3 /h n x kW

RPM

V/Ph/Hz kW l/s l/h kPa type n n kg kg

7.2

68,9

3,292

11.852

43,8

68,5

3,274

11.787

43,3

2

1

21,7

22,1

0/50/100

4,528

16.300

2 x 0,6

1 x 19,5

1 x 22 l

8.2

9.2

78,9

3,771

13.577

45,2

93,4

4,460

16.057

47,9

79,7

3,807

13.704

46

92,6

4,425

15.931

47,2 scroll

2

1

25

25,5

0/50/100

2

1

29,7

29,8

0/50/100 axial

4,389

15.800

2 x 0,6

860

230/~/50

6,833

24.600

3 x 0,6

1 x 22

1 x 27

1 x 27,5

1 x 32

1 x 27,5

1 x 32

2 x 4

4,2

160 P

2 x 6,6 1 x 8 + 1 x 6,6

Maneurop

320 SZ plate

4,8 6,3

30

2 x 8

7,3

2.233

1.043

1.740

690

2.233

1.043

1.740

737

3.234

1.144

1.740

981

3.234

1.144

1.740

1.058

10.2

105,4

5,034

18.121

45,6

105,6

5,044

18.158

45,8

2

1

35,7

34,1

0/50/100

6,833

24.600

3 x 0,6



Blue Box - 8

TECHNICAL DATA

R22 refrigerant

MODEL ZETA 2002

Cooling (*)

Nominal capacity



Heating (**)

Nominal capacity



Compressors

Quantity




Capacity steps


Total air flow

Fan motor power




Chiller version

Heat pump version

Oil

Oil charge

Oil producer

Oil type

Evaporator




Length

Width

Heigth

Shipping weight type l bar mm mm mm kg kW l/s l/h kPa kW l/s l/h kPa type n n kW kW


RPM

V/Ph/Hz kg kg

12.2

13.2

14.4

16.4

120,4

5,754

20.715

50,9

130,3

6,225

22.409

44

139,4

6,659

23.974

51,6

159,6

7,626

27.453

55,1

118,4

5,656

20.362

49,2

2

1

38,1

37,7

0/50/100

6,600

23.760

3 x 0,6

230/~/50

131,2

6,268

22.566

44,6

2

1

43,6

41,3

0/50/100

6,583

23.700

3 x 0,6

137,1

6,548

23.573

50

159,4

7,614

27.409

55 scroll

4 4

44,1 51

0/25/50/75/100 0/25/50/75/100 axial

2

42,6

2

49

11,267

40.560

2 x 2,0

11,267

40.560

2 x 2,0

860

400/3~/50

1 x 32

1 x 36

1 x 32

1 x 36

2 x 19,5

2 x 22

2 x 21

2 x 23 l 2 x 8

8,4

320 SZ

2 x 8

Maneurop

4 x 4 plate

9,4 5,2

30

160 P

4 x 6,6

4,8

3.234

1.144

1.740

1.124

3.234

1.144

1.740

1.158

3.234

1.119

2.380

1.400

3.234

1.119

2.380

1.464



Blue Box - 9

TECHNICAL DATA

R22 refrigerant

MODEL ZETA 2002

Cooling (*)

Nominal capacity



Heating (**)

Nominal capacity



Compressors

Quantity




Capacity steps


Total air flow

Fan motor power




Chiller version

Heat pump version

Oil

Oil charge

Oil producer

Oil type

Evaporator




Length

Width

Heigth

Shipping weight

18.4

20.4

24.4

26.4

kW l/s l/h kPa

188,8

9,019

32.469

61,6

215,5

10,298

37.073

64

240,9

11,508

41.430

71,4

266,2

12,718

45.786

70,9


RPM

V/Ph/Hz kW l/s l/h kPa type n n kW kW

185,2

8,851

31.863

59,4

211,1

10,088

36.316

61,6

236,8

11,312

40.724

69,1

262,4

12,536

45.131

68,9 scroll

4

2

58,2

59,6

4

2

68,7

68,2

4

2

76,3

75,4

4

2

83,9

82,7

0/25/50/75/100 0/25/50/75/100 0/25/50/75/100 0/25/50/75/100 axial

16,417 19,389 16,375

58.950

3 x 2,0

59.100

3 x 2,0

880

400/3~/50

69.800

4 x 2,0

18,500

66.600

4 x 2,0 kg kg

2 x 27

2 x 30

2 x 27

2 x 30

2 x 26

2 x 30

2 x 31,5

2 x 35

4 x 8 l 2 x 8 + 2 x 6,6 type l bar mm mm mm kg

6,3

4.234

1.119

2.380

1.930

4 x 8

Maneurop

320 SZ plate

7,3

30

4 x 8

8,4

4.234

1.119

2.380

2.089

4.234

1.119

2.380

2.208

9,4

4.234

1.119

2.380

2.349



Blue Box - 10

TECHNICAL DATA - ELECTRICAL CHARACTERISTICS AND COMPONENTS

R22 refrigerant

MODEL ZETA 2002

Maximum absorbed power (1)

Maximum starting current

Full load current (2)

Fan motor nominal power

Fan motor nominal absorbed current

Pump motor nominal power

Pump motor nominal absorbed power

Power supply

Control power supply

Control circuit supply

Condenser fans supply

Pump supply, ST groups

MODEL ZETA 2002








Power supply




Pump supply, ST groups kW kW

A

A

A

A n x kW n x A kW

A

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

3.2

17,6

(18,1)

120,4

(122,1)

39,4

(41,1)

2 x 0,6

2 x 2,7

(1 x 0,5)

(1 x 1,7)

4.2

5.2

19,6

(20,1)

155,4

(157,1)

24

(24,5)

150,4

(152,1)

45,4

(47,1)

2 x 0,6

2 x 2,7

55,4

(57,1)

2 x 0,6

2 x 2,7

(1 x 0,5)

(1 x 1,7)

(1 x 0,5)

(1 x 1,7)

400V 3N ~ 50Hz ±5% V

230V/ ~/50Hz

24V/~/50Hz

230V/ ~/50Hz

400V/3~/50

6.2

27

(28,1)

205,4

(208,3)

65,4

(68,3)

2 x 0,6

2 x 2,7

(1 x 1,1)

(1 x 2,9) kW kW

A

A

A

A n x kW n x A kW

A

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

7.2

30

(31,1)

215,4

(218,3)

75,4

(78,3)

2 x 0,6

2 x 2,7

(1 x 1,1)

(1 x 2,9)

8.2

9.2

35,2

(36,3)

215,4

(218,3)

41,7

(43,2)

258,1

(262,4)

75,4

(78,3)

2 x 0,6

2 x 2,7

93,1

(97,4)

3 x 0,6

3 x 2,7

(1 x 1,1)

(1 x 2,9)

(1 x 1,5)

(1 x 4,3)

400V 3N ~ 50Hz ±5% V

230V/ ~/50Hz

24V/~/50Hz

230V/ ~/50Hz

400V/3~/50

10.2

47,6

(49,1)

273,1

(277,4)

108,1

(112,4)

3 x 0,6

3 x 2,7

(1 x 1,5)

(1 x 4,3)

(1) mains power supply to allow unit operation.

(2) maximum current before safety cut-outs stop the unit. This value is never exceeded and must be used to size the electrical supply cables and relevant safety devices (refer to electrical wiring diagram supplied with the unit).

All values in brackets are refer to /ST version (units with storage tank) or units with pump.

Blue Box - 11


R22 refrigerant

MODEL ZETA 2002








Power supply




Pump supply, ST groups

MODEL ZETA 2002








Power supply




Pump supply, ST groups kW kW

A

A

A

A n x kW n x A kW

A

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

12.2

13.2

14.4

16.4

52,4

(54,6)

328,1

(333,4)

127,1

57,2

(59,4)

347,1

(352,4)

146,1

61,6

(63,8)

288

(293,3)

148

72

(74,2)

288

(293,3)

148

(132,4)

3 x 0,6

3 x 2,7

(1 x 2,2)

(1 x 5,3)

(151,4)

3 x 0,6

3 x 2,7

(1 x 2,2)

(153,3)

2 x 2,0

2 x 4,0

(1 x 2,2)

(1 x 5,3) (1 x 5,3)

400V 3N ~ 50Hz ±5% V

230V/ ~/50Hz

24V/~/50Hz

230V/ ~/50Hz

400V/3~/50

400V/3~/50

(153,3)

2 x 2,0

2 x 4,0

(1 x 2,2)

(1 x 5,3) kW kW

A

A

A

A n x kW n x A kW

A

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

18.4

85,8

(89,8)

347

(356,5)

182

(191,5)

3 x 2,0

3 x 4,0

(1 x 4,0)

(1 x 9,5)

20.4

24.4

26.4

97,6

(101,6)

377

(386,5)

212

(221,5)

3 x 2,0

3 x 4,0

109,2

(113,2

455

(464,5)

254

(263,5)

4 x 2,0

4 x 4,0

118,8

(124,3)

493

(505)

292

(304)

4 x 2,0

4 x 4,0

(1 x 4,0)

(1 x 9,5)

(1 x 4,0) (1 x 5,5)

(1 x 9,5) (1 x 12,0)

400V 3N ~ 50Hz ±5% V

230/~/50

24V ~ 50Hz

400V/3~/50

400V/3~/50




Blue Box - 12

TECHNICAL DATA - ZETA 2002 /ST 2PS

R22 refrigerant

MODEL ZETA 2002

Pump section


Pump nominal power

External available pressure

Storage tank water volume


Length

Width

Heigth

Shipping weight

MODEL ZETA 2002

Pump section


Pump nominal power




Length

Width

Heigth

Shipping weight

MODEL ZETA 2002

Pump section


Pump nominal power




Length

Width

Heigth

Shipping weight

MODEL ZETA 2002

Pump section


Pump nominal power




Length

Width

Heigth

Shipping weight l/s l/h kW kPa l mm mm mm kg l/s l/h kW kPa l mm mm mm kg l/s l/h kW kPa l mm mm mm kg l/s l/h kW kPa l mm mm mm kg

5,03

18.121

1,5

107

450

3.234

1.144

1.740

1.219

16.4

6.2

2,94

10.596

1,1

139

200

2.233

1.043

1.740

807

10.2

7,63

27.453

2,2

98

340

3.234

1.119

2.380

1.678

26.4

12,72

45.786

5,5

159

700

5.234

1.119

2.380

2.749

4,46

16.057

1,5

122

450

3.234

1.144

1.740

1.142

14.4

5.2

2,53

9.102

0,5

93

200

2.233

1.043

1.740

755

9.2

6,66

23.974

2,2

134

340

3.234

1.119

2.380

1.642

24.4

11,51

41.430

4

100

700

5.234

1.119

2.380

2.622

3,77

13.577

1,1

113

200

2.233

1.043

1.740

868

13.2

4.2

2,25

8.105

0,5

95

200

2.233

1.043

1.740

734

8.2

6,23

22.409

2,2

108

450

3.234

1.144

1.740

1.309

20.4

10,30

37.073

4

123

700

5.234

1.119

2.380

2.449

3,29

11.852

1,1

134

200

2.233

1.043

1.740

825

12.2

3.2

1,84

6.607

0,5

114

200

2.233

1.043

1.740

724

7.2

5,75

20.715

2,2

114

450

3.234

1.144

1.740

1.275

18.4

9,02

32.469

4

139

700

5.234

1.119

2.380

2.290

Blue Box - 13

TECHNICAL DATA

R407C refrigerant

MODEL ZETA 2002

Cooling (*)

Nominal capacity



Heating (**)

Nominal capacity



Compressors

Quantity




Capacity steps


Total air flow

Fan motor power




Chiller version

Heat pump version

Oil

Oil charge

Oil producer

Oil type

Evaporator




Length

Width

Heigth


% type m

3

/s m 3 /h n x kW

RPM

V/Ph/Hz kg kg

3.2

37,1

1,77

6.377

57,2

36,4

1,74

6.267

55,3

2

1

12,3

12,7

0-50-100

4,47

16.100

2 x 0,6

1 x 14,5

1 x 15

2 x 3,3

4,6

2.233

1.043

1.740

594

4.2

1 x 15

5.2

44,7

2,13

7.682

55,4

51,4

2,45

8.833

45,9

44,8

2,14

7.698

55,6

51,9

2,48

8.923

46,8 scroll

2

1

14,8

15,9

0-50-100

2

1

17,5

18,4

0-50-100 axial

4,47

16.100

2 x 0,6

860

230/~/50

4,47

16.100

2 x 0,6

1 x 14,5 1 x 14,5

1 x 15

1 x 19,5

1 x 22

2 x 3,3

Maneurop

2 x 3,8

160 SZ plate

5,7 7,4

30

2.233

1.043

1.740

604

2.233

1.043

1.740

625

1 x 4 + 1 x 3,8

8,4

2.233

1.043

1.740

672

6.2

60,3

2,88

10.379

51,4

60

2,87

10.318

50,8

2

1

19,7

20,9

0-50-100

4,53

16.300

2 x 0,6



Blue Box - 14

TECHNICAL DATA

R407C refrigerant

MODEL ZETA 2002

Cooling (*)

Nominal capacity



Heating (**)

Nominal capacity



Compressors

Quantity




Capacity steps


Total air flow

Fan motor power




Chiller version

Heat pump version

Oil

Oil charge

Oil producer

Oil type

Evaporator




Length

Width

Heigth


% type m

3

/s m 3 /h n x kW

RPM

V/Ph/Hz kg kg

7.2

67,5

3,23

11.608

43,7

68,1

3,25

11.712

44,4

2

1

22,7

23,4

0-50-100

4,53

16.300

2 x 0,6

1 x 19,5

1 x 22

2 x 4

4,2

2.233

1.043

1.740

690

8.2

9.2

77,6

3,71

13.347

45,4

91,6

4,37

15.748

47,9

78,7

3,76

13.530

46,5

92,7

4,43

15.937

49 scroll

2

1

26,6

27,5

0-50-100

2

1

31,3

32,1

0-50-100 axial

4,39

15.800

2 x 0,6

860

230/~/50

6,83

24.600

3 x 0,6

1 x 22

1 x 27

1 x 27,5

1 x 32

2 x 6,6 1 x 8 + 1 x 6,6

Maneurop

160 SZ plate

4,8 6,3

30

2.233

1.043

1.740

737

3.234

1.144

1.740

981

1 x 27,5

1 x 32

2 x 8

7,3

3.234

1.144

1.740

1.058

10.2

102,4

4,89

17.611

44,8

106,6

5,10

18.343

48,4

2

1

37,6

36,7

0-50-100

6,83

24.600

3 x 0,6



Blue Box - 15

TECHNICAL DATA

R407C refrigerant

MODEL ZETA 2002

Cooling (*)

Nominal capacity



Heating (**)

Nominal capacity



Compressors

Quantity




Capacity steps


Total air flow

Fan motor power




Chiller version

Heat pump version

Oil

Oil charge

Oil producer

Oil type

Evaporator




Length

Width

Heigth

Shipping weight kW l/s l/h kPa kW l/s l/h kPa type n n kW kW


RPM

V/Ph/Hz kg kg

12.2

13.2

14.4

16.4

117,9

5,63

20.283

50,7

126,6

6,05

21.780

43,2

137

6,55

23.567

51,8

157,6

7,53

27.103

55,8

119,5

5,71

20.561

52

2

1

40

40,5

0-50-100

6,60

23.760

3 x 0,6

132,4

6,33

22.779

47

136,2

6,51

23.425

51,2

157,3

7,52

27.061

55,6 scroll

2

1

45,9

44,4

4

2

44,4

46,8

4

2

52

55

0-50-100 0-25-50-75-100 0-25-50-75-100 axial

6,58

23.700

3 x 0,6

11,27

40.560

2 x 2,0

11,27

40.560

2 x 2,0

860

230/~/50 400/3~/50

1 x 32

1 x 36

1 x 32

1 x 36

2 x 19,5

2 x 22

2 x 21

2 x 23 l type l bar mm mm mm kg

2 x 8

8,4

3.234

1.144

1.740

1.124

2 x 8

Maneurop

160 SZ plate

9,4

30

4 x 4

5,2

3.234

1.144

1.740

1.158

3.234

1.119

2.380

1.400

4 x 6,6

4,8

3.234

1.119

2.380

1.464



Blue Box - 16

TECHNICAL DATA

R407C refrigerant

MODEL ZETA 2002

Cooling (*)

Nominal capacity



Heating (**)

Nominal capacity



Compressors

Quantity




Capacity steps


Total air flow

Fan motor power




Chiller version

Heat pump version

Oil

Oil charge

Oil producer

Oil type

Evaporator




Length

Width

Heigth

Shipping weight

18.4

20.4

24.4

26.4

kW l/s l/h kPa

185,8

8,88

31.965

62

211

10,08

36.296

63,8

235,8

11,27

40.565

71,1

260,7

12,45

44.834

70,6


RPM

V/Ph/Hz kW l/s l/h kPa type n n kW kW

185,3

8,85

31.873

61,6

213,3

10,19

36.686

65,1

239,1

11,42

41.122

73

264,9

12,66

45.558

72,8 scroll

4

2

61,2

64,2

4

2

72

73,3

4

2

80

81,1

4

2

88,1

88,8

0-25-50-75-100 0-25-50-75-100 0-25-50-75-100 0-25-50-75-100 axial

16,42 19,39 16,38

58.950

3 x 2,0

59.100

3 x 2,0

880

400/3~/50

69.800

4 x 2,0

18,50

66.600

4 x 2,0 kg kg

2 x 27

2 x 30

2 x 27

2 x 30

2 x 26

2 x 30

2 x 31,5

2 x 35

4 x 8 l 2 x 8 + 2 x 6,6 type l bar mm mm mm kg

6,3

4.234

1.119

2.380

1.930

4 x 8

Maneurop

160 SZ plate

7,3

30

4 x 8

8,4

4.234

1.119

2.380

2.089

4.234

1.119

2.380

2.208

9,4

4.234

1.119

2.380

2.349



Blue Box - 17


R407C refrigerant

MODEL ZETA 2002








Power supply




Pumps supply, ST groups

Maximum absorbed power

(1)







Power supply




Pumps supply, ST groups kW kW

A

A

A

A n x kW n x A kW

A

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

3.2

17,6

(18,1)

120,4

(122,1)

39,4

(41,1)

2 x 0,6

2 x 2,7

(1 x 0,5)

(1 x 1,7)

4.2

5.2

20,6

(21,1)

155,4

(157,1)

25,6

(26,1)

150,4

(152,1)

45,4

(47,1)

2 x 0,6

2 x 2,7

55,4

(57,1)

2 x 0,6

2 x 2,7

(1 x 0,5)

(1 x 1,7)

(1 x 0,5)

(1 x 1,7)

400V 3N ~ 50Hz ±5% V

230/~/50

24V ~ 50Hz

230V/ ~/50Hz

400V/3~/50

6.2

28,5

(29,6)

205,4

(208,3)

65,4

(68,3)

2 x 0,6

2 x 2,7

(1 x 1,1)

(1 x 2,9) kW kW

A

A

A

A n x kW n x A kW

A

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

53,4

(55,6)

328,1

(333,4)

127,1

(132,4)

3 x 0,6

3 x 2,7

(1 x 2,2)

(1 x 5,3)

58,4

(60,6)

347,1

(352,4)

64,4

(66,6)

288

(293,3)

146,1

(151,4)

3 x 0,6

3 x 2,7

148

(153,3)

2 x 2,0

2 x 4,0

(1 x 2,2)

(1 x 5,3)

(1 x 2,2)

(1 x 5,3)

400V 3N ~ 50Hz ±5% V

230/~/50

24V ~ 50Hz

230V/ ~/50Hz

400V/3~/50

76,4

(78,6)

288

(293,3)

148

(153,3)

2 x 2,0

2 x 4,0

(1 x 2,2)

(1 x 5,3)




Blue Box - 18


R407C refrigerant








Power supply





A

A

A

A n x kW n x A kW

A

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

53,4

(55,6)

328,1

(333,4)

127,1

(132,4)

3 x 0,6

3 x 2,7

(1 x 2,2)

(1 x 5,3)

58,4

(60,6)

347,1

(352,4)

64,4

(66,6)

288

(293,3)

146,1

(151,4)

3 x 0,6

3 x 2,7

148

(153,3)

2 x 2,0

2 x 4,0

(1 x 2,2)

(1 x 5,3)

(1 x 2,2)

(1 x 5,3)

400V 3N ~ 50Hz ±5% V

230/~/50

24V ~ 50Hz

230V/ ~/50Hz

400V/3~/50

76,4

(78,6)

288

(293,3)

148

(153,3)

2 x 2,0

2 x 4,0

(1 x 2,2)

(1 x 5,3)

Maximum absorbed power

(1)







Power supply





A

A

A

A n x kW n x A kW

A

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

V/Ph/Hz

88,8

(92,8)

347

(356,5)

182

(191,5)

3 x 2,0

3 x 4,0

(1 x 4,0)

(1 x 9,5)

99,2

(103,2)

377

(386,5)

111,2

(115,2)

455

(464,5)

212

(221,5)

3 x 2,0

3 x 4,0

254

(263,5)

4 x 2,0

4 x 4,0

292

(304)

4 x 2,0

4 x 4,0

(1 x 4,0)

(1 x 9,5)

(1 x 4,0) (1 x 5,5)

(1 x 9,5) (1 x 12,0)

400V 3N ~ 50Hz ±5% V

230/~/50

24V ~ 50Hz

400V/3~/50

400V/3~/50

121,2

(126,7)

493

(505)




Blue Box - 19

TECHNICAL DATA - ZETA 2002 /ST 2PS

R407C refrigerant

MODEL ZETA 2002

Pump section


Pump nominal power




Length

Width

Heigth

Shipping weight

MODEL ZETA 2002

Pump section


Pump nominal power




Length

Width

Heigth

Shipping weight

MODEL ZETA 2002

Pump section


Pump nominal power




Length

Width

Heigth

Shipping weight

MODEL ZETA 2002

Pump section


Pump nominal power




Length

Width

Heigth

Shipping weight l/s l/h kW kPa l mm mm mm kg l/s l/h kW kPa l mm mm mm kg l/s l/h kW kPa l mm mm mm kg l/s l/h kW kPa l mm mm mm kg

6.2

2,88

10.379

1,1

139

200

2.233

1.043

1.740

807

10.2

4,89

17.611

1,5

109

450

3.234

1.144

1.740

1.219

16.4

7,53

27.103

2,2

96

340

3.234

1.119

2.380

1.678

26.4

12,45

44.834

5,5

159

700

5.234

1.119

2.380

2.749

5.2

2,45

8.833

0,5

96

200

2.233

1.043

1.740

755

9.2

4,37

15.748

1,5

122

450

3.234

1.144

1.740

1.142

14.4

6,55

23.567

2,2

134

340

3.234

1.119

2.380

1.642

24.4

11,27

40.565

4

101

700

5.234

1.119

2.380

2.622

4.2

2,13

7.682

0,5

103

200

2.233

1.043

1.740

734

8.2

3,71

13.347

1,1

112

200

2.233

1.043

1.740

868

13.2

6,05

21.780

2,2

110

450

3.234

1.144

1.740

1.309

20.4

10,08

36.296

4

124

700

5.234

1.119

2.380

2.449

3.2

1,77

6.377

0,5

117

200

2.233

1.043

1.740

724

7.2

3,23

11.608

1,1

134

200

2.233

1.043

1.740

825

12.2

5,63

20.283

2,2

115

450

3.234

1.144

1.740

1.275

18.4

8,88

31.965

4

138

700

5.234

1.119

2.380

2.290

Blue Box - 20

SOUND POWER AND PRESSURE LEVELS

STANDARD UNITS

Z E T A

2002

63 dB

125 dB

250 dB

Octave band [Hz]

500 dB

1000 dB

2000 dB

4000 dB

8000 dB

Total dB(A)

Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp

3.2

96,1 78,8 87,3 70,0 81,2 63,8 79,7 62,4 78,6 61,3 73,2 55,9 69,8 52,4 60,7 43,4 83,0 65,7

4.2

96,5 79,1 87,7 70,3 81,5 64,2 80,0 62,7 78,9 61,6 73,6 56,2 70,1 52,8 61,0 43,7 83,3 66,0

5.2

96,6 79,2 87,8 70,4 81,6 64,3 80,1 62,8 79,0 61,7 73,7 56,3 70,2 52,9 61,1 43,8 83,4 66,1

6.2

97,3 79,9 88,5 71,1 82,3 65,0 80,8 63,5 79,7 62,4 74,4 57,0 70,9 53,6 61,8 44,5 84,1 66,8

7.2

97,5 80,1 88,7 71,3 82,5 65,2 81,0 63,7 79,9 62,6 74,6 57,2 71,1 53,8 62,0 44,7 84,3 67,0

8.2

98,1 80,8 89,3 72,0 83,2 65,8 81,7 64,4 80,6 63,2 75,2 57,9 71,8 54,4 62,7 45,3 85,0 67,7

9.2

99,7 81,8 90,9 73,0 84,8 66,8 83,3 65,4 82,2 64,2 76,9 58,9 73,4 55,4 64,3 46,3 86,6 68,7

10.2

100,0 82,0 91,2 73,2 85,0 67,0 83,5 65,6 82,4 64,5 77,1 59,1 73,6 55,6 64,5 46,6 86,8 68,9

12.2

100,1 82,2 91,3 73,4 85,1 67,3 83,7 65,8 82,6 64,7 77,2 59,3 73,7 55,9 64,7 46,8 87,0 69,1

13.2

100,3 82,3 91,5 73,5 85,3 67,3 83,8 65,9 82,7 64,8 77,4 59,4 73,9 55,9 64,8 46,9 87,1 69,2

14.4

101,1 82,5 92,3 73,7 86,1 67,5 84,6 66,0 83,5 64,9 78,2 59,6 74,7 56,1 85,6 47,0 87,9 69,3

16.4

103,6 85,0 94,8 76,2 88,6 70,1 87,2 68,6 86,1 67,5 80,7 62,1 77,2 58,7 68,2 49,6 90,5 71,9

18.4

104,5 85,4 95,7 76,6 89,6 70,5 88,1 69,0 87,0 67,9 81,6 62,5 78,2 59,1 69,1 50,0 91,4 72,3

20.4

105,2 86,1 96,4 77,3 90,3 71,2 88,8 69,7 87,7 68,6 82,3 63,2 78,9 59,8 69,8 50,7 92,1 73,0

24.4

106,1 87,0 97,3 78,2 91,2 72,1 89,7 70,6 88,6 69,5 83,2 64,1 79,8 60,7 70,7 51,6 93,0 73,9

26.4

106,2 87,1 97,4 78,3 91,3 72,2 89,8 70,7 88,7 69,6 83,3 64,2 79,9 60,8 70,8 51,7 93,1 74,0

LOW NOISE UNITS

Octave band [Hz]

Z E T A

2002

63 dB

125 dB

250 dB

500 dB

1000 dB

2000 dB

4000 dB

8000 dB

Total dB(A)

/LN Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp

3.2

93,4 76,0 84,6 67,2 78,4 61,1 76,9 59,6 75,8 58,5 70,5 53,1 67,0 49,7 57,9 40,6 80,2 62,9

4.2

93,5 76,2 84,7 67,4 78,5 61,3 77,0 59,8 75,9 58,7 70,6 53,3 67,1 49,9 58,0 40,8 80,3 63,1

5.2

93,7 76,4 84,9 67,6 78,7 61,5 77,2 60,0 76,1 58,9 70,8 53,5 67,3 50,1 58,2 41,0 80,5 63,3

6.2

94,3 77,0 85,5 68,2 79,3 62,1 77,8 60,6 76,7 59,5 71,4 54,1 67,9 50,7 58,8 41,6 81,1 63,9

7.2

94,4 77,1 85,6 68,3 79,4 62,2 77,9 60,7 76,8 59,6 71,5 54,2 68,0 50,8 58,9 41,7 81,2 64,0

8.2

96,3 79,0 87,5 70,2 81,3 64,1 79,8 62,6 78,7 61,5 73,4 56,1 69,9 52,7 60,8 43,6 83,1 65,9

9.2

97,3 79,0 88,5 70,6 82,3 64,5 80,9 63,0 79,8 61,9 74,4 56,5 70,9 53,1 61,9 44,0 84,2 66,3

10.2

97,8 79,5 89,0 71,1 82,8 65,0 81,4 63,5 80,3 62,4 74,9 57,0 71,4 53,6 62,4 44,5 84,7 66,8

12.2

97,3 79,0 88,5 70,6 82,3 64,5 80,9 63,0 79,8 61,9 74,4 56,5 70,9 53,1 61,9 44,0 84,2 66,3

13.2

97,6 79,3 88,8 70,9 82,6 64,8 81,2 63,3 80,1 62,2 74,7 56,8 71,2 53,4 62,2 44,3 84,5 66,6

14.4

99,1 80,5 90,3 71,7 84,1 65,5 82,6 64,0 81,5 62,9 76,2 57,6 72,7 54,1 63,6 45,0 85,9 67,3

16.4

101,8 82,6 93,0 74,4 86,8 68,3 85,4 66,8 84,3 65,7 78,9 60,3 75,4 56,9 66,4 47,8 88,7 70,1

18.4

102,6 82,7 93,8 74,7 87,7 68,6 86,2 67,1 85,1 66,0 79,7 60,6 76,3 57,2 67,2 48,1 89,5 70,4

20.4

103,0 83,1 94,2 75,1 88,1 69,0 86,6 67,5 85,5 66,4 80,1 61,0 76,7 57,6 67,6 48,5 89,9 70,8

24.4

103,9 84,0 95,1 76,0 89,0 69,9 87,5 68,4 86,4 67,3 81,0 61,9 77,6 58,5 68,5 49,4 90,8 71,7

26.4

104,0 84,1 95,2 76,1 89,1 70,0 87,6 68,5 86,5 67,4 81,1 62,0 77,7 58,6 68,6 49,5 90,9 71,8

Lw: sound power values in free field conditions are calculated in accordance with ISO 3746.

Lp : sound pressure values measured at 1 m from the unit in free field conditions in compliance with ISO 3746

Blue Box - 21

SOUND POWER AND PRESSURE LEVELS

EXTRA LOW NOISE UNITS

Octave band [Hz]

Z E T A

2002

63 dB

125 dB

250 dB

500 dB

1000 dB

2000 dB

4000 dB

8000 dB

Total dB(A)

/SLN Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp

3.2

90,2 73,0 81,4 64,2 75,3 58,1 73,8 56,6 72,7 55,5 67,3 50,1 63,9 46,7 54,8 37,6 77,1 59,9

4.2

90,6 73,5 81,8 64,7 75,7 58,6 74,2 57,1 73,1 56,0 67,7 50,6 64,3 47,2 55,2 38,1 77,5 60,4

5.2

91,1 73,9 82,3 65,1 76,2 59,0 74,7 57,5 73,6 56,4 68,2 51,0 64,8 47,6 55,7 38,5 78,0 60,8

6.2

91,8 74,6 83,0 65,8 76,9 59,7 75,4 58,2 74,3 57,1 68,9 51,7 65,5 48,3 56,4 39,2 78,7 61,5

7.2

92,1 74,9 83,3 66,1 77,2 60,0 75,7 58,5 74,6 57,4 69,2 52,0 65,8 48,6 56,7 39,5 79,0 61,8

8.2

94,8 76,8 86,0 68,0 79,9 61,9 78,4 60,4 77,3 59,3 71,9 53,9 68,5 50,5 59,4 41,4 81,7 63,7

9.2

95,0 77,1 86,2 68,3 80,1 62,2 78,6 60,7 77,5 59,6 72,1 54,2 68,7 50,8 59,6 41,7 81,9 64,0

10.2

95,7 77,8 86,9 69,0 80,8 62,9 79,3 61,4 78,2 60,3 72,8 54,9 69,4 51,5 60,3 42,4 82,6 64,7

12.2

95,3 77,4 86,5 68,6 80,4 62,5 78,9 61,0 77,8 59,9 72,4 54,5 69,0 51,1 59,9 42,0 82,2 64,3

13.2

95,6 77,7 86,8 68,9 80,7 62,8 79,2 61,3 78,1 60,2 72,7 54,8 69,3 51,4 60,2 42,3 82,5 64,6

14.4

97,1 78,1 88,3 69,3 82,1 63,1 80,6 61,6 79,5 60,5 74,2 55,2 70,7 51,7 61,6 42,6 83,5 64,9

16.4

99,6 81,0 90,8 72,2 84,7 66,1 83,2 64,6 82,1 63,5 76,7 58,1 73,3 54,7 64,2 45,6 86,5 67,9

18.4

100,1 80,9 91,3 72,1 85,2 66,0 83,7 64,5 82,6 63,4 77,2 58,0 73,8 54,6 64,7 45,5 87,0 67,8

20.4

100,7 81,5 91,9 72,7 85,8 66,6 84,3 65,1 83,2 64,0 77,8 58,6 74,4 55,2 65,3 46,1 87,6 68,4

24.4

101,6 82,5 92,8 73,7 86,7 67,6 85,2 66,1 84,1 65,0 78,7 59,6 75,3 56,2 66,2 47,1 88,5 69,4

26.4

102,3 82,7 93,5 73,9 87,4 67,8 85,9 66,3 84,8 65,2 79,4 59,8 76,0 56,4 66,9 47,3 89,2 69,6

Lw: sound power values in free field conditions are calculated in accordance with ISO 3746.

Lp : sound pressure values measured at 1 m from the unit in free field conditions in compliance with ISO 3746

Blue Box - 22

1. FIELD OF APPLICATION

The equipment is designed for cooling (chiller only versions) or cooling/heating (heat pump version) water, which is usually utilised for air conditioning or refrigeration applications.

The units must be used exclusively within the operating limits specified in Section 4.

1.1 INTRODUCTION

- When installing or servicing the unit, it is necessary to strictly 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 shock can be hazardous when installing or servicing the unit.

- The warranty will be invalid if the rules described in this manual are not observed and if any modifications are made to the unit without prior authorisation of the manufacturer.

Any work on the unit must be carried out by trained people only.

Attention: before repairing or servicing the unit, ensure that the electrical supply is disconnected.

2. INSPECTION, TRANSPORT, SITE HANDLING

2.1 INSPECTION

After receiving the unit, immediately check its integrity. The unit will have left the factory in perfect condition.

Therefore on receiving the unit any damage must be verbally described to the carrier and recorded on the

Delivery Note before it is signed by both parties. Blue Box or their Agent must be informed as soon as possible of the extent of the damage.

The Customer should prepare a written statement and photographic evidence regarding any severe damage.

2.2 LIFTING AND SITE HANDLING

Avoid sudden movements and jolts when unloading and positioning the unit. Internal handling procedures must be conducted with care. Do not exert leverage on the components of the machine. The unit must be lifted by inserting steel tubes through the lifting attachments shown by the relative signs (yellow arrow).

The unit must be lifted by harnessing it as shown in figure 1: use ropes or straps of sufficient length and spacer bars to avoid damage to the unit’s side panels and cover. Alternatively, the unit (with a maximum length less than

3.5 m) can be lifted by a forklift truck, inserting the forks under the pallet.

Blue Box - 23

2.5 m min.

mind. 2.5 m

1 2

3.5 m max

(1) Space bar (not supplied)

(2) Side panel protection (not supplied)

(3) Lifting holes

(4) Pallet

3

4

Figure 1

Caution: ensure that the method of lifting does not allow the unit to slip from chains and slings and does not allow the unit to turn over or slide from lifting devices.

2.3 UNPACKING

When unpacking the unit pay attention not to damage the unit.

Packaging consists of different materials: wood, paper, nylon etc.

Separate the materials and deliver to the proper gathering centre in order to reduce their environmental impact.

Blue Box - 24

3. SAFETY PRECAUTIONS

3.1 DEFINITION OF DANGER ZONE

Only authorised operators must be allowed in the vicinity of the unit.

- The external danger zone concerns a space of approximately 2 m in width around the perimeter of the machine.

Access to this area must be prevented by suitable guarding in the event that the unit is located in an unprotected area that is easily accessible to unauthorised persons.

- The internal danger zone is defined as the interior of the machine. Access to the interior of the machine must not be permitted to unqualified personnel and never before the machines' electrical supply has been disconnected.

3.2 SAFETY PRESCRIPTIONS

The unit is designed and built in accordance with the PED 97/23CE rules, to ensure the maximum level of safety.

To avoid possible situations of risk adhere to the following rules at all times:

- All work on the unit must be performed by qualified personnel. Before working on the unit, ensure that the designated personnel are conversant with the documentation supplied. Always ensure there is a copy of the documentation in the immediate vicinity of the unit.

- Use the appropriate personal safety equipment (gloves, helmet, safety goggles, safety footwear, etc.) for all maintenance and control operations on the unit.

- Use only tools and equipment that are in good working order.

- The fans have protective grilles to prevent accidental contact. Use the maximum caution to avoid inserting or dropping objects through the grilles.

- The exchanger coils have sharp edges. Do not touch the coils without using suitable protection.

- The compressor compartment contains various high temperature components. Adopt the maximum caution when working in the vicinity of the compressors and avoid touching any parts of the unit without appropriate protection.

- Do not work within the theoretical discharge trajectory of the relief valves.

Blue Box - 25

MECHANICAL HAZARDS

Operating mode

Normal operating regime

Maintenance

Handling during transport and installation.


Maintenance

Operating regime

Maintenance


Maintenance


Analysed risk or hazard

Stability

Stability

Pipeline bursts.

Surfaces, sharp corners and edges.

Surfaces, sharp corners and edges.

Cutting or severing.



Solution adopted

Because of their intrinsic characteristics, the units are not associated with problems of possible falling or tipping while in operation.

Carefully read the items described in this manual concerning the methods of positioning the unit.

The unit's base frame has specific lifting holes; the positions of which are marked with yellow decals. Following this procedure will eliminate the risk of the unit tipping.

Carefully read the items descriptions in this manual concerning the methods of handling the unit.

Pipes are rigidly anchored to reduce the degree of vibration.

The machine is designed and built in such a way as to minimise the presence of sharp corners and edges as far as possible.

In the interior parts of the unit it is not possible to totally eliminate risks from the presence of surfaces, sharp corners and edges. The operating, installation, 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.

The moving parts of the unit are located in clearly defined areas. Specifically, the fans are enclosed in an inaccessible compartment and are equipped with an upper protection grille to UNI EN 294. All the protections supplied to limit and enclose the fan compartments cannot be removed without the use of special tools.

The moving parts of the unit are located in clearly defined areas. Specifically, the fans are enclosed in an inaccessible compartment and are equipped with an upper protective grille to UNI EN 294. If present, the fan speed regulator accessory, located in the condensing section compartment, does not require adjustment or calibration during maintenance operations.

All units are supplied as standard with specific protection grilles designed to protect against accidental contact with the finned coils, which can cause minor cuts to the hands.

Blue Box - 26

MECHANICAL HAZARDS

Operating mode

Maintenance


Maintenance


Maintenance



Entanglement, dragging, impact.

Entanglement, dragging, impact.

Projection of high pressure jets of fluid - Explosion hazard


The operating, installation, and maintenance manual describes the use of suitable protections to avoid contact with the finned coils, which can cause slight wounds to the hands.

The moving parts of the unit are located in clearly defined areas. Specifically, the fans are enclosed in an inaccessible compartment and they are equipped with an upper protective grille to UNI EN 294. All the protections supplied to limit and enclose the fan compartments cannot be removed without the use of special tools.

The moving parts of the unit are located in clearly defined areas. Specifically, the fans are enclosed in an inaccessible compartment and they are equipped with an upper protective grille to UNI EN 294.

If present, the fan speed regulator accessory, located in the condensing section compartment, does not require adjustment or calibration during maintenance operations.

All units are equipped with relief valves to eliminate the risk of pressure bursts.

The outlet from relief valves must be piped appropriately to eliminate risks associated with the expulsion of gas at high pressure from the machine. The warnings regarding these expulsion points are fixed to the outside of the unit and given in the operating and maintenance manual.

THERMAL HAZARDS

Operating mode


Maintenance


Burns caused by high temperatures.

Burns caused by high temperatures.


Most of the pipelines that could cause burns, when touched, are lagged with heat insulating material. All the parts that are potentially dangerous are confined in compartments that cannot be accessed without the use of tools

Most of the pipelines that could cause burns, when touched, are lagged with heat insulating material. The operating, installation, and maintenance manual describes the use of suitable protections to avoid contact with high temperature pipelines that could result in burns.

Blue Box - 27

NOISE-RELATED HAZARDS

Operating mode


Maintenance


Hearing damage.


All units are designed and built with the aim of reducing noise emissions to the minimum.

ELECTRICAL HAZARDS

Operating mode


Maintenance


Maintenance


Maintenance


Maintenance


Contact with electrically live parts (direct contact).

Elements carrying electrical current in the case of faults.

Inappropriate insulation.

Radiated heat due to shortcircuits or overloads.


All units are designed and built in compliance with harmonised standard EN

60204-1.

Blue Box - 28

R407C REFRIGERANT SAFETY SHEETS

1. IDENTIFICATION OF

THE SUBSTANCE

1.1 Identification of the preparation:

Synonyms:

Formula:

EE-No:

407C

HFC-32lHFC-125IHFG134a

Mixture difluoromethane (HFC-32) : 200-839-4

1-1-1-2-tetrafluoroethane UHFC-134a) : 212-377-0 pentafluoroethane (HFC-125) : 206-557-8

2. COMPOSITION /

INFORMATION ON

INGREDIENTS

Chemical Name difluoromethane

1-2-2-2-tetrafluoroethane pentafluoroethane

CAS-No - Wt % - Symbol(s): & phrases "R"

75/10/5 - 23 - F+;R12

811/97/2 - 52

354/33/ 6 - 25

3. HAZARDS

IDENTIFICATION:

4. FIRST-AID

MEASURES:

3.1 Most important hazards:

Liquefied gas: may cause frostbite. Contact with eyes may cause irritation.

4.1 Eyes

Skin

Inhalation

Ingestion

General advice

Rinse immediately with plenty of water for at least 15 minutes.

Keep eye wide open while rinsing. If symptoms persist, call a physician.

Liquefied gas may cause frostbite. Wash frostbitten areas with plenty of water. Do not remove clothing. Wash off with warm water. if skin irritation persists, call a physician.

Move to fresh air in case of accidental inhalation of vapours.

Oxygen or artificial respiration if needed. Do not apply artificial respiration if patient is breathing; Consult a physician after significant exposure. Do not give adrenaline or similar drugs.

Do not induce vomiting without medical advice. Call a physician immediately. Do not give drugs from adrenaline-ephedrine group.

Consult a physician alter significant exposure.

5. FIRE-FIGHTING

MEASURES:

5.1 Suitable extinguishing media:

5.2 Extinguishing media which must not be used for safety reasons:

5.3 Specific hazards:

The product itself does not burn. Extinguish with carbon dioxide, dry chemical, foam or water spray. Use extinguishing measures that are appropriate to the environment.

None

5.4 Special protective equipment for firefighters:

5.5 Specific methods:

Possibility of generating hazardous reactions during a fire due to the presence of F and/or Cl groups. Fire or intense heat may cause violent rupture of packages.

In case of fire, west a self contained breathing apparatus.

Protective suit.

Standard procedure for chemical fires. In the event of fire, cool tanks with water spray.

6. ACCIDENTAL

RELEASE MEASURES:

6.1 Personal precautions: Use personal protective equipment. Evacuate personnel to safe areas. Do not breath vapours or spray mist. Ensure adequate ventilation.

6.2 Methods for cleaning up:

Shut off leaks it without risk. Solid evaporates. Ensure adequate ventilation.

Blue Box - 29

7. HANDLING AND

STORAGE:

7.1 Handling:

7.2 Storage:

Keep away from heat, sources of ignition. Do not puncture or drop container, Provide sufficient air exchange and / or exhaust in work rooms.

Keep containers tightly closed in a cool, well-ventilated place.

Store in a cool and shaded area. Do not expose to temperatures above 50 °C. Keep tightly closed.

8. EXPOSURE

CONTROLS /

PERSONAL

PROTECTION:

8.1

8.2

8.3

Engineering measures to reduce exposure:

Personal protection equipment:

Ensure adequate ventilation, especially in confined areas.

Respiratory protection: In case of insufficient ventilation wear suitable respiratory equipment, preferably a compressed airline breathing apparatus.

Hand protection: Impervious butyl rubber gloves.

Eye protection: Wear as appropriate: safety glasses, gaggles, Wear face-shield and protective suit for abnormal processing problems.

Skin and body protection:

Exposure limit(s):

Chemical resistant apron, long sleeved clothing, safety shoes.

1-1-1-2-tetrafluoroethane 1000 ppm (TWA); difluoromethane: 1000 ppm (TWA); pentafluoroethane: 1000 ppm (TWA)(AIHA);

9. STABILITY AND

REACTIVITY:

9.1 Stability:

9.2 Conditions to avoid:

9.3 Materials to avoid:

9.4 Hazardous decomposition products:

10. TOXICOLOGICAL

INFORMATION:

10.1 Acute toxicity:

10.2 Irritation :

Skin:

Eyes:

10.4 Chronic toxicity:

11. DISPOSAL

CONSIDERATIONS:

11.1 Waste from residues / unused products:

Contaminated packaging:

Stable at normal conditions. No decomposition if stored and applied as directed. Decomposition starting from 250°C.

Do not expose to temperatures above 50 °C. Fire or Intense heat may cause violent rupture of packages. alkaline metals (Na, K), alkaline earth metals (Ca, Mg), finely divided aluminium, zinc. halogenated compounds, hydrogen halides (HF, HCI), carbonyl halides (COCl

2

), carbon monoxide, carbon dioxide (C0

2

).

LC50/inh./4 h/rat : > 500000 ppm slightly irritant, may cause frostbite. slightly irritant. chronic inhalation, no-observed-effect level (NOEL):> 10000pprn rat.

Offer surplus and non-recyclable solutions to an established disposal company. In accordance with local and national regulations. S59 - Refer to manufacturer/supplier for information on recovery/recycling.

Do not reuse empty containers. Empty pressure vessels should be returned to supplier.

12. TRANSPORT

INFORMATIQN:

No. O.N.U.

ADR/RID

3340

UN 3340 Refrigerant gas R407C, 2, 2° A, ADR/RID

Label: 2

Blue Box - 30

R22 REFRIGERANT SAFETY SHEETS

1. IDENTIFICATION OF

THE SUBSTANCE

1.1 Identification of the preparation:

Synonyms:

Formula:

CAS-No

EEC-No

HCFC-22 chlorodifluoromethane

CHClF

2

75-45-6

200-871-9

2. COMPOSITION /

INGREDIENTS

3. HAZARDS

4. FIRST-AID

MEASURES:

Chemical Name

Chlorodifluoromethane

3.1 Major hazards:

CAS-No - Wt % - Symbol(s): & phrases "R"

75/45/6 - 100 - R59

Causes damage to ozone layer.

4.1 Eyes

Skin

Inhalation

Ingestion

General advice

Rinse immediately with plenty of water for at least 15 minutes.

Keep eye wide open while rinsing. If symptoms persist, call a physician.

Liquefied gas may cause frostbite. Wash frostbitten areas with plenty of water. Do not remove clothing. Wash off with warm water. if skin irritation persists, call a physician.

Move to fresh air in case of accidental inhalation of vapours.

Oxygen or artificial respiration if needed. Do not apply artificial respiration if patient is breathing; Consult a physician after significant exposure. Do not give adrenaline or similar drugs.

Do not induce vomiting without medical advice. Call a physician immediately. Do not give drugs from adrenaline-ephedrine group.

Consult a physician alter significant exposure.

5. FIRE-FIGHTING

MEASURES:

5.1 Suitable extinguishing media:

5.2 Extinguishing media which must not be used for safety reasons:

5.3 Specific hazards:

The product itself does not burn. Extinguish with carbon dioxide, dry chemical, foam or water spray. Use extinguishing measures that are appropriate to the environment.

None

5.4 Special protective equipment for firefighters:

5.5 Specific methods:

Possibility of generating hazardous reactions during a fire due to the presence of F and/or Cl groups. Fire or intense heat may cause violent rupture of packages.

In case of fire, west a self contained breathing apparatus.

Protective suit.

Standard procedure for chemical fires. In the event of fire, cool tanks with water spray.

6. ACCIDENTAL

RELEASE MEASURES:

6.1 Personal precautions: Use personal protective equipment. Evacuate personnel to safe areas. Do not breath vapours or spray mist. Ensure adequate ventilation.

6.2 Methods for cleaning up:

Shut off leaks it without risk. Solid evaporates. Ensure adequate ventilation.

Blue Box - 31

7. HANDLING AND

STORAGE:

7.1 Handling:

7.2 Storage:

Keep away from heat, sources of ignition. Do not puncture or drop container. Provide sufficient air exchange and / or exhaust in work rooms.

Keep containers tightly closed in a cool, well-ventilated place.

Store in a cool and shaded area. Do not expose to temperatures above 50 °C. Keep tightly closed.

8. EXPOSURE

CONTROLS /

PERSONAL

PROTECTION:

8.1

8.2

Engineering measures to reduce exposure:

Personal protection equipment:

Respiratory protection: In case of insufficient ventilation wear suitable respiratory equipment, preferably a compressed airline breathing apparatus.

Hand protection:

Eye protection:

Impervious butyl rubber gloves.

Wear as appropriate: safety glasses, gaggles, Wear face-shield and protective suit for abnormal processing problems.

Skin and body protection:

8.3 Exposure limit(s):

Ensure adequate ventilation, especially in confined areas.

Chemical resistant apron, long sleeved clothing, safety shoes.

Chlorodifluoromethane: 3600 mg/m3, 1000 ppm (TLV)

9. STABILITY AND

REACTIVITY:

9.1

9.2

Stability:

Conditions to avoid:

9.3 Materials to avoid:

9.4 Hazardous decomposition products:

10. TOXICOLOGICAL

INFORMATION:

10.1 Acute toxicity:

10.2 Irritation:

10.3 Sensitisation:

10.4 Chronic toxicity:

11. DISPOSAL

CONSIDERATIONS:

11.1 Waste from residues / unused products:

Contaminated packaging:

Stable

Keep well clear of naked flame and sparks. Do not smoke. If burned, the product can give off toxic fumes . use self-contained breathing apparatus. alkaline earth metals, alkaline metals, aluminium precipitate, zinc. halogenated compounds (e. g. acids), carbonyl halides.

LC50/inh./4 h/rat : > 300,000 ppm

Hearth sensitisation: 50,000 ppm

Sub-chronic exposure, effects not observed below level (NOEL):

10,000 ppm

Offer surplus and non-recyclable solutions to an established disposal company. In accordance with local and national regulations. S59 - Refer to manufacturer/supplier for information on recovery/recycling.

Do not reuse empty containers. Empty pressure vessels should be returned to supplier.

12. TRANSPORT

INFORMATIQN:

No. O.N.U.

ADR/RID

1018

UN 1018 Chlorodifluoromethane, 2, 2° A, ADR/RID

Label: 2

Blue Box - 32

3.3 POSITIONING

Read the following points carefully when choosing the most suitable site for the unit and its connections:

- dimensions and connection point of hydraulic pipelines;

- location of the electrical power connection point;

- accessibility for maintenance and repair work;

- loading capacity and compactness of the supporting surface;

- ventilation of air-cooled condenser;

- orientation and exposure to sunlight; as far as possible the condenser coil should not be

exposed to direct sunlight;

- direction of prevailing winds: do not position the unit in such a way that prevailing winds can give rise to 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);

- possible sound reverberation.

All models in the ZETA 2002 series are designed for exterior installation (patios, gardens, etc.): of undesirable air recirculation, these units must not be covered by a shelter roof or located under trees (even if the unit is only partially covered).

It is advisable to make a supporting plinth of dimensions commensurate with the footprint of the unit. This precaution is indispensable if the unit is to be located on unstable ground (various types of terrain, gardens, etc.).

to avoid the risks of undesirable air recirculation, these units must not be covered by a shelter roof or located under trees (even if the unit is only partially covered).

It is advisable to make a supporting plinth of dimensions commensurate with the footprint of the unit. This precaution is indispensable if the unit is to be located on unstable ground.

The unit transmits a low level of vibration to the supporting structure: we recommend interposing a layer of rigid rubber sheeting between the base of the unit and the supporting surface.

If a higher level of vibration damping is required, use anti-vibration mounts (contact Bluebox for details).

The units should not be installed next to offices, bedrooms, or other areas where low noise levels are a necessity.

To avoid excess sound reverberation do not install the units in narrow or confined spaces.

15 mm gauge hard rubber sheet

Foundation plinth made of 500 kg/mm 2 reinforced concrete

Plinth slab

15-20 cm

Sealant

Cork underlayment

Soil

Figure 2

Blue Box - 33

4. INSTALLATION

4.1 INSTALLATION CLEARANCES

It is important that an adequate air volume is available at the intake and exhaust sides of the condenser coil. It is essential to avoid air recirculation between the intake and exhaust sides to prevent a reduction of the rated performance levels and unit operating problems.

The minimum clearances required for satisfactory operation of the unit is as follows (refer to figures 3 and 4):

- condensing coil side: 1.5 metres

- electrical panel side: 1 metre

- compressors compartment side: 1 metre

- hydraulic connection sides: 1 metre.

- top: no impediments that obstruct the air discharge.

- units installed side by side: 4 metres.

1 m

1 m

Figure 3

SIDE BY SIDE UNITS

4 m min.

Figure 4

Blue Box - 34

4.2 ANTI-VIBRATION ISOLATORS (option)

It is recommended that the unit is installed on rubber or spring anti-vibration mountings, supplied as an option, to reduce vibrations transmitted to the building structure. It is advisable to use rubber isolators for units installed in the basement, or ground floors in contact with the earth, and spring isolators for units installed on intermediate floors.

The anti-vibration isolators must be installed before the unit is positioned.

Ensure that during lifting the unit is firmly secured with straps.

4.2.1 Rubber Anti-Vibration Isolators

Rubber isolators are made of an upper metallic bell with a fixing screw to the base-frame of the unit. The isolator is fixed at the foundation via 2 holes on the flange. On the flange there is a number (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 anti-vibration i s o l a t o r

Designed to reduce the vibration.

Figure 5

4.2.2 Spring Anti-Vibration Isolators

Anti-Vibration Isolators with cylindrical springs are recommended to reduce any mechanical and sound vibration.

Each isolator has a code which identifies the maximum permitted load.

When installing spring Anti-Vibration Isolators, it is compulsory to carefully follow all recommendations and assembly instructions. The dimensional drawing, enclosed in the machine, shows the footprint with the position and weight of each isolator.

Standard spring antivibration isolators

The isolator is fixed to the unit's baseframe with a nut and two bolts and washers.

Spring anti-vibration isolators for heavy l o a d s

The load of the unit is supported by the full surface of the isolators. The load is not exerted on the bolt.

Figure 6

Blue Box - 35

4.3 WATER PIPING CONNECTIONS

Unit water pipework must be installed in accordance with national and local regulation and codes.

Follow the recommendations below when designing the water piping circuit (refer to the diagrams included in this manual).

- Piping should be connected to the unit with flexible joints, to avoid vibration transmission and allow for thermal expansion (the same procedure should be adopted for the circulating pumps).

- 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.

- Serviceable mesh strainer, with a filtration level no larger than 1mm, located on the unit inlet to prevent debris from entering the heat exchangers.

- vent valves, to be installed in the upper parts of the circuit, for air bleeding.

- expansion device with accessories for circuit pressurisation, water thermal expansion compensation and system filling.

- unload valve and if necessary drainage tank for circuit emptying during maintenance and seasonal stop.

Blue Box - 36

Blue Box - 37

Blue Box - 38

HYDRAULIC CIRCUIT DIAGRAM VERSION ST /2PS

Blue Box - 39

4.4 EVAPORATOR WATER PIPE CONNECTIONS

The water inlet and outlet must be connected in the positions indicated as labelled on the unit.

EVAPORATOR WATER

If incorrectly connected the antifreeze thermostat will not operate and the evaporator may freeze.

The hydraulic connections are threaded. The type and size are indicated on the dimensional drawings at the end of this manual.

A constant water flow to the evaporator must be guaranteed at all operating conditions to prevent liquid refrigerant from entering the compressor and causing irreparable damage.

Compressors start and stop often due to changes in cooling demand. In hydraulic circuits with low water volume, where the thermal inertia action is low, it is advisable to verify that the water volume equals or exceeds the following ratio:

24 · Q

COMPTOT

M>= ---------------------

N where:

M

Q

COMPTOT

N

= system water content [kg]

= unit cooling capacity [kW]

= number of capacity steps

If the water volume does not reach the value given by the formula, it is advisable to provide the circuit with a storage vessel to increase the volume (tank + circuit) to match the result of the formula.

The chilled water piping and storage vessel must be insulated to prevent condensation on the pipe surfaces and to avoid circuit performance losses.

For models from 3.2 to 13.2 it is mandatory to install a flow switch

(supplied with the unit) on the evaporator water outlet connection identified by the following decal:

USER WATER

For models from 14.4 to 26.4 the flow switch is already installed as part of the standard equipment.

Blue Box - 40

All units are equipped with plate heat exchangers. It is compulsory to install a metallic filter, on the water inlet piping, with a mesh not larger than 1 mm. If a filter is not installed the warranty will be terminated immediately.

We strongly recommend installing a pressure relief valve on the hydraulic circuit. In the event of serious system breakdown or emergency (e.g.

fire), the relief valve will make it possible to depressurise the system thus forestalling possible pipe bursts. Always connect the relief valve outlet to a pipe of diameter no smaller than the valve opening, and route it to a location in which persons are protected from the jet of expelled water.

Caution: When making hydraulic connections never use naked flames close to or inside the unit.

4.5 WATER FLOW SWITCH INSTALLATION INSTRUCTIONS (models 3.2 to 13.2)

- Clean the pipeline system into which the flow switch is to be fitted and take away any magnetic particle, such as welding residues. To prevent turbulent flow there must be straight pipework, equal to 5 times the diameter of the pipe, either side of the flow switch.

" Connect the "T" shaped metallic manifold (on which the flow switch is mounted) into the evaporator male threaded water outlet labelled with:

USER WATER

To avoid leakage, seal the connection by using teflon. The flow switch should be installed on the heat exchanger that is closer to the electrical board.

User exchanger

(evaporator)

Make the electrical connections on the unit’s terminal board

Figure 7

Blue Box - 41

- The flow switch must be tightened on the “T” shaped metallic manifold by the plastic knurled union nut. Check that the arrow located on the upper side is pointing in the direction of flow.Be sure to fit the O-ring seal, through the brass manifold and the plastic ring nut. The O-ring seal is supplied in a plastic cover to protect the flow switch shaft.

- Connect the flow switch to the other end of the “T” manifold.

- Route the flow switch electrical cable through the hole in the unit structure and run it to the electrical panel by ascending the upright in the machine interior. Connect the flow switch to terminals 1-14 as indicated on the electrical drawing.

- The flow switch can be removed by screwing out the plastic knurled union nut. In order to reassemble it, ensure that the o-ring seal is positioned in the proper location. (See figure10).

Arrow

Flow switch

Seal

Electric cable

Ring nut

“T” Connector

Figure 8

4.6 DESUPERHEATER HYDRAULIC CONNECTION (optional)

For all units equipped with desuperheaters 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.

Heat recovery water inlet:

IN

WATER DESUPERHEATER

Heat recovery water outlet:

OUT

WATER DESUPERHEATER

On HP version units the hydraulic connection to the desuperheater must be isolated during heat pump operation

Blue Box - 42

4.7 ZETA 2002/DC HEAT RECOVERY EXCHANGER HYDRAULIC CONNECTIONS

For all units equipped with a recovery condenser, the relative hydraulic circuit connections are male threaded steel pipes (the diameter depends on the unit's size)

The units are equipped with a probe that monitors the temperature of the water returning from the system. The microprocessor controller enables recovery when necessary, disconnecting the fans, and restarting regular 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 pressure switches are given in the relevant controller instruction manual.

For units equipped with a recovery condenser:

The water inlet and outlet must be connected in the positions indicated as labelled on the unit.

IN

3-way valve

Recovery water outlet

Recovery water inlet

It is mandatory to install a three-way modulating, valve with water temperature probe, on the inlet to the unit to ensure that, at steady state conditions, the inlet water temperature is not less than 20 °C.

DIAGRAM WITH 3-WAY VALVE

Figure 9

Blue Box - 43

Alternatively: a condensing pressure control valve for each refrigerant circuit that ensures an average condensing temperature of at least 33

°C.

DIAGRAM WITH CONDENSING PRESSURE CONTROL VALVE

Condensing pressure control valve

To the refrigerant circuit

Recovery water outlet

Recovery water inlet

×

Ø

Figure 10

This method ensures that the recovery unit is supplied with a flow that increases as the water temperature rises, thus allowing the system to operating with optimum functional parameters at all times.

4.8 PRESSURE RELIEF VALVES

Pressure relief valves 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 relief valve and it must not be supported from the valve.

Caution: The relief valve must be directed into a safe zone where no injuries can be caused to people.

Blue Box - 44

4.9 CONNECTIONS FOR VERSION /LE (MOTOCONDENSING UNIT)

/LE (condensing unit) versions must be connected to a remote evaporator by means of refrigerant lines.

For separate section type /LE versions, the route followed by refrigerant lines depends on the location of the sections and the characteristics of the surrounding building structure.

Pipe runs should be as short as possible to limit the pressure drop and the refrigerant charge volume. The maximum permissible pipeline length is 30 metres.

If this limits cannot be adhered to contact Blue Box for further information.

4.9.1 Procedures to follow when sizing refrigerant lines

Depending on the relative position of the sections, there are certain procedures to follow when installing the refrigerant line.

4.9.2 Evaporating section at lower level than condensing section: a) The vertical riser must be equipped with siphons at least every 6 metres to facilitate the return of oil to the compressor; b) Make a collection pit on the suction line downstream of the thermostatic valve bulb; c) Horizontal sections of the suction line should follow a grade of at least 1% to facilitate oil return to the compressor (see above).

The diameter of pipes can be obtained from table 1, according to the selected model and length of connecting pipes.

1 %

Figure 11

6 m

6 m

1 %

Evaporator

Blue Box - 45

4.9.3 Evaporating section positioned higher than the condensing unit section: a) Form a siphon on the suction line,at the same height as the evaporator, to avoid drainage of liquid towards the compressor when the unit is stopped.

b) Make a collection pit on the suction line, downstream from the thermostatic valve bulb, for the collection of liquid refrigerant that can accumulate during unit shutdown. When the compressor restarts the refrigerant will evaporate rapidly: it is advisable to create the accumulation pit well away from the bulb to avoid the risk of affecting the operation of the thermostatic valve.

c) Horizontal sections of the suction line should follow a grade of at least 1% to facilitate oil return to the compressor.

Evaporator

1 %

Figure 12

TABLE 1 - EXTERNAL PIPE DIAMENTERS FOR /LE VERSIONS

Distance [m]

MODEL

ZETA 2002

3.2

4.2

5.2

6.2

7.2

8.2

9.2

10.2

12.2

13.2

14.4

16.4

18.4

20.4

24.4

26.4

Suction

[mm]

35

35

35

54

54

54

42

42

42

42

54

42

54

54

54

54

10

28

35

35

28

22

28

28

28

28

28

28

35

35

Liquid

[mm]

18

22

22

Suction

[mm]

35

42

42

54

54

67

42

42

42

42

54

42

54

54

54

67

20

28

35

35

28

22

28

28

28

28

28

28

35

35

Liquid

[mm]

18

22

22

Suction

[mm]

35

42

42

54

54

67

54

42

54

54

54

54

54

54

67

67

30

Liquid

[mm]

18

22

22

28

35

35

28

22

28

28

28

28

28

28

35

35

Blue Box - 46

4.10 WATER FLOW RATE TO EVAPORATOR

The nominal water flow rate is based on a 5 °C temperature difference between inlet and outlet in relation to the supplied cooling capacity.

The maximum permissible flow rate is that which results in a temperature difference of 3 °C: higher flow rates will lead to excessive pressure drops and could damage the evaporator.

The minimum permissible flow rate is that which results in a temperature difference of 8 °C or a pressure drop of no less than 10 kPa: lower flow rates will lead to excessively low evaporation temperatures with consequent tripping of safety devices and shutdown of the unit.

4.11 CHILLER WATER TEMPERATURE (summer cycle)

For the minimum water temperature at the evaporator outlet refer to section 4.14.

The maximum water temperature at the evaporator inlet is 20 °C. In the case of higher temperatures specific solutions are necessary (dual circuits, three-way valves, by-pass, storage tanks): consult the Bluebox Engineering

Department to discuss the most suitable solution for your application.

4.12 HOT WATER TEMPERATURE (winter cycle)

The minimum water temperature at the condenser inlet, once the system is operating in steady state conditions, must be no lower than 23 °C: lower values could result in operating anomalies of the compressor with the consequent risk of compressor breakdown.

The maximum water temperature at the condenser outlet must be no higher than 48 °C. In the event of higher temperatures the safety devices will trip causing the unit to shut down.

Warning: speed control calibration settings must not be altered. If it proves necessary to alter speed calibration settings, this task must be entrusted to a skilled engineer, who should refer to the attached instruction sheet.

4.13 Ambient air temperature

- The units are designed and built to operate with ambient air temperatures within the limits shown on the operating limits diagrams. Contact Bluebox if the unit is required to operate at different ambient temperatures.

- It should be noted that the performance of heat pump units decreases significantly at lower ambient temperatures.

- The units can be optionally equipped with an electric element for heating the evaporator. The heater cuts in, when the machine is switched off, if the water temperature in the evaporator falls below the freeze protection calibration temperature.

4.14 FAN SPEED CONTROL (optional)

If the unit is required to operate at ambient air temperatures less than 18 °C a fan speed controller must be included. With fan speed control the unit can function correctly, at low ambient temperatures, by reducing the air flow supplied to the condenser so that it operates within acceptable parameters.

This control is calibrated and tested in the factory.

Blue Box - 47

4.15 OPERATION WITH LOW TEMPERATURE CHILLED WATER AT EVAPORATOR

Units from the normal production range are not designed to operate with lower chilled water temperatures, at the evaporator outlet, than those indicated in the operating limit diagrams. To operate outside this limit the unit may require structural modifications. If this should become necessary Bluebox.

With temperatures lower than those shown in the operating limit diagrams, the hydraulic circuit should be filled with a suitable water and antifreeze solution. In such cases the service thermostat and the freeze protection thermostat must be reset:

These calibrations are normally set in the factory.

The ethylene glycol percentage must be selected in relation to the required chilled water temperature.

See Table 2.

TABLE 2 - FREEZING POINT FOR WATER-ANTIFREEZE MIXTURES

LIQUID OUTLET TEMPERATURE

OR MINIMUM AMBIENT TEMPERATURE (°C)

FREEZING POINT (°C)

ANTIFREEZE

ETHYLENE GLYCOL

PROPYLENE GLYCOL

METHANOL

CALCIUM CHLORIDE

TEMPER -20

TEMPER -40

TEMPER -60

TIFOXITE

FREEZIUM

PEKASOL 50

+0° -5° -10° -15° -20° -25° -30° -35° -40°

6

15

8

9

-5°

10

50

-10° -15° -20° -25° -30° -35° -40° -45°

% BY WEIGHT

22

25

14

14

30

33

20

18

T -20°C

36

39

26

21

41

44

30

24

46

48

34

26

50

51

38

27

---

53

54

41

28

56

57

45

30

---

40

20 25

59

50

30

T -40°C

T -60°C

60

34

68 75

63

37

81

69

40

86

73

43

90

---

45

---

In the case of ST versions with a glycol content greater than 30% pumps with special seals must be specified at the time of the order.

Blue Box - 48

OPERATING LIMITS

ZETA 2002 - R22 refrigerant

20

15

10

Con dispositivi opzionali per basse temperature dell’aria esterna.

With low ambient temperature kit.

(1)

5

0

-25 -20 -15 -10 -5 0 5 10 15

Refrigeratore

Chiller

Raffreddamento

Cooling

(1)

20 25 30 35 40 45 50

Ambient air temperature [°C]

55

50

45

40

35

30

25

20

15

10

5

0

-25 -20 -15 -10 -5

(1)

0

Riscaldamento

Heating



5 10


Pompa di calore

Heat pump

Raffreddamento

Cooling

(1)

20 25 30 35 40 45 50

The water temperature rise for all versions must be between 3 °C (min) and 8 °C (max)

(1) Working limits of units with 2 compressors

Blue Box - 49


ZETA 2002/LE - R22 refrigerant

20

10

0

-10



-20

-25 -20 -15 -10 -5 0 5 10 15 20 25

Refrigeratore

Chiller

Raffreddamento

Cooling

30 35 40 45 50


70

60

50

40

30

20

10

0

-10

-20

-30

Riscaldamento

Heating



Pompa di calore

Heat pump

Raffreddamento

Cooling

-25 -20 -15 -10 -5


0 5 10 15 20 25 30 35 40 45 50


Blue Box - 50


ZETA 2002 - R407C refrigerant

20

15

10

5



(1)

0

-25 -20 -15 -10 -5 0 5 10 15 20 25

Refrigeratore

Chiller

Raffreddamento

Cooling

(1)

30 35 40 45 50


55

50

45

40

35

30

25

20

15

10

5

0

-25 -20 -15 -10 -5


0

Riscaldamento

Heating



(1)

5 10 15

Pompa di calore

Heat pump

Raffreddamento

Cooling

(1)

20 25 30 35 40 45 50


(1) Working limits of units with 2 compressors

Blue Box - 51


ZETA 2002/LE - R407C refrigerant

20

10

0



-10

-20

-25 -20 -15 -10 -5 0 5 10 15 20 25

Refrigeratore

Chiller

Raffreddamento

Cooling

30 35 40 45 50


40

30

20

10

70

60

50

0

-10

-20

-30

Riscaldamento

Heating



Pompa di calore

Heat pump

Raffreddamento

Cooling

-25 -20 -15 -10 -5


0 5 10 15 20 25 30 35 40 45 50


Blue Box - 52

EVAPORATOR PRESSURE DROP

100

90

80

70

60

50

40

3.2

4.2

5.2

6.2

7.2

8.2

9.2

10.2

12.2

13.2

30

20

100

90

80

70

60

50

40

30

20

10

1 2 3 4 5

Portata acqua [ l/s]

6

Water flow

7 8 9 10

16.4

18.4

20.4

24.4

14.4

26.4

10

2

4 6 7 8 9 10 11 12

Portata acqua [l/s]

Water flow

14 16 18 20


Blue Box - 53

PUMPS AVAILABLE PRESSURE - MODEL ZETA 2002 /ST 2PS

AVAILABLE PRESSURE

300

250

200

7.2

26.4

150

100

50

3.2

6.2

5.2

4.2

0

1 3

14.4

8.2

13.2

9.2

10.2

12.2

16.4

5

24.4

18.4-20.4

7 9

Portata acqua [l/s]

Water flow

11 13 15 17

Blue Box - 54

4.16 ELECTRICAL CONNECTIONS

4.16.1 General

Electrical connections must be made in accordance with the information given on the electrical drawing attached to the unit and in compliance with the applicable local regulations.

An Earth (ground) connection is compulsory. The installer must connect the earth cable with a dedicated terminal on the earth bar in the electrical board (refer to the illustration on the following page) labelled PE.

It must be verified that the electrical supply corresponds to the unit electrical nominal data (tension, phases, frequency) indicated on the label on the front panel of the unit.

Line voltage fluctuations must not be more than ±5% of the nominal value, while the voltage unbalance between one phase and another must not exceed 2%. If these tolerances are not possible contact Blue Box to provide the necessary devices.

Check that the line is connected with the correct phase sequence.

The cable inlet point is created by drilling a hole in the side or base of the electrical enclosure, depending on the model.

The control circuit is derived from the power supply through a transformer 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 torsional stress.

Before any operation on the electrical section, be sure that the electric supply is disconnected.

Power cable and line protection must be sized according to the specification indicated on the wiring diagram and the documents supplied with the unit.

The crankcase heaters must be connected at least 12 hours before starting the unit; the heaters are automatically connected when the main disconnect switch is set to the ON position.

The electrical supply must be within the limits shown. If this is not the case the warranty will be terminated immediately.

Blue Box - 55

4.16.2 Power supply to crankcase heaters

1) Close the main disconnect switch by turning it from position “0” to position “1”

2) Check that the word “OFF” is shown on the display

3) Ensure that the unit is in “OFF” status and that the external enabling contact is open

4) After a few moments, if the phase sequence is incorrect the alarm “INCORRECT PHASE SEQUENCE” will be displayed (4-compressor models from 14.4 to 26.4 only, with pCO2 controller). In this case invert the connections of two of the power line phase wires.

5) Leave the unit in this condition for at least 12 hours to allow the crankcase heaters to perform their function

4.16.3 Potential free contacts

The following potential free contacts are available:

- 1 potential free contact for general alarm (terminals 100 - 101 - 102)

- 1 potential free contact for each compressor (option)

- 1 contact for each pair of fans (option)

- 1 contact for each pump (option - ST models)

4.16.4 Flow switch electrical connections

Flow switch electrical connections (see paragraph 4.4 ) must be connected to terminal 1-14 for chiller units.

4.16.5 Circulating pump electrical connections

The external interlocks of unit must close for the unit to operate. The normally open external water circulating pump contactor terminals must be wired in series with terminals 1 and 2, on the unit control panel, to ensure that the chiller can only start after the pump is in operation.

In ST units external enabling contacts 1-2 must be jumpered (unless they are required for system functions).

Turn on the pump before the unit starts and stop it after the unit has stopped (recommended time delay: 60 sec.).

4.17 MICROPROCESSOR CONTROLLERS

Chillers in the ZETA 2002 series with 2 scroll compressors, models from 3.2 to 13.2, are equipped with the mCHILLER type microprocessor controller.

Chillers in the ZETA 2002 series with 4 scroll compressors, models from 14.4 to 26.4, are equipped with the pCO2 microprocessor controller.

Blue Box - 56

4.17.1 Microprocessor controller for /LE and HP/LE versions

- Versions ZETA 2002 /LE and ZETA 2002 HP/LE with two compressors are equipped with an mchiller controller.

- Versions ZETA 2002 /LE and ZETA 2002 HP/LE with four compressors do not have an integral controller and therefore an external controller, or thermostats, must be connected to the auxiliary terminals 1-21, 1-31, 1-41 and 1-51.

Consult the electrical diagram attached to the unit.

4.17.2 RS485 serial interface (optional)

All units can be equipped with a serial interface board for supervision or remote diagnostics functions by means of a computer.

The serial interface board plugs into a dedicated slot on the connection board.

Connection to the supervision or remote diagnostics serial line is executed in compliance with standard RS485 and is achieved by means of the serial interface boards.

Models from 3.2 to 13.2 with two scroll compressors and µchiller controller

When the serial interface board is inserted the Carel communications protocol is available.

A conversion gateway is required for the Modbus-jbus and BacNet protocols.

Models from 14.4 to 26.4 with 4 scroll compressors and pCO 2 controller

When the serial interface board is inserted the following communications protocols are available: Carel, Modbusjbus, BacNet. If a connection is to be made with networks that utilise the Lon-Talk protocol, a dedicated board must be installed.

In this case, a conversion gateway is not required.

Blue Box - 57

ELECTRICAL PANEL LAY OUT

Unit with 2 compressors - µchiller controller

ZETA 2002 - Models 3.2 - 8.2

REMOTE CONTROL CARD -

OPTIONAL

MICRO CHILLER CARD -

1 COMPRESSOR

POSITION OF CONNECTION

TO EARTH TERMINAL


2 COMPRESSOR

ZETA 2002 - Models 9.2 - 13.2

REMOTE CONTROL CARD -

OPTIONAL


1 COMPRESSOR

POSITION OF CONNECTION

TO EARTH TERMINAL


2 COMPRESSOR

KEY TO ELECTRICAL COMPONENT PART NUMBERS

A10 ON/OFF CONTROL CIRCUIT BOARD

A5 SPEED REGULATOR

A8 SPEED REGULATOR

FU1 COMPRESSOR 1 FUSES

FU2 COMPRESSOR 2 FUSES

FU21 FAN UNIT FUSES

FU21 FAN UNIT FUSES

FU40 HEATER FUSES

FU50 AUXILIARY TRANSFORMER FUSES

FU51 CONTROL CIRCUITS FUSE

FU52 CONTROLLER FUSE

FU56 PHASE SEQUENCE RELAY FUSES

KA1 POWER “ON” RELAY

KA2 FAN UNIT ALARMS RELAY

KA3 HP RELAY

KA5 PHASE SEQUENCE RELAY

KM1 COMPRESSOR 1 CONTACTOR

KM13 PUMP 1 CONTACTOR



KM21 FAN UNITS CONTACTOR

KM40 EVAPORATOR HEATER CONTACTOR

QM13 PUMP 1 MOTOR OVERLOAD CUT-OUT


QS1 MAIN POWER DISCONNECT SWITCH

TC1 CONTROL CIRCUITS TRANSFORMER

Blue Box - 58

ELECTRICAL PANEL LAY OUT

Unit with 4 compressors - pCO 2 controller

ZETA 2002 - Models 14.4 - 26.4

RGF EXPANSION

MODULE FOR LE UNIT

KEY TO ELECTRICAL COMPONENT PART NUMBERS

A2

A3

A5

A7

CONTROL BOARD

2-COMPRESSOR EXPANSION BOARD

SPEED REGULATOR

RGF EXPANSION MODULE, UNIT /LE

FU1

FU2

COMPRESSOR 1 FUSES

COMPRESSOR 2 FUSES

FU20 RGF FUSES

FU21 FAN UNIT FUSES

FU22 FUSES - FAN UNITS 2

FU23 FUSES - FAN UNITS 3

FU3

FU4

FUSES - COMPRESSOR 3

FUSES - COMPRESSOR 4

FU40 FUSES- HEATERS

FU50 FUSES - AUXILIARY TRANSFORMER

FU51 CONTROL CIRCUITS FUSE

FU52 CONTROLLER FUSE

FU56 PHASE SEQUENCE RELAY FUSES

KA1

KA2

KA5

KM1

POWER “ON” RELAY

FAN UNIT ALARMS RELAY

PHASE SEQUENCE RELAY

COMPRESSOR 1 CONTACTOR




KM21 FAN UNITS CONTACTOR

KM22 FAN UNIT 2 CONTACTOR

KM23 FAN UNIT 3 CONTACTOR

KM3

KM4



KM40 EVAPORATOR HEATER CONTACTOR



QS1 MAIN POWER DISCONNECT SWITCH

TC1 CONTROL CIRCUITS TRANSFORMER

Blue Box - 59

5. START-UP

5.1 PRELIMINARY CHECKS

- Check that the electrical connections have been made correctly, and that all terminals are well tightened.

- Check that the voltage on the RST terminals is 400 V ± 5% (or the unit’s rated value, in the event of units supplied to run on non-standard power supplies). If the mains voltage is subject to frequent fluctuations, consult our Engineering Department to discuss the necessary protection systems.

- Check that the display shows the gas pressure in the refrigerant circuit (4-compressor models only).

- Inspect the unit for refrigerant leaks using a leak detector if necessary.

- Check that the crankcase heaters are correctly supplied with power.

Significant leakage of R407C refrigerant in the gaseous state will alter the percentages of the remaining mixture with consequent fall-off of performance.

The heaters must be connected at least 12 hours before starting the unit; the heaters are automatically connected when the main disconnect switch is set to the ON position.

- Verify that heaters are working correctly: after the warm up period the crankcase must be warm to the touch and must have at least a temperature 10 - 15 °C higher than ambient temperature.

- Check that all hydraulic connections are correctly installed and all indications on unit labels are observed.

- Check that the hydraulic system has been vent to eliminate any air remaining; charge it gradually and open the vent devices on the upper part, provided at the care of the installer together with an expansion tank of a proper size.

Warning: before starting up the unit check that all the closing panels are in position and secured with the relative screws.

Blue Box - 60

Models 3.2 - 13.2, µ chiller control

6 UNIT WITH mCHILLER MICROPROCESSOR (models from 3.2 to 13.2)


“µchiller” is an electronic microprocessor system designed to control all the unit’s functions.

The terminal is equipped with five LEDs indicating the operating status of the machine (summer/winter), the compressor status (On/Off) and indication of the compressors/pump hour counter after the first 100 hours of operation. An internal beeper (which can be inhibited by means of a microswitch or a parameter) sounds to warn of machine operating anomalies.

6.1.1 Display

The display comprises three digits with automatic display of the decimal point. During normal operation the display shows the value of the evaporator inlet water temperature.

“µchiller” can be connected to a computer, by means of an optional electronic board, making available remote supervision and telediagnostic services for complete management, supervision and diagnostics of the systems from a remote location.

Figure 13

6.1.2 Machine status information

Machine status information is shown by five LEDs on the remote control display (figure 14).

Figure 14

6.1.3 Keypad

The keypad allows machine operating parameters to be programmed. The wall-mounted version features an extended number of keys to facilitate use. The function of each key is illustrated on the following pages.

Figure 15

Blue Box - Page 61


6.1.4 Control and display screens

Method of accessing the set-point and main machine control parameters.

Parameter scroll keys

Figure 16

Pressing the keys marked with an up or down arrow allows you to scroll through the parameters. The SEL key is pressed again to display the value of the selected parameter, with the facility to edit the value if required using the Up or Down keys. The PRG key is pressed to store changed values and to stop the procedure, while pressing the SEL key returns you to the parameter selection menu. If no keys are pressed, in an interval of 10 seconds, during parameter editing the display starts flashing. If no keys have been pressed within 60 seconds, after activating the programming procedure, the controller will return to the temperature display without saving any changes that have been made. This procedure is useful if it proves unnecessary to alter any parameters.

6.1.5 Muting the BUZZER

Press the MUTE key to silence the buzzer if it is currently sounding.

Figure 17

6.1.6 ALARMS reset

Pressing the Up or Down keys for more than 5 seconds cancels any alarms currently in the memory (manual reset), clear the associated message from the display and deactivate the alarm relay. In wall mounted models this function is obtained by pressing the CLEAR key for 5 seconds.

Figure 18

Blue Box - Page 62


6.1.7 Activation/deactivation of COOLING operation (summer mode)

Pressing the key for more than 5 seconds activates or deactivates the summer operating mode (refer also to parameter P6). It is not possible to switch directly from Winter mode to Summer mode without first deactivating

Winter mode. If the machine was previously running in Winter mode pressing this key will have no effect.

Figure 19

6.1.8 Activation/deactivation of HEATING mode (winter mode)

Pressing the key for more than 5 seconds activates or deactivates the winter operating mode. It is not possible to switch directly from Summer mode to Winter mode. If the machine was previously running in Summer mode pressing this key will have no effect - Summer mode must be deactivated before the change can be made.

Figure 20

6.1.9 Switching off the machine (stand by)

To switch off the machine deactivate both Summer and Winter modes.

Switch off the unit when working in cooling mode

(Summer).

Figure 21

Switch off the unit when working in heating mode

(Winter).

Figure 22

Blue Box - Page 63


6.1.10 Inlet water temperature control:

To edit the operating values (within the operating limits) hold down the SEL button for 5 seconds. When it flashes use the Up or Down arrow keys to enter the required inlet water temperature on the display. Confirm the value you have just entered by pressing the SEL button again (figure 23).

Parameter scroll keys

Figure 23

6.1.11 Defrosting (heat pump mode only)

During winter heat pump mode operation the finned coil of the air cooled condenser functions as an evaporator, cooling and dehumidifying ambient air.

During heat pump operation, the evaporation pressure is monitored to prevent it from falling below a preset value. The evaporation control is active only during heating mode operation.

Depending on the ambient air temperature and humidity conditions, condensate or frost will tend to form, consequently obstructing the free passage of air and causing thermal insulation. The frost that builds up on the coil obstructs the passage of air and reduces the available heat exchange surface area (and thus the thermal efficiency) and can damage the heat exchanger.

Defrosting is the procedure that eliminates the ice that has formed on the evaporator coil during heat pump mode operation of an air/water unit.

Defrosting is performed simultaneously for the entire unit.

All heat pump versions are equipped with a control that activates an automatic coil defrost cycle when necessary.

After starting however, the first defrost cycle will be started after a preset minimum operating time to allow the formation of sufficient thermal inertia to allow the cycle to be completed successfully.

Defrost cycle activation is based on the detection of a low suction pressure value due to insufficient heat exchange between the evaporator and the air due to the formation of a layer of ice, which exerts a thermal insulation effect. For a defrost cycle to be able to start a suction pressure of at least one of the currently operating compressors must remain below the pressure set for the defrost cycle trip signal for a preset time interval.

Before starting to defrost the coils, all the compressors are started, after which the unit reverses its operation from heat pump to chiller mode.

When the cycle is reversed the fans stop and the compressors force hot gas into the coil.

A pressure switch on the high pressure circuit maintains the discharge gas pressure below the defrost end value.

To maintain the pressure lower than the defrost end pressure the pressure switch activates the fans.

To reduce the air flow and obtain more efficient heating of the outer part of the coil, the pressure switch signal causes the fans to rotate in reverse.

When the defrost end temperature is reached, as measured by a thermostat with a probe located in the lower part of the coil, the pressure switch allows the discharge pressure to reach the defrost end pressure.

When the defrost end pressure has been reached, the controller reverses the unit from chiller mode to heat pump mode, thereby terminating the defrost procedure.

Even though in certain conditions the surface temperature of the coil and the condensation pressure fail to reach the defrost values within the 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 reverses the unit’s operating mode again.

If the defrost cycle is forcibly interrupted, with the timeout signal, a message is displayed on the controller, although no controller functions are activated.

The defrost timeout alarm is automatically cleared from the active alarms menus when a defrost cycle terminates

Blue Box - Page 64

Models 3.2 - 13.2, µ chiller control normally because the defrost end pressure has been reached. In any event, the alarms historical file will contain a record of all defrost cycles that were terminated forcibly due to a timeout intervention.

Consecutive defrost cycles must be at least 30 minutes apart. If the forced defrost signal persists, inform the

Service organisation.

If the unit fails to start: do not change internal electrical connections on penalty of immediate invalidation of the warranty.

Warning: The operating mode changeover should only be seasonal.

Frequent changeover from summer to winter operating mode and viceversa could cause damage to the compressors.

During idle periods do not disconnect the unit from the power supply (the compressor crankcase heaters must remain switched on). Disconnect the unit from the power supply only in the event of prolonged disuse (e.g.

seasonal shutdowns). For temporary shutdown of the unit refer to the guide lines given in the specific headings of this manual.

Electronic components of the microprocessor may be damaged at temperatures below - 20 °C.

Blue Box - Page 65


6.2 STARTING THE UNIT

The ZETA 2002 unit is equipped, as standard, with direct keypad control.

Optionally the unit can be equipped to operate via a remote permissive (e.g. a clock, etc.). The remote interlock must be connected across terminals 1-2. Enabling the unit to start or stop is only possible via the keypad.

6.2.1 COOLING:

- Press the button as shown in figure 24.

Figure 24

6.2.2 HEATING (operation in heat pump mode):

- Press the button as shown in figure 25.

Figure 25

6.3 STOPPING THE UNIT

6.3.1 Temporary stop

The unit is stopped by pressing the cooling key or, in the case of a heat pump unit operating in winter mode, by pressing the heating key.

Shutdown of unit operating in summer cooling mode

Figure 26

Shutdown of unit operating in winter heating mode

Figure 27

Warning: do not use the machine main power switch to stop the unit.

The crankcase heaters will be disconnected, resulting in serious risk to the compressors when the unit is started again.

Blue Box - Page 66


6.3.2 Seasonal stop:

- Disconnect the power supply

- Drain the system circuit (unless it contains a water/glycol solution)

- When the unit is to be restarted repeat the initial start-up procedure

Warning: 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 status.

Note also that if power is disconnected from the unit the crankcase heaters will be switched off with the resulting risk of compressor damage at the time of restarting.

6.4 EMERGENCY STOP

Emergency stops are obtained by turning the red colour main disconnect switch on the electrical panel to position

0.

7. TROUBLESHOOTING

The following pages contain a list of the most common causes that can result in the shutdown or anomalous operation of the chiller. Faults are arranged in accordance with easily identifiable symptoms.

In relation to possible corrective action pay maximum attention to the operations you intend to perform as overconfidence coupled with insufficient attention due to lack of expertise can lead to serious accidents.

We therefore recommend that Blue Box or other skilled HVAC engineers are contacted to identify and correct the problem.

Blue Box - Page 67


SYMPTOM

A)

No compressor running. Fans stopped (display off)

OPERATION

COOLING HEATING

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

PROBABLE CAUSE POSSIBLE CORRECTIVE ACTION

No mains power Check presence of mains power

Main power switch Off

(position "O")

Turn mains power selector to position "I"

No power to control circuits Check condition of fuses FU50,

FU51, FU52.

Check operation of the transformer

Incorrect phase sequence

(relay KA5 with only green

LED illuminated)

Invert two of the phase wires of the power feed line; when the unit is powered up again both the green LED and the yellow

LED should light

Relay KA5 with green and yellow LEDs off

Check fuses FU56;

If fuses are OK replace phase sequence relay

B)

No compressor running. Fans stopped (display on no alarm messages)

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

Unit in stand-by mode

No consent from service thermostat

Start unit (see relative section of the manual)

System at set-point temperature, no heating/cooling demand; check settings and operation.

No external consent Check operation of circulating pumps, flow switches, bleed air from the system; check that contacts 1 and 2 are closed, check other external consents.

Compressor motor burnt out or compressor seized

Replace compressor

Anti-recycle timer running Wait for 5 minutes until the timer generates a consent

Blue Box - Page 68


SYMPTOM

C)

No compressor running. Fans stopped

(display On with alarm "FL")

OPERATION

COOLING HEATING

⊗

⊗

⊗

⊗

PROBABLE CAUSE

No water flow at evaporator

Faulty flow switch

D)


(display On with alarm

“F1” or “F2”)

E)


(display On with alarm

"A1")

⊗

⊗

⊗

⊗

⊗

⊗

Fan thermal protection intervention

No consent of defrost thermostat due to insufficient water flow rate

No consent of defrost thermostat due to insufficient glycol concentration

POSSIBLE CORRECTIVE ACTION

Check hydraulic system

Check contact of flow switch and replace if necessary

Check insulation between windings and between windings and earth; replace fan if necessary.

Check hydraulic circuit and wait until the water temperature exceeds the value necessary for the unit to restart

The programmed set-point is too low for the percentage of glycol in the circuit. Increase the glycol percentage and reduce the defrost set-point.

F)


(display On with alarm "E1")

⊗

⊗

⊗

⊗

Connections to evaporator inlet temperature sensor interrupted

Evaporator inlet temperature sensor faulty

Restore correct connection of temperature sensor

Replace temperature sensor

Blue Box - Page 69


SYMPTOM

G)

No compressor running. Fans running

(display On with alarm "E3" or "E5")

OPERATION

COOLING HEATING

⊗

⊗

⊗

⊗

⊗ ⊗

PROBABLE CAUSE

Resistance RK3 or RK4 faulty or disconnected

Connections to pressure sensor interrupted (HP version only or if condensation pressure control with fan speed regulator is fitted)

Faulty pressure sensor (only on HP version or if condensation pressure control with fan speed regulator is fitted)

H)

Unit runs with insufficient capacity

(Display On without alarms)

⊗

⊗

⊗

⊗

Insufficient refrigerant charge

Presence of moisture in refrigerant circuit

⊗

⊗

⊗

⊗

⊗

One compressor fails to start, power circuit open and compressor contactor energised

A compressor fails to start, fuses are OK and compressor contactor is deenergised

4-way reversing valve seized or coil faulty


Check resistance and replace if necessary

Restore correct connections to pressure sensor ("E3" refers to compressor 1, "E5" refers to compressor 2)

Replace pressure sensor ("E3" refers to compressor 1, "E5" refers to compressor 2)

Check refrigerant circuits with leak detector, repair leak and recharge circuit

Replace refrigerant filter and, if necessary, dehydrate and recharge circuit

Find and eliminate the cause of the protection intervention; change the fuses.

If the fuses blow immediately, replace the compressor.

Check voltage across compressor contactor coil and continuity of coil; if necessary, replace coil

Check power supply and coils of valves and replace valves if necessary

Blue Box - Page 70


SYMPTOM

I)

Compressor 1 and/or 2 not working (display

On with alarm

“H1” and/or “H2”)

OPERATION

COOLING HEATING

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗


Circuit overcharged Check refrigerant charge and remove if necessary;

High pressure switch faulty Check and replace if necessary

Coil filters clogged; air flow too low

Presence of incondensable gas in the refrigerant circuit

Clean filters with compressed air

Empty circuit, apply vacuum, and recharge

Fans faulty

Faulty circulating pump

Defrost-end pressure switch not working

Fan motor electrical connections incorrect

Fan contactors not energised

Check and replace fans

Check and replace

Check and replace

Check that connections are as indicated on electrical drawing

Check voltage across coil of contactor KM21 and electrical continuity of coil circuit

Blue Box - Page 71


SYMPTOM

L)


On with alarm “L1” and/or “L2”)

OPERATION

COOLING HEATING

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗


Refrigerant circuit completely empty

Check refrigerant circuit with leak detector after pressurising to approximately 4 bar. Repair leak, apply vacuum, charge circuit.

Low pressure switch faulty Check and replace if necessary

Coil filter clogged; air flow too low

Clean filter with compressed air

Refrigerant filter clogged Check and replace if necessary

Fans faulty Check and replace if necessary

Faulty water circulating pump

Defrost pressure switch has incorrect setting

Liquid refrigerant valve not completely open (if present)

Check and replace if necessary

Check and correct setting

Check and open fully

Thermostatic expansion valve not operating correctly

Fan motor electrical connections incorrect

Check, clean, or replace if necessary

Check that connections are as indicated on electrical schematic

Fan contactors not energised

Check voltage across coil of contactor KM21 and electrical continuity of coil circuit

Blue Box - Page 72


SYMPTOM

M)


On with alarm

“C1” and/or “C2”)

OPERATION

COOLING HEATING

⊗

⊗

⊗

⊗

⊗

N)

Ice on liquid refrigerant pipe

⊗

⊗

O)

Compressor 1 and/or 2 running. Ice on coil

(display On with warning message “r1”)

P)

Compressors run constantly

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

PROBABLE CAUSE


4-way valve locked

Lack of oil

Liquid refrigerant filter clogged

Valve on liquid refrigerant line (if present) not completely open

Replace filter

Open valve fully


Operating thermostat incorrectly set or faulty

Lack of refrigerant gas charge

Excess thermal load


Find leak with leak detector, repair, and recharge circuit

Replace valve

Check quantity of oil in circuit and replenish as necessary.

Check that the circuit has all the necessary measures to ensure oil return to the compressor

Find leak with leak detector, repair, and recharge circuit

Check setting; replace thermostat if necessary

Check and recharge if necessary

Reduce thermal load

Blue Box - Page 73


SYMPTOM

Q)

Anomalous noise from system

OPERATION

COOLING HEATING

⊗ ⊗

PROBABLE CAUSE

Compressor noisy

⊗ ⊗ Thermostatic valve noisy

⊗

⊗

⊗

⊗

⊗

⊗

Vibrating pipes

Casing panels vibrate

Worn fan bearings


Contact service organisation for check and replacement if necessary

Contact service organisation for check and replenish refrigerant charge

Contact service organisation to secure piping

Check that panels are properly fastened; contact service organisation if necessary

Check; replace fan if necessary

If the display presents alarms other than those described previously, contact the Service organisation.

Blue Box - Page 74

Models 14.4 - 26.4, pCO 2 control

8 UNIT WITH pCO

2

MICROPROCESSOR (models from 14.4 to 26.4)


The pCO 2 electronic microprocessor controller with the DBBB0*P20Z program is designed to manage chiller and heat pump units, with control of 4 compressors.

The program configuration manages the total control of the air-cooled unit with plate exchangers including compressor start/stop times, safety devices and other auxiliary functions such as condensation control in cooling mode, free-cooling, heat recovery and other functions described later in this manual.

The necessary hardware is optimised to obtain the maximum advantage from the available inputs and outputs; the connection between various circuit boards and the user interface terminal is achieved via the pLANE using the dedicated RS485 serial connector for network connections.

Each unit can also be connected to remote supervision and/or telediagnostics systems by means of an RS485 serial line.

Detailed information on the operation of the above systems is provided in the specific controller manual supplied with the unit.

8.1.1 Display

The back-lit LCD display comprises 4 lines and 20 columns.

Figure 28

8.1.2 Keypad

In addition to the LCD display, the user interface is equipped with the following function keys:

“Menu” key: press this key from any menu to return to the opening 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 and outputs together with the values read on the analogue inputs and the value of the analogue outputs

Blue Box - Page 75


“Clock” key: press this key to open the clock menus.

“Set” key: this key opens the menus in which the various operating set-points can be edited.

“Prog” key: this key opens the service menus.

"? info" key: pressing this key opens a menu in which the address of the component connected to the terminal can be changed.

"Summer" key (blue) and "winter" key (red): in the case of chiller + heat-pump units, press these keys to select the required operating mode.

“ON/OFF” 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 allow you to navigate through the menus; when an editable field is selected, the arrow keys serve to change the current value.

“Enter” key: pressing this key allows you to access fields containing editable parameters and also to confirm any changes you make to such parameters.

Electronic components could be damaged by air temperature below -20

°C.

Blue Box - Page 76


8.2 OPERATING DESCRIPTION

8.2.1 Introduction

The microprocessor control regulates the water temperature of the evaporator maintaining it at the set-point value acting on the compressors management.

As well as the compressors the controller manages the operation of other components of the chiller such as the pumps (ST version) and fans, with relative operating times and alarms, and "ancillary" functions such as condensation control, etc., as described below.

Almost all the parameters referred to below (set-points, differentials, calibration, delays...) can be programmed by means of the various menus. Refer to the specific manual for the pCO 2 controller.

8.2.2 Unit in stand-by mode

The unit is in stand-by mode when it is correctly supplied with power but not actually enabled to operate.

In this condition the display shows the values of the various machine parameters, but the operation of the compressor is not inhibited.

Power-on is obtained by pressing the “ON-OFF” button of the microprocessor control or via an external interlock.

8.2.3 Enabling the unit

Start-up of the unit from stand-by mode can be achieved after closing the external enabling contact, by pressing the “ON/OFF” button, or by means of a signal on the serial line.

Activation of the controller outputs that manage the various sections of the chiller is executed in strict compliance with the operating times. If the “ON” button is pressed before the external interlocks are closed, the display indicates which of the external interlocks is not yet enabled.

Operation of the pump has priority to the compressors, which can start only after the evaporator and condenser pumps are running.

8.2.4 Pump management (ST units only)

If system pump control is included switching on the unit will automatically enable the pump.

If there are two pumps (run and stand-by) they will be activated alternately when the programmed operating time limit for each pump has elapsed.

When the pumps are switched over both pumps will run in tandem, for a few seconds, to ensure a constant flow of water in the system circuit.

When the unit is switched from active status to stand-by, if performed by opening an external permissive, the currently active pump of the ST unit will be stopped with a delay interval, after the disconnection of the last compressor in operation, making it possible to exploit the thermal inertia of the system.

8.2.5 Compressor start-up

The controller allows the compressors to be started if the flow switch input is closed within the compressor startup delay time interval. If the flow switch input opens, after the compressor has 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 stopping of the compressors and capacity step control is managed by the controller in accordance with the building cooling demands.

8.2.6 Chiller mode operation

In chiller operation, the controller lowers the water temperature value, maintaining it as close as possible to the programmed set-point.

Blue Box - Page 77


In the standard version, in which the control acts on the evaporator entering water, the management of compressor operation and capacity steps is linked to the difference between the entering water temperature and the programmed set-point.

8.2.7 Heat pump mode operation

In heat pump operation, the controller increases the water temperature value, maintaining it as close as possible to the programmed set-point.

Management of compressor operation is performed in the same way as already illustrated for chiller mode operation.

8.2.8

Evaporator low temperature chilled water protection

If the evaporator leaving water temperature is lower than the limit value programmed in the low temperature chilled water protection set-point, the controller will stop all the compressors and activate the low temperature water alarm.

This alarm must be reset manually and the compressor restarted only when the evaporator leaving water temperature is equal to or higher than the alarm trip value, increased by the low temperature water differential.

The low temperature water alarm can only appear when the unit is switched on (in stand-by conditions the freeze alarm is not operational).

8.2.9 Evaporator anti-freeze protection electric heater (optional)

In conditions that lead to tripping the freeze alarm, the controller energises the heater.

The heater remains powered for the entire time that the conditions for the freeze alarm continue.

Unlike the low water temperature alarm, which is enabled only when the unit is powered on, the anti-freeze heater can be energised when the machine is on stand-by.

8.2.10 Compressor operation

When the unit is running correctly and no general alarms are present, the microprocessor controller starts the compressors in accordance with the water temperature reading.

Compressor starts are staggered in accordance with preset delay intervals, thus avoiding excess input current surges.

Before starting a compressor, the microprocessor checks the value of the delivery pressure by means of the relevant transducer, the status of the high pressure switch and the compressor motor windings temperature by checking the thermal protection.

When the compressor has been started, tripping of any of the safety devices will cause the compressor to stop immediately and an alarm will be displayed.

While the compressor is running, discharge pressure and suction pressure are monitored constantly by means of the relevant sensors.

On unit start-up the first compressor is started with a delay, set on the microprocessor controller, after the start of the hydraulic system circulating pump.

Once started, each compressor must run for a minimum operating period, unless a critical alarm should trip in the meantime.

The critical alarms which can stop the compressor during the minimum operating time are the high pressure alarm and the compressor thermal cut-out alarm. Once stopped each compressor can 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 compressor, is executed with minimum delay intervals equal to the capacity step activation time.

Stopping compressors is also performed with a minimum programmed delay interval.

Blue Box - Page 78


8.2.11 Compressor management

Start-up of the compressors is automatic when the reference water temperature changes with respect to the programmed set-point.

Normally the reference water temperature is the value detected at the inlet to the chiller unit.

Balancing of duty hours over all the compressors in the unit is performed by selecting the rotation of starts.

With the rotation function of starts active, the first compressor to start is the first one that previously stopped. The first compressor to start will be the one with the least operating hours.

8.2.12 High and low pressure alarms

Discharge pressure (high pressure) and suction pressure (low pressure) are managed by the microprocessor controller through the relevant sensors.

When a compressor is running, the controller checks that:

- Discharge pressure is always lower than the safety value set for cooling or heating mode operation. If the values are exceeded, the controller immediately stops the compressor and displays a high pressure alarm. The high pressure alarm can be reset manually on the controller only when the pressure detected by the discharge pressure sensor is lower than the value that caused the alarm to trip, less the differential value.

- The suction pressure is always higher than the safety value set for operation in cooling or heating mode. If the value read by the suction pressure sensor is lower than the limits set for the relative operating conditions, the controller will stop the compressor and generate a low pressure alarm. The low pressure alarm is not instantaneous, but operates after a preset delay interval, both in the starting phase and during the normal running of the machine. The low pressure alarm can be reset automatically or manually, depending on the relative parameter setting. In all cases the low pressure alarm can only be reset when the pressure detected by the suction sensor is higher than the value that caused the alarm to trip, plus the differential value. It is possible to program the number of permissible consecutive compressor starts before the unit shuts down in safety status.

8.2.13 Low ambient temperature kit (option - condensing control with fan speed regulator)

As the ambient air temperature decreases the necessary condensing pressure for correct operation of the chiller cycle is maintained, within the machine operating range, by adjusting the cooling air flow through the condenser.

Condensing pressure control is only active when the machine is operating in chiller mode.

When the unit is operating in heat pump mode this function is inhibited and the fans are forced to their maximum speed.

The controller checks the condensing pressure and adjusts fan speed on the basis of the circuit with the highest pressure reading. The speed regulator adjusts fan speed with a phase control system that minimises problems related to electromagnetic compatibility.

Speed control is available over a 40-100% range. At the time of start-up the fans always run at 40% nominal speed.

8.2.14 Changeover from chiller to heat pump and vice versa

The changeover from chiller to heat pump and back can be performed at any time, either by means of an external signal on a digital input, from the keypad, or via the serial line. The operating mode changeover must be only seasonal and only with the unit off.

After a mode changeover, the controller re-starts the unit in the new mode with a factory set minimum delay time.

The unit operates with temperature control on the inlet to which has been inactive for the longest time. the unit

(or return from the system).

8.2.15 Defrosting (heat pump units only)

Blue Box - Page 79


During winter heat pump mode operation the finned coil of the air cooled condenser functions as an evaporator, cooling and dehumidifying ambient air.

During heat pump operation, the evaporation pressure is monitored to prevent it from falling below a preset value. The evaporation control is active only during heating mode operation.

Depending on the ambient air temperature and humidity conditions, condensate or frost will tend to form, consequently obstructing the free passage of air and causing thermal insulation. The frost that builds up on the coil obstructs the passage of air and reduces the available heat exchange surface area (and thus the thermal efficiency) and can damage the heat exchanger.

Defrosting is the procedure that eliminates the ice that has formed on the evaporator coil during heat pump mode operation of an air/water unit.

Defrosting is performed simultaneously for the entire unit.

All heat pump versions are equipped with a control that activates an automatic coil defrost cycle when necessary.

After starting however, the first defrost cycle will be started after a preset minimum operating time to allow the formation of sufficient thermal inertia to allow the cycle to be completed successfully.

Defrost cycle activation is based on the detection of a low suction pressure value due to insufficient heat exchange between the evaporator and the air due to the formation of a layer of ice, which exerts a thermal insulation effect. For a defrost cycle to be able to start a suction pressure of at least one of the currently operating compressors must remain below the pressure set for the defrost cycle trip signal for a preset time interval.

Before starting to defrost the coils, all the compressors are started, after which the unit reverses its operation from heat pump to chiller mode.

When the cycle is reversed the fans stop and the compressors force hot gas into the coil.

A pressure switch on the high pressure circuit maintains the discharge gas pressure below the defrost end value.

To maintain the pressure lower than the defrost end pressure the pressure switch activates the fans.

To reduce the air flow and obtain more efficient heating of the outer part of the coil, the pressure switch signal causes the fans to rotate in reverse.

When the defrost end temperature is reached, as measured by a thermostat with a probe located in the lower part of the coil, the pressure switch allows the discharge pressure to reach the defrost end pressure.

When the defrost end pressure has been reached, the controller reverses the unit from chiller mode to heat pump mode, thereby terminating the defrost procedure.

Even though in certain conditions the surface temperature of the coil and the condensation pressure fail to reach the defrost values within the 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 reverses the unit’s operating mode again.

If the defrost cycle is forcibly interrupted, with the timeout signal, a message is displayed on the controller, although no controller functions are activated.

The defrost timeout alarm is automatically cleared from the active alarms menus when a defrost cycle terminates normally because the defrost end pressure has been reached. In any event, the alarms historical file will contain a record of all defrost cycles that were terminated forcibly due to a timeout intervention.

Consecutive defrost cycles must be at least 30 minutes apart. If the forced defrost signal persists, inform the

Service organisation.

8.2.16 Total heat recovery (option)

Heat recovery is the function where all the energy that would normally be rejected to the air cooled condenser is recovered at a refrigerant to water condenser installed in series with the air-cooled condenser.

The heat recovery process is managed by the microprocessor controller.

During energy recovery the fans are stopped and the condensing coil is by-passed via solenoid valves connected downstream of the thermostat valve. The machine is equipped with a liquid receiver.

Heat recovery can only occur when the water temperature at the recovery exchanger inlet is lower than the recovery set-point. Heat recovery is terminated when the temperature increases by the recovery differential value.

It is mandatory to use a condensing pressure control valve (one for each hydraulic circuit) or three-way valve, fitted by the installer, to avoid condensation values that are incompatible with operation of the machine.

8.2.17 Dual set-point (option)

Blue Box - Page 80


Operation with a dual set-point is possible only in chiller mode.

With double thermostatic valves and solenoid valves that are automatically switched according to the required expansion temperature. Two set-point values can be programmed on the microprocessor controller via the keypad or a digital input. Switching of the thermostatic valves is always automatic, in accordance with the water temperature.

The valves are sized on the basis of the temperature values specified at the time of the order. The machine operating limits shown in the catalogue are not affected. If the hydraulic circuit contains glycol in sufficient quantities to eliminate the risk of freezing, the lower limit is extended to a minimum of -5 °C leaving water temperature.

8.2.18 Operation leaving water temperature control (option)

With leaving chilled water temperature control the reference sensor must be installed on the evaporator outlet or, if there is more than one evaporator, on the common outlet pipeline downstream from the relative manifold.

The unit’s capacity steps are activated / deactivated with delay intervals in relation to a dead zone. When the leaving water temperature is higher than the programmed set-point compressors start is enabled.

Blue Box - Page 81


8.3 STARTING THE UNIT

For the start-up procedure refer also to the microprocessor controller manual.

- Close the external enabling contacts

- Press the "ON" button on the microprocessor controller

- If all the controls are 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 signals of the microprocessor, the flow switches, and the water pumps continue to be present.

If the unit fails to start: do not change internal electrical connections on penalty of immediate invalidation of the warranty.

Important: on heat pump versions the operating cycle must be reversed at the start and end of the season. Frequent switching from summer to winter mode, and vice versa, should be avoided at all costs because it can lead to malfunctions and subsequent breakdown of the compressors.

During idle periods do not disconnect the unit from the power supply (the compressor crankcase heaters must remain switched on in these intervals).

Disconnect the unit from the power supply only in the event of prolonged disuse (e.g. seasonal shutdowns). For temporary shutdown of the unit refer to the guide lines given in paragraph 8.4.

8.4 STOPPING THE UNIT

8.4.1 Temporary stop:

- To stop the unit press the "OFF" button on the front panel.

8.4.2 Seasonal stop:

- Disconnect the power supply

- Drain the system circuit (unless it contains a water/glycol solution)

- When the unit is to be restarted repeat the initial start-up procedure

Figure 29

Warning: 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 status.

Note also that if power is disconnected from the unit, the crankcase heaters will be switched off with the resulting risk of compressor damage at the time of restarting.

Blue Box - Page 82


8.5 EMERGENCY STOP

Emergency stops are obtained by turning the red colour main disconnect switch on the electrical panel to position 0.

9. TROUBLESHOOTING

The following pages contain a list of the most common causes that can result in the shutdown or anomalous operation of the chiller. Faults are arranged in 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 attention due to lack of expertise can lead to serious accidents.

We therefore recommend that Blue Box or other skilled HVAC engineers are contacted to identify and correct the problem.

Blue Box - Page 83


SYMPTOM

A)

No compressor running. Fans stopped (display Off)

OPERATION

COOLING HEATING

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

PROBABLE CAUSE

No mains power


Check presence of mains power

Main power switch Off

(position "O")

Turn main power selector to position "I"

No power to control circuits Check fuses FU50, FU51, FU52.

Check operation of transformer


(relay KA5 with only green

LED lit)

Invert two of the 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 phase sequence relay

B)

No compressor running. Display On:

”OFF from external consent”

C)


”OFF from supervision system”

D)


”OFF”

⊗

⊗

⊗

⊗

⊗

⊗

No external consent

No consent from supervision system

No consent from “on/off” key of user interface

Check presence of external consent; if not present, bridge terminals 1 and 2

Activate operation from supervision system

Press “on/off” key

Blue Box - Page 84


SYMPTOM

E)

No compressor running. Display On: unit ON with alarm

“High Pressure

Compressor 1, 2, 3, 4”

OPERATION

COOLING HEATING

⊗

⊗

⊗

⊗

⊗


220V fuses burnt-out

(FU51)

Change fuses. If fuses burn-out again, contact assistance

Fans contactor not energised

Check voltage across the contactor coil and coil continuity

Fan fuses burnt-out (FU21) Check cause of burn-out and change fuses.

Fan motor faulty Check and replace if necessary

F)


“Fans protection”

G)


“Thermal protections

Compressor 1, 2, 3, 4”

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

Fan thermal protection intervention

Fan motor faulty

Faulty fan alarm relay

Drop in power feeding voltage

Check insulation between windings and from windings to ground


Check and replace relay

Check voltage stability and fit appropriate protection if necessary

Setting of thermal protections

Contact assistance

Circuits partially discharged Call service to replenish charge

Blue Box - Page 85


SYMPTOM

H)


“Low Pressure compressor 1, 2, 3, 4”

OPERATION

COOLING HEATING

⊗

⊗

⊗

PROBABLE CAUSE

Insufficient percentage of glycol in hydraulic circuit

⊗ Both circuits have insufficient refrigerant charge

⊗ Fans contactor not energised

⊗ Fan motor faulty

Insufficient water flow to evaporator

⊗ Incorrect setting of defrost set-point

I)


“Exceeded Threshold

Low Temperature of leaving User Water”

J)



Low Temperature User

Water Reference”

⊗

⊗

⊗

⊗

⊗

Insufficient water flow to evaporator

Faulty controller

Excessive thermal load


Restore correct glycol percentage

Check voltage across the contactor coil and coil continuity


Check hydraulic circuit

Check and correct setting if necessary

Increase water flow to evaporator and check temperature rise

Find possible leaks in circuit, repair, and recharge

Contact service organisation

Defrost sensor short circuit Contact service organisation

Reduce thermal load

Blue Box - Page 86


K)

SYMPTOM



High Temperature of entering User Water

L)


“No power to

Control circuits”

M)

No compressor running.

Display On: unit

OFF with alarm

“Flow Switch Alarm”

N)

No compressor running. Display On: unit OFF with alarm

”Incorrect Phase

Sequence” and phase sequence relay with green LED On and orange LED Off

O)


”Incorrect Phase

Sequence” and phase sequence relay with green and orange LEDs

On

OPERATION

COOLING HEATING

⊗

⊗



Refrigerant circuits partially discharged

Wait until entering water temperature is below the alarm set point. Start hydraulic circuit of evaporator and unit. If not sufficient contact assistance.

Call assistance

⊗

⊗

⊗

⊗

Power supply voltage not stable

Fuses FU51 burnt-out

Check power supply voltage; if not correct contact the electricity company

Check cause of fuse burn-out and replace fuses.

⊗

⊗

⊗

⊗

No water flow to evaporator

Flow switch faulty

Check hydraulic circuit

Check flow switch contact and replace if necessary

⊗

⊗

⊗

⊗


Faulty relay

Invert two of the phase wires of the power supply line

Check to ensure that relay closes contact

Blue Box - Page 87


SYMPTOM

P)


”Incorrect Phase

Sequence” and phase sequence relay with green and orange LEDs Off

Q)

No compressor running. Display On: unit ON without alarm

OPERATION

COOLING HEATING

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

R)

One or more compressors switched off. Display On with alarm “High Pressure

Compressor”

⊗

⊗

⊗

⊗

Fuses FU56 burnt-out

One of the three phases is not present

PROBABLE CAUSE

No consent from digital input to compressors

⊗ Unit at temperature

⊗ Compressor fuses burntout

⊗ Controller faulty

Excess refrigerant charge

Check fuse FU56 and replace if necessary

Check connection of each phase

Check consent to compressors and close relative contacts

Normal operation

Check continuity of fuses; if burnt-out call service

Call service


Check refrigerant charge and call service organisation

⊗

⊗

⊗ Refrigerant circuit contains non-condensable gas

⊗ High pressure switch incorrectly set or faulty

Condenser coil or coil filters

(if present) clogged

Empty circuit, apply vacuum, and recharge

Check pressure switch setting

Clean coil and filters (if present) with compressed air

Blue Box - Page 88


SYMPTOM

S)

One or more compressors switched off. Display On with alarm “Low Pressure

Compressors”

OPERATION

COOLING HEATING

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗


Insufficient refrigerant charge due to leak in circuit

Call service organisation

Thermostatic valve faulty Call service organisation

Solenoid valve of liquid refrigerant line faulty (if present)


Dehydrating filter clogged Call service organisation

Evaporator coil or coil filters

(if present) clogged

Clean coil and filters (if present) with compressed air

T)

One or more compressors switched off. Display On with alarm “Compressor

Thermal Protections”

U)

One or more compressors Off.

Display On without alarms

V)

All compressors running. Display On with alarm

“Compressor

Maintenance”

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

Problems at the compressor Call service organisation

Unit capacity step active

Fuses burnt-out

Faulty controller

No external consent to compressor

Compressors specified by alarm require maintenance

Normal operation



Check compressor external consent

Call service for scheduled maintenance

Blue Box - Page 89


SYMPTOM

W)

All compressors running. Display On with alarm “Unit

Maintenance”

X)

All compressors running without stopping. Display

On without alarm ⊗

⊗

⊗

OPERATION

COOLING HEATING

⊗ ⊗


Unit maintenance required Call service for scheduled maintenance

⊗ ⊗

⊗

⊗

⊗

Y)

Anomalous noise from system

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗

⊗


Refrigerant circuits partially discharged

Liquid refrigerant filter clogged

Controller not working

4-way reversing valve not energised



Clean or replace


Check power supply and solenoid valve coils and replace if necessary

Compressor noisy

Thermostatic valve noisy

Vibrating pipes

Casing panels vibrate

Worn fan bearings

Contact service organisation for check and replacement if necessary

Contact service to check and add refrigerant

Contact service organisation to secure pipes

Check that panels are properly fastened; contact service organisation if necessary

Check; replace fan if necessary

If the display presents alarms other than those described above, contact the service organisation.

Blue Box - Page 90

10 CHECKS DURING OPERATION


- Check that the water temperature at the evaporator inlet is close to the set-point value of the service thermostat.

- For units equipped with pump units, if the pump runs noisily, close the relative delivery cock until the pump starts running smoothly again. This situation can occur when system pressure drops deviate significantly from the pump available pressure.

10.1.1 Checking the refrigerant charge

- After a few hours of unit operation check that the sight glass moisture indicator has a green coloured core. if the core is yellow, moisture is present in the circuit. In such a situation the circuit must be dehydrated by a qualified technician.

- Check the sight glass for air bubbles. A constant passage of bubbles through the sight glass could indicate that the refrigerant must be replenished. Occasional bubbles are considered normal.

- Check that refrigerant liquid superheating is between 5 and 7 °C; to do this:

1) measure the temperature using a contact thermometer placed on the compressor suction pipeline;

2) read the temperature, equivalent to the pressure read on the pressure gauge connected to the compressor suction side (saturation temperature corresponding to suction pressure); for units charged with R407C refrigerant, refer to the D.P. (Dew Point) pressure gauge scale.

The difference between the temperatures measured in this manner is equivalent to the superheating value.

- Check that refrigerant subcooling is between 5 and 7 °C; to do this:

1) measure the temperature using a contact thermometer placed on the compressor discharge pipeline;

2) read the temperature, equivalent to the pressure read on the pressure gauge connected to the liquid connection at the condenser outlet (saturation temperature corresponding to condenser delivery pressure); for units charged with R407C refrigerant, refer to the B.P. (Bubble Point) pressure gauge scale.

The difference between the temperature values measured in this manner is equivalent to the subcooling value.

Blue Box - 91

11. CALIBRATION OF CONTROL EQUIPMENT


All the control equipment is factory calibrated before the machine is shipped. Control equipment and safety devices should nonetheless be checked after a reasonable period of operation. Calibration values are given in

Tables 3 and 4.

All service operations on the control equipment must be carried out by

QUALIFIED PERSONNEL ONLY; incorrect calibration values can cause serious damage to the unit and personal injury.

TABLE 3 - CALIBRATION OF CONTROL EQUIPMENT

CAPACITY STEPS

CONTROL ELEMENT

Service calibration (summer)

Service calibration (winter)

°C

°C

SET POINT

10

42

2

DIFFERENTIAL

2

2

SET POINT

9

43

4

DIFFERENTIAL

3

3

TABLE 4 - CALIBRATION OF SAFETY DEVICES

CONTROL ELEMENT

No-frost setting

Maximum pressure switch setting

Minimum pressure switch setting

Evaporator heater setting

Defrost start setting

Defrost end setting

Defrost end thermostat setting

Defrost pressure switch setting

°C bar bar

°C bar bar

°C bar

ACTIVATION

SET-POINT

3

27

2.5 / 0.7 *

3

2

18

5

16

DIFFERENTIAL

--

--

1

6

6

7

--

2

RESET manual manual manual (from controller) automatic automatic automatic automatic automatic

* Chiller / heat pump

Blue Box - 92

12. MAINTENANCE AND PERIODIC CHECKS

12. 1 WARNINGS

All operations described in this chapter MUST BE PERFORMED

EXCLUSIVELY BY QUALIFIED PERSONNEL.

Make sure that the unit has been disconnected from the power supply before carrying out any work or accessing internal parts.

The compressor head and discharge pipeline can reach high temperatures.

Always exert caution when working in the vicinity of the compressor.

Adopt the maximum caution when working in the vicinity of the finned coils because of the sharp edges of the aluminium fins.

After performing maintenance work always refit the outer panels and secure them with the screws.


Carry out the following periodic checks to ensure the unit is operating correctly:

CHECK

Check that safety and control devices work correctly as previously described

Check that all the terminals within the electric panel and compressor are tight The sliding terminals of the contactors should be periodically cleaned: if any damage is found, replace the contactors

Check the sight glass to verify the refrigerant charge.

Check that there is no oil leakage from the compressor

Check that there is no water leakage in the hydraulic system

If the unit is to be stopped for a long period the hydraulic circuit, including all pipes and heat exchangers, should be drained. This is compulsory if the ambient temperature is expected to fall below the freezing point of the liquid employed.

Check process water levels

Check that the flow switch is operating correctly.

Check that the crankcase heater is operating correctly and there is a power supply.

Clean metallic filters on water piping

Clean the finned coil or the filter coils, if present, by means of compressed air, which should be directed in the opposite direction to the normal direction of air flow. If the coil is completely clogged clean with a jet of water.

Execute a defrost test (heat pump units only)

Check the condition, anchorage, and balancing of fans

Check the colour of the sight glass core (green = no moisture, yellow = moisture present): if it is yellow change the refrigerant filter

Check that the noise level has not increased.

PERIOD monthly monthly monthly monthly monthly seasonal operation monthly monthly monthly monthly monthly monthly every 4 months every 4 months every 4 months

Blue Box - 93

12.3 REPAIRING THE REFRIGERANT CIRCUIT

If repairs have been made to the refrigerant circuit, perform the following steps:

- leak test;

- vacuum and dehydration of refrigerant circuit;

- refrigerant charge.

If the circuit is to be emptied, use the appropriate equipment to collect the refrigerant.

12.3.1 Leak test

Charge the refrigerant circuit to a pressure of 15 bar with dry nitrogen gas by means of a cylinder fitted with a pressure reducer. Check the circuit for leaks with a leak detector. The formation of bubbles or foam indicates the presence of leaks.

If leaks are found during the test, empty the refrigerant circuit and then repair the point of leakage by welding with appropriate alloys.

Do not use oxygen instead of nitrogen: explosion hazard.

12.3.2 High vacuum and dehydration 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, a single vacuum cycle is normally sufficient to reach an absolute pressure of 0.1 mbar.

If this type of pump is not available, or in the event that the circuit has been left open for a long period of time, you are strongly advised to use the triple evacuation method. This procedure is also prescribed in the event of moisture in the refrigerant circuit.

Connect the vacuum pump to the charge connector.

Proceed as follows:

- Evacuate the circuit to a pressure of at least 35 mbar absolute. Charge the circuit with nitrogen to a relative pressure of approx. 1 bar.

- Repeat the operation described above.

- Repeat the operation described above for the third time in order to reach the highest degree of vacuum possible.

This procedure should guarantee the elimination of up to 99% of contaminants.

Blue Box - 94

12.3.3 Refrigerant charge

- Connect the refrigerant gas cylinder to the male 1/4 SAE charge connector on the liquid line and allow a small amount of gas to escape in order to purge the connection hose of air.

- The circuit must be charged exclusively with liquid; therefore, if the cylinder is not equipped with a dip pipe it must be turned upside-down.

Units operating with R407C must be charged exclusively with liquid refrigerant by way of the charge connection on the liquid line.

A unit that was originally factory charged with R22 cannot be charged with R407C (and vice versa) without major modifications. Consult Bluebox if necessary.

12.4 ENVIRONMENTAL CONSIDERATIONS

Laws governing the use of substances detrimental to the ozone layer prohibit the dispersal of refrigerant gases in the environment, obliging users to recover refrigerants at the end of their useful life and consign them to the dealer or to specific collection centres.

Refrigerants R22 and R407C are mentioned among substances subject to special monitoring regimes established by law, and as such they are subject to the prescriptions indicated above.

Use special care during maintenance work in order to limit the risk of refrigerant leakage as far as possible.

Blue Box - 95

13. DECOMMISSIONING THE UNIT

When the unit has reached the end of its useful life and must therefore be removed and replaced, adhere to the following rules:

- the refrigerant must be recovered by a qualified technician and sent to an authorised 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 material type; this is particularly important for copper and aluminium, which are fairly abundant on the machine.

This procedure is designed to assist the work of collection, disposal, and recovery specialists and to reduce the associated environmental impact.

Blue Box - 96


ZETA 2002 - MODELS 3.2 - 13.2

Blue Box - 97


ZETA 2002 - MODELS 14.4 - 26.4

Blue Box - 98


ZETA 2002/HP - MODELS 3.2 - 8.2

Blue Box - 99


ZETA 2002/HP - MODELS 9.2 - 13.2

Blue Box - 100


ZETA 2002/HP - MODELS 14.4 - 16.4

Blue Box - 101


ZETA 2002/HP - MODELS 18.4 - 26.4

Blue Box - 102


ZETA 2002/LE - MODELS 3.2 - 13.2

Blue Box - 103


ZETA 2002/LE - MODELS 14.4 - 26.4

Blue Box - 104


ZETA 2002/LE/HP - MODELS 3.2 - 13.2

Blue Box - 105


ZETA 2002/LE/HP - MODELS 14.4 - 26.4

Blue Box - 106


ZETA 2002/DC - MODELS 3.2 - 13.2

Blue Box - 107


ZETA 2002/DC - MODELS 14.4 - 26.4

Blue Box - 108

OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS

ZETA 2002 - ZETA 2002/HP - MODELS 3.2 - 8.2

Blue Box - 109


ZETA 2002 - ZETA 2002/HP - FOOTPRINT - MODELS 3.2 - 8.2

MODELLO

MODEL

ZETA 2002 3.2

ZETA 2002 4.2

ZETA 2002 5.2

ZETA 2002 6.2

ZETA 2002 7.2

ZETA 2002 8.2

ZETA 2002/ST 1P-2P 3.2

ZETA 2002/ST 1P-2P 4.2

ZETA 2002/ST 1P-2P 5.2

ZETA 2002/ST 1P-2P 6.2

ZETA 2002/ST 1P-2P 7.2

ZETA 2002/ST 1P-2P 8.2

ZETA 2002/DC/DS 3.2

ZETA 2002/DC/DS 4.2

ZETA 2002/DC/DS 5.2

ZETA 2002/DC/DS 6.2

ZETA 2002/DC/DS 7.2

ZETA 2002/DC/DS 8.2

ZETA 2002/DC/DS/ST 1P-2P 3.2






ZETA 2002/HP 3.2

ZETA 2002/HP 4.2

ZETA 2002/HP 5.2

ZETA 2002/HP 6.2

ZETA 2002/HP 7.2

ZETA 2002/HP 8.2

ZETA 2002/HP/ST 1P-2P 3.2






ZETA 2002/HP/DS 3.2

ZETA 2002/HP/DS 4.2

ZETA 2002/HP/DS 5.2

ZETA 2002/HP/DS 6.2

ZETA 2002/HP/DS 7.2

ZETA 2002/HP/DS 8.2

ZETA 2002/HP/DS/ST 1P-2P 3.2






ZETA 2002/ST 1PS-2PS-S 3.2






ZETA 2002/HP/ST 1PS-2PS-S 3.2






PESO IN FUNZIONE(Kg)

OPERATING WEIGHT(Kg)

601

610

631

679

795

846

650

663

683

731

741

790

696

706

726

776

806

829

830

644

653

677

724

752

802

699

713

733

785

804

854

949

959

981

1031

1051

751

775

830

704

715

749

753

799

655

671

699

699

748

649

660

680

734

1096

979

990

1010

1061

1080

1128

PESO(Kg)

WEIGHT(Kg)

594

604

625

672

788

835

643

654

675

723

734

781

689

699

719

770

789

812

810

638

648

669

716

741

790

693

704

724

776

794

843

724

734

755

807

825

735

758

810

693

703

732

744

791

644

658

683

690

737

644

654

674

726

868

754

764

785

836

854

902

G1(Kg) G2(Kg) G3(Kg) G4(Kg)

270

230

236

247

256

268

283

271

284

232

238

251

258

271

284

233

238

251

258

264

279

295

232

238

251

258

271

284

232

238

250

257

270

283

220

225

236

244

257

265

280

295

225

231

247

251

261

226

234

248

217

222

235

241

255

268

215

219

231

238

175

159

160

164

169

170

174

84

89

58

59

62

67

67

72

73

74

77

83

95

97

86

58

58

62

67

85

89

160

161

68

73

73

74

77

84

165

170

171

78

80

86

84

85

92

86

91

69

71

76

67

72

73

75

78

85

57

58

61

67

134

125

125

124

133

132

137

68

74

50

51

51

58

56

61

61

61

61

69

74

73

67

49

49

50

57

70

76

121

121

58

63

62

63

63

71

121

130

129

61

61

67

67

67

68

67

73

55

56

57

54

59

58

59

59

68

47

47

47

54

208

181

184

187

201

208

223

220

236

202

205

206

223

224

240

195

198

199

214

204

210

229

198

201

202

218

229

246

197

201

203

218

224

241

167

170

173

187

194

208

213

229

177

180

182

196

210

181

183

185

176

178

180

196

202

218

172

173

175

190

Blue Box - 110


ZETA 2002/LE - ZETA 2002 /LE/HP - MODELS 3.2 - 8.2

Blue Box - 111


ZETA 2002/LE - ZETA 2002 /LE/HP - FOOTPRINT - MODELS 3.2 - 8.2

MODELLO

MODEL

ZETA 2002/LE 3.2

ZETA 2002/LE 4.2

ZETA 2002/LE 5.2

ZETA 2002/LE 6.2

ZETA 2002/LE 7.2

ZETA 2002/LE 8.2

ZETA 2002/LE/HP 3.2

ZETA 2002/LE/HP 4.2

ZETA 2002/LE/HP 5.2

ZETA 2002/LE/HP 6.2

ZETA 2002/LE/HP 7.2

ZETA 2002/LE/HP 8.2



582

592

601

649

665

705

626

634

646

692

708

750

G1(Kg) G2(Kg) G3(Kg) G4(Kg)

200

206

208

214

223

232

216

221

224

231

240

249

57

58

61

66

67

71

58

58

61

66

67

72

49

49

50

58

58

63

51

51

53

60

60

65

170

172

171

187

192

205

192

195

194

209

214

227

Blue Box - 112



Blue Box - 113



ZETA 2002 9.2

MODELLO

MODEL

ZETA 2002 10.2

ZETA 2002 12.2

ZETA 2002 13.2

ZETA 2002/ST 1P-2P 9.2

ZETA 2002/ST 1P-2P 10.2

ZETA 2002/ST 1P-2P 12.2

ZETA 2002/ST 1P-2P 13.2

ZETA 2002/DC-DS 9.2

ZETA 2002/DC-DS 10.2



ZETA 2002/DC-DS/ST 1P-2P 9.2




ZETA 2002/HP 9.2

ZETA 2002/HP 10.2

ZETA 2002/HP 12.2

ZETA 2002/HP 13.2


ZETA 2002/HP/ST 1P-2P 10.2

ZETA 2002/HP/ST 1P-2P 12.2

ZETA 2002/HP/ST 1P-2P 13.2

ZETA 2002/HP/DS 9.2

ZETA 2002/HP/DS 10.2







PESO(Kg)

WEIGHT(Kg)

981

1058

1124

1158

1035

1112

1233

1305

1346

1027

1104

1170

1204

1081

1177

1212

1072

1159

1232

1272

1146

1158

1223

1258

1052

1160

1195

1234

1106

1183

1248

1288



993

1068

1136

1169

1045

1122

1258

1333

1378

1037

1114

1180

1217

1091

1190

1223

1095

1184

1261

1301

1168

1168

1234

1271

1068

1177

1211

1253

1122

1199

1265

1306

G2(Kg)

140

144

148

116

132

132

139

170

178

185

106

118

122

126

127

138

151

155

162

106

118

123

127

128

141

145

149

130

147

154

161

153

G1(Kg)

259

272

284

240

262

275

288

284

300

314

231

253

266

278

237

246

268

281

294

223

245

258

269

228

251

264

275

248

274

290

303

259

G4(Kg)

201

216

220

190

208

213

217

200

214

218

191

199

214

218

193

192

200

215

218

178

185

201

204

180

187

203

206

186

193

208

211

192

G3(Kg)

108

114

115

92

105

103

104

120

127

129

87

92

98

99

104

108

112

118

120

96

101

105

111

112

97

103

111

112

113

85

90

95

MODELLO

MODEL









PESO(Kg)

WEIGHT(Kg)

1142

1219

1275

1309

1178

1255

1321

1355



1594

1670

1728

1762

1630

1706

1776

1808

Blue Box - 114

G1(Kg)

234

257

271

281

230

249

261

271

G2(Kg)

208

221

223

226

214

223

224

227

G3(Kg)

176

173

178

177

170

171

175

175

G4(Kg)

197

202

216

220

183

192

204

208


ZETA 2002/LE - ZETA 2002/LE/HP - MODELS 9.2 - 13.2

Blue Box - 115


ZETA 2002/LE - ZETA 2002/LE/HP - FOOTPRINT - MODELS 9.2 - 13.2

Blue Box - 116



Blue Box - 117



Blue Box - 118


ZETA 2002/LE - ZETA 2002 /LE/HP - MODELS 14.4 - 16.4

Blue Box - 119


ZETA 2002/LE - ZETA 2002 /LE/HP - FOOTPRINT - MODELS 18.4 - 26.4

Blue Box - 120



Blue Box - 121



Blue Box - 122


ZETA 2002/LE - ZETA 2002/LE/HP - MODELS 18.4 - 26.4

Blue Box - 123


ZETA 2002/LE - ZETA 2002/LE/HP - FOOTPRINT - MODELS 18.4 - 26.4

Blue Box - 124


ZETA 2002/ST - ZETA 2002/HP/ST - MODELS 18.4 - 26.4

Blue Box - 125


ZETA 2002/ST - ZETA 2002/HP/ST - FOOTPRINT - MODELS 18.4 - 26.4

Blue Box - 126

BLUE BOX srl

is an associate company of

BLUE BOX GROUP

BLUE BOX srl

Via E. Mattei, 20

35028 Piove di Sacco PD Italy

Tel. +39.049.9716300

Fax +39.049.9704105

BLUE BOX GROUP

on the internet www.blueboxgroup.it

[email protected]

Manual 101010A02 - Issued 11.02 - Replaces 04.02

All data in this manual is subject to change without prior notice

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