BlueBox Datatech Installation, Use And Maintenance Manual Download Page 56

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UM_0000_Datatech_EN_07-10-2016_rev01

Blue Box Group S.r.l.

Via Valletta, 5 - 30010

Cantarana di Cona, (VE) Italy - T. +39 0426 921111 - F. +39 0426 302222

www.blueboxcooling.com - [email protected]

Blue Box Group S.r.l. a socio unico - P.IVA 02481290282
Company directed and coordinated by Investment Latour (Sweden)

Summary of Contents for Datatech

Page 1: ...Datatech EN 07 10 2016 Installation use and maintenance manual ...

Page 2: ... Safety Directive The quality level is constantly monitored and therefore our products are synonymous with Safety Quality and Reliability Changes considered necessary for product improvement may be made to the stated data at any time without any obligation to give prior notice Thank you again Read this manual carefully before installing testing or starting this unit Give this manual and all comple...

Page 3: ...id 13 2 5 1 Hazards and health consequences 13 3 Receiving the product and storage 14 3 1 Reception 14 3 2 Transport 14 3 3 Handling 15 3 3 1 Monobloc unit 15 3 3 2 Units with separate ventilation section 17 3 4 Storage 17 4 Product description 18 4 1 Intended use 18 4 2 Unintended use 18 4 3 Control and safety devices 19 4 4 Principles of operation 19 4 5 Structure 19 4 6 Specifications 19 4 7 Ai...

Page 4: ...30 5 4 3 Connection to the condensate drain 30 5 4 4 Connection to the hot water coil 31 5 4 5 Connection to the humidifier 31 5 5 Electrical connections 32 5 6 Refrigeration connections 33 5 6 1 Piping implementation 33 5 6 2 Changes in temperature and speed in the cooling lines 38 5 6 3 Change in performance 40 5 7 Vacuum and refrigerant charge 41 6 Commissioning 42 6 1 Preliminary operations 42...

Page 5: ...5 We reserve the right to make changes without any prior notice Translation from original instructions 8 Decommissioning 52 ...

Page 6: ...ives see the declaration of conformity that is an integral part of the manual 1 2 Description 1 2 1 Symbols A description of the main symbols used in this manual and on the labels affixed to the unit is given below Danger symbol take extreme care Danger symbol moving mechanical parts Danger symbol live parts Warning symbol important information Note symbol suggestions and advice ...

Page 7: ...own on the labels affixed to the unit the following illustrations are shown only as an example The Manufacturer adopts a continuous development policy and in this perspective reserves the right to make changes and improvements to the documentation and to the units without prior notice The technical booklet the labels placed directly on the unit and the various diagrams referred to below must be co...

Page 8: ...ing the protective devices and entering the unit On no account must unqualified personnel be allowed to enter the unit and no one should be allowed to enter before the power to it has been turned off The user can interact with the unit only through the control and external OK signals Only authorised knowledgeable personnel may access the unit in compliance with safety in the workplace regulations ...

Page 9: ... of refrigerant gases into the environment and obliges owners to recover and return them to the dealer or take them to special collection centres at the end of their operational life The refrigerant contained in the refrigerant circuit is included among the substances subject to special con trol regulations provided for by law and must therefore be disposed of as indicated above Particular care sh...

Page 10: ... the immediate vicinity be careful to avoid touching any components of the unit without suitable protection do not work in the discharge trajectory of the safety valves if the units are positioned in unprotected places which can easily be reached by unqualified persons suitable protection devices must be installed the user must consult the installation and use system manuals incorporated and attac...

Page 11: ... pH 7 5 8 5 Electrical conductivity 10 500 µS cm Organic elements Hydrogen carbonate HCO3 70 300 ppm Sulphates SO42 50 ppm Hydrogen carbonate Sulphates HCO3 SO42 1 Chlorides Cl 50 ppm Nitrates NO3 50 ppm Hydrogen sulphide H2S 0 05 ppm Ammonia NH3 0 05 ppm Sulphites SO3 free chlorine Cl2 1 ppm Carbon dioxide CO2 5 ppm Metal cations 0 2 ppm Manganese ions Mn 0 2 ppm Iron ions Fe2 Fe3 0 2 ppm Iron Ma...

Page 12: ...not reasonably be eliminated or sufficiently reduced through design The presence of an operator is not required for normal operation of the unit The change from the OFF state to the ON state and vice versa of the unit can be carried out remotely or through the display without having to enter areas at risk Access restriction is part of correct installation to eliminate residual risks during normal ...

Page 13: ...nce with local and or European regulations 2 5 1 Hazards and health consequences If accidentally released rapid evaporation of the liquid can cause freezing In case of contact with the liquid defrost the various part with water remove clothing carefully rinse thoroughly with water Contaminated clothing and shoes should be washed before reuse High vapour concentrations can cause headaches dizziness...

Page 14: ...the responsibility of the consignee and must be carried out in compliance with the regu lations in force in the country in which it is carried out 3 2 Transport The unit is sent from the factory using suitable vehicles with correct locking in order to prevent any possibility of movement whilst in transit by road that may damage it or cause accidents If there is to be trans shipment to other vehicl...

Page 15: ...nery and lifting ropes are of suitable size and capacity and strictly follow their operating instructions Use only equipment that is in excellent working order All work on the unit including unpacking and connections must be carried out with the unit resting on the ground Refer in any case to the lifting instructions provided with the unit Be careful when handling The centre of gravity of the unit...

Page 16: ...ort forks At least two people must be present while the unit is being handled with forklift trucks with short forks Before sliding out the pallet remove the screws fixing it to the unit Use a 13 mm spanner to unscrew them The screws which fix the pallet to the unit are located in correspondence with the holes on the pallet s bottom axis Fig 3 Position of fixing screws To remove the fork lift truck...

Page 17: ...built to be installed in indoor environments Storage outdoors is not allowed Upon receipt they must be put in locations protected from weather agents Since the remote condensing unit is designed to be installed outdoors it can withstand outdoor atmospheric conditions For the condensing unit must be pay attention to the place where it is placed which must be on the flat in order to avoid deformatio...

Page 18: ... Unintended use The unit must not be used in an explosive atmosphere in a flammable atmosphere in extremely dusty environments in an environment that is not compatible with the stated IP protection rating by untrained personnel in a way that does not comply with the regulations in force with incorrect installation with power supply defects with total or partial failure to comply with the instructi...

Page 19: ...ions where an uninterrupted service must be guaranteed and are therefore equipped with redundancy features 4 5 Structure The cabinet is made with sandwich panels of galvanized steel sheet and coated with epoxy The panels are internally insu lated with glass wool to obtain fire insulation class A1 in accordance with EN13501 This type of panel allows good thermal and acoustic insulation Air tightnes...

Page 20: ...icroprocessor mounted on board the unit It is thus possible to set the required speed directly through the parameter being displayed Both motors are equipped with an alarm signal which in the AC version is in fact equal to the thermal protection whilst in the EC version it includes thermal protection overcurrent under voltage the lack of one or more phases rotor blockage The EC fan is not equipped...

Page 21: ...al pressure switch which measures the upstream and downstream pressure drop of the filter The control panel will signal via an alarm on the display the need to replace or clean the filter The machine will continue to work in any case The fouling of the filter may cause a decrease in the flow rate and therefore of the machine s performan ce restoring the filter as quickly as possible from the time ...

Page 22: ...cally controlled by the microprocessor which regulates the amount of water present inside the boiler according to specific algorithms and according to the request for moisture production For further details concerning the operation of the humidifier refer to the humidifier and microprocessor manuals Should it be necessary to carry out maintenance or replace the humidifier components first empty th...

Page 23: ... for the following instructions is the main screen that is accessed from any other screen by pressing the Esc button repeatedly 4 8 1 Switching the unit on off For units with on off compressors from the main screen by pressing the Esc key you will see the power unit s start up window press Enter to turn the unit on For units with inverter controlled compressor you can access the list of control me...

Page 24: ...n and is present inside each unit It is essential to refer to this document if you are unsure about anything or need further explanations regarding the auxiliary electrical connections and power connections as well as for the electrical specifications In particular refer to the wiring diagram as regards the possibility of remotely managing the functionalities that contemplate this ...

Page 25: ...uired for this purpose please consult the documentation As for the installation of the remote air condenser please also take into consideration positioning and exposure to solar radiation of the air condenser Keep the condensing coil out of direct sunlight as far as possible direction of prevailing winds Do not position the unit in a such a way that prevailing winds could cause air recirculation t...

Page 26: ...g and electrical connections is from the bottom of the unit Should a raised floor not be available a base in order to access the bottom of the unit and make the connections must be provided The base may be provided as an accessory Make sure that the floor can support the weight of the unit refer to the documentation attached to the unit Since all connections are on the bottom of the unit the holes...

Page 27: ...unit must be installed on top of the fan unit The two sections must be connected with M8 screws with an appropriate length using the pre set holes and threaded in serts on the unit s base and on the top ring of the fan unit If not all of the fastening points are accessible due to the position of installation simply fasten the unit to the fan section at 4 of the 6 points provided It is advisable to...

Page 28: ...e operations In particular refrigeration plumbing and electrical connections must be accessed from the bottom of the unit In case a raised floor is not available provide a base in order to make the connections The base can be provided as an accessory Fig 8 Units with base Refer to dimensional drawings for details of the diameters of the couplings Concerning the distances to be respected regarding ...

Page 29: ...o the heat exchangers install drain taps at the lowest points of the circuit display relief valves at highest points It is obligatory to install a mesh filter with a mesh size not exceeding 1 mm on the capacitors inlet in order to avoid clogging due to dirt Respect the direction of the capacitors inlet output otherwise there will be loss of performance The use of silty water or with a high limesto...

Page 30: ...be able to fall to near or below zero Celsius add an appro priate percentage of antifreeze 5 4 3 Connection to the condensate drain All units are equipped with a condensate drip tray underneath the coil A rubber siphon is connected to the condensate drip tray which is joined to the base in all the units except for the vertical upward air flow water chillers in sizes S M L and when there is a separ...

Page 31: ...sius add an appro priate percentage of antifreeze 5 4 5 Connection to the humidifier Where present the humidifier must be supplied with untreated mains water preferably filtered from impurities and or wa ste The diameters of the couplings are reported in the dimensional drawings We recommend that the drain duct should consist of a non electrically conductive material The water discharged from the ...

Page 32: ...er supply voltage see specific wiring diagram must not fluctuate by more than 10 and the unba lance between phases must always be less than 2 If this does not occur contact our technical department to choose suitable protection devices Make sure the power line is correctly connected with a clockwise phase sequence The control circuit power supply is taken from the power line via a transformer situ...

Page 33: ...ith use the fewest number of bends possible preferably as wide as possible provide a slight slope of the flow line 1 downwards in the horizontal sections in order to facilitate the passage of the oil provide suitable syphons every 6 metres 5 metres for circuits with inverter controlled compressor in the vertical stretches of the gas discharge pipe to the condenser placing the first one immediately...

Page 34: ... 14 16 16 18 16 22 1 1 16 12 16 14 18 16 18 16 18 16 26 1 1 18 14 18 16 18 16 18 16 22 18 30 2 2 14 12 14 12 16 14 16 14 16 16 32 1 1 18 14 18 16 22 16 22 18 22 18 36 1 1 18 16 18 16 22 18 22 18 22 18 34 2 2 16 12 16 14 16 14 16 14 16 16 38 1 1 18 16 18 16 22 18 22 18 22 22 38 2 2 16 12 16 14 16 14 18 16 18 16 46 2 2 16 14 16 14 18 16 18 16 18 16 49 1 1 22 18 22 18 22 18 28 22 28 22 56 2 2 18 14 1...

Page 35: ... 18 16 22 16 22 16 22 16 66 3 1 16 16 16 16 18 16 18 16 18 16 2 18 18 18 18 22 18 22 18 22 18 82 3 1 16 16 16 16 18 16 18 16 18 16 2 22 18 22 18 22 22 22 22 22 22 100 4 1 22 18 22 18 22 18 22 18 22 18 2 22 18 22 18 22 18 22 18 22 18 Should the length of the cooling lines envisage an increase of the diameters compared with those required for a length of 10 m we recommend implementing the horizontal...

Page 36: ... 4 9 49 1 4 7 6 9 7 7 8 6 8 6 56 2 3 5 5 5 4 5 8 5 7 66 2 4 5 9 6 6 2 7 72 2 4 6 6 6 6 8 6 8 7 6 85 2 4 9 7 7 9 7 9 8 7 95 2 4 9 7 1 7 9 7 9 8 7 104 2 7 1 10 2 10 2 11 11 Table 2B Refrigerant charges for units with separate section circuits excluding pipelines inverter controlled compressors Model Refrigerant charge Refrigerant charge Refrigerant charge Refrigerant charge Refrigerant charge withou...

Page 37: ...50S oil the circuit featuring ON OFF compressors only uses EMKARARE RL 32 H oil If needed do not forget to top up the level with the correct type of oil without mixing the two different oils as they are not compatible Always use the oil recommended by the Manufacturer of the compressor or a perfect ly equivalent oil The use of an incorrect type of oil may cause serious damage to the compressors an...

Page 38: ...pes Fig 11 Change of saturation temperature in the discharge lines This diagram is useful in order to approximately determine the variation in saturation temperature per equivalent linear metre of pipe on the basis of the cooling capacity and the diameter of the discharge line Fig 12 Speed in the discharge lines This diagram is useful in order to determine the approximate speed of the refrigerant ...

Page 39: ...sis of the cooling capacity and the diameter of the liquid line Fig 14 Speed in the liquid lines This diagram is useful in order to determine the approximate speed of the refrigerant in metres per second on the basis of the cooling capacity and the diameter of the liquid line These diagrams and those of the previous page are valid for the following conditions saturation evaporation temperature equ...

Page 40: ...us diameters have been used sum the result obtained in order to obtain the total pressure drop per refrigerant circuit expressed in C Based on the total pressure loss verify the yield loss percentage and the increase of power consumption in the graph below Pay attention to size 66 3 and 82 3 whose circuits are divided according to 1 3 2 3 Fig 15 Loss of yield curve A and increase of power absorbed...

Page 41: ... system with a high vacuum pump able to reach 0 1 mbar of residual pressure Connect the vacuum pump to several points of the refrigerant circuit in order to ensure better evacuation Never use the compressor as a vacuum pump doing so will invalidate the warranty Once the vacuum has been obtained load the system from the charging socket 5 16 SAE placed on the liquid line Perform charging in liquid f...

Page 42: ...leaks Be careful with the electrical checks and use only suitable tools Move the main switch of the unit to the ON position and verify on the user interface that the unit is OFF Check that the crankcase heaters are powered correctly The crankcase heaters are switched on when the main disconnect switch is closed and this must be done at least 12 hours before starting the unit To check that the heat...

Page 43: ...mpressors and or heating elements and the humidifier if present may start up After a few hours of operation of the compressors check that the liquid sight glass has a green ring if it is yellow there is moisture in the circuit In this case the circuit must be dried by qualified authorised personnel Check that bubbles do not appear at the liquid sight glass The continuous passage of bubbles can ind...

Page 44: ... equipment is calibrated and tested in the factory before the unit is shipped However after the unit has been started the safety devices must be checked only the high and low pressure switches The checks must be carried out as described in the Periodic checks chapter The calibration values are shown in the table Control and safety components Activation set point Differential Reset High pressure sw...

Page 45: ...own in the wiring diagram Considerably different values may be due to the reduced capacity operation of the unit at working conditions very different from nominal ones or to the mal functioning of one or more components the liquid sight glass must be green that no bubbles appear on the sight glass placed in the liquid pipe The continuous presence of bubbles may indicate a lack of refrigerant charg...

Page 46: ...is switched off from the di splay and the display is disconnected or not working Restore the connection of the display or replace it The unit does not start the display is off the control is powered correctly but the LEDs are not flashing The control is not working Replace the control The unit is operating normally the display is off The connection of the display to the control is disconnected Res...

Page 47: ...hat needs to be done to restart the unit is to set the control to ON 6 7 Stop for long periods of time When the unit is not used for months this is considered a long period shutdown Should the unit be expected to stop for long periods it is necessary to turn the unit off by means of the control switch disconnect the power supply using the switch general switch of the unit empty and clean the conde...

Page 48: ...inutes before working on the electrical parts of the unit Circuits supplied from external sources made with orange cable can remain live even after the power sup ply to the unit has been turned off Work on the unit only if there is sufficient lighting for the type of work to be carried out 7 1 Adjustments All the parameters that control the operation of the unit can be set through the user interfa...

Page 49: ...l cleaning It is essential to keep the installation site clean and tidy for correct maintenance of the unit and to keep it in good working order 7 3 1 Cleaning the unit Keep the inside of the electrical control panel and where present the compressor compartment clean After working on the unit always clean the electrical control panel of any work remnants and extraneous components Restore the safet...

Page 50: ...he instructions in the section entitled Recommendations for car rying out maintenance and cleaning of finned coils according to the type of coil installed Monthly If the unit also has metal filters clean them with compressed air blown in the opposite direction to that of the air flow during operation Use a jet of water if they are completely clogged Monthly Clean the air filters Monthly Clean the ...

Page 51: ...estore the charge of refrigerant gas In the case of small oil leaks clean the dirty parts with absorbent cloths otherwise recover the leaked oil with absorbent sheets In any case the material used must be disposed of in accordance with current rules and regulations Check whether it is necessary to restore the oil charge In the case of spillage of the water and glycol mixture of the system stop the...

Page 52: ...nment and obliges owners to recover and return them to the dealer or take them to special collection centres at the end of their ope rational life The refrigerant gas present in the unit is included among the substances subject to special control regulations provided for by law and must therefore be disposed of as indicated above In the compressors and in the refrigerant circuit there is lubricati...

Page 53: ...53 We reserve the right to make changes without any prior notice Translation from original instructions Page intentionally blank ...

Page 54: ...54 We reserve the right to make changes without any prior notice Translation from original instructions Page intentionally blank ...

Page 55: ...55 We reserve the right to make changes without any prior notice Translation from original instructions Page intentionally blank ...

Page 56: ... Group S r l Via Valletta 5 30010 Cantarana di Cona VE Italy T 39 0426 921111 F 39 0426 302222 www blueboxcooling com info swegon it Blue Box Group S r l a socio unico P IVA 02481290282 Company directed and coordinated by Investment Latour Sweden ...

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