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1 INTRODUCTION

1.1 Conformity

With regard to relevant regulations and directives, 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

Содержание BlueBox WESTERN Mu Echos A

Страница 1: ...Mu Echos A EN 24 02 2020 Installation use and maintenance manual ...

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

Страница 3: ...on control at the source hydraulic circuit 15 2 2 9 Condensation control at the source hydraulic circuit for HP units 16 2 2 10 Refrigerant leak detector 17 2 3 Noise 18 2 4 Residual risks 18 2 5 Safety information on the refrigerant fluid 19 2 5 1 Hazards and health consequences 19 3 Receiving the product and storage 20 3 1 Reception 20 3 2 Transport 20 3 3 Handling 21 3 4 Storage 21 4 Ecodesign ...

Страница 4: ... 2 Sizing of lines for LE and LE HP units 37 6 6 3 LE version unit installed at a higher level than the remote exchanger 37 6 6 4 LE version unit installed at a lower level than the remote exchanger 38 6 6 5 LE HP version unit installed at a higher level than the remote exchanger 38 6 6 6 LE HP version unit installed at a lower level than the remote exchanger 39 6 6 7 Sizing of lines for LC and LC...

Страница 5: ...raulic tests 49 7 2 2 Functional tests 50 7 3 Calibration of safety components 51 7 4 Checks during operation 52 7 5 Alarms and malfunctions 53 7 5 1 General troubleshooting 53 7 6 Temporary stop 55 7 7 Stop for long periods of time 55 8 Maintenance 56 8 1 Adjustments 56 8 2 Internal cleaning 57 8 2 1 Cleaning the unit 57 8 2 2 Cleaning the plate heat exchangers 57 8 3 Cleaning the remote exchange...

Страница 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 ...

Страница 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 Catalogue the labels placed directly on the unit and the various diagrams referred to below must be ...

Страница 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 ...

Страница 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...

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

Страница 11: ...6 0 f Langelier index 0 4 0 4 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...

Страница 12: ...ents where v Minimum water content of the system l Ρtot Total refrigeration capacity kW N N of capacity reduction steps Δτ Time interval the greater between minimum OFF time and minimum ON time s ΔΤ Allowed differential on the water temperature C unless specified this is 2 5 C ρ Water density 1000 kg Сp Specific heat of water 4 186 kJ kg C Fm Q factor experimental factor different from 1 for some ...

Страница 13: ...ush rod must be in the vertical position The electrical connection of the flow switch should be made in the terminal board of the electrical control panel using the prepared terminals as shown in the wiring diagram Lock the cable in place with cable ties in the section between the flow switch and the inlet to the electrical control panel 2 2 5 Hydraulic components for reversible heat pump units Fo...

Страница 14: ...3 56 Propylene glycol 15 25 33 39 44 48 51 54 57 If ambient temperatures are expected to be lower than the freezing point of water it is essential to use an ti freeze mixtures in the above mentioned percentages In the case of units with pump units applied in systems with glycol percentages above 30 when ordering a request must be made for a technical check for compatibility of the pumps and if nec...

Страница 15: ...nal diagram and with the relevant plate on the unit A modulating three way valve that will ensure an incoming water temperature within the operating limits stated in the Technical Catalogue must be installed for correct operation of the unit Fig 1 3 way valve installation layout 02 Condenser EL Motor driven pump V3 Thermostatic three way valve As an alternative to the modulating valve it is possib...

Страница 16: ...some models these components are already installed in the unit whereas for others they are assembled in kits and supplied loose with the unit If the kit is supplied loose with the unit it is mandatory to install it and this must be done by the installer The flow switch in the source hydraulic circuit should be installed on the heat exchanger outlet with the same measures used for the flow switch o...

Страница 17: ... check with tests at least once a year Check your local regulations on calibration and the testing requirements The detector must be tested and or calibrated by a qualified technician To test and calibrate the device qualified operators must know the rules and regulations laid down by the industrial sector and or by the country of installation In the event of a significant refrigerant leak with pr...

Страница 18: ...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 ...

Страница 19: ...onsequences 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 drowsiness and nausea and may lead to unconsciousness and cardiac ar...

Страница 20: ...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...

Страница 21: ... case to the lifting instructions provided with the unit The units are dispatched screwed onto pallets having anti overturning boards To unload them from the vehicle use a forklift truck Insert the forks under the unit on the side where the anti overturning boards are fixed with the forks as far apart as possible until they protrude from the back of the base and keep the centre of gravity of the u...

Страница 22: ...can be put on the market in any country More specifically they are allowed to be put on the market in member countries of the European Union hereinafter EU Putting the units on the market in the EU entails installation and running of the unit within this scope Putting the units on the market in the EU is bound by the effective dates required by each Regulation The EC Declaration of Conformity here...

Страница 23: ...quired by Regulation 2013 813 2 Where provided for by Regulation 2013 811 applies to heat pumps with Pdesign 70kW 4 1 5 Efficiency parameters required for conformity To avoid ambiguity this chapter identifies efficiency parameters with the acronyms indicated below Regulation 2016 2281 envisages conformity according to the following efficiency parameters ηsc low temperature user side inlet outlet t...

Страница 24: ...emperature LWT cooling C Conformity Notes 1 Comfort cooling only 18 SEER ηsc LT 2 Comfort cooling only 18 SEER ηsc MT 1 3 Process cooling only 2 LWT 12 SEPR HT 4 Process cooling only 12 none 5 Process cooling only 8 LWT 2 none 1 All the more so SEER ηsc LT conformity is also valid In the Process cooling only case with delivery temperature between 8 C and 2 C point 5 of table b no type of conformit...

Страница 25: ...ide the operating limits stated in the Technical Catalogue will cause the unit to stop 5 2 Unintended use The unit must not be used in an explosive atmosphere in a flammable atmosphere in extremely 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 install...

Страница 26: ... and rejects the heat through another water heat exchanger condenser This happens in units intended for operation in cooling mode In units in heat pump operation where hot water is produced there is refrigeration cycle reversal that reverses the function of the two heat exchangers so that the evaporator becomes a condenser and vice versa In LC version units the same functionalities made by the hea...

Страница 27: ...so operate in heating mode may be started in cooling mode as described above or in heating mode by pressing and holding down the following button for 5 seconds To switch off the unit from the keypad press the button with the same symbol present on the display and hold it down for 5 seconds If you want to use the digital input for switching the unit on off the function must be enabled on the contro...

Страница 28: ... 5 7 1 3 Displaying and changing the set point With the parametric control with a single access the set temperature set point values can be displayed and changed within factory set limits The sequence of operations to carry out is as follows press for 5 seconds button to access the parameter loop for programming with pressing twice on button to reach the group of parameters r confirm with button i...

Страница 29: ...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 ...

Страница 30: ...t 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 to the condensing coil type of ground Avoid placing the condensing unit on dark coloured ground for example tarred surfaces in order to avoid overheating during operation All models in the series are designed and built for indoor install...

Страница 31: ...xchanger To position the remote heat exchanger see the relevant manual 6 3 3 Noise attenuation The units are designed and built paying particular attention to keeping down noise emission during operation In addition to the standard versions there are LN Low Noise versions for which further devices are used for lower noise emission Correct installation for both the place and the components as shown...

Страница 32: ...n the pipes Air valves to be placed in the highest parts of the hydraulic circuit to allow the non condensable gases to be bled off Expansion vessel and automatic charging valve for maintaining system pressure and to compensate thermal expansion Drain valves so that the system can be emptied for maintenance operations or seasonal stops It is mandatory to comply with the above requirements to facil...

Страница 33: ...afety valve SB Storage tank SF Air valve VE Expansion vessel VR Check valve It is essential for the water to come in at the connection indicated in the dimensional diagram and with the relevant plate on the unit If it does not there would be a risk of the evaporator being frozen since the antifreeze probe control would be thwarted The hydraulic circuit must be made in such a way as to ensure a con...

Страница 34: ...ansion vessel VR Check valve It is essential for the water to come in at the connection indicated in the dimensional diagram and with the relevant plate on the unit Failing this there would be a decline in the operating efficiency of the heat exchanger and in HP units there would be a risk of it being frozen since control by the antifreeze probe would be thwarted The hydraulic circuit must be made...

Страница 35: ...gram 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 situated in the electrical control panel the ...

Страница 36: ...f the pipes must be as short and straight as possible making sure the following basic rules are complied with use the fewest number of bends possible preferably as wide as possible make a slight slope in the suction line 1 in the horizontal sections so that the oil is carried more easily in the instal lations of cooling only units LE and LC For the installation of reversible units LE HP and LC HP ...

Страница 37: ...8 16 28 28 16 28 16 35 18 32 28 16 35 18 35 18 35 28 16 35 18 35 18 42 28 16 35 18 35 22 48 35 16 35 22 35 22 The above mentioned diameters were chosen in order to optimise the performance of the units contempo raneously ensuring the proper operation at the permissible conditions and to contain the refrigerant charge within reasonable limits 6 6 3 LE version unit installed at a higher level than t...

Страница 38: ... the compressor when the unit is not running In the horizontal sections of the suction line G it is advisable to have a slope of at least 1 to facilitate oil return to the compressor 6 6 5 LE HP version unit installed at a higher level than the remote exchanger There must be syphons on the vertical sections of the suction delivery line G to facilitate oil return to the compressor The height h must...

Страница 39: ...on the highest suction delivery line G of the evaporator in order to prevent liquid refrigerant from going towards the compressor when the unit is not running There must be syphons on the vertical sections of the suction delivery line G to facilitate oil return to the compressor The height h must be less than 4 metres The horizontal sections of the suction delivery line G must not slope at all ...

Страница 40: ...18 16 18 18 32 18 16 18 18 22 18 35 18 16 22 18 22 18 42 22 16 22 18 22 22 48 22 16 22 22 22 22 Recommended diameters for R410A for LC HP units The thickness of the pipe must be compatible with the refrigerant used and with current regulations Model Equivalent length 10 m Equivalent length 20 m Equivalent length 30 m Gas Liquid Gas Liquid Gas Liquid 6 16 10 16 10 16 12 8 16 10 18 12 22 12 11 18 10...

Страница 41: ...ons of the delivery line G make a slope of at least 1 to facilitate oil return to the compressor install a non return valve near the condenser inlet in order to prevent liquid refrigerant from returning to the compressor when the unit is not running 6 6 9 LC version unit installed at a higher level than the remote exchanger A summary is given below of the measures to be taken if the unit is instal...

Страница 42: ...ilitate oil return to the compressor The height h must be less than 4 metres The horizontal sections of the suction delivery line G must not slope at all 6 6 11 LC HP version unit installed at a lower level than the remote exchanger There must be syphons on the vertical sections of the suction delivery line G to facilitate oil return to the compressor The height h must be less than 4 metres The ho...

Страница 43: ...Expansion valve The LE LE HP and LC HP units can have an expansion valve supplied as accessory to be installed by the installer on the remote heat exchanger The supplied expansion valve is sized with reference to the envisaged operating conditions for the unit Carry out the installation following the documentation attached to the valve 6 7 2 Remote heat exchanger with two connections In this case ...

Страница 44: ...e the refrigerant circuit open for more than 15 30 min as the high hygroscopic nature of the oil can cause it to absorb moisture that would be detrimental to the circuit Carry out the vacuum of the entire 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 ...

Страница 45: ...e system is reached The unit should only be started up by qualified personnel authorised by the manufacturer All the units are pre charged with refrigerant gas so the refrigerant circuit is pressurised Check that the electrical connection has been made correctly and that all terminals are properly tightened that the voltage on the RST terminals is 400 V 10 or the rated voltage of the unit if there...

Страница 46: ...The values of the pre charge pressure and the maximum pressure at which it can operate are stated on the label present on the expansion vessel The pre charge pressure of the expansion vessel must be adjusted to the hydraulic pressure at the point of installation At the time of installing the unit make sure the pre charge value is equal to the hydrostatic pressure value at the point of installation...

Страница 47: ...re charge pressure of the expansion vessel barg pVS calibration pressure of the safety valve barg If the actual volume of the system is higher than this maximum value an additional expansion vessel of adequate volume must be installed After filling the hydraulic circuit the pressure at the expansion vessel must be just a little higher than the pre charge pres sure If there are points of use placed...

Страница 48: ...mote exchanger in the case of units with several remote exchan gers a flow control switch must be installed for each one make sure the fans are turning the right way follow the instructions given in the documentation for the remote exchanger 7 1 4 Preliminary operations for LC and LC HP units In addition to the previous general checks further checks are needed for units with remote condenser excha...

Страница 49: ... the starting of the pump takes place with the starting of the first compressor If the control for water circulation in the source system is not present in the electrical control panel of the unit make sure there is water circulation in the source system with the starting of the first compressor Check the pumps are rotating in the correct direction Start the unit by acting on the user interface of...

Страница 50: ... liquid sight glass The continuous passage of bubbles can indicate there is insuffi cient refrigerant and it needs to be topped up In this case check that the subcooling value is at least 5 C But the presence of a few bubbles is allowed during transients The end user is required to keep a register of the unit not supplied which will allow a record to be kept of the work carri ed out on the unit Th...

Страница 51: ...Incorrect calibration values can cause serious damage to the unit and harm people The control and safety equipment is calibrated and tested in the factory before the unit is shipped However after the unit has been started the safety devices must be checked only the high and low pressure switches The checks must be carried out as described in the Periodic checks chapter The calibration values are s...

Страница 52: ...re working correctly lower values indicate that the water flow rate through the unit is too high In this case the water flow rate through the system must be reduced by acting on the control switch if any of the pumps or by partially closing the shut off device placed at the outlet of the unit the superheating value of the suction gas The optimal value must be between 4 and 7 C the subcooling value...

Страница 53: ...the cause that trigge red it The unit does not start the display is off the control is powered correctly The unit is switched off from the di splay and the display is disconnected or not working 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 ...

Страница 54: ...ailure of the protective devices to operate Check that the high pressure switches are working and if necessary replace them The valve must be replaced Opening of the valve due to overtem perature Replace the valve and restore the charge Water leaks from the pump on first start up Bedding in the mechanical seal Pressurize the pump body 2 or 3 times by closing and opening the delivery valve so as to...

Страница 55: ...g it If in the previous conditions the circulation pump is not managed by the control the pump must always be kept running When the temporary stop is carried out in this way all that needs to be done to restart the unit is to set the control to ON 7 7 Stop for long periods of time If the unit is to remain stopped for a season or for long periods of time it is necessary to turn the unit off by mean...

Страница 56: ...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 8 1 Adjustments All the parameters that control the operation of the unit can be set through the user interfa...

Страница 57: ...rease in head losses on the hydraulic circuit and a decrease in temperature difference between water inlet and outlet are a sign that the exchanger is becoming fouled In such cases the heat exchanger can always be cleaned by circulating an in situ cleaning fluid CIP When carrying out the operations described here adopt all the technical and organisational measures provi ded for by workplace safety...

Страница 58: ... to the manual for the timing and modes of operation 8 3 2 LC and LC HP condenserless units For the LC and LC HP condenserless and reversible condenserless units the component that needs looking after the most is the finned pack heat exchanger It is essential to keep it clean and free of dirt and or deposits that can hinder or prevent air flow Regular cleaning of the surface of the coil is essenti...

Страница 59: ... fluid used are expected during the time it is to remain stopped Seasonal Check the filling of the water circuit Monthly Check that the differential water pressure switch or the flow switch where present is working cor rectly Monthly If present check the crankcase heaters of the compressors Monthly Clean the air filters Monthly Clean the ventilation filters of the electrical control panel Monthly ...

Страница 60: ...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...

Страница 61: ...local regulations The owner can return EEE to the dealer at the end of its life when purchasing equivalent new equipment This EEE may contain hazardous substances such as refrigerant gases lubricating oils and accumulators or other mate rials and improper or incorrect disposal of them may have adverse effects on human health and the environment Incorrect disposal of them also entails penalties as ...

Страница 62: ...62 We reserve the right to make changes without any prior notice Translation from original instructions Page intentionally blank ...

Страница 63: ...63 We reserve the right to make changes without any prior notice Translation from original instructions Page intentionally blank ...

Страница 64: ...UM 0000_Mu Echos A EN 24 02 2020 rev03 ...

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