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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

Danger sign: flammable gas.

Содержание BlueBox Zeta Rev Series

Страница 1: ...Zeta Rev EN 19 02 2021 Installation use and maintenance manual...

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

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

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

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

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

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

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

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

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 unpro...

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

Страница 12: ...ng on the type of compressor With some terms grouped together the formula can be rewritten as follows If the carrying fluid consists of mixtures of water glycol ethylene or propylene the density and s...

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

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

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

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

Страница 17: ...drain only for heat pump units As an accessory all heat pump version units can have a condensate drip tray with drain holes at the base of each conden sing evaporating coil If the supplied holes are...

Страница 18: ...r local regulations on calibration and the testing requirements The alarm contact opens for 5 seconds any time power is cut out and then restored to the sensor Set a suitable delay in the warning mess...

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

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

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

Страница 22: ...uring unloading and positioning of the unit great care must be taken to prevent sudden or violent manoeuvres and the components of the unit must not be used as lifting points Make sure the machinery a...

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

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

Страница 25: ...an be put on the market in any country More specifically they are allowed to be put on the market in member countries of the European Union hereinafter EU Putting the units on the market in the EU ent...

Страница 26: ...quired by Regulation 2013 813 2 Where provided for by Regulation 2013 811 applies to heat pumps with Pdesign 70kW 4 1 5 Efficiency parameters required for conformity To avoid ambiguity this chapter id...

Страница 27: ...temperature LWT cooling C Conformity Notes 1 Comfort cooling only 18 SEER sc LT 1 2 Comfort cooling only 18 SEER sc MT 3 Process cooling only 2 LWT 12 SEPR HT 4 Process cooling only 12 none 5 Process...

Страница 28: ...de the operating limits stated in the Technical Catalogue will cause the unit to stop 5 2 Unintended use The unit must not be used in an explosive atmosphere in a flammable atmosphere in extremely dus...

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

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

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

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

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

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

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

Страница 36: ...f the unit does not affect its correct installation or its correct operation That is why it is necessary to avoid restricting the service spaces and installing covers that create recirculation between...

Страница 37: ...n the exchanger inlet pipe to protect the exchanger from slag or impurities in the pipes Air valves to be placed in the highest parts of the hydraulic circuit to allow the non condensable gases to be...

Страница 38: ...levant label on the unit If it does not there would be a risk of the evaporator being frozen since the antifreeze probe control would be thwarted The hydraulic circuit must be made in such a way as to...

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

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

Страница 41: ...lance between phases must always be less than 2 If this does not occur contact our technical department to choose suitable protection devices Make sure the power line is correctly connected with a cl...

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

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

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

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

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

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

Страница 48: ...ng the water filling valve When water begins to come out through the air valves close them and continue filling until the pressure value envisaged for the system is reached The unit should only be sta...

Страница 49: ...olute as shown in the image Fig 17 Bleeding the pump Before starting the unit check that all the closing panels of the unit are in place and secured with fixing screws 7 1 1 Checking the pre charge of...

Страница 50: ...e expansion coefficient of water pVE pre charge pressure of the expansion vessel barg pVS calibration pressure of the safety valve barg If the actual volume of the system is higher than this maximum v...

Страница 51: ...nstructions given in the documentation for the remote exchanger 7 1 4 Preliminary operations for the Free Cooling No Glycol circuit The units are dispatched from the factory with the free cooling circ...

Страница 52: ...revent damage to the hydraulic seals For units equipped with pump unit check that the pumps controlled with direct starting are rotating in the correct direction 7 2 2 Start Start the unit by acting o...

Страница 53: ...liquid sight glass The continuous passage of bubbles can indicate there is insuffi cient refrigerant and it needs to be topped up In this case check that the subcooling value is at least 5 C But the p...

Страница 54: ...er coil For free cooling units with decoupling exchanger FC NG where the head losses do not change only one value is set Do not set the water flow rate outside the operating limits allowed in the Tech...

Страница 55: ...and when it is not The operator has to repeat the manual procedure to find the pump operating speed with the free cooling valve open and then closed For free cooling units with decoupling exchanger F...

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

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

Страница 58: ...must be paid to the construction arrangements of the system 7 3 2 3 System type 1 The pump in the unit is also used for circulating water in the system A sample diagram is shown below Vmin U2 U1 Un Y2...

Страница 59: ...cal catalogue 7 3 2 2 System type 2 This system consists of a primary and a secondary circuit and it is also fitted with a hydraulic circuit breaker to make up for any difference in flow rate between...

Страница 60: ...t button click the arrow down button to select the Flowzer function and then press Enter to confirm Press the SET button and access the screen where the setpoint difference value is set up Press ENTER...

Страница 61: ...lp reduce the capacity of the buffer tank To this purpose the 3 way valves should be fitted on the furthest user points The bypass pipe must be of the same diameter as the connections of the unit 7 3...

Страница 62: ...here the unit can be installed Vmin U2 U1 Un Y2V Y2V Y3V VP A2 UL UE BT2 BT1 Pex BP41 The abbreviations present in the diagram indicate A2 cooling unit controller BT1 unit input temperature sensor BT2...

Страница 63: ...load varies If the demand from the system is reduced the pressure difference increases and the controller offsets it by reducing the pump speed which results in energy consumption saving The controlle...

Страница 64: ...reen where the setpoint difference value is set up use the arrow buttons to move and select the parameter to be edited Press ENTER to enable the edit window Use the arrow buttons to set the new value...

Страница 65: ...o set a pressure difference for operation in cooling mode and a pressure difference for operation in heating mode which helps the unit adapt to seasonal requirements This function requires the install...

Страница 66: ...is means that the water flow rate calculated by the system is higher than the required rated flow as a result of which the Pp setpoint must be reduced until the Pex parameter falls within the value ra...

Страница 67: ...Checking the minimum flow rate Progressively close all the user points and check that the pump speed slows progressively If the pump speed fails to be reduced the reason could be an excessive number...

Страница 68: ...P BTWB VPP A2 UL UE BT2 BT1 Pex BP41 The abbreviations present in the diagram indicate A2 cooling unit controller BT1 unit input temperature sensor BT2 unit output temperature sensor EU heat exchanger...

Страница 69: ...lant operating conditions with a flow rate lower than 50 of the rated flow rate of the refrigerant unit the primary circuit water will go through the bypass For correct operation of the unit even when...

Страница 70: ...m original instructions Letter L appears in the first screen of the Flowzer menu to indicate that the value Pex is lower than the setpoint stored in parameter PA22 If the value Pex is higher than the...

Страница 71: ...after the unit has been started the safety devices must be checked only the high and low pressure switches The checks must be carried out as described in the Periodic checks chapter The calibration v...

Страница 72: ...of water through the unit In this case it is necessary to check for closed or partially closed shut off devices in the hydraulic circuit and check the characteristics of the pumps and that they are wo...

Страница 73: ...he cause that trigge red it The unit does not start the display is off the control is powered correctly The unit is switched off from the di splay and the display is disconnected or not working Restor...

Страница 74: ...ilure of the protective devices to operate Check that the high pressure switches are working and if necessary replace them The valve must be replaced Opening of the valve due to overtem perature Repla...

Страница 75: ...e control the pump must always be kept running When the temporary stop is carried out in this way all that needs to be done to restart the unit is to set the control to ON 7 8 Stop for long periods of...

Страница 76: ...nutes before working on the electrical parts of the unit Circuits supplied from external sources made with orange cable can remain live even after the power sup ply to the unit has been turned off Wor...

Страница 77: ...in coastal or industrial areas or in areas where there are aggressive chemicals in the air periodic rinsing with clean water is considerably beneficial and helps counter corrosive effects Never clean...

Страница 78: ...vacuum cleaner clean the surface using a high pressure water cleaner and evenly and steadily spray the coil from the bottom upwards keeping the jet at an angle never more than 45 to the surface never...

Страница 79: ...the jet at an angle never more than 45 to the surface never exceed a jet pressure of 50 bar and always use a diffuser nozzle that is large enough 25 30 keep the diffuser nozzle at least 300 mm away fr...

Страница 80: ...the unit always clean the electrical control panel of any work remnants and extraneous components Restore the safety devices and protective devices that had to be removed in order to carry out the wo...

Страница 81: ...e equipment in accordance with the instructions in the safety data sheets for the chemical products used Also all technical and organisational measures for waste water treatment must be applied in acc...

Страница 82: ...where present is working cor rectly Monthly Check the crankcase heaters of the compressors Monthly Clean the metal filters in the hydraulic pipes Monthly Clean the finned coil by following the instru...

Страница 83: ...store the charge of refrigerant gas In the case of small oil leaks clean the dirty parts with absorbent cloths otherwise recover the leaked oil with absorbent sheets In any case the material used must...

Страница 84: ...ocal regulations The owner can return EEE to the dealer at the end of its life when purchasing equivalent new equipment This EEE may contain hazardous substances such as refrigerant gases lubricating...

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

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

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

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

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