BlueBox KAPPA V 2001 Manuale utente

ManualManual

Manual M 55M 55

M 55M 55

M 55

Issued 03.0103.01

03.0103.01

03.01

Replaces - - -- - -

- - -- - -

- - -

Operating,Operating,

Operating,

installationinstallation

installation

and maintenance manualand maintenance manual

and maintenance manual

KAPPA.V 2001

155 ÷ 539 kW

Air/Water chillers and heat pumpsAir/Water chillers and heat pumps

Air/Water chillers and heat pumps

Axial fans and screw compressorsAxial fans and screw compressors

Axial fans and screw compressors

i

INDEX Page

KAPPA V 2001 water chiller 1

OTHER VERSIONS 2

ACCESSORIES: 2

THE SERIES 3

FIELD OF APPLICATION 4

1. GENERAL 4

2. INSPECTION, TRANSPORTATION AND POSITIONING 4

2.1 INSPECTION 4

2.2 LIFTING AND TRANSPORTATION 4

3. SAFETY REQUIREMENTS 6

3.1 DANGEROUS AREA 6

3.2. SAFETY 6

MECHANICAL SAFETY DATA 7

THERMAL SAFETY DATA 8

NOISE SAFETY DATA 8

ELECTRICAL SAFETY DATA 8

REFRIGERANT SAFETY DATA - R407C 9

3.3 POSITIONING 11

4. INSTALLATION 12

4.1 INSTALLATION CLEARANCES 12

4.2 GENERAL RECOMMENDATIONS FOR WATER PIPE CONNECTION 12

HYDRAULIC CIRCUIT “ST” VERSION 14

4.3 WATER CONNECTIONS TO EVAPORATOR 15

4.4 INSTRUCTIONS FOR ASSEMBLING THE WATER FLOW SWITCH 16

4.5 WATER CONNECTION TO THE DESUPERHEATER (optional) 17

4.6 HYDRAULIC CONNECTION TO THE RECOVERY CONDENSER (optional) 18

THREE-WAY VALVE LAYOUT 18

4.7 SAFETY VALVE DISCHARGE 19

PRESSURE-OPERATED VALVE LAYOUT 19

4.8 ELECTRICAL CONNECTIONS 20

4.8.1 GENERAL NOTES 20

4.8.2 POTENTIAL FREE CONTACTS 21

4.8.3 CIRCULATOR PUMP ELECTRICAL CONNECTIONS 21

4.8.4 MICROPROCESSOR CONTROLS INSTALLED ON THE UNITS 21

4.8.6 USER INTERFACE - MICROPROCESSOR pCO222

4.9 CONNECTIONS FOR “LE” VERSION (CONDENSING UNIT) 23

4.9.1 REFRIGERANT CONNECTIONS 23

4.9.2 PIPELINE ROUTES AND MAXIMUM DISTANCE BETWEEN SECTIONS 23

4.9.3 RECOMMENDATIONS FOR INSTALLATION OF THE REFRIGERANT LINE 24

Evaporator section located below the condensing unit: 24

Evaporator section located above the condensing unit: 24

TABLE I - CONNECTION PIPE DIAMENTERS FOR “LE” VERSIONS 25

4.9.4 “LE” VERSIONS - ELECTRICAL CONNECTIONS 25

5. START-UP 26

5.1 PRELIMINARY CHECKS 26

5.2 WORKING DESCRIPTION 26

5.2.1 General 26

5.2.2 Unit in stand-by mode 26

5.2.3 Enabling the unit 27

5.2.4 Pump control (ST unit only) 27

5.2.5 Compressor start-up 27

5.2.6 Chiller operation 27

5.2.7 Heat pump operation 27

5.2.8 Evaporator antifrost 27

5.2.9 Antifrost heater (optional) 28

5.2.10 Compressors 28

5.2.11 High and low pressure alarms 28

5.2.12 Compressor operation 28

ii

5.2.13 Compressor and step capacity control 28

5.2.14 Low temperature kit (option) 29

5.2.15 Changeover between chiller and heat pump modes 29

5.2.16 Defrosting (heat pump only) 29

5.3 COMMISSIONING 31

5.4 CHECKS DURING OPERATION 32

5.5 REFRIGERANT CHARGE CHECK 32

REFRIGERANT CIRCUIT:

KAPPA V 2001 - CHILLER VERSION 33

KAPPA V 2001HP - HEAT PUMP VERSION 33

KAPPA V 2001 DC - FULL RECOVERY VERSION 34

KAPPA V 2001 LE - MOTOCONDENSING UNIT VERSION 34

5.6 SHUTTING DOWN THE UNIT 36

5.7 EMERGENCY SHUTDOWN 36

6. OPERATING LIMITS 37

PRESSURE DROP 39

6.1 EVAPORATOR WATER FLOW RATE 40

6.2 CHILLED WATER TEMPERATURE (summer cycle) 40

6.3 HOT WATER TEMPERATURE (winter cycle) 40

6.4 AMBIENT AIR TEMPERATURE 40

6.5 FAN SPEED CONTROL (optional) 40

6.6 OPERATION WITH LOW TEMPERATURE WATER 41

TABLE III - WATER/ANTIFREEZE MIXTURES FREEZING POINTS 41

7. CALIBRATION OF CONTROL DEVICES 42

7.1 GENERAL 42

TABLE IV - CONTROL DEVICE SETTINGS 42

TABLE V - SAFETY DEVICE SETTINGS 42

8. MAINTENANCE AND PERIODIC CHECKS 43

8.1 WARNINGS 43

8.2 GENERAL 43

8.3 REPAIRS TO REFRIGERANT CIRCUIT 44

8.3.1 LEAKAGE CHECK 44

8.3.2 VACUUM AND DRYING REFRIGERANT CIRCUIT 44

8.3.3 REFRIGERANT CHARGE 45

8.4 ENVIRONMENTAL STANDARDS 45

9. PUTTING THE MACHINE OUT OF SERVICE 46

10. TROUBLESHOOTING 46

OVERALL DIMENSIONS AND HYDRAULIC CONNECTIONS 54

WEIGHT DISTRIBUTION ON BASE FRAME 59

SOUND PRESSURE LEVEL 61

a

TECHNICAL DATATECHNICAL DATA

TECHNICAL DATA

Refrigerant R407cRefrigerant R407c

Refrigerant R407c

MODEL KAPPA V 2001 16.1 18.1 23.1 27.1 32.2

Cooling (*)

Nominal capacity kW 155,9 180,2 223,8 269,5 311,7

Water flow evaporator (1) l/s 7,447 8,608 10,691 12,878 14,894

l/h 26.810 30.990 38.489 46.360 53.619

Pressure drop evaporator kPa 39,6 45,2 26,7 38,7 39,6

Heating (**)

Nominal capacity kW 154,5 178,7 219,5 263,4 309,1

Water flow condenser (1) l/s 7,383 8,536 10,487 12,586 14,767

l/h 26.580 30.728 37.753 45.311 53.160

Pressure drop condenser kPa 38,9 44,5 25,7 37 38,9

Compressors tipo

Number n11112

Absorbed power cooling (*) kW 60,1 69,5 83,9 100,1 120,3

Absorbed power heating (**) kW 58,4 67,5 81,4 97,1 116,7

Capacity steps % 0-50-100 0-50-100 0-50-100 0-50-100 0-25-50-

75-100

Condenser cooling fans type

Total air flow m3/s 10,833 10,833 22,222 20,889 21,111

m3/h 39.000 39.000 80.000 75.200 76.000

Fan motor capacity n x kW 2 x 2,0 2 x 2,0 4 x 2,0 4 x 2,0 4 x 2,0

Nominal fan speed RPM

Motor power supply V/Ph/Hz

Refrigerant charge

Chiller version kg 1 x 38 1 x 39 1 x 68 1 x 82 2 x 38

Heat pump version kg 1 x 44,0 1 x 45,0 1 x 81,4 1 x 95 2 x 44,0

Oil

Oil charge kg 1 x 10 1 x 10 1 x 11 1 x 11 2 x 10

Oil brand

Oil Type

Evaporator type

Evaporator water content l 1 x 14,3 1 x 15,7 1 x 22,0 1 x 22,0 2 x 14,3

Exchanger max working pressure

waterside bar3030252530

Dimensions and weights

Length mm 2.649 2.649 2.789 2.789 2.796

Width mm 1.256 1.256 2.303 2.303 2.280

Height mm 2.385 2.385 2.385 2.385 2.385

Shipping weight kg 1.305 1.331 1.842 1.892 2.583

(1) total water flow

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

(**) outside air temperature 8 °C BS, 50% U.R. - water temperature entering/leaving condenser 40-45 °C.

DEA

SE 170

semiermetico a vite

assiali

900

400V 3 ~ 50Hz

scambiatore a piastre

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b

TECHNICAL DATATECHNICAL DATA

TECHNICAL DATA

Refrigerant R407cRefrigerant R407c

Refrigerant R407c

MODEL KAPPA V 2001 37.2 41.2 46.2 50.2 55.2

Cooling (*)

Nominal capacity kW 360,3 403,9 447,5 493,3 539,1

Water flow evaporator (1) l/s 17,217 19,3 21,383 23,569 25,755

l/h 61.980 69.479 76.978 84.849 92.719

Pressure drop evaporator kPa 45,2 29,9 36,7 32,4 38,7

Heating (**)

Nominal capacity kW 357,3 398,1 439 482,9 526,9

Water flow condenser (1) l/s 17,071 19,023 20,974 23,073 25,173

l/h 61.456 68.481 75.506 83.064 90.622

Pressure drop condenser kPa 44,5 29 35,3 31,1 37

Compressors tipo

Number n

Absorbed power cooling (*) kW 139,1 153,5 167,9 184 200,2

Absorbed power heating (**) kW 134,9 148,9 162,9 178,5 194,1

Capacity steps %

Condenser cooling fans type

Total air flow m3/s 21,667 31,5 31,556 42,556 41,778

m3/h 78.000 113.400 113.600 153.200 150.400

Fan motor capacity n x kW 4 x 2,0 6 x 2,0 6 x 2,0 8 x 2,0 8 x 2,0

Nominal fan speed RPM

Motor power supply V/Ph/Hz

Refrigerant charge

Chiller version kg 2 x 39 2 x 61 2 x 61 1 x 82 2 x 82

+ 1 x 68

Heat pump version kg 2 x 45,0 2 x 74 2 x 74 1 x 95 2 x 95

+ 1 x 81,4

Oil

Oil charge kg 2 x 10 1 x 11 2 x 11 2 x 11 2 x 11

+ 1 x 10

Oil brand

Oil Type

Evaporator type

Evaporator water content l 2 x 15,7 1 x 42,8 1 x 42,8 2 x 22,0 2 x 22,0

Exchanger max working pressure

waterside bar3025252525

Dimensions and weights

Length mm 2.796 3.991 3.991 5.201 5.201

Width mm 2.280 2.280 2.280 2.280 2.280

Height mm 2.385 2.385 2.385 2.385 2.385

Shipping weight kg 2.625 3.267 3.412 3.899 3.961

(1) total water flow

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

(**) outside air temperature 8 °C BS, 50% U.R. - water temperature entering/leaving condenser 40-45 °C.

scambiatore a piastre

DEA

SE 170

0-25-50-75-100

2

900

400V 3 ~ 50Hz

semiermetico a vite

assiali

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c

TECHNICAL DATATECHNICAL DATA

TECHNICAL DATA Refrigerant R407cRefrigerant R407c

Refrigerant R407cRefrigerant R407c

Refrigerant R407c

CHARACTERISTICS AND ELECTRICAL DATACHARACTERISTICS AND ELECTRICAL DATA

CHARACTERISTICS AND ELECTRICAL DATA

(1) Electric power supply which must be available from the net

(2) Current of intervention of the internal protections of unit. It is the max absorbed current of unit. This value is

never exceeded and must be utilized to dimension the line supply and the protections (see el. diagram of unit).

The values in parenthesis are referred to /ST versions (units with storage tank) or units with pumps only

MODEL KAPPA V 2001 16.1 18.1 23.1 27.1 32.2

Max absorbed power (1) Kw 74,3 85,3 106,1 124,9 148,6

Kw (74,3) (85,3) (111,6) (134,1) (157,8)

Max starting current A 163 196 256 279 295

A (163) (196) (268) (298) (314)

Max absorbed current (2) A 132 148 184 212 264

A (132) (148) (196) (231) (283)

Nominal capacity fan motor kW

Nominal current fan motor kW

Nominal capacity pump motor kW

Nominal current pump motor A

Power supply V/Ph/Hz

Control power supply V/Ph/Hz

2 x 2,0

2 x 4,0

4 x 2,0

4 x 4,0

400V 3N ~ 50Hz ±5% V

230V 1 ~ 50Hz ±5% V

---

(1 x 5,5)

(1 x 12,0)

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MODEL KAPPA V 2001 37.2 41.2 46.2 50.2 55.2

Max absorbed power (1) Kw 170,6 191,4 208,2 231 249,8

Kw (179,8) (200,6) (217,4) (240,2) (259)

Max starting current A 344 404 432 463 491

A (363) (423) (451) (482) (510)

Max absorbed current (2) A 296 332 360 396 424

A (315) (351) (379) (415) (443)

Nominal capacity fan motor kW 4 x 2,0

Nominal current fan motor kW 4 x 4,0

Nominal capacity pump motor kW (1x55)

Nominal current pump motor A (1x12)

Power supply V/Ph/Hz

Control power supply V/Ph/Hz

6 x 2,0

6 x 4,0

8 x 2,0

8 x 4,0

400V 3N ~ 50Hz ±5% V

230/~/50

(1 x 9,2)

(1 x 19,0)

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d

TECHNICAL DATATECHNICAL DATA

TECHNICAL DATA Refrigerant R407cRefrigerant R407c

Refrigerant R407cRefrigerant R407c

Refrigerant R407c

VERSION WITH STORAGE TANK - STVERSION WITH STORAGE TANK - ST

VERSION WITH STORAGE TANK - ST

MODEL KAPPA V 2001 16.1 18.1 23.1 27.1 32.2

Pumps group

Water flow evaporator l/s --- --- 10,691 12,878 14,894

l/h --- --- 38.489 46.360 53.619

Nominal pump capacity kW --- --- 5,5 5,5 5,3

Available pump head kPa --- --- 253 231 205

Storage tank capacity l --- --- 600 600 600

Dimensions and weights

Length mm --- --- 2.789 2.789 2.796

Width mm --- --- 2.303 2.303 2.280

Height mm --- --- 2.385 2.385 2.385

Shipping weight kg --- --- 2.167 2.217 2.908

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MODEL KAPPA V 2001 37.2 41.2 46.2 50.2 55.2

Pumps group

Water flow evaporator l/s 17,217 19,3 21,383 23,569 25,755

l/h 61980 69479 76.978 84.849 92.719

Nominal pump capacity kW 5,5 9,2 9,2 9,2 9,2

Available pump head kPa 164 219 199 186 159

Storage tank capacity l 600 750 750 750 750

Dimensions and weights

Length mm 2796 3.991 3.991 5.201 5.201

Width mm 2280 2.280 2.280 2.280 2.280

Height mm 2385 2.385 2.385 2.385 2.385

Shipping weight kg 2950 3.905 4.050 5.637 5.697

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1

KAPPA V 2001 water chillerKAPPA V 2001 water chiller

KAPPA V 2001 water chiller

UNIT FRAMEUNIT FRAME

UNIT FRAME

Self-supporting frame made from galvanised steel protected with polyester powder paint enamel (stoved at 180°)

for resistance to atmospheric agents. Stainless steel screws and bolts.

COMPRESSORS

screw-type semi-hermetic compressor, direct male rotor/female rotor drive, with crankcase heater. Lubrification

ensured by delivery and intake pressure difference.

Continuous cooling capacity control available, enabling to maximise the energetic efficiency of the unit in any

working condition.

Integral electronic motor protection and temperature sensors inserted directly in windings.

Delta-star motor start-up and standard capacity step reduction.

CONDENSERSCONDENSERS

CONDENSERS

Feature tube bundle coils made of copper tubes and high-efficiency aluminium fins. The use of V condensing coils

enables to reduce the unit dimensions, as well as to increase the air suction surface.

FANSFANS

FANS

Axial fans featuring sickle-shaped vane and conveyer designed to reduce noise emissions, directly driven by 6-

pole three-phase electric motor with integrated klixon thermal overload protection. IP 54 motor protection grading.

Fitted with safety fan guard.

EVAPORATOREVAPORATOR

EVAPORATOR

AISI 316 stainless steel braze-welded plate type. The use of plate-type exchangers enables to:

-

reduce the amount of refrigerant fluid in the cicuit

-

reduce the weight of the unit

-

make maintenance easier

-

reach higher COP/EER ratios

Insulated with closed-cell foam material for reduced heat loss.

All evaporators are fitted with temperature probe for anti-freeze protection.

REFRIGERANT CIRCUITREFRIGERANT CIRCUIT

REFRIGERANT CIRCUIT

Includes: compressor delivery valves, liquid line shut-off valve, charging connection, liquid sight glass, drier filter,

thermostatic valve, high and low pressure gauges, evaporation and condensation temperature readout by control.

ELECTRICAL PANELELECTRICAL PANEL

ELECTRICAL PANEL

IP 54 category includes:

-

main switch

-

power cicuit automatic circuit breakers and fuses

-

compressor contactors

-

fan contactors

-

microprocessor for control of the following functions:

- water temperature control

- anti-freeze protection

- compressor operation timing

- compressor automatic start-up sequence

- alarm signals

- alarm reset

- potential contact for remote alarm signals

- digital display of:

-

inlet and outlet water temperature

-

temperature and differential settings

-

alarm description

-

hour meters readout of operation and number of unit, compressor and pump (if present) start-ups

- high and low pressures, relative condensation and evaporation temperature controls.

2

CONTROL AND SAFETY DEVICESCONTROL AND SAFETY DEVICES

CONTROL AND SAFETY DEVICES

- manual-reset high pressure switch

- manual-reset low pressure switch

- safety valve

- mechanical flow switch

- compressor overload cut-out device

TESTSTESTS

TESTS

Units are factory tested and come with oil and refrigerant fluid charges.

OTHER VERSIONSOTHER VERSIONS

OTHER VERSIONS

KAPPA V 2001 /HP: reversible heat pumpKAPPA V 2001 /HP: reversible heat pump

KAPPA V 2001 /HP: reversible heat pump

Besides the standard components of the KAPPA V 2001 version, the unit includes:

- Cooling circuit: 4-way diverting valve, suction line separator, liquid accumulator, second thermostatic expansion

valve.

- Electric panel: Microprocessor is configured for summer/winter changeover and automatic defrost, autonomously

controlled for each compressor (except models 41.2 and 46.2).

KAPPA V 2001 /DC: unit with heat recovery condenserKAPPA V 2001 /DC: unit with heat recovery condenser

KAPPA V 2001 /DC: unit with heat recovery condenser

Besides the standard components of the KAPPA V 2001 version, for each compressor the unit includes a 100%

heat recovery condenser for hot water production. The recovery water temperature control, the condensing

pressure step control and the safety heat recovery disabling are automatically handled by the microprocessor.

KAPPA V 2001 ST:KAPPA V 2001 ST:

KAPPA V 2001 ST:

unit with storage tank and water pumpsunit with storage tank and water pumps

unit with storage tank and water pumps (except 16.1-18.1).(except 16.1-18.1).

(except 16.1-18.1).(except 16.1-18.1).

(except 16.1-18.1).

Besides the standard components of the KAPPA V 2001 version, the unit includes:

insulated storage tank, two water pumps, one of which in stand-by, with automatic timed commutation and in

case of failure. Expansion vessel, check valves, gate valves and mechanical flow switch installed.

KAPPA V 2001 /LE: condensing unitKAPPA V 2001 /LE: condensing unit

KAPPA V 2001 /LE: condensing unit

The unit is manufactured without evaporator, thermostatic expansion valve and microprocessor control. Liquid

receivers can be supplied on request. Liquid line solenoid valves are supplied as standard equipment.

KAPPA V 2001 /LN: low noise unitKAPPA V 2001 /LN: low noise unit

KAPPA V 2001 /LN: low noise unit

Besides the standard components of the KAPPA V 2001 version, the unit includes:

compressors fitted in soundproofed compartment made of painted galvanized sheet with internal insulation,

sound-absorbing mat with inserted lead plate.

ACCESSORIES:ACCESSORIES:

ACCESSORIES:

- no-frost electric heater on evaporator

- fan speed regulator for operation in low ambient temperatures

- desuperheaters

- external water supply side collectors (mod. 32.2 and 37.2)

- internal water supply side collectors (mod. 50.2 and 55.2)

- rubber or spring vibration dampers

- microprocessor serial interface for supervision or tele-maintenance via personal computer

- additional compressor step control

- continuous compressor step control electronic expansion valve

- tube bundle and compressor compartment protective metal filter mesh

- compressor power factor correction

- remote control terminal

- anti-corrosion treted coils for use in aggressive atmospheres

3

THE SERIESTHE SERIES

THE SERIES

KAPPA.V 2001 2000 chillers and heat pump series are available in various sizes with capacities ranging from

155.9 to 539.1 kW kW (capacities refer to water temperatures at inlet/outlet of 12°/7°C, ambient air tempera-

ture 35° C) in the following basic versions:

- KAPPA.V 2001 chiller only

- KAPPA.V/HP 2001 heat pump

The model can be identified by two numbers:

Kappa V 2001 37.2Kappa V 2001 37.2

Kappa V 2001 37.2

Nominal cooling capacity * in kW x 10 number of circuits

* Capacity refers to water inlet/outlet 12°/7°C, ambient air temperature 35°C.

Model, factory number, technical data, electric power supply, etc. are reported on the labels of the unit.

BlueBox KAPPA V 2001 Manuale utente

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