BlueBox KAPPA V SR Guida all'installazione

Manual 101070B02

Issue 02.03

Replaces 06.02

KAPPA V SR

635 ÷ 1065 kW

0062

Installation, operating,

and maintenance

manual

Water chillers Air/water Axial fans and

self-contained screw compressors

ISO9001-Cert.n.0201

INDEX Page

KAPPA V SR water chiller 1

UNIT FRAME 1

COMPRESSORS 1

CONDENSER FANS 1

REFRIGERANT CIRCUIT 1

ELECTRICAL PANEL 1

CONTROLS AND SAFETY DEVICES 1

TESTING 2

KAPPA V SR UNIT VERSIONS 2

HYDRAULIC MODULE OPTIONS 2

ACCESSORY VERSIONS 2

REFRIGERANT CIRCUIT ACCESSORIES 2

HYDRAULIC CIRCUIT ACCESSORIES 3

ELECTRICAL ACCESSORIES 3

VARIOUS ACCESSORIES 3

SERIES 4

TYPE DESIGNATION 4

TECHNICAL DATA 5

ELECTRICAL CHARACTERISTICS AND COMPONENTS 7

TECHNICAL DATA - KAPPA V SR /ST 2PS 8

SOUND PRESSURE LEVELS 9

1. FIELD OF APPLICATION 10

1.1 INTRODUCTION 10

2. INSPECTION, TRANSPORT, SITE HANDLING 10

2.1 INSPECTION 10

2.2 LIFTING AND SITE HANDLING 10

3. SAFETY PRECAUTIONS 12

3.1 DEFINITION OF DANGER ZONE 12

3.2 SAFETY PRESCRIPTIONS 12

MECHANICAL HAZARDS 13

THERMAL HAZARDS 14

NOISE-RELATED HAZARDS 14

ELECTRICAL HAZARDS 14

REFRIGERANT SAFETY DATA - R407C 15

3.3 POSITIONING 17

4. INSTALLATION 19

4.1 INSTALLATION CLEARANCES 19

4.2 ANTI-VIBRATION ISOLATORS (option) 20

4.2.1 RubberAnti-VibrationIsolators 20

4.2.2 SpringAnti-VibrationIsolators 20

4.3 WATER PIPING CONNECTIONS 21

RECOMMENDED HYDRAULIC CIRCUIT DIAGRAM FOR KAPPA V SR 22

HYDRAULIC CIRCUIT DIAGRAM VERSION KAPPA V SR /ST 2PS 23

4.4 EVAPORATOR WATER PIPE CONNECTIONS 24

4.5 FLEXIBLE JOINTS 25

4.6 DESUPERHEATER HYDRAULIC CONNECTION (optional) 26

4.7 HEAT RECOVERY EXCHANGER HYDRAULIC CONNECTIONS (OPTIONAL) 27

DIAGRAM WITH 3-WAY VALVE 27

4.8 PRESSURE RELIEF VALVES 28

DIAGRAM WITH CONDENSING PRESSURE CONTROL VALVE 28

4.9 WATER FLOW RATE TO EVAPORATOR 29

4.10 CHILLER WATER TEMPERATURE (SUMMER CYCLE) 29

4.11 HOT WATER TEMPERATURE (winter cycle) 29

4.12 AMBIENT AIR TEMPERATURE 29

4.13 FAN SPEED CONTROL (optional) 29

4.14 OPERATION WITH LOW TEMPERATURE CHILLED WATER AT EVAPORATOR 30

TABLE 1 - FREEZING POINT FOR WATER-ANTIFREEZE MIXTURES 30

OPERATING LIMITS 31

EVAPORATOR PRESSURE DROP 32

PUMPS AVAILABLE PRESSURE - MODEL KAPPA V SR /ST 2PS 33

ELECTRICAL PANEL LAY OUT 34

4.15 ELECTRICAL CONNECTIONS 37

4.15.1 General 37

4.15.2 Power supply to crankcase heaters 37

4.15.3 Potential free contacts 38

4.15.4 Circulating pump electrical connections 38

4.15.5 Microprocessorcontrollers 38

4.15.6 RS485 serial interface (optional) 38

4.15.7 User interface - Microprocessor pCO239

5. START-UP 41

5.1 PRELIMINARY CHECKS 41

5.2 OPERATING DESCRIPTION 41

5.2.1 Introduction 41

5.2.2 Unit in stand-by mode 41

5.2.3 Enabling the unit 42

5.2.4 Pump management (ST units only) 42

5.2.5 Compressorstart-up 42

5.2.6 Chiller mode operation 42

5.2.7 Heat pump mode operation 42

5.2.8 Evaporator low temperature chilled water protection 42

5.2.9 Evaporator anti-freeze protection electric heater (optional) 42

5.2.10 Compressoroperation 43

5.2.11 Compressors and capacity steps management 43

5.2.12 High and low pressure alarms 44

5.2.13 Low ambient temperature kit (option - condens. control with fan speed regulator) 44

5.2.14 Changeover from chiller to heat pump and vice versa 44

5.2.15 Defrosting (heat pump units only) 44

5.2.16 Total heat recovery (option) 45

5.2.17 Dualset-point(option) 45

5.2.18 Operation leaving water temperature control (option) 46

5.3 STARTING THE UNIT 46

5.4 STOPPING THE UNIT 47

5.4.1 Temporarystop: 47

5.4.2 Seasonal stop: 47

5.5 EMERGENCY STOP 47

6CHECKS DURING OPERATION 48

6.1 INTRODUCTION 48

6.1.1 Checking the refrigerant charge 48

7. CALIBRATION OF CONTROL EQUIPMENT 49

7.1 INTRODUCTION 49

TABLE 2 - CALIBRATION OF CONTROL EQUIPMENT 49

TABLE 3 - CALIBRATION OF SAFETY DEVICES 49

8. MAINTENANCE AND PERIODIC CHECKS 50

8.1 WARNINGS 50

8.2 INTRODUCTION 50

8.3 REPAIRING THE REFRIGERANT CIRCUIT 51

8.3.1 Leak test 51

8.3.2 High vacuum and dehydration of the refrigerant circuit 51

8.3.3 Refrigerantcharge 52

8.4 ENVIRONMENTAL CONSIDERATIONS 52

9. TROUBLESHOOTING 53

10. DECOMMISSIONING THE UNIT 62

REFRIGERANT CIRCUIT 63

OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS 66

Blue Box 1

KAPPA V SR water chiller

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

Direct drive semihermetic screw compressors. Crankcase heater and lubrication through pressure difference

between suction and discharge pressure.

Optional continuous capacity control available, to maximize the efficiency of the unit in all working conditions.

Electronic motor protection via thermal sensors embedded in the windings. Star-Delta start and capacity step as

standard.

CONDENSER

Composed of a high efficiency coil manufactured from copper tubes and aluminium fins. Mesh guard to protect

the coil supplied as standard.

CONDENSER FANS

Axial fans, with sickle shaped blades and special bell mouth designed to reduce noise, directly coupled toa 6 pole

motor with internal Klixon overload protection. Motor protection category is IP 54. The fan is equipped with a

safety grille to UNI EN 294.

EVAPORATOR

Shell and tube direct expansion evaporator. The evaporator is thermally insulated with closed cell expanded

material. Each evaporator is equipped with a low water temperature probe for freeze protection.

REFRIGERANT CIRCUIT

Comprising: compressor discharge shut-off valve, liquid valve, charge connection, liquid line sight-glass, filter/

dryerwithinterchangeablesolidcartridge,thermostaticexpansionvalvewithexternalpressure equalisation, high

and low pressure values and relative condensation and evaporation temperatures are measured by pressure

transducers that relay signals that are displayed on the controller.

ELECTRICAL PANEL

The electrical panel includes:

- main switch

- fuses to protect auxiliary and power circuits

-compressorcontactors

-fancontactors

Themicroprocessor controls thefollowing functions:

- water temperature regulation

- freeze protection

- compressor time intervals

- compressor start sequence and automatic lead/lag selection

- alarm signalling

- alarm reset

- common alarm contact for remote signalling

LCD display of the following information:

- water inlet and outlet temperature

-programmed temperature set-point and differential

- alarm descriptions

- compressor hours run meter, number of unit and compressor starts and pumps (if installed)

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

CONTROLS AND SAFETY DEVICES

- safety high pressure switch with manual reset

- high/low pressure safety with manual reset controlled by the microprocessor control

- high pressure relief valve

Blue Box 2

- compressors over-temperature protection on discharge gas with liquid injection

- chilled water temperature probe (at evaporator inlet)

- freeze protection probe at the evaporator outlet

-compressor over-temperature protection

-fanover-temperature protection

TESTING

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

KAPPA V SR UNIT VERSIONS

KAPPA V SR /HP: reverse cycle heat pump

In addition to the components of version KAPPA V SR, this unit includes:

- Refrigerant circuit: 4-way reversing valve, suction separator, liquid receiver, second thermostatic expansion

valve.

- Electrical panel: Microprocessor enabled for summer/winter changeover and automatic defrost,

HYDRAULIC MODULE OPTIONS

KAPPA V SR 2PS: unit with storage tank and pumps.

In addition to the components of version KAPPA V SR this unit includes:

insulated storage tank; run and standby circulating pumps, with automatic changeover by time or fault.

Expansion tank, check valves and gate valves.

Version ST is available in the following additional four configurations:

- ST 1PS : with 1 pump and a tank;

- ST 2P : with 2 pumps without a tank;

- ST S : with tank without pumps;

- ST 1P : with 1 pump without a tank.

ACCESSORY VERSIONS

KAPPA V SR /DC: unit with heat recovery condenser.

In addition to the components of version KAPPA V SR this unit includes for each compressor a 100% heat

recoverycondenser for the production of hot water. The microprocessor automaticallycontrolsthe water tempe-

rature and the heat recovery safety switch.

KAPPA V SR /LN: low noise unit

In addition to the components of version KAPPA V SR this unit includes:

compressors located in a sound absorbing enclosure of painted galvanized steel, internally lined with sound

absorption material having an intermediate layer of high acoustic impedance material.

REFRIGERANT CIRCUIT ACCESSORIES:

- Desuperheaters

The desuperheater heat exchanger is arranged in series with the condensing coil. It is also available in a

heat pump configuration. In this case a shut-off valve must be fitted on the water recovery circuit, to be

closed during heat pump mode operation, as described in the manual.

- Pressure gauges.

Available on all models. Suction and discharge pressure values, read by transducers that relay the results to

the controller display, are already displayed as standard on all models.

Blue Box 3

HYDRAULIC CIRCUIT ACCESSORIES

- Anti-freeze evaporator heater

- Water side relief valve (version ST only). The value is set at 6 bar, corresponding to the maximum permissible

workingpressure.

- Leaving water temperature control (Not available on HP version).

- Mechanical flow switch

ELECTRICAL ACCESSORIES

-Serial interface RS 485 with protocol Modbus; thefollowingoptional protocols are also available: Carel; Echelon

version RS485 or version FTT10

- Power factor correction cosf≥0.9 at nominal operating conditions

- Single voltage-free contacts for machine status signals

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

- Set-point variable with remote signal (0-1 V, 0-10 V, 0-4 mA, 0-20 ma)

- Dual set-point

With double thermostatic valves + solenoid valves. Two set-points can be programmed and switched

between each other from the keypad or using a digital input. The type of selection must be specified at the

time of order. In all cases the thermostatic valves switch automatically on the basis of the water temperature.

- 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.

- 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.

- Additional compressor capacity step

-Compressor continuous capacity step control

- Electronic expansion valve

- Liquid line solenoid valve

- Liquid receivers (standard on version /HP)

- Compressor suction valves

VARIOUS ACCESSORIES

-Rubberor spring type anti-vibration mounts

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

- Timber crate packing

- Pallet/skid for container shipment

-Non-standard RAL paint colours

Blue Box 4

SERIES

The KAPPA V SR series of water cooled chillers and heat pumps, are available in various sizes with capacities

from 635 to 1.065 kW (capacities refer to water entering/leaving 12/7 °C, ambient air 35 °C) in the following

basic versions:

- KAPPA V SR coolingonly

- KAPPA V SR/HP heat pump

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

TYPE DESIGNATION

unit type series /version /option hydraulic modul /accessory version size

KAPPA V SR 65.2

/ST 1P 73.2

/HP /ST 2P /LN 80.2

/ST 1PS /DS 84.2

/ST 2PS /DC 88.2

/ST S /LN/DS 93.2

/LN/DC 100.2

106.3

Type designation example: KAPPA.V SR /HP/DS 100.2

Meaning of values 100 . 2

Number to identify the indicative Number of compressors

cooling capacity (in this case 100 kW)

Corrente massima di spunto

Max starting current

Max. Anlaufstrom

Courant maxi démarrage

Tipo refrigerante

Refrigerant type

Kältemittel Typ

Type de refrigerant

Numero circuiti refrigerante

Refrigerant circuit number

Anzahl des Kältemittelkreislaufes

Numero circuits refrigerant

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

Press. massima circuito refriger.

Max. Refrigerant circuit pressure

Max. Druck Kältekreislauf

Pression maxi circuit refrigerant

IP quadro elettrico

IP electrical board

IP E-Schrank

IP tableau electrique

Tensione circuiti ausiliari

Auxiliary circuit voltage

Steuerspannung

Tension circuits auxiliares

Matricola/Serial number

(BBOX) Matrikel/Matricule

Corrente massima assorbita

Max absorbed current

Maximalstromverbrauch

Courant maxi absorbée

Modello/Model

Modell/Modèle

Tensione-Fasi-Frequenza

Voltage-Phasses-Frequency

Spannung-Phasses-Frequenz

Tension-Phasses-Fréquence

A A

kPa

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

Kältemittelfüllung KreislaufCharge de refigerant chaque circuit

(kg)

/(kg)/(kg)

bar

0062

ViaEnricoMattei,20

35028 PiovediSacco(PD)

ITALY

Tel.+039.049.9716300

Corrente massima di spunto

REFRIGERANTE - REFRIGERANT - KÄLTEMITTEL - REFRIGERANT

MATRICOLA - MATRICULE - SERIAL NO. - SERIENUMMER

MODELLO - MODELE - MODEL - TYP

0062

ViaEnricoMattei,20

35028 PiovediSacco(PD)

ViaEnricoMattei,20

35028 PiovediSacco(PD)

ITALY

Tel.+039.049.9716300

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