Blue Box ZETA 2002 3,2 Installation, Operating And Maintenance Manual
  1. Manuals
  2. Brands
  3. Blue Box Manuals
  4. Chiller
  5. ZETA 2002 3,2
  6. Installation, operating and maintenance manual

Blue Box ZETA 2002 3,2 Installation, Operating And Maintenance Manual

Zeta 2002
Hide thumbs
Table of Contents

Advertisement

Quick Links

ZETA 2002
38 - 266 kW
Installation, operating,
and maintenance
manual
Water chillers
Manual 101010B02
Issue
Replaces
Air/water
self-contained
ISO 9001 - Cert. n. 0201
11.02
04.02
0062
Axial fans and
scroll compressors

Advertisement

Table of Contents

Troubleshooting

loading
Need help?

Need help?

Do you have a question about the ZETA 2002 3,2 and is the answer not in the manual?

Questions and answers

Related Manuals for Blue Box ZETA 2002 3,2

Summary of Contents for Blue Box ZETA 2002 3,2

  • Page 1 ZETA 2002 Manual 101010B02 11.02 Issue 38 - 266 kW 04.02 Replaces Installation, operating, and maintenance manual 0062 Water chillers Air/water Axial fans and self-contained scroll compressors ISO 9001 - Cert. n. 0201...

  • Page 3: Table Of Contents

    - Timber packing crate ....................5 - Pallet/skid for shipment in a container ..............5 - Mesh coil guard with metallic filter ................5 - Anticorrosion treatment of coils for use in aggressive environments ......5 - Non-standard RAL paint colours ................5 Blue Box...
  • Page 4 TABLE 1 - EXTERNAL PIPE DIAMENTERS FOR /LE VERSIONS ......... 46 4.10 WATER FLOW RATE TO EVAPORATOR ..............47 4.11 CHILLER WATER TEMPERATURE (SUMMER CYCLE) ..........47 4.12 HOT WATER TEMPERATURE (WINTER CYCLE) ............47 4.13 AMBIENT TEMPERATURE ..................47 4.14 FAN SPEED CONTROL (OPTIONAL) ................47 Blue Box...
  • Page 5 Heat pump mode operation ................. 78 8.2.8 Evaporator low temperature chilled water protection ..........78 8.2.9 No-frost heater installed on the evaporator (optional) ..........78 8.2.10 Compressor operation ..................78 8.2.11 Compressors management .................. 79 8.2.12 High and low pressure alarms ................79 Blue Box...
  • Page 6 High vacuum and dehydration of the refrigerant circuit .......... 94 12.3.3 Refrigerant charge ....................95 12.4 ENVIRONMENTAL CONSIDERATIONS ............... 95 DECOMMISSIONING THE UNIT ................96 REFRIGERANT CIRCUIT ..................97 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CIRCUIT CONNECTIONS ..109 Blue Box...

  • Page 7: Zeta 2002 - Water Chiller

    The microprocessor controls the following functions on all units: - water temperature regulation - freeze protection - compressor time intervals - compressor start sequence and automatic lead/lag selection - alarm reset - common alarm contact for remote signalling - operating and alarm indicator LEDs Blue Box - 1...

  • Page 8: Controls And Safety Devices

    The basic ZETA 2002/HP model is not equipped with an evaporator, a thermostatic valve and four compressor models are not supplied with a microprocessor controller. Liquid receivers can be supplied as an accessory. The solenoid valve on the liquid line is supplied as standard. Blue Box - 2...

  • Page 9: Hydraulic Module Options

    ZETA 2002 /SLN: extra low noise unit In addition to the components of version LN, this unit is designed to operate with a slower fan speed to further reduce noise levels. Blue Box - 3...

  • Page 10: Refrigerant Circuit Accessories

    - Single voltage-free contacts for machine status signals - Set-point variable in a range of 3 °C with remote signal (0-1V, 0-10V, 0-4mA, 0-20mA). Available only for models from 16.4 to 26.4 - Remote user terminal panel (in addition to the standard terminal) Blue Box - 4...

  • Page 11: Various Accessories

    - Timber crate packing - Pallet/skid for container shipment - Mesh coil guard with metallic filter. Standard equipment on models from 14.4 to 26.4. - Anti-corrosion treatment of coils for use in aggressive environments - Non-standard RAL paint colours Blue Box - 5...

  • Page 12: Series

    Kältemittelfüllung Kreislauf (kg)/ Charge de refigerant chaque circuit (kg) SCHEMA IDRAULICO REFRIGERANTE - REFRIGERANT - KÄLTEMITTEL - REFRIGERANT DISEGNO MECCANICO MODELLO MODELE MODEL -TYP MATRICOLA - MATRICULE SERIAL NO. - SERIENUMMER Buono di Produzione Buono di Produzione Blue Box - 6...

  • Page 13: Technical Data - R22

    Width 1.043 1.043 1.043 1.043 Heigth 1.740 1.740 1.740 1.740 Shipping weight (*) ambient air temperature 35°C; evaporator entering/leaving water temperature 12-7 °C;. (**) ambient air temperature 8°C DB, 70%RH; condenser entering/leaving water temperature 40-45 °C. Blue Box - 7...
  • Page 14 1.043 1.043 1.144 1.144 Heigth 1.740 1.740 1.740 1.740 Shipping weight 1.058 (*) ambient air temperature 35°C; evaporator entering/leaving water temperature 12-7 °C;. (**) ambient air temperature 8°C DB, 70%RH; condenser entering/leaving water temperature 40-45 °C. Blue Box - 8...
  • Page 15 1.119 Heigth 1.740 1.740 2.380 2.380 Shipping weight 1.124 1.158 1.400 1.464 (*) ambient air temperature 35°C; evaporator entering/leaving water temperature 12-7 °C;. (**) ambient air temperature 8°C DB, 70%RH; condenser entering/leaving water temperature 40-45 °C. Blue Box - 9...
  • Page 16 1.119 Heigth 2.380 2.380 2.380 2.380 Shipping weight 1.930 2.089 2.208 2.349 (*) ambient air temperature 35°C; evaporator entering/leaving water temperature 12-7 °C;. (**) ambient air temperature 8°C DB, 70%RH; condenser entering/leaving water temperature 40-45 °C. Blue Box - 10...

  • Page 17: Technical Data - Electrical Specifications And Components R22

    (2) maximum current before safety cut-outs stop the unit. This value is never exceeded and must be used to size the electrical supply cables and relevant safety devices (refer to electrical wiring diagram supplied with the unit). All values in brackets are refer to /ST version (units with storage tank) or units with pump. Blue Box - 11...
  • Page 18 (2) maximum current before safety cut-outs stop the unit. This value is never exceeded and must be used to size the electrical supply cables and relevant safety devices (refer to electrical wiring diagram supplied with the unit). All values in brackets are refer to /ST version (units with storage tank) or units with pump. Blue Box - 12...

  • Page 19: Technical Data - Zeta 2002 /St 2Ps - R22

    41.430 45.786 Pump nominal power External available pressure Storage tank water volume Dimension and weight Length 5.234 5.234 5.234 5.234 Width 1.119 1.119 1.119 1.119 Heigth 2.380 2.380 2.380 2.380 Shipping weight 2.290 2.449 2.622 2.749 Blue Box - 13...

  • Page 20: Technical Data - R407C

    Width 1.043 1.043 1.043 1.043 Heigth 1.740 1.740 1.740 1.740 Shipping weight (*) ambient air temperature 35°C; evaporator entering/leaving water temperature 12-7 °C;. (**) ambient air temperature 8°C DB, 70%RH; condenser entering/leaving water temperature 40-45 °C. Blue Box - 14...
  • Page 21 1.043 1.043 1.144 1.144 Heigth 1.740 1.740 1.740 1.740 Shipping weight 1.058 (*) ambient air temperature 35°C; evaporator entering/leaving water temperature 12-7 °C;. (**) ambient air temperature 8°C DB, 70%RH; condenser entering/leaving water temperature 40-45 °C. Blue Box - 15...
  • Page 22 1.119 Heigth 1.740 1.740 2.380 2.380 Shipping weight 1.124 1.158 1.400 1.464 (*) ambient air temperature 35°C; evaporator entering/leaving water temperature 12-7 °C;. (**) ambient air temperature 8°C DB, 70%RH; condenser entering/leaving water temperature 40-45 °C. Blue Box - 16...
  • Page 23 1.119 Heigth 2.380 2.380 2.380 2.380 Shipping weight 1.930 2.089 2.208 2.349 (*) ambient air temperature 35°C; evaporator entering/leaving water temperature 12-7 °C;. (**) ambient air temperature 8°C DB, 70%RH; condenser entering/leaving water temperature 40-45 °C. Blue Box - 17...

  • Page 24: Technical Data - Electrical Specifications And Components R407C

    (2) maximum current before safety cut-outs stop the unit. This value is never exceeded and must be used to size the electrical supply cables and relevant safety devices (refer to electrical wiring diagram supplied with the unit). All values in brackets are refer to /ST version (units with storage tank) or units with pump. Blue Box - 18...
  • Page 25 (2) maximum current before safety cut-outs stop the unit. This value is never exceeded and must be used to size the electrical supply cables and relevant safety devices (refer to electrical wiring diagram supplied with the unit). All values in brackets are refer to /ST version (units with storage tank) or units with pump. Blue Box - 19...

  • Page 26: Technical Data - Zeta 2002 /St 2Ps - R407C

    40.565 44.834 Pump nominal power External available pressure Storage tank water volume Dimension and weight Length 5.234 5.234 5.234 5.234 Width 1.119 1.119 1.119 1.119 Heigth 2.380 2.380 2.380 2.380 Shipping weight 2.290 2.449 2.622 2.749 Blue Box - 20...

  • Page 27: Sound Power And Pressure Levels

    Lw: sound power values in free field conditions are calculated in accordance with ISO 3746. Lp : sound pressure values measured at 1 m from the unit in free field conditions in compliance with ISO 3746 Blue Box - 21...
  • Page 28 Lw: sound power values in free field conditions are calculated in accordance with ISO 3746. Lp : sound pressure values measured at 1 m from the unit in free field conditions in compliance with ISO 3746 Blue Box - 22...

  • Page 29: Field Of Application

    Therefore on receiving the unit any damage must be verbally described to the carrier and recorded on the Delivery Note before it is signed by both parties. Blue Box or their Agent must be informed as soon as possible of the extent of the damage.

  • Page 30: Unpacking

    When unpacking the unit pay attention not to damage the unit. Packaging consists of different materials: wood, paper, nylon etc. Separate the materials and deliver to the proper gathering centre in order to reduce their environmental impact. Blue Box - 24...

  • Page 31: Safety Precautions

    - The compressor compartment contains various high temperature components. Adopt the maximum caution when working in the vicinity of the compressors and avoid touching any parts of the unit without appropriate protection. - Do not work within the theoretical discharge trajectory of the relief valves. Blue Box - 25...

  • Page 32: Mechanical Hazards

    Normal operating regime Cutting or severing. All units are supplied as standard with specific protection grilles designed to protect against accidental contact with the finned coils, which can cause minor cuts to the hands. Blue Box - 26...

  • Page 33: Thermal Hazards

    Most of the pipelines that could cause burns, temperatures. when touched, are lagged with heat insulating material. operating, installation, maintenance manual describes the use of suitable protections to avoid contact with high temperature pipelines that could result in burns. Blue Box - 27...

  • Page 34: Noise-Related Hazards

    EN Maintenance 60204-1. Normal operating regime Elements carrying electrical current in the case of faults. Maintenance Normal operating regime Inappropriate insulation. Maintenance Normal operating regime Radiated heat due to short- circuits or overloads. Maintenance Blue Box - 28...

  • Page 35: R407C Refrigerant Safety Sheets

    Personal precautions: Use personal protective equipment. Evacuate personnel to safe RELEASE MEASURES: areas. Do not breath vapours or spray mist. Ensure adequate ventilation. Methods for cleaning Shut off leaks it without risk. Solid evaporates. Ensure adequate ventilation. Blue Box - 29...
  • Page 36 S59 - Refer to manufacturer/supplier for information on recovery/recycling. Contaminated Do not reuse empty containers. Empty pressure vessels should be packaging: returned to supplier. 12. TRANSPORT No. O.N.U. 3340 INFORMATIQN: ADR/RID UN 3340 Refrigerant gas R407C, 2, 2° A, ADR/RID Label: 2 Blue Box - 30...

  • Page 37: R22 Refrigerant Safety Sheets

    Personal precautions: Use personal protective equipment. Evacuate personnel to safe RELEASE MEASURES: areas. Do not breath vapours or spray mist. Ensure adequate ventilation. Methods for cleaning Shut off leaks it without risk. Solid evaporates. Ensure adequate ventilation. Blue Box - 31...
  • Page 38 S59 - Refer to manufacturer/supplier for information on recovery/recycling. Contaminated Do not reuse empty containers. Empty pressure vessels should be packaging: returned to supplier. 12. TRANSPORT No. O.N.U. 1018 INFORMATIQN: ADR/RID UN 1018 Chlorodifluoromethane, 2, 2° A, ADR/RID Label: 2 Blue Box - 32...

  • Page 39: Positioning

    To avoid excess sound reverberation do not install the units in narrow or confined spaces. 15 mm gauge hard rubber sheet Foundation plinth made of 500 kg/mm reinforced concrete Plinth slab Sealant Cork underlayment 15-20 cm Soil Figure 2 Blue Box - 33...

  • Page 40: Installation

    - compressors compartment side: 1 metre - hydraulic connection sides: 1 metre. - top: no impediments that obstruct the air discharge. - units installed side by side: 4 metres. Figure 3 SIDE BY SIDE UNITS 4 m min. Figure 4 Blue Box - 34...

  • Page 41: Anti-Vibration Isolators (Option)

    The load of the unit is and two bolts and washers. supported by the full surface of the isolators. The load is not exerted on the bolt. Figure 6 Blue Box - 35...

  • Page 42: Water Piping Connections

    - vent valves, to be installed in the upper parts of the circuit, for air bleeding. - expansion device with accessories for circuit pressurisation, water thermal expansion compensation and system filling. - unload valve and if necessary drainage tank for circuit emptying during maintenance and seasonal stop. Blue Box - 36...

  • Page 43: Recommended Hydraulic Circuit Diagram For Zeta 2002 Units

    Blue Box - 37...

  • Page 44: Recommended Hydr. Circuit Diagr. For Models Zeta 2002 / St 2Ps

    Blue Box - 38...

  • Page 45: Hydraulic Circuit Diagram Version St /2Ps

    HYDRAULIC CIRCUIT DIAGRAM VERSION ST /2PS Blue Box - 39...

  • Page 46: Evaporator Water Pipe Connections

    For models from 3.2 to 13.2 it is mandatory to install a flow switch (supplied with the unit) on the evaporator water outlet connection identified by the following decal: USER WATER For models from 14.4 to 26.4 the flow switch is already installed as part of the standard equipment. Blue Box - 40...

  • Page 47: Water Flow Switch Installation Instructions (Models 3.2 To 13.2)

    To avoid leakage, seal the connection by using teflon. The flow switch should be installed on the heat exchanger that is closer to the electrical board. User exchanger (evaporator) Make the electrical connections on the unit’s terminal board Figure 7 Blue Box - 41...

  • Page 48: Desuperheater Hydraulic Connection (Optional)

    The water inlet and outlet must be connected in the positions indicated as labelled on the unit. Heat recovery water inlet: WATER DESUPERHEATER Heat recovery water outlet: WATER DESUPERHEATER On HP version units the hydraulic connection to the desuperheater must be isolated during heat pump operation Blue Box - 42...

  • Page 49: Zeta 2002/Dc Heat Recovery Exchanger Hydraulic Connections

    20 °C. DIAGRAM WITH 3-WAY VALVE 3-way valve Recovery water outlet Recovery water inlet Figure 9 Blue Box - 43...

  • Page 50: Diagram With Condensing Pressure Control Valve

    The vent pipe must be sized no smaller than the relief valve and it must not be supported from the valve. Caution: The relief valve must be directed into a safe zone where no injuries can be caused to people. Blue Box - 44...

  • Page 51: Connections For Version /Le (Motocondensing Unit)

    Pipe runs should be as short as possible to limit the pressure drop and the refrigerant charge volume. The maximum permissible pipeline length is 30 metres. If this limits cannot be adhered to contact Blue Box for further information. 4.9.1 Procedures to follow when sizing refrigerant lines Depending on the relative position of the sections, there are certain procedures to follow when installing the refrigerant line.

  • Page 52: Evaporating Section Positioned Higher Than The Condensing Unit Section

    Figure 12 TABLE 1 - EXTERNAL PIPE DIAMENTERS FOR /LE VERSIONS Distance [m] MODEL Suction Liquid Suction Liquid Suction Liquid ZETA 2002 [mm] [mm] [mm] [mm] [mm] [mm] 10.2 12.2 13.2 14.4 16.4 18.4 20.4 24.4 26.4 Blue Box - 46...

  • Page 53: Water Flow Rate To Evaporator

    With fan speed control the unit can function correctly, at low ambient temperatures, by reducing the air flow supplied to the condenser so that it operates within acceptable parameters. This control is calibrated and tested in the factory. Blue Box - 47...

  • Page 54: Operation With Low Temperature Chilled Water At Evaporator

    TEMPER T -40°C TEMPER T -60°C TIFOXITE FREEZIUM PEKASOL 50 In the case of ST versions with a glycol content greater than 30% pumps with special seals must be specified at the time of the order. Blue Box - 48...

  • Page 55: Operating Limits - R22 Refrigerant

    Cooling With low ambient temperature kit. Ambient air temperature [°C] The water temperature rise for all versions must be between 3 °C (min) and 8 °C (max) (1) Working limits of units with 2 compressors Blue Box - 49...
  • Page 56 Con dispositivi opzionali per basse Raffreddamento temperature dell’aria esterna. Cooling With low ambient temperature kit. Ambient air temperature [°C] The water temperature rise for all versions must be between 3 °C (min) and 8 °C (max) Blue Box - 50...

  • Page 57: Operating Limits - R407C Refrigerant

    Cooling With low ambient temperature kit. Ambient air temperature [°C] The water temperature rise for all versions must be between 3 °C (min) and 8 °C (max) (1) Working limits of units with 2 compressors Blue Box - 51...
  • Page 58 Raffreddamento Con dispositivi opzionali per basse temperature dell’aria esterna. Cooling With low ambient temperature kit. Ambient air temperature [°C] The water temperature rise for all versions must be between 3 °C (min) and 8 °C (max) Blue Box - 52...

  • Page 59: Evaporator Pressure Drop

    12.2 13.2 Portata acqua [ l/s] Water flow 16.4 18.4 20.4 24.4 26.4 14.4 Portata acqua [l/s] Water flow The water temperature rise for all versions must be between 3 °C (min) and 8 °C (max) Blue Box - 53...

  • Page 60: Pumps Available Pressure - Model Zeta 2002 /St 2Ps

    PUMPS AVAILABLE PRESSURE - MODEL ZETA 2002 /ST 2PS AVAILABLE PRESSURE 26.4 14.4 24.4 16.4 13.2 18.4-20.4 10.2 12.2 Portata acqua [l/s] Water flow Blue Box - 54...

  • Page 61: Electrical Connections

    Line voltage fluctuations must not be more than ±5% of the nominal value, while the voltage unbalance between one phase and another must not exceed 2%. If these tolerances are not possible contact Blue Box to provide the necessary devices.

  • Page 62: Power Supply To Crankcase Heaters

    Chillers in the ZETA 2002 series with 2 scroll compressors, models from 3.2 to 13.2, are equipped with the mCHILLER type microprocessor controller. Chillers in the ZETA 2002 series with 4 scroll compressors, models from 14.4 to 26.4, are equipped with the pCO2 microprocessor controller. Blue Box - 56...

  • Page 63: Microprocessor Controller For /Le And Hp/Le Versions

    When the serial interface board is inserted the following communications protocols are available: Carel, Modbus- jbus, BacNet. If a connection is to be made with networks that utilise the Lon-Talk protocol, a dedicated board must be installed. In this case, a conversion gateway is not required. Blue Box - 57...

  • Page 64: Electrical Panel Lay Out

    KM40 EVAPORATOR HEATER CONTACTOR FU51 CONTROL CIRCUITS FUSE QM13 PUMP 1 MOTOR OVERLOAD CUT-OUT FU52 CONTROLLER FUSE QM14 PUMP 2 MOTOR OVERLOAD CUT-OUT FU56 PHASE SEQUENCE RELAY FUSES MAIN POWER DISCONNECT SWITCH POWER “ON” RELAY CONTROL CIRCUITS TRANSFORMER Blue Box - 58...
  • Page 65 FU50 FUSES - AUXILIARY TRANSFORMER QM13 PUMP 1 MOTOR OVERLOAD CUT-OUT FU51 CONTROL CIRCUITS FUSE QM14 PUMP 2 MOTOR OVERLOAD CUT-OUT FU52 CONTROLLER FUSE MAIN POWER DISCONNECT SWITCH FU56 PHASE SEQUENCE RELAY FUSES CONTROL CIRCUITS TRANSFORMER Blue Box - 59...

  • Page 66: Start-Up

    Warning: before starting up the unit check that all the closing panels are in position and secured with the relative screws. Blue Box - 60...

  • Page 67: Units With Μchiller Microprocessor (Models From 3.2 To 13.2)

    6.1.3 Keypad The keypad allows machine operating parameters to be programmed. The wall-mounted version features an extended number of keys to facilitate use. The function of each key is illustrated on the following pages. Figure 15 Blue Box - Page 61...

  • Page 68: Controls And Display Screens

    Pressing the Up or Down keys for more than 5 seconds cancels any alarms currently in the memory (manual reset), clear the associated message from the display and deactivate the alarm relay. In wall mounted models this function is obtained by pressing the CLEAR key for 5 seconds. Figure 18 Blue Box - Page 62...

  • Page 69: Activation/Deactivation Of Cooling Operation (Summer Mode)

    To switch off the machine deactivate both Summer and Winter modes. Switch off the unit when working in cooling mode (Summer). Figure 21 Switch off the unit when working in heating mode (Winter). Figure 22 Blue Box - Page 63...

  • Page 70: Inlet Water Temperature Control

    If the defrost cycle is forcibly interrupted, with the timeout signal, a message is displayed on the controller, although no controller functions are activated. The defrost timeout alarm is automatically cleared from the active alarms menus when a defrost cycle terminates Blue Box - Page 64...
  • Page 71 For temporary shutdown of the unit refer to the guide lines given in the specific headings of this manual. Electronic components of the microprocessor may be damaged at temperatures below - 20 °C. Blue Box - Page 65...

  • Page 72: Starting The Unit

    Shutdown of unit operating in winter heating mode Figure 27 Warning: do not use the machine main power switch to stop the unit. The crankcase heaters will be disconnected, resulting in serious risk to the compressors when the unit is started again. Blue Box - Page 66...

  • Page 73: Seasonal Stop

    We therefore recommend that Blue Box or other skilled HVAC engineers are contacted to identify and correct the problem.
  • Page 74 1 and 2 are closed, check other external consents. ⊗ ⊗ Compressor motor burnt Replace compressor out or compressor seized ⊗ ⊗ Anti-recycle timer running Wait for 5 minutes until the timer generates a consent Blue Box - Page 68...
  • Page 75 No compressor ⊗ ⊗ Connections to evaporator Restore correct connection of running. Fans stopped inlet temperature sensor temperature sensor (display On with interrupted alarm "E1") ⊗ ⊗ Evaporator inlet Replace temperature sensor temperature sensor faulty Blue Box - Page 69...
  • Page 76 ⊗ 4-way reversing valve Check power supply and coils of seized or coil faulty valves and replace valves if necessary Blue Box - Page 70...
  • Page 77 ⊗ Fan motor electrical Check that connections are as connections incorrect indicated on electrical drawing ⊗ Fan contactors not Check voltage across coil of energised contactor KM21 and electrical continuity of coil circuit Blue Box - Page 71...
  • Page 78 ⊗ Fan motor electrical Check that connections are as connections incorrect indicated on electrical schematic ⊗ Fan contactors not Check voltage across coil of energised contactor KM21 and electrical continuity of coil circuit Blue Box - Page 72...
  • Page 79 Compressors run Operating thermostat Check setting; replace constantly incorrectly set or faulty thermostat if necessary ⊗ ⊗ Lack of refrigerant gas Check and recharge if necessary charge ⊗ ⊗ Excess thermal load Reduce thermal load Blue Box - Page 73...
  • Page 80 Check that panels are properly fastened; contact service organisation if necessary ⊗ ⊗ Worn fan bearings Check; replace fan if necessary If the display presents alarms other than those described previously, contact the Service organisation. Blue Box - Page 74...

  • Page 81: Microprocessor (Models From 14.4 To 26.4)

    Print key: this key is currently not used. "I/O" key: pressing this key opens the menus containing the status of the digital inputs and outputs together with the values read on the analogue inputs and the value of the analogue outputs Blue Box - Page 75...
  • Page 82 “Enter” key: pressing this key allows you to access fields containing editable parameters and also to confirm any changes you make to such parameters. Electronic components could be damaged by air temperature below -20 °C. Blue Box - Page 76...

  • Page 83: Operating Description

    Starting and stopping of the compressors and capacity step control is managed by the controller in accordance with the building cooling demands. 8.2.6 Chiller mode operation In chiller operation, the controller lowers the water temperature value, maintaining it as close as possible to the programmed set-point. Blue Box - Page 77...

  • Page 84: Heat Pump Mode Operation

    The consecutive starting of two compressors or the consecutive starting of one compressor, is executed with minimum delay intervals equal to the capacity step activation time. Stopping compressors is also performed with a minimum programmed delay interval. Blue Box - Page 78...

  • Page 85: Compressors Management

    After a mode changeover, the controller re-starts the unit in the new mode with a factory set minimum delay time. The unit operates with temperature control on the inlet to which has been inactive for the longest time. the unit (or return from the system). 8.2.15 Defrosting (heat pump units only) Blue Box - Page 79...

  • Page 86: Defrosting (Heat Pump Mode Operation Only)

    It is mandatory to use a condensing pressure control valve (one for each hydraulic circuit) or three-way valve, fitted by the installer, to avoid condensation values that are incompatible with operation of the machine. 8.2.17 Dual set-point (option) Blue Box - Page 80...

  • Page 87: Dual Set-Point (Option)

    The unit’s capacity steps are activated / deactivated with delay intervals in relation to a dead zone. When the leaving water temperature is higher than the programmed set-point compressors start is enabled. Blue Box - Page 81...

  • Page 88: Starting The Unit

    OFF status. Note also that if power is disconnected from the unit, the crankcase heaters will be switched off with the resulting risk of compressor damage at the time of restarting. Blue Box - Page 82...

  • Page 89: Emergency Stop

    We therefore recommend that Blue Box or other skilled HVAC engineers are contacted to identify and correct the problem.
  • Page 90 No consent from Activate operation from running. Display On: supervision system supervision system ”OFF from supervision system” No compressor ⊗ ⊗ No consent from “on/off” Press “on/off” key running. Display On: key of user interface ”OFF” Blue Box - Page 84...
  • Page 91 Display On: voltage appropriate protection if unit ON with alarm necessary “Thermal protections Compressor 1, 2, 3, 4” Setting of thermal Contact assistance ⊗ ⊗ protections ⊗ ⊗ Circuits partially discharged Call service to replenish charge Blue Box - Page 85...
  • Page 92 Contact service organisation ⊗ ⊗ ⊗ Defrost sensor short circuit Contact service organisation No compressor ⊗ Excessive thermal load Reduce thermal load running. Display On: unit ON with alarm “Exceeded Threshold Low Temperature User Water Reference” Blue Box - Page 86...
  • Page 93 LED Off No compressor ⊗ ⊗ Faulty relay Check to ensure that relay closes running. Display On: contact unit OFF with alarm ”Incorrect Phase Sequence” and phase sequence relay with green and orange LEDs Blue Box - Page 87...
  • Page 94 Empty circuit, apply vacuum, and non-condensable gas recharge ⊗ ⊗ High pressure switch Check pressure switch setting incorrectly set or faulty ⊗ Condenser coil or coil filters Clean coil and filters (if present) (if present) clogged with compressed air Blue Box - Page 88...
  • Page 95 Call service organisation ⊗ ⊗ No external consent to Check compressor external compressor consent ⊗ ⊗ All compressors Compressors specified by Call service for scheduled running. Display On alarm require maintenance maintenance with alarm “Compressor Maintenance” Blue Box - Page 89...
  • Page 96 Check that panels are properly fastened; contact service organisation if necessary ⊗ ⊗ Worn fan bearings Check; replace fan if necessary If the display presents alarms other than those described above, contact the service organisation. Blue Box - Page 90...

  • Page 97: Checks During Operation

    (saturation temperature corresponding to condenser delivery pressure); for units charged with R407C refrigerant, refer to the B.P. (Bubble Point) pressure gauge scale. The difference between the temperature values measured in this manner is equivalent to the subcooling value. Blue Box - 91...

  • Page 98: Calibration Of Control Equipment

    2.5 / 0.7 * manual (from controller) Evaporator heater setting °C automatic Defrost start setting automatic Defrost end setting automatic Defrost end thermostat setting °C automatic Defrost pressure switch setting automatic * Chiller / heat pump Blue Box - 92...

  • Page 99: Maintenance And Periodic Checks

    Check the colour of the sight glass core (green = no moisture, yellow = moisture every 4 months present): if it is yellow change the refrigerant filter Check that the noise level has not increased. every 4 months Blue Box - 93...

  • Page 100: Repairing The Refrigerant Circuit

    - Repeat the operation described above. - Repeat the operation described above for the third time in order to reach the highest degree of vacuum possible. This procedure should guarantee the elimination of up to 99% of contaminants. Blue Box - 94...

  • Page 101: Refrigerant Charge

    Refrigerants R22 and R407C are mentioned among substances subject to special monitoring regimes established by law, and as such they are subject to the prescriptions indicated above. Use special care during maintenance work in order to limit the risk of refrigerant leakage as far as possible. Blue Box - 95...

  • Page 102: Decommissioning The Unit

    This procedure is designed to assist the work of collection, disposal, and recovery specialists and to reduce the associated environmental impact. Blue Box - 96...

  • Page 103: Refrigerant Circuit

    REFRIGERANT CIRCUIT ZETA 2002 - MODELS 3.2 - 13.2 Blue Box - 97...
  • Page 104 REFRIGERANT CIRCUIT ZETA 2002 - MODELS 14.4 - 26.4 Blue Box - 98...
  • Page 105 REFRIGERANT CIRCUIT ZETA 2002/HP - MODELS 3.2 - 8.2 Blue Box - 99...
  • Page 106 REFRIGERANT CIRCUIT ZETA 2002/HP - MODELS 9.2 - 13.2 Blue Box - 100...
  • Page 107 REFRIGERANT CIRCUIT ZETA 2002/HP - MODELS 14.4 - 16.4 Blue Box - 101...
  • Page 108 REFRIGERANT CIRCUIT ZETA 2002/HP - MODELS 18.4 - 26.4 Blue Box - 102...
  • Page 109 REFRIGERANT CIRCUIT ZETA 2002/LE - MODELS 3.2 - 13.2 Blue Box - 103...
  • Page 110 REFRIGERANT CIRCUIT ZETA 2002/LE - MODELS 14.4 - 26.4 Blue Box - 104...
  • Page 111 REFRIGERANT CIRCUIT ZETA 2002/LE/HP - MODELS 3.2 - 13.2 Blue Box - 105...
  • Page 112 REFRIGERANT CIRCUIT ZETA 2002/LE/HP - MODELS 14.4 - 26.4 Blue Box - 106...
  • Page 113 REFRIGERANT CIRCUIT ZETA 2002/DC - MODELS 3.2 - 13.2 Blue Box - 107...
  • Page 114 REFRIGERANT CIRCUIT ZETA 2002/DC - MODELS 14.4 - 26.4 Blue Box - 108...

  • Page 115: Overall Dimensions, Weights And Hydraulic Circuit Connections

    OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002 - ZETA 2002/HP - MODELS 3.2 - 8.2 Blue Box - 109...
  • Page 116 ZETA 2002/ST 1PS-2PS-S 7.2 1051 ZETA 2002/ST 1PS-2PS-S 8.2 1096 ZETA 2002/HP/ST 1PS-2PS-S 3.2 ZETA 2002/HP/ST 1PS-2PS-S 4.2 ZETA 2002/HP/ST 1PS-2PS-S 5.2 1010 ZETA 2002/HP/ST 1PS-2PS-S 6.2 1061 ZETA 2002/HP/ST 1PS-2PS-S 7.2 1080 ZETA 2002/HP/ST 1PS-2PS-S 8.2 1128 Blue Box - 110...
  • Page 117 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002/LE - ZETA 2002 /LE/HP - MODELS 3.2 - 8.2 Blue Box - 111...
  • Page 118 ZETA 2002/LE 3.2 ZETA 2002/LE 4.2 ZETA 2002/LE 5.2 ZETA 2002/LE 6.2 ZETA 2002/LE 7.2 ZETA 2002/LE 8.2 ZETA 2002/LE/HP 3.2 ZETA 2002/LE/HP 4.2 ZETA 2002/LE/HP 5.2 ZETA 2002/LE/HP 6.2 ZETA 2002/LE/HP 7.2 ZETA 2002/LE/HP 8.2 Blue Box - 112...
  • Page 119 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002 - ZETA 2002/HP - MODELS 9.2 - 13.2 Blue Box - 113...
  • Page 120 ZETA 2002/ST 1PS-2PS-S 12.2 1275 1728 ZETA 2002/ST 1PS-2PS-S 13.2 1309 1762 ZETA 2002/HP/ST 1PS-2PS-S 9.2 1178 1630 ZETA 2002/HP/ST 1PS-2PS-S 10.2 1255 1706 ZETA 2002/HP/ST 1PS-2PS-S 12.2 1321 1776 ZETA 2002/HP/ST 1PS-2PS-S 13.2 1355 1808 Blue Box - 114...
  • Page 121 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002/LE - ZETA 2002/LE/HP - MODELS 9.2 - 13.2 Blue Box - 115...
  • Page 122 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002/LE - ZETA 2002/LE/HP - FOOTPRINT - MODELS 9.2 - 13.2 Blue Box - 116...
  • Page 123 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002 - ZETA 2002/HP - MODELS 14.4 - 16.4 Blue Box - 117...
  • Page 124 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002 - ZETA 2002/HP - FOOTPRINT - MODELS 14.4 - 16.4 Blue Box - 118...
  • Page 125 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002/LE - ZETA 2002 /LE/HP - MODELS 14.4 - 16.4 Blue Box - 119...
  • Page 126 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002/LE - ZETA 2002 /LE/HP - FOOTPRINT - MODELS 18.4 - 26.4 Blue Box - 120...
  • Page 127 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002 - ZETA 2002/HP - MODELS 18.4 - 26.4 Blue Box - 121...
  • Page 128 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002 - ZETA 2002/HP - FOOTPRINT - MODELS 18.4 - 26.4 Blue Box - 122...
  • Page 129 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002/LE - ZETA 2002/LE/HP - MODELS 18.4 - 26.4 Blue Box - 123...
  • Page 130 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002/LE - ZETA 2002/LE/HP - FOOTPRINT - MODELS 18.4 - 26.4 Blue Box - 124...
  • Page 131 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002/ST - ZETA 2002/HP/ST - MODELS 18.4 - 26.4 Blue Box - 125...
  • Page 132 OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS ZETA 2002/ST - ZETA 2002/HP/ST - FOOTPRINT - MODELS 18.4 - 26.4 Blue Box - 126...
  • Page 134 BLUE BOX srl is an associate company of BLUE BOX GROUP BLUE BOX srl Via E. Mattei, 20 35028 Piove di Sacco PD Italy Tel. +39.049.9716300 Fax +39.049.9704105 BLUE BOX GROUP on the internet www.blueboxgroup.it Info@blueboxgroup.it Manual 101010A02 - Issued 11.02 - Replaces 04.02...

This manual is also suitable for:

Zeta 2002 4,2Zeta 2002 5,2Zeta 2002 6,2Zeta 2002 7,2Zeta 2002 8,2Zeta 2002 9,2 ... Show all

Table of Contents

Save PDF