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Swegon BlueBox WESTERN Mu Echos A Installation, Use And Maintenance Manual

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Mu Echos A
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Installation, use and maintenance manual
24-02-2020

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  • Page 1 Mu Echos A Installation, use and maintenance manual 24-02-2020...
  • Page 2 THANK YOU Thank you for choosing our product. It is the result of many years’ experience and careful design and has been built with first-class quality materials and advan- ced technologies. Declaration or certificate of conformity also guarantees that the equipment meets the requirements of the European Machi- nery Safety Directive.

  • Page 3: Table Of Contents

    Contents Introduction Conformity Description 1.2.1 Symbols 1.2.2 Labels Safety General safety precautions 2.1.1 Discharge of the safety valves Basic rules 2.2.1 Water flow rate at the heat exchangers 2.2.2 Water composition 2.2.3 Minimum water content in the system 2.2.4 Installing the flow switch 2.2.5 Hydraulic components for reversible heat pump units 2.2.6 Operation with water to the evaporator at low temperature 2.2.7 Operation with water to the condenser at low temperature 2.2.8 Condensation control at the source hydraulic circuit 2.2.9 Condensation control at the source hydraulic circuit for HP units 2.2.10 Refrigerant leak detector Noise Residual risks Safety information on the refrigerant fluid...
  • Page 4 Intended use Unintended use Control and safety devices Principles of operation Structure Specifications Control panel 5.7.1 Parametric control 5.7.2 Remote terminal Wiring diagram Installation Dimensions and weight Place of installation Installation 6.3.1 Positioning the units 6.3.2 Positioning the remote heat exchanger 6.3.3 Noise attenuation 6.3.4 Minimum distances Hydraulic connections 6.4.0 User hydraulic circuit 6.4.1 Source hydraulic circuit...
  • Page 5 Preliminary operations 7.1.1 Checking the pre-charge of the expansion vessel 7.1.2 Checking the volume of the expansion vessel 7.1.3 Preliminary operations for LE and LE/HP units 7.1.4 Preliminary operations for LC and LC/HP units First starting 7.2.1 Hydraulic tests 7.2.2 Functional tests Calibration of safety components Checks during operation Alarms and malfunctions 7.5.1 General troubleshooting Temporary stop Stop for long periods of time Maintenance Adjustments Internal cleaning 8.2.1 Cleaning the unit 8.2.2...

  • Page 6: Introduction

    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;...

  • Page 7: Labels

    1.2.2 Labels For the constructional features, available models and technical data, please refer to the Technical Catalogue. The model, serial number, features, power supply voltage and so on are shown 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.

  • Page 8: Safety

    SAFETY 2.1 General safety precautions The equipment operator is responsible for complying with regulatory obligations. The equipment operator is the person who has actual control over the technical operation and free access, which means the possibility of monitoring its components and their operation and the possibility of granting access to third parties. The equipment operator has the power (including financial power) to decide on technical modifications, checks and repairs.

  • Page 9: Discharge Of The Safety Valves

    In units with capacitors and/or inverters, certain components can remain live for several minutes even after having turned off the main switch. Wait 10 minutes 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.

  • Page 10: Basic Rules

    2.2 Basic rules All the units are designed and built in compliance with Directive 2014/68/EU of the European Parliament and of the Council of 15 May 2014 on the approximation of the laws of the Member States relating to pressure equipment. To ensure maximum safety, in order to prevent possible risks, follow the instructions below: - this product contains pressurised vessels, live components, moving mechanical parts and very hot and cold surfaces that, in certain situations, can pose a risk: all maintenance work must be carried out by skilled personnel equipped with...

  • Page 11: Water Flow Rate At The Heat Exchangers

    2.2.1 Water flow rate at the heat exchangers It is necessary to ensure that the water flow rate during operation is no higher than 1.5 times and no lower than 0.5 times the nominal flow rate of the unit stated in the Technical Catalogue. In any case, refer to the specific Technical Catalogue for the allowed conditions for water flow in and out of the exchangers.

  • Page 12: Minimum Water Content In The System

    2.2.3 Minimum water content in the system For correct operation of the unit, it is necessary to ensure a buffering on the system such as to comply with the minimum operating time considering the greater between the minimum OFF time and the minimum ON time. In short, these contribute to limiting the number of times the compressors are switched on per hour and to preventing un- desired deviations from the set point of the delivered water temperature.

  • Page 13: Installing The Flow Switch

    2.2.4 Installing the flow switch The units are shipped from the factory without the flow switch installed. The flow switch is supplied with the unit and must be connected by the installer. The flow switch is complete with cable for the electrical connection and the paddle that detects water flow is already fitted. The flow switch must be inserted on the water pipe at the outlet of the unit in a straight and horizontal section of the pipe well away from filters, valves etc.

  • Page 14: Operation With Water To The Evaporator At Low Temperature

    2.2.6 Operation with water to the evaporator at low temperature With temperatures below 5°C, it is mandatory to work with water and anti-freeze mixtures, and also change the safety devi- ces (anti-freeze, etc.), which must be carried out by qualified authorised personnel or by the manufacturer. The glycol percentage by weight is determined based on the desired temperature of the chilled water (see table). Minimum ambient temperature or liquid outlet temperature (°C) Freezing point (°C)
  • Page 15 2.2.8 Condensation control at the source hydraulic circuit The temperature and flow rate of the source circuit water must be maintained within the operating limits stated in the Tech- nical Catalogue. 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.

  • Page 16: Condensation Control At The Source Hydraulic Circuit For Hp Units

    2.2.9 Condensation control at the source hydraulic circuit for HP units For the source-side heat exchanger, the hydraulic circuit of the reversible heat pump units requires a pressure switch valve, a by-pass solenoid valve and a second paddle flow switch. For some models, these components are already installed in the unit whereas for others, they are assembled in kits and supplied loose with the unit.

  • Page 17: Refrigerant Leak Detector

    2.2.10 Refrigerant leak detector A refrigerant leak detector with semiconductor sensor can be installed on the units. This device allows immediate detection of refrigerant leaks, with a warning or with stopping of the unit in pump down, de- pending on how it is managed. The installation of the device is in line with European F-GAS regulations and USA ASHRAE regulations.

  • Page 18: Noise

    2.3 Noise The starting of the unit, with activation of its components, emits a noise whose intensity varies depending on the operating level. The correct location choice and the correct installation prevent the unit causing annoying noise due to resonances, reflections and vibrations.

  • Page 19: Safety Information On The Refrigerant Fluid

    2.5 Safety information on the refrigerant fluid This product contains fluorinated greenhouse gases included in the Kyoto protocol. Do not release these gases into the atmosphere. Type of refrigerant: R410A GWP value: 2088. GWP is the global warming potential. The quantity of refrigerant fluid is indicated in the unit’s data label. Periodic inspections are necessary to check for refrige- rant fluid leaks in accordance with local and/or European regulations.

  • Page 20: Receiving The Product And Storage

    RECEIVING THE PRODUCT AND STORAGE 3.1 Reception On receiving the unit, check that it is undamaged, bearing in mind that it left the factory in perfect condition. Report any signs of damage immediately to the transporter and make a note of these on the Delivery Sheet before signing The relevant sales department or the manufacturer should be informed of the extent of the damage as soon as possible.

  • Page 21: Handling

    3.3 Handling Before each unit handling operation, check that the lifting capacity of the machinery used is compatible with the weight of the unit. Handling must be carried out by adequately equipped qualified personnel. In all lifting operations, make sure the unit is firmly secured in order to prevent accidental falls or overturning. Lifting must be carried out by qualified and authorised personnel taking the necessary precautions;...

  • Page 22: Ecodesign Conformity

    ECODESIGN CONFORMITY 4.1 Documentation supplied with the product Listed below are the documents supplied with the machine according to its type, with particular reference to conformity with Directive 2009/125/EC of the European Parliament and of the Council, of 21 October 2009, regarding the establishment of a framework for drafting specifications for the eco-friendly design of energy-related products, and relevant Regulations (hereinafter "Ecodesign").

  • Page 23: Partly Completed Machine

    4.1.3 Partly completed machine Units for which conformity with the Ecodesign Directive must be related to a 'partly completed machine plus remote heat exchanger' system. Otherwise, the unit conforms to all EC requirements. All the points described in the first paragraph apply, with the exceptions stated below. The EC Declaration is not accompanied by Attached Documents Conformity with the Ecodesign Directive depends on the combination of partly completed machine plus remote heat exchan- ger and is therefore the responsibility of the person who makes the selection and combination at the installation stage.

  • Page 24: Conformity Of The Application

    4.2 Conformity of the application The applications allowed as regards the documentation supplied with the unit are indicated below. This applies only in the case of units intended for installation and operation in the European Union. The customer is required to select the unit with regard to the expected operating condition and the Ecodesi- gn conformity required for that condition.

  • Page 25: Product Description

    PRODUCT DESCRIPTION 5.1 Intended use These units are intended for cooling (unit in cooling only version) or for cooling/heating (heat pump version) of heat-carrying fluid; they are generally used in applications in the air-conditioning and refrigeration field. Their use is recommended within the operating limits indicated in the Technical Catalogue. Use outside the operating limits stated in the Technical Catalogue will cause the unit to stop.

  • Page 26: Control And Safety Devices

    5.3 Control and safety devices The unit is integrally managed by an electronic microprocessor control that, through the various temperature and pressure sensors installed in the unit, keeps its operation within the safety limits. All the parameters involved with control of the unit are shown in the “Control Manual” that is an integral part of the docu- mentation of the unit.

  • Page 27: Control Panel

    5.7 Control panel This line of units is managed with a parametric electronic microprocessor controller. The next sections describe the basic operations, such as starting and stopping the unit, changing the operating mode from cooling to heating and vice versa (in units with heat pump), and changing the set point. For the other operations, refer to the manual of the control that is an integral part of the documentation of the unit.

  • Page 28: Remote Terminal

    5.7.1.2 Changing the operating mode from cooling to heating and vice versa It is possible to change the operating mode from cooling to heating and vice versa only in units that have this feature. The change can be made using the display keypad or from digital input. Unless a specific request is made, the units are shipped programmed for changing from cooling to heating and vice versa from the keypad.

  • Page 29: Wiring Diagram

    5.8 Wiring diagram The wiring diagram is an essential part of the documentation 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.

  • Page 30: Installation

    INSTALLATION During installation or whenever work must be carried out on the unit, it is essential to strictly follow the instructions in this manual, comply with the directions on the unit and in any case take all necessary precautions. The pressures in the refrigerant circuit and the electrical components can create risky situations during installation and maintenance work.

  • Page 31: Installation

    6.3 Installation The units are shipped from the factory already tested and they need only the electrical and hydraulic connections for in- stallation, except for the "LC" (condenserless), "LC/HP" (reversible condenserless), "LE" (motocondensing) and "LE/HP" (reversible motocondensing) versions for which the refrigerant connections with the remote exchanger must also be made. 6.3.1 Positioning the units The units must be positioned in covered areas where temperatures are kept above 4°C.

  • Page 32: Hydraulic Connections

    6.4 Hydraulic connections When preparing to make the hydraulic circuits, it is good practice to comply with the following instructions and in any case follow the national and local regulations (refer to the layouts included in the manual). Fit the pipes to the unit using flexible couplings in order to prevent transmission of vibrations and compensate thermal expansion.

  • Page 33: User Hydraulic Circuit

    6.4.0 User hydraulic circuit Reference hydraulic diagram for connecting the unit to the user circuit. Fig. 6 Recommended hydraulic circuit Evaporator Water filter Thermometer Motor-driven pump Flow switch Flexible coupling System filling unit Water pressure gauge Valve Safety valve Storage tank Air valve Expansion vessel Check valve...

  • Page 34: Source Hydraulic Circuit

    6.4.1 Source hydraulic circuit Reference hydraulic diagram for connecting the unit to the source circuit. Fig. 7 Recommended hydraulic circuit Condenser Water filter Thermometer Motor-driven pump Flow switch (mandatory in "HP" versions) Flexible coupling System filling unit Water pressure gauge Valve Safety valve Air valve...

  • Page 35: Electrical Connections

    6.5 Electrical connections All electrical operations must be carried out by personnel having the necessary legal requirements, and trained and infor- med on the risks connected with these operations. The sizing and characteristics of the power lines and relevant components must be determined by staff qualified to design electrical systems, following the international and national regulations of the place of installation of the units in conformity with the regulations in force at the time of installation.

  • Page 36: Refrigeration Connections

    6.6 Refrigeration connections For the "LE" (motocondensing),"LE/HP" (reversible motocondensing), "LC" (condenserless) and "LC/HP" (reversible con- denserless) versions, refrigerant connections between the unit and the remote heat exchanger are necessary. The "LE", "LE/HP", "LC" and "LC/HP"version units are "dry run" tested, and the refrigerant circuit is charged at the factory with a mixture of nitrogen and helium at a pressure of about 10 bar.

  • Page 37: Sizing Of Lines For "Le" And "Le/Hp" Units

    6.6.2 Sizing of lines for "LE" and "LE/HP" units The recommended diameters for equivalent lengths up to 30 m are given below. Recommended diameters for R410A - The thickness of the pipe must be compatible with the refrigerant used and with current regulations. Equivalent length 10 m Equivalent length 20 m Equivalent length 30 m Model Liquid Liquid Liquid 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.

  • Page 38: Le Version: Unit Installed At A Lower Level Than The Remote Exchanger

    6.6.4 LE version: unit installed at a lower level than the remote exchanger Fit a syphon on the highest suction line "G" of the evaporator in order to prevent liquid refrigerant from going towards 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.

  • Page 39: Le/Hp Version: Unit Installed At A Lower Level Than The Remote Exchanger

    6.6.6 LE/HP version: unit installed at a lower level than the remote exchanger Fit a syphon 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"...

  • Page 40: Sizing Of Lines For "Lc" And "Lc/Hp" Units

    6.6.7 Sizing of lines for "LC" and "LC/HP" units The recommended diameters for equivalent lengths up to 30 m are given below. Recommended diameters for R410A for "LC" units - The thickness of the pipe must be compatible with the refri- gerant used and with current regulations. Equivalent length 10 m Equivalent length 20 m Equivalent length 30 m Model Liquid Liquid Liquid Recommended diameters for R410A for "LC/HP" units - The thickness of the pipe must be compatible with the refrigerant used and with current regulations.

  • Page 41: Lc Version: Unit Installed At A Lower Level Than The Remote Exchanger

    6.6.8 LC version: unit installed at a lower level than the remote exchanger A summary is given below of the measures to be taken if the unit is installed at a lower level than the condenser: make a well on the delivery line just downline of the compressor to collect the liquid refrigerant that can form during the stops of the unit and can irreparably damage the compressor;...

  • Page 42: Lc/Hp Version: Unit Installed At A Higher Level Than The Remote Exchanger

    6.6.10 LC/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 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"...

  • Page 43: Refrigerant Connections On The Remote Exchanger

    6.7 Refrigerant connections on the remote exchanger For the "LE" motocondensing units, connect the liquid pipe that comes out of the unit to the expansion valve installed on the distributor of the remote heat exchanger and the suction pipe of the unit to the relevant manifold on the remote heat exchanger.

  • Page 44: Vacuum Of The System

    6.8 Vacuum of the system Open the taps of the unit and evacuate the pre-charge of nitrogen and helium before completing the refrigerant connections. Do not leave 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.

  • Page 45: Commissioning

    COMMISSIONING 7.1 Preliminary operations Make sure the main disconnect switch is in the OFF position. In units with pumps, their power supply is mechanically locked. Restore functional conditions only on starting. If the pumps of the unit are not locked, electrically isolate them by operating the protective devices, to pre- vent automatic starting, in the event of antifreeze function activation, during the preliminary operations.

  • Page 46: Checking The Pre-Charge Of The Expansion Vessel

    Check: - that the hydraulic connections have been made properly, according to the instructions given on the inlet / output plates and that a mechanical filter has been installed at the unit’s inlet (a mandatory component, whose absence will invalidate the warranty);...

  • Page 47: Checking The Volume Of The Expansion Vessel

    7.1.2 Checking the volume of the expansion vessel As the pre-charge pressure increases, the maximum volume of the system supported by the expansion vessel supplied as standard, decreases. where - VI: volume of the system supported by the expansion vessel [l] - VVE: volume of the expansion vessel [l] - Ce: expansion coefficient of water - pVE: pre-charge pressure of the expansion vessel [barg] - pVS: calibration pressure of the safety valve [barg]...

  • Page 48: Preliminary Operations For Le And Le/Hp Units

    7.1.3 Preliminary operations for LE and LE/HP units In addition to the previous general checks, the units with remote exchanger require further investigation: - check the correct connection of the environment control to the terminals as in the wiring diagram; - make sure there is an air flow control switch in the remote exchanger (in the case of units with several remote exchan- gers, a flow control switch must be installed for each one);...

  • Page 49: First Starting

    7.2 First starting When the unit is started for the first time, some important tests and checks must be done. 7.2.1 Hydraulic tests So that the unit can operate, the external OK signal device must be closed (refer to the wiring diagram provided with the unit).

  • Page 50: Functional Tests

    7.2.2 Functional tests With the starting of the unit, a few seconds after the starting of the pump, if managed by the control, the compressors will start according to the request of the thermoregulation. After a few hours of operation of the compressors, check that the liquid sight glass has a green ring: if it is yellow, there is moisture in the circuit.

  • Page 51: Calibration Of Safety Components

    7.3 Calibration of safety components Any work on the unit must be carried out by qualified authorised personnel. 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).

  • Page 52: Checks During Operation

    7.4 Checks during operation With the circuits operating at 100% and stable at working conditions near the nominal ones, check: - that the electrical absorption of the unit is close to the data shown in the wiring diagram. Considerably different values may be due to the reduced capacity operation of the unit, at working conditions very different from nominal ones, or to the malfunctioning of one or more components.

  • Page 53: Alarms And Malfunctions

    7.5 Alarms and malfunctions Possible malfunctions will trigger the protective devices and safety devices of the unit before serious faults occur. All the “warnings” and “alarms” are recorded in the memory of the control and displayed on the display of the unit. Before resetting an alarm, the cause that triggered it must be found and eliminated.
  • Page 54 SYMPTOM LIKELY CAUSE POSSIBLE SOLUTION Check that the high pressure switches Opening of the valve due to failure of are working and, if necessary, replace Presence of oil on the discharge of the the protective devices to operate. them. safety valve. The valve must be replaced.

  • Page 55: Temporary Stop

    7.6 Temporary stop The stopping of the unit for a few hours in the day “during non-working hours” or for a few days “over the weekend” is con- sidered temporary. The unit must be stopped using the display of the control, the external OK signal or via serial if included. During the temporary stop, the unit must be powered correctly.

  • Page 56: Maintenance

    MAINTENANCE All the operations described in this chapter must always be carried out by qualified and authorised person- nel. Before carrying out any work on the unit or accessing internal parts, make sure you have turned off the power supply to it. The compressors and delivery pipes are very hot.

  • Page 57: Internal Cleaning

    8.2 Internal cleaning It is essential to keep the installation site clean and tidy for correct maintenance of the unit and to keep it in good working order. 8.2.1 Cleaning the unit Keep the inside of the electrical control panel and (where present) the compressor compartment clean. After working on the unit, always clean the electrical control panel of any work remnants and extraneous components.

  • Page 58: Cleaning The Remote Exchanger

    8.3 Cleaning the remote exchanger When present, the remote heat exchanger is the component that needs looking after the most. 8.3.1 LE and LE/HP motocondensing units For the "LE" and "LE/HP" motocondensing and reversible motocondensing units, the component that needs looking after the most is the remote finned pack heat exchanger installed in the room. Please refer to the manual for the timing and modes of operation.

  • Page 59: Periodic Checks

    8.4 Periodic checks Carry out periodic checks to make sure the unit is working correctly: RECOMMEN- OPERATION DED FREQUEN- Check the operation of all the control and safety equipment as described previously. Monthly Check the tightness of the electrical terminals in the electrical control panel and in the terminal bo- ards of the compressors.

  • Page 60: Unscheduled Maintenance

    8.5 Unscheduled maintenance After correctly starting-up and carrying out the relevant checks, the units normally do not need any intervention by the cu- stomer service in order to check the charge of the refrigerant gas. 8.5.1 Special work With use of the unit, particular situations may occur that require work to be carried out promptly. Even in an emergency, work on the unit must be carried out by skilled personnel in safe conditions.

  • Page 61: Decommissioning

    DECOMMISSIONING With reference to the European waste management directive, we inform you of the following: - The owner of electrical and electronic equipment (EEE) is obliged not to dispose of it as non-separated municipal waste, and must dispose of it via separate collection through public or private waste collection systems as required by local regulations.
  • Page 62 Page intentionally blank Translation from original instructions We reserve the right to make changes without any prior notice.
  • Page 63 Page intentionally blank We reserve the right to make changes without any prior notice. Translation from original instructions...

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