Swegon BlueBox Tau SKY Hi HP Instructions For Installation, Use And Maintenance Manual
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Swegon BlueBox Tau SKY Hi HP Instructions For Installation, Use And Maintenance Manual

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Tau SKY Hi HP
EN
Installation, use and maintenance manual
05-08-2020

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  • Page 1 Tau SKY Hi HP Installation, use and maintenance manual 05-08-2020...
  • 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 Unit operating in heat pump mode 2.2.6...
  • Page 4 Principles of operation Structure Specifications Control panels 5.7.1 Base controller (V5+) 5.7.2 Advanced controller (V6) Wiring diagram Cables supplied with the unit Installation Dimensions and weight Installation site Installation 6.3.1 External positioning 6.3.2 Base frame assembly procedure (option) 6.3.3 Internal unit positioning 6.3.4 Anti-vibration mounts 6.3.5...
  • Page 5 External cleaning 8.2.1 Cleaning traditional finned coils in Cu/Al 8.2.2 Cleaning the plate heat exchangers Internal cleaning 8.3.1 Cleaning the unit Periodic checks Unscheduled maintenance 8.5.1 Special work Decommissioning 10 Symbols and acronyms used 11 Appendixes We reserve the right to make changes without any prior notice. Translation from original instructions...

  • 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 serial number is stamped on the ID plate of the external unit.

  • Page 8: Safety

    SAFETY 2.1 General safety precautions A space of about 3 metres around the unit is identified as external danger zone. If the unit is positioned in an unprotected place that can be reached by unqualified persons, access to this area must be prohibited by special guarding.

  • 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. It is necessary to ensure that the water flow rate during operation is the nominal flow rate of the unit stated in the Technical Catalogue.

  • 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 with the flow switch installed. The arrow on the switch must be aligned with the water flow. 2.2.5 Unit operating in heat pump mode The performance of units in heat pump operation goes down as the external air temperature falls. The units are fitted with an antifreeze heater to heat the plate heat exchanger and the bottom of the external coil.

  • Page 14: Warnings Concerning Flammable Refrigerants

    2.2.9 Warnings concerning flammable refrigerants Units with mildly flammable refrigerants (A2L), such as R32, shall be installed in accordance with the Euro- pean standards and regulations and with the local regulations, where applicable. The information below is provided in accordance with standard IEC 60335-2-40 and its annexes and clauses (hereinafter “Annex”...
  • Page 15 (Annex DD.4) Information on servicing (Annex DD.4.1) General (Annex DD.4.2) Checks to the area Prior to beginning work on systems containing flammable refrigerants, safety checks in the area are necessary to ensure that the risk of ignition is minimised. For repair to the refrigerating system, DD.4.3 to DD.4.7 shall be completed prior to conducting work on the system.
  • Page 16 (Annex DD.4.8) Ventilated area Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work. A degree of ventilation shall continue during the period that the work is carried out. The ventilation should safely disperse any released refrigerant and preferably expel it externally into the atmosphere.
  • Page 17 (Annex DD.5.2) Particular attention shall be paid to the following to ensure that by working on electrical components, the casing is not alte- red in such a way that the level of protection is affected. This shall include damage to cables, excessive number of connections, terminals not made to original specification, dama- ge to seals, incorrect fitting of glands, etc.
  • Page 18 (Annex DD.9) Removal and evacuation When breaking into the refrigerant circuit to make repairs – or for any other purpose – conventional procedures shall be used. However, it is important that best practice is followed since flammability is a consideration. The following procedure shall be adhered to: •...
  • Page 19 d) Pump down refrigerant system, if possible. e) If a vacuum is not possible, make a manifold so that refrigerant can be removed from various parts of the system. f) Make sure that cylinder is situated on the scales before recovery takes place. g) Start the recovery machine and operate in accordance with instructions.

  • Page 20: 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 21: 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: R32. GWP value: 677. Based on "IPCC Fifth Assessment Report". GWP is the global warming potential. The quantity of refrigerant fluid is indicated in the unit data label.

  • Page 22: 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 23: 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 24: Storage

    3.4 Storage Units are suitable for storage both indoors and outdoors. Units with mildly flammable refrigerants (A2L), such as R32, shall be stored in accordance with the Europe- an standards and regulations, as well as the local regulations, where applicable. The manufacturer of the refrigerant unit (or simply the unit) shall in no way be liable for events resulting from storage e siting against the above-mentioned European and local standards and regulations.

  • Page 25: 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 26: 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 27: 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 28: Product Description

    PRODUCT DESCRIPTION 5.1 Intended use These units are made for cooling and/or heating (heat pump version) heat-carrying fluid and they are generally used in applications in the air conditioning and refrigeration sector. 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 29: 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 30: Control Panels

    5.7 Control panels This line of units can be controlled with two electronic microprocessor controllers: a base controller (V5+) and an advanced controller (V6). The next sections describe the basic operations which both controllers perform, including unit start and stop, operating mode switching from cooling to heating and vice versa (in units fitted with a heat pump), and setpoint editing.
  • Page 31 5.7.1.3 Setpoint viewing and editing Unit with single working mode (heating only or cooling only or domestic hot water only) and water temperature control If the unit is controlled according to the water temperature (“Water temperature” symbol displayed), the following procedu- re must be followed to edit the setpoint of the output water temperature from the system: press the “SET” button until the symbol of the operating mode flashes, set the desired temperature using the “Arrow Up”...

  • Page 32: Advanced Controller (V6)

    5.7.2 Advanced controller (V6) As an alternative to the base controller, this line of units can be controlled by a programmable microprocessor controller featuring a user interface that comes in the form of an advanced touch screen control panel. 5.7.2.1 Switching the unit on/off Normally, the units are shipped with standard programming for switching on and off from the keypad.

  • Page 33: 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 34: 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 35: Installation

    6.3 Installation The units are shipped from the factory already tested and only need electrical and hydraulic connections for installation. 6.3.1 External positioning The external unit must be installed at a height of at least 200 mm from ground level. If the place of installation is snowy and the possibility exists for snow to build up on the ground, the min.
  • Page 36 The frame installation surface must be perfectly flat. The frame installation surface must be capable of supporting at least 5 times the unit weight. Screws, bolts and nuts must be tightened properly before the unit is installed on the frame. Check the tighte- ning level periodically.

  • Page 37: Internal Unit Positioning

    6.3.3 Internal unit positioning When provided, the internal unit must be installed inside the building. It must be wall-mounted using the support bracket supplied with the unit. The place of installation must be dry, properly ventilated and duly lighted. No volatile and/or corrosive substances and no flammable liquids or gas must be stored in the vicinity of the unit.

  • Page 38: Anti-Vibration Mounts

    6.3.4 Anti-vibration mounts In order to reduce vibrations transmitted to the structure, it is advisable to install the unit on rubber or spring anti-vibration mounts, supplied as an accessory and to be requested when placing the order. The dimensional diagram with footprint shows the position and load of each anti-vibration mount. The anti-vibration mounts must be fixed on before positioning the unit on the ground.

  • Page 39: Possible System Layouts

    6.4 Possible system layouts The controller is characterised by such flexibility that units may be combined with different systems, ranging from easy systems with one single temperature zone to more complex systems with two temperature zones and domestic hot water production.

  • Page 40: Hydraulic Connections

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

  • Page 41: Electrical Connections

    6.6 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 42: Vacuum And Refrigerant Charge

    Power must be supplied to the internal and external units independently. Provision must be made for suitable electric pro- tections to the power level and the current absorbed by each unit. The electric heaters in the external unit must be energised by mean of a connection between the terminals provided in the internal unit and the terminals provided in the external unit.

  • Page 43: Wifi Module Configuration (Applies To Advanced Controller V6 Only)

    6.8 WiFi module configuration (applies to advanced controller V6 only) The WiFi module is designed for the connection of units featuring an advanced controller (V6) to an Internet data network in order to implement remote monitoring and to use the application for remote control of the unit. WiFi module installation and configuration require that the unit operating data be visible to the Manufactu- rer, Fitter and the authorised Service Centre.

  • Page 44: Commissioning

    COMMISSIONING 7.1 Preliminary operations Make sure the main disconnect switch is in the OFF position. 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. Restore functional conditions only on starting.

  • Page 45: 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 46: 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]...

  • Page 47: 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 48: 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 49: 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 50: 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 51: 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 52: External Cleaning

    The component of the unit that needs most care is the finned pack heat exchanger. It is essential to keep it clean and free of dirt and/or deposits that can hinder or prevent air flow. Regular cleaning of the surface of the coil is essential for the unit to work correctly and also increases the operating life of the exchanger and the unit.

  • Page 53: Cleaning The Plate Heat Exchangers

    8.2.2 Cleaning the plate heat exchangers Thanks to the generally very high level of turbulence, in plate heat exchangers, a self-cleaning effect takes place in the channels. However, in some applications the tendency to scaling and/or the formation of deposits in the heat exchanger can be very high (e.g.

  • Page 54: 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 55: 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. The unit must be serviced, even in emergency conditions, by qualified staff and safely, following the guideli- nes provided in the section concerning operations on units that contain flammable refrigerants.

  • Page 56: 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 57: Symbols And Acronyms Used

    SYMBOLS AND ACRONYMS USED List of hydraulic symbols used Cooling Water filter Heating Air venting Temperature probe Water pump Water-side safety valve kit Expansion vessel Ball valve List of display buttons in base controller (V5+) On/Off button Arrow Down button Mode button SET button Arrow Up button...
  • Page 58 List of acronyms used Plate heat exchanger Water filter 2-way water valve on system side 3-way water valve on system side 4-way water valve on system side 4WVR 4-way valve in refrigerant circuit Thermometer Diverter valve Feet height adjustment range in base frame Air inlet Air outlet Serial communication cable between internal and external units...
  • Page 59 Water temperature probe in zone 2 Domestic hot water temperature probe Expansion vessel Check valve Water filter Hydraulic connection for input water Hydraulic connection for output water Water pump Communication cable shield WWHE Water/Water plate heat exchanger List of symbols in internal unit exploded view V6 (A.1) Control panel WiFi module (option) Check sheet Water temperature probe...
  • Page 60 List of symbols in external unit exploded view: sizes 15 - 19 (figure A.4) Fan nozzle Service panel Front panel Fixing plate 1 for terminal block Fan impeller Fixing plate 2 for terminal block Fan motor bracket Fixing plate for plate heat exchanger Fan motor DC Fixing plate Compressor Top cover Base Electric box cover Liquid receiver Electric box Bulkhead...

  • Page 61: Appendixes

    APPENDIXES List of Appendixes Appendix A – Unit exploded views Appendix B – Images Appendix C – Unit drawings and min. installation spaces Appendix D – Wiring diagrams Appendix E – System diagrams Appendix F – Base frame assembly procedure Appendix G –...
  • Page 62 A.1 bis Translation from original instructions We reserve the right to make changes without any prior notice.
  • Page 63 We reserve the right to make changes without any prior notice. Translation from original instructions...
  • Page 64 Translation from original instructions We reserve the right to make changes without any prior notice.
  • Page 65 We reserve the right to make changes without any prior notice. Translation from original instructions...
  • Page 66 B.10 Translation from original instructions We reserve the right to make changes without any prior notice.
  • Page 67 B.11 B.12 We reserve the right to make changes without any prior notice. Translation from original instructions...
  • Page 68 B.13 B.14 Translation from original instructions We reserve the right to make changes without any prior notice.
  • Page 69 We reserve the right to make changes without any prior notice. Translation from original instructions...
  • Page 70 B A GND 12V WATER INLET TEMP.SENSOR WATER OUTLET TEMP.SENSOR INDOOR COIL ON DIP ON DIP TEMP.SENSOR 1 2 3 4 WATER FLOW SWITCH PE N PUMPH/PUMPC PE N SECONDARY CIRCULATING PUMP POWER SUPPLY OUTDOOR UNIT MAX. 600W 230V 50HZ ANTI-FREEZE ²...
  • Page 71 NTC 5K PT1000 PT1000 black blue brown IU V6 We reserve the right to make changes without any prior notice. Translation from original instructions...
  • Page 72 THERMOSTAT，7 OU 6-9-12 Translation from original instructions We reserve the right to make changes without any prior notice.
  • Page 73 To CN485-3 Indoor coil temp. sensor Water inlet temp. sensor PT1000 Water outlet temp. sensor PT1000 Water ow switch Water inlet temp. sensor (V5+) Water outlet temp. sensor (V5+) ANTI-FREEZE HEATER black blue brown CN27 CN17 CN18 CNTs CN16 CNTa CNTp CNTd CN58 CN59 CN8 FAN1 CN8 FAN2 pressure...
  • Page 74 Translation from original instructions We reserve the right to make changes without any prior notice.
  • Page 75 We reserve the right to make changes without any prior notice. Translation from original instructions...
  • Page 76 Translation from original instructions We reserve the right to make changes without any prior notice.
  • Page 77 We reserve the right to make changes without any prior notice. Translation from original instructions...
  • Page 78 E.10 Translation from original instructions We reserve the right to make changes without any prior notice.
  • Page 79 We reserve the right to make changes without any prior notice. Translation from original instructions...
  • Page 80 F.10 F.11 F.12 Translation from original instructions We reserve the right to make changes without any prior notice.
  • Page 81 F.13 F.14 F.15 F.16 We reserve the right to make changes without any prior notice. Translation from original instructions...
  • Page 82 Translation from original instructions We reserve the right to make changes without any prior notice.
  • Page 83 We reserve the right to make changes without any prior notice. Translation from original instructions...
  • Page 84 Translation from original instructions We reserve the right to make changes without any prior notice.
  • Page 85 G.10 G.11 We reserve the right to make changes without any prior notice. Translation from original instructions...
  • Page 86 G.12 G.13 G.14 Translation from original instructions We reserve the right to make changes without any prior notice.
  • Page 87 We reserve the right to make changes without any prior notice. Translation from original instructions...

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