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Related Manuals for Swegon BlueBox Titan Sky Hi R0
Summary of Contents for Swegon BlueBox Titan Sky Hi R0
- Page 1 Titan Sky Hi R0 Installation, use and maintenance manual 08-07-2021...
- 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.
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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 2.1.2 Emergency stop 2.1.3 Atex cable glands 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 Operation with water to the evaporator at low temperature 2.2.7 Operation in heat pump mode with low temperature water 2.2.8 Refrigerant leak detector Noise Residual risks Safety information on the refrigerant fluid 2.5.1 Hazards and health consequences Receiving the product and storage... - Page 4 Unintended use Control and safety devices Principles of operation Structure Specifications Control panel Wiring diagram Installation Dimensions and weight Place of installation Installation 6.3.1 External positioning 6.3.2 Noise attenuation 6.3.3 Minimum distances Hydraulic connections 6.4.4 Hydraulic connection to the desuperheater (DS option) 6.4.5 Condensate drain (only for heat pump units) 6.4.6 Oversized anti-freeze heater for condensate drip tray System components 6.5.1 Installation of pressure sensors 6.5.2 Installation of temperature sensor...
- Page 5 Maintenance Adjustments External cleaning 8.2.1 Cleaning traditional finned coils in Cu/Al Internal cleaning 8.3.1 Cleaning the unit 8.3.2 Cleaning the plate heat exchangers Periodic checks Unscheduled maintenance 8.5.1 Special work Decommissioning We reserve the right to make changes without any prior notice. Translation from original instructions...
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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 Access to the area around the unit must be prevented by special guarding where this is positioned in a location that is not protected and can be reached by unqualified persons. 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. -
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: Emergency Stop
A threaded connector is provided on the side to connect the exhaust pipe of the safety valve. Refer to the dimensional diagram for the required diameter. Fig. 1 Connection to convey the material exhausted from the safety valve Zone 2 forming from the emissions of a safety valve may extend horizontally up to 10 metres and vertically up to 11 metres. -
Page 11: Atex Cable Glands
2.1.3 Atex cable glands Cables are run into the electrical cabinet and the junction boxes of the electrically-controlled actuators in the unit by means of Atex-certified cable glands. The certified protection level is guaranteed if they are tightened correctly. The tightening torque recommended by the supplier must be checked at the time of installation and at periodic intervals. The time interval required for the checks is specified in the chapter on maintenance. -
Page 12: Basic Rules
2.2 Basic rules All units are designed and manufactured in accordance with the applicable European Directives that are referenced in the declaration of conformity. 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 the necessary qualifications in accordance with current regulations. -
Page 13: 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 14: 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 15: Installing The Flow Switch
2.2.4 Installing the flow switch The units are equipped between the evaporator inlet and outlet with a differential pressure switch. A flow switch, that must be connected by the installer, can be supplied as accessory. The installed flow switch is provided with a 1” male connector. The unit must be installed following the arrow that shows the direction of flow. -
Page 16: 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 17: Refrigerant Leak Detector
2.2.8 Refrigerant leak detector A refrigerant leak detector with an IR sensor is installed on the units. This device is designed to immediately identify any refrigerant leakage. When 10% LFL is exceeded, the detector enables ventilation in the technical compartment and ventilation in the electrical panel (where it is not enabled yet); additionally, it switches on the red light on the door of the electrical panel, it closes the alarm potential free contact, and finally it cuts out power to the electrical panel by means of a specific circuit breaker, excepting the side where the detector power connectors are located. -
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 In a “zone 2”: - installation of equipment unsuitable for use in such potentially explosive zones must be avoided (the minimum equip- ment requirements are: 3G IIB T4); - naked flames, sparks and hot work must be avoided; - sources of ignition that are due to processes must be avoided, since they are likely to give way to remote ignition (io- nizing and non-ionizing radiation);...
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Page 20: Safety Information On The Refrigerant Fluid
2.5 Safety information on the refrigerant fluid This product is filled with a flammable natural gas (hydrocarbon), classed A3 under ISO 817. Type of refrigerant: R290. GWP value: 3. Based on "IPCC Fifth Assessment Report". 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 21: 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 22: 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. Smoking and the use of naked flames are not permitted during handling operations. In all lifting operations, make sure the unit is firmly secured in order to prevent accidental falls or overturning. -
Page 23: Storage
When a crane is used, harness the unit with slings using the yellow lifting brackets on the base. Fig. 3 Focus on the attachment of the sling to the lifting bracket It is mandatory to use a lifting beam adjusted to the width of the unit in order to ensure lifting stability. Also, suitable pro- tective devices must be placed on the upper edges to prevent the slings from coming into contact with the unit. -
Page 24: 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 25: 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 26: 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 27: 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 28: 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 29: Control Panel
5.7 Control panel The unit is integrally managed by an electronic system with microprocessor, having a graphic display as interface. The display can be used to access all the functionalities of the unit starting with the setting of the parameters and manage- ment and analysis of any problems. -
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 high flammability of the refrigerant gas used, the pressures in the refrigerant circuit and the electrical components fitted can create risky situations during installation and maintenance work. - Page 31 As defined in standard EN378-1, these units are designed for exclusive installation outdoors, in other words in class III locations (see relevant classification in the above standard). Based on the location classification and the intended access category, standard EN 378-1 defines the following refrigerant charge limits for each individual machine belonging to this specific class (class III) of this product type: - access by general public: 5 kg;...
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Page 32: 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 A solid base on which to position the unit must be created. This base must be perfectly flat and horizontal. Its dimensions must be adequate for those of the unit. The slab must be: - made in a suitable foundation about 15-20 cm higher than the surrounding ground;... - Page 33 6.3.1.1 Rubber 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.
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Page 34: Noise Attenuation
6.3.2 Noise attenuation The units are designed and built paying particular attention to keeping down noise emission during operation. Correct installation for both the place and the components, as shown in the relevant chapter, prevents resonances, reflections and vibrations that can be particularly bothersome. If, after following the instructions above, further attenuation is required, the use of acoustic barriers is a valid solution. -
Page 35: Hydraulic Connections
6.4 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 36 If fitted, open type expansion vessels must be installed outside the unit. If they are already installed in the unit, they must be moved outside or they must be replaced with hermetic type vessels. Outdoor installation always requires the fitting of safety valves. It is mandatory to instal mechanical vents outdoor.
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Page 37: Hydraulic Connection To The Desuperheater (Ds Option)
6.4.4 Hydraulic connection to the desuperheater (DS option) The heat desuperheater must be connected to a closed hydraulic circuit. Constant renewal of water causes limescale to build up in the exchanger, which reduces its efficiency in a short time and makes it unserviceable. Part of the heat rejected in the condenser can be recovered with a “desuperheater”... -
Page 38: Condensate Drain (Only For Heat Pump Units)
6.4.5 Condensate drain (only for heat pump units) All the units in heat pump version are equipped, at the base of each condensing/evaporating coil, with a condensate drip tray provided with an electric heater. Each tray has a 1” gas male connector that is used for drainage. A piece of the electric heater in the tray is free so that it can be introduced in the drain pipe. -
Page 39: System Components
6.5 System components 6.5.1 Installation of pressure sensors If the operating logic requires the installation of pressure sensors in the system, the Manufacturer supplies a kit of measu- ring devices to be assembled by the fitter. The kit consists of: - 2 pressure sensors;... -
Page 40: Installation Of Temperature Sensor
6.5.2 Installation of temperature sensor If the operating logic requires the installation of a temperature sensor in the system, the Manufacturer supplies the neces- sary kit to be assembled by the fitter. The kit consists of: - 1 threaded probe pocket G1/2"; - 1 temperature sensor. -
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 If the circulation pumps are not installed on the unit, potential free contacts are available as accessory for controlling the external pumps. If the potential free contacts for controlling the circulation pumps are present, connect the pumps as shown in the wiring diagram. The electrical connections to potential-free contacts, which are powered by external sources, must be sui- tably protected against overcurrent and earth faults.
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Page 43: 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 44: Checking The Pre-Charge Of The Expansion Vessel
The heaters in the compressor crankcase are switched on when the master disconnect switch is closed: this must be done at least 12 hours before starting the unit. To check that the heaters are working correctly, check that the lower part of the compressors is hot and in any case at a temperature of 10 - 15 °C above ambient temperature. -
Page 45: 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 46: First Starting
7.2 First starting When the unit is started for the first time, some important tests and checks must be done. The unit must be started up for the first time by trained personnel from authorised service centres. The electrical cabinet must be opened exclusively after checking for refrigerant in the air with the help of a gas detector. -
Page 47: Start
7.2.2 Start Start the unit by acting on the user interface of the control. Check that the water flow switch/differential pressure switch is working correctly by closing the shut-off valve at the outlet of the unit; this should cause the alarm to be displayed on the user interface of the unit. If not, restore correct operation. -
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: 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 50: 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 51 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.
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Page 52: 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 53: Maintenance
MAINTENANCE Unit filled with refrigerant classified as A3 (flammable) A refrigerant leak alarm identifies the potential forma- tion of flammable atmospheres. The electrical cabinet must be opened exclusively after checking for refrigerant in the air with the help of a gas detector. -
Page 54: External Cleaning
8.2 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 55: Internal Cleaning
8.3 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. 8.3.1 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 56: Cleaning The Plate Heat Exchangers
8.3.2 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 57: 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 58: 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 59: 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 60 Page intentionally blank Translation from original instructions We reserve the right to make changes without any prior notice.
- Page 61 Page intentionally blank We reserve the right to make changes without any prior notice. Translation from original instructions...
- 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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