gelsystem CUBIC Series User And Maintenance Manual

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Gelsystem srl

Industrial refrigeration and air conditioning systems

Registered Office: Viale Parioli 73 Roma 00197

Production Site: strada Teverina Km5,4 Loc. Acquarossa 01100 Viterbo VT

Tel (+39) 0761.17.63.927, Fax (+39) 0761.1871.004, E-mail:

ufficiotecnico@gelsystem.eu

CUBIC SERIES COOLING SYSTEMS

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Page 1 Gelsystem srl Industrial refrigeration and air conditioning systems Registered Office: Viale Parioli 73 Roma 00197 Production Site: strada Teverina Km5,4 Loc. Acquarossa 01100 Viterbo VT Tel (+39) 0761.17.63.927, Fax (+39) 0761.1871.004, E-mail: ufficiotecnico@gelsystem.eu CUBIC SERIES COOLING SYSTEMS...
Page 2 Gelsystem srl Industrial refrigeration and air conditioning systems Registered Office: Viale Parioli 73 Roma 00197 Production Site: strada Teverina Km5,4 Loc. Acquarossa 01100 Viterbo VT Tel (+39) 0761.17.63.927, Fax (+39) 0761.1871.004, E-mail: ufficiotecnico@gelsystem.eu In accordance with the provisions of DIRECTIVE 2014/68/EU...
Page 3: Table Of Contents
User and Maintenance Manual INDEX INDEX INTRODUCTION ........................3 GENERALITIES ........................4 2.2 M ................4 ENTIONED FIGURES 2.3 S ............... 5 YSTEM IDENTIFICATION 2.4 S ................5 YSTEM DESCRIPTION Reference Community Standards ....................7 WARRANTY ..........................8 SAFETY ........................... 10 5.1 A ..............
Page 4: Introduction
INTRODUCTION INTRODUCTION Gelsystem thanks you for choosing this product and recommends you carefully read all the pages that compose this User and Maintenance Manual. The information within is of fundamental importance for a safe and long-lasting use of the CUBIC Series you have been supplied.
Page 5: Generalities
User and Maintenance Manual GENERALITIES GENERALITIES CUBIC Series Centralised Inverter Refrigeration Units are manufactured following the best design and engineering standards, to guarantee the highest levels in terms of performance, reliability, and adaptability of any kind of system. Always refer to the present manual before operating. Please make sure it is preserved carefully and is always available close to the equipment.
Page 6: System Identification
SET SAFETY VALVE 2.4 System description The CUBIC Series Unit is composed of a compressor compartment along with a cabinet where all the electronics are stored; it oversees powering all LT (negative) and/or MT (positive) outlets and can also power terminal units for direct expansion air conditioning (e.g., fan coil units), but only in cold...
Page 7 Circuit linking’s Input and Output for both the production and storing of hot water (where applicable, being an optional) Among the main Gelsystem Centralised Unit’s pluses, you can find: Electronic management of every mechanical component (compressors, remote condenser fans, hot water recirculation pump, etc.);...
Page 8: Reference Community Standards
User and Maintenance Manual STANDARDS Reference Community Standards The whole unit’s manufacturing and inspection are fulfilled in accordance with the following standards:  UNI EN 378-1 Refrigerating systems and heat pumps. Safety and environmental requirements. Basic requirements.  UNI EN 378-2 Refrigerating systems and heat pumps.
Page 9: Warranty
EU. The manufacturer, Gelsystem Srl, guarantees the system has been designed and manufactured in compliance with the regulations in force and by using materials consistent with them. The unit is supplied in full, tested, and ready to work.
Page 10 User and Maintenance Manual WARRANTY Refrigeration plants are not built to endure any stress or load that may come from adjacent units. Any external stress or load coming unto the unit may cause failures, structural collapses, or potential danger to people. In this case, any kind of warranty is thus invalidated. Failure to meet any of these conditions invalidates both the equipment’s homologation and warranty, in compliance with PED 2014/68/EU, DLGS 26 OF 15/02/2016 on equipment and pressure assemblies.
Page 11: Safety
It is fundamental to have read and understood the content of the present manual, before using the system and the refrigerating equipment. For any doubt or required information, please contact Gelsystem Service Centre. As per rule, any operation on the equipment during installation and maintenance is to be performed only after ensuring the power supply is interrupted.
Page 12: Access To Engine Room
User and Maintenance Manual SAFETY Said documentation is carefully read and the requirements in place acted upon; Only adequately qualified personnel are assigned to the device and the electrical equipment. 5.1 Access to engine room When accessing the engine room or condensing or evaporating batteries, it is mandatory: Not to remove protections and safety devices the system and the equipment are fitted with;...
Page 13: Fire And Explosion Hazards
User and Maintenance Manual SAFETY Protect your hands and skin in general from any contact with the coolant, especially in its liquid state (it might induce cold burns or make your skin prone to infections); Protect your eyes from any splash of coolant. 5.3 Fire and explosion hazards Fire hazards closely linked to the cooling system are to be considered almost non-existent;...
Page 14: Environmental Protection
User and Maintenance Manual SAFETY 5.5 Environmental protection Coolants, as well as lubricating oils, are subject to legal regulations that prohibit their disposal into the environment and enforces their recovery. This must be considered concerning both maintenance and dismantling of the cooling systems. In accordance with the law 549 of 28/12/1993: ...
Page 15 User and Maintenance Manual SAFETY  Urgent: (circulatory and/or respiratory crisis) immediately contact the emergency response service by calling 112/999 and focus on two crucial goals: 1. Ensure your own safety 2. Secure, as far as possible, the injured person’s circulatory functions, then his/her breathing and heart rate.
Page 16 User and Maintenance Manual SAFETY  Ingestion of liquid state coolant: Do not induce vomiting and immediately contact a doctor.
Page 17: Installation
(cooling circuit, control panel, casing, and chassis); subsequently, taking care not to use cutting tools that might damage the internal equipment, unpack it to verify its integrity. Please give immediate notice of any damage caused by transport to Gelsystem Technical Support.
Page 18: Placement
For a summary on the minimum clearance to observe when installing Gelsystem systems and remote condensers (if any), please refer to the following tables. Please keep in mind that the minimum clearance from hind impediments changes from 250mm to 500mm for COMPACT models with on- board condensers.
Page 19: Thermodynamic Piping
CLEARANCE FROM CLEARANCE FROM SIDE BARRIERS FRONT AND REAR BARRIERS FAN SIDE 6.3 Thermodynamic piping It is MANDATORY to use piping manufactured by Gelsystem when installing. The company declines any responsibility in case any third-party or non-compliant piping is used.
Page 20 User and Maintenance Manual INSTALLATION Both workmanlike manner and the following instructions must be followed for a successful installation. For any doubt or information, please contact Gelsystem Technical Support, which will swiftly provide all the necessary directions. Precautions:  Pipes must be nitrogen-brazed, making sure that no slag sticks inside; to this end, it is suggested to rinse with specific fluid, which will then need to be eliminated.
Page 21: Power Connection
User and Maintenance Manual INSTALLATION  Insulate LT suction lines with 19mm wide Armaflex, and MT suction, liquid, and defrost lines with 13mm wide Armaflex. 6.4 Power connection The systems’ power connection must be built by qualified technicians in full observance of the profession’s workmanlike manner.
Page 22: Cold Water Module (Optional)
Technical Department, which will guide you in the procedure. 6.6 Cold water module (optional) CUBIC Series Refrigeration Unit’s WATERCUBIC setup enables the production of cold water for industrial and technical use (ice cream machines and other generally water-condensed equipment).
Page 23 MPa (8 bar). For specific requirements, like outlet relocations for distances exceeding 10 metres from the economiser or height differences between the two, contact GELSYSTEM for information on the piping to be observed and eventual additional pumps to be added to the hydraulic circuit. Regardless, it is recommended to refer to the pump’s hydraulic output board and make sure the installed type is...
Page 24: Control Panel
User and Maintenance Manual CONTROL PANEL CONTROL PANEL Every Gelsystem refrigeration system is equipped with a control panel made of two on/off switches, a reset switch (to be used in case of inverter deadlock), and an electronic unit for system programming.
Page 25 User and Maintenance Manual CONTROL PANEL • LEDs n°1-2 (With RTC – on-board Real-Time Clock): If on the time is shown in the lower display, the clock icon lights up and LEDs n°1/2 flash; • LEDs n°1-2 (In functions menu): While consulting the functions menu, LEDs n°1/2 flash when the time left to launch defrosting is displayed;...
Page 26: Icon Meaning
User and Maintenance Manual CONTROL PANEL 7.2 Icon meaning...
Page 27: Key Functions
User and Maintenance Manual CONTROL PANEL 7.3 Key functions FRONT VIEW...
Page 28: Combinations
User and Maintenance Manual CONTROL PANEL 7.4 Combinations 7.5 Front LEDs...
Page 29: Start-Up And Testing
8.2 Testing Like every Gelsystem product, CUBIC Series Refrigeration Units are tested inside the manufacturing plant post-production, where they are checked, and their operative and productive features verified. Testing of the system on the end-user’s premises must be performed by qualified technical personnel or by a GELSYSTEM expert after placing the equipment correctly and adequately connecting it to a power supply network.
Page 30 Once the test is complete, an attestation of installation in a workmanlike manner must be redacted, stating that all the stages for the appropriate performance of the equipment have been followed and the necessary measures taken. This must be sent to Gelsystem to validate the warranty, effective as of the date of the test.
Page 31: Shutdown And Reboot
Turn off all the outlets from the respective electronic units. Turn off the system after about 5 minutes. In this regard, it is recommended to contact Gelsystem’s Service Centre by calling 0039 0761.17.63.927 and let a qualified expert operate the system.
Page 32: Defrosting
This may also happen when rebooting the outlets after eventual blackouts. 9.5 Defrosting Defrosting times and intervals are pre-set by Gelsystem. If you were to execute a manual defrosting, it would be possible to operate on the electronic or mechanical programmer observing the instructions given in paragraph 7.4...
Page 33: Maintenance
Before performing maintenance of any kind, it is mandatory to switch off the feeder disconnector, removing voltage from the entire system. Gelsystem S.r.l. declines any responsibility for damage to things or people in the event of tampering or unauthorised attempt to repair.
Page 34: Routine Maintenance
10.3 Special maintenance Special maintenance assistance during the warranty period must be performed exclusively by qualified personnel authorised by Gelsystem S.r.l., using only original spare parts and in compliance with the rules of the profession and the regulations in force.
Page 35 Any work on the system can only be performed after shutting down the power. If in any doubt on the unit’s model you are operating and its characteristics, please refer to its serial number and contact Gelsystem Service Centre by calling +39 0761 1763927; you’ll be provided with all the information requested.
Page 36 MAINTENANCE The systems are equipped with under-pressure components. It is therefore crucial to either use original spare parts or with adequate characteristics to be used on Gelsystem Units; Piping replacements must be performed using exclusively copper pipes with the same characteristics as those installed on the equipment.
Page 37 User and Maintenance Manual MAINTENANCE -AP 2 - Wrong reading; Probe 2 failure (Ptc Check probe reading with a discharge Comp.2) comparison probe; Check proper out-of-range detection wiring; Replacement -AP 3 Probe failure - Wrong reading; - Check probe reading with pressure (Transd.
Page 38 User and Maintenance Manual MAINTENANCE -C(n)oP - Oil level sensor - Low Oil level on - Check Oil on Compressor; Dirty Optical compressor Sensor; Optical Sensor Off; Fluid Leakage -C(n)Tr - Thermal Compressor - Compressor Inverter - Check the alarm in the Inverter and alarm perform the recommended checks -C(n*) dt...
Page 39: Inverter Alarms
User and Maintenance Manual MAINTENANCE 10.5 Inverter alarms...
Page 40 User and Maintenance Manual MAINTENANCE Inverter alarm reset Inverter alarms can be reset through the dedicated key, placed next to the system’s control box...
Page 41: System Log
User and Maintenance Manual SYSTEM LOG SYSTEM LOG 1. Type of operation: ……………………………………………………………………………….. ……………………………………………………………………………….. Description: ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Date:……………………. Stamp:…………………………… 2. Type of operation: ……………………………………………………………………………….. ……………………………………………………………………………….. Description: ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Date:……………………. Stamp:……………………………...
Page 42 User and Maintenance Manual SYSTEM LOG 3. Type of operation: ……………………………………………………………………………….. ……………………………………………………………………………….. Description: ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Date:……………………. Stamp:…………………………… 4. Type of operation: ……………………………………………………………………………….. ……………………………………………………………………………….. Description: ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Date:……………………. Stamp:…………………………… 5. Type of operation: ……………………………………………………………………………….. ……………………………………………………………………………….. Description: ……………………………………………………………………………….. ………………………………………………………………………………..
Page 43 User and Maintenance Manual SYSTEM LOG 6. Type of operation: ……………………………………………………………………………….. ……………………………………………………………………………….. Description: ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Date:……………………. Stamp:…………………………… 7. Type of operation: ……………………………………………………………………………….. ……………………………………………………………………………….. Description: ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Date:……………………. Stamp:…………………………… 8. Type of operation: ……………………………………………………………………………….. ……………………………………………………………………………….. Description: ……………………………………………………………………………….. ………………………………………………………………………………..
Page 44 User and Maintenance Manual SYSTEM LOG 9. Type of operation: ……………………………………………………………………………….. ……………………………………………………………………………….. Description: ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Date:……………………. Stamp:…………………………… 10. Type of operation: ……………………………………………………………………………….. ……………………………………………………………………………….. Description: ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Date:……………………. Stamp:…………………………… 11. Type of operation: ……………………………………………………………………………….. ……………………………………………………………………………….. Description: ……………………………………………………………………………….. ………………………………………………………………………………..
Page 45 User and Maintenance Manual SYSTEM LOG 12. Type of operation: ……………………………………………………………………………….. ……………………………………………………………………………….. Description: ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Date:……………………. Stamp:…………………………… 13. Type of operation: ……………………………………………………………………………….. ……………………………………………………………………………….. Description: ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. ……………………………………………………………………………….. Date:……………………. Stamp:…………………………… 14. Type of operation: ……………………………………………………………………………….. ……………………………………………………………………………….. Description: ……………………………………………………………………………….. ………………………………………………………………………………..
Page 46: Attachments
User and Maintenance Manual ATTACHMENTS ATTACHMENTS 1. R449A REFRIGERANT GAS SAFETY DATA SHEET 2. R448A REFRIGERANT GAS SAFETY DATA SHEET 3. R452A REFRIGERANT GAS SAFETY DATA SHEET 4. R404A REFRIGERANT GAS SAFETY DATA SHEET 5. R410A REFRIGERANT GAS SAFETY DATA SHEET 6.
Page 47 User and Maintenance Manual NOTES NOTES……………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… …………………………………………………………………………………………………………...
Page 48 User and Maintenance Manual NOTES NOTES……………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… ………………………………………………………………………………………………………… …………………………………………………………………………………………………………...