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Sigma Zero Installation, use and maintenance manual 18-10-2024...
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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 of conformity also guarantees that the equipment meets the requirements of the European Machinery Safety Directive.
Contents Introduction Conformity Description 1.2.1 Symbols 1.2.2 Labels Safety General safety precautions 2.1.1 Discharge of the safety valves present on the refrigeration circuit 2.1.2 Routing of exhausted air from technical compartment 2.1.3 Atex cable glands 2.1.4 Emergency stop 2.1.5 Double safety valve option Basic rules 2.2.1 Water flow rate at the heat exchangers...
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Product description Intended use Unintended use Control and safety devices Principles of operation Structure Specifications Control panel Wiring diagram Installation Dimensions and weight Place of installation 6.2.1 Indoor unit "Ventilated enclosure" 6.2.2 Unit for outdoor installation Installation 6.3.1 External positioning 6.3.2 Internal unit positioning 6.3.3...
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7.2.2 Inspection of differential air pressure switch - Indoor unit 7.2.3 Inspection of air ejection ducting for head losses - Indoor unit 7.2.4 Start 7.2.5 Functional tests 7.2.6 Units provided with taps in the compressors System testing 7.3.1 Flowzer DT Calibration of safety components Checks during operation Alarms and malfunctions...
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;...
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 unit model, serial number, specifications, power voltage etc.
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.
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Before work is started on the unit: check for potentially flammable atmospheres; Make sure there are no possible ignition sources Adhere to the requirements set by the local legislation and by European standards EN378-4 and EN13313. In units with capacitors and/or inverters, certain components can remain live for several minutes even after having turned off the main switch.
2.1.1 Discharge of the safety valves present on the refrigeration circuit The refrigeration circuit is always equipped with a safety valve(s) which is/are conveyed flush with the machine. The exit point and connection characteristics are indicated on the dimensional diagram of the unit. Fig.
2.1.2 Routing of exhausted air from technical compartment Indoor version units An “Atex” fan is installed inside the unit to eject the air from the technical compartment. Alternatively, where differently se- lected, the supply includes the “Atex” fan for installation outside the unit. The fan is activated when the refrigerant detector measures a concentration exceeding 10% “LFL”.
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Fan installed outside unit When the air ejection fan is selected as an option provided with the standard supply, the fan may be at the service of either one or multiple units, based on the options available in the price list. In this case, it may serve 1 to 5 units. When it is included in the standard supply, the fan must be powered by a dedicated power line to the electrical control panel it is provided with.
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The abbreviations shown in the figure refer to: - VC - centrifugal fan - ps - measurement outlet; - sr - damper for leak adjustment - gr - anti-intrusion protection grid - Qev - ejection fan control panel When designing the ducting, outlets must be included to measure the head generated by the fan and an adjustment dam- per;...
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 installed cable glands are ingress protection IP65, including II 2GD marking, protection type Ex eb IIC Gb.
2.1.5 Double safety valve option When they are released from the factory, the shut-off elements in the safety valves, if any, are open and protected by a tamper-proof seal. When the DSV (Double Safety Valve) option is featured, the shut-off elements in the safety valves are set up in the factory in such way that a safety valve is open and the corresponding backup valve is closed.
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.
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.
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.
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 flow switch supplied has a 1” male fitting The unit must be installed following the arrow that shows the direction of flow.
2.2.5 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)
2.2.7 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.
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As accessory, a two-way modulating valve can be supplied by the manufacturer as an alternative to the three-way valve. The hydraulic connection of the two-way modulating valve must be made as shown in the illustration. Fig. 6 Hydraulic connection of two-way valve Condenser Two-way valve For some sizes, the manufacturer supplies a three-way modulating valve, with way "B"...
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 detect 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.
2.2.9 Safety potential free contacts The terminal board is fitted with safety potential free contacts, in addition to the lights installed on the door of the electric panel that warn about operation of the refrigerant leak detector. The contacts are activated to warn about the following alarm conditions: •...
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.
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Safe area when installed opposite a wall 0,3 m 1,5 m 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 IIA T2); - 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);...
2.5 Safety information on the refrigerant fluid This product is filled with a flammable natural gas (hydrocarbon), classified as 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.
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.
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.
The hole diameter of the lifting bracket for fixing the shackle is 22.5mm. U-bolts and any other lifting equipment are not supplied with the unit. If you are using a crane, sling the unit with slings using suitable lifting tubes (not supplied with the unit) inserted in the slots on the base of the unit.
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").
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.
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.
PRODUCT DESCRIPTION 5.1 Intended use These units are intended to cool (units in cooling only version), to heat (units in heating only version) or to cool/to heat (heat pump version) heat-carrying fluid; they are generally used in applications in the air-conditioning and refrigeration fields. Their use is recommended within the operating limits indicated in the Technical Catalogue.
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.
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.
5.8 Wiring diagram The wiring diagram is an essential part of the documentation. 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. In particular, refer to the wiring diagram as regards the possibility of remotely managing the functionalities that contemplate this.
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.
As the units are designed according to the “ventilated enclosure” criteria specified in standard EN 378, no danger zone is created around them if they are correctly powered, all their safety systems are in good wor- king order, and they are maintained properly. Fire extinguishers (CO or dry powder) must be installed near the unit.
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;...
6.3.3 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.
6.3.4 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, avoids 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.
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.
Breakage of the heat exchanger may cause the refrigerant to flow into the vector fluid and be transferred to confined spaces. An automatic air/refrigerant separator and a safety valve must be used: these components must be installed as the first element at the outlet of the plate heat exchanger. The air/refrigerant separator and the safety valve must be placed at a higher level than the outlet of the heat exchanger where refrigerant may build up.
6.4.0 User hydraulic circuit Reference hydraulic diagram for connecting the unit to the user circuit. Fig. 12 Recommended hydraulic circuit Evaporator Water filter Thermometer Motor-driven pump Flow switch Flexible coupling System filling unit Water pressure gauge Valve Safety valve Automatic air/refrigerant separator Storage tank Air valve Expansion vessel...
6.4.1 Source hydraulic circuit Reference hydraulic diagram for connecting the unit to the source circuit. Fig. 13 Recommended hydraulic circuit Condenser Water filter Thermometer Motor-driven pump Flow switch (mandatory) Flexible coupling System filling unit Water pressure gauge Valve Safety valve Automatic air/refrigerant separator Air valve Expansion vessel...
6.4.2 Hydraulic circuit for heat pump units with reversal on the water In these units, operation reversal takes place with reversal of the hydraulic circuits. Reversal of the hydraulic circuits can be done using two 4-way valves or four 3-way valves. Fig. 14 Reversal with 4-way valves Fig. 15 Reversal with 3-way valves Whatever solution is adopted, in cooling mode, the evaporator "E"...
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;...
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.
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.
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The electrical connections to potential-free contacts, which are powered by external sources, must be sui- tably protected against overcurrent and earth faults. The circuit of the potential-free contacts inside the electrical control panel is made using orange cable. Use the free cable glands in the electrical cabinet to remote the controls and signals featured in the electrical cabinet.
6.7 Aeraulic connections A duct must be built on units intended for indoor installation to connect the technical compartment to the outside. 6.7.1 Exhaust duct for air ejected from the technical compartment It is mandatory, and the responsibility of the installer, to set up a duct for correct routing of the air ejected from the technical compartment into the open air should a refrigerant leak be experienced.
COMMISSIONING 7.1 Preliminary operations Make sure the main disconnect switch is in the OFF position. In units fitted with anti freeze heaters, their power supply is mechanically locked. Operating conditions must be restored exclusively after the machine is totally filled with water. Before filling the hydraulic system, check that the drain valve is closed and that all the air valves are open.
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.
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]...
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.
7.2.3 Inspection of air ejection ducting for head losses - Indoor unit If the centrifugal fan used to convey the air out of the technical room is installed at the end of the air ejection ducting, a check must be made that the head loss in the ducting is at acceptable levels. The fan supplied by the manufacturer is appropriately sized with the number of units intended to be connected to one single duct.
7.2.4 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.
7.3 System testing Specific logics have been developed according to which the controller manages the hydraulic systems connected to the unit. The management logics are intended to increase system efficiency and save energy for water circulation at the same time. With the help of these logics, the circulating water fulfils the demands of the system, without exceeding the design flow rate limits and without jeopardising correct operation of the cooling unit.
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This type of system requires that the min. water flow rate is also guaranteed when there is no load. This is made possible through the installation of 3-way valves on the user points. The installation of 3-way valves on the furthest user points also provides for greater thermal flywheel, which enables limiting the capacity of the buffer tank.
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- Vmin = minimum water volume in the system/plant - UL = limit of the supply. If the operating logic of the secondary circuit includes stopping of the water flow rate, the capacity of the buffer tank must be sized against the min. volume of water required for unit operation. If user points with 3-way valves are installed in the system and water is circulated to the secondary circuit, the capacity of the buffer tank can be reduced.
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The abbreviations present in the diagram indicate: - A2 = cooling unit controller - BT1 = unit input temperature sensor - BT2 = unit output temperature sensor - EU = heat exchanger in cooling unit - BP41= differential pressure sensor; - ΔPex = pressure difference at the ends of the unit;...
7.4 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).
7.5 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.
7.6 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.
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SYMPTOM LIKELY CAUSE POSSIBLE SOLUTION Check that the air valves are not shut Abnormal noises on the hydraulic Presence of air in the system. off by valves. pipes. Vent the system. 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.
7.7 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.
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.
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.
8.3 Periodic checks Carry out periodic checks to make sure the unit is working correctly: Work on the unit must be performed exclusively after checking for refrigerant in the air, as a result of which a potentially flammable atmosphere may form. Unit filled with refrigerant classified as mildly flammable A2L or with flammable refrigerant A3, pursuant to ISO 817.
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These operations do not include work or adjustments on the refrigerant system and they do not require any specific know- ledge. They can be performed by adequately trained staff following the instructions given in this manual and the correct procedures defined by the existing regulations.
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The operations contemplated below must always be performed by qualified and authorised staff, pursuant to the provisions laid down in Directive EN378-4 and Directive EN22712; staff shall be duly trained on the test procedures, in compliance with all the required safety precautions. RECOMMEN- OPERATION DED FRE-...
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RECOMMEN- OPERATION DED FRE- QUENCY Check for abnormal vibration/noise or mechani- Visual and noise level inspection. Fix any malfunctioning part. cal malfunctions in the refrigerant circuit and its components, including pipes, valves, compressors, Contact the After-Sales Service dept. if you en- counter difficulties.
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RECOMMEN- OPERATION DED FRE- QUENCY Remove the filters from the unit and clean them If the unit features metal filters on the coils, clean with compressed air blown in the opposite direction 6(*) them. to the air flow during unit operation. Use a jet of water if they are completely clogged.
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RECOMMEN- OPERATION DED FRE- QUENCY Refrigerant leak detector reading test. Contact the After-Sales Service dept. Check that the differential air pressure switch is in Refer to the chapter “Inspection of differential air good working order. pressure switch”. Check that the cable glands in the unit are correctly Refer to the chapter “Atex cable glands”.
8.3.1 Logbook When the refrigerant charge exceeds 3 kg, a logbook shall be prepared upon installation of the system by the installer. In the logbook, at least the following information shall be recorded: - a) the details of the maintenance and repair works; - b) the quantities, kind of (new, reused, recycled, reclaimed) refrigerant which have been charged on each occasion, the quantities of refrigerant which have been transferred from the system on each occasion ( see also EN 378-4);...
8.4 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. 8.4.1 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.
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.
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Page intentionally blank We reserve the right to make changes without any prior notice. Translation from original instructions...
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Via Valletta, 5 - 30010 Cantarana di Cona, (VE) Italy - T. +39 0426 921111 - F. +39 0426 302222 www.blueboxcooling.com - info@swegon.it Swegon Operations s.r.l. with sole shareholder - VAT no. 02481290282 Company directed and coordinated by Investment Latour (Sweden)
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