BlueBox KAPPA V SR Installation guide

Manual 101070B02
Issue 02.03
Replaces 06.02
KAPPA V SR
635 ÷ 1065 kW
0062
Installation, operating,
and maintenance
manual
Water chillers Air/water Axial fans and
self-contained screw compressors
ISO9001-Cert.n.0201

INDEX Page
KAPPA V SR water chiller 1
UNIT FRAME 1
COMPRESSORS 1
CONDENSER FANS 1
REFRIGERANT CIRCUIT 1
ELECTRICAL PANEL 1
CONTROLS AND SAFETY DEVICES 1
TESTING 2
KAPPA V SR UNIT VERSIONS 2
HYDRAULIC MODULE OPTIONS 2
ACCESSORY VERSIONS 2
REFRIGERANT CIRCUIT ACCESSORIES 2
HYDRAULIC CIRCUIT ACCESSORIES 3
ELECTRICAL ACCESSORIES 3
VARIOUS ACCESSORIES 3
SERIES 4
TYPE DESIGNATION 4
TECHNICAL DATA 5
ELECTRICAL CHARACTERISTICS AND COMPONENTS 7
TECHNICAL DATA - KAPPA V SR /ST 2PS 8
SOUND PRESSURE LEVELS 9
1. FIELD OF APPLICATION 10
1.1 INTRODUCTION 10
2. INSPECTION, TRANSPORT, SITE HANDLING 10
2.1 INSPECTION 10
2.2 LIFTING AND SITE HANDLING 10
3. SAFETY PRECAUTIONS 12
3.1 DEFINITION OF DANGER ZONE 12
3.2 SAFETY PRESCRIPTIONS 12
MECHANICAL HAZARDS 13
THERMAL HAZARDS 14
NOISE-RELATED HAZARDS 14
ELECTRICAL HAZARDS 14
REFRIGERANT SAFETY DATA - R407C 15
3.3 POSITIONING 17
4. INSTALLATION 19
4.1 INSTALLATION CLEARANCES 19
4.2 ANTI-VIBRATION ISOLATORS (option) 20
4.2.1 RubberAnti-VibrationIsolators 20
4.2.2 SpringAnti-VibrationIsolators 20
4.3 WATER PIPING CONNECTIONS 21
RECOMMENDED HYDRAULIC CIRCUIT DIAGRAM FOR KAPPA V SR 22
HYDRAULIC CIRCUIT DIAGRAM VERSION KAPPA V SR /ST 2PS 23
4.4 EVAPORATOR WATER PIPE CONNECTIONS 24
4.5 FLEXIBLE JOINTS 25
4.6 DESUPERHEATER HYDRAULIC CONNECTION (optional) 26
4.7 HEAT RECOVERY EXCHANGER HYDRAULIC CONNECTIONS (OPTIONAL) 27
DIAGRAM WITH 3-WAY VALVE 27
4.8 PRESSURE RELIEF VALVES 28
DIAGRAM WITH CONDENSING PRESSURE CONTROL VALVE 28

4.9 WATER FLOW RATE TO EVAPORATOR 29
4.10 CHILLER WATER TEMPERATURE (SUMMER CYCLE) 29
4.11 HOT WATER TEMPERATURE (winter cycle) 29
4.12 AMBIENT AIR TEMPERATURE 29
4.13 FAN SPEED CONTROL (optional) 29
4.14 OPERATION WITH LOW TEMPERATURE CHILLED WATER AT EVAPORATOR 30
TABLE 1 - FREEZING POINT FOR WATER-ANTIFREEZE MIXTURES 30
OPERATING LIMITS 31
EVAPORATOR PRESSURE DROP 32
PUMPS AVAILABLE PRESSURE - MODEL KAPPA V SR /ST 2PS 33
ELECTRICAL PANEL LAY OUT 34
4.15 ELECTRICAL CONNECTIONS 37
4.15.1 General 37
4.15.2 Power supply to crankcase heaters 37
4.15.3 Potential free contacts 38
4.15.4 Circulating pump electrical connections 38
4.15.5 Microprocessorcontrollers 38
4.15.6 RS485 serial interface (optional) 38
4.15.7 User interface - Microprocessor pCO239
5. START-UP 41
5.1 PRELIMINARY CHECKS 41
5.2 OPERATING DESCRIPTION 41
5.2.1 Introduction 41
5.2.2 Unit in stand-by mode 41
5.2.3 Enabling the unit 42
5.2.4 Pump management (ST units only) 42
5.2.5 Compressorstart-up 42
5.2.6 Chiller mode operation 42
5.2.7 Heat pump mode operation 42
5.2.8 Evaporator low temperature chilled water protection 42
5.2.9 Evaporator anti-freeze protection electric heater (optional) 42
5.2.10 Compressoroperation 43
5.2.11 Compressors and capacity steps management 43
5.2.12 High and low pressure alarms 44
5.2.13 Low ambient temperature kit (option - condens. control with fan speed regulator) 44
5.2.14 Changeover from chiller to heat pump and vice versa 44
5.2.15 Defrosting (heat pump units only) 44
5.2.16 Total heat recovery (option) 45
5.2.17 Dualset-point(option) 45
5.2.18 Operation leaving water temperature control (option) 46
5.3 STARTING THE UNIT 46
5.4 STOPPING THE UNIT 47
5.4.1 Temporarystop: 47
5.4.2 Seasonal stop: 47
5.5 EMERGENCY STOP 47
6CHECKS DURING OPERATION 48
6.1 INTRODUCTION 48
6.1.1 Checking the refrigerant charge 48
7. CALIBRATION OF CONTROL EQUIPMENT 49
7.1 INTRODUCTION 49
TABLE 2 - CALIBRATION OF CONTROL EQUIPMENT 49
TABLE 3 - CALIBRATION OF SAFETY DEVICES 49
8. MAINTENANCE AND PERIODIC CHECKS 50
8.1 WARNINGS 50

8.2 INTRODUCTION 50
8.3 REPAIRING THE REFRIGERANT CIRCUIT 51
8.3.1 Leak test 51
8.3.2 High vacuum and dehydration of the refrigerant circuit 51
8.3.3 Refrigerantcharge 52
8.4 ENVIRONMENTAL CONSIDERATIONS 52
9. TROUBLESHOOTING 53
10. DECOMMISSIONING THE UNIT 62
REFRIGERANT CIRCUIT 63
OVERALL DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS 66

Blue Box 1
KAPPA V SR water chiller
UNIT FRAME
Self supporting frame with removable panels, internally coated with expanded polyurethane sound-absorbing
material; constructed from galvanized sheet steel with RAL 5014 powder paint baked at 180°C to provide a
durable weatherproof finish. Threaded fasteners in stainless steel.
COMPRESSORS
Direct drive semihermetic screw compressors. Crankcase heater and lubrication through pressure difference
between suction and discharge pressure.
Optional continuous capacity control available, to maximize the efficiency of the unit in all working conditions.
Electronic motor protection via thermal sensors embedded in the windings. Star-Delta start and capacity step as
standard.
CONDENSER
Composed of a high efficiency coil manufactured from copper tubes and aluminium fins. Mesh guard to protect
the coil supplied as standard.
CONDENSER FANS
Axial fans, with sickle shaped blades and special bell mouth designed to reduce noise, directly coupled toa 6 pole
motor with internal Klixon overload protection. Motor protection category is IP 54. The fan is equipped with a
safety grille to UNI EN 294.
EVAPORATOR
Shell and tube direct expansion evaporator. The evaporator is thermally insulated with closed cell expanded
material. Each evaporator is equipped with a low water temperature probe for freeze protection.
REFRIGERANT CIRCUIT
Comprising: compressor discharge shut-off valve, liquid valve, charge connection, liquid line sight-glass, filter/
dryerwithinterchangeablesolidcartridge,thermostaticexpansionvalvewithexternalpressure equalisation, high
and low pressure values and relative condensation and evaporation temperatures are measured by pressure
transducers that relay signals that are displayed on the controller.
ELECTRICAL PANEL
The electrical panel includes:
- main switch
- fuses to protect auxiliary and power circuits
-compressorcontactors
-fancontactors
Themicroprocessor controls thefollowing functions:
- water temperature regulation
- freeze protection
- compressor time intervals
- compressor start sequence and automatic lead/lag selection
- alarm signalling
- alarm reset
- common alarm contact for remote signalling
LCD display of the following information:
- water inlet and outlet temperature
-programmed temperature set-point and differential
- alarm descriptions
- compressor hours run meter, number of unit and compressor starts and pumps (if installed)
- high and low pressure values and relative condensation and evaporation temperature values.
CONTROLS AND SAFETY DEVICES
- safety high pressure switch with manual reset
- high/low pressure safety with manual reset controlled by the microprocessor control
- high pressure relief valve

Blue Box 2
- compressors over-temperature protection on discharge gas with liquid injection
- chilled water temperature probe (at evaporator inlet)
- freeze protection probe at the evaporator outlet
-compressor over-temperature protection
-fanover-temperature protection
TESTING
The units are subjected to a dry run in the factory and supplied complete with oil and refrigerant.
KAPPA V SR UNIT VERSIONS
KAPPA V SR /HP: reverse cycle heat pump
In addition to the components of version KAPPA V SR, this unit includes:
- Refrigerant circuit: 4-way reversing valve, suction separator, liquid receiver, second thermostatic expansion
valve.
- Electrical panel: Microprocessor enabled for summer/winter changeover and automatic defrost,
HYDRAULIC MODULE OPTIONS
KAPPA V SR 2PS: unit with storage tank and pumps.
In addition to the components of version KAPPA V SR this unit includes:
insulated storage tank; run and standby circulating pumps, with automatic changeover by time or fault.
Expansion tank, check valves and gate valves.
Version ST is available in the following additional four configurations:
- ST 1PS : with 1 pump and a tank;
- ST 2P : with 2 pumps without a tank;
- ST S : with tank without pumps;
- ST 1P : with 1 pump without a tank.
ACCESSORY VERSIONS
KAPPA V SR /DC: unit with heat recovery condenser.
In addition to the components of version KAPPA V SR this unit includes for each compressor a 100% heat
recoverycondenser for the production of hot water. The microprocessor automaticallycontrolsthe water tempe-
rature and the heat recovery safety switch.
KAPPA V SR /LN: low noise unit
In addition to the components of version KAPPA V SR this unit includes:
compressors located in a sound absorbing enclosure of painted galvanized steel, internally lined with sound
absorption material having an intermediate layer of high acoustic impedance material.
REFRIGERANT CIRCUIT ACCESSORIES:
- Desuperheaters
The desuperheater heat exchanger is arranged in series with the condensing coil. It is also available in a
heat pump configuration. In this case a shut-off valve must be fitted on the water recovery circuit, to be
closed during heat pump mode operation, as described in the manual.
- Pressure gauges.
Available on all models. Suction and discharge pressure values, read by transducers that relay the results to
the controller display, are already displayed as standard on all models.

Blue Box 3
HYDRAULIC CIRCUIT ACCESSORIES
- Anti-freeze evaporator heater
- Water side relief valve (version ST only). The value is set at 6 bar, corresponding to the maximum permissible
workingpressure.
- Leaving water temperature control (Not available on HP version).
- Mechanical flow switch
ELECTRICAL ACCESSORIES
-Serial interface RS 485 with protocol Modbus; thefollowingoptional protocols are also available: Carel; Echelon
version RS485 or version FTT10
- Power factor correction cosf≥0.9 at nominal operating conditions
- Single voltage-free contacts for machine status signals
- Remote user terminal panel (in addition to the standard terminal)
- Set-point variable with remote signal (0-1 V, 0-10 V, 0-4 mA, 0-20 ma)
- Dual set-point
With double thermostatic valves + solenoid valves. Two set-points can be programmed and switched
between each other from the keypad or using a digital input. The type of selection must be specified at the
time of order. In all cases the thermostatic valves switch automatically on the basis of the water temperature.
- Step type condensing pressure control (ambient air minimum temperature 0 °C)
The control is managed in On/Off mode by the microprocessor by means of the pressure transducers.
- Condensing pressure control by fan speed regulator (ambient air minimum temperature -20 °C).
Fan speed is regulated in accordance with the condensation pressure read by the pressure transducers.
- Additional compressor capacity step
-Compressor continuous capacity step control
- Electronic expansion valve
- Liquid line solenoid valve
- Liquid receivers (standard on version /HP)
- Compressor suction valves
VARIOUS ACCESSORIES
-Rubberor spring type anti-vibration mounts
- Anti-corrosion treatment of coils for use in aggressive environments
- Timber crate packing
- Pallet/skid for container shipment
-Non-standard RAL paint colours

Blue Box 4
SERIES
The KAPPA V SR series of water cooled chillers and heat pumps, are available in various sizes with capacities
from 635 to 1.065 kW (capacities refer to water entering/leaving 12/7 °C, ambient air 35 °C) in the following
basic versions:
- KAPPA V SR coolingonly
- KAPPA V SR/HP heat pump
The model, serial number, characteristics, power supply, etc. are shown by means of decals on the unit.
TYPE DESIGNATION
unit type series /version /option hydraulic modul /accessory version size
KAPPA V SR 65.2
/ST 1P 73.2
/HP /ST 2P /LN 80.2
/ST 1PS /DS 84.2
/ST 2PS /DC 88.2
/ST S /LN/DS 93.2
/LN/DC 100.2
106.3
Type designation example: KAPPA.V SR /HP/DS 100.2
Meaning of values 100 . 2
Number to identify the indicative Number of compressors
cooling capacity (in this case 100 kW)
Corrente massima di spunto
Max starting current
Max. Anlaufstrom
Courant maxi démarrage
Tipo refrigerante
Refrigerant type
Kältemittel Typ
Type de refrigerant
Numero circuiti refrigerante
Refrigerant circuit number
Anzahl des Kältemittelkreislaufes
Numero circuits refrigerant
Press. massima circuito idraulico
Max. Hydraultic circuit pressure
Max. Druck im Hydraul. Kreislauf
Pression maxi circuit hydraulique
Data di produzione
Manufacturing date
Erstellungsdatum
Date de fabrication
Press. massima circuito refriger.
Max. Refrigerant circuit pressure
Max. Druck Kältekreislauf
Pression maxi circuit refrigerant
IP quadro elettrico
IP electrical board
IP E-Schrank
IP tableau electrique
Tensione circuiti ausiliari
Auxiliary circuit voltage
Steuerspannung
Tension circuits auxiliares
Matricola/Serial number
(BBOX) Matrikel/Matricule
Corrente massima assorbita
Max absorbed current
Maximalstromverbrauch
Courant maxi absorbée
Modello/Model
Modell/Modèle
Tensione-Fasi-Frequenza
Voltage-Phasses-Frequency
Spannung-Phasses-Frequenz
Tension-Phasses-Fréquence
A A
kPa
kPa
Carica refrigerante per circuito(kg)/Refrigerant charge per circuit
Kältemittelfüllung KreislaufCharge de refigerant chaque circuit
(kg)
/(kg)/(kg)
C2
C1
C3
C4
bar
bar
0062
ViaEnricoMattei,20
35028 PiovediSacco(PD)
ITALY
Tel.[phone]
Corrente massima di spunto
REFRIGERANTE - REFRIGERANT - KÄLTEMITTEL - REFRIGERANT
MATRICOLA - MATRICULE - SERIAL NO. - SERIENUMMER
MODELLO - MODELE - MODEL - TYP
0062
ViaEnricoMattei,20
35028 PiovediSacco(PD)
ViaEnricoMattei,20
35028 PiovediSacco(PD)
ITALY
Tel.[phone]

Blue Box 5
TECHNICAL DATA
Refrigerant R407C
(1) total water flow
(*) ambient air temperature 35 °C; evaporator entering/leaving water temperature 12-7 °C;.
(**) ambient air temperature 8 °C DB, 50%RH; condenser entering/leaving water temperature 40-45 °C.
MODEL KAPPA V SR 65.2 73.2 80.2 84.2
Cooling (*)
Nominal capacity kW 635,6 710,2 769,3 813,7
Evaporator water flow (1) l/s 30,37 33,93 36,76 38,88
l/h 109.316 122.150 132.323 139.963
Evaporator pressure drop kPa 53 60,2 61,8 28,6
Heating (**)
Nominal capacity kW 610,1 679,6 736,7 785,5
Condenser water flow (1) l/s 29,15 32,47 35,20 37,53
l/h 104.929 116.889 126.707 135.108
Condenser pressure drop kPa 49 55,4 56,9 26,8
Compressors type
Quantity n 2 2 2 2
Refrigerant circuits n 2 2 2 2
Absorbed power cooling (*) kW 224,1 248,1 269,3 291
Absorbed power heating (**) kW 217,3 240,7 261,2 282,2
Capacity steps %0-25-50-75-100 0-25-50-75-100 0-25-50-75-100 0-25-50-75-100
Condenser cooling fans type
Total air flow m3/s 61,33 58,67 71,56 69,60
m3/h 220.800 211.200 257.600 250.560
Fan motor power n x kW 12 x 2,0 12 x 2,0 14 x 2,0 14 x 2,0
Nominal revolution speed RPM
Electric motor supply V/Ph/Hz
Refrigerant charge
Chiller version kg 2 x 89 2 x 109 2 x 106 1x106 + 1x127
Heat pump version kg 2 x 110 2 x 135 2 x 130 1x130 + 1x155
Oil
Oil charge l2 x 15 2 x 15 2 x 18 2 x 18
Oil producer
Oil type
Evaporator type
Heat exchanger water volume l184,4 225 403 403,0
Max operating pressure water side bar
Dimension and weight
Length mm 8.190 8.190 9.240 9.240
Width mm 2.390 2.390 2.390 2.390
Heigth mm 2.432 2.432 2.432 2.432
Shipping weight kg 5.901 6.111 7.225 7.536
screw semihermetic
880
DEA
axial
400/3~/50
shell and tube
10
SE 170

Blue Box 6
TECHNICAL DATA
Refrigerant R407C
(1) total water flow
(*) ambient air temperature 35 °C; evaporator entering/leaving water temperature 12-7 °C;.
(**) ambient air temperature 8 °C DB, 50%RH; condenser entering/leaving water temperature 40-45 °C.
MODEL KAPPA V SR 88.2 93.2 100.2 106.3
Cooling (*)
Nominal capacity kW 858,2 907,1 956 1065,3
Evaporator water flow (1) l/s 41,00 43,34 45,68 50,90
l/h 147.603 156.017 164.431 183.224
Evaporator pressure drop kPa 31,6 35,1 74 70
Heating (**)
Nominal capacity kW 834,4 881,1 927,9 1019,4
Condenser water flow (1) l/s 39,86 42,10 44,34 48,70
l/h 143.510 151.557 159.604 175.334
Condenser pressure drop kPa 30 33,3 70 64,5
Compressors type
Quantity n 2 2 2 3
Refrigerant circuits n 2 2 2 3
Absorbed power cooling (*) kW 312,7 330,4 348,1 372,2
Absorbed power heating (**) kW 303,1 320,3 337,5 361
Capacity steps %0-25-50-75-100 0-25-50-75-100 0-25-50-75-100 0-16.7-33.5-50-
66.7-83.3-100
Condenser cooling fans type
Total air flow m3/s 68,33 81,26 81,26 85,78
m3/h 246.000 292.528 292.528 308.800
Fan motor power n x kW 14 x 2,0 16 x 2,0 16 x 2,0 16 x 2,0
Nominal revolution speed RPM
Electric motor supply V/Ph/Hz
Refrigerant charge
Chiller version kg 2 x 127 2 x 123 2 x 123 3 x 92
Heat pump version kg 2 x 155 2 x 150 2 x 150 3 x 115
Oil
Oil charge l2 x 18 2 x 18 2 x 18 3 x 15
Oil producer
Oil type
Evaporator type
Heat exchanger water volume l403,0 378,0 378,0 442,0
Max operating pressure water side bar
Dimension and weight
Length mm 9.240 10.290 10.290 12.110
Width mm 2.390 2.390 2.390 2.390
Heigth mm 2.432 2.432 2.432 2.432
Shipping weight kg 7.681 7.632 7.816 8.576
10
screw semihermetic
880
axial
400/3~/50
DEA
SE 170
shell and tube

Blue Box 7
ELECTRICAL CHARACTERISTICS AND COMPONENTS
Refrigerant R407C
(1) mains power supply to allow unit operation.
(2) maximum current before safety cut-outs stop the unit. This value is never exceeded and must be used to size the electrical supply
cables and relevant safety devices (refer to electrical wiring diagram supplied with the unit).
All values in brackets are refer to /ST version (units with storage tank) or units with pump.
MODEL KAPPA V SR 65.2 73.2 80.2 84.2
Maximum absorbed power (1) Kw 285,8 314 342,6 360,4
Kw (296,8) (325) (357,6) (375,4)
Maximum starting current A596 667 779 869
A(619) (690) (809) (899)
Full load current (2) A498 538 596 626
A(521) (561) (626) (656)
Fan motor nominal power n x kW 12 x 2,0 12 x 2,0 14 x 2,0 14 x 2,0
Fan motor nominal absorbed current n x A 12 x 4,0 12 x 4,0 14 x 4,0 14 x 4,0
Pump motor nominal power kW (1 x 11,0) (1 x 11,0) (1 x 15,0) (1 x 15,0)
Pump motor nominal absorbed power A(1 x 23,0) (1 x 23,0) (1 x 30,0) (1 x 30,0)
Power supply V/Ph/Hz
Control power supply V/Ph/Hz
Control board supply V/Ph/Hz
Condenser fans supply V/Ph/Hz
ST Hydraulic module pumps suppy V/Ph/Hz
400V 3N ~ 50Hz ±5% V
230V/ ~/50Hz
24V/~/50Hz
400V/3~/50
400V/3~/50
MODEL KAPPA V SR 88.2 93.2 100.2 106.3
Maximum absorbed power (1) Kw 378,2 402,1 422 467
Kw (393,2) (424,1) (444) (489)
Maximum starting current A899 959 993 928
A(929) (1001) (1035) (970)
Full load current (2) A656 698 732 799
A(686) (740) (774) (841)
Fan motor nominal power n x kW 14 x 2,0 16 x 2,0 16 x 2,0 16 x 2,0
Fan motor nominal absorbed current n x A 14 x 4,0 16 x 4,0 16 x 4,0 16 x 4,0
Pump motor nominal power kW (1 x 15,0) (1 x 22,0) (1 x 22,0) (1 x 22,0)
Pump motor nominal absorbed power A(1 x 30,0) (1 x 42,0) (1 x 42,0) (1 x 42,0)
Power supply V/Ph/Hz
Control power supply V/Ph/Hz
Control board supply V/Ph/Hz
Condenser fans supply V/Ph/Hz
ST Hydraulic module pumps suppy V/Ph/Hz 400V/3~/50 400V/3~/50
400V 3N ~ 50Hz ±5% V
230V/ ~/50Hz
24V/~/50Hz

Blue Box 8
TECHNICAL DATA - KAPPA V SR /ST 2PS
Refrigerant R407C
MODEL KAPPA V SR 65.2 73.2 80.2 84.2
Pump section
Evaporator water flow l/s 30,37 33,93 36,76 38,88
l/h 109.316 122.150 132.323 139.963
Pump nominal power kW 11 11 15 15
External available pressure kPa 168 140 197 216
Storage tank water volume l1000 1000 1000 1000
Dimension and weight
Length mm 8.190 8.190 9.240 9.240
Width mm 2.390 2.390 2.390 2.390
Heigth mm 2.432 2.432 2.432 2.432
Shipping weight kg 6.416 6.626 7.882 8.027
MODEL KAPPA V SR 88.2 93.2 100.2 106.3
Pump section
Evaporator water flow l/s 41,00 43,34 45,68 50,90
l/h 147.603 156.017 164.431 183.224
Pump nominal power kW 15 22 22 22
External available pressure kPa 195 279 216 154
Storage tank water volume l1000 1000 1000 1000
Dimension and weight
Length mm 9.240 10.290 10.290 12.110
Width mm 2.390 2.390 2.390 2.390
Heigth mm 2.432 2.432 2.432 2.432
Shipping weight kg 8.172 8.660 8.844 9.468

Blue Box 9
SOUND PRESSURE LEVELS
STANDARD UNITS
LOW NOISE UNITS
Lcc: sound pressure values measured in free field conditions with phonometer at 1 m from the unit and 1,5 m from ground levelon the
condensing coil side.
Model Total
KAPPA V SR 63 [dB] 125 [dB] 250 [dB] 500 [dB] 1000 [dB] 2000 [dB] 4000 [dB] 8000 [dB] dB(A)
Lcc Lcc Lcc Lcc Lcc Lcc Lcc Lcc Lcc
65.2 71,7 75,6 74,4 73,9 76,4 74,2 65,2 54,6 80,0
73.2 71,7 75,4 74,4 73,9 76,5 74,1 65,0 54,0 80,0
80.2 72,7 76,6 75,4 74,9 77,4 75,2 66,2 55,6 81,0
84.2 73,4 77,6 75,8 75,6 77,9 75,7 67,1 56,6 81,5
88.2 73,4 77,4 75,8 75,6 78,0 75,6 66,9 56,0 81,5
93.2 73,9 77,9 76,4 76,2 78,5 76,1 67,4 56,3 82,0
100.2 73,9 77,9 76,4 76,0 78,3 76,2 67,6 56,5 82,0
106.3 73,9 77,9 76,4 78,5 78,1 76,3 67,8 56,7 82,0
Octave band [Hz]
Model Total
KAPPA V SR /LN 63 [dB] 125 [dB] 250 [dB] 500 [dB] 1000 [dB] 2000 [dB] 4000 [dB] 8000 [dB] dB(A)
Lcc Lcc Lcc Lcc Lcc Lcc Lcc Lcc Lcc
65.2 71,0 74,9 74,0 72,1 73,2 73,2 63,1 54,1 78,0
73.2 70,5 74,7 73,9 71,7 73,9 72,8 62,8 53,7 78,0
80.2 73,0 76,0 74,7 72,8 74,8 73,8 64,1 53,8 79,0
84.2 73,0 76,4 74,7 72,8 74,8 73,8 64,3 54,0 79,5
88.2 72,8 76,5 74,8 73,3 76,0 73,6 64,9 54,5 79,5
93.2 73,5 76,9 75,4 75,1 76,3 74,1 65,4 54,3 80,0
100.2 73,3 77,1 75,7 75,0 76,2 74,0 65,2 54,3 80,0
106.3 73,1 77,3 76,0 74,9 76,1 73,9 65,0 54,3 80,0
Octave band [Hz]

Blue Box 10
2.2 LIFTING AND SITE HANDLING
Avoid sudden movements and jolts when unloading and positioning the unit. Internal handling procedures
must be conducted with care. The unit must be lifted using spreader bars. Do not exert leverage on the
components of the machine. The unit must be lifted by inserting steel tubes through the lifting attachments
shown by the relative labels (yellow arrow). The unit must be lifted by harnessing it as shown in figure 1: use
ropes or straps of sufficient length. The width of the spreader bars must not be less than that of unit.
1. FIELD OF APPLICATION
Theequipment is designed forcooling (chiller only versions)orcooling/heating (heat pump versions)water, which
is usually applied to air conditioning or refrigeration systems. Units must be used exclusively within the operating
limits specified in Section 4.
1.1 INTRODUCTION
- When installing or servicing the unit, it is necessary to strictly follow the rules described in this manual, to
conform to all the items detailed on the unit labels and take any necessary precaution.
-Pressure in refrigerantcircuits and dangerfrom electrical shockcanbe hazardous wheninstalling or servicingthe
unit.
Any work on the unit must be carried out only by trained personnel.
Attention: before repairing or servicing the unit, ensure that the electrical
supply is disconnected.
The warranty will be invalid if the rules described in this manual are not observed and if any modifications are
made to the unit without prior authorisation of the manufacturer.
2. INSPECTION, TRANSPORT, SITE HANDLING
2.1 INSPECTION
After receiving the unit, immediately check its integrity. The unit will have left the factory in perfect condition
thereforeon receiving the unit any damage mustbeverbally described to the carrier and recordedonthe Delivery
Note which must be signed by both parties. Blue Box or their Agent must be informed, as soon as possible, of the
extent of the damage.
The Customer should prepare a written statement and photographic evidence regarding any severe damage.

Blue Box 11
Figure 1
1
2
Caution: ensure that the method of lifting does not allow the unit to slip
from chains and slings or turn-over or slide from lifting devices.
(1) Side panel protection (not supplied)
(2) Lifting holes

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3. SAFETY PRECAUTIONS
3.1 DEFINITION OF DANGER ZONE
Only authorised operators must be allowed in the vicinity of the unit.
-The external danger zone concerns a space of approximately2m in width around the perimeter of themachine.
Access to this area must be prevented by a suitable enclosure if the unit is located in an unprotected area that
is easily accessible to unauthorised persons.
- The internal danger zone is defined as the interior of the machine. Access to the interior of the machine must
notbepermitted tounqualifiedpersonnel andneverbefore themachines’electricalsupplyhas beendisconnected.
3.2 SAFETY PRESCRIPTIONS
The unit is designed and built in accordance with the PED 97/23CE rules, to ensure the maximum level of safety.
To avoid possible situations of risk adhere to the following rules at all times:
-Allwork onthe unitmust beperformed byqualifiedpersonnel.Beforeworking onthe unit,ensure thatdesignated
personnelare conversant with the documentation supplied. Alwaysensurethere is a copy of thedocumentation
in the immediate vicinity of the unit.
- Use appropriate personal safety equipment (gloves, helmet, safety goggles, safety footwear, etc.) for all
maintenance and control operations on the unit.
- Use only tools and equipment that are in good working order.
- The fans have protective grilles to prevent accidental contact. Use the maximum caution to avoid inserting or
droppingobjects through the grilles.
- The exchanger coils have sharp edges. Do not touch the coils without using suitable protection.
- The compressor compartment contains various high temperature components. Adopt maximum caution when
workinginthe vicinityof thecompressors andavoidtouchinganyparts ofthe unitwithoutappropriateprotection.
- Do not work within the theoretical discharge trajectory of the relief valves.

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MECHANICAL HAZARDS
Operating mode Analysed risk or hazard Solution adopted
Normal operating regime
Maintenance
Stability Because of their intrinsic characteristics, the
units are not associated with problems of
possible falling or tipping while in operation.
Carefully read the items described in this
manual concerning the methods of
positioning the unit.
Handling during transport
and installation. Stability The unit's base frame has specific lifting holes; the positions of which are marked
with yellow decals. Following this procedure
will eliminate the risk of the unit tipping.
Carefully read the items descriptions in this
manual concerning the methods of handling
the unit.
Normal operating regime
Maintenance Pipeline bursts. Pipes are rigidly anchored to reduce the degree of vibration.
Normal operating regime Surfaces, sharp corners and
edges. The machine is designed and built in such a way as to minimise the presence of sharp
corners and edges as far as possible.
Maintenance Surfaces, sharp corners and
edges. In the interior parts of the unit it is not possible to totally eliminate risks from the
presence of surfaces, sharp corners and
edges. The operating, installation, and
maintenance manual specifies that
maintenance operations should be carried
out exclusively by qualified personnel, and
provides indications of the protective
equipment to be used.
Normal operating regime
Cutting or severing. The moving parts of the unit are located in clearly defined areas. Specifically, the fans
are enclosed in an inaccessible compartment
and are equipped with an upper protection
grille to UNI EN 294. All the protections
supplied to limit and enclose the fan
compartments cannot be removed without
the use of special tools.
Maintenance Cutting or severing.The moving parts of the unit are located in
clearly defined areas. Specifically, the fans
are enclosed in an inaccessible compartment
and are equipped with an upper protective
grille to UNI EN 294.
Normal operating regime
Cutting or severing. All units are supplied as standard with specific protection grilles designed to protect
against accidental contact with the finned
coils, which can cause minor cuts to the
hands.
Normal operating regime Entanglement, dragging,
impact. The moving parts of the unit are located in clearly defined areas. Specifically, the fans
are enclosed in an inaccessible compartment
and they are equipped with an upper
protective grille to UNI EN 294. All the
protections supplied to limit and enclose the
fan compartments cannot be removed
without the use of special tools.

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Operating mode Analysed risk or hazard Solution adopted
Maintenance Entanglement, dragging,
impact. The moving parts of the unit are located in clearly defined areas. Specifically, the fans
are enclosed in an inaccessible compartment
and they are equipped with an upper
protective grille to UNI EN 294.
Normal operating regime
Maintenance
Projection of high pressure jets
of fluid -Explosion hazard All units are designed and manufactured in accordance with rule EN 378-2 and are
equipped with relief valves to eliminate the
risk of pressure bursts.
The outlet from relief valves must be piped
appropriately to eliminate risks associated
with the expulsion of gas at high pressure
from the machine.
Operating mode Analysed risk or hazard Solution adopted
Normal operating regime
Maintenance
Burns caused by high
temperatures. Most of the pipelines that could cause burns, when touched, are lagged with heat
insulating material.
Operating mode Analysed risk or hazard Solution adopted
Normal operating regime
Maintenance
Hearing damage. All units are designed and built with the aim
of reducing noise emissions to the minimum.
Operating mode Analysed risk or hazard Solution adopted
Contact with electrically live
parts (direct contact).
Elements carrying electrical
current in the case of faults.
Inappropriate insulation.
Normal operating regime
Maintenance
Radiated heat due to short-
circuits or overloads.
All units are designed and built in
compliance with harmonised standard EN
60204-1.
MECHANICAL HAZARDS
THERMAL HAZARDS
NOISE-RELATED HAZARDS
ELECTRICAL HAZARDS