Blue Box KAPPA V SR - User Manual

Questions and Answers

L
lindsay90Aug 16, 2025
How to troubleshoot a Blue Box Chiller with no compressor running and fans stopped?
- E
  Elizabeth MarshallAug 16, 2025
  If your Blue Box Chiller's compressor isn't running, the fans have stopped, and the display is off, here's what you can check: 1. **Mains Power:** Verify that the chiller is receiving mains power. 2. **Main Power Switch:** Ensure the main power switch is in the "I" position, not "O". 3. **Control Circuit Power:** Check fuses FU50, FU51, and FU52, and inspect the transformer's operation. 4. **Phase Sequence:** If relay KA5 has only a green LED lit, invert two of the phase wires of the power supply line. Both green and yellow LEDs should light upon restart. 5. **Relay KA5 LEDs:** If relay KA5 has both green and yellow LEDs off, check fuse FU56. If the fuse is okay, replace the phase sequence relay.
E
Erika TranAug 19, 2025
Why is my Blue Box KAPPA V SR showing a 'Low Pressure' alarm and the compressor is not running?
- B
  Brianna DixonAug 19, 2025
  If your Blue Box Chiller displays a 'Low Pressure' alarm and the compressor is not running, consider the following: 1. **Glycol Percentage:** Ensure the hydraulic circuit has the correct percentage of glycol. 2. **Refrigerant Charge:** Check for leaks and recharge both circuits if they have insufficient refrigerant. 3. **Fans Contactor:** Verify the voltage across the contactor coil and its continuity. 4. **Fan Motor:** Inspect the fan motor and replace if faulty. 5. **Water Flow:** Check for sufficient water flow to the evaporator in the hydraulic circuit. 6. **Defrost Set-Point:** Ensure the defrost set-point is correctly set.
S
sarahclineAug 21, 2025
What causes a 'Fans protection' alarm on a Blue Box Chiller, and how do I fix it?
- R
  Robert ZunigaAug 22, 2025
  If your Blue Box Chiller displays a 'Fans protection' alarm and the compressor is not running, here's what you should investigate: * **Fan Thermal Protection:** Check the insulation between windings and from windings to earth (ground). * **Fan Motor:** Check the fan motor for faults and replace if necessary. * **Fan Alarm Relay:** Check and replace the faulty fan alarm relay.
C
csweeneyAug 25, 2025
What does it mean when my Blue Box KAPPA V SR Chiller displays a 'Thermal protections Compressor' alarm?
- M
  Michael MooreAug 25, 2025
  If your Blue Box Chiller displays a 'Thermal protections Compressor' alarm and the compressor is not running, the possible causes are: * **Power Voltage Drop:** There may be a drop in power feeding voltage. Check voltage stability and fit appropriate protection if necessary. * **Setting of Thermal Protections:** Contact assistance. * **Circuits Partially Discharged:** Call service to replenish charge.
R
Richard SilvaAug 27, 2025
What does 'OFF from external consent' mean on my Blue Box KAPPA V SR Chiller display?
- A
  aaron36Aug 27, 2025
  If your Blue Box Chiller displays 'OFF from external consent' and the compressor isn't running, it means there is no external consent. Check the presence of external consent; if it is not present, bridge terminals 1 and 2.
A
April Johnson MDAug 30, 2025
What should I do if my Blue Box Chiller shows an alarm for 'Exceeded Threshold High Temperature of entering User Water'?
- A
  aramosAug 30, 2025
  If your Blue Box Chiller displays an alarm for 'Exceeded Threshold High Temperature of entering User Water' and the compressor is not running: * **Thermal Load:** Wait until the entering water temperature is below the alarm set point. Start the hydraulic circuit of the evaporator and unit. If this is not sufficient, contact assistance. * **Refrigerant Circuits:** The refrigerant circuits may be partially discharged. Call assistance.
B
briangomezSep 2, 2025
How to fix a 'Exceeded Threshold Low Temperature of leaving User Water' alarm on a Blue Box KAPPA V SR?
- P
  Parker FergusonSep 2, 2025
  If your Blue Box Chiller displays an alarm for 'Exceeded Threshold Low Temperature of leaving User Water' and the compressor is not running: * **Water Flow:** Increase water flow to the evaporator and check the temperature rise. * **Faulty Controller:** Contact service organisation. * **Defrost Sensor:** Contact service organisation.
T
Trevor LongSep 4, 2025
Why does my Blue Box KAPPA V SR Chiller display a 'No power to Control circuits' alarm?
- L
  leemcleanSep 4, 2025
  If your Blue Box Chiller displays a 'No power to Control circuits' alarm and the compressor is not running: * **Power Supply Voltage:** Check the power supply voltage. If it's incorrect, contact the electricity company. * **Fuses:** Check the cause of fuse FU51 burnout and replace the fuses.
J
jedwardsSep 7, 2025
What does 'OFF from supervision system' mean on my Blue Box Chiller display?
- J
  Jennifer PhillipsSep 7, 2025
  If your Blue Box Chiller displays 'OFF from supervision system' and the compressor isn't running, activate operation from the supervision system.
I
imillerSep 10, 2025
What to do if my Blue Box KAPPA V SR displays 'OFF' and the compressor isn't running?
- T
  Tony McdonaldSep 10, 2025
  If your Blue Box Chiller displays 'OFF' and the compressor isn't running, press the “on/off” key on the user interface.

Summary

1. FIELD OF APPLICATION

1.1 INTRODUCTION

Rules for installation and servicing, emphasizing manual adherence and precautions.

2. INSPECTION, TRANSPORT, SITE HANDLING

2.1 INSPECTION

Procedures for checking unit integrity upon receiving it, documenting any damage.

2.2 LIFTING AND SITE HANDLING

Guidelines for safe unloading, positioning, and handling of the unit using appropriate equipment.

3. SAFETY PRECAUTIONS

3.1 DEFINITION OF DANGER ZONE

Defines external and internal danger zones and access restrictions for personnel safety.

3.2 SAFETY PRESCRIPTIONS

General safety rules including PPE, tool usage, and caution around moving parts and hot components.

MECHANICAL HAZARDS

Details risks and solutions related to unit stability, sharp edges, moving parts, and entanglement.

THERMAL HAZARDS

Details risks of burns from high temperatures and their mitigation through insulation.

NOISE-RELATED HAZARDS

Addresses hearing damage risks and the unit's design for noise reduction.

ELECTRICAL HAZARDS

Covers risks from contact with live parts and inappropriate insulation.

3.3 POSITIONING

Guidelines for selecting a suitable site, considering dimensions, connections, and environmental factors.

REFRIGERANT SAFETY DATA - R407 C

4. INSTALLATION

4.1 INSTALLATION CLEARANCES

Ensuring adequate air volume around the condenser for performance and preventing recirculation.

4.2 ANTI-VIBRATION ISOLATORS (option)

Details on rubber and spring anti-vibration isolators for reducing vibration transmission.

4.3 WATER PIPING CONNECTIONS

Requirements for water pipework installation, including flexible joints and necessary devices.

4.4 EVAPORATOR WATER PIPE CONNECTIONS

Details on connecting water inlet and outlet to the evaporator, emphasizing correct flow and antifreeze.

4.5 FLEXIBLE JOINTS

Information on flexible joints for axial movement, vibration elimination, and assembly procedures.

4.6 DESUPERHEATER HYDRAULIC CONNECTION (optional)

Connection details for desuperheaters using steel tubes with male threads.

4.7 HEAT RECOVERY EXCHANGER HYDRAULIC CONNECTIONS (OPTIONAL)

Hydraulic connection requirements for heat recovery condensers and their management.

4.8 PRESSURE RELIEF VALVES

Details on the placement and venting of pressure relief valves for refrigerant circuit safety.

4.9 WATER FLOW RATE TO EVAPORATOR

The nominal water flow rate is based on a 5 °C temperature difference between inlet and outlet.

4.10 CHILLER WATER TEMPERATURE (summer cycle)

The minimum evaporator leaving water temperature is 6 °C; for lower water temperatures at the evaporator outlet refer to section 6.6.

4.11 HOT WATER TEMPERATURE (winter cycle)

The minimum water temperature at the condenser inlet, once the system is operating in steady state conditions, must not be lower than 28 °C.

4.12 AMBIENT AIR TEMPERATURE

The units are designed and built to operate with ambient air temperatures within the limits shown on the operating limits diagrams.

4.13 FAN SPEED CONTROL (optional)

If the unit is required to operate at ambient air temperatures less than 15 °C a fan speed controller must be included.

4.14 OPERATION WITH LOW TEMPERATURE CHILLED WATER AT EVAPORATOR

Units from the normal production range are not designed to operate with chilled water temperatures lower than 6 °C.

OPERATING LIMITS

EVAPORATOR PRESSURE DROP

PUMPS AVAILABLE PRESSURE - MODEL KAPPA V SR;ST 2 PS

ELECTRICAL PANEL LAY OUT

KEY TO ELECTRICAL COMPONENT PART NUMBER

4.15 ELECTRICAL CONNECTIONS

4.15.1 General

Electrical connections must be made in accordance with the information given on the electrical drawing attached to the unit.

4.15.2 Power supply to crankcase heaters

Details the procedure for connecting power supply to crankcase heaters and their initial warm-up.

4.15.3 Potential free contacts

Lists the available potential free contacts for unit alarms, compressors, fans, and pumps.

4.15.4 Circulating pump electrical connections

Explains the electrical connections for circulating pumps and their role in unit operation.

4.15.5 Microprocessor controllers

Describes the pCO2 microprocessor controller and its functions for managing the unit.

4.15.6 RS485 serial interface (optional)

Details the optional RS485 serial interface for supervision and remote diagnostics.

4.15.7 User interface - Microprocessor pCO2

Explains the LCD display and function keys of the user interface for unit control.

5. START-UP

5.1 PRELIMINARY CHECKS

Essential checks before unit start-up, covering electrical, refrigerant, and system integrity.

5.2 OPERATING DESCRIPTION

Overview of microprocessor control managing water temperature and compressor operations.

5.3 STARTING THE UNIT

Procedure for starting the unit, including enabling contacts and microprocessor controller manual.

5.4 STOPPING THE UNIT

Instructions for stopping the unit temporarily, seasonally, or in an emergency.

5.5 EMERGENCY STOP

Method for performing an emergency stop using the main disconnect switch.

6. CHECKS DURING OPERATION

6.1 INTRODUCTION

General checks for unit operation, including water temperature and pump noise.

6.1.1 Checking the refrigerant charge

Procedures for checking refrigerant charge via sight glass, temperature, and pressure.

7. CALIBRATION OF CONTROL EQUIPMENT

7.1 INTRODUCTION

Guidance on checking factory-calibrated control equipment and safety devices.

8. MAINTENANCE AND PERIODIC CHECKS

8.1 WARNINGS

General safety warnings for maintenance, emphasizing qualified personnel and precautions.

8.2 INTRODUCTION

Lists periodic checks for unit operation, categorized by frequency.

8.3 REPAIRING THE REFRIGERANT CIRCUIT

Procedures for repairing the refrigerant circuit, including leak testing, vacuuming, and charging.

8.4 ENVIRONMENTAL CONSIDERATIONS

Information on refrigerant recovery, disposal, and environmental regulations for R407C.

9. TROUBLESHOOTING

10. DECOMMISSIONING THE UNIT

Blue Box KAPPA V SR Specifications

General

Brand	Blue Box
Model	KAPPA V SR
Category	Chiller
Language	English

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