Zanotti Bi-Block BGS330DB13XXB - Fridge DAIKIN - Free user manual and instructions

USER MANUAL Zanotti Bi-Block BGS330DB13XXB DAIKIN

Safety recommendations

Table of warning and attention plates

Description of the unit

Fitting the remote panel

Connection to water system

Checks, regulations and adjustments

Maintenance and repairs

Service operations to be carried out by qualified technicians or by the manufacturer

How to order spare parts

How to dispose of the packing

How to dispose of the unit CONTENT18 Thank you for choosing Uniblock. Please read these instructions carefully. They provide details and advice on the correct method of installing, using and maintaining this unit, in order to obtain maximum reliability, efficiency and long life.

Safety recommendations When installing and using the unit please follow the recommendations listed here below. Installation shall be carried out in strict compliance with the diagrams and instructions supplied by the manufacturer. Damages due to improper connections are excluded. The electric system available where the unit is installed shall meet the relevant standards in force. Maintenance shall be effected by trained personnel or by the manufacturer according to the provisions supplied by EN378. WARNING Use safety gloves to protect your hands from possible cuts.

The user is strongly recommended to contact the manufacturer before attempting any intervention on the unit and any use not corresponding to the manufacturer’s indications (in particular as for the field of application) and to enquire about the possible dangers and contra-indications connected with an improper use of the machine. The unit shall be used following these instructions and sticking to the destination of use indicated by the supplier. Any incorrect use can result in damages to the unit and represents a serious danger for people’s health. ATTENTION The unit is not suitable for working in explosive environments. Therefore the use of the unit in an explosion-dangerous atmosphere is absolutely forbidden.

ATTENTION The unit is not suitable for working in salty environments. In such a case protect condenser and evaporator with appropriate means.

When maintenance involves operations on the refrigerating circuit, empty the system and let it reach the atmospheric pressure. WARNING Do not discharge the refrigerant in the atmosphere. It must be recovered by specialized technicians using suitable equipment.

Quantity and quality of the refrigerant to be charged are indicated on the data plate. Do not use refrigerants of different kind (especially inflammable fluids, for example hydrocarbons) or air. Do not modify or alter the refrigerating circuit or its components (for example: welding on compressor body) The final user shall protect the system from external fire dangers.19

Table of warning and attention plates

Attention: hot or cold parts

Attention: switch off before operating on the unit.

Attention: danger of electrocution

Connect this cable to a circuit breaker, never to the main line directly.

Colours of supply cable wires

Attention – important : clean the condenser periodically by blowing air from the inside outwards. Stop the unit before cleaning.

1) Year of manufacture

Description of the unit The GS series includes air-cooled or water-cooled (optional) condensing units built in split version. They consist of:

a condensing unit placed outside the cold room;

an evaporator installed inside the cold room;

an electric control panel placed on the condensing unit, complete with wall-mounted remote control panel;

two tubes (pre-charged with refrigerant) to be connected to the corresponding fittings placed on the evaporating and condensing units. GS single blocks are compression units where cold is produced by vaporizing a liquid refrigerant (HFC type) at low pressure in a heat exchanger (evaporator). The resulting vapour is brought again into the liquid state by mechanical compression at a higher pressure, followed by cooling in another heat exchanger (condenser). The compressor is hermetic, with reciprocating motion, supplied with single-phase or three-phase power. Defrost takes place automatically in pre-set cycles, by means of heaters; manual defrost is also possible.

Handling The unit can be handled by lifting and transport means. UNSCREW THE FIXING SCREWS TO REMOVE CRATING FROM THE UNIT. (fig. A). WARNING Make sure that no one is in transit in the operating area of the lifting/transport means to prevent any possible accidents to people.

If the unit is in a wooden case or crate, sling the packing properly before handling it.

Lifting speed shall be such as not to make the packed unit oscillate dangerously and possibly fall. Fig. A21

Plates The unit is supplied with warning and attention plates as listed in the relevant table.

To obtain optimal operation of the unit act as follows:

Place the unit in a well ventilated room, far from heat sources.

Limit the number of door openings.

Make sure that the unit has good air supply and discharge.

Fit a drain line to the defrost water drain connection in the lower part of the evaporator. Solution 1

Solution 2 Installation in a coldroom with more than one unit22

Free room When installing the unit leave enough free room to allow opening, correct use and easy maintenance in safe conditions.

Installation Secure the condenser unit to the wall by means of the specially supplied Fischer screws. Install the evaporator as follows:

Drill the holes in the ceiling keeping the necessary distance from the wall 140 cm.

Please select the matching cable length for sensor cables and power cables between the evaporating unit and the condensing unit. (The length must be equal to the length of the pre-charged pipe for the models SPO/GS and standard length of 10 meters for the models DBO/DBS up to the model 135).

Fit a drain line to the condensate water drain connection in the lower part of the evaporator.

Fitting the remote panel: Fix the back plate to the wall using the pre-drilled holes; be careful the panel is kept in a vertical position. Fit the connecting cable between panel and unit making sure not to bundle it with other cables. ATTENTION Maximum distance between panel and unit is 10 mt. For longer distances the special “long distance module” should be used.

ATTENTION Check that the unit and its devices have suffered no damages during transport. Pay special attention to the components secured to the electric panel door and to the refrigerating circuit pipes. Mount the unit as shown in the drawings; make sure that the electric connections are carried out properly.

The following mechanical safety devices are supplied: 1. Fixed front and side protections for evaporator and condensing unit, secured by locking screws. 2. External fan protections placed on the evaporating unit, secured with screws. The following electrical safety devices are supplied: a. Protection of fans (belonging to motors) against high power absorption; with automatic reset. b. High pressure switch (only for special components) to protect against excessive pressure; with automatic reset.

WARNING Above devices have been developed to safeguard the operator’s safety.

Cleaning Clean the unit carefully. Remove any dust, foreign substances and dirt possibly deposited during handling. Use detergents and degreasers. ATTENTION Solvents are not allowed.24

ATTENTION Before connecting the unit make sure that mains voltage and frequency correspond to the values shown in the data plate. Voltage tolerance: +/- 10% compared to nominal value.

Electric connection Connect the unit after checking the panel components. ATTENTION Connection to the electric line shall be effected applying a suitable safety device (a circuit breaker or a ground fault interrupter) selected by the installer on the basis of the line involved and of the absorption indicated on the unit plate. If a cold room includes more units, each unit shall be provided with its own safety device. Connect the unit paying attention to the colours of the supply cable wires: a) 230V/1/50-60Hz 3 wires Yellow/Green = Ground Brown = Phase b) 230V/3/50-60Hz 4 wires Grey = Phase Yellow/Green = Ground Brown = Phase Black = Phase c) 400/3/50 Hz 5 wires Blue = Neutral Yellow/Green = Ground Brown = Phase Grey = Phase Black = Phase We advise to install a microswitch (not supplied) on the cold room door which will: switch on the light in the cold room, stop compressor and evaporator fan override the temperature alarm (for about one hour after door closing) every time the door is opened. Should microdoor, cold room light, door heater be necessary, carry out following connections: Microdoor Remove the jumper between terminals DI3 of the electronic control box and connect the microdoor cable according to the following condition: closed contact with closed door. Cold room light Connect as shown in the wiring diagram. Cold room lamp features: 230 Volt and 100 Watt max. Door heater Connect as indicated by the plate on terminal board. Heater is indicated by "EP". Output voltage: 230 Volt. WARNING Any defective electrical part should be replaced by trained personnel exclusively. The electric connection should be effected by qualified personnel.

Connection to water system

This connection is only necessary if the unit has a water-cooled condenser. It is effected by following the indications of the tags positioned by the inlet and outlet pipes. Connection pipes should never be smaller in diameter than those on the unit. A minimum water pressure of 1 bar is required for correct operation of the unit.25

SET Press and release Display and modify the Setpoint Confirms commands PRG Press and release Displays any alarms (if active) Opens Machine Status menù Confirms commands Press for at least 3 sec Opens Programming menù TOUCH KNOB Clockwise Scroll through menù options Increases values Anti-clockwise Scroll through menù options Decreases values ON/OFF Press and release ESC function Press for at least for 3 sec Turns instrument ON/OFF (Standby) LIGHT Press and release Turn light ON/OFF26

Permanently on: alarm present Blinking: alarm acknowledged Off: otherwise

Permanently on: the machine is OFF Off: the machine is ON

Permanently on: parameters edit lock Permanently on: compressor active Blinking: navigation of menus in progress Blinking: delay, protection or start blocked Off: otherwise Off: otherwise

Permanently on: defrost active Permanently on: evaporator fans active Blinking: dripping Blinking: fans forced manually or from D.I. Off: otherwise Off: otherwise

NOT USED Accesa fissa: the room light is ON Off: otherwise

NOT USED NOTES: When the controller is powered on it performs a lamp test, during which time the display and LEDs will Flash for several seconds to check that they all function correctly. If the room light is on, the “Light” icon will be permanently on and the display shows alternately the room temperature value and the word ON. ATTENTION If the keyboard is not recognized, the display shows E8. If happens, check the state and the correct insertion of the flat on the connector of the display card. If the flat is good, replace the polycarbonate front panel. DEFROST Press for at least 3 sec Activates the Manual Defrost function

PARAMETERS EDIT LOCK

Press the 2 keys at the same time for at least 3 secs for disabling the access to the Programing menù. To disable the keypad lock, repeat the above-mentioned procedure.27

Checks, regulations and adjustments Before turning the unit on, check that: - locking screws are tight - electrical connections have been carried out correctly. In the event that the unit has been opened: - no tools were left inside - assembly is correct - there are no gas leaks - front cover is secured correctly

Starting Before starting the unit act as follows:

Connect the unit to the mains. The display is turned on and shows OFF.

If the unit has a preheating cycle, leave it in this condition for at least 3 hours.

If the unit has a voltage monitor, leave it in this condition for at least 7 minutes to have the counting phase carried out

Setting room temperature: Connect the unit to the mains. OFF is displayed. Press ON/OFF key, for 3 seconds, to switch the unit on. Press SET key. The yellow led lights up and the previously set temperature is displayed. To change this value rotate following knob touch: UP to increase temperature

DOWN to decrease temperature

Press SET key to confirm the set value or wait 15 seconds Now the unit is operating and does not require any further programming. The refrigerating cycle is fully automatic according to the factory-set parameters, which can be modified by authorised personnel only. ATTENTION 24 hours after starting check evaporator state. If ice has formed, defrost frequency should be increased. In low temperature units the evaporator condition should be checked every week during the first month of operation.

Wiring A wiring diagram, specific for the units of the GS series, is enclosed with these use and maintenance instructions.

Maintenance and repairs Suitable maintenance is crucial for obtaining longer life, perfect working conditions and high efficiency of the unit as well as for ensuring the safety features provided by the manufacturer.28

Routine maintenance Good operation of the unit requires the condenser to be cleaned periodically (frequency of cleaning depends on the environment where the unit is installed). Turn off the unit and clean it by blowing air from the inside outwards. Should no air jet be available, use a long- haired brush and work on the outside of the condenser. In case of water-cooled condensers have the unit cleaned by a plumber with special descaling agents. WARNING Use safety gloves to protect your hands from possible cuts.

WARNING Disconnect the unit before working on it.

Periodical maintenance Periodically check wear condition of electrical contacts and remote switches; if necessary replace them.

Service operations to be carried out by qualified technicians or by the manufacturer Following operations shall be carried out by qualified technicians or by the manufacturer exclusively. Under no circumstances the user is allowed to: replace electrical components work on the electric equipment repair mechanical parts work on the refrigerating system work on the control panel, ON/OFF and emergency switches work on protection and safety devices.

Troubleshooting During operation following troubles may occur: 1. Compressor stops. The unit is equipped with an overtemperature device which stops the compressor every time the max. allowable temperature of motor windings is exceeded. Possible causes are: - insufficient ventilation of the room where the unit is installed; - anomaly in mains voltage; - faulty operation of condenser fan. Device reset is automatic. 2. Ice forms on the evaporator preventing air from flowing regularly. Possible causes are: - the door is opened too frequently; faulty operation of evaporator fan; faulty solenoid valve (in models with hot gas defrost); faulty defrost heater (in models with electric defrost); faulty defrost process. In this case some measures can be taken: increase defrost termination temperature by some degrees, increase number of defrosts. ATTENTION Do not use either hot water or any pointed, cutting, metal objects to remove ice blocks.

3. Display does not light up. Check: - if there is power to the unit; -

if mains cable is connected properly; - fuses inside the electric panel 4. Unit does not start operating when pressing ON/OFF key (the display is turned on): check microdoor connection keeping in mind that the switch contact must be closed when the door is closed.29 Unsatisfactory efficiency of the unit: If no defects are found in the unit check that: cold room doors are perfectly tight; there is no cold dispersion; the cold room is used wisely; no unfrozen liquids or foodstuffs are placed in the low temperature room; the evaporator is ice-free. We recommend installation of the machines far from the doors especially when the cold room is expected to be opened many times a day.

Removal of protections during machine operation is absolutely forbidden. They have been developed to safeguard the operator’s safety.

Alarms When an alarm condition occurs the following warning devices are activated (depending on the nature of the alarm): alarm led alarm relay. The alarm relay can be muted by pressing any key. When a key is pressed, the led flashes as long as the alarm condition is present. To have the alarm code displayed, press ENTER key: AL appears. Press ENTER key. At this point a code is displayed indicating the cause of the alarm. To leave the alarm menu wait 15 seconds or press SET as long as cold room temperature is displayed. ALARM DISPLAY CAUSE REMEDY High temperature (AH1) Red led and alarm relay are activated; HI is displayed in the alarm menu as indicated above. Excessive door openings Excessive product load Product too warm Malfunction of the unit

Low temperature (AL1) Red led and alarm relay are activated; AL1 is displayed in the alarm menu. Malfunction of the electronic controller Service intervention Room sensor (E1) Red led and alarm relay are activated; E1 is displayed. Faulty sensor Sensor with wrong connection Replace sensor Evaporator sensor (E2) Red led and alarm relay are activated; E2 and cold room temperature are displayed alternately. Faulty sensor Sensor with wrong connection Replace sensor Condenser sensor (E3) Red led and alarm relay are activated; E3 and cold room temperature are displayed alternately. Faulty sensor Sensor with wrong connection Replace sensor Condenser temperature If the condensing temperature exceeds a factory pre- set value, red led is activated; AH3 is displayed in the alarm menu. Dirty condenser Clean condenser High pressure (nPA) Each time the pressure switch trips, the red led is activated. If more than 10 trips occur in 1 hour, then the unit is turned off automatically. The alarm relay is activated, nPA is displayed in the alarm menu. To reset the unit turn it off and then on again Faulty operation of condenser fan. Dirty condenser. Switch off the refrigerating unit, wait a few seconds and switch on again.30 Voltage monitor (EA) The voltage monitor is an electronic device which checks the supply voltage of the unit. When voltage variations exceed +/- 12% the device activates the red led and the alarm led. EA is displayed in the alarm menu. The unit stops for about 6 minutes

d restarts automatically if voltage is within the prescribed limits.

Warning: On first starting the monitor carries out a counting

phase of 7 minutes, during which the unit should be left connected but in OFF condition. Wrong supply voltage

Alarm open door (Opd) In case of presence of door open and passed the delay tdO=60 min (not visible parameter to the first level). Led signalling blinking. Recording of label the Opd in the folder AL of the menu be machine. Manual halt of relé the alarm. Led and the signalling in the folder AL will remain active until at the close of the door.

How to order spare parts When ordering spare parts make reference to the number written on the unit plate. WARNING Worn parts should be replaced only by qualified personnel or by the manufacturer.

How to dispose of the packing Wooden, plastic, polystyrene packing shall be disposed of according to the regulations in force in the country where the unit is used.

How to dispose of the unit Do not discharge scrapped components in the environment. They should be disposed of by companies dealing with special waste collection and recovery, according to the regulations in force in the country where the unit is used. WARNING Do not discharge the refrigerant in the atmosphere. It should be disposed of by companies dealing with special waste collection and recovery.31