IV Produkt Envistar Top 04-21 Operation And Maintenance Download

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Operation and Maintenance

Envistar Top 04-21

DSET.190501.01.EN

Continuous product development may give rise to specification changes without notice.

3.3 EcoCooler cooling unit (code TEC)

Envistar Top with EcoCooler (code TEC) size 10

The integrated cooling unit with EcoCooler (code TEC) cooling recovery

is available as an optional extra to an Envistar Top unit with a rotary heat

exchanger. Cooling recovery means that the heat exchanger starts up when the

extract air/room temperature drops below the outdoor temperature and cooling

is required.

The unit has an electronic expansion valve, rotary compressor size 04, scroll

compressor size 06-12 and reciprocating compressor size 16-21.

Compressor

Power control takes place with a speed-controlled compressor. When

increased cooling is required, the frequency inverter increases the speed of the

compressor.

Compressor protection

In the event of an alarm initiated by the frequency inverter or the safety circuit,

the compressor stops and an alarm indication is given. If the unit is equipped

with control equipment, the alarm can be read on the Climatix display.

In the event of an alarm, correct the fault and then reset the alarm. If the safety

circuit alarm trips repeatedly, an authorised refrigeration service company must

be called in.

For size 04-12

The safety circuit consists of a high pressure switch (HP), which protects by trip-

ping when there is high pressure in the system. Use the manual reset button on

the pressure switch to perform a reset.

For size 16-21

The safety circuit consists of a low pressure control and a high pressure switch

with a manual reset button. The safety circuit can trip for two different faults:

• High pressure in the system, HP (manual reset on the pressure switch)
• Low pressure in the system, LP (resets itself automatically)

Summary of Contents for Envistar Top 04-21

Page 1: ...Operation and Maintenance Envistar Top Order number Project ...

Page 2: ...Translation of the original instructions ...

Page 3: ...EM TXM TER TXR TEC 1V 2V TTC Home Concept model Unit parts and accessories Rotary heat exchanger TXRR Counter flow exchanger TXMM Air heater water ETAB VV Output var 1 2 3 ETAB TV Output var 1 2 Air heater electric ETAB EV Output var 1 2 3 Air heater electric ETKB EV Output var 1 2 3 4 Air cooler water ETKB VK Damper ETSP UM ETSP TR ETRL Sound attenuator ETLD Unit specifications ...

Page 4: ...d warranty 10 2 8 Spare parts 10 2 9 Dismantling and decommissioning 10 3 Technical description 3 1 Envistar Top air handling unit 11 3 2 Home Concept model 11 3 3 EcoCooler cooling unit code TEC 12 3 4 Reversible heat pump ThermoCooler HP code TTC 15 4 Wiring instructions and fuse protection 4 1 MX Complete control equipment and UC Complete electrical connection to terminal without controller uni...

Page 5: ...6 2 Filters code ELEF 34 6 3 Rotary heat exchanger code TXRR 37 6 4 Counter flow exchanger code TXMM 42 6 5 Air heater water code ETAB VV and Thermoguard ETAB TV 44 6 6 Air Heater electric Code ETAB EV ETKB EV ETAB SV 46 6 7 Air cooler water code ETKB VK 47 6 8 Fan unit code ELFF 48 6 9 Damper code ETSP UM ETSP TR ETRL 51 6 10 Sound attenuator code ETLD 52 6 11 Cooling unit code TEC and reversible...

Page 6: ...WARNING Rotating fan impeller risk of personal injury Shut down the unit via the service switch in the control equipment then turn the safety switch to the 0 position and lock it Wait at least 3 min utes before opening inspection doors NB The doors in front of moving parts should normally be locked there are no safety guards Before carrying out work unlock the doors with the key provided 1 3 Elect...

Page 7: ... Any other use and installation in other environments is prohibited unless specifi cally permitted by IV Produkt AB 2 2 Manufacturer The Envistar air handling units AHUs are manufactured by IV Produkt AB Sjöuddevägen 7 SE 350 43 VÄXJÖ 2 3 Designations The unit and cooling unit reversible heat pump if selected have a model type plate affixed to the front The model type plate shows the series number...

Page 8: ... 0409 Cooling unit Order number Code Key Model Name of project Date of manufacture PS Max allowable pressure PT Test pressure TS Temperature range Protection level low Protection level high Refrigerant Fluid group GWP Refrigerant charge Circuit 1 Refrigerant charge Circuit 2 Refrigerant charge Circuit 3 IV Produkt AB VÄXJÖ SWEDEN Contains fluorinated greenhouse gases covered by the Kyotot protocol...

Page 9: ...tally secure manner and in accordance with national regulations By operator we refer to the European Parliament s definition the natural or legal person exercising actual power over the technical functioning of the equip ment and systems The levels for the various actions to be taken for a system are calculated using carbon dioxide equivalents CO2e tonnes This figure is calculated by multiply ing ...

Page 10: ...and reversible heat pump code TTC size 06 is not subject to registering or leakage inspection require ments 2 7 Extended warranty In cases in which the equipment delivered falls under a 5 year warranty in ac cordance with ABM 07 with supplement ABM V 07 or in accordance with NL 09 with supplement VU13 the IV Produkt Service and Warranty Manual is supplied with the product In order to lay claim to ...

Page 11: ...to facilitate transport and entry and are assembled on site The unit is available in different sizes and in right hand or left hand versions All units have duct connections in the top up The units are equipped with either a counter flow exchanger code TEM TXM or rotary heat exchanger code TER TXR The units are usually supplied with integrated control equipment but can also be obtained without cont...

Page 12: ... frequency inverter increases the speed of the compressor Compressor protection In the event of an alarm initiated by the frequency inverter or the safety circuit the compressor stops and an alarm indication is given If the unit is equipped with control equipment the alarm can be read on the Climatix display In the event of an alarm correct the fault and then reset the alarm If the safety circuit ...

Page 13: ...MK the interlock signal must be sent via a potential free relay The demand signal must be sent via 0 10 V The cooling unit has internal communication between the frequency inverter and the expansion valve s control equipment Communication takes place through the Modbus protocol Circuit board The circuit board in the cooling unit is internally prewired and tested at the fac tory The circuit board c...

Page 14: ...ressure sensor low pressure Cooling circuit function From the compressor the refrigerant is compressed as hot gas to the condenser where heat is emit ted The refrigerant condenses from gas to liquid when it is cooled by the extract air The refrigerant passes the pressure reducing expansion valve and undergoes a phase transformation in the evaporator from liquid to gas the refrigerant evaporates In...

Page 15: ...d reversible heat pump ThermoCooler HP code TTC is available as an optional extra to an Envistar Top unit with a rotary heat exchanger The units are intended to be used to cool or heat supply air in properties The heating pump function takes the heat content of the extract air and reuses it supplying the same heat to the ventilation unit s supply air The cooling function moves the heat content in ...

Page 16: ...s is also used for cooling the compressor s electric motor The refrigerant now contains the heat from the supply air the compressor s motor heat and the compression heat Flow chart for refrigerant system Heating mode The function of heating mode is similar to that of cooling mode The difference between the cooling and heating modes is that the 4 way valve is in the heating position This means that...

Page 17: ...e compressor Compressor protection In the event of an alarm initiated by the control equipment or the safety circuit the compressor stops and an alarm indication is given The alarm can be read on the Climatix display or the Carel unit on the unit s circuit board In the event of an alarm correct the fault and then reset the alarm If alarm trips repeatedly an authorised refrigeration service company...

Page 18: ...unit For further connection to an external process unit we recommend using a multi conductor cable Safety switch A safety switch must be fitted and wired on each power supply Wiring diagrams For wiring diagrams for units with control equipment see the order unique wiring diagram supplied with the unit at docs ivprodukt com Control Diagram Unit functions power supply and fuse protection For recomme...

Page 19: ...ust be fitted and wired on each power supply 4 3 HS US Without control and without electrical connection Code HS for units without control equipment and without electrical con nection control diagrams are available for the heat exchanger and cooling unit under order unique documentation at docs ivprodukt com for other connection instructions see below Code HS for units without control equipment an...

Page 20: ...ol 0 10 V RS 485 Modbus D1 24 V Brandfunktion Fire mode LARM Bryter vid larm ALARM Opens when triggered Ref Vit White Brun Brown Grå Grey Rosa Pink Gul Yellow Grön Green Rotor Code TXRD 2 0 10V 1 GND 10 NO 9 C 8 NC L N PE CONTROL POWER SUPPLY 1 230 V AC ALARM CLOSES IN EVENT OF ALARM Air Heater electric Code ETAB EV ETKB EV For power supply output variant and recommended fuse refer to Order Unique...

Page 21: ... design of the duct system and the settings configuration of the control system e g soft start of fans open damper when the fans are in opera tion 5 2 Actions in case of standstill According to guidelines for hygienic design VDI 6022 Part 1 In case of prolonged standstill in air treatment systems more than 48 hours it should be ensured that no moist areas can be found downstream of the cooling coi...

Page 22: ...ng procedure applies to units that are supplied with control equipment code MX The validity of the product warranty is conditional on the system having been correctly commissioned Working on the cooling unit during the warranty period without the approval of IV Produkt shall render the warranty void Prior to commissioning the contractor must NB Wiring of connections and other electrical work may o...

Page 23: ...rm OFFbyDIN Switched off due to interlock Climatix interlocks cooling operation OFFbyKey Switched off due to Carel s ON OFF menu High cond temp The compressor s speed is limited due to high pressure Cooling Cooling load sent from Climatix to Carel Frequency inverter output Compr no Compressor number 1 x compressor C1 Compr Sum alarm Alarm management Compressor_C1 Off On Compressor operating mode S...

Page 24: ... set J6 Modbus Online No Yes Information about Modbus communication is received Modbus command Stop start Information about command received from Climatix Modbus demand 50 Information about cooling load received from Climatix Status A02 High Press 25 00 bar High pressure Disch temp 50 00 C Hot gas temperature Low press 10 00 bar Low pressure Suct temp 17 00 C Suction gas temperature Status A03 U7 ...

Page 25: ...Hot gas temperature Suction gas temperature Low pressureEvaporating temperature Status A08 Status Off Run Alarm Heat Current 4 3 Arms Compressor s power consumption Voltage 124 Vrms Power to compressor Power 0 92 kW Electrical output used by compressor DC voltage 391 V Internal voltage of the inverter DC ripple 6 V Variation of internal voltage of the inverter Drive temp 40 0 C The inverter s inte...

Page 26: ...with the inverter or compressor In the event of an alarm see Alarm information for inverter and compressor page 57 Safety mode OK VSD restr No The inverter restricts the speed Cooling 50 Cooling load from Climatix cooling regulator Compr frequency 60 Hz Frequency to the compressor Hot gas temp 75 C Hot gas temperature Danfoss VSD EEV Electronic Expansion Valve Suction gas temp 17 C Measured suctio...

Page 27: ...High pressure relative Discharge 75 C Hot gas Status A03 Inverter temp 60 C Internal temp of the inverter Voltage supply 230 V Supply voltage to inverter 1 phase Voltage DClink 390 V Internal DC voltage of the inverter Compressor power 2200 W Electrical power use Compressor current 10 0 10 0 10 0 A Compressor current Status A05 NO1 Compressor O Relay status of operating indication NO2 Global alarm...

Page 28: ...byALR Switched off caused by alarm OFFbyDIN Switched off due to interlock Climatix interlocks cooling operation OFFbyKey Switched off due to Carel s ON OFF menu High cond temp The compressor s speed is limited due to high pressure Cooling 50 Cooling load sent from Climatix to Carel Frequency inverter output 60 Compr no Compressor number 1 x compressor C1 Compr Sum alarm Alarm management Compressor...

Page 29: ...tus A03 ID1 Comp 1 amarm O Alarm IN for high pressure switch and frequency inverter B6 Remote on off O Interlocking of ventilation control Status A04 EVD 1 DI 1 O IN expansion control EVD EVD 1 DI 2 O IN expansion control EVD Status A05 NO1 Compressor 1 O OUT for compressor 1 NO2 Global alarm C Alarm OUT for ventilation control NO3 4way valve C Not used Status A06 Y2 Comp inverter 0 OUT signal 0 1...

Page 30: ...is not a fault but a result of extract air flow and extract air temperature Status HP Alarm The heat pump is in alarm mode OffbyKey Switched off due to Carel s ON OFF menu Temp ctrl off The unit is shut off Cooling mode The heat pump is in cooling mode Low outdoor temp The heat pump is blocked as the out door temperature is too low Low air flow The heat pump is blocked as the air flow is too low L...

Page 31: ...n Off Compressor operating mode Suction gas temp C1 17 C Measured suction gas temp Evaporation temp C1 10 C Calculated evaporation temp based on low pressure Low pressure C1 10 bar Relative pressure from low pressure sensor Overheating C1 7 K Measured overheating High pressure C1 25 bar Relative pressure from high pressure sensor Expansion valve_1 80 Expansion valve position Condensation temp C 42...

Page 32: ...tary heat exchanger TXRR Visual inspection Check press balance Check diff pressure Control rotor speed Clean if necessary 37 signature signature signature signature Counter flow exchanger size 04 12 TXMM Visual inspection Clean if necessary Check function 42 signature signature signature signature H O 2 Air heater water ETAB VV ETAB TV Visual inspection Clean if necessary Check function 44 signatu...

Page 33: ... signature signature Every 5000th hour in operation or every 12 months depending on which occurs first More frequent servic ing may be required in certain environments Reversible heat pump code TTC Service year 20 for unit no Service performed date and signature Functional section Code Recommended action insp Page ref 5000 h 12 mths 10 000 h 24 mths 15 000 h 36 mths 20 000 h 48 mths date date date...

Page 34: ...he unit The inside surfaces of the filter sections should therefore also be cleaned when the filters are changed Lifespan and filter control Carbon filter The function and lifespan of the carbon filters depends on the volume of air that passes through and on the molecular density of odorous substances This means that the time intervals for filter replacement can vary from unit to unit depending on...

Page 35: ... filters Pressure drops are measured with a pressure gauge connected to the measurement outlets The measurement out lets are connected to each side of the filter If the filter has reached its specified final pressure drop it should be changed The final pressure drop is specified on the filter section decal filled in when the air handling unit is put into operation Art Nr 19121 1101_02SV FILTERDATA...

Page 36: ...g stopping the unit Always use the control equipment to start and shut down the unit 2 Wait until the fans have stopped then open the inspection door WARNING Positive pressure inside the unit risk of personal injury Allow the pressure to drop before you open the inspection doors 3 Loosen the eccentric rails 4 Remove the old filter by pulling it towards you Discarded filters should be disposed of c...

Page 37: ...age function and purging function For units supplied with control equipment the function is connected and activated at the factory For units without control equipment this function must be connected to the unit Inspection 1 Shut down the unit via the service switch in the control equipment safety switch in the 0 position NB The safety switch is not designed for starting stopping the unit Always us...

Page 38: ...red pressure balance between measurement tappings P2 and P3 corresponds to the set pressure balance setpoint in the controller unit 10 Pa Example Measurement outlets for P2 Downstream supply air fan SF generates negative pressure in relation to the atmospheric pressure atm e g 100 Pa Measurement outlets for P3 Downstream extract air fan EF and trim damper generate greater negative pressure than at...

Page 39: ...le in the correct pressure balance Example Measurement outlets for P2 Downstream supply air fan SF generates negative pressure in relation to the atmospheric pressure atm e g 100 Pa Measurement outlets for P3 Downstream extract air fan EF and any trim damper generate greater negative pressure than at P2 e g 125 Pa 25 Pa P3 P2 100 Pa 125 Pa P1 P4 P 1 atm 101 kPa Trim damper Measurement outlets for ...

Page 40: ...ws Measure and write down the differential pressure between the outdoor air P1 and the extract air P3 P2 P1 P4 P3 xx Pa see table below Purging sector Read the recommended setting adjustment hole in the purging sector from the table below Rotor vari ant Adjustment hole in the purging sector 3 open 2 intermediate position 1 closed Diff pressure between P1 and P3 Pa NO NE 300 300 NP NX 400 400 maxim...

Page 41: ...zle should not be held any closer to the rotor than 5 10 mm A hygroscopic rotor variant can absorb particles which in some cases give off odours To prevent odours arising exercise run the hygroscopic rotor using the integrated control function If an odour persists we recommend cleaning the ro tor with a mild alkaline detergent For cleaning it is recommended that the purge sector is fully open and ...

Page 42: ...sing completely A reduction of the extract air flow e g due to fouling of the extract air filter entails reduced heat recovery efficiency Inspection 1 Shut down the unit via the service switch in the control equipment safety switch in the 0 position NB The safety switch is not designed for starting stopping the unit Always use the control equipment to start and shut down the unit 2 Wait until the ...

Page 43: ...ounter flow exchange exceeds a certain value Defrosting takes place through the regulation of dampers on the outdoor air side of the counter flow exchanger The dampers have separate damper motors that are con trolled by a defrost program Damper control means that there are a number of different combinations of damper positions for instance that one of the dampers can be partly open while another i...

Page 44: ...eposits will form on the front edges of the coil fins at the inlet side To utilise its full capacity the coil must be well vented The pipework should be vented by opening the bleeder screws in pipe connections and or an air vessel Inspection Check 1 The coil fins to detect possible mechanical deformity 2 That the water coil is not leaking Cleaning If the fins on the batteries are dirty clean them ...

Page 45: ...t clean If the safety valve continues to leak you will have to replace it with a new one of the same type and with the same opening pressure 2 Any shut off valves on the supply or return lines may not be closed if freez ing temperatures are likely 3 If a ThermoGuard coil has frozen let it thaw completely before restarting operation If the heat recovery unit is installed upstream of the coil it is ...

Page 46: ...e all surfaces with a cloth Function 1 Simulate reduced required output by temporarily lowering the temperature setting setpoint so that all the electric output steps contactors switch out 2 Then sharply increase the setpoint setting and check that the electric output steps switch in 3 Restore the temperature setting 4 Stop the air handling unit NB Do not break the circuit with the safety switch A...

Page 47: ...oil fins to detect possible mechanical deformity 2 That the water coil is not leaking 3 That cooling energy is uniformly distributed across the coil surfaces in op eration 4 The drip tray and drain with water trap clean if necessary 5 That the water trap without non return valve is filled with water Cleaning If the fins on the batteries are dirty clean them by vacuuming from the inlet side or care...

Page 48: ... ventilation capacity will be unsatisfactory Imbalance may also force moist air out into the building structure One reason why the fans are generating too little air flow may be that impuri ties have collected on the fan impeller blades WARNING High voltage risk of personal injury Working on servicing the unit Shut down the unit via the ser vice switch in the control equipment then turn the safety...

Page 49: ...gs If the bearings are in good condition you will hear a slight purring sound A scraping or pounding sound may mean that the bearings are damaged and service is then required 4 For size 04 06 Check that the fan impeller with motor position 7 is firmly mounted in the upper fan support position 9 and that it has not shifted sideways toward the inlet cone position 3 Also check to make sure that the i...

Page 50: ...the unit s air flow label and see which flow corresponds to the measured Δp Luftflöde Airflow Luftvolumenstrom Ilmamäärä Przepływ powietrza Art Nr 19121 1201 Q 154 P m h EC400ZCPR G1 Q 1 23 38 P 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 0 4 0 5 0 6 0 8 0 7 0 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 Example of air flow label Cleaning 1 Follow item 1 under Inspection 2 Wipe the fan impeller ...

Page 51: ... likely to freeze seal properly leaks this will result in increased energy use If the trim damper for the rotor purging function is not working or is not cor rectly adjusted possible odours in the extract air are likely to be transferred via the rotor to the supply air Inspection 1 Check the function of the damper actuator 2 Check the dampers for tightness when they are closed If they are not seal...

Page 52: ...tenuator code ETLD Sound attenuator TER 04 Sound attenuator size 04 21 The function of the sound attenuator is to reduce the sound level in the system Inspection Check that the baffle elements are intact and have clean surfaces Take action if necessary Cleaning Vacuum and or wipe all surfaces with a damp cloth In the event of stubborn dirt use a mild alkaline detergent ...

Page 53: ...9 Visual check Check 1 fins on the supply air coil extract air coil for mechanical damage 2 The drip tray and drain with water trap clean if necessary 3 that the water trap is filled with water Cleaning If the fins on the batteries are dirty clean them by vacuuming from the inlet side or carefully blow them clean with compressed air from the outlet side In the event of stubborn dirt use a mild alk...

Page 54: ...condenser Check the air flow across the condenser Reset the pressure switch manually Defective high pressure switch Check replace NO Is Carel alarm LOP displayed YES Insufficient refrigerant volume Look for leakage seal the leak and top up with refrigerant No or too low air flow across evaporator Check adjust the flow Defective expansion valve or low pressure control Check replace NO Is Carel alar...

Page 55: ...k the control safety switches and fuses Compressor has opened a safety circuit Check and reset if needed The control unit is switched off Start the control unit Compressor defect Check replace Frost on the evaporator The expansion valve is incorrectly preset defective Check replace Insufficient refrigerant volume Look for leakage seal the leak and top up with refrigerant Low supply air flow Adjust...

Page 56: ...alve or low pressure control Check replace The LED is off or flashing green on the frequency inverter see also information below Phase failure voltage failure Check the 1 phase supply measure the incoming voltage Check the high pressure switch by pressing the button Reset the frequency inverter by switching off the voltage for 1 minute or more Check that the compressor is running without dissonanc...

Page 57: ...rm reset High inverter temp AL H03 Compressor Drive DRIVE_TEMPERATURE_HIGH A too high temperature in the inverter has been reg istered 115 C and the inverter stopped The alarm may be caused by e g a defective cool ing fan blocked air flow or abnormally high ambient temperature The alarm needs to be reset Low supply voltage AL H04 Compressor Drive SUPPLY_VOLTAGE_LOW A too low supply voltage has bee...

Page 58: ... reset Too many starts AL D15 Compressor Drive RESTART_TOO_FREQUENTLY The compressor has been restarted too many times in a 10 minute period and the inverter stopped The alarm needs to be reset Check that the air flow is correct Set the start delay for the compressor to 3 minutes after the compressor is turned off For UC MK US Check that the regulator that starts stops cooling mode is not too fast...

Page 59: ...larm is displayed Since the inverter loses all power when the high pressure switch is tripped a communication error alarm is also displayed Com Modbus alarm Danfoss Alarm Alarm reset Manually reset alarms caused by a tripped high pressure switch by pressing the red button on the pressure switch Reset alarms from the inverter or the compressor by turning off the power to the unit inverter for at le...

Page 60: ...ant No or too low air flow across evaporator Check adjust the flow Defective expansion valve Check replace NO Is the LED flashing red on the frequency inverter YES Phase failure voltage failure Check the 3 phase supply measure the incoming voltage Reset the frequency inverter by switching off the voltage for 1 minute or more Check that the compressor is running without dissonance Overload defectiv...

Page 61: ...s on the Carel unit wiring and sensors Alarm C1 low overheating Compressor stoppage caused by low overheating Alarm C1 LOP Compressor stoppage caused by low evaporation temperature Alarm C1 MOP Compressor stoppage caused by high evaporation temperature Alarm C1 communication EVD Fault on communication to EVD expansion valve control Alarm C1 low suction gas temp Low suction gas temperature Alarm Ca...

Page 62: ...d fuses Incorrect phase sequence compressor 2 Switch two of the incoming phases Compressor has opened a safety circuit Check and reset if needed Defective compressor Check replace Frost on the evaporator heating application Expansion valve is defective Check replace Insufficient refrigerant volume Look for leakage seal the leak and top up with refrigerant Low return air flow Adjust the flow Alarm ...

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Page 64: ... 47 075 88 00 Control support 46 0 47 075 89 00 styr ivprodukt se Service 46 0 47 075 89 99 service ivprodukt se Spare parts 46 0 470 75 88 00 order ivprodukt se Visit us at www ivprodukt com Documentation for your unit docs ivprodukt com Technical documentation docs ivprodukt se ...

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