IV Produkt Envistar Top Series, Operation And Maintenance

Page 1: ...Operation and maintenance Translation of the original instructions Order number Project Air Handling Unit Envistar Top and Home Concept FTX Top 04 21 Envistar Top ...

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Page 3: ...e ATEM ATER ATCR 1V 2V Home Concept model Control equipment MX UC MK US HS Unit parts and accessories Recovery rotor ATRR Counter flow exchanger ATMM Air heater water ATEV ATTV Air heater electric ATEE Output var 1 2 3 Air heater electric ATET EV Output var 1 2 3 4 Air cooler water ATET VK Damper ATET UM ETET UM ETET TR ATET 09 Sound attenuator ETET LD Unit specifications ...

Page 4: ... refrigerant 9 2 7 Extended 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 Cooling unit code ATCR 12 4 Wiring instructions and fuse protection 4 1 MX Complete control equipment and UC Complete electrical connection to terminal without DUC 15 4 2 MK Fans and heat exchangers electricall...

Page 5: ...1 Service schedule 27 6 2 Filter 29 6 3 Rotary heat exchanger code ATRR 33 6 4 Counter flow exchanger code ATMM 37 6 5 Air heater water code ATEV 39 6 6 Air heater Electric code ATEE ATET EV 41 6 7 Air cooler water code ATET VK 42 6 8 Fan unit code ELFF 43 6 9 Damper code ATET UM ETET UM ETET TR ATET 09 48 6 10 Sound attenuator code ETET LD 49 6 11 Cooling unit code ATCR 50 7 Alarm management and ...

Page 6: ...inspection doors 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 p...

Page 7: ... AHUs are manufactured by IV Produkt AB Sjöuddevägen 7 SE 350 43 VÄXJÖ 2 3 Designations The unit and cooling unit if selected have a model type plate affixed to the front The model type plate shows the series number and the requisite designations to identify the unit Kodnyckel Code key Beteckning Project name Ordernummer Order number Max varv Max rev Tillv ort Made in Tillv månad Manuf month Y Y M...

Page 8: ... at docs ivprodukt com The CE marking applies to units that IV Produkt AB manufactures and supplies in the form of a unit without additional control equipment For the CE marking of IV products to apply the applicable requirements of the EU Machinery Direc tive 2006 42 EC and related directives for control equipment shall be met when installed for the unit 0 1 Art Nr 19194 0001_01 1 2 3 180s Typica...

Page 9: ...efer 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 CO2 e tonnes This figure is calculated by multiply ing the refrigerant s GWP value Global Warming Potential by the filling amount in k...

Page 10: ...ed warranty a complete documented and signed IV Produkt Service and Warranty Manual must be presented 2 8 Spare parts Spare parts and accessories for this unit are ordered from your nearest IV Produkt sales representative When ordering state the order number and designation These are stated on a model type plate affixed to each component There is a separate spare parts list for the unit refer to O...

Page 11: ...ct connections in the top up The units are equipped with either a counter flow exchanger code ATEM or rotary heat exchanger code ATER The units are usually supplied with integrated control equipment but can also be obtained without control equipment Envistar TOP sizes 04 06 10 and 12 with counter flow exchanger can be sup plied modularly 3 2 Home Concept model Units with a rotary heat exchanger or...

Page 12: ...or type Refrigerant volume CO2e tonnes 04 Rotary compressor 1 1 kg 2 30 06 Scroll compressor 1 7 kg 3 55 10 Scroll compressor 2 1 kg 4 38 12 Scroll compressor 2 38 kg 4 97 16 Piston compressor 5 0 kg 7 15 21 Piston compressor 5 2 kg 7 47 Compressor Power control takes place with a speed controlled compressor When increased cooling is required the frequency inverter increases the speed of the compr...

Page 13: ...cally Cooling function For integrated control equipment MX the cooling unit is interlocked across the ventilation unit If any of the fans stop the cooling unit will also stop The interlock and demand signal is sent via Modbus For external control equipment US UC 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 c...

Page 14: ...ressed and thus heated The gas is also used for cooling the compressor s electric motor The refrigerant now con tains the heat from the supply air the compressor s motor heat and the compression heat 15 13 14 10 4 11 2 12 5 6 1 9 7 8 3 1 Compressor 2 Condensor 3 Extract air fan 4 High pressure switch 4 High pressure switch 5 Measurement tapping high pressure 6 Drying filter 7 Expansion valve 8 Eva...

Page 15: ...tion 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 recommended fuses refer to Ord...

Page 16: ... docs ivprodukt com Terminal Connection and Technical Data Safety switch A safety switch must be fitted and wired on each power supply 4 3 HS US Without control and without electrical connection For units without control equipment and without electrical connection code HS control diagrams are available for the heat exchanger and cooling unit code ATCR at docs ivprodukt com for other connection ins...

Page 17: ...un Brown Grå Grey Rosa Pink Gul Yellow Grön Green Rotary recovery unit code EMX P Size 04 16 33 34 36 37 41 42 43 L N PE CONTROL 0 10 V DC POWER SUPPLY 1 230 V AC ALARM CLOSES IN EVENT OF ALARM COOLING RECOVERY CLOSED CONTACT GIVES FULL SPEED Rotary recovery unit EMX B Size 21 36 35 34 41 42 43 L N PE CONTROL 0 10 V DC POWER SUPPLY 1 230 V AC ALARM CLOSES IN EVENT OF ALARM COOLING RECOVERY CLOSED ...

Page 18: ...h the 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 from the cool...

Page 19: ...ontrol 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 only be carried out by a qualified electrician or by se...

Page 20: ...d 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 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 Compress...

Page 21: ...nline 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 start stop Stop ...

Page 22: ...erature 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 internal tempera...

Page 23: ...with the inverter or compressor In the event of an alarm see Alarm IN for high pressure switch and frequency inverter page 26 Safety mode OK VSD restr No The inverter restricts the speed Cooling x Cooling load from Climatix cooling regulator Compr frequency x xHz Frequency to the compressor Hot gas temp x x C Hot gas temperature Danfoss VSD EEV Electronic Expansion Valve Suction gas temp x x C Mea...

Page 24: ...0 b High pressure relative Discharge 0 0 C Hot gas Status A03 Inverter temp 0 0 C Internal temp of the inverter Voltage supply 0 V Supply voltage to inverter 1 phase Voltage DClink 0 0 V Internal DC voltage of the inverter Compressor power 0 W Electrical power use Compressor current 0 0 0 0 0 0 A Compressor current Status A05 NO1 Compressor O Relay status of operating indication NO2 Global alarm C...

Page 25: ...the cooling load OFFbyALR 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 Cooling load sent from Climatix to Carel Frequency inverter output Compr no Compressor number 1 x compressor C1 Compr Sum alarm Alarm managem...

Page 26: ...tatus A03 ID1 Comp 1 amarm O Alarm IN for high pressure switch and frequency in verter 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 Compres sor 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...

Page 27: ...f neces sary 29 signature signature signature signature Rotary heat exchanger ATRR Visual inspection Check press balance Check diff pressure Clean if necessary 33 signature signature signature signature Counter flow exchanger only 04 12 ATMM Visual inspection Clean if necessary Check function 37 signature signature signature signature H O 2 Air heater water ATEV ATTV Visual inspection Clean if nec...

Page 28: ...operation or every 6th month depending on which occurs first More frequent servic ing may be required in certain environments Home Concept model Service year 20 for unit no Service performed date and signature Functional section Code Recommended action insp Page ref 3000 h 6 mths 6000 h 12 mths 9000 h 18 mths 12 000 h 24 mths date date date date AL Aluminium filter in filter cabinet ATET 08F size ...

Page 29: ...nge them According to guidelines for hygienic design VDI 6022 Part 1 The supply air filter must be class ePM1 50 F7 or have a greater filtration efficiency The filters are designed for one time use If they become fouled the unit will lose capacity The filters should therefore be changed if the pressure drop across them exceeds the specified final pressure drop It is important to stop the unit befo...

Page 30: ...r density of odorous substances This means that the time intervals for filter replacement can vary from unit to unit depending on operation mode and the volume of odorous substances in the air Units delivered with control equipment code MX are equipped with the filter control function FLC Filter Lifetime Control FLC indicates when it is time to replace the carbon filter Indication is through an al...

Page 31: ...ops are measured with a pressure gauge connected to the measurement outlets The measurement outlets 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 Nominellt luftflöde ...

Page 32: ...or starting 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 dis...

Page 33: ...function for the pressure balance over the purge sector which means that the pressure balance does not have to be in spected or adjusted 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...

Page 34: ...diff 25 Pa Otherwise an ETET TR trim damper can be used on the extract air side in order to throttle 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 ...

Page 35: ...easure 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 maximum o...

Page 36: ...the nozzle 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 op...

Page 37: ...ot closing 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 unti...

Page 38: ...the counter 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 controlled 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 anoth...

Page 39: ...t deposits 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 th...

Page 40: ...alve seat 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 coi...

Page 41: ...tion 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 All the electric output steps sho...

Page 42: ...ty 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 carefully blow them clean with compressed air from...

Page 43: ... too low the 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 tur...

Page 44: ...mounted in the upper fan support position 7 and that it has not shifted sideways toward the inlet cone position 6 Also check to make sure that the inlet cone is properly secured 5 The fan unit is mounted on the connection plate by means of rubber anti vi bration mountings position 3 between the lower fan support position 8 and the anti vibration supports position 4 Check that the anti vibration mo...

Page 45: ...0 15 0 20 51 43 1 0 25 0 30 0 35 0 40 0 45 0 50 0 55 0 60 50 100 200 150 250 300 800 500 600 700 400 900 Example of air flow label Cleaning 1 Follow item 1 under Inspection 2 Wipe the fan impeller blades to remove any coatings Use a mild alkaline detergent 3 The external surfaces of the motor must be kept clean Remove any dust dirt and oil Clean with a dry cloth In the event of stubborn dirt use a...

Page 46: ... to the fan impeller blades 3 Listen to the sound from the motor bearings 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 The fan impeller and motor are mounted on a support fitted with rubber anti vibration mountings Check that the anti vibration mountings are securely mou...

Page 47: ...5 0 20 51 43 1 0 25 0 30 0 35 0 40 0 45 0 50 0 55 0 60 50 100 200 150 250 300 800 500 600 700 400 900 Example of air flow label Cleaning 1 Follow item 1 under Inspection 2 Wipe the fan impeller blades to remove any coatings Use a mild alkaline detergent 3 The external surfaces of the motor must be kept clean from dust dirt and oil Clean with a dry cloth In the event of stubborn dirt use a mild alk...

Page 48: ...isturbances that may result in serious problems If the outdoor air damper does not Open completely this reduces the air flow Close completely when the unit stops the heating coil is 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...

Page 49: ...nuator code ETET LD Sound attenuator for ATER 04 Sound attenuator for ATCR 04 21 The purpose of the sound attenuator is to reduce the sound power 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 50: ...page 9 Visual check Check 1 The fins on the condenser evaporator to detect mechanical deformations 2 The drip tray and drain with water trap clean if necessary 3 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 carefully blow them clean with compressed air from the outlet side In the eve...

Page 51: ...16 displayed YES No or too low air flow across the 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 ...

Page 52: ...d Check 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 ...

Page 53: ...the flow Defective expansion valve 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 compresso...

Page 54: ...he alarm 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 h...

Page 55: ...he alarm 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 ...

Page 56: ...larm Alarm 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...

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Page 60: ... 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 our website www ivprodukt com Documentation for your unit docs ivprodukt com Technical documentation docs ivprodukt se ...