Installer manual GreenMaster-HP

Transcription

1 Installer manual GreenMaster-HP Transport and installation Ventilation unit IHB EN

2 2 GreenMaster-HP Transport and installation

3 Introduction Here you can read about how best to handle the GreenMaster-HP heat pump unit. The instructions consist of basic information and recommendations regarding transport and installation. 1 The instructions should be complied with to ensure safe, trouble-free operation. The key to trouble-free and safe operation of the unit is to carefully read this manual, together with the corresponding manual for the heat pump unit. Use the unit in accordance with the guidelines provided, and follow all safety provisions. Index 1. Transport Unloading and lifting with forklift trucks or pallet trucks Unloading and lifting with a crane Storage before installation Angle Separated version due to narrow transport route Installation Installation of unit and ducting Load-bearing surface Protection of chassis for outdoor installation Joining unit sections Installation of ducting Electrical installation and pipe laying Electricity for unit including control unit GreenManager control unit Cable drawing and installation of external components Pressure sensor Switches Certifications The owner's responsibility Specific risks Switches Water traps for condensation Pipe connections to the coil Valves Wastewater and water traps Protective measures Dismantling/recycling General NB! All service and installation work should be carried out by experienced or trained staff. 1 Air-Site retains the right to make changes and improvements to the content of this manual without prior notice. Transport and installation GreenMaster-HP 3

4 1. Transport The GreenMaster-HP is normally delivered complete, in composite version, and filled with cooling media, with a bottom frame attached under the heat pump section. Upon request, the unit can be delivered without liquid for easy dismantling and reinstallation in a fan room. See section 1.5 Separated version due to narrow transport route. Loading, unloading and transport on site should be carried out using forklift trucks, pallet trucks or cranes. Suitable lifting straps must always be used. 1.1 Unloading and lifting with forklift trucks or pallet trucks The forks of the truck must be long enough that no damage is caused to the underside of the unit. Ensure that the forks reach through to the other side of the unit. 1.2 Unloading and lifting with a crane A unit delivered on a wooden pallet must be lifted off with straps according to the figure below. A unit delivered with pre-installed machine feet must be lifted with the straps inside the machine feet and with the straps fully tightened. A unit delivered without machine feet must be lifted with the straps through the lifting hole of the bottom frames and with the straps fully tightened. Lifting beams should be positioned so that there is no risk of the unit falling. Ensure that the beams are strong enough to lift the load and the straps are not rubbing against and damaging the upper part of the unit. Use beams or a lifting yoke to keep the straps away from the upper part of the unit. NB! Use flat beams and ensure that the straps are fully tightened. 1.3 Storage before installation The unit must be protected from weather and impacts. The packaging must be removed, and the unit covered with a tarpaulin or similar. To ensure as little condensation as possible, good air circulation must be provided between the protective cover and the unit. 4 GreenMaster-HP Transport and installation

5 1.4 Angle The unit should be transported upright or with less than a 30 angle. 1.5 Separated version due to narrow transport route Upon request, the unit can be delivered without cooling media, which means that the unit can be divided into six parts + bottom frame. This design is intended for units to be moved into fan rooms in properties where the transport route is narrow and where drilling for lifting into position is not possible. NB! Don't forget to disconnect the control cables and pipe couplings before separating parts for lifting into position. Start by placing the bottom frame in position and checking that it is completely horizontal. Then install the remaining parts one by one on top of the bottom frame into the pre-drilled holes that attached the parts on delivery. NB! Read and follow the instructions under point Joining unit sections. Cooling media pipes between the heat pump module/modules and the cooling coil in the ventilation section must be connected on site. The weight per section is provided in the unit specification for installed units. 2. Installation 2.1 Installation of unit and ducting Important! When a unit is installed, we recommend a free space in front of the unit of at least 950 mm but ideally as large as the unit is wide, to facilitate maintenance and inspection. NB! To be able to screw together the unit sections and to carry out future servicing, we recommend a minimum distance between wall and unit of 600 mm Load-bearing surface The surface under the unit should be level, so that the unit's final position is and remains completely horizontal. The machine feet can be used to adjust the chassis so that the unit achieves a horizontal position. The surface must be able to support the load of the unit. If the installation uses lightweight constructions or has particularly sensitive areas, the unit should be placed on a vibration absorbing foundation with the required characteristics. Remember! Ducting must be vibration and noise insulated and may not be installed directly on joists, trusses or other critical building sections Protection of chassis for outdoor installation The unit has no drip plates between the unit and the chassis. A local installer must therefore install additional protection and insulation for the chassis, so that the water does not run down beneath the unit. Air-Site's design assumes that the unit will be installed on a watertight roof, which does not risk moisture damage because of water run-off from the condensation trough or external moisture such as rain or snow. NB! Water traps placed outdoors must be protected with a heating cable (accessory kit; electrical heating loop) to avoid freezing when subject to cold outdoor temperatures Joining unit sections Prior to dismantling for transport to the fan room, note which sections are positioned where to facilitate installation when the sections are in the fan room. Transport and installation GreenMaster-HP 5

6 1. Start by placing the bottom frame in position and checking that it is completely horizontal. 2. Then position the first heat pump section and ensure that it is completely horizontal. Screw it to the bottom frame in the pre-drilled holes to which it was attached on delivery. 3. Continue with the middle section in the lower part and screw to the bottom frame as for the previous section. 6 GreenMaster-HP Transport and installation

7 4. Then install the last section of the heat pump section and screw to the bottom frame as for the previous section. After this, all sections should be screwed together with their connection brackets as was the case on delivery. Screw or clamp cooling media pipes and check that they are completely tight before installing the upper part/ventilation section on top of the heat pump section. 5. Install the fan section as shown in the image. Note that the fan section can be positioned on the right if the unit is delivered as a right-hand inspection version. In the example below, the unit is a left inspection version. 6. Install the coil section in the middle according to the image. NB! Cooling media pipes between the coil and heat pump section must be screwed or clamped together by an authorised HVAC and sanitation Transport and installation GreenMaster-HP 7

8 installer/pipefitter. The inspection/service hatch is accessible from both in front and behind on the coil section to access the pipe connection between the ventilation and heat pump sections. 7. Finally, install the filter unit (which includes the control panel) according to the image. After this, all sections should be screwed together with their connection brackets as was the case on delivery. Connection brackets are also used between the upper and lower level, both front and back. NB! Don't forget to reconnect cables in the relevant couplings/connection boxes. NB! Do not open the doors of the sections before they are positioned closely together, and you have ensured that they are level both vertically and horizontally. 8 GreenMaster-HP Transport and installation

9 NB! The recommended minimum distance between wall and unit is 600 mm. Connection brackets are generally used on the outside of the sections, but where it is not possible to screw together the sections with external connection brackets and where extra stability and rigidity may be required, internal connection brackets can be used. Carefully check each section so that no connection brackets are missed when joining parts together. The standard version of the GreenMaster-HP uses 12 connection brackets on sizes 2 and 3. On sizes 4 and 5, 16 connection brackets are used Installation of ducting If flexible connections are to be used between the unit and ducting, ensure that the duct connections are almost completely taut, but with a little play to prevent damage to the fabric. At the fan outlet, the duct size should be as like the outlet size as possible. For the minimum distance between the fan wheel and the nearest ducting part, please read the unit specification for the installed unit. Avoid blocking and creating turbulence at the fan outlet. 2.2 Electrical installation and pipe laying Electricity for unit including control unit The control system is configured according to specifications in the order. A report containing the final test is supplied together with the GreenMaster unit. Transport and installation GreenMaster-HP 9

10 GreenManager control unit Indoor version: The control unit for the ventilation section is installed inside the filter unit in the ventilation section according to the drawing in the unit specification. Internal and external connections belonging to the unit's components are as a rule pre-installed and function tested. An extension cable is present in the heat pump section, electrically linking the ventilation parts. Hoses are pre-installed according to the same principle. The control unit for the heat pump section is placed in the middle of the heat pump section, together with the supply box for the entire unit. These are internally connected with the control unit in the ventilation section, so that the only external connections required to the unit are one network connection (RJ45) and one supply cable. Please read the unit specification for the rated electrical data. Outdoor version: The control unit for the ventilation section is installed inside the filter unit in the ventilation section according to the drawing in the unit specification. Internal and external connections belonging to the unit's components are as a rule pre-installed and function tested. An extension cable is present in the heat pump section, electrically linking the ventilation parts. Hoses are pre-installed according to the same principle. The control unit for the heat pump section is placed in the middle of the heat pump section, together with the supply box for the entire unit. These are internally connected with the control unit in the ventilation section, so that the only external connections required to the unit are one network connection (RJ45) and one supply cable. Please read the unit specification for the rated electrical data Cable drawing and installation of external components Indoor version: Temperature sensors, hoses and other ordered components will be supplied in a box inside or beside the unit. External cabling should be connected to the control unit according to the circuit diagram in the technical specification. NB! Where the unit is delivered in separate sections, some parts of the electrical cabling may be disconnected. An authorised electrician or Air-Site representative must be present when this cabling is connected. External components such as dampers are installed with guide strips and corners. You should then follow the circuit diagram for connection to the relevant control unit. Outdoor version: Temperature sensors, hoses and other ordered components will be supplied in a box inside or beside the unit. External cabling should be connected to the control unit according to the circuit diagram in the technical specification. NB! Where the unit is delivered in separate sections, some parts of the electrical cabling may be disconnected. An authorised electrician or Air-Site representative must be present when this cabling is connected. External components such as dampers are installed with guide strips and corners. You should then follow the circuit diagram for connection to the relevant control unit Pressure sensor A differential pressure transmitter for flow control is pre-installed in the plenum. A pressure sensor for regulation of duct pressure is integrated into the GreenManager, and measures the duct pressure directly outside the filter section. If an extension of the duct pressure hose is required, this should be undone internally in the filter section and an external hose extended further on in the extract air duct. 10 GreenMaster-HP Transport and installation

11 A pressure sensor for the extract air filter is integrated into the GreenManager and is generally pre-connected to the control unit. A pressure sensor for measuring pressure over the coil is integrated into the GreenManager and is generally pre-connected to the control unit. Hoses Unit deliveries where the control unit is included are pre-equipped with pressure hoses for pressure regulation, extract air filter and pressure measurement of the coil. Each measurement outlet on the GreenMaster unit is marked with the object's designations. The hoses on the GreenMaster-HP unit are generally pre-connected at both ends, but may be disconnected if the unit was delivered in separate sections. When installing the unit, it is therefore important for all hoses which will be used in the installation to be installed correctly according to the markings on the unit and control unit Switches The main switch is generally delivered installed and connected. An authorised electrician must lay the supply cable to the unit's main switch Certifications According to the Swedish Work Environment Authority s regulations, an authorised HVAC and sanitation installer/pipefitter must carry out the work required on the cooling and heating sections and relating to external pipe connections. Electrical connections must be carried out by unauthorised electrician The owner's responsibility The owner is responsible for informing local authorities of the below information. Similar provisions apply in other countries to a certain extent. Information about the site, function, size and maintenance schedule Specific risks Uncertified technicians may never open the cooling circuit when it is under pressure from the cooling media. Changes and repairs to the cooling circuit may only be carried out by trained technicians from certified companies. Never open the inspection hatch before the fans have been switched off Switches The main switch must be installed in accordance with applicable regulations. Study the circuit diagram supplied carefully! Water traps for condensation An integrated water trap is installed inside the GreenMaster-HP unit, and run-off tubes are positioned along the outside of the unit in proximity to the external pipe connection. This must be connected to an external wastewater line/drain. Any external water traps must function for underpressure and be installed according to the principle in Section Wastewater and water traps. NB! Condensation run-off hoses for compressors in the heat pump section are at the front edge of the unit and must also be connected to run-off/wastewater line/drain. Transport and installation GreenMaster-HP 11

12 2.2.5 Pipe connections to the coil If the unit is delivered in separate sections, be careful to check that all of the pipes have been connected correctly according to the delivery principle. Normally all pipe parts are pressure tested together with the unit, but if the unit is refilled after delivery, the pipe connection must be pressure tested after refilling. Pipe connections are checked during Air-Site's factory tests Valves The connection pipe is externally threaded. Any valves and valve motors included in the delivery will be in a box inside the unit. Connect actuators according to the circuit diagram Wastewater and water traps Drip trays/troughs are installed under any cooling hoses and heat exchangers to collect condensation water. All drip trays are equipped with drainage outlets. The water traps ensure that water can run away from the trays. The water traps are delivered in a box inside or beside the unit. To ensure that the water can run away in a secure manner, Air-Site's water traps should be used. NB! Insulate the pipe to avoid it freezing. Installation at the underpressure The water trap is connected to the unit where the condensation outlet and underpressure (suction fan) is located. The condensation outlet and underpressure are present on the plate heat exchanger (GreenMaster-XXL), coil heat exchanger, coil recycling (GreenMaster-HP) etc. The water trap can be rotated to the right or left. The non-return valve should always be in a vertical position. The outlet of the water trap should be positioned so that damage does not occur to adjacent unit sections or building constructions. Drainage that leads to a cold space should be insulated against cold. A heating cable may be required, for example in the case of installation outdoors. Height A (distance between the unit's run-off level and the water trap's run-off level) must be at least as big in millimetres as the underpressure in the unit is in Pa/10 (Example: Underpressure 250 Pa/10 = 25 mm). If necessary for space reasons, pipes can be cut or inclined, provided that the conditions above are fulfilled. Installation at the overpressure The water trap is connected to the section where the condensation outlet and overpressure (pusher fan) is located. The condensation outlet and overpressure normally only occur on cooling coils (air coolers). Remove the cover and the ball inside the non-return valve so that air can pass freely. Replace the cover. The included pipe and T-connection are installed according to the sketch. Pipes from the T-connection can be adapted if necessary by cutting the pipe (or a corresponding pipe) so that it leads to a floor drain. See below and sketch. Height A (distance between the water surface and end of the pipe) must be at least as big in millimetres as the overpressure in the relevant section is in Pa/10 (Example: Overpressure 250 Pa/10 = 25 mm). 12 GreenMaster-HP Transport and installation

13 If there are additional drainage outlets, a water trap is required at each outlet. The diameter of the pipe in the water trap and wastewater system must agree with the diameter of the pipe in the drainage outlet. 3. Protective measures Read the description in the operating manual (OHB). 4. Dismantling/recycling Disconnect all electrical and pipe connections before dismantling. Any liquids must be emptied from the unit and the unit must then be recycled according to current local regulations. When the unit has been dismantled, the sections must be taken to pieces and all parts sorted by material type. The material must then be transported to the intended location. More information is available in the maintenance instructions. 5. General For additional information, read the operating manual (OHB). Transport and installation GreenMaster-HP 13

14 Notes 14 GreenMaster-HP Transport and installation

15 Notes Transport and installation GreenMaster-HP 15

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