ReCOOLER HP INSTALLATION AND COMMISSIONING

Transcription

1 ReCOOLER HP INSTALLATION AND COMMISSIONING Content Page 1. Safety 2 2. Product description 3 Generell information 3 Overview 3 ErP 2016/2218 compliance 4 3. Lifting and transport 7 4. Installation and jointing 7 5. Assembly instructions for split casing 9 6. Commissioning Maintenance Functional diagram Alarm list eq with other AHU controller than FläktGroup 22 ReCooler HP, heat-pump with heat recovery

2 2 ReCooler HP - Installation and commissioning 1. SAFETY Important! The unit must NOT be used for purposes other than as a reversible heat pump unit. The unit s Installation and Commissioning Instructions must be studied carefully before starting/operating/servicing/ maintaining/scrapping the unit. Keep these instructions in a safe place for future reference! All service and maintenance must be carried out by certified personnel. Service/maintenance of the refrigerant system must only be carried out by an accredited company and certified personnel wearing required protective equipment (gloves and protective eyeglasses). Lock and tag the heat pump prior to performing service on the unit. Do NOT stand on the heat-pump unit! Use only genuine spare parts for maintenance! Installation of units with split casing is to be performed only by certified refrigerant technicians. Failure to comply with above terms and conditions can result in serious injury and will void the warranty.

3 ReCooler HP - Installation and commissioning 3 2. PRODUCT DESCRIPTION GENERAL INFORMATION ReCooler HP is a module with rotary heat exchanger and reversible heat pump included in the FläktGroup AHU range eq. ReCooler HP can be used in the modular range eq Master and compact range eq Prime. This manual mainly focuses on eq Master, but most of the information is applicable to eq Prime and will give detailed info compared to the general eq Prime manuals. SIMPLIFIED OVERVIEW OF INSTALLED COMPONENTS The drawing shows a left hand version with supply air on top deck. 1. Outdoor air 2. Supply air 3. Extract air 4. Exhaust air 5. Rotary heat exchanger - service hatch 6. Compressor 7. Frequency inverter for compressor 8. Drainage (Note: 2 drain connections) 9. Control system for the ReCooler HP way valve 11. Main switch disconnector 12. Optional Electrical heater for defrost in exhaust air coil 13. Cable glands for incomming power 14. Electrical expansion valves 15. Handheld HMI for the ReCooler HP

4 4 ReCooler HP - Installation and commissioning ERP 2016/2218 COMPLIANCE eq with ReCooler HP is compliant with ErP 2016/2218 AHUs with an integrated heat pump (like eq with ReCooler HP) are exempted from the normal ErP directive for Air Handling Units, ErP 1253/2014. However they fall under the ErP directive for air conditioners, unit heaters, chillers etc. ErP 2016/2218 in case the AHU gives all the heating load for the building. eq with ReCooler HP is compliant with this directive and the table below contains all compulsory information per AHU size required by the directive. COOLING MODE Roof top air conditioner Roof top air conditioner with Roof top air conditioner with Roof top air conditioner with Roof top air conditioner with Roof top air conditioner with Roof top air conditioner with Roof top air conditioner with Roof top air conditioner with Model: EQKR 008 EQKR 011 EQKR 018 EQKR 023 EQKR 032 EQKR 041 EQKR 050 EQKR 072 Outdoor side heat exchanger: Air Air Air Air Air Air Air Air Indoor side heat exchanger: Air Air Air Air Air Air Air Air Type: Driver of compressor: Electric motor Electric motor Electric motor Electric motor Electric motor Electric motor Electric motor Electric motor Rated cooling capacity, total (Prated,c,tot) Rated cooling capacity, compressor, Prated,c,compr) Seasonal space cooling energy efficiency, total (hs,c.tot) Seasonal space cooling energy efficiency, total (hs,c. compr) Supply temp 20 C with nominal air flow Outdoor temperature (Tj) Cooling cap EER Com Cooling cap. EER Cooling cap. EER Cooling cap. +35 C C C C C Degradation coefficient (Cdc) Power consumption Off mode (POFF), Thermostat off mode (PTO) and Standby mode (PSB) Crancase heater mode (PCK) EER Cooling cap. EER Cooling cap. EER Cooling cap. EER Cooling cap. EER Rotor mode (PR) Cabinet fan mode (PFAN) Capacity contol Variable speed Variable speed Variable speed Variable speed Variable speed Variable speed Variable speed Variable speed Air flow rate outdoor (Supply/Exhaust) Sound power level See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification Refrigerant R410A R410A R410A R410A R410A R410A R410A R410A GWP value Com Com Com Com Com Com Com Com Com Com Com Com Com Com Com

5 ReCooler HP - Installation and commissioning 5 HEATING MODE Roof top heat pump Roof top heat pump with Roof top heat pump with Roof top heat pump with Roof top heat pump with Roof top heat pump with Roof top heat pump with Roof top heat pump with Roof top heat pump with Model: EQKR 008 EQKR 011 EQKR 018 EQKR 023 EQKR 032 EQKR 041 EQKR 050 EQKR 072 Outdoor side heat exchanger: Air Air Air Air Air Air Air Air Indoor side heat exchanger: Air Air Air Air Air Air Air Air Supplementary heater Option. Not needed for Option. Not needed for Option. Not needed for Option. Not needed for Option. Not needed for Option. Not needed for Option. Not needed for Option. Not needed for Average climate Average climate Average climate Average climate Average climate Average climate Average climate Average climate Type: Driver of compressor: Electric motor Electric motor Electric motor Electric motor Electric motor Electric motor Electric motor Electric motor Rated heating capacity, total (Prated,h,tot) Rated heating capacity, compressor, Prated,h,compr) Seasonal space heating energy efficiency, total (hs,h.tot) Seasonal space heating energy efficiency, total (hs,h. compr) Supply temp at -15 C is 19.1 C Outdoor temperature (Tj) Heating cap. COP Heating cap. COP Heating cap. COP Heating cap. COP Heating cap. COP Heating cap. COP Heating cap. COP Heating cap. COP -7 C C C C C Bivalent temperature C Operation limit without electric heater (-20 C with heater) Degradation coefficient (Cdc) Power consumption Off mode (POFF), Thermostat off mode (PTO) and Standby mode (PSB) Crancase heater mode (PCK) Rotor mode (PR) Cabinet fan mode (PFAN) Drain pan heater mode(pdp1) Drain pan defrost mode(pdp2) Capacity contol Variable speed Variable speed Variable speed Variable speed Variable speed Variable speed Variable speed Variable speed Air flow rate outdoor (Supply/Exhaust) Sound power level See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification Refrigerant R410A R410A R410A R410A R410A R410A R410A R410A GWP value

6 6 ReCooler HP - Installation and commissioning TECHNICAL DATA eq size 3x400 VAC Operating current (A) (without electric heater) 3x400 VAC Operating current (A) (with electric heater) Refrigerant charge EQKR version 4 Circuit 1 Circuit 2 Circuit 3 kg R410A ton CO 2 e kg R410A ton CO 2 e kg R410A ton CO 2 e kg R410A Oil/Circuit (l) The charge is the same for eq Master and eq Prime but in eq Prime there is only one common supply and the ReCooler gets the power from the AHU. Refrigerant charge could be changed without notice. See EQKR data lable on delivered unit. REFRIGERATION SYSTEM The Reversible Heat-pump unit in the ReCooler HP is designed at the following external air temperatures: For cooling from +20 to +40 C For heating from +20 to -15 C with defrost system For heating from +20 to -20 C with Integrated electrical defrost heater. Temperature at installation site from -20 C to +35 C. At temperatures below +10 C ReCooler HP must be supplied with crankcase heater on the compressor. An eq for outdoor installation is equipped with crankcase heater as default. Indoor units that risk being in a room with less than +10 C at start up must be equipped with a crankcase heater which needs to be ordered separately. The ReCooler HP is also designed for extract air temperatures of +16 to +28 C. ROTARY HEAT EXCHANGER The rotor unit in the ReCooler HP is designed to recover heat energy from the extract air. It operates in sequence with the reversible heat pump unit to heat and cool the air using as little electrical power as possible. INTEGRATED ELECTRICAL DEFROST HEATER The electrical defrost heater is mainly used to shorten defrost cycle time. It s also used to maintain the evaporating temperature at very low external air temperature. At design temperatures below -15 C the heater is a requirement due to the limitations of the compressor. The electrical heater includes two thermal protectors: An auto reset A manual reset

7 ReCooler HP - Installation and commissioning 7 3. LIFTING AND TRANSPORT Important! The unit s centre of gravity is not in the middle of the unit. Take care when lifting. Because of its design, the centre of gravity is offset towards the inspection side. This must be taken into account when lifting the unit. The unit should first be lifted slightly, and then inspected to ascertain that it does not tilt or appear unstable before being lifted higher. The unit can be lifted usings its eye bolts if its weight does not exceed kg. If the unit weighs more than kg, it must be lifted by a forklift truck from below using the specified holes. Lifting by any other means can cause the unit to tip over due to the offset centre of gravity. WEIGHT eq size Weight (kg) Non split version Weight (kg) Split version weight (including casing and base frame). L L 4. INSTALLATION AND JOINTING REQUIREMENTS RELATED TO THE FLOOR The floor must be level. This is to avoid torsional forces and stresses which could damage the internal pipework in the refrigerant circuit. The base frame or thermal wheel must not be removed. REQUIREMENTS RELATED TO PLACEMENT The unit must be installed in such a way that allows service in accordance with this service manual. DRAIN CONNECTIONS The ReCooler HP has 2 drain connections. Both must be connected to the drain with water traps. FläktGroup can supply water trap with the AHU delivery, ordering code EQAZ-08. If installed outdoors in cold climate the drains should be fitted with heating cables for frost protection.

8 8 ReCooler HP - Installation and commissioning JOINTING A B, D C JOINTING EXTERNALLY A C B JOINTING INTERNALLY D

9 ReCooler HP - Installation and commissioning 9 5. ASSEMBLY INSTRUCTIONS FOR SPLIT CASING SIZE The unit is tested at the factory and supplied with refrigerant and closed valves (2). Most of the refrigerant is collected in the large section and a small amount into the small section. Important! Please note that the work on the refrigerant circuit must be done by a certified refrigeration engineer according to description. In accordance with F-GAS regulation 517/2014 (or later editions to that regulation). Other work required to disconnect large and small section can be done by a ventilation installer. Description for splitting of refrigerant circuit: 1. Remove the front panel on the small section of the Recooler HP. 2. Remove the refrigerant from the small section with recovery unit into a service cylinder using schrader valve (1) (located under the ceiling in large section). Use digital scale to weigh removed refrigerant amount from the system. 3. Open the flare connectors (3) (located near the joint between sections) and cover them. 4. The unit can now be split in two sections. 5. When the sections are assembled again, connect the flare connectors. 6. Perform a leakage test of the flare connectors. 7. Evacuate the small section by using the schrader valve. The pressure after evacuation shall be under 2 mbar. 8. Open the closed valves (2) (located under the ceiling in large section). 9. Charge the circuit with refrigerant removed from the small section. 10. The unit is ready to run. CHECK THE POSITION ON THE SHUT-OFF VALVE Fully closed Fully open NOTE: If the unit is not to be split, just open the closed valves (2)!

10 10 ReCooler HP - Installation and commissioning 6. COMMISSIONING Important! Check list Always read the safety work on the unit, on page 2 before beginning work on the unit. The air handling unit must not be commissioned until the installation has been inspected according to the check list below! Before commissioning check the following: Condition on delivery - no transport damage, installation site, (adequate lighting, mounting surface etc.). No leakage of compressor oil. Proper connection of the supply power. Control signal. Energy recovery not disabled. Condensate drainage. installation report submitted: There are no loose cables. Installation of units with split casing to be carried out by a certified refrigerant technician. After commissioning check the following: Outdoor/supply air temperature. Condensing/evaporating temperature. Discharge gas temperature/subcooling/ superheating. Operating currents. Brief the operators of the unit. Complete the commissioning report TO SET THE SETPOINT FOR COOLING AND HEATING The capacity of the ReCooler HP module is dependent on the need for cooling or heating of the supply air. The temperature set point that drives the capacity is defined by air handling unit control, either via Modbus (Climatix only) or via analog signals (0-10 V and potential free contacts) for other AHU controllers than FläktGroup. MAIN CONTROL COMPONENTS A separate controller is installed in the service section of the ReCooler HP and includes the following components: Main electrical panel disconnect switch Miniature circuit breaker Control unit with display The controller is separate from the FläktGroup AHU controller and is a microprocessor-based, programmable electronic version. MINIATURE CIRCUIT BREAKER Automatically operated electrical switch designed to protect an electrical circuit from damage caused overload or short circuit. Warning! The circuit breaker does NOT isolate the power supply to the entire cooling unit! Therefore always open and lock the main switch before you begin any work on the cooling unit. MAIN ELECTRICAL PANEL DISCONNECT SWITCH The disconnect switch is used to turn on/off power to the Re- Cooler heat pump unit. If the ReCooler HP is included in an eq Prime with FläktGroup controller the disconnect switch is combined for ReCooler HP and AHU. For eq Master with FläktGroup controller it is different switches for AHU part and ReCooler HP. Always lock and tag the unit prior to performing any maintenance or servicing work. MINIMUM DESIGN AIR FLOW RATE IN ACON eq size Min. Design airflow m 3 /s m 3 /h

11 ReCooler HP - Installation and commissioning 11 MINIMUM AIR FLOW RATE AT TURN-DOWN eq size Min. Design airflow m 3 /s m 3 /h Min. air flows through the ReCooler HP are valid with: 1. Balanced air flows (supply/exhaust), large variation are not allowed. Exhaust air flow must be higher, equal or max 20 % lower than supply air flow. 2. AHU fans operation limits (min. airflow and pressure). 3. Correction of defrost factor (CAREL controller) under winter conditions for EQKR size 041, 050 and 072, with CAREL software up to version 5.0. the speed of the compressor and then reversing the circuit followed by a return to the required compressor speed according to the temperature control signal. If there is a reheater in the AHU, it can be activated during the defrost operation. Defrost operation can be detected on terminals C1/NO1 if that has been selected in the Carel HMI by means of the set up wizard. Those terminals can alternatively be used as an alarm signal for the rotor. RETURN AIR SECTION The eq air handling unit can be equipped with both a ReCooler HP and a return air section for night heating. The AHU must in this case be equpped with a separate reheater, since the ReCooler HP shall be out of operation when the return air damper is opened. It is not possible to use ReCooler HP with mixing section where extract and outdoor air is mixed. The ReCooler HP controller includes a protection that prevents start of the compressor if the air flow of the eq AHU is below the minimum stated above. OPERATING MODE Two operating modes are available: Economy and Comfort mode. Economy mode In economy mode we prioritise energy recovery so the rotor is operating at full speed while the compressor is operating in onoff mode when there is a small re-heating demand. This means there will be small temperature variations in the supply air. Comfort mode In comfort mode we prioritise a constant supply air temperature so when the re-heating demand is small we reduce the speed of the rotor so that the compressor can run continuously. DEFROSTING The ReCooler HP is equipped with a defrost system that uses the pressure drop over the coils to decide if there is frost in the extract coil. On detection of frost in the exhaust coil the circuit is reversed to heat the extract coil. The rotor speed is reduced and the electric heater in the exhaust side is started if present in the unit. Defrosting will run for a minimum time or as long as it takes to reach a set condensing temperature. When those conditions are met the unit reverts to normal operation by first reducing ALARM All the alarms are indicated on the display of the Carel control unit. A global alarm is available on the terminal block from a potential-free relay (normally open) (terminals 900, 901). Most alarms are automatically reset 5 times within a 24 hour period. If additional alarms are generated then a manual reset will be necessary. To restart the unit in this case press the alarm button for 5 seconds. The controller in the unit checks that the correct mass of refrigerant is present in the circuit. A warning is issued from the controller if the refrigerant quantity falls below the minimum limit. Qualified refrigeration personnel can check the circuit operation by means of the data given in the controller HMI. See page 16 of document for complete alarm list.

12 12 ReCooler HP - Installation and commissioning HMI DISPLAY PGD1 INSTRUCTIONS The ENTER button is used to scroll through the list of available languages and the ESC button is used to confirm the users selection. Alarm button Button for service mode Esc Button Button up Enter button Button down The home screen shows the following information: Circuit that the display is connected to Operating mode (Cooling/Heating) Status: Standby Start phase Unit running Start delay Defrost Alarm & etc. The current example shows: Compressor speed demand sent from external control system: 75 % Current rotation speed of the compressor: 35 % Current speed of Rotary Heat Exchanger: 100 % FläktGroup This screen displays information related to the current status (operating mode) of the coils (condensing + / evaporating ), position of the expansion valves and whether the AHU is configured with supply air in the upper or lower deck. Supply Temperature and pressure values.

13 ReCooler HP - Installation and commissioning 13 Super-heat and sub-cooling. Access to additional basic configuration settings. Used to select the heat pump control method (Analog/Modbus). Analog - Third party. Modbus - FläktGroup controls. Activating quick start will bypass the normal compressor start up sequence. Valid for two and three circuits only.

14 14 ReCooler HP - Installation and commissioning 1. At start-up, the rotating heat exchanger speed will be reduced when the demand compressor speed is less than the actual compressor speed. 2. With low demand and the compressor at its lowest speed, the rotating heat exchanger will reduce speed. When the unit is running in economy mode, the rotating heat exchanger is always first in the heating sequence and only begins to decelerate when the compressor is off. Software information of the system.

15 ReCooler HP - Installation and commissioning 15 ALARM LOG The alarm button is lit. At the bottom of the menubar information regarding which circuit that is alerting is shown. Switch to the current circuit by pressing the Enter key. FläktGroup Circuit 01 Off by low flow Press the alarm button to see the active alarm for the selected ciruit. Follow instructions on the screen to get to the Alarm log/data logger. FläktGroup Circuit 01 Mode Cooling Control signal 000% Off by low flow % The log shows information from the time when the alarm was activated. Alarm reset is possible only when the fault is remedied, most alarms have automatic reset up to 5 times but can be reset by pressing the alarm button for 5 sec. Some alarms require a reboot. If you contact Helpdesk at FläktGroup for support on your ReCooler HP please take pictures of the Data logger of your last 10 alarms and attach them to the helpdesk request. FläktGroup Circuit 01 Data logger E08 AL12 12:33 07/07/15 BMS offline Low suction press 0: No alarm Hi.Press 14.9 Comp031% Lo.press DiscTemp 081 c SSH 00.1

16 16 ReCooler HP - Installation and commissioning 7. MAINTENANCE COMPULSORY DECLARATION AND RECURRING INSPECTION Compulsory declaration The function of this product relies on the refrigerant R410A; which is a fluorinated greenhouse gas. The European Union is committed to reducing emissions of such gases. Ensure that you are fully aware of your local regulations and that they are complied with. R410A has an equivalent mass of CO 2 of 2088 according to F-GAS Regulation 517/2014. Global Warming Potential, GWP is According to the F-Gas Regulation, ReCooler HP must be leak tested once every 12 months. This is the responsibility of the end user/operator. With a leakage detection system the frequency of leak checks is 24 months. Production of the ReCooler HP is carried out in accordance with Commission Regulation 517/2014. The ReCooler HP is an equipment in which all fluorinated greenhouse gas containing parts are made tight by welding, brazing or a similar permanent connection including capped valves and capped service ports that allow proper repair or disposal. Any service or repair work must be carried out by an authorised person with the necessary training and certification in accordance with the F-Gas Regulation and this instruction. ReCooler HP size Important! Always read the safety directions on page 2 prior to beginning any work! Leak testing minimum frequency Without Refrigerant charge detector With Refrigerant charge detector 8 1 test/12 months 1 test/24 months 11 1 test/12 months 1 test/24 months 18 1 test/12 months 1 test/24 months 23 1 test/12 months 1 test/24 months 32 1 test/12 months 1 test/24 months 41 1 test/12 months 1 test/24 months 50 1 test/12 months 1 test/24 months 72 1 test/12 months 1 test/24 months DUTY OF NOTIFICATION AND IN-SERVICE INSPECTION Duty of notification If the installation contains fluorinated greenhouse gases in quantities of 14 tonnes of CO 2 equivalent or more the supervisory authorities, generally the environmental health department, must be informed. This information must be provided well in advance of installation. For more information see local refrigeration legislation. INSPECTION/MAINTENANCE Regular inspection and maintenace in accordance with legislation in force must be carried out by a certified refrigeration technician. INSPECTION To be carried out by the owner/user once a week. Check the following: 1. Indicated alarms 2. Abnormal noise/vibrations 3. Leakage 4. Corrosion, wear and tear 5. The interior of the unit, light fittings MAINTENANCE Check the following: 1. Electrical equipment 2. Coils, drip tray and the drainage system 3. Air filter RECURRING CHECKS Must only be carried out by a certified refrigeration technician. Inspect the system at least once every 12 months and maintain a journal. This is the responsibility of the end user/operator. With a leakage detection system the frequency of leak checks is 24 months. Check the following wherever applicable: 1. Piping and refrigerant components 2. Inspection to detect refrigerant leakage 3. Check for abnormal vibrations 4. Check to detect possible corrosion 5. Whether filling with additional refrigerant is needed 6. Check to detect possible oil leakage 7. Safety equipment 8. Connection joints/seals

17 ReCooler HP - Installation and commissioning 17 DISMANTLING When dismantling (scrapping) this type of unit, the refrigerant and compressor oil must unconditionally be collected and contained for destruction/recycling. SPARE PARTS Spare parts can be bought via local refrigeration suppliers. Contact your local FläktGroup office for information regarding components that need to be replaced. 8. DESCRIPTION OF THE FUNCTIONS 2: GT6 GT7 18 1:1-3 10:1-3 6:1-3 17:1-3 12:1-3 13:1-3 16:1-3 VVX 14:1-3 Unit sizes have 1 circuit Unit sizes have 2 circuits Unit size 072 have 3 circuits 3:1-3 S 4:1-3 18:1-3 11:1-3 15:1-3 5:1-3 9:1-3 7:1-3 Room Cooling mode Heating mode Pos Component 1:1-3 Supply air coil 2:1-3 Exhaust air coil 3:1-3 4 way valve 4:1-3 Compressor 5:1-3 Liquid separator 6:1-3 Reciever 7:1-3 Filter dryer 9:1-3 EEV 2 cooling 10:1-3 EEV 1 heating 11:1-3 High pressure sensor 12:1-3 Low pressure sensor 13:1-3 Suction gas sensor 14:1-3 Liquid temperature sensor 15:1-3 Discharge gas sensor 16:1-3 Low pressure service connector 17:1-3 High pressure service connector 18:1-3 High pressure service connector 18 Defrosting pressure sensor GP8 19 Rotor 20 Electrical heater GT6 Automatic thermal protection GT7 Manual thermal protection

18 18 ReCooler HP - Installation and commissioning 9. ALARM LIST Alarm code Alarm displayed Alarm description/cause for alarm Possible solutions AL01 Clock board fault or not connected Check connections. Contact FG CSS control department. AL02 Extended memory error Contact FG CSS control department. AL03 High pressure alarm The high pressure sensor has detected max. working pressure of 39 bar and the controller stops the compressor. At 38 bar compressor start to ramp down. Cause: Extract air flow is too low over condensing coil; overcharged system. AL04 Low pressure alarm The low pressure sensor has detected value under min. allowed pressure of 1 bar. Cause: Start up without Rotor running; At start up with low ambient temperature/condensing temperature, several start attempts could be needed; low air flow over evaporator; expansion valve is in the wrong position; leakage in the system or Insufficient refrigerant charge. Check: 1. Air flow on extract side. 2. Min airflow rate over condensing coil according FG. 3. Filter or coil (they need to be clean). 4. Refrigerant charge/subcooling. Check: 1. Rotor must be running before compressor is started. 2. Min airflow rate over evaporating coil according FG. 3. Refrigerant charge/superheat. 4. Search for possible leakage of the system. 5. Allow the system to make several attempts to start. AL05 Frequency drive offline Check: 1. Cabel connection and 3-phase fuse AL06 Power + alarms 0 - No alarm Overcurrent The drive has detected a current supplied that is too high due to: too high load or sudden large load increase, wrong parameter values or an inadequate motor. 2 - Motor overload The current supplied has exceeded the rated current over the maximum time accepted. 3 - Overvoltage The DC voltage of the intermediate circuit has exceeded the limits envisioned due to: deceleration that is too high or high over-voltage peaks on the power supply network. 4 - Undervoltage The DC voltage of the intermediate circuit is below the limits envisioned due to: insufficient power supply voltage or a fault inside the drive. 5 - Drive overtemperature The temperature inside the drive has exceeded the maximum level allowed. 6 - Drive undertemperature The temperature inside the drive is less than the minimum level allowed. 7 - overcurrent HW The drive has detected an instataneous current supplied that is too high due to: sudden strong load increase, motor cables short circuit, wrong parameter values or inadequate motor. 8 - Motor overtemperature The temperature detected by the PTC thermistor corresponds to a resistance > 2600 ohm. Check the load, the dimension of the motor and the cables. Check power supply voltage In the event of temporary cut-off of the power supply, reset the alarm and restart the drive. Check the power supply voltage. Check the 3-phase fuse and power supply voltage Check that the flow of cooling air is correct. Check filter and fans in cabinet. Check thermostat for fan. Check that there is not dust in the heat sink. Check the enviroment temperature. Ensure that the switching frequency is not too high with respect to the enviroment temperature and the motor load. Check the enviroment temperature Check the load, the dimension of the motor and the cables. Reduce the motor load. Check motor cooling. 9 - IGBT module error Internal fault Call FG CSS for assistance CPU error Loss of data in memory Call FG CSS for assistance 11 - Parameter default Execution of reset parameter default command. -

19 ReCooler HP - Installation and commissioning 19 Continued Alarm list 12 - DC-bus ripple Input power supply phase loss Check the input power supply phases to the drive Data communication fault Data reception failure Check the serial connection. Switch the drive off and back on again Drive thermistor fault Internal fault Restart the unit. Contact FG CSS control department for assistance 15 - Autotuning fault Wrong parameter values Check the parameter values. Restart the unit Drive disabled (STO input open or not powered) Alarm input on Power+ Frequency drive is activated. Check the wiring. Check alarm input Motor phase fault Motor cable disconnected Check the connections of the motor cable. Contact FG CSS control department for assistance 18 - Internal fan fault Restart the unit. Contact FG CSS control department for assistance 19 - Speed fault Wrong parameter values or unsuited load. High condensing temperature and very low speed PFC module error (only for PSD00**2*0) PFC overcurrent; C1, C2 terminals shortcircuit not used PFC undervoltage (only for PSD00**2*0) Insufficient power supply voltage Switch the drive off and back on again and check the parameters are properly set. Check the motor load. Increase minimum speed.default min. speed is 25 rps.change min. speed to 40 rps. Make a factory reset. Contact FG CSS control department for assistance. Check input power supply 23 - STO detection error Internal fault Restart the unit. Contact FG CSS control department for assistance 24 - STO detection error Internal fault Restart the unit. Contact FG CSS control department for assistance AL07 N/A N/A AL08 Low superheat Suction gas temperature sensor has detected superheat temperature (suction pipe temp evaporating temperature) under minimum value. Cause: Expansion valve in wrong position or sensors are not correct. AL09 AL10 Low evaporation temperature (LOP) High evaporation temperature (MOP) Not used AL11 Low suction gas temperature Not used AL12 AL13 Attempt to start compressor failed Compressor outside envelop limits Can be activated together with AL14. Compressor has not increased pressure difference of 0.2 bar in 60s compared with the conditions before start. Automatic restart 5 times. After that a manual reset is needed. Condensing or evaporating temperatures out of allowed area. AL14 Low differential pressure Pressure difference (DELTA P) between evaporating and condensing pressure is too low. Pressure ratio must be min. 1.8 according compressor envelope. If pressure ratio is under 1.8 in 120s than alarm is coming. AL15 High discharge temperature Compressor is overheated. Too high condensing temperature and too low evaporating temperature. Too high suction gas superheat. Frosted evaporater. Check: 1. Turn main switch off and on again. 2. Check suction gas sensor and low pressure sensor. Manual reset. Check compressor electric wires. Increase in M06/Co08 pressure variation monitoring delay from 15 to 60s. Check: 1. Air flow on supply/exhaust side 2. Too low outdoor temperature Check: 1. If expansion valves are connected correctly 2. ROTOR is not working Check: 1. Air flow on supply/exhaust side 2. Low outdoor temperature (heating) 3. Check defrosting 4. If discharge temperature is high and low/high pressure normal, contact FG CSS

20 20 ReCooler HP - Installation and commissioning Continued Alarm list AL16 AL17 AL18 AL19 AL20 AL21 Rotor reference analog input fault (U1) connected with analog signal (0-10V) Defrost temperature probe fault (U2) Suction temperature probe fault (U3) Discharge temperature probe fault (U4) Discharge pressure probe fault (U5) Suction pressure probe fault (U6) Alarm is coming from CAREL controler because of inter-ruption,short circuiting and if voltage is higher than 12V. "Check: 1. If polarity is connected right 2. Check voltage 3. Input impedance is 20k ohm 4. With 10V current is 0,5mA (theoretical) Check the defrost temperature sensor/ sensor wiring Check the suction gas temperature sensor/sensor wiring Check the discharge temperature sensor/sensor wiring Check the high pressure sensor/sensor wiring Check the low pressure sensor/sensor wiring AL22 Electrical heater alarm Overheat protection is activated. Reset overheat protection AL23 AL24 AL25 AL26 Maximum defrost duration exceeded (defrost terminated) Compressor speed reference analog input fault (U7) connected with analog signal (0-10V) Inverter model not compratible. Only power+ allowed Compressor unable to start due to excessive delta pressure Too much ice on evaporater. In older softwares before 4.9 the 4-way valve is not activated and this alarm is coming. Alarm is coming from CAREL controler because of interruption,short circuiting and if voltage is higher than 12V. Max allowed delta P for start of compressor is 9bar. If this can't be reached in 300s alarm AL26 is activated. Expansion valve is 32 % open to equalize pressure. Before AL26 is coming the following information is shown on the display: Pressure diff. limit. (in heating mode only) Make manual defrost. Update software to 5.0. Check timer/temperature settings under M05/Df05/08/09/10. Make a factory reset if anything has been changed. "Check: 1. If polarity is connected right 2. Check voltage 3. Input impedance is 20k ohm 4. With 10V current is 0,5mA (theoretical) Check inverter model. Factory reset. Make right selection for all parameters in Wizard. Check that ROTOR is runing 100 %. Activate cooling mode and back again to heating mode.(directly in CAREL or from external control). M03/Ma02 (Switch compressor mode). For help please contact FG CSS. AL27 Rotor alarm Alarm present on the rotating heat exchanger. Check if ROTOR is runing. Check connections according installation manual. When upgrading to software 5.0 please change to NC in Parameters, M04/P05, 1. Rotor alarm. Contact FG CSS. AL28 N/A N/A AL29 AL30 AL31 Communication with slave unit 1 is lost (J14 plan) Communication with slave unit 2 is lost (J14 plan) Communication with the master unit is lost (J14 plan) Circuit number 2 is offline. Circuit number 3 is offline. Slave unit 1 (Circuit2) and/or slave unit 2 (Circuit 3) unable to communicate with the master unit (Circuit 1). Check connections between master and slave Check connections between master and slave Check the wiring and termination between the plan terminals (J14 plan). Check that the master unit is not powered OFF. AL32 Liquid temperature sensor Check the liquid temperature sensor/ sensor wiring AL33 Low refrigerant charge Warning level: valve 98%, superheat > 12, subcooling <3 at the same time. Alarm level: valve 100%, superheat > 15, subcooling <2 at the same time. AL34 AL35 Pressure sensor across the supply air coil Pressure sensor across the exhaust air coil Check: 1. Leakage 2. Charge refrigerant according to label Check the pressure sensor across the supply air coil/sensor wiring Check the pressure sensor across the exhaust air coil/sensor wiring

21 ReCooler HP - Installation and commissioning 21 Continued Alarm list AL36 Loss of communication (Modbus J11 BMS2) Control unit Circuit 1 is configured to communicate with external control unit via modbus but is unable to establish communication. Confirm that the heat pump is to be controlled via modbus signal and if not select analog control. Check the wiring and termination between the modbus terminal of the external control signal and the modbus terminal of the heatpump control unit (Circuit 1). AL37 Gas detector sensor No power supply to gas detector sensor or sensor is faulty. Check power supply. Replace gas detector AL38 Gas detector alarm Gas detector is activated. Possible refrigerant leakage, make a leakage check. AL39 Gas detector off line No Modbus connection to gas detector. Check Modbusconnection to Gas detector. AL40 Gas detector service Service/test/calibration is needed for Gas detector. Contact FG CSS control department or Refrigeration service company. AL41 Low airflow supply Difference pressure sensor GP8 has indicated low supply air flow. AL42 Low airflow exhaust Difference pressure sensor GP8 has indicated low exhaust air flow. Check supply air flow, fan, filter and damper. Check exhaust air flow, fan, filter and damper.

22 22 ReCooler HP - Installation and commissioning 10. eq WITH OTHER AHU CONTROLLER THAN FLÄKTGROUP 0-10V CONTROL OF RECOOLER HP WITH THIRD PARTY INSTALLED CONTROLS The ReCooler HP should be interlocked across the extract and supply air fans. It is important that the compressors stop if the air fans stop. Otherwise the ReCooler HP will stop in safety mode when this occurs. CONTROL SEQUENCE The ReCooler HP must have both fans and the rotary heat exchanger running to be able to work. To start the compressor for either heating or cooling, the ReCooler HP must be enabled. The Unit enable (terminals 904,905) must be interlocked with an airflow switch or fans. Heating or cooling is selected by opening or closing terminals 902,903. Open = heating Compressor operation is controlled with a 0-10V signal on terminals 908, 909. The rotary heat exchanger is also controlled by a 0-10V signal (terminals 906, 907). The rotor will run with the enable either open or closed. Heating and cooling is controlled in sequence with the rotor rotor first then compressor operation. STARTING THE RECOOLER HP Start the exhaust fan, then the rotary heat exchanger and than the supply fan. To enable heating mode, open terminals 902, 903. When heating is required and with the unit enable terminal closed the ReCooler HP is started with a constant control signal of 2.5V for 1 minute followed by a signal between 1V and 10V for 6-9 minutes. The compressor starts with 40 % of maximum speed and after 3 minutes goes to normal operation according to the 0-10V signal. This start sequence can mean that the supply air temperature rises above the set-point. The ReCooler HP will not react to the control signal during this time. To enable cooling close terminals 902, 903. When cooling is required and with the unit enable terminal closed the ReCooler HP is started with a constant control signal of 2.5V for 1 minute followed by a signal between 1V and 10V for 6-9 minutes. The compressor starts with 40 % of maximum speed and after 3 minutes goes to normal operation according to the 0-10V signal. This start sequence can mean that the supply air temperature fall below the set-point. The ReCooler HP will not react to the control signal during this time. The above start sequence is designed to prevent compressor cycling on/off. After a stop the compressor must be held off for a period of minimum 5 minutes before being allowed to restart in order to protect the compressor by limiting the number of starts to 4-5 per hour. When switching from heating to cooling or vice versa the signal should be reduced to 0V and held at that for at least 15 minutes before switching on the signal the heating/cooling mode terminals 902, 903.

23 ReCooler HP - Installation and commissioning 23 WIRING Power Supply 3 Phase Neutral & Earth, 5 Wire, 400v, 50Hz (wired directly to the isolator) Control Signals Common Alarm L1 L2 L3 N PE C NO U/T1 V/T2 W/T3 N PE Alarm / Status Modbus -J11 +J11 GNDJ Heating / Cooling Selection Open=Heating Closed=Cooling Unit Enable (Airflow Proven) Open=Disabled Closed=Enabled VFC VFC VFC VFC Rotary Exchanger Speed Control 0-10V DC COM/M Compressor(s) Capacity Control 0-10V DC COM/M Rotary Exchanger Alarm / Defrost Indication * C NO C1 NO1 Compressor running indication C NO C8 NO8 * Configured in the software, Default is Rotary Exchanger Alarm ** Not on the Dln-Rall (Terminals), direct to the controller pcb sockets

24 24 ReCooler HP - Installation and commissioning MODBUS REGISTER FOR ALARMS AND OPERATION STATUS WHEN USING OTHER AHU CONTROLLER THAN FLÄKTGROUP Carel modbus Criticality (Recommendation) Description 4x0107 ReCooler HP operation status 0 = Stop 1 = Running Full 2 = Defrost 3 = In Alarm 4 = Heating 5 = Cooling 6 = Mandatory OFF 7 = Stand By 8 = Start Up 3x5043 ReCooler HP circuit 1 operation status 9 = Alarm 13 = Alarm unit 1 3x5059 ReCooler HP circuit 2 operation status 9 = Alarm 14 = Alarm unit 2 3x5066 ReCooler HP circuit 3 operation status 9 = Alarm 15 = Alarm unit 3 4x0109 = 1 High (Critical) ReCooler HP Alarm present on the rotor 4x0109 = 2 Low (Info) ReCooler HP Compressor failure to start alarm 4x0109 = 3 Low (Info) ReCooler HP Compressor unable to start alarm (Diff. pressure) 4x0109 = 4 Low (Info) ReCooler HP Maximum discharge pressure alarm 4x0109 = 5 Low (Info) ReCooler HP VFD alarm 4x0109 = 6 Low (Info) ReCooler HP VFD offline alarm 4x0109 = 7 Low (Info) ReCooler HP Minimum suction pressure alarm 4x0109 = 8 Low (Info) ReCooler HP EEV error alarm 4x0109 = 9 Low (Info) ReCooler HP Discharge gas temperature alarm 4x0109 = 10 Low (Info) ReCooler HP Discharge gas pressure alarm (Probe) 4x0109 = 11 Low (Info) ReCooler HP Suction pressure alarm (Probe) 4x0109 = 12 Low (Info) ReCooler HP Low super heat alarm 4x0109 = 13 Low (Info) ReCooler HP Maximum discharge pressure alarm (Envelope zone) 4x0109 = 14 Low (Info) ReCooler HP Minimum discharge pressure alarm (Envelope zone) 4x0109 = 15 Low (Info) ReCooler HP Other alarms 3x5043 = 9 or Low (Info) ReCooler HP circuit 1 alarm 3x5043 = 13 3x5059 = 9 or Low (Info) ReCooler HP circuit 2 alarm 3x5059 = 14 3x5066 = 9 or 3x5066 = 15 Low (Info) ReCooler HP circuit 3 alarm High: Recommendation to close the AHU Low: Given as information and less critical