COMBI COOLER EQKC INSTALLATION AND MAINTENANCE INSTRUCTIONS SAFETY INSTRUCTIONS. Warning! IMPORTANT INFORMATION! LIFTING. Warning!

Transcription

1 OMBI OOLER EQK INSTALLATION AND MAINTENANE INSTRUTIONS SAFETY INSTRUTIONS Warning! The unit must be commissioned by authorised Fläktroup personnel. IMPORTANT INFORMATION! Study the unit s installation and maintenance instructions carefully prior to starting/operating/servicing/maintaining/ dismantling it. Keep these instructions for future use. All service and maintenance must be carried out by experts. The service/maintenance of cooling and water systems may only be carried out by authorised companies using certified personnel in accordance with European Union Regulation 0/008 and the necessary protective equipment. The necessary protective equipment should include safety goggles and gloves. Automatic start! Open and lock the cooling unit s main circuit breaker before starting any work. Do NOT tread on the unit. Use only original spare parts. Disregarding any of the above points can lead to a serious safety risk and the withdrawal of the guarantee/ product liability. LIFTIN Warning! The unit s centre of gravity is not in the centre of the unit. Because of its design, the centre of gravity is offset towards the inspection side. This must be taken into account when lifting the unit in any way. The unit should first be lifted slightly, and then checked so that it does not tilt or appear unstable before being lifted higher. Fläktroup D_89B 0800_R0 We reserve the right to make changes without prior notice

2 Installation and maintenance instructions DUTY OF NOTIFIATION AND IN-SERVIE INSPETION Duty of notification If the amount of refrigerant in a unit exceeds 0 kg the supervisory authorities, generally the environmental health department, must be informed. This information must be provided well in advance of installation. More information about this is contained in local refrigerant legislation. Leak tracing during installation and in-service inspection A leakage inspection must be carried out during installation if the unit contains more than kg of refrigerant (see local restrictions). If the unit contains between kg and 0 kg of refrigerant, the unit must be inspected for leakage at least every twelve months. This conforms to the EU regulation on fluorinated greenhouse gases 84/006. LIFTIN AND TRANSPORT The unit can be lifted by its lifting eyes if its weight does not exceed,050 kg. If the unit weighs more than,050 kg, it must be lifted by a forklift truck from below using the specified holes. Lifting the unit other than by using the specified holes can cause the unit to overturn due to the offset centre of gravity. WEIHT Standard isolation Min. weight Max. weight EQK EQK EQK EQK EQK Heavy isolation Min. weight Max. weight EQK EQK EQK EQK EQK MAX. 050 kg L L Important! The unit s centre of gravity is not in the centre of the unit. Always take this into account when lifting the unit. 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 and brine system. The base frame must not be removed. Requirements related to siting The unit must be installed in such a way that allows service in accordance with this service manual. Fläktroup D_89B 0800_R0 We reserve the right to make changes without prior notice

3 Installation and maintenance instructions ALARMS AND WARNINS The ombi ooler can be connected to an external control system in several ways. The two most common are shown below. Option describes how the integrated control unit can be maximised. This option has a number of advantages over option. This is because the system is controlled optimally, based on the all the expertise gained from product development. Option describes how much of this functionality is transferred to an external control system. When this type of connection is used the external control system must deal with some functions that are crucial to the system s performance. BMS/Unit ooler alarm Room condensation indication Unit interlocked by P5 4 V A nd 0-0 V D External H5 Room condensation sensor T5 hilled beam water temperature sensor SV5 hilled beam water valve actuator Power supply x 400 A 0 Q Q 0 Y 0 Y L L L N PE L L L N PE 0 Y ombi ooler Summation alarm ondensation alarm P5 Operation SV Supply air coil Valve actuator Interlocked by the outdoor temperature Interlocked by the extract air fan To be connected to the main circuit breaker 0-0 V D BMS/Unit 4 V A nd D 4 V A nd 0-0 V D 4 V A nd Min value 0 ooler alarm Unit interlocked by P5 4 V A nd 0-0 V D Power supply x 400 A 4 min L L L N PE Q Q 0 Y 0 Y L L L N PE External H5 Room condensation sensor T5 hilled beam water temperature sensor SV5 hilled beam water valve actuator ombi ooler Summation alarm Signal for slow valve closure P5 Operation SV Supply air coil Valve actuator Interlocked by the outdoor temperatur Interlocked by the extract air fan Room condensation indication To be connected to the main circuit breaker Option. Option. Fläktroup D_89B 0800_R0 We reserve the right to make changes without prior notice

4 4 INSTALLATION AT HIH ALTITUDES Installation and maintenance instructions ontrol system eq ontrol system ombi ooler START NO 64 6 START ALARM 0-0 V 4 VA O AR O P/4 Z O A YR YH Y O Alt Interlocking Summation Alarm P5 Operation Supply air coil actuator eq Styrlåda ontrol box eq Valve Ventilställdon actuator heating värme ontrol signal heating HEATIN (M) (Y) (0) () M Y 0 Fläktroup D_89B 0800_R0 We reserve the right to make changes without prior notice

5 Installation and maintenance instructions 5 FROST PROTETION SENSORS ELETRIAL DATA, FUSE PROTETION AND AMOUNT OF REFRIERANT OMPONENT DESRIPTION ontrol unit (R) The control unit is located in the control cabinet. See description on Page 9. ontrol circuit fuse Important! The setting of the frost protection sensors must not be altered. This could lead to frost bursting the exchangers. Burst pipes due to frost will result in major leakage of fluid and risk of compressor damage. The control circuit fuse does NOT cut the power to the entire cooling unit. When performing work on the cooling unit, always open and lock the main circuit breaker. Unit size Power model Min. fuse A Refrigerant kg ircuit ircuit This product contains fluorinated greenhouse gas, R4A, with a WP-factor of 40. Refrigerant quantity: 5,,8 kg, corresponding to 7,4,6 tonnes of O equivalent. hoice of cable The choice of cable depends on the method of installation. The cable must be dimensioned by an authorised electrician. Reset the automatic fuse by pulling the green control upwards. Main circuit breaker Fuse protection The level of fuse protection must be decided by an authorised electrician based on the currents indicated in the table. The brine circuit The brine circuit must be filled with deacidified water. Otherwise there is a risk of standing air in the system that can lead to impaired performance. Important! There must be no additives in the water. The main circuit breaker is used to switch the cooling unit off and on. When performing work on the cooling unit, always open and lock the main circuit breaker. ertain terminal blocks can be live even when the circuit breaker is switched off, such as the terminal blocks for outgoing summation alarms. Fläktroup D_89B 0800_R0 We reserve the right to make changes without prior notice

6 6 Installation and maintenance instructions Aeration All valves must be opened / closed several times during aeration for all trapped air to escape. Since the subsystems are connected in common water system will not be any part of the work unless the aeration is performed correctly. Important! Aeration must be made of all subsystems. Brine connections general onnected pipes are to have as few bends and variations in size as possible. If the pressure drop is too high, the pump will not provide the design flow, leading to insufficient heat transfer in the heat exchangers. Ensure that the pipe system is flushed and drained before connection to the cooling unit. Automatic or manual bleed valves Automatic or manual bleed valves must be installed in enough places to bleed the system. Drain valve The drain valve must be installed at the lowest point in order to drain the system. Filter (max. gauge = 500 μm) It is essential that the water is free of impurities. If not the heat transfer in the heat exchangers will be reduced as they get dirty. In the worst case the exchanger can be permanently damaged. The filter should be mounted on the water circuit s inlet to the cooling unit, in a position where it can be easily flushed or replaced. For simplicity s sake there should be shut-off valves on both sides of the filter. Brine The cooling unit is designed for pure water. In other words, there should be no additives in the water. Expansion tank The expansion tank should be installed in a suitable location. ADJUSTIN THE FLOW SWITH The function of the flow switch is to stop the compressors if the brine flow drops below a critical level or stops completely. Because every cooling unit undergoes pre-delivery testing, the flow switch is factory set. Testing is carried out at the flow set out in table. However, this adjustment must still be checked due to possible differences in flow measurement methods. Leakage testing A leak tightness test must be carried out before insulating the pipes. Expansion forces on the connections All connections for the brine and the external heating system outputs on the cooling unit must be made in such a way that there are no forces acting on them caused by the thermal expansion of the pipes. Leakage testing A leak tightness test must be carried out before insulating the pipes. Insulating the pipes All pipes must be insulated to prevent condensation. The insulation must be diffusion tight. It must be possible to access bleed valves and drain valves following insulation. Actual flow: reen LEDs Alarm limit: Orange LED Triggered alarm: Red LED Step alibrate the flow switch. heck that the brine flow is the intended operating flow.. Press the right button (black arrow) for five seconds.. The flow switch is now calibrated. Step Setting the alarm limit Set the alarm limit (orange LED) by pressing the black or white arrow. The alarm limit is recommended to be set about - LEDs below the top green LED. Fläktroup D_89B 0800_R0 We reserve the right to make changes without prior notice

7 Installation and maintenance instructions 7 FOLLOWIN A FLOW ALARM heck why the alarm was generated. Possible causes: Dirt in the system. Incorrectly set flow switch. The brine pump is defective or incorrectly set. FROST PROTETION A frost protection sensor must be installed in the supply air coil to prevent it freezing. UNIT SPEIFI FLOW Table eq size Power model Brine flow l/s Warning! Adjustment of flow. The right flow through the evaporators has to be set in accordance with table. The safety and function of the cooling unit are at risk if a flow other than the specified in table is used. THE OIL IRUIT Table eq size Output variant Supply coil Min. flow Warning! Adjustment of flow. You will find the flow in the unit (summer case) or current sellers. FLOW THROUH THE SUPPLY AIR OIL Max. flow The flow through the supply air coil has to be adjusted to obtain the correct power distribution between the supply air and the chilled beam circuit. The flow is both adjusted and measured with the STAD valve located inside the ombi ooler. The right flow over the supply air coil is available in the unit documentation. The technical sales support division at Fläktroup has to be contacted if the unit documentation is not supplied at delivery. It s summer case that the flow is adjusted for. Therefore, valve SV shall take the entire flow from the cooling circuits of primary flow, ie the connection that comes from above. Fläktroup D_89B 0800_R0 We reserve the right to make changes without prior notice

8 8 Installation and maintenance instructions WATER-OOLED ONDENSER The water-cooled condenser is activated by an automatic water regulating valve. The water regulating valve is factory set and should not be adjusted. Incorrect adjustment can result in high water consumption. ONNETIN THE WATER-FILLED ONDENSER If there is a water-cooled condenser, tap water at a minimum 0.5 and maximum 0 bar pressure must be connected. Tap water is to be connected using a suitable union. Outgoing pipes are 5 mm copper pipe. Follow the arrows carefully. Water leaving the water-filled condenser can be connected to an accumulator tank so as to recover the heat. In cooling units with a water-cooled condenser the tap water inlet can not be closed. DRAINAE FROM A WATER-FILLED ONDENSER When the water-cooled condenser is in use, it must be drained to an outflow. If this does not take place, there is a risk of water damage. Drainage takes place through the copper pipe on the front of the cooling unit beneath the inspection hatch. The white plastic pipe is for condensate runoff from the supply air coil and should be connected to a water trap. INSTALLATION AND OMMISSIONIN hecklist Important! Always study the safety instructions on Page prior to carrying out any work. The unit must not be commissioned before its installation has been inspected in accordance with the following list. BEFORE STARTUP, HEK THE FOLLOWIN: eneral Transport damage, installation site (good lighting, level surface etc.) ondensation drain Oil level in compressors Runoff from the water-filled condenser Refrigerant circuit Leakage of refrigerant, leakage of compressor oil rankcase heater in operation Runoff from the supply air coil off from the supply coil Runoff from the water-filled condenser off from the water-filled condenser Electrical connection and control checking for loose cables Phase sequence and post-tightening power connections Post-tightening all wiring including those for control signals Start signal from the air handling unit ooling recovery not activated in the main unit Valve governing the water temperature to the chilled beam circuit connected Temperature sensors on the chilled beam circuit connected Brine brine circuit leakage Is the specific flow for the unit size adjusted (see page 7) Is the right flow for the coil circuit adjusted (see page 7) Has the system been bled Filter installed Pumps for the supply air coil and main circuit working Pump for the chilled beam circuit working heck for the need for an accumulator tank STARTIN THE EUKN OOLIN UNIT The crankcase heaters must have been in operation for at least 4 hours before commissioning:. Set the compressor motor circuit breaker to position 0 (Off).. Set the main circuit breaker in the cooling unit to position (On) and activate the control circuit fuse. The compressors are now heated by the crankcase heater. Fläktroup D_89B 0800_R0 We reserve the right to make changes without prior notice

9 Installation and maintenance instructions 9 OOLIN UNIT Inspecting the sight glasses The unit has two sight glasses, one mounted between the condenser coil and subcooling coil, and the other downstream of the subcooling coil. The purpose of the first sight glass is to check whether gas is entering the subcooler. If this is the case, the subcooler will not operate optimally and will just act as an extension of the condenser coil. It is difficult to avoid a small amount of gas, but large amounts can be an indication that there is too little refrigerant in the system. Because the amount is adjusted at the factory, this means that there is a risk of leakage in the refrigerant circuit. hecking subcooling Subcooling can be checked by measuring the temperature difference between the inlet and outlet of the subcooling coil. Superheating The correct degree of superheating is important for optimum and reliable operation. If superheating is too great, the hot vapour downstream of the compressor will get unnecessarily hot. If superheating is insufficient there is a risk of liquid leaking into the compressor. This can result in compressor damage. ondensation temperature At times the condensation temperature can be quite high, almost 60. This is normal. The system is designed for such temperatures. portant that the compressors stop if the extract air fan stops. The cooling unit is also internally interlocked by a flow switch in the water circuit and the pump for the supply air coil. Because of the location of the condenser coil, the cooling recovery function cannot operate in the unit while the cooling unit is in operation. Overriding the chilled beam circuit valve If the heating load on the chilled beam circuit exceeds the design cooling power, the valve for the outgoing water temperature to the chilled beam circuit will be overridden, so as to prioritize the supply air coil. This is to ensure that the supply air coil can dehumidify air when required. If this function is not used in the integrated control unit, it must be added to the controller that replaces it. apacity regulation The capacity of each circuit is regulated individually. If the pressure is too high, one or both of the compressors will be shut down. This is to maintain as high a cooling power as possible and to prevent a shutdown that would require a manual reset. The compressors are restarted in sequence. Water-cooled condenser A water-cooled condenser can be ordered as an option. If the condenser heat cannot be released to the extract air, the condenser temperature will rise. In that case the watercooled condenser is automatically engaged at 60 to reduce the temperature. Inspection The function of the cooling unit can be tested by checking the temperature difference with the control unit. This check can also be carried out during maintenance in order to check the cleanliness/performance of the heat exchangers in the system. AFTER STARTUP, HEK THE FOLLOWIN: Operating flows Flow to the supply air coil and main circuit correct Information to personnel undertaken FUNTION The compressors are connected in three cooling stages. The outgoing water temperature depends on whether there is a risk of condensation in the chilled beams or not. See Page 9 for a description of the control unit. The air handling unit can be used for both supply air and extract air control. The cooling unit must be interlocked by the extract air fan and main pump (and any outdoor thermostat). It is im- OOLIN UNIT eq size Nominal power Power model with water at 8/ Fläktroup D_89B 0800_R0 We reserve the right to make changes without prior notice

10 0 Installation and maintenance instructions ontrol The cooling unit supplies cold water in the brine circuit to the integrated supply air coil and to the chilled beam circuit. Hot water enters the circuit via the integrated plate heat exchanger. The valve governing the amount of water to the supply air coil and plate heat exchanger is controlled by external control equipment. The valve and valve actuator for the supply air coil are mounted in the cooling unit, and are included in the delivery. The valve and valve actuator for the plate heat exchanger are not included in the delivery, but are available as accessories. The cooling unit governs both the temperature to the main circuit and to the chilled beam circuit. Both of these setpoints change depending on whether the unit is in normal operation or setpoint offset (risk of condensation). Normal operation The compressors are controlled by the return temperature from the chilled beam circuit. If the system is correctly adjusted, the output temperature in the main circuit should be approximately, irrespective of how many compressors are in operation. In normal operation, the setpoint of the water to the chilled beam circuit is 5 as standard. Setpoint offset (risk of condensation) The compressors are controlled by the water temperature downstream of the evaporators. The temperature in the main circuit must be approximately 6, otherwise there is a risk that the adjustment will be incorrect. In setpoint offset operation the setpoint of the water to the chilled beam circuit is 7 as standard. omponents placed in ombi ooler P5 P5 T5 hilled beam circuit Buffer tank SV P5 SV SV5 P5 T5 H5 Outdoor air T5 + Supply air Label Function Delivery P5 irculation pump, supply air coil Included, mounted and connected P5 irculation pump, cold water circuit Not included P5 irculation pump, chilled beam water circuit Not included H5 ondens indicator Included, lose accessory P5 Flow indicator Included, mounted and connected T5 Frost sensor Included when delivered with factory mounted control T5 Temp sensor, cold water circuit Included, mounted and connected T5 Temp sensor, chilled beam water circuit Included, lose accessory SV Heating valve Not included SV ooling valve Included, mounted and connected SV5 hilled beam valve Not included Fläktroup D_89B 0800_R0 We reserve the right to make changes without prior notice

11 Installation and maintenance instructions OPERATION OF THE PL By pressing the button A, the next picture comes up. Returning to picture by pressing button B. To change the values, press button up (+) or button down (-) to get to the actual value. Press OK and then adjust the value with Button Up (+) or button down (-). Press OK to store the value. Return to Figure by pressing button B. SREENS ON THE PL Screen oolwater In 8.0 = Wait (s) 00 =Run Screen Normal running/ ondense sensor= ON oolwater Out 8.0 oolwater Out 8. Screen BeamWater In 5. (--.-)* Valve signal % 085 (---) (Forced closing) Screen 4 Setpoints when Normal running oolwater In 8.0 BeamWater In 5.0 (--.-) The screen displays operational and alarm information (also see the separate description of screen ). Input water temperature (return temp.) For example KM has a 5 min. start delay. (The time is counted down) For example KM is in operation. Displays the applicable setpoint. See screens 4 and 5. Output water temperature from cooling circuit. Output water temperature from cooling circuit. Input water temperature to the chilled beam circuit. ontrol signal to the chilled beam valve 0 00 % = 0 0V. The text is displayed in the event of the forced closure of the chilled beam valve. The setpoints applicable during normal operation, i.e. when the condensation sensor in the room is not generating an alarm (=OFF). Input brine temperature setpoint (return temp.) Input water temperature setpoint to the chilled beam circuit. Screen 5 Setpoints when ondense sensor= ON oolwater In 0.0 BeamWater In 7.0 (--.-) The setpoints applicable when there is a risk of condensation, i.e. when the condensation sensor in the room is generating an alarm (=ON). Input brine temperature setpoint (return temp.) Input water temperature setpoint to the chilled beam circuit. Screen 6 Total run time for each Run Time (h) compressor. For example KM has been in KM Total= operation for 48 hours. For example KM has been in KM Total= 0005 operation for 5 hours. (Step )= 000 KM and KM. Joint operation h. Screen 7 urrent time. an be set if P5 Time:.5 is to be exercised at the desired time (:00). ombioolerprogram KM: V.0 Program version Date : 0900 Program release * (--.-) No value is displayed if the temperature sensor from the chilled beam circuit is connected to the BMS, i.e. when the BMS is controlling the chilled beam circuit instead of the ooler/pl. ontinued on next page Fläktroup D_89B 0800_R0 We reserve the right to make changes without prior notice

12 Installation and maintenance instructions OPERATIONAL AND ALARM INFORMATION Display message Explanation * -Fase Alarm * Alarm from the phase break relay, phase sequence fault relay Water flow in the brine circuit too * Low Water Flow * low. * ooler stopped * (Interlocked) * Start up delay * Wait (s) 0 =Alarm Q / Term. =Alarm Q / Term. =Alarm HP push ES =Alarm HP push ES =Alarm Low press. =Alarm Low Press. =WaterTemp Alarm =WaterTemp Alarm =WatTemp Stop 00 =WatTemp Stop 00 =apacity Alarm ooler and P5 interlocked by the fan/outdoor temperature sensor.* Start delay minutes so the unit damper has time to open. KM s Motor protection or Thermistor has tripped. KM s Motor protection or Thermistor has tripped. KM s High pressure switch has tripped. KM s High pressure switch has tripped. KM s Low pressure switch has tripped. KM s Low pressure switch has tripped. Ouput Temp. circuit is less than. Reset the alarm relay Ouput Temp. circuit is less than. Reset the alarm relay KM stopped for 5 min. if the temp. in circuit is less than 4. KM stopped for 5 min. if the temp. in circuit is less than 4. KM s apacity switch has tripped. Alarm locked for min. KM s apacity switch has tripped. KM stopped for 0 min. =apacity Alarm =apac. Stop :600 =apac. Stop :600 KM stopped for 0 min. =Blocked (s) :80 =Blocked (s) :80 =Wait (s) :00 =Wait (s) :00 =Wait (s) :00 =Run =Run Stage blocked for mins. during down regulation from stage. Stage blocked for mins. during down regulation from stage. Start delay of stage for 5 min. Start delay of stage for 5 min. Start delay of stage for 5 min. KM in operation. KM in operation. * An external start signal to the cooling unit also starts/ stops P5. When stopping, the pump runs for a further minutes before it stops. The pump is also exercised daily between :00-:0. Fläktroup D_89B 0800_R0 We reserve the right to make changes without prior notice

13 Installation and maintenance instructions OPERATION AND MAINTENANE Inspecting the sight glasses The cooling unit is part of the air handling unit and is installed as a unit module The cooling unit operates independently and has its own control cabinet. Start signals are provided by the air handling unit. The cooling unit is intended to cool supply air in the temperature range Lowering the temperature of the brine by 5 7 is possible depending on the selected air temperature, supply air/extract air ratio and operational case. Inspecting the sight glasses The cooling unit s service component has an electrical apparatus cabinet generally containing the following equipment: Main circuit breaker ontrol circuit fuse Motor circuit breaker One frost protection sensor for each circuit ontrol unit with display The service component also contains sections of the piping that distributes the brine (the cold water) to the supply air coil and chilled beam circuit. The illustration below shows the components in the service compartment, the components included in the delivery, and the components required to allow the entire cooling unit to be utilised fully. INSPETION (arried out by the owner/user once a week) heck (look/ listen for) the following:. Alarm indications. Abnormal noise/vibrations. Fluid leakage (oil, water) 4. orrosion, wear 5. Mountings, brackets 6. Unit compartment, lighting MAINTENANE Important! Always study the safety instructions on Page prior to carrying! out any work. (Must be carried out by a refrigeration service company or corresponding undertaking at least once a year). heck the following:. Evaporation/condensation temperature. Leakage inspection (every months) in accordance with EU requirements.. Hot vapour temperature.. Expansion valve (superheating of suction vapour). 4. Safety equipment (pressure switch trip function). 5. ooling capacity. 6. Automation and control equipment (functional inspection) 7. Electrical equipment (post-tightening power connection). 8. leaning (batteries, drip trays, drains). 9. Outlet filters. Water circuit 0. leanliness and effectiveness of all plate heat exchangers (evaporators, incoming).. Filter.. Pipe connectors and welds.. Pipe insulation. 4. The temperature differential across the heat exchangers is checked via the control unit. arried out to check cleanliness/performance across the exchanger. IN-SERVIE INSPETION Inspections must take place at least once a year and be registered in accordance with EU regulations on fluorinated greenhouse gases 84/006, Article. heck the following:. Pipes. Leak trace the refrigerant system. Vibration test 4. orrosion inspection 5. Refrigerant filling 6. Oil leakage 7. Safety equipment 8. Joints/seals REMOVAL When removing, (scrapping) this type of unit all refrigerant and compressor oil must always be taken for destruction/recovery. TROUBLESHOOTIN NOTE! Faults must always be remedied without delay. The service/maintenance of cooling and water systems may only be carried out by authorised companies using certifiedpersonnel in accordance with European Union Regulation 0/008 and the necessary protective equipment. SPARE PARTS Spare parts can be bought via local cooling suppliers. ontact your local Fläktroup office for information regarding components that need to be replaced. Fläktroup D_89B 0800_R0 We reserve the right to make changes without prior notice