OPERATION AND MAINTENANCE MANUAL COMPACT VENTILATION UNIT WITH HEAT PUMP MCKT-HPX SERVICE

Transcription

1 GDYNIA COMPACT AHU MCKT-HPX /14 COMPACT VENTILATION UNIT WITH HEAT PUMP MCKT-HPX SERVICE Tel.: (+48 58) /51 Fax: (+48 58) Mobile: (+48) GDYNIA, October 2016

2 GDYNIA COMPACT AHU MCKT-HPX /14 TABLE OF CONTENT GENERAL INFORMATION TECHNICAL SPECIFICATION AND APPLICATION AHU CONSTRUCTION OPERATION PRINCIPLE THERMAL BALANCE OPERATION OF CROSS-FLOW EXCHANGER OPERATION OF THE HEAT PUMP DESCRIPTION OF THE COOLING DEVICE OPERATION OF COOLING DEVICE OPERATION OF THE HEAT PUMP AT LOW EXTERNAL TEMPERATURES CONTROL SYSTEM DIAGRAM OF THE CONTROL SYSTEM CONTROL OF STANDARD EQUIPMENT TURNING ON THE AHU DELAYED COOLING SYSTEM PROTECTION COOLING SYSTEM PROTECTION AIR PARAMETER ADJUSTMENT FILTER PRESSURE GAUGES DEFROSTING THE CROSS-FLOW EXCHANGER FAN OPERATION ADJUSTMENT SIGNALS CONTROL OF OPTIONAL EQUIPMENT DAMPERS PRELIMINARY HEATER COMMISSIONING SCOPE OF THE DELIVERY TRANSPORT AND STORAGE AHU ASSEMBLY SUSPENDING THE AHU DRAINING CONDENSATE ELECTRICAL CONNECTION FEATURED OPTIONAL EQUIPMENT NGS PRELIMINARY ELECTRICAL HEATER FIRST START-UP OPERATION AND MAINTENANCE FAULTY AHU OPERATION H&S PRECAUTIONS SERVICE INFO COMMISSIONING PROTOCOL... 14

3 GDYNIA COMPACT AHU MCKT-HPX /14 1. GENERAL INFORMATION The purpose of this OMM manual is to made the installers and users aware of the construction as well as correct operation and maintenance of the MCKT-HPX Air Handling Unit. Before the device installation as well as before launching and operating the device you should carefully read this OMM and strictly follow all instructions herein. Failing to observe the guidelines and recommendations contained in the operation and maintenance manual exempts the manufacturer from any warranty-related obligations. KLIMOR reserves the rights to implement design and material changes without prior notice, in relation to modernization and improvement of the product. The device is not subject to qualification by Commission Regulation No. 1253/ TECHNICAL SPECIFICATION AND APPLICATION Compact MCKT-HPX AHU is an air supply-exhaust unit designed for ventilation with heat recovery in any rooms such as: shops, restaurants, offices, production halls, residential buildings, houses, etc. The AHU is located inside the building. It is powered with electric energy. The heat pump enables to cool down the air in summer and heat it up in winter. AHU's operating position suspended. The unit is not designed to operate in environments with air temperature exceeding 45 C and relative humidity over 60% as well as in environments endangered by explosion of flammable gases and vapors containing organic solvents or other aggressive substances. 3 L Rozdzielnica RZS 2 H 3 2 W+200 W 1 MCKT-HPX 4 A 1 4 B Uchwyt zawiesia Okno inspekcyjne Picture no. 1 Compact MCKT-HPX AHU (main picture, top view) Arrangement possibilities for inlets and outlets of air streams 1 Inlet of external air 2 Outlet of supply air 3 Inlet of exhaust air 4 Discharge of extracted air

4 GDYNIA COMPACT AHU MCKT-HPX /14 Table no. 1 Technical parameters, part 1 MCKT HPX 1 MCKT HPX 2 MCKT HPX 3 Length L [mm] Width W [mm] Hight H [mm] Ventilation port A x B [mm] Connector size A x B [mm] Weight kg Air filters Type FS x350 G4 FS x450 G4 FS x500 G4 *For the unit equipped with the control system the W dimension is enlarged by 250mm. Table no. 2 Technical parameters, part 2 MCKT HPX 1 MCKT HPX 2 MCKT HPX 3 Range of airflow rate m 3 /h Heating 1 kw 7,3 8,4 14,4 16,8 21,0 25,4 Cooling 2 kw 5,5 6,9 10,0 11,7 15,0 17,6 Fan power output kw 2 0,5 2 0,5 2 1,1 Fan voltage Ph/V/Hz 1 230V/ V/ /50 Fan current A 2 2,2 2 2,2 2 2,3 Compressor power 1,5 1,6 3,0 3,2 4,3 4,9 kw consumption (winter) Compressor power 1,8 1,9 3,3 3,4 4,7 5,6 kw consumption (summer) Compressor voltage Ph/V/Hz 1x230V/ / /50 Max compressor current 3 A 14,0 10,4 15,8 Cooling medium R407C R407C R407C Amount of cooling medium kg 2,0 3,0 4 Sound power level for suction/pressing duct db(a) 55/60 63/68 62/67 71/76 69/75 76/81 Level of acoustic pressure at 1m 2 from the casing for A=15m db(a) For parameters: external temperature -5 C; φ=80%, room temperature 20 C; φ=40% 2- For parameters: external temperature 30 C; φ=45%, room temperature 24 C; φ=40% 3- Max nominal compressor engine current. Table no. 3 Dedicated optional equipment MCKT HPX 1 MCKT HPX 2 MCKT HPX 3 Size Max output Size Max output Size Max output Electrical heater NGE NGE-1 4.5kW NGE-2 9kW NGE-3 13,5kW Multi-surface damper A.DPR A.DPR A.DPR 560x500 Flexible connection FC FC FC 560x500 Detailed data are listed in the chapter related to the optional equipment. Chart no. 1 MCKT-HPX available pressure

5 GDYNIA COMPACT AHU MCKT-HPX /14 3. AHU CONSTRUCTION - The MCKT-HPX AHU's casing is made of framework casing made of anodized aluminum profiles and plastic corners, and galvanized steel sheet and non-flammable mineral wool which provides appropriate thermal and acoustic insulation. The casing panels are 50 mm thick. Inspection panels are equipped with handles and are mounted to the framework with oneand two-side clamps The AHU's framework is equipped with handles enabling suspension of the unit to ceiling with bars. Picture no. 2 Inspection panels AHU's side masking covers can be arranged in different ways, enabling 16 combinations of ventilation port arrangements. Picture no. 3 Side covers masking the ventilation ports - MCKT-HPX AHU internal equipment: two G4-class cartridge filters, plate cross-flow heat exchanger, two axialradial fans with direct drive and complete sets of heat pump: air-air with cooling system and two CuAl exchangers. The heat pump enables cooling of supply air in summer and heating it in winter. In the lower part of the inspection plate there are connections (hose connectors) for draining condensate water from the cross-flow heat exchanger and cooler outside the AHU. - The MCKT-HPX AHU is equipped with complete system of power supply and control system. The RZS box is attached to the AHU side wall. The AHU is directly controlled by the control panel. Information regarding operating the unit are attached. 4. OPERATION PRINCIPLE The MCKT-HPX AHU can operate only with the cross-flow exchanger or with the cross-flow exchanger and heat pump. The most beneficial external air temperate enabling the highest heat pump efficiency for cooling is above -5 C. In case of lower temperatures the control system switches off the cooling system and the unit operates in heat recovery mode only with the cross-flow exchanger. To ensure proper operation of the heat pump, in order to heat up air to required temperature, it is necessary to use preliminary NGE electrical heaters which heat up external air up to -5 C. 4.1 THERMAL BALANCE Compact MCKT-HPX AHU equipped with the cross-flow heat exchanger and heat pump forms a high-performance heat recovery system for a ventilated room. However ventilated rooms have to be source of heat in order to enable heat recovery. That is why at the stage of designing heating and ventilation system it is necessary to carry out the room's thermal balance a balance of profit and loss. Ventilated rooms should be equipped with independent heating provided by radiators, floor heating or other heating method, while the MCKT-HPX AHU should only take care of heating up the supply air.

6 GDYNIA COMPACT AHU MCKT-HPX / OPERATION OF CROSS-FLOW EXCHANGER Calculating heat amount to heat up the air is provided using the records below. Table no. 4 Sample operation spots at max air flow rate and min exchange efficiency while the heat pump is not operating. t1 [ o C] t2 [ o C] φ2 [%] η [%] Q [kw] Tlz [ o C] t12 [ o C] Designation t1 external air temperature t2 room air temperature φ2 - room air humidity η - t12 heat exchange efficiency air temperature after the exchange Q - thermal power recovered Tlz - freezing limit temperature t12 - air temperature after the exchange Temperature value downstream the cross-flow exchanger is determined using the diagram in picture no. 4 Przykład: temp. powietrza zewnętrznego t1 = -8 C temp. powietrza wewnętrznego t2 =+22 C przy zakładanej sprawności h=60%, temperatura powietrza po wymianie wynosi: t12 = h / 100 x (t2 - t1) + t1 t12 = +10 C Jak widać stosując HPX, powietrze po wymianie należy podgrzać o 12 C, podczas gdy bez wymiennika aż o 30 C. 20 C 10 C 0 C -10 C -20 C 30 C 20 C 10 C 0 C 30 C 20 C 10 C Dla sprawności wymiany η = 60%. Picture no. 4 Determining temperature at the cross-flow exchanger Characteristics of plate heat exchangers used in the MCKT-HPX AHU - The exchangers are characterized by high heat recovery efficiency at low investment costs. - The exchangers do not have any moving parts so they do not wear out and they are always ready to work. - Flowing air streams do not mix with each other and they do not carry over any contaminants. - The exchangers do not require electrical power supply. - The heat exchangers are lightweight, compact and are easy to assemble. - The exchangers are produced using the top level global standards. Problems with freezing condensate in the exchanger and countermeasures If warm air stream gets significantly cooled down, beside condensation freezing may also occur. In practice it does not happen so commonly several conditions must be met at the same time: - very low external air temperature - higher air flow of cool air than warm air - high efficiency of the exchanger - relatively low level of condensation - problems with draining out condensate - high humidity of extracted air If several of these conditions occur at the same time, the exchanger may start covering with frost, starting from the cold corner. Standard anti-freeze countermeasure for the exchanger in the MCKT-HPX AHU is temporary limiting flow of the air supply fan.

7 GDYNIA COMPACT AHU MCKT-HPX / OPERATION OF THE HEAT PUMP The heat pump, depending on needs, enables cooling down or heating up external air. Treated air has to be chemically inert, cannot contain caustic or explosive components as well as oily, viscous and fibrous slurries. The R407C Freon is used as the cooling medium. Correct operation of the cooling system requires sufficient amount and appropriate parameters of supplied air. The technical parameters table in the Air flow range line lists min air flow efficiency depending on the unit size. All data refer to summer period (cooling mode operation) and air extracted from a room at 24 C because these are the least favorable operating conditions. Setting lower air flow of the AHU will lead to turning off the cooling system by low or high pressure gauges Description of the cooling device The cooling sets are enclosed inside the AHU. The compressors are protected using high and low pressure gauges with automatic reset function. Triggering high pressure gauge requires reset to be carried out at the hand-held control unit. The cooling system is delivered together with the control system. It provides full protection during AHU operation, maintaining required air parameters and its maximizing output. In order to protect the compressor against flooding with the liquid medium, the system operates with removing by suction the medium vapor once turned off (the solenoid valve is closed before turning off the compressor). Removing the medium by suction is done at each system deactivation. Due to operation in heating and cooling modes at variable air parameters, the systems have got wide ranges of permissible operating pressure. Filling the system with Freon R407C should be carried out with the compressor operating, till the eyehole is filled with the medium Compressor 2. Low pressure gauges 3. High pressure gauges 4. Four-way valve 5. DX reservoir 6. DX fill-up valve 7. Filter dehydrator 8. Solenoid valve 9. Eyehole 10. Expansion valve 11. Check valve at the medium line 12. Solenoid valve to adjust performance 13. Valve to adjust performance Figure no. 5 Cooling system diagram Table no. 5 Range of manometric pressures for heat pump operation Min [MPa] Max [MPa] Pressure gauge setting Pabs [bar] Low pressure 0,2 0,65 4 High pressure 1,1 2, Operation of cooling device The cooling unit is an autonomous system fully controlled and supervised by control system. For that reason it does not require outside interference. All works should be done by personnel having appropriate certificated qualifications. However the personnel can reduce potential failures by following the unit s operation carefully. NOTE! The compressor requires appropriate operating parameters of the cooling oil. That is why before the first start and after each longer downtime of the whole AHU (when the switchboard is not energized) it is necessary to turn on the switchboard and do not enable to start the cooling system. It will initiate starting the compressor casing heater and heating up the oil. Appropriate time to ensure correct oil parameters is 8h. The basic parameter that should be taken into account is the amount and parameters of air flowing through the cooling system exchangers. The flow adjustment should ensure min air amount listed in the table no. 2 with MCKT-HPX AHU parameters. The condition of air filters should be monitored. Contamination of air filters causes considerable drops in airflow rate.

8 GDYNIA COMPACT AHU MCKT-HPX /14 Monitoring the cooling system may be limited to checking pressure ranges when the system is in operation. The user has to carry out a visual inspection of the cooling system condition. Oily spots on the pipeline can indicate leakage of the medium from the system. They should be wiped dry. If oil appear in the same spots, there is a leakage. NOTE! Visual inspection of the cooling system should be carried out when the compressor and fans are turned off. Temperature of the pipeline directly downstream the compressor during operation can exceed 100 C. Pay particular attention while inspecting the cooling system Operation of the heat pump at low external temperatures At low temperatures of external air there is a drop of the heat pump efficiency. In order to prevent such situation it is recommended to use the preliminary heater with output dependent on the air flow and estimated temperature of external air. The preliminary heater ensures heating up the external air to the level enabling efficient operation of the heat pump. Depending on parameter relations between air supply and air exhaust streams, such as temperature, humidity, volume, the critical point temperature usually is about: -5 C. The heater output should be calculated for the most extreme operating conditions. For preliminary heating up the supply air you can use the NGE electrical heater. The heaters are optional equipment of the MCKT-HPX AHU. 5. CONTROL SYSTEM Detailed description of the MCKT-HPX AHU's control system is provided in a separate attachment to the OMM ( User s manual of the suspended MCKT-HPX AHU s automatic system controller ). 5.1 DIAGRAM OF THE CONTROL SYSTEM Picture no. 6 Diagram of the control system for the MCKT-HPX

9 GDYNIA COMPACT AHU MCKT-HPX / CONTROL OF STANDARD EQUIPMENT Turning on the AHU Turning on the system from the control panel. Common start of fans 20s after turning on the system. 30 seconds after starting the fans permit to start the cooling system. Once the system is turned off the fans keep operating for 30 seconds Delayed cooling system protection Once the compressor (3) is turned off, it can be turned on again only after 180 seconds Cooling system protection The cooling system is equipped with low pressure (4) and high pressure gauges with automatic reset function. If any of the pressure gauges is triggered, the cooling system is stopped. If the high pressure gauge (5) is activated 3 times within an hour, the cooling system is blocked and requires restarting from the control panel Air parameter adjustment Room temperature adjustment is carried out based on the air exhaust temperature sensor (11). The air supply sensor (10) enables reduction of min/max air supply temperature. Max air supply temperature at C. Min air supply temperature at 5 24 C. Min allowable difference between max and min air supply temperature is 16K Filter pressure gauges Filters of pressure gauges indicate filter contamination with a summary signal Defrosting the cross-flow exchanger If the sensor (12) detects temperature 0 C, the air supply fan reduces its output to 20% for 120 seconds Fan operation adjustment signals Fan operation adjustment signals are independent for air supply and air exhaust. Fans controlled with signal (13 and 8) 0-100% output. Fan start from the signal (9 and 14). The cooling system can operate for the control range of %. Below this setting at the air supply or exhaust operation of the heat pump is not allowed. 5.3 CONTROL OF OPTIONAL EQUIPMENT Dampers Both dampers (20 and 21) 24V AC/DC-powered open when the AHU is started. The air supply damper with a spring, the air exhaust damper without a spring Preliminary heater The preliminary heater (optionally, water or electrical one) ensures initial air heating to enable operation of the heat pump at external temperature below -5 C. The temperature measured at the temperature sensor (1) set from the panel in the 5 C 10 C range. Electrical heater Power supply and control with a separate module controlled by signal (18) from the main switchboard. The heater protection (19), once temperature exceeds 90 C, turning off the heater, while other AHU devices are operating.

10 GDYNIA COMPACT AHU MCKT-HPX /14 6. COMMISSIONING Compact MCKT-HPX AHU in fully assembled condition are subject to the manufacturer's quality control commissioning, which guarantees meeting quality requirements and parameters defined in the unit's data sheet. 7. SCOPE OF THE DELIVERY The delivery includes, standard equipment: - Compact MCKT-HPX AHU, fully assembled with enclosed control system. - The remote control panel and duct sensors supplied in a separate package (a shielded control cable, 4x0,5mm 2 is not provided) - Operation and Maintenance Manual (OMM) - The system control documentation ("User s manual of the suspended MCKT-HPX AHU s automatic system controller"). Additional equipment (on individual request): - Air damper and flexible connectors - NGE electrical heater 8. TRANSPORT AND STORAGE The MCKT-HPX AHU is delivered fully assembled to the final place of operation. Loading onto/unloading from a means of transport to a warehouse can be carried out manually or with a lift. The units should be stored in enclosed, roofed places. The AHU should be stored, transported and operated in horizontal position with the inspection panels facing downward. 9. AHU ASSEMBLY 9.1 SUSPENDING THE AHU The compact MCKT-HPX AHU should be installed in rooms which do not contain any airborne chemical contaminants reacting with non-ferrous metals. The AHU can be suspended using four side holder located at both sides of the casing. A M8 threaded bar is inserted into the lower part of the holder and a nut with a washer is screwed on. Next, the bar is inserted into the groove of the upper part of the holder, and at the same time they are joined together by pushing a lower element into an element at the bottom. Usage of M8 threaded bars enables easy and quick suspension and leveling of the unit. The M8 threaded bars are not supplied. The minimum retained distance of the upper surface of the unit to the partition should be min. 20mm. The AHU should be leveled and the final assembly should enable inclining the unit towards the air flow at 1 (about 1,5 2%). Picture no. 7 Optimal inclination of the AHU The unit should be assembled and connected using cables to ensure appropriate air flow. The air system should be connected using flexible connectors.

11 GDYNIA COMPACT AHU MCKT-HPX / DRAINING CONDENSATE The condensate should be drained from both trays using flexible hoses with drain traps, see picture no O króćca 13mm Picture no. 8 Drain traps NOTE! Estimated amount of condensate depending on air parameters: - up to 3 l/h for the MCKT-HPX1, - up to 6 l/h for the MCKT-HPX2, - up to 10 l/h for the MCKT-HPX3. Incorrect condensate drainage can lead to: - Flooding fan sections of the MCKT-HPX and damaging fan motors and electronic modules installed in these sections, - Flooding air ducts and in result rooms which are air-conditioned and the room where the AHU is installed. 9.3 ELECTRICAL CONNECTION Provide the power supply to the control system box of the MCKT-HPX AHU. If an additional electrical heater is used, make sure to provide a separate power supply to the heater control module and in case of the water heater connect an additional temperate sensor and power supply for the three-way valve and circulating pump. Connect the control panel to the control box with a shielded cable 4x0.5mm 2 (max cable length 25m). Other electrical elements should be installed in line with guidelines of the "User s manual of the suspended MCKT- HPX AHU s automatic system controller". While connecting electrical devices and components it is necessary to strictly follow the H&S requirements stated in appropriate standards and regulations related to the installation and operation of electrical devices. 10. FEATURED OPTIONAL EQUIPMENT Size 10.1 NGE PRELIMINARY ELECTRICAL HEATER Table no. 7 Family of the NGE preliminary electrical heaters for use with the MCKT-HPX AHU Max output MCKT HPX 1 MCKT HPX 2 MCKT HPX 3 No. of stages Current Power supply Size Max output No. of stages Current Power supply Size Max output No. of stages Current kw - A V/Hz kw - A V/Hz kw - A V/Hz Power supply NGE-1 4,5 1 19,6A 1 230/50 NGE-2 9, , /50 NGE-3 13,5 3 19, /50 NGE-1 NGE-2 NGE T T PE 1x230V T T PE T T PE 3x400V 3x400V Picture no. 9 NGE heater diagram

12 GDYNIA COMPACT AHU MCKT-HPX / FIRST START-UP The AHU start-up can be carried out only by authorized personnel with sufficient knowledge and experience in this particular ventilation or air conditioning system. Once the installation process and all connections (electrical, ducts and controls) are complete: - Check if the electrical connections are correct - Check tightness of air duct connectors - Check if all other additional devices working with MCKT-HPX AHU are connected in a correct way. If no connection faults are found you can proceed with the AHU start-up procedure. The unit is started via the control panel. The description in provided in the attachment related to the control. - Turn on the AHU - Adjust and preset appropriate air flow of the fans - Adjust the temperatures. The first start-up of the unit requires filling in the commissioning protocol. Fill instalation of the R407C up to fill the viewport when the compressor is working Setting of pressure switch low pressure P = 2,5 bar g Setting of pressure switch high pressure P = 27 bar g 12. OPERATION AND MAINTENANCE Compact MCKT-HPX AHU is designed for continuous operation. In order to keep the AHU in continuous operation it is necessary to carry out the following inspections every 3 months: - Check the MCKT-HPX anticorrosive protection - Check condition of filters and exchangers - Check condition of cables - Check condition of fans (they should operate without excessive noise and vibration) - Check tightness of the cooling system. 13. FAULTY AHU OPERATION Table no. 8 Remedy actions in case of faulty AHU operation Symptoms Cause Remedy action Fans do not start No voltage in the system The protection is disconnected Check the electrical system Check the fuses Fans generate vibrations of AHU Contaminated fans' rotors Clean fans' rotors The compressor does not turn on Activated HP* pressure gauge Check condition of the filters Air flow is too small increase Reset the HP alarm high condensing pressure at the control system panel Incorrect temperature settings Change the temperature settings The compressor turns on and off Faulty compressors Activated LP** pressure gauge External air temperature is too low Not enough cooling medium Contact the service personnel Check condition of the filters Air flow is too small increase Change the Tz*** sensor setting Eliminate leakages, fill up the R407C The solenoid valve is faulty Check the valve's coil Cooling instead of heating The 4-way valve is faulty Check the valve's coil * Activation of HP pressure gauge is an alarm condition. The alarm has to be reset at the control panel. * Activation of LP pressure gauge is not an fault condition. It will be restarted automatically. In both cases the compressor will be activated at least 3 minutes after the stop. *** It is recommended to use the preliminary NGE electrical heater to heat up air at min -5 C.

13 GDYNIA COMPACT AHU MCKT-HPX / H&S PRECAUTIONS The compact MCKT-HPX AHU is not dangerous for personnel provided the basic operational Health & Safety precautions are observed. Specific requirements which must be obeyed: - Installation and first start-up of the units shall be done in conditions provided for in applicable regulations, and in particular in regulations concerning operation of electric appliances. - Connecting the unit to a protective installation shall be a condition for switching on the power supply. - Power supply shall be switched off prior to repair and maintenance operations. - Operation of the unit without any of the inspection panels is not allowed. - Servicing, repair and maintenance of the units may be done only by personnel having appropriate qualifications confirmed by a relevant certificate provided for by a competent ministry in a regulation concerning qualifications of personnel employed to maintain power appliances. - Protective equipment ensuring safe maintenance should be available at the maintenance post. 15. SERVICE INFO Please contact our Service department in order to learn more about operating the unit: Fax: (+48 58) Tel.: (+48 58) /51 Mobile: serwis@klimor.pl

14 GDYNIA COMPACT AHU MCKT-HPX / COMMISSIONING PROTOCOL Date Place Name and surname of the commissioner Device serial number Commissioning company (stamp) Installation actions (description) Remarks User approval of the provided actions Signature Date