Envistar Operation and Maintenance Instructions

Transcription

1 Air Handling Unit Envistar Instructions Project:... Air handling with the focus on LCC

2 Address and Telephone Register for Service Supplier: IV Produkt AB Box 3103 SE VÄXJÖ, Sweden Street address: Sjöuddevägen 7 Telephone: +46 (0) Telefax: +46 (0) Vendor:... Service:... Postal address:... Postal address:... Telephone:... Telephone:... Other particulars: Particulars of the Ventilation System Air handling unit code:... Order number:... Year of manufacture:...

3 Air handling with the focus on LCC Page 1 Contents 1. General 2 2. Main Switch/Safety Switch 2 3. Maintenance 3 4. Service Intervals 3 5. Spare Parts 3 6. Filters, disposable General Inspection Filter Change 5 7. Rotary Heat Exchanger General Inspection Cleaning Lubrication Electrical Wiring 8 8. Plate Heat Exchanger General Remedial Measures 9 9. Fan and Motor General Fan Motor Electrical Wiring Duct Accessories Dampers Air Heater for hot water Air Heater, electric Air Cooler for chilled water StarCooler Cooling Unit Technical Survey 26 Item of equipment is included in the AHU Supply air EU6 Extract air EU6 Yes Yes Yes Yes Yes Yes Yes EU7 EU7 No No No No No No No

4 Page Air handling with the focus on LCC 1 General The periodic maintenance of this air handling unit shall be carried out by a qualified person who has the necessary know-how required for the servicing of air handling units. 2 Main Switch/Safety Switch Main switch/ safety switch Figure 1. Main switch/safety switch The main switch (safety switch) is located on the front panel of the control unit. Caution! The main switch must not be used for normally starting and stopping the air handling unit. The unit shall be stopped by pressing the appropriate button on the terminal display. The safety switch shall be locked in the 0 position while servicing the unit. Caution! The safety switch shall be locked in the 0 position before servicing or modifying the air handling unit. Wait at least 3 minutes before opening any inspection panel. A special key must be used for opening the inspection panels. There is no guard behind the inspection panels. Electrical connections and other electro-technical work must only be carried out by a qualified electrician or by service technicians approved by IV Produkt.

5 Air handling with the focus on LCC Page 3 3 Maintenance The periodic maintenance of this air handling unit shall be carried out either by the person normally responsible for the maintenance of the building or a service agreement can be concluded with an authorised service company. 4 Service Intervals The service schedule includes the inspection and service work necessary for the functional sections that may be included in the air handling unit, see Table 1. The unit contains one or more of these unit sections. The unit sections in your particular unit are marked on the list in the table of contents, see page 1. The intervals between service are based on the assumption that the unit is in operation for about 2000 hours per 12-month period in a normal comfort installation. If the supply air and/or extract have high dust content, the unit should be serviced more frequently. 5 Spare Parts Spare parts and accessories for this unit should be ordered from your nearest IV Produkt sales representative. Specify the product code whenever you order spares and accessories. This product code can be found on a separate identification label on each unit section. A separate spare parts list is supplied with the air handling unit. Table 1. Service Schedule Unit Section/Unit Filter, Supply air Filter, Extract air Rotary heat exchanger 3-monthly service 9-monthly service Check the pressure drop and change the filter if necessary Carry out visual inspection. 6-monthly service 12-monthly service Check the pressure drop and change the filter if necessary Clean the rotor. Plate heat exchanger Carry out visual inspection Clean the air passages Fans and motors Carry out visual inspection Clean Dampers Carry out visual inspection Clean Air heater for hot water Carry out visual inspection Clean Electric air heater Carry out visual inspection Clean Air cooler for chilled water Carry out visual inspection Clean Starcooler Carry out visual inspection Clean Condenser & evaporator Carry out visual inspection Clean

6 Page Air handling with the focus on LCC 6 Filters, disposable 6.1 General Filters Figure 2. The filters The air filter in an air handling system shall prevent dust and other impurities from entering the building. They shall also protect any sensitive components of the AHU, such as air heaters and heat recovery components, from becoming fouled. The collecting efficiency can vary considerably between various types of filter. The ability of filters to accumulate dust also varies substantially. It is therefore important to use filter of the same quality and capacity when changing the filters. The collecting class is specified with standard designations, such as EU6 EU7 that denote fine filters. A higher digit denotes a higher collecting efficiency. The filter media are intended for one-time use. If the filter becomes clogged, this will lower unit performance. The filters shall therefore be changed if the pressure drop across the filter exceeds the preset final pressure drop. It is important to stop the unit while changing the filter medium to prevent any loose dust from being sucked into the system. For the same reason, clean the surfaces inside the filter section as well, while changing the filters. 6.2 lnspection Check the pressure drop across the filter. To measure the pressure drop, use a U- tube manometer connected to the pressure probes fitted to each side of the filter section. The filter medium must be changed when the pressure drop across the filter reaches the final pressure drop.

7 Air handling with the focus on LCC Page Filter Change Figure 3. To change filters Table 2. Filter Data Size Number Frame dim. (mm) x x / x x Final pressure drop Filter class EU6: 150 Pa Filter class EU7: 200 Pa 592 x x x x x x x 592 Caution! Before beginning any work: 1 Stop the air handling unit. 2 Turn the safety switch to the 0 position and lock it. 1. Remove the fouled filter by pulling the red straps (see Figure 3). This will release the filter from its locking mechanism. Then remove the filter from its holder. 2. Clean the filter cabinets. 3. Fit the new filter and close the inspection panel. 4. If the filter is fitted with a permanent filter monitor: secure the probes on each side of the filter. 5. Restart the air handling unit.

8 Page Air handling with the focus on LCC 7 Rotary Heat Exchanger 7.1 General Rotary heat exchanger Figure 4. Rotary heat exchanger The function of a heat exchanger is to recover heat from the extract air and to transfer the heat to the supply air. This reduces the power demand and the unit consumes less power. Faulty heat exchanger operation lowers energy recovery performance and causes the unit to consume more energy. This also means that the design supply air temperature cannot be obtained under low outdoor temperature conditions. A probable cause of unsatisfactory heat recovery performance is that the drive belt is slipping, causing the rotor to rotate too slowly. It is unlikely that the laminar passages in the rotor will become clogged with dust, since the rotor is normally self-cleaning. However, the dust can be of a sticky nature. A reduction in the extract airflow, e.g. due to a fouled extract air filter, can reduce heat recovery performance. 7.2 Inspection Caution! Before beginning any work: 1 Stop the air handling unit. 2 Turn the safety switch to the 0 position and lock it in position. Avoid any hand or tool contact with the inlet and outlet surfaces of the rotor.

9 Air handling with the focus on LCC Page 7 Figure 5. To check the pressure balance. 1. Check that the rotor rotates easily. If it turns sluggishly, the brush seal may have to be adjusted. 2. Check that the drive belt is properly tensioned and doesn t slip. If the tensioning device is tensioned to its limit, the belt will have to be shortened. 3. Check that the drive belt is intact and clean. 4. Check that the inlet surface of the rotor isn t coated with dust or other impurities. 5. Check the pressure balance, see Figure 5. To guarantee correct purging sector operation, the sub-atmospheric pressure at P3 must be greater than the pressure at P2. Otherwise, use an ESET-TR trim damper on the extract air side. 7.3 Cleaning Remove dust by carefully vacuum cleaning using a nozzle incorporating a soft brush. If the surfaces are heavily laden with dust or if the dust is greasy, spray the rotor with water mixed with dishwashing detergent (such that won t corrode aluminium). The surfaces can also be blown clean using low-pressure compressed air (max. 6 atmosphere gauge). The nozzle must not be held closer than 5 10 mm to the rotor surface. 7.4 Lubrication The bearings of the drive motor are permanently greased and do not require lubrication.

10 Page Air handling with the focus on LCC 7.5 Electrical Wiring Motor Data Size Output W Power supply Rated current/ Fuse rating V V 6 A, delayed 6 A, delayed Wiring Diagram Wiring Diagram V input signal Temp. contact input Rotation monitor input Alarm relay ouput (Max. 8 A 250 V AC) 0-10 V input signal Temp. contact input Rotation monitor input Alarm relay ouput (Max. 8 A 250 V AC) Condenser 1 x 230 V power supply 1 x 230 V power supply

11 Air handling with the focus on LCC Page 9 8 Plate Heat Exchanger 8.1 General Figure 6. BPU1 The primary function of the heat exchanger is to recover heat from the extract air and to transfer it to the supply air in order to reduce energy consumption of the AHU. Faulty heat exchanger operation lowers heat recovery performance and firstly causes the unit to consume more energy and secondly means that the design supply air temperature cannot be obtained under low outdoor temperature conditions. The probable causes of reduced heat recovery performance are dust laden heat transfer surfaces or that the by-pass damper doesn t close completely. A reduction in the extract airflow, e.g. due to a fouled extract air filter, can reduce heat recovery performance in all sizes of this heat exchanger. Special consideration should be given to the problems caused by ice forming in the extract air passages of the heat exchanger. If stoppages arise due to frosting, check to make sure that the anti-frosting protection equipment is operating correctly. 8.2 Remedial Measures Inspection Caution! Before beginning any work: 1 Stop the air handling unit. 2 Turn the safety switch to the 0 position and lock it. Inspect the cross-flow passages to detect any fouling. This inspection can be carried out after opening the inspection panel of the filter section, for instance. Inspect the automated anti-frosting equipment and make sure that the by-pass damper is tightly closed when the unit is not defrosting Cleaning If cleaning is necessary, this can be carried out by vacuum cleaning, blowing clean with compressed air or by applying a cleaning agent well suited for cleaning aluminium and by flushing with water. Cleaning is best carried out by flushing each individual air channel with water (if required, mixed with common detergent that will not corrode aluminium) across the entire length of the heat exchanger. For operating temperature below 0 C, the heat exchanger package must be dry before the AHU is started up. At the same time, check the drip tray, drain and water trap below the heat exchanger. If the water trap lacks a non-return valve, it must be filled with water.

12 Page Air handling with the focus on LCC 9 Fan and Motor 9.1 General The function of the fan is to transport air through the system, i.e. the fan must be able to overcome the flow resistance caused by air devices, the ducting and the unit. The speed of the fan is adapted for providing the correct airflow. If the fan discharges a lower airflow, this will impair the operation of the ventilation system. If the supply airflow rate is too low, this will cause imbalance in the system, and this will lead to a poor room climate. If the extract airflow rate is too low, the ventilation output will be too poor. This imbalance may also give rise to the discharge of humid air into the building structure. One reason why the fan generates to little airflow can be that the fan blades are coated with impurities. If a centrifugal fan impeller rotates in the wrong direction, the air will circulate in the right direction but this will occur with substantial reduction in capacity. The direction of rotation may have been reversed due to electrical installations. Therefore check the direction of rotation. Caution! Before starting any work: 1 Stop the air handling unit. 2 Turn the safety switch to the 0 position and lock it Windstar A Rail 1 Motor 2 Fan impeller 3 Anti-vibr. mounting 4 Controller 5 Diffuser Figure 7. Fan and motor for sizes 03, 05 and 08 (Windstar)

13 Air handling with the focus on LCC Page Back off the screws (see Item A in Figure 7) and withdraw the fan unit. 2. Check that the fan impeller rotates easily, has correct balance and doesn t vibrate. Imbalance can be due to damaged impeller blades or impurities on them. 3. Check that the fan impellers fit tightly on their shafts and that they cannot be shifted sideways toward the inlet cones. 4. The fan impeller, bearing blocks and motor are mounted on a rack isolated by rubber anti-vibration mountings. Check that the latter are secure and intact. 5. Check the mounting bolts and the suspension devices and the base. 6. Check that the impellers are clean from any accumulations of particles. 7. Check the airflow rate by measuring the p in the tappings for flow measurement. p is used for obtaining the airflow in a chart affixed to the air handling unit. see Figure 9.

14 Page Air handling with the focus on LCC 9.2 Fan Inspection Windstrong A 1 Motor 2 Fan impeller 3 Anti-vibr. mounting 4 Controller 6 Energy spoiler Figure 8. Fan and motor for sizes 9, 12, 18, 28 and 33 (Windstrong) 1. Back off the screws (see Item A in Figure 8) and withdraw the fan unit (the fan and motor are mounted on rails). 2. Check that the fan impeller rotates easily, has correct balance and doesn t vibrate. Imbalance can be due to damaged impeller blades or impurities on them. 3. Check that the fan impellers fit tightly on their shafts and that they cannot be shifted sideways toward the inlet cones. 4. The fan impeller, bearing blocks and motor are mounted on a rack isolated by rubber anti-vibration mountings. Check that the latter are secure and intact. 5. Check the mounting bolts and the suspension devices and the base. 6. Check that the impellers are clean from any accumulations of particles. 7. Check the airflow rate by measuring the p in the tappings for flow measurement. p is used for obtaining the airflow in a chart affixed to the air handling unit, see Figure 9.

15 Air handling with the focus on LCC Page 13 Pa SIZE p 400 p m3/s m3/s Read the pressure differential p on the measurement tapping. Plot from p in the chart, affixed to the AHU, to the relevant unit size and read the air flow. Figure 9. To check the airflow Cleaning 1. Wipe the fan impeller blades clean to remove possible deposits. Use an environmentally compatible degreasing agent. Don t use kerosene, since its use may cause the surfaces to rust. 2. The vacuum clean the air handling unit, to prevent loose dust from being discharged to the duct system. 3. Clean the fan casings in the same way as the impellers. Check that casings and inlet cones are securely mounted. 9.3 Motor Inspection 1. Check that the motor mounts are intact and that the mounting bolts are tightened. 2. Listen to the bearings. If the bearing operates correctly, you ll hear a slight purring sound. A scraping or thumping sound can mean that the balls or races are damaged. If this is the case, servicing will be necessary Cleaning The inside of the motor and controller shall be kept clean, free from dust, impurities and oil. Wipe surfaces with a dry cloth. If surfaces are substantially fouled, use an environmentally compatible degreasing agent as a solvent. The motor is likely to overheat if a thick coating of impurities impedes the inflow of air for cooling the stator frame.

16 Page Air handling with the focus on LCC 9.4 Electrical Wiring Wiring the fan motors. Size Motor Output kw Power supply Rated current A Rec. fuse V V V x 230 V V V V V V Wiring diagram Wiring diagram Group 1 Group 2 Group 3 Junction box by fan spoiler Junction box on motor START STOP 0-10 V= control Alarm 230 V~ Power Supply START STOP Alarm (closes in event of an alarm) 0-10 V= control 400 V~ Power Supply Indicating lamps The motor junction box has one red and one green indicating lamp: Green indicates that power is being supplied to the motor. Red indicates that the motor is in the alarm condition. If an alarm has been initiated, the frequency inverter can be reset by de-energising the motor for at least 45 seconds. Check the voltage at all three phases and check that the air handling unit is correctly installed. Then try to restart the motor.

17 Air handling with the focus on LCC Page Duct Accessories 10.1 Damper General Sizes Sizes Figure 10. ESET-SP Damper The function of a damper is to restrict or shut off the airflow. Faulty damper operation causes disturbances leading to serious consequences. If the outdoor air damper doesn t open completely, this reduces the airflow. If the outdoor air damper doesn t close completely when the air handling unit stops, the air heater may freeze and burst. If the damper leaks air, the unit to consume more energy due to leakage caused by thermal lift Inspection 1. Check how the damper actuator operates. 2. Check that the damper blades seal tightly when they are closed. If they don t, adjust the damper actuator to make them seal as tight as possible in the closed position (not applicable to trim dampers). 3. Check that the sealing strips aren t damaged Cleaning Wipe the damper blades clean with a dry cloth. If they are especially dirty, clean them using an environmentally compatible degreasing agent.

18 Page Air handling with the focus on LCC 10.2 Air Heater, for hot water General Sizes Sizes Figure 11. ESET-VV Air heater The air heater consists of a number of copper tubes with press-fitted aluminium fins. The capacity of the coil is impaired if its surfaces become coated with dust. This will not only impair its heat transfer performance; it will also increase the pressure drop on the air side. Even if the unit is equipped with excellent filters, with the passing of time, dust will collect on the front edge of the coil fins (inlet side). In order to utilise full coil output, the water circuit of the coil must be adequately vented. The coil tubes can be purged of air by opening air release screws in the pipe connections and/or by means of an air vessel Inspection 1. Inspect the coil fins to detect any mechanical deformation. 2. Check that the coil isn t leaking Cleaning If the fins on the coil are fouled: vacuum clean them from the inlet side, or carefully blow them clean with compressed air from the outlet side. If the fins are especially dirty, spray them with warm water mixed with dishwashing detergent (such that doesn t corrode aluminium) Venting Vent the air heater and pipe connections if necessary. The air release screws are located on the top of the coil or on the connected piping Operation Check that hot water is circulating through the coil. This can be done by briefly raising the temperature setting (set point).

19 Air handling with the focus on LCC Page Air Heater, electric General Sizes Sizes Figure 12. ESET-EV Electric air heater The electric air heater consists of "exposed" heating rods. A substantial coating of impurities on the heating rods will cause them to overheat. This will shorten their useful product life. This may also give rise to an odour of burnt dust and at worst a fire hazard. Overheated heating rods can become deformed or loosen from their hangers. This will cause non-uniform heating of the air Inspection 1. Check that the electric heating rods are secure at their locations and that they aren t deformed in any way Cleaning 1. Remove any impurities by vacuum cleaning or wiping with a cloth Operation 1. Simulate a reduced heating demand by temporarily lowering the temperature setting (the set point), so that all the electrical output steps (contactors) switch out. 2. Then substantially increase the set point setting and check that the electrical output steps switch in. 3. Return to the appropriate temperature setting. 4. Stop the air handling unit (IMPORTANT! Do not open the safety switch). All the electrical output steps shall switch out (= the contactors in the off position). The air handling unit fans may continue to operate for approx. 2 5 minutes after the unit has stopped, to cool the heating energy that is stored in the air heater. The electric air heater is equipped with three temperature limit switches. The two that automatically reset themselves shall be set to 70 C. The overheating protection with manual reset opens the circuit at approx. 120 C and is located on the cover panel on the side of the coil. Prior to resetting, determine what caused the unit section to overheat and take appropriate remedial action. Note that the risk of overheating increases on decreasing airflow. The air velocity should not exceed 1.5 m/s.

20 Page Air handling with the focus on LCC 10.4 Air Cooler, for chilled water General Sizes Sizes Figure 13. ESET-VK Air cooler The air cooler for chilled water consists of a number of copper tubes with press-fitted aluminium fins. The capacity of the coil is impaired if its surfaces become coated with dust. This will not only impair its heat transfer performance; it will also increase the pressure drop on the air side. Even if the unit is equipped with excellent filters, with the passing of time, dust will collect on the front edge of the coil fins (inlet side). A drip tray with a drain is located below the air cooler for draining condensate across a water trap. In order to utilise full coil output, the water circuit of the coil must be adequately vented. The coil tubes can be purged of air by opening air release screws in the pipe connections and/or by means of an air vessel Inspection 1. Inspect the condition of the coil fins. 2. Check that the coil isn t leaking. 3. Check the drip tray, drain and water trap, and clean if necessary. If the water trap lacks a non-return valve, it shall have to be filled with water Cleaning If the fins on the coil are fouled: vacuum clean them from the inlet side, or carefully blow them clean with compressed air from the outlet side. If the fins are especially dirty, spray them with warm water mixed with dishwashing detergent (such that doesn t corrode aluminium) Venting Vent the air cooler and its piping.

21 Air handling with the focus on LCC Page StarCooler Cooling Unit 11.1 Cooling and heat pump system General All cooling and heat pump systems basically operate according to the same principle. The system transports the heat content in the medium, such as air, water, gas, etc. from one place where the heat isn t desirable or needed, to a place where it is possible to utilize the heat, or get rid of it. Your plant is designed and installed to meet specific requirements. Special components have been selected and combined into a system to meet these requirements offering optimal safety and lowest possible overall cost. The system has been designed in accordance with specific fundamental prerequisites that must exist for it to operate. These prerequisites must not be altered without first investigating whether this system change is feasible How the cooling circuit works See the flow diagram. The refrigerant in the cooling circuit absorbs heat in the component to be chilled as it passes through the evaporator. As its pressure drops, the refrigerant evaporates and transforms from liquid to gas. The cold suction gas that has now absorbed the heat from the chilled space/medium is drawn back to the compressor where it is compressed and heats up. In all fully hermetic compressors, the suction gas is also used to cool the electric motor that drives the compressor. The refrigerant now contains heat from the component being chilled, heat from the compressor motor and heat generated by compression. The refrigerant is in the form of hot gas when it leaves the compressor and circulates to the condenser where it gives off its heat. The refrigerant then condenses as it cools, transforming from gas to liquid. This occurs repeatedly in a totally closed system, until the temperature in the chilled/heated medium drops/rises to its set point Operation, control, ECU Interlocking The compressors are interlocked across the supply air fan and the extract air fan. If one of these fans should stop, the compressors will be switched out Operation On an increasing control signal for cooling, the compressors are started in response to a signal from the compressor control circuit board, KSK. On a decreasing control signal for cooling the compressors are stopped. The in-operation status of each compressor is indicated by a lit green LED.

22 Page Air handling with the focus on LCC Compressor protection If the motor protection or the safety circuit alarm trips, the compressor will stop, a red LED will light up and the group alarm relay on the KSK will be energised. In the event of an alarm, trace and remedy the fault. Then press the reset button on the KSK. The tripped safety circuit alarm (high pressure) can be reset on the KSK and the manual reset button on the pressure switch. A tripped safety circuit alarm (low pressure) can only be reset on the KSK. Important! Each pressure switch has a manual reset button. The safety circuit alarm will trip in the event of two different faults: High pressure in the system, HP Low pressure in the system, LP If the safety circuit alarm trips repeatedly, get in touch with an authorised refrigeration service technician Technical description The electrical equipment panel for the ECU unit contains the following: Main switch Protective motor switch Contactors Auxiliary relays Compressor control circuit board The electrical equipment panel is fitted inside the ECU unit and is supplied with fully wired internal electrical connections and has been tested at the factory. Electrical connections: Terminals L1, L2, L3, N, PE Power supply: 400 V+N and earth Terminals Group alarm for the compressors Terminals Interlock from potential-free contacts, SF and EF Terminals Voltage supply: 24 V AC to KSK 3 VA Terminals 207 Control signal: 0-10 V DC cooling signal Size Type Rec. fuse rating 09 ECU AT 13 ECU AT 18 ECU AT 28 ECU AT 33 ECU AT

23 Air handling with the focus on LCC Page Summary of specific rules in the Refrigerant Act One-piece AHUs incorporating cooling circuits that contain less refrigerant than 3 kg The maintenance and operation of these units must be carried out with good judgement and at one s own responsibility. This means, for example, that if you discover a leak, you must not charge the refrigeration circuit with additional refrigerant until the leak has been sealed. Furthermore, one must always take charge of refrigerant emptied from the refrigerant circuit and see to it that it either is reused or sent to an appropriate facility for destruction. As far as service and maintenance are concerned, no qualifications stipulated by authorities are required of the technician who carries out this work. Nevertheless common sense and good judgement are important when servicing the unit. If servicing the unit involves work in the refrigeration circuit, only technicians with certified qualification shall be permitted to carry out this work. No reporting to the authorities is required in conjunction with these cooling units. One-piece units charged with 3 kg or less refrigerant shall be rated in system calculations as if they didn t contain any refrigerant at all. This means that you can add or include any number of one-piece units of the type described above in a ventilation system, without being required to take increased refrigerant volume into account One-piece AHUs incorporating cooling circuits that contain more refrigerant than 3 kg Besides complying with the above, the units and components of these systems shall be inspected in accordance with local standards and regulations at least once a year. The responsibility for seeing to it that this inspection is carried out rests on the owner of the system. A permit/authorisation for this is required for all permanent installations Instructions for operating the system Regulations for Commissioning The StarCooler is a factory-built one-piece unit tested and documented at the factory. The size 09, 13 or 18 units done not required special commissioning by a certified person. The contractor himself can commission the system after the following work has been completed: DX Cooling unit 1. Wiring the power supply to the main switch and the control signal leads for cooling operation. 2. The condensate discharge pipe has been connected to a drain across a water trap. 3. The supply air and extract air flows through the air handling unit have been adjusted in accordance with the design flows.

24 Page Air handling with the focus on LCC 11.4 Maintenance Instructions and Procedures General This section of the instructions is intended for general use. We ve worded it in such a way so as to enable you to carry out simple periodical inspections of the system and to show you simple checks that you can carry out before having to call for qualified service help in the event of a malfunction. If more advanced troubleshooting in the system is necessary, you will find the information you need in the accompanying wiring diagrams and special instructions for the components of the system Requirements by authorities in accordance with the Refrigerant Act An inspector from an accredited company shall in accordance with Local Cooling Standards, inspect one-piece cooling units containing more than 3 kg of refrigerant. All service and modifications carried out in the cooling system as well as the charging or emptying of refrigerant shall be recorded in the journal. If the total volume of refrigerant exceeds 10 kg (N.B! Applicable to the total volume of all the units in the building), this must be reported to the local Environmental and Public Health Authorities and must be submitted in an annual report to them Periodic inspection 1. Appoint someone or qualified staff to be responsible for periodical inspections of the cooling system. Make sure that these technicians possess knowledge of how the system operates and where system components are located. 2. The system is designed to operate automatically. The Commissioning Record indicates the settings at which the system was set when it was commissioned. Make sure that the settings on the thermostats, controllers, pressure switches and other adjustable components have not been altered by someone who lacks knowledge about how the system operates. 3. See to it that the plant room or other locations of components included in the system are kept clean. 4. Certain components in the system may require open space for contact with the surrounding air to operate properly. Make sure that this open space is not temporarily or permanently blocked in any way. If any of these components is equipped with an air filter or dirt filter, check these filters every third month. Replace filters whenever needed. 5. The cooling unit does not normally require any lubrication, oil changes or the like. In cases where special regulations pertain to any specific system component, this is explained in the instructions for that particular component. 6. The system and its components shall be inspected by qualified service technicians at least once a year. The inspection should include the following: Check the refrigerant system for tightness. Check that the system hasn t sustained any serious corrosion damage. Check that the safety equipment is in good condition. 7. Keeping a journal. Entries shall be made every time each system is charged or emptied of refrigerant, the results of searches for leakage and other measures in conjunction with inspecting and servicing the refrigerant circuit and its operation. 8. Are you unsure about anything inside or around your cooling system? If so, get in touch with your supplier! Sometimes it s better and cheaper to call once too often than too seldom.

25 Air handling with the focus on LCC Page Fault tracing and leakage tracing Fault tracing schedule Symptom Possible cause Remedial measures Too high temperature in the cooled item/medium The power supply has been isolated. Check the control/safety switch and the relevant fuses. None or poor flow across the evaporator. Check that nothing is restricting the flow. The compressor is not operating The low pressure switch switches out compressor. The high pressure switch switches out compressor. Substantial frosting on the evaporator, Thermostat/control equipment incorrectly set/faulty. Compressor isn t operating. The power supply has been isolated. Adjust the setting or replace the equipment. See under "Compressor" Check the control/safety switch and the relevant fuses. Compressor switched out by safety circuit. Check and reset if necessary. Faulty compressor Determine the fault. Fit new compressor. Insufficient volume of refrigerant. There is a leak in the system. Seal the leak and charge with refrigerant. No flow or poor flow across the evaporator. Check the flow across the evaporator. Expansion valve is faulty. Examine the valve, replace it. Faulty low pressure switch. Examine the switch, replace it. No flow or poor flow across the condenser. Check the flow across the condenser. Faulty high pressure switch. Expansion valve is incorrectly set/faulty. Insufficient volume of refrigerant. Examine the switch, replace it. Examine the valve, replace it. Check in sight glass. The system has a leak. Seal the leak; charge w. refrigerant Searching for leakage A search to detect leakage in the system should be made at least once per calendar year as a preventive measure. This leakage search should be recorded and entered in the journal. The cooling system can develop a leak. This becomes apparent first by impaired cooling performance or the system won t operate at all due to a momentary leakage. If you suspect refrigeration leakage, check the level of refrigerant in the sight glass of the system. The sight glass is located in the fluid pipe by the cooling unit. If you see bubbles continuously forming in the sight glass, and at the same time the cooling performance of the system is poor, there is probably a leak in the system. If you see just a few bubbles in the sight glass when the machine starts up, and notice that it operates with reduced output or operates normally this does not necessarily mean that there is too little refrigerant. IF BUBBLES APPEAR IN THE SIGHT GLASS AND THE PERFORMANCE OF THE COOLING UNIT IS APPRECIABLY POOR GET IN TOUCH WITH AN AUTHOR- ISED REFRIGERATION SERVICE COMPANY FOR HELP. Bear in mind that refrigerant must not be discharged to the atmosphere and that leaking refrigerant can cause scalding injuries if it comes in contact with the skin. Whenever service work is done on the refrigerant circuit, the technicians involved must use proper protective equipment. ANY MODIFICATIONS IN THE REFRIGERANT SYSTEM MUST ONLY BE CAR- RIED OUT BY AN ACCREDITED INSPECTORATE A COMPANY WITH THE PERMIT REQUIRED

26 Page Air handling with the focus on LCC 11.6 Flow chart for the refrigerant system Flow chart for the ECU refrigerant system Service space Circuit 1 Circuit 2 1:1 KK Compressor 2:1 KK Compressor 1:2 GP Pressure switch-high 2:2 GP Pressure switch-high 1:3 KD Condenser 2:3 KD Condenser 1:4 FT Drying filter 2:4 FT Drying filter 1:6 MU Meas. tapping-high PRESSURE 2:6 MU Meas. tapping-high PRESSURE 1:7 VS Thermostatic expansion valve 2:7 VS Thermostatic expansion valve 1:8 MU Meas. tapping-low PRESSURE 2:8 MU Meas. tapping-low PRESSURE 1:9 EV Evaporator 2:9 EV Evaporator 1:10 GP Pressure switch-low 2:10 GP Pressure switch-low 11 Supply air fan 12 Extract air fan

27 Air handling with the focus on LCC Page Technical specification Technical specification for the ECU Survey of the capacities Size Output variant Air flows: Rated supply/extract air (m 3 /s) Air flows: Min. supply/extract air (m 3 /s) Air flows: Max. supply/extract air (m 3 /s) Rated cooling power at: t outdoor air: 26 C, RH 50 % extract air: 22 C 50 % Rated power demand, compr. (kw) (kw) Rated cooling efficiency factor (C.O.P) Number of compressors (st) Number of control steps (st) Max conn. power, compr. (kw) Max op current, 3 x 400 V, 50 Hz (A) Rec. fuse rating, 3 x 400 V, 50 Hz (A) Refrigerant: R407C, Circuit 1 (kg) Refrigerant: R407C, Circuit 2 (kg) ECU Wiring Diagram Group alarm, cooling unit Cooling unit interlocking via supply air and extract air fan G Go 0-10 V= 24 V~ Control

28 Page Air handling with the focus on LCC 12 Technical Survey Rot. heat exch. Functions Plate heat exchanger Cool. unit Delivery Option One-piece unit Block unit Flow range (m3/s) One-piece AHU with rotary heat exchanger Block AHU with rotary or plate heat exchanger Block AHU with rotary or plate h exch, cooling unit Size Dimensions Width* (mm) Height** (mm) Duct connection (mm) ø250 ø315 ø x x x x x x800 Cooling power, Starcooler (kw) External fuse rating Starcooler, 3-phase 400 V 10 A 16 A 20 A 35 A 35 A AHU Control, 3-phase 400 V 16 A 16 A 16 A 20 A 16 A 16 A 16 A 25 A 25 A * Add 200 mm for the StarCooler ** Add 350 mm for the control equipment cubicle

29 Air handling with the focus on LCC IV Produkt AB, Box 3103, SE Växjö, Sweden Phone: +46 (0) D