Technical instructions

Transcription

1 Energie Transfert Thermique Technical instructions A different climate Environmental control solutions Version

2 IMPORTANT The validity of our guarantee is conditional upon compliance with these technical instructions as stipulated in ETT General Terms of Sales. Maintenance shall be performed by a specialised company. Special attention shall be paid to cleaning and replacing filters regularly. We hope that you will enjoy your ETT equipment and trust that it will provide you total satisfaction.

3 Energie Transfert Thermique Contents A. Maintenance intervals...4 B. Specific recommendations...5 C. Specific operational recommendations...10 D. Controller operation...12 E. Diagnostics and troubleshooting support...13 Appendix 1. HÉOLAIR unit (adiabatic air washer)...17

4 A. Maintenance intervals Please remember: > Use the unit maintenance book provided by ETT to follow up and keep track of the maintenance operations described hereafter. > The validity of ETT guarantee is conditional upon strict compliance with operation and maintenance instructions presented in this document. > The application of operation and maintenance recommendations is essential to ensure units efficiency and durability. Maintenance intervals: Q (Quarterly), H (Half-yearly), A (Annually) Operations: Q H A General control: Check casing Clean siphons and condensate drain Read operating time Check securities Ventilation: Clean or replace filters (4 mm thickness filters) Clean or replace filters (96 mm thickness filters) Check servomotors and dampers Check and clean fans turbines Check and tighten fans and motors pulleys (if applicable) Check fans bearings (if applicable) Grease fans bearings or change grease cartridges Check fans rotation speed and air flow rates Check ventilation motors Check belts and belts tension (if applicable) Replace belts (if applicable) Read fans motors currents Check propeller fans (if applicable) Read propeller fans motor currents (if applicable) Refrigeration circuits: Control circuit tightness (unit load >2kg "A" >30kg "H" >300 kg "Q") Check refrigerant load and adjust if necessary Check compressor compressor(s) parameters Check compressor(s) currents Check pressures: HP and LP Check temperatures: gas and liquid Check and clean refrigerant-to-air exchangers Check expansion valves Check 4-way valve(s) Heating (if applicable): Check hot water coil Check water quality in hot water coil Check 3-way valve operation Check electric heaters Check warm air heaters (50 to 400 kw capacity) Check warm air heaters (over 400 kw) 4

5 Maintenance intervals: Q (Quarterly), H (Half-yearly), A (Annually) Operations: Q H A Heat pipe (if applicable): Check heat pipe efficiency by measuring temperatures Control heat pipe tightness Check heat pipe jack operation (if applicable) Clean heat pipe Rotary exchanger (if applicable): Check heat exchanger efficiency by measuring temperatures Control brushes / gaskets tightness Check and clean heat exchanger Check heat exchanger drive motor Check heat exchanger belt Check bearing greasing (if not life-time lubricated) Replace heat exchanger belt Every 3 years Replace heat exchanger bearing Every 5 years Electricity/Control: Check controller clock Check setpoints Tighten electrical connections Check temperature probes Clean smoke detector head Replace smoke detector head Nota: Maintenance intervals are given as an indication only. Replacement may be needed more regularly in polluted atmospheres. Replace smoke detection box battery Replace hygrometry probes (if applicable) Replace CO 2 probes (if applicable) Every 2 years Every 2 years Every 2 years Every 2 years B. Specific recommendations 1/ Heat exchangers cleaning If necessary, clean the heat exchangers using a stiff bristle brush, a vacuum cleaner or a compressed air jet. Rinse with cold and low pressure water, avoid spattering water on the fan motor. Clean in counter flow of the air flow way. 2/ Filtration Poor filtration or significant fouling can affect unit efficiency and damage the refrigeration circuit. Nota: The filters referred to in the above table cannot be cleaned more than 2 or 3 times. Cleaning more times would dramatically reduce filtration performance. Filters should not be regenerated more than three times. If a filter cannot be regenerated, replace it. 5

6 Metal filters regeneration > Clean the filter with warm water and liquid detergent. > Rinse thoroughly and dry using compressed air or air current. > Re-treat filter media with "filter-coat" or a similar product, to restore original performance. > Check that filtering elements are correctly installed when reassembling. "Fabric" filters regeneration > Clean and dry as metal filters. > Reassemble in the support frame. 3/ Fan bearings Most centrifugal fans in ETT units are equipped with life-time lubricated ball bearings which require no maintenance. However, bearings clearance must be checked. > For other fans equipped with lubricators, we advise you to check and add grease on a quarterly basis. > For your information, our fan bearings have an expected lifespan of 100,000 hours. 4/ Particularities of corrosive / saline atmospheres > Grease fan bearings and shaft monthly (whatever the type). > Check and clean fans monthly. > Clean heat exchangers with clear water 5/ Smoke detector head cleaning Operation must be controlled periodically, according to regulations applicable to the building. For type 1 detectors (S6), the secondary source must be controlled monthly by holding the "secondary source test" button for at least 5 seconds. The "power" indicator must remain switched on. 6/ Accessing the rotary exchanger (D module and PACARE HPE+) The rotary exchanger is track-mounted to facilitate access. For interventions, open the access, dismount the angles and slide the rotary exchanger out.! In accordance with installation instructions, The unit must be installed with sufficient lateral space to allow interventions. 6

7 Rotary exchanger lateral space: Loosen fixing angles Teflon plate to slide the exchanger Nota: Maintenance zone must be sufficient to fully slide out and access both sides of the heat exchanger. The following table indicates the minimum space required. Unit Required lateral maintenance zone (in mm) CH D HPE CH D HPE CH D HPE+ 150 PACARE HPE PACARE HPE PACARE HPE PACARE HPE PACARE HPE PACARE HPE

8 7/ Condensing boiler module 1 - Maintenance Correct operation and regular maintenance (at least once a year) are the best way to ensure unit rational and efficient operation, low consumption and high durability. The unit must be cold and gas and power supplies must be cut before any maintenance operation. Maintenance operations must be performed by qualified personnel only. Parts CC+ Module Exhaust duct Condensates evacuation (siphon) Maintenance operations Control all securities operation and check all screws tightening. Control fresh air intake ducts and smoke evacuation ducts. Ducts must be smoke-tight and corrosion-resistant. Water acidity after natural gas combustion is of PH. The condensates neutralisation kit must be replaced yearly. ETT cannot be held responsible for any damage to equipment that has not been properly maintained. Check condensates evacuation siphon Burner Unplug electrodes, burner fan electrical connection, venturi tube / gas block. Dismount the gas injector from the gas block. Dismount the front plate / fan / combustion chamber venturi assembly. Clean the burner using a hand brush, a vacuum cleaner or a blow gun. Check the burner for damage or cracks on the surface. Replace the burner in case of damage. WARNING! Use a new gas gasket when reassembling the gas injector on the gas block. Ignition / Ionisation Heating element Control electrodes fouling and clean if necessary. Check the ignition electrode gap (4 +/- 0.5 mm) and the gap between the electrodes and the burner ( +/- 1 mm). Check the sealing gasket. Replace if necessary. Check the ionisation current value. If ionisation current is lower than 3μA, check the ignition / ionisation electrode, the ignition line and earthing. Control the front plate gasket. Check the insulating part between the thermal exchanger front and back plates. Handle the plates with care. Any damaged or hard gasket must be replaced. Clean inside the heat exchanger using a hard brush (available as an option). Do not open the expansion tank if it is still hot, severe burns may occur! Check level, with the unit stopped and cold! Fluid level should reach the cap. Fill with fluid with -20 C antifreeze, only if necessary. Warning: Use only antifreeze fluid specified by the manufacturer. Expansion vessel

9 Parts Maintenance operations Pump Control pump operation. Check the pressure sensor for potential pump fault. In a few cases of long-term interruption, the pump might need to be unjammed. In such case, switch off the unit, unscrew the pump cap, put a flat screwdriver through the hole and turn until completely unjammed. Measure O 2 /CO 2 level and smoke temperature. Warning: regulations impose maximum values. Refer to your distributor or local organisations for more information. If the values indicated in the table below are not reached, the boiler requires complete maintenance Combustion Type of gas Pressure when stopped Pressure during operation O 2 with screw A high flow rate O 2 with screw B low flow rate Maxi CO in PPM NG LPG G20 (natural gas) 20 to 50 mbar mini 1 mbar 5% 6% G25 (natural gas) 25 to 50 mbar mini 20 mbar 5% 6% G31 (LPG gas) 2 to 50 mbar mini 25 mbar 5% 6% Control the flame through the lens. It must be stable, blue with orange particles around the burner (High Speed). During inspection, check that the analysis probe is hermetic at the sampling point, i.e. the probe end that is in the middle of the smoke evacuation flue. 2 - Recommendations to the user Safety rules - Never block smoke evacuation and fresh air suction. - Do not change the settings made by the qualified professional. - Do not touch hot and/or moving parts of the module. - Do not put any object on the unit or hang anything from it. - Power and gas supplies must be cut before any intervention on the unit. - Do not change the type of gas used, the unit settings, the security or control systems. It may result in hazardous situations. - Contact the after-sales technician in case of change of gas, gas pressure or supply voltage There is a problem. What should I do Problem Gas smell Burner safety lock-out Solution Close the external gas valve and cut off the power supply. Reset the burner from the control box. If the problem persists, please contact ETT Services. 9

10 C. Specific operational recommendations 1/ Refrigeration system logbook (EN 37-2): For equipment with refrigerant charges of 3 kg or over, the concerned party shall keep an up-to-date logbook of the refrigeration system. The logbook shall be prepared by the installer during installation. It shall be updated after every maintenance operation, as indicated in EN 37-4 standard. The logbook shall include the following information: A. Detailed report of any maintenance or repair operation B. Quantity and nature (new, reused, recycled) of refrigerant added during the operation Quantity of refrigerant transferred during the operation (see also EN 37-4 standard) C. Results of reused refrigerant analysis (if such analysis was performed) D. Reused refrigerant origin E. System components replacement or modification F. Routine or periodic tests results G. Significant non-use periods 2/ Refrigerant handling Refrigerant handling must comply with French Decree no and European legislation: - Operators must be trained and must hold the relevant F-gas qualification - The company employing the operator must hold an F-gas Company Certificate - Refrigerant leaks must be handled and declared according to the installation refrigerant charge 3/ Unit temporary shutdown! Caution: Special precautions must be taken for refrigerant handling. Please follow the recommendations of the refrigerant supplier. A. Stop the unit. B. If the unit is installed in an area where the temperature is likely to fall below 0 C, do not shut off power to the evaporator crankcase heater (air-to-water, water-to-water heat pump) or to the line heaters. This operation may be handled automatically. 4/ Start-up after temporary shutdown No special precautions are required. To start the unit, reverse the procedure outlined in paragraph "C3 Unit temporary shutdown". 10

11 5/ Unit seasonal shutdown A. If the heat pump includes water circuits, drain them. Also drain the connection lines if the unit is installed in an area where the temperature is likely to fall below 0 C. B. Open the main power switch. Remove the fuse block or lock the main switch in opened position. C. If the heat pump is installed in an area subject to condensation, you may spray oil on mechanical parts which are likely to rust (fan bearings, pulleys, etc.). 6/ Seasonal start-up A. Perform annual maintenance operations (refer to the table in paragraph A. Maintenance intervals). B. Fill the water circuits and bleed the air out as necessary. C. Fully open the compressor discharge valve. D. Open the liquid line stop valve (if applicable). E. Control refrigeration circuit tightness. F. Switch on the main power switch. G. Acknowledge faults on the detection station (if applicable). H. Allow the compressor crankcase heaters to preheat (72 hours). I. Start the system. J. Check operation of all interconnected devices. K. Check oil level and operating pressures after 15 to 20 minutes of operation. Make sure that refrigerant flows in a steady stream with no bubbles. 7/ Generating set - EJP (peak load reduction) Equipment powered by a generating set must be correctly stopped. Refer to the procedure detailed in paragraph "C3. Unit temporary shutdown". This can be managed manually or by programming the BMS according to feedback from your energy supplier if you have a peak load reduction agreement. Failure to take this precaution could result major damage to the unit or cause components to break (electrical components, compressors). In such circumstances, components are not covered by ETT guarantee. 11

12 Technical instructions D. Controller operation 9 1/ Starting or stopping the unit Press and hold the ENTER key for 5 seconds. ON 2/ Acknowledging faults Press the ALARM key to view the fault. 9 Correct the fault on the corresponding component (reset smoke detector, fire thermostat or freezestat, activate thermal protection, etc.). Press and hold the ALARM key for 5 seconds to acknowledge the fault. ON 9 3/ Access level 0 - User settings Access to: - points - Operating schedule - Clock setting ON Hold the UP and DOWN arrow keys simultaneously for 2 seconds. Password = 0 9 Use the arrow keys to scroll through menus. Press the the selected menu. ENTRER key to 9ON 9 to scroll through the masks. Use the arrow keys 9 Press the ENTER key to access mask setpoints. 9ON ON Use the arrow keys to select the setpoint to edit. Press the ENTER key to access the setpoint. 9ON ON 9ON Press the ESC key to return to the main mask Use the arrow keys to adjust the setpoint. 9 9ON ON ON 12

13 4/ Access level 1 - Maintenance Access to: - Maintenance - Communication - Alarms history - Energy meter - Inputs - Outputs - Meter reset Hold the UP and DOWN arrow keys simultaneously for 2 seconds. Password = 1 n-off n-off n-off larm nter Use the arrow keys to scroll through menus. Press the ENTRER key to the selected menu. 9 Use the arrow keys to scroll through the masks. Press the ENTER key to access mask setpoints. 9ON Press the ESC key to return to the main mask Use the arrow keys to select the setpoint to edit. Press the ENTER key to access the setpoint. ON Use the arrow keys to adjust the setpoint. 9ON 9 E. Diagnostics and troubleshooting support ON 9 ON 1/ Smoke fault Smoke detection Fouled detector head ON - Check for smoke or dust - Clean detector head - Replace detector head - Acknowledge the fault (see D.2) - Check for smoke or dust - Clean detector head - Replace detector head - Acknowledge the fault (see D.2) Backup battery out of service - Replace battery 13

14 2/ Filter fault Fouled filters Fouled exchangers - Clean filters - Replace filters - Clean exchangers according to the recommendations 3/ Air flow fault Fouled filters Leak on air network Transmission problem Fouled air network - Clean filters - Replace filters - Repair air distribution network - transmissions - Clean air distribution network 4/ Fire fault Insufficient air flow Transmission problem Faulty thermostat - Check filters - Check fan and fan motor - Check transmission - Check thermostat 5/ Antifreeze fault Insufficient air flow Transmission problem Faulty thermostat Lack of hot water - Check filters - Check fan and fan motor - Check transmission - Check thermostat - Check boiler house and pump 6/ Drives fault Current fault - Check power supply network for disturbances 14

15 7/ Low pressure fault Poor air flow Low pressure switch malfunction Fouled filters Expansion valve malfunction Inefficient defrosting Refrigerant charge problem - Refer to E3. Air flow fault - Check pressure switch operation - Check pressure switch connections - Clean filters - Replace filters - Check expansion valve (status, settings, operation) - Check refrigeration circuit probes - Check 4-way valve - Check defrost settings - Check tightness / High pressure fault Poor air flow High pressure switch malfunction Fouled filters Outside T out of application range Poor air distribution - Refer to E3. Air flow fault - Check pressure switch operation - Check pressure switch connections - Clean filters - Replace filters - No action - Check air distribution network 9/ Refrigeration circuit fault A. The compressor does not start. Electrical protection fault Control security Abnormal supply voltage Propeller fault - Check protections - Check control parameters - Check securities - Reset controller if authorised - Check phases - Check voltage drop at unit start-up - Check power supply chain (wire, connections, contactor, etc.) - Check propellers 15

16 B. The compressor stops. Low pressure fault High pressure fault Ipsotherm fault Thermal fault Power supply chain interruption Propeller fault - Refer to E7. Low pressure fault - Refer to E. High pressure fault - Check compressor cooling - Check ipsotherm probe - Check filters for fouling - Check compressor's absorbed current - Check voltage drop at start-up Check power supply chain (wire, connections, contactors, etc.) - Check propellers C. The compressor is noisy. Knocks Slugging Grunts - Check compressor suction pressure - Check valves status - Check overheating - Check expansion valve bulb fixation - Check supply voltage - Check phases - Galling => broken part D. The compressor does not stop. Temperature setpoint too far from recommended temperatures Stuck contactor - Check temperature setpoints - Check contactor E. Lack of capacity. The expansion valve hisses Severe overheating Pre-expansion Wrong flow rates - Check expansion valve settings - Check charge - Check expansion valve settings - Check charge - Check drier filter - Check flow rates 16

17 Appendix 1. HÉOLAIR unit (adiabatic air washer) Maintenance operations must comply with the following instructions from the supplier (MUNTERS). 1/ Dispensing orifices cleaning 1- Before cleaning, shut off water supply and open the drain valve to empty the tank. 2- Remove the pipe connected to the distribution header. 3- Turn the distribution header lock a quarter turn to open it. This lock holds the header into position during operation. 4- Remove the distribution header from its support, on the front of the humidifier. 17

18 5- Clean the dispensing orifices as follows: Method 1: Connect the distribution pipe to a pressured tap water system and rince it. In most cases, the results are satisfactory. Method 2: Remove end caps. Turn the distribution tube to remove it. You can now see the dispensing orifices. Clean the orifices using a pointed tool and rince the inside of the distribution pipe. 6- Reverse this procedure to reassemble. 2/ Pump tank and filter cleaning 1- Remove the end plate above the pump filter and take out the filter. Clean the filter. 2- Clean the bottom of the tank. Wash it and make sure that there is no dirt left. 1

19 3/ Restarting 1- Close the bottom valve. 2- Check and adjust the tank water level by screwing the float. The level must be approximately 5 mm below the overflow protection. 3- Switch on the pump circuit breaker. 4- Check that the distribution header's pressure locks are in the locking position. Press the locks to lock them. 5- Check the drain rate. 19

20 4/ Cassettes and eliminator plate dismounting (during mat replacement only) 1- Remove the distribution header as indicated in the pictures 9 to If an eliminator plate is installed, remove it as indicated for cassettes in pictures 17 or 1. Handle the cassettes with care to avoid damaging the GLASdek material. Use the metal frame to insert, remove or lift the cassette. 3 a- If you need to remove cassettes from the side, first lift the guillotine. 3 b- You may also remove cassettes from the back, in the air flow way. 20

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22 T r a n s f e r t T h e r m i q u e Design: ETT - Document printed by an environmentally friendly printer using vegetable based ink on PEFC paper created from sustainably-managed forest. E n e r g i e A different climate Environmental control solutions 56 Route de Brest - BP PLOUDALMEZEAU - France Tel: +33 (0) Fax: +33 (0) Export Contact: +33 (0) ETT Services: +33 (0)