Systemair DVCompact Softcooler Installation and Service Manual
Contents
1. gt systemair Complete cooling unit for DVCompact DVCompact Softcooler 20 DVCompact Softcooler 80 Installation and Service EG nie EN_GB eae Se Document in original language 04 02 2014 A001 Contents Declaration of Conformity acicate ads 1 E O 2 3 Description of DVCompact Softcooler ccccecceeceeceeeeceeeee ae eeeeeeeeeaeeeeeaeeeeaeeeeeaeeessaeeeeaeeeeseeees 3 3 1 DVCompact Softcooler Cooling SCCtION 0 cece cece eee teeeeee aaa tere eeaaeeeeeeaaeeeeeeaaeeeeeeaaeees 3 3 TA Batteries oa AA Ar AL da des 3 SkA COMPTesSs OMS limosna tecabecatbeeatadantecabedadtulstadatebevtadansgaviddaddeess 3 Ska REMO id A A A bd 3 3 1 4 Control panel and automatic CONTTO S oooooocococcccnncccnoccccnncnnnncnncnnnnnnnnnnnnnnnnnnnnnnnnnnannnn 4 4 FUNCHON principle oi ii e A added 4 A V Function ANA CONO oca a A a aa e Al an 4 4 2 Other regulation cui es 5 Dc lInstallationis lt 2 E capebaes 5 5A ASSOMDIY A E ii dc 7 6 Positions and placement 2 ccccccccceeeceeeee raaa TAn eae Ene anar a aama a aA ALe A eroa aa aaraa fisa 8 6 1 Positioning Of Compressors riseire e ae eea EAA aE a RA EET ARAKEA EA RAAEN 8 Electrical COMME CUOMM a AATE T E A E E AE 8 7 1 Rotational direction of compressor S eesssssssrresecrrsesssrrrreerrritesrnireedantedsantireernetaeranineenne 9 8 COMMISSIONING eriein ienien d dabid lane O A pda 9 8 1 Before Starnmt up aia tt beck Be race acest DAA DAL diate a ei 9 8 2 Contr2. is the installer s responsibility to carry out a comprehensive safety assessment of the unit as well as preparing safety regulations so that that user is able to secure the unit such that it does not cause harm to people animals material or environment If there is any doubt about how to interpret the regulations covering safety installation operation and maintenance it is of the utmost importance that advice is sought from Systemair LT or its distributors Complete cooling unit for DVCompact Installation and Service 2 Systemair AB 3 Description of DVCompact Softcooler 3 1 DVCompact Softcooler Cooling section The DVCompact Softcooler cooling section is a complete unit with integrated cooling In other words all electrical and pipe work is completed at the factory The enclosures are in the same design as the DVCompact unit series i e 50 mm Rockwool in a sandwich construction consisting of two aluzinc 185 steel plates Corrosion class C4 On the front of DVCompact Softcooler there is a large door for easy access to the components There is also an integrated window and control panel door for easy access and inspection during operation The sections come in seven different sizes and 12 power variants all DVCompact compatible 3 1 1 Batteries The batteries are already fitted in the box with all pipe connections complete Evaporator and condenser batteries are mounted on the same side in the box so that the piping bet
3. 1 One or two room sensors must be mounted These functions can be chosen freely Constant supply air control must not be used during cooling All required set points for temperature are set according to the selected form of regulation 8 4 Other DX functions e Blocking of DX using the outdoor temperature e Blocking machines when there is low fan acceleration e g low airflow Own set point for minimum supply air with active DX Exchange control form using outdoor temperature e Delayed connection and disconnection of DX machines e Option for setting of P and time for temperature Complete cooling unit for DVCompact Installation and Service 10 Systemair AB With sensible selection of functions and set points you ensure problem free operation and cooling on demand thanks to the compressor frequency control Demand control also ensures that you do not have to activate the uneconomical compensation with rotors that some single ON OFF compressors need to maintain the minimum temperature 9 Service and maintenance A Warning Before you begin maintenance make sure that the voltage to the unit is switched off All maintenance must be carried out by authorised personnel All maintenance and service relating to cooling technology must be carried out by an authorised cooling company 9 1 Cooling technical maintenance An annual inspection service and check of the cooling technology is required This needs to be c
4. arried out more often in relation to any special conditions to which the unit is exposed This is a requirement for the warranty conditions to be valid Suggestions for checks may include e Drain trap and draining from tray Any abnormal noises from the compressor s Loose clamps for fastening pipes and components Oil leaks from pipes or compressor s e General cleaning vacuuming and if necessary washing using detergent Any corrosion on soldering or pipes e Checking for leaks in the cooling circuit e Connection of manometer for reading pressure e Any refilling with refrigerant R410A e Visual checks in sight glass Any replacement of dry filters A manometer can be connected from the control panel during operation to achieve normal operating conditions Detailed written reports must be made and handed to the person responsible for keeping a log 9 2 Electronic expansion valve The expansion valve is one of the most important components of the cooling system This is adjusted at the factory and superheating lies between 4 6 K Warning If there are any leaks in the refrigerant circuit Systemair must be contacted for further handling 9 3 Other maintenance DVCompact Softcooler does not require any maintenance other than the annual service During this service things to be checked in addition to the cooling technology should include Tightening of clamps in the cabinet e Measuring power con
5. calise the fault easily ensure that there is a cooling need by turning down the desired exhaust room temperature After a while the k4 6 relay or k4 7 relay should kick in Cooling levels 1 and 2 If they do not there is a setting that is preventing the regulator from kicking in the cooling See DVCompact Operating and maintenance Also check that the analogue output 0 10 V increases with the cooling need If the relay s kick in but the compressor does not start the fault is located in the cooling box or cabling between this and the unit cabinet 10 2 1 High exhaust temperature or insufficient air volumes Check the technical calculations for the unit and see which air volumes the unit is calculated for The problem that may occur is that the condenser cannot get rid of the excess heat and the high pressure pressostat trips Increase the set air volume or with variable air volumes VAV block cooling when there is low fan acceleration This is a setting that can be made on the control The temperature of the exhaust is as a starting point dimensioned for max 254 C to the condenser at higher temperatures the cooling capacity is gradually reduced by the control to avoid that the unit is stopped by the high pressure pressostat Significantly higher temperatures can lead to problems The same problem solution as above Also activates summer night cooling to bring down the temperature in the building using cool night air so that the buildi
6. ct Softcooler and any electrical batteries are made for separate power supply which is basically sensible considering that these are high currents and require cables with a large cross section However if desirable it is possible to pull one main cable out and divide conduits at the unit Dimensioning of the conduit can also be drawn according to either the unit electrical battery or unit DVCompact Softcooler or according to which has the greatest power This is possible as there is never simultaneous acceleration for the electrical battery and cooling 8 Commissioning 8 1 Before start up Power and snap on connectors in place Correct voltage connected e Safety switches and fuses on e Visual check of the unit no loose objects everything electric connected Drain trap fitted Complete cooling unit for DVCompact Installation and Service 9 Systemair AB E Systemair 8 2 Control of DVCompact Softcooler The DVCompact Softcooler cooling section is controlled as needed from the regulator on the unit DVCompact is supplied with a Corrigo E28 regulator Functions for control of DVCompact Softcooler are set in the regulator at the factory Similarly there are settings that shall and must be carried out on commissioning These settings can be made with the supplied control display or by connecting to a PC and using E tool which is a free PC configuration tool This can be downloaded from our website Note This docum
7. eeding with Al an Al Cu transition is used Depending on local rules and regulations correctly dimensioned earth fault switches must also be used on power circuits for DVCompact Softcooler Earth fault switches must be at least 100mA and one attribute must be adapted to frequency converter operation EMC filter must be removed Complete cooling unit for DVCompact Installation and Service 8 Systemair AB 7 1 Rotational direction of compressor s Caution When connecting power it is important that an electrician first checks that the phases are in the right place It is only necessary to check this on Softcooler Compact with two compressors here the phase guard ensures that the compressor works in the right direction This can be checked easily after the power has been connected by seeing whether the phase guard has triggered relay output at point 11 and 14 or that relay 7k02 has kicked in This relay must always be in when the power supply is connected Phases are switched if this does not happen On DVCompact Softcooler with one compressor the rotational direction of the compressor is taken care of using a frequency converter and rotational direction is independent of the phases of the main switch An electrician must also check the snap on connectors between unit sections are in place These are checked simply by opening doors and checking that all plugs are fitted between the modules Note Unit DVCompa
8. ent refers only to the overview of possible functions and settings that apply to cooling Detailed descriptions of how you find these functions are available in the Operating and maintenance instructions for the unit 8 2 1 General Control unit E28 UC senses the temperature via the extract temperature sensor ETS and then keep the set extract temperature by sequense controlling the compressor CPR heat exchanger HE and hot water electrical heater HWL H ELH The temperature sensor in the supply air SS is min and max limiting the supply air temperature 8 2 2 Power control The compressor CPR are step less controlled between in the frequence converter FC set minimum and maximum frequency 8 2 3 Power limitation The frequency converter FC is continouously sensing the condensing pressure via the high pressure sensor HPS and gradually slows down the speed of the compressor CPR if the pressure exceeds the set limiation value This is done to avoid a high pressure alarm 8 3 Forms of temperature regulation It can be good to start with which form of regulation you require Here are the possible forms of regulation from which you can choose Extract air control factory standard e Cascade room temperature control room control e Outdoor temperature controlled exchange between room control and supply air control 1 Outdoor temperature controlled exchange between extract air control and supply air control
9. from the supplier The refrigerant must under no circumstances be released into the environment As the refrigerant is heavier than air the refrigerant may displace the air and cause asphyxiation in unfavorable conditions A Warning There may be serious mechanical electrical noise or vibration hazards associated with using the equipment contained in the unit In order to reduce the risk of these hazards it is absolutely necessary to observe all regulations that apply to safety installation operation and maintenance For safety reasons only personnel with relevant technical competence may perform installation work The installation instructions supplied must be followed The unit is not to be taken into operation before all protective devices are in place and function tested Any air intake and air exhaust must be protected with grilles No maintenance work may be carried out and no inspection doors may be opened before the unit is switched off and isolated from the power supply You must ensure that rotating parts have stopped and the electrical battery s heating rods have cooled Service switches are locked to prevent unauthorised start up during maintenance work Where condensation water needs to be drained away correct connection to the drain must ensure this The installer must equip the unit with operating and maintenance instructions These safety regulations only apply to products supplied by Systemair LT It
10. greater need for cooling the second compressor starts following an equivalent process 4 2 Other regulation DVCompact Softcooler is always equipped with a frequency controlled compressor i e the cooling effect is adapted to the need either due to variable low air volumes or variable low outdoor temperatures or a combination of these This ensures a more stable operation and energy saving cooling in relation to ON OFF solutions The frequency converter allows a compressor regulation range of between 30 and 60 Hz this gives a cooling effect capacity regulation of 50 Regulation of the compressor s is thus as follows At a given outdoor temperature and when there is a need for cooling in the premises a start signal will be given to the frequency converter pot free from the cooling outlet on the automatic controls The compressor starts and regulates quickly up to 60 Hz before it immediately begins to adjust the frequency downwards as required from the control 0 10 V signal When there is an increasing cooling need the compressor gears up to the maximum before the next compressor gets the start signal The frequency controlled compressor will then sink to a minimum and sit and regulate accurately according to the cooling need For all functions linked to the forms of regulation and settings see chapter 8 in this document In case of alarm either from the pressostats or frequency converter an indication will be given in the un
11. it display Operating fault cooling In case of alarm see chapter 10 in this document 5 Installation Note These installation instructions are only a supplement to the DVCompact installation instructions see our website DVCompact Softcooler cooling box is either supplied with fitted legs or on a pallet depending on size Be particularly aware that the cooling section may have a high centre of gravity if the compressor is positioned at the top of the cooling section Complete cooling unit for DVCompact Installation and Service 5 Systemair AB When lifting with forklift trucks or pallet jacks ensure that the forks go under the entire length of the box otherwise the underside of the box may be damaged When using a crane straps must be secured to legs or any pallets it is important that the straps do not slip during lifting Caution As for all equipment with electrical components it is important that the cooling section is not stored outdoors Water and condensation may in the worst case lead to full short circuit and breakdown when the power is connected If the unit must be stored outdoors ensure that it is protected against rain and allow air to circulate to prevent condensation Complete cooling unit for DVCompact Installation and Service 6 Systemair AB 5 1 Assembly Fitting of the cooling section to other units is carried out using disc lock and assembly fi
12. ling section has to be placed between the rotor box and supply air fan box DVCompact Softcooler is produced in four positions supply air down right and left and supply air up right and left See below for variations Supply air down cooling section marked Supply air left Supply air up Supply air left Supply air right 6 1 Positioning of compressors The compressor s always end up in the exhaust section This is a great benefit as you then have good access to the compressors from the filter side regardless of the position of the unit 7 Electrical connection All electrical work requires a qualified electrician DVCompact Softcooler is delivered completely wired which means that the electrician is only required for connection to the mains DVCompact Softcooler is delivered in all sizes with an external safety switch which cuts all phases and power supply when switched off This is the connection point for the electrician The safety switch is not fixed in place on delivery due to transport The safety switch must be fitted on the front of the large cooling units and on the roof of the smaller ones Wires from the cooling section are routed to the safety switch A Warning Make sure that the voltage in the building is checked against the marking on the unit Voltage is either 3 phase 230 V or 3 phase 400 V An N conductor must be used with 400 V Connection is made for Cu wire when f
13. ne tests referring to appliances under the scope of EN 60 335 1 and EN 60967 EN 60 529 Degrees of protection provided by enclosures IP Code EN 61000 6 2 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments EN 61000 6 3 Electromagnetic compatibility EMC Part 6 3 Generic standards Emission standards for residential commercial and light industrial environments The complete technical documentation is available Skinnskatteberg 31 08 2012 Mats Sandor Technical Director Complete cooling unit for DVCompact Installation and Service 1 Systemair AB 2 Warnings The cooling unit can cause personal injury if installed or used incorrectly Read the documentation for the product carefully before it is installed or commissioned e Inspection doors must always be closed and locked with the corresponding key when the voltage is on Under no circumstances may the box be left with the door unlocked Any work on the product should be carried out by knowledgeable and authorised service personnel When carrying out work service on the cooling circuit s the power must be disconnected and the work only performed by authorised personnel e Delivery pipes are hot during and after operation and contact with bare skin may cause burn injuries The refrigerant for this cooling unit is R410A and cannot be replaced with any other type of refrigerant without written approval
14. ng has a low indoor temperature in the morning This is also sensible in terms of energy use instead of loading the cooling machines with full acceleration on start up in the morning Complete cooling unit for DVCompact Installation and Service 12 Systemair AB 10 3 Electrical faults If the k4 6 relay and possibly k4 7 relay have been triggered in the unit cabinet but the compressor s do not start check the cabling and that the snap on connectors between the unit sections are connected The control for the cooling equipment is located in the cooling box check that operation alarm relay 7k02 kicks in This should kick in when voltage is switched on If this does not kick in the fault is located in the following High pressure pressostat e Low pressure pressostat Fault output on converter High pressure pressostats and low pressure pressostats have an automatic reset Also check whether there are any fault alerts in the converter display see the manual supplied for this If the relay has kicked in and there is still no operation check the start relay s for the compressor s these are marked 7k01 and 7k2 These kick in according to cooling need and follow the named relays in the unit cabinet k4 6 and k4 7 Check the relay and cabling to these in the event of faults If they kick in and the compressor s do not operate see chapter 10 4 10 4 Faults in cooling technology A Important Before carrying out any work
15. ol of DVCompact Softcooler ccecccececeeeeeeeeeecee cess ee ee cea cess ae eeseaeeeeseeeesaeeeeaeeeesaeeees 10 A ral ote esse Pan see san sc Aedes ara Paaa A aa ete araa Aa ADEA AARTE ATREA ATANA aan ANT 10 8 2 2 POWER COMO A a a cans aa 10 8 273 Power IMAN A T A EEEE 10 8 3 Forms of temperature regulatioN ooconniciccconniccccnoosonnnnnnonnncnnnnnnancnnrnnnnn an rra na PERA ET PEASE 10 8 4 Other DX functions a aeea adan 10 9 Service and maintenance r iat aape naet aee aa aaae a A r Aa r aE aaae aae 11 9 1 Cooling technical Maintenance cece cece eee eee ee ee aaa eter ee sane eeeeaaeeeeeeeaaeeeeeeeaaeeeeeaaaeeees 11 9 2 Electronic expansion valves oent iae aa aa an aa aada aa aaa e atanda aeai Taat 11 9 3 Other Maintenance tii a dt aa dada 11 10 TrOUDIGSHOOUNG ca oa 12 10 1 DIAGFAINS vicctiasitio dios a a ar a aa a aa 12 10 2 GENIS criin A A EA E ATAS abe 12 10 2 1 High exhaust temperature or insufficient air VOIUMES ce eeeeeeeeeeeeeeeeeeeeeeeeeeanees 12 10 3 Electrical faults iii ld eves cage Mec ae de ghee edeeha esol aaa 13 10 4 Faults in cooling technology c0cceccecnedeesenccedencenccedeecencuedeecancusenssencudenenanensetesnecsdens 13 1 Declaration of Conformity Manufacturer Systemair AB Industrivagen 3 SE 739 30 Skinnskatteberg SWEDEN Office 46 222 440 00 Fax 46 222 440 99 hereby confirms that the following products Air handling units DVC
16. ompact Softcooler 20 DVCCompact Softcooler 25 DVCompact Softcooler 30 DVCompact Softcooler 40 DVCompact Softcooler 50 DVCompact Softcooler 60 DVCompact Softcooler 80 The declaration applies only to product in the condition it was delivered in and installed in the facility in accordance with the included installation instructions The insurance does not cover components that are added or actions carried out subsequently on the product Comply with all applicable requirements in the following directives Machinery Directive 2006 42 EC Low Voltage Directive 2006 95 EC e EMC Directive 2004 108 EC The following harmonized standards are applied in applicable parts EN ISO 12100 1 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN ISO 12100 2 Safety of machinery Basic concepts general principles for design Part 2 Technical principles EN ISO 14121 1 2007 Safety of machinery Risk assessment Part 1 Principles EN 13857 Safety of machinery Safety distances to prevent hazard zones being reached by upper or lower limbs EN 60 335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 60 335 2 40 Safety of household and similar electrical appliances Part 2 40 Particular requirements for electrical heat pumps air conditioners and dehumidifiers EN 50 106 Safety of household and similar appliances Particular rules for routi
17. on the cooling technology within the warranty period Systemair must be contacted first if necessary with any requests for covering costs Only authorised cooling companies may carry out work on the cooling circuit A manometer should be connected and the pressure checked The temperatures of the different processes are also checked Typical faults may be Compressor cuts out at low pressure pressostat Not enough refrigerant e Insufficient air volume e Electronic expansion valve defect e Pressostat defect Cuts out at high pressure pressostat e Too much refrigerant e High exhaust air temperature e Pressostat defect Freezing of evaporator e Electronic expansion valve defect Not enough air to the battery A leak search is to be carried out when leaks are suspected and during the annual inspection Complete cooling unit for DVCompact Installation and Service 13 Systemair AB Systemair AB reserves the right to make changes and improvements to the contents of this manual without prior notice amp systemair Systemair AB Industrivagen 3 SE 739 30 Skinnskatteberg Sweden Phone 46 222 440 00 Fax 46 222 440 99
18. sumption e Cleaning Complete cooling unit for DVCompact Installation and Service 11 Systemair AB e Review settings and set points e Check vibration dampers A Warning Frequency converters must not be touched normally Converter settings are made at the factory and it is important that the parameters are not changed without consultation with Systemair This could have critical consequences for compressors and the warranty may be invalidated Also see the more detailed maintenance instructions supplied with the unit All technical data for DVCompact Softcooler is supplied and is stuck to the inside of the control panel cabinet The test diagram from the factory instructions for installation maintenance and operation connection diagram and other documents are also supplied with the unit in a plastic wallet 10 Troubleshooting 10 1 Diagrams For troubleshooting use the supplied connection diagram Potential faults are divided into four main categories in practice e Incorrectly set parameters and set points on commissioning e Insufficient air volume or abnormally high exhaust temperatures e Electrical faults e Faults in the cooling technology As a starting point it is sensible to begin with the first two categories 10 2 Settings See chapter 8 for all setting options for cooling lt may for example be the outdoor temperature that is preventing the cooling machine kicking in To be able to lo
19. ttings for the largest see details in the installation instructions for the unit Parts for assembly are supplied with the unit and are found with other parts drain trap handle etc in a box It is important to make sure that the packing between the parts is in place and wires plugs are not crushed Snap on connectors can also be connected together at the same time For service inspection a minimum measurement is required in front of the unit corresponding to the door width of the box When replacing batteries a measurement corresponding to the depth of the unit is required lt is important to make sure that the back edge of the unit is not in contact with the wall in order to avoid transferring noise vibrations Fit the handle supplied Also remember to fit the drain trap supplied This is equipped with a water trap so that the height from the drain to the floor is taken care of with either the supplied feet or base frame Caution It is important to make sure that the unit is completely level after installation so that the condensation water is drained from the tray It is also important that the cooling section is not tilted more than 30 during the entire transportation and installation process Complete cooling unit for DVCompact Installation and Service 7 Systemair AB E Systemair 6 Positions and placement DVCompact Softcooler must always be placed on the warm side of the rotor In other words the coo
20. vice work This is possible to access during normal operating conditions for the unit There are also nipples for refilling and checking the pressures in the cooling circuits The cabinet is equipped with an approved control panel lock and must only be opened by authorised personnel The frequency converter is positioned in the unit section that allows reading through a window in the door 4 Function principle Le 0O OW 4 1 Function and content The main components of the cooling system are 1 Condenser battery 2 Evaporator battery 3 Compressor 4 High pressure switch 5 Low pressure switch 6 Electronic expansion valve 7 Filter drier 8 Sight glass 9 Ball valve 10 Angle valves Complete cooling unit for DVCompact Installation and Service Systemair AB The cooling process is either carried out using one compressor or with two of which one is frequency controlled When required one of the compressors starts so that the refrigerant is compressed and transported to the condenser the refrigerant is cooled in the condenser using extract air and then takes on liquid form The R410A then continues to the expansion valve and reduces pressure and temperature over that before continuing to the evaporator DX battery The liquid evaporates in the DX battery and simultaneously cools the external air The refrigerant then moves on to the suction side of the compressor and the process is repeated If there is a
21. ween the batteries is tidy and service friendly in terms of access during a service The batteries fit the unit s cross section and use all available area in the air flow This ensures low speed and low decrease in pressure Carry over of condensation is thus eliminated The DX battery is placed in a drip tray to drain condensation The tray has an external connection for a drain trap AN Caution It is important that the supplied drain trap with ball is fitted before commissioning 3 1 2 Compressor s From size DVCompact Softcooler 20 and up to DVCompact Softcooler 50 Power variant 1 a frequency controlled compressor is supplied On the largest variants from DVCompact Softcooler 50 Power variant 2 toDVCompact Softcooler 80 two compressors are supplied one frequency controlled and one fixed level The compressor types used are Scroll compressors from Copeland 3 1 3 Refrigerant The refrigerant used for DVCompact Softcooler is R410A This is initially filled at the factory and the relevant quantity is indicated on the cooling section A long term test is carried out with a vacuum to ensure that the cooling circuits are completely free of leaks before refilling with R410A Complete cooling unit for DVCompact Installation and Service 3 Systemair AB 3 1 4 Control panel and automatic controls The automatic controls cabinet is supplied as an integrated part of the cooling box with a door for inspection and ser
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