IV Produkt EcoCooler 100 User manual

Translation of the original instructions
Operation and Maintenance
EcoCooler 100-1280
Order number:
Project name:

Table of Contents
1 Safety precautions
1.1 Personal protective equipment ....................................................................1
1.2 Prevent injury to personal and damage to air handling units 1
1.3 Product signs, information and warning stickers ...........................2
1.4 Safety message ......................................................................................................2
1.5 General safety messages ................................................................................3
2 General
2.1 Intended use .............................................................................................................6
2.2 Manufacturer ............................................................................................................6
2.3 Designations .............................................................................................................7
2.4 CE marking and EU Declaration of Conformity ...............................8
2.5 Maintenance ..............................................................................................................8
2.6 Handling of refrigerant .......................................................................................9
2.7 Extended warranty ................................................................................................11
2.8 Spare parts .................................................................................................................11
2.9 Dismantling and decommissioning .........................................................11
3 Technical description
3.1 Cooling unit, EcoCooler ....................................................................................12
3.2 Detector system, refrigerant ..........................................................................13
4 Wiring instructions
4.1 Electrical connections, ECO and ECX cooling units ....................17
5 Operation
5.1 Commissioning .......................................................................................................18
5.2 Cooling status ........................................................................................................19
6 Maintenance instructions
6.1 Service schedule ...................................................................................................21
6.2 Periodic inspection ...............................................................................................21
7 Alarm management and troubleshooting
7.1 Troubleshooting in the event of an alarm .............................................22
7.2 Troubleshooting via symptoms ...................................................................24

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Operation and Maintenance
NEW EcoCooler
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Continuous product development may give rise to specification changes without notice.
1 Safety precautions
Follow all safety precautions in this document and pay attention to all warning
signs on the air handling unit.
Failure to comply with the safety precautions may result in injury to persons or
damage to air handling units.
1.1 Personal protective equipment
Personal protective equipment must always be used based on the risks present
at the workplace. Comply with national and local laws and regulations.
The following personal protective equipment is recommended where the work
requires:
• Protective shoes with steel cap
• Hearing protectors
• Safety helmet
• Gloves
• Goggles
• Covering clothing
• Protective overalls
• Mouthguard/protective mask
• Fall protection
1.2 Prevent injury to personal and damage to air handling units
To avoid injury to persons or damage to air handling units, pay attention to the
following:
• Read the entire document before working on the unit.
• Comply with national and local laws and regulations for work safety.
• Do not wear loose clothing or jewellery that may get fasten.
• Do not step or climb on the unit.
• Use recommended tools and equipment intended for the job.
• Use recommended personal protective equipment when the work requires it.
• Observe the unit's product signs, information and warning stickers.
• Keep the unit clean and follow the Operation and Maintenance Instructions.
• Make sure that all covers are in place, that inspection covers are closed and
that lockable inspection covers are locked before starting the unit and after
repairs/service.
• Use appropriate fall protection when working at heights - normally over 2
meters. Even work at lower heights may require protective measures.

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1.3 Product signs, information and warning stickers
Keep signs and stickers free from soiling and replace them if they are lost,
damaged or illegible. Contact IV Produkt for replacement stickers; specify the
item number.
1.4 Safety message
The following warning symbols and signal words are used in this document to
inform of risks.
DANGER!
Danger - indicates an imminent dangerous situation which,
if not avoided, can result in death or serious injury.
WARNING!
Warning - indicates a potentially dangerous situation which,
if not avoided, can lead to serious injury.
CAUTION!
Caution - indicates a less potentially dangerous situation
which, if not avoided, can lead to less serious or minor
injuries.
NB:
NB: – indicates a potentially hazardous situation which, if
not avoided, may result in damage or impaired function of
the air handling unit.

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1.5 General safety messages
Comply with the following general safety messages.
Lockable safety switch
DANGER!
Risk of serious injury.
Electrical power can cause electric shock, burns and death.
Working on/servicing the unit –Shut down the unit via the
service switch in the control equipment, then turn the safety
switch to the 0 position and lock it.
There may be several safety switches serving the different
parts of the unit. All safety switches must be switched off
before repairs/service.
NB:
The safety switch is not designed for starting/stopping the
unit. Always use the service switch in the control equipment
to start and shut down the unit.
Electrical connections
DANGER!
Risk of serious injury.
Electrical power can cause electric shock, burns and death.
Working on/servicing the unit –Shut down the unit via the
service switch in the control equipment, then turn the safety
switch to the 0 position and lock it.
There may be several safety switches serving the different
parts of the unit. All safety switches must be switched off
before repairs/service.
WARNING!
Risk of personal injury.
Rotating fan impellers can cause crushing injuries or
lacerations.
The unit must not be energised until all ducts have been
connected.
NB:
Wiring of connections and other electrical work may only be
carried out by a qualified electrician or by service personnel
recommended by IV Produkt.

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Inspection hatches
WARNING!
Risk of personal injury.
Overpressure in unit.
Allow the pressure to drop before you open the inspection
doors.
WARNING!
Risk of personal injury.
The doors in front of moving parts shall normally be locked;
there are no contact guards.
During repairs/service, the inspection doors are locked with
the supplied keys.
Make sure that all hatches are closed and that lockable
inspection hatches are secured before starting the unit and
after repairs/service.
Heating coil
WARNING!
Risk of personal injury.
Hot surfaces can cause burns.
Working on/servicing the unit –Shut down the unit via the
service switch in the control equipment, then turn the safety
switch to the 0 position and lock it.
There may be several safety switches serving the different
parts of the unit. All safety switches must be switched off
before repairs/service.
Wait at least 5 minutes before opening the battery
inspection hatches.

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Cooling unit
WARNING!
Risk of personal injury.
Hot surfaces can cause burns.
Working on/servicing the unit –Shut down the unit via the
service switch in the control equipment, then turn the safety
switch to the 0 position and lock it.
There may be several safety switches serving the different
parts of the unit. All safety switches must be switched off
before repairs/service.
Wait at least 30 minutes before opening the compressor
inspection hatches.
WARNING!
Risk of fire in the event of a refrigerant leak.
A2L refrigerants are mildly flammable and can ignite in the
event of a leak.
If external damage to the cooling circuit has led to a
refrigerant leak, evacuate the ventilation room, ensure good
ventilation, and call in a certified refrigeration technician.
Service of cooling units may only be carried out by a
certified refrigeration technician. Working on/servicing
the unit – Shut down the unit via the service switch in the
control equipment, then turn the safety switch to the 0
position and lock it.
There may be several safety switches serving the different
parts of the unit. All safety switches must be switched off
and locked before repairs/service.
Due to the risk of sparks, safety switches must not be used
if there is a suspected refrigerant leak.
When detector system installed:
- Make sure the detector system is functioning.
- Make sure that external dampers in the ductwork do not
block the unit’s air flow through uncontrolled closing.

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2 General
2.1 Intended use
The EcoCooler cooling unit is designed to cool supply air in buildings (comfort
cooling). The unit is designed to be installed together with IV Produkt AB air
handling units.
When installed indoors, the unit must be installed in an area that maintains a
temperature between +7 and +30°C, and with a moisture content of <3.5 g/kg in
dry air in the winter. The unit can also be equipped for outdoor installation.
Any other use and installation in other environments are prohibited unless
specifically permitted by IV Produkt AB.
It is not permitted to use the unit in potentially explosive environments, Eex.
Intended users
The contents of this manual are intended for personnel who commission and
carry out regular maintenance on the unit. Maintenance and servicing of the
cooling unit must be carried out by a certified refrigeration technician.
2.2 Manufacturer
The EcoCooler cooling unit is manufactured by:
IVProdukt AB
Sjöuddevägen 7
S-350 43 VÄXJÖ

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2.3 Designations
The EcoCooler comes with a model rating plate placed on the front.
The model type plate shows the series number and the requisite designations to
identify the unit.
00351
0409
Kylaggregat
Ordernummer
Kodnyckel
Modell
Anläggningsbeteckning
Tillverkningsdatum
PS Max tillåtet tryck
PT Provtryck
TS Temperaturområde
Avsäkring LT-sidan
Avsäkring HT-sidan
Köldmedietyp, Fluidgrupp
GWP
Köldmediemängd Krets 1
Köldmediemängd Krets 2
Köldmediemängd Krets 3
IV Produkt AB
VÄXJÖ, SWEDEN
Innehåller sådana fluorerande växthusgaser
som omfattas av Kyotoprotokollet.
Hermetiskt slutet system
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Example of a cooling unit type plate
1. Order number
2. Code key
3. Model
4. Plant designator
5. Date of manufacture
6. PS Max allowed pressure, bar
(e)
7. PT Pressure test, bar (e)
8. TS Temperature range, ºC
9. Fuse protection LT/HT side,
bar (e)
10. Refrigerant type, Fluid Group
11. GWP
12. Refrigerant volume, Circuit 1, 2, 3 (kg,
CO₂e)
13. Contains fluorinated greenhouse gases
controlled by the Kyoto Protocol.
14. Hermetically sealed system. Applies to
refrigerants R410A and R454B (not avai-
lable for Easy Access)
15. Cooling unit

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2.4 CE marking and EU Declaration of Conformity
The cooling unit is CE-marked, which means that upon delivery, it conforms to
applicable provisions in the EU Machinery Directive 2006/42/EC as well as to the
EU Directives applicable to the type of unit, e.g. Pressure Equipment Directive.
As certification confirming that the requirements have been met, we pro-
vide an EU Declaration of Conformity, which is available under Documenta-
tion at ivprodukt.docfactory.com, or under Order Unique Documentation at
docs.ivprodukt.com.
0
1
Art. Nr. 19194-0001_01
12 3
180
s
Typical CE label for air handling units
For units without integrated control equipment
The EC declaration applies only to units in the condition in which they have been
delivered and installed at the facility in accordance with the enclosed installation
instructions. The declaration does not include components that were subse-
quently added or measures subsequently taken on the unit.
2.5 Maintenance
Maintenance and servicing of the cooling unit must be carried out by a certified
refrigeration technician.

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2.6 Handling of refrigerant
The following information summarises the requirements and guidelines for hand-
ling the refrigerant used in cooling units. For further information, see the F-gas
Regulations and the National Refrigerant Handling Regulations.
Responsibility
The physical or legal person (also referred to as ‘operator’) exercising actual
responsibility over the technical functioning of the equipment and systems cove-
red by the F-gas Regulation. The operator is usually the owner of the system.
Operator responsibilities:
• Minimise and prevent leakage
• Take corrective action to remedy any leakage that arises
• Ensure that leak inspection, service and repair of the refrigerant circuit are
carried out by a certified refrigeration technician
• Ensure that refrigerant is handled in an environmentally safe manner and in
accordance with national regulations.
Use and inspection of pressurised equipment
Inspection must be carried out in accordance with the applicable national legis-
lation.
Leakage control and registration
Leakage control must be carried out by a certified refrigera-
tion technician.
Different countries may have different regulations regarding
leakage control and record keeping.
Leakage control and record keeping must be carried out in accordance with
national applicable regulations.
Refer to the unit’s type plate for refrigerant type, refrigerant quantity, and carbon
dioxide equivalent.
All units with refrigerant R410A or R454B are classified as hermetically sealed.

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Leakage control Register admi-
nistration
Size Refrigerant Assembly leak
detection
Every 12 months In case of con-
trol/intervention
100 R410A - - -
R454B - - -
150 R410A Yes 1- -
R454B - - -
190 R410A Yes 1- -
R454B - - -
240 R410A Yes 1- -
R454B - - -
300 R410A Yes Yes Yes
R454B - - -
360 R410A Yes Yes Yes
R454B - - -
400 R410A Yes Yes Yes
R454B - - -
480 R410A Yes Yes Yes
R454B - - -
600 R410A Yes Yes Yes
R454B - - -
740 R410A Yes Yes Yes
R454B - - -
850 R410A Yes Yes Yes
R454B Yes 1, 2- -
980 R410A Yes Yes Yes
R454B Yes 1, 2- -
1080 R410A Yes Yes Yes
R454B Yes 1, 3- -
1280 R410A Yes Yes Yes
R454B Yes 1, 3- -
1 Applicable in Sweden.
2Applies to output variant 1.
3Applies to output variants 2 and 3.

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2.7 Extended warranty
In cases in which the equipment delivered is covered by a 5-year warranty, in
accordance with ABM 07 with appendix ABM-V 07 or in accordance with NL 17
with appendix VU20, the IV Produkt Service and Warranty Manual is supplied
with the product.
In order to claim an extended warranty, a complete, documented and signed IV
Produkt Service and Warranty Manual must be presented.
2.8 Spare parts
Spare parts and accessories for this unit can be ordered from IV Produkt's
nearest dealership. When ordering, the order number and designation must be
given. These are stated on a model identification label, affixed to each functional
section.
There is a separate spare parts list for the unit, refer to Order Unique
Documentation at docs.ivprodukt.com.
2.9 Dismantling and decommissioning
When an air handling unit is to be dismantled, separate instructions must be fol-
lowed, see Dismantling and decommissioning the AHU under Documentation at
ivprodukt.docfactory.com.

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3 Technical description
3.1 Cooling unit, EcoCooler
EcoCooler is a range of integrated speed controlled cooling units with stepless
cooling power.
Two different versions of EcoCooler are available:
• without cooling recovery (without rotary heat exchanger), code ECO
• with cooling recovery (with rotary heat exchanger), code ECX. Cooling
recovery means that the thermal wheel starts up when the extract air/room
temperature drops below the outdoor temperature and cooling is required.
Cooling units with R454B refrigerant are equipped with integrated control equip-
ment (code MX).
EcoCooler cooling unit
(with cooling recovery, code ECX)
Fan and filter section
(extract air fan)
Fan and filter section
(supply air fan)

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3.2 Detector system, refrigerant
Cooling units with refrigerant R454B are equipped as standard with detectors
to detect refrigerant leaks. An exception applies to Size 100, where the detector
equipment is available as an optional extra. For units with refrigerant R410A, the
detector equipment is available as an optional extra.
To guarantee approved dilution in the event of a refrigerant leak, ensure that the
air volumes are greater than the unit’s specified minimum air flow, both on the
supply air side and extract air side (see docs.ivprodukt.com - Technical data).
In the event of a refrigerant leak, the installed detector system ensures that the
minimum permissible air flow is always achieved, which dilutes the refrigerant to
an approved level.
For leak detection and ventilation to work effectively, the unit must have power
and the service switch must remain in the ‘Auto’ position at all times after instal-
lation, except during work/servicing.
If the detector triggers a leak alarm, the unit’s fans are started to dilute the refri-
gerant to an approved level, and an alarm notification is shown on the Climatix
display.
Should a detector be non-functional, an alarm is triggered and the air handling
unit is kept running until the fault is rectified.
In the event of an alarm, correct the fault and then reset the alarm.
If necessary, call a certified refrigeration service with the necessary knowledge
of handling and maintaining equipment with refrigerants.

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Cooling circuit function
A cooling system has four basic components: evaporator, condenser, expansion
valve and compressor.
The compressor carries out the work required to run the cooling process.
The evaporator is located in the supply air for the unit. The heat from the outdoor
air is taken up in this coil, thereby cooling the supply air.
The energy supplied to the cooling system from the evaporator and the com-
pressor leaves the unit via the condenser. The condenser is located in the ex-
tract air (ECO) or the exhaust air (ECX). This means that the exhaust air becomes
hot when the cooling unit is running.
It is important to ensure that the air volumes are above the specified minimum
flow on both the outdoor air and extract air side. The process cannot work if
these air volumes are not available.
14
12
13
8
39
15
10
411
16
17
1
7
5
6
2
Flow chart for EcoCooler refrigerant system
1 Compressor 10 Measurement outlets – low pressure
2 Condenser 11 Liquid line sensor
3 Extract air fan 12 Control unit
4 Pressure switch – high pres-
sure
13 Temperature sensor suction gas
5 Measurement outlet – high
pressure
14 Pressure sensor – low pressure
6 Drying filter 15 Hot gas sensor
7 Expansion valve 16 Temperature sensor sump
8 Evaporator 17 Frequency inverter
9 Supply air fan

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Compressor
EcoCooler is equipped with a speed-controlled PM scroll compressor. Depen-
ding on its size, the unit may be equipped with one or two additional fixed com-
pressors.
When cooling is required, the frequency inverter increases the speed of the
compressor.
If the EcoCooler is equipped with two or more compressors, the fixed com-
pressors will engage when the speed-controlled compressor has reached its
maximum speed. The speed-controlled compressor returns to its minimum
speed and can then adjust back up to maximum speed. This achieves infinitely
adjustable cooling power.
The function is reversed where less cooling is needed.
Compressor protection
In the event of an alarm initiated by the control equipment or the high pressure
switch, the compressor stops and an alarm indication is given. If the unit is
equipped with integrated control equipment, the alarm can be read on the Cli-
matix display.
In the event of an alarm, correct the fault and then reset the alarm. If the high
pressure alarm trips repeatedly, an authorised refrigeration service company
must be called in.
The high pressure switch is tripped when the system is at high pressure and has
a manual reset button. To avoid accidental stoppages at high pressure, the unit
will lower the power using the high pressure sensor.
Cooling function
For internal control (MX), the cooling unit is interlocked across the air handling
unit. If any of the fans stop, the cooling unit will also stop. The interlock and de-
mand signal is sent via Modbus.
For external control (US, UC and MK), the interlock signal must be sent via a
potential-free relay. The demand signal must be sent via 0–10 V.
Circuit board
The circuit board for the cooling unit contains the following:
• Main switch
• Fuse
• Control unit with integrated control for expansion valve next to speed control-
led compressor
• Control unit for expansion valve next to fixed speed compressor
The circuit board is installed inside the unit and is internally prewired and tested
at the factory.

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Current limiting
The control unit for EcoCooler is equipped with a function that measures the
cooling unit’s power consumption. The power consumption can be limited to an
adjustable value. If the unit is connected to a fuse that is less than the one re-
commended in Chapter 3, this function should be used.
To activate the function, do the following in the control unit:
IV Produkt
%
000
Demand:
083%
Status: OFFbyKEY
Inv
OFF
1. Press the circle button.
2. Press the down arrow to highlight “Status – I/O”.
3. Press the enter arrow button.
4. Press the up arrow to access the “Current limit” menu.
5. Press the enter arrow button so that the cursor starts flashing.
6. Press the up arrow to change “NO” to “YES”.
7. Press the enter arrow button so that the cursor starts flashing on the row
below.
8. Use the up/down arrows to set the fuse size.
9. Press the enter arrow button.
10.Press the back arrow button twice to return to the start menu.

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4 Wiring instructions
For connection instructions for an associated electrical air heater, refer
to the separate wiring diagram under Order-specific Documentation at
docs.ivprodukt.com.
For connection instructions for the rotary heat exchanger, refer to Operation and
Maintenance under Order-specific Documentation at docs.ivprodukt.com.
4.1 Electrical connections, ECO and ECX cooling units
301
302
303
304
305
306
307
308
L1
N
PE
G
G0
L2
L3
8
2
4
6
7
MS1
1
3
5
–
+
INTERLOCK,
FROM SF AND EF
POWER SUPPLY
3×400V~50Hz
ALARM, COMPRESSOR
(CLOSES IN EVENT
OF ALARM)
CONTROL
0-10 V=
POWER SUPPLY
24 V~
301
302
303
304
305
306
307
308
L1
N
PE
L2
L3
8
2
4
6
7
MS1
1
3
5
–
+
INTERLOCK,
FROM SF AND EF
POWER SUPPLY
3×400V~50Hz
ALARM, COMPRESSOR
(CLOSES IN EVENT
OF ALARM)
CONTROL
0-10 V=
Sizes 100-980 Sizes 1080 and 1280

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5 Operation
5.1 Commissioning
Commissioning of the cooling unit must be carried out by qualified personnel
in accordance with the Commissioning Record, which can be downloaded at
docs.ivprodukt.com or ivprodukt.docfactory.com.
The Commissioning Record applies to units that are supplied with control equip-
ment (code MX).
The validity of the product warranty is conditional on the system having been
commissioned correctly. Working on the cooling unit during the warranty period
without the approval of IV Produkt shall render the warranty void.
Prior to commissioning, the contractor must:
DANGER!
Risk of serious personal injury and/or damage to air handling
unit.
Read and understand the entire chapter "1.5 General safety
messages" before working on, servicing, or inspecting the air
handling unit.
NB!
Risk of compressor damage.
The oil in the speed-controlled compressor must be warm
before commissioning. The cooling unit must be powered up
for at least 8 hours before commissioning.
1. Connect the unit to the power supply via a lockable safety switch.
2. Connect all ducts.
3. For cooling units with refrigerant R454B – make sure that external dampers
communicate with the unit’s control equipment so that the air flow through the
unit cannot be blocked uncontrollably.
Follow the troubleshooting instructions in the troubleshooting chart before
contacting a service representative for servicing a unit under warranty. This will
prevent any unnecessary service calls.