Iv produkt Envicooler Troubleshooting guide

Industriventilation Produkt AB, Box 3103, SE-350 43 Växjö, Sweden

Phone: +46 (0)470-75 88 00 email: info.ivp@skanska.se www.ivprodukt.se

Air handling with the focus on LCC

Cooling Unit for Producing Chilled Water

Envicooler

Operation and Maintenance Instructions

20010309E-D

Address and telephone list for calling for service

Supplier:

IV Produkt

Box 3103

SE-350 43 VÄXJÖ, Sweden

Street address: Sjöuddevägen 7

Phone: +46 (0)470-75 88 00

Telefax: +46 (0)470-75 88 77

Seller: .......................................................................... Service: ........................................................................

Post address: .............................................................. Post address: ...............................................................

Telephone: ................................................................... Telephone: ...................................................................

Other: ...................................................................................................................................................................

..............................................................................................................................................................................

System Data

Type of unit: .................................................................

Order number: .............................................................

Year manufactured: .....................................................

Supply voltage: ............................................................

Refrigerant: .................................................................

SAQ approved HP: ......................................................

Hydrostatic test: ..........................................................

Operation and Maintenance Instructions

Envicooler

2001-03-09 Pa

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Air handling with the focus on LCC

Contents

1. The Cooling and Heat Pump System_______________________________________ 4

1.1 General ____________________________________________________________ 4

1.2 How the Cooling Circuit Works ________________________________________ 4

1.3 How the Controller Works _____________________________________________ 4

2. Summary of Specific Rules in the Refrigerant Act____________________________ 6

2.1 One-piece Units containing less than 3 kg of Refrigerant ___________________ 6

2.2 One-piece Units containing more than 3 kg of Refrigerant __________________ 6

2.3 One-piece Units containing a total of more than 10 kg of Refrigerant _________ 6

3. Operating Instructions for Components and Assembled Equipment ____________ 7

3.1 Regulations for Commissioning________________________________________ 7

3.2 Checklist ___________________________________________________________ 8

4.Maintenance Instructions and Procedures __________________________________ 9

4.1 General ____________________________________________________________ 9

4.2 Requirements by Authorities according to the Refrigerant Act ______________ 9

4.3 Periodic Inspection __________________________________________________ 9

5. Fault Tracing and Searching for Leakage __________________________________ 10

5.1 Fault-tracing Schedule ______________________________________________ 10

5.2 Searching for Leakage_______________________________________________ 11

6. Flow Diagram for the Refrigerant System__________________________________ 12

7. Technical Specification_________________________________________________ 13

8. Appendices

8:1 Pressure and Tightness Tests - Refrigerant Circuit

8:2 Safety Equipment

8:3 Commissioning Report

8:4 Pressure and Tightness Tests - Liquid Circuits

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Operation and Maintenance Instructions

Envicooler

2001-03-09

Air handling with the focus on LCC

1. The Cooling and Heat Pump System

1.1 General

All coolin

and heat pump systems operate accordin

to the same principle. The sys-

tem moves the heat content in a medium, such as air, water,

as, etc. from one space

where the heat isn’t wanted or needed, to another place where it is possible to utilise

the heat, or

et rid of it.

Your system has been desi

ned and installed to meet

iven performance require-

ments. We’ve selected and combined special components to meet these require-

ments with optimum safety and at lowest possible total cost.

We’ve desi

ned the system accordin

to specific fundamental prerequisites, which

must exist for it to operate. These prerequisites should not be altered without first

checkin

that the system can cope with this chan

1.2 How the Cooling Circuit Works

See the flow dia

ram.

The refri

erant in the coolin

circuit absorbs heat from the component bein

chilled

while it passes throu

h the evaporator. As its pressure drops, the refri

erant evapo-

rates and transforms from liquid to

as.

The cold suction

as that now has absorbed heat from the cooled space/medium is

sucked back into the compressor where it is compressed and heats up.

In all fully hermetic compressors, the suction

as is also used to cool the electric mo-

tor that drives the compressor. The refri

erant now contains heat from the component

bein

chilled, heat from the compressor motor and heat

enerated by compression.

The refri

erant is in the form of hot

as when it leaves the compressor and circulates

to the condenser where it

ives off its heat.

The refri

erant then condenses as it cools, transformin

from

as to liquid. This oc-

curs repeatedly in a totally closed system, until the temperature in the chilled/heated

medium drops/rises to its set point.

1.3 How the Controller Works

1.3.1 Interlocking

EVC is interlocked across an external start si

nal.

1.3.2 Operation

The selector switch S1 is used for initiatin

start-up (yellow LED is lit). When the tem-

perature at the heatin

medium sensor drops below the preset value, a si

nal is trans-

mitted across the steppin

switch to start the compressors in a preset startin

order

so as to maintain the preset temperature. The in-operation condition of each com-

pressor is indicated across the steppin

switch. Output terminal blocks are provided

for in-operation indication.

Operation and Maintenance Instructions

Envicooler

2001-03-09 Pa

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Air handling with the focus on LCC

1.3.3 Compressor Protection

If the safety circuit alarm trips the compressor will stop and a red LED will li

ht up. A

flow monitor supervises the water flow in the coolin

medium circuit. On insufficient

flow the monitor stops the compressors and initiates an alarm across a steppin

switch. The flow monitor alarm can be reset by settin

the selector switch S1 in the 0

position. The safety circuit alarm will trip if any of the followin

four conditions arises:

•Hi

h pressure in the system, HP

•Low pressure in the system, LP

•Tripped protective motor switch Q

•Tripped thermocouple in the compressor

The

roup alarm safety circuit has output terminal blocks. If the safety circuit alarm

trips repeatedly,

et in touch with an authorised refri

eration service company.

1.3.4 Technical Description

The compressor power cubicle of the EVC unit contains the followin

•Main switch

•Protective motor switch

•Contactors

•Auxiliary relays

•Controller

•Selector switch

•Flow monitor

The cubicle is mounted inside the EVC unit and has been internally prewired and

tested at the factory.

L1 L2 L3 NPE

Power supply

3*x 400 V + N 50 Hz

Size Rec. fuse Rec. cable section

EVC-1610

EVC-2410

EVC-3110

EVC-4020

EVC-4820

EVC-6220

EVC-7830

EVC-9330

20 AT

25 AT

35 AT

50 AT

63 AT

80 AT

100 AT

4 mm2

6 mm2

10 mm2

16 mm2

25 mm2

35 mm2

50 mm2

Envicooler

251 252

External start signal

Potential-free, NO

253 254

Group alarm

Potential-free, NO

C1 C2 C3 C4 ((!))

SET

prg

XC440C

Dixell

Set point

To show the set point

: press the SET key.

To change the set point

: press the SET key for

at least 2 sec. Alter the setting by pressing the

arrow up or arrow down key. Then press the

SET key to save your setting.

Running period – compressors

Press and hold the clock button

for at least 3 sec. Shows the run-

ning period of each compressor.

Flow monitor alarm

If a buzzer sounds and a

red LED is lit, the flow

monitor alarm has

tripped.

In-operation indication

A red LED indicates that

the compressors are

running.

Input cables

EVC Selector switch

O= EVC switched off

I= EVC start mode

To reset the flow

monitor alarm

Press the switch to O;

then press it to Iagain.

Safety circuit alarm

If a red LED is lit, the safety circuit of

the relevant compressor has tripped.

To reset the safety circuit

Press the reset button on the high

pressure switch or low pressure

switch. Reset the protective motor

switch.

I O

255 256

In-operation indication

C1, C2, C3

Potential-free, NO

257 258 259 260

LJ 990520

*) If the order of phases is wrong, the machine will run unusually loud.

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Operation and Maintenance Instructions

Envicooler

2001-03-09

Air handling with the focus on LCC

2. Summary of Specific Rules in the Refrigeration Act

2.1 One-piece Units containing less than 3 kg of Refrigerant

The maintenance and service of these units should be carried out with

ood jud

ment and a certain de

ree of responsibility. This means, for example, that if you dis-

cover a leak, you must not char

e the refri

eration circuit with additional refri

erant

unit the leak has been sealed.

Furthermore, you must always take care of refri

erant that you’ve emptied from the

unit either by reusin

it or sendin

it to an appropriate facility for destruction.

As far as service and maintenance are concerned, no qualifications stipulated by au-

thorities are required of the technician who carries out this work. Althou

h common

sense and

ood jud

ement are important when servicin

the unit.

If servicin

calls for a modification of the refri

erant circuit, only a certified refri

era-

tion technician shall be permitted to carry out this work.

No reportin

to the authorities is required in conjunction with these coolin

units.

One-piece coolin

units char

ed with 3 k

or less refri

erant are treated in system cal-

culations as if they didn’t contain any refri

erant at all. This means that you can add

or include any number of one-piece coolin

units of the type described above in a sys-

tem, without bein

required to take increased refri

erant volume into consideration.

2.2 One-piece Units containing more than 3 kg of Refrigerant

Besides complyin

with the above, the units and components of these systems shall

be inspected in accordance with local standards and re

ulations at least once a year.

The responsibility for seein

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 installa-

tions.

2.3 One-piece Units containing a total of more than 10 kg of Refrigerant

Besides complyin

with the above, entries concernin

the performance and mainten-

ance of the units and components of these systems must be entered in a journal. The

responsibility for seein

to it that such a journal is kept up-to-date rests on the owner.

This journal must then be sent to an inspectorate for scrutiny once a year. If each cir-

cuit is char

ed with refri

erant in excess of 10 k

, special requirements are made on

the equipment in the system.

Operation and Maintenance Instructions

Envicooler

2001-03-09 Pa

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Air handling with the focus on LCC

3. Operating Instructions for Components and Assembled

Equipment

3.1 Regulations for Commissioning

All wirin

shall be completed prior to commissionin

The coolin

medium and heatin

medium flows shall be adjusted accordin

to spec-

ifications and these settin

s shall be entered in the Commissionin

Report.

Only qualified technicians shall be allowed to commission the system accordin

to an

accompanyin

checklist complete with commissionin

record. A copy of the Commis-

sionin

Record shall first be si

ned by the technician who has commissioned the unit,

then be si

ned by the seller and after that be sent in to IV Produkt. The validity of the

product warrantee is conditional on the system havin

been correctly commissioned.

No modifications in the machine are permissible durin

the warrantee period without

the approval by IV Produkt.

Follow the fault tracin

directions in the fault tracin

schedule before you contact a

service representative for servicin

the unit under warrantee. This will prevent any un-

necessary service calls.

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Operation and Maintenance Instructions

Envicooler

2001-03-09

Air handling with the focus on LCC

3.2 Checklist

1. Check the power supply. Make sure that

the phase leads are wired to the correct

terminal. Make sure that the zero lead and

the earth lead are wired.

2. Check that input cables from an external

control cubicle are wired to the correct

terminal and in the correct manner

accordin

to the wirin

dia

ram, e.

–shielded cable

–wirin

to correct terminal in motors

–terminal block screws are ti

htened

3. Switch off ALL protective motor switches

4. Switch in the power supply and fuses.

5. Feel the compressors to make sure that

the crankcase heatin

is switched in.

6. Check that the water connections are

complete and that there is water.

7. Switch in the pumps. Make sure that they

dischar

e in the ri

ht direction.

8. A pump that won’t start: check the wirin

dia

ram. If it is interlocked: Temporarily

cancel the interlock.

9. Check the pump data a

ainst the motor

protection and the dia

ram.

10. Make sure that the water system has been

carefully pur

ed of air.

11. Check that water is flowin

in the circuit.

The measurement valves are on the EVC.

See flow data in EVC specification.

12. When the flow is correctly set, lock the

valves.

13. If you’ve cancelled any interlock in order to

start the pumps, restore it.

14. Check that the transducer is wired to the to

the ri

ht measurement point.

15. Check that the sensor is at the correct

location accordin

to the dia

ram and that

it works properly.

16. Check that the protective motor switch and

the time relay are correctly set accordin

to the Commissionin

Report.

17. Now run throu

h all the control functions

accordin

to their functional description in

the wirin

dia

ram. Both AHU and EVC

WITHOUT STARTING THE

COMPRESSORS.

18. It is important that the oil in the compressor

crankcase is warm before the compressor

is switched in. The crankcase heat should

be switched in well in advance of commis-

sionin

(2–3 hours) to allow the oil to reach

a temperature of at least 30 °C ca.The

temperature can be measured externally

on the bottom of the compressor.

19. Connect the manometer mount on the

service outlet; pur

e the air hoses.

NOTE: Type of refrigerant

20. Start up the AHU and the EVC. Now test

the compressors separately and follow the

commissionin

record. Let the

compressors run for a while before you

in measurin

, approx.10 minutes. Test

the safety functions

21. After the compressors have been tested

separately, test all of them at the same

time. Review the commissionin

record.

22. Now let the unit run until it stops as

intended accordin

to the preset control

function.

23. Send one set of the commissionin

records to: IV Produkt.

Operation and Maintenance Instructions

Envicooler

2001-03-09 Pa

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Air handling with the focus on LCC

4. Maintenance Instructions and Procedures

4.1 General

This section of the instructions is intended for

eneral 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 havin

to call for qualified

service help in the event of a malfunction. If more advanced troubleshootin

in the

system is necessary, you will find the information you need in the accompanyin

wir-

dia

rams and special instructions for the components of the system.

4.2 Requirements by Authorities according to the Refrigerant Act

An inspector from an accredited company shall in accordance with Local Coolin

Standards, inspect one-piece coolin

units containin

more than 3 k

of refri

erant.

All service and modification of the coolin

system and char

ed or emptied refri

erant

shall be recorded in the journal.

If the total volume of refri

erant exceeds 10 k

(Note! The total volume of all the units

in the buildin

), this must be reported to the local Environmental and Public Health

Authorities and an annual report must be submitted to them.

4.3 Periodic Inspection

1. Appoint someone or qualified staff to be responsible for periodical inspections of

the coolin

system. Make sure that these technicians possess knowled

e of how

the system operates and where system components are located.

2. The system is desi

ned to operate automatically.The Commissionin

Record

indicates the settin

s at which the system was set when it was commissioned.

Make sure that the settin

s on the thermostats, controllers, pressure switches

and other adjustable components have not been altered by someone who lacks

knowled

e about how the system operates.

3. See to it that the machine room or other component locations are kept clean.

4. Certain components in the system may require open space for contact with the

surroundin

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 coolin

unit does not normally require any lubrication, oil chan

es or the like.

In cases where special re

ulations pertain to any specific system component,

this is explained in the instructions for that component.

6. The system and its components shall be inspected by qualified service

technicians at least once a year. The inspection should include the followin

–Check the refri

erant system for ti

htness.

–Check that the system hasn’t sustained any serious corrosion dama

–Check that the safety equipment is in

ood condition.

7. Keeping a journal. Entries shall be made every time each system is char

ed or

emptied of refri

erant, the results of searches for leaka

e and other measures in

conjunction with inspectin

and servicin

the refri

erant circuit and its operation.

8. Are you uncertain about anythin

ardin

your coolin

system? If so,

et in

touch with your supplier! Sometimes it’s better and cheaper to call once too often

than too seldom.

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Operation and Maintenance Instructions

Envicooler

2001-03-09

Air handling with the focus on LCC

5. Fault Tracing and Searching for Leakage

5.1 Fault-tracing Schedule

SYMPTOM POSSIBLE CAUSE REMEDIAL MEASURE

Too hi

h temperature in

cooled component/medium

The power supply has been interrupted. Check the control/safety switches and

fuses.

No flow or poor flow across the

evaporator.

Check that nothin

is blockin

the flow.

Check that the system is well pur

ed of

air.

The thermostat/control equipment is

incorrectly set/faulty.

Adjust the settin

or replace the

equipment.

The compressor doesn’t work. See under “Compressor”

The compressor doesn’t

work.

The power supply has been interrupted. Check the control/safety switches and

fuses.

The safety circuit has switched out the

compressor. Pressure switches,

temperature monitor, flow monitor, anti-

frostin

protection or motor protection.

Check and reset if required.

Faulty compressor. Determine the fault. Replace the

compressor.

The low-pressure switch

switches out the

compressor.

Too little refri

erant. There is a leak in the system. Seal the

leak and char

e with refri

erant.

No flow or poor flow across the

evaporator.

Check the flow.

Check the static pressure in the

expansion vessel.

Check the circulation pump.

Too hi

lycol content. Check the

lycol content.

Faulty expansion valve. Check, replace.

Faulty low-pressure switch. Check, replace.

The hi

h-pressure switch

switches out the

compressor.

No flow or poor flow across the

condenser.

Check the flow across the condenser.

Check the static pressure in the

expansion vessel.

Check the circulation pump.

Too much refri

erant in the system. Reduce the refri

erant volume.

Faulty hi

h-pressure switch. Check, replace.

Substantial frostin

on the

evaporator.

The expansion valve is incorrectly set/

faulty.

Check, replace.

Too little refri

erant. Check in the si

lass. The system is

leakin

; seal the leaka

e; char

e with

refri

erant.

The evaporator is fouled. Check the flow, filter if fitted, clean the

evaporator if needed.

Operation and Maintenance Instructions

Envicooler

2001-03-09 Pa

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Air handling with the focus on LCC

5.2 Searching for Leakage

A search to detect leaka

e in the system should be made at least once per calendar

year as a preventive measure. This leaka

e search should be recorded and entered

in the journal.

The coolin

system can develop a leak. This becomes apparent first by impaired cool-

performance or the system won’t operate at all due to a momentary leaka

If you suspect refri

eration leaka

e, check the level of refri

erant in the si

lass of

the system. The si

lass is located in the fluid pipe by the refri

eratin

machine.

If you see bubbles continuously formin

in the si

lass, and the coolin

perform-

ance of the system is at the same time poor, the probable cause is that the system is

leakin

. If you see one or two or just a few bubbles in the si

lass when the ma-

chine starts up, and notice that it operates with reduced output or operates normally

does not necessarily mean that the refri

erant volume is too low.

IF BUBBLES APPEAR IN THE SIGHT GLASS AND THE PERFORMANCE OF THE

SYSTEM IS NOTICEABLY BAD –CALL AN AUTHORISED SERVICE REPRESEN-

TATIVE FOR HELP.

Keep in mind that refri

erant must not be released into the atmosphere and that es-

capin

refri

erant can cause burns if it comes into contact with skin. If it becomes nec-

essary to make modifications in the refri

erant circuit, the staff doin

this work must

wear the proper protective equipment.

MODIFICATIONS IN THE REFRIGERANT SYSTEM MUST ONLY BE CARRIED

OUT BY AN ACCREDITED INSPECTORATE –A COMPANY WITH A REQUIRED

PERMIT –

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Operation and Maintenance Instructions

Envicooler

2001-03-09

Air handling with the focus on LCC

6. Flow Diagram for the Refrigerant System

1. KK Coolin

compressor

2. VO Oil heater

3. GP Hi

h-pressure switch

4. MU Measurement tappin

of Schrader valve

5. KD Liquid coolin

condenser

6. SG Si

lass

7. FT Dryin

filter

8. MU Measurement tappin

of Schrader valve

9. VS Thermostatic expansion valve with external pressure compensation

10. EV Liquid cooler

11. MU Measurement tappin

of Schrader valve

12. GP Low pressure switch

Operation and Maintenance Instructions

Envicooler

2001-03-09 Pa

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Air handling with the focus on LCC

7. Technical Specification

Specification

EVC: 1610 2410 3110 4020 4820 6220 7830 9330

Cooling power (Pk) kW 17.6 26.1 34.0 43.7 52.2 68.1 85.6 102.1

Condenser power (Pvv) kW 22.1 32.7 42.7 54.8 65.3 85.5 107.6 128.2

Compressors (Qty)each 11122233

Coolin

circuits (Qty)each 11122233

Cooling medium

Water temp. +7/+12.5 °C l/s 0.78 1.16 1.52 1.96 2.33 3.03 3.82 4.55

Internal pressure in

connection point

kPa 4040404040404040

Connection diameter (dy) mm 28 35 35 42 42 54 54 54

Rec. coolin

medium

volume

(min) l 287 431 556 359 432 556 467 556

Heating medium

Water temp. +31/+39 °C l/s 0.66 0.98 1.28 1.64 1.95 2.56 3.22 3.83

Internal pressure in

connection point

kPa 3535353535353535

Connection diameter (dy) mm 28 35 35 42 42 54 54 54

Refrigerant

HFC 407C k

/circuit 1 1.6 2.6 3.0 1.6 2.6 3.0 1.6 3.0

/circuit 2 2.6 2.6 3.0 3.0 3.0

/circuit 3 3.0 3.0

Total k

1.6 2.6 3.0 4.2 5.2 6.0 7.6 9.0

Electrical data

Recommended fuse AT 20 25 35 50 50 63 80 100

Casing

Version size A A A B B B C C

Wei

ht k

212 248 255 310 346 360 482 525

Envicooler Coolin

Unit EVC-a

Size 1610, 2410, 3110,

4020, 4820, 6220,

7830, 9330

for liquid

e 14

Operation and Maintenance Instructions

Envicooler

2001-03-09

Air handling with the focus on LCC

Industriventilation Produkt AB, Box 3103, SE-350 43 Växjö, Sweden

Phone: +46 (0)470-75 88 00 email: [email protected] www.ivprodukt.se

Air handling with the focus on LCC

Cooling Unit for Producing Chilled Water

Envicooler

Operation and Maintenance Instructions

20010309E-D

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