IV Produkt EcoCooler Series Troubleshooting guide

Original instructions
Order number :
Project :
Cooling unit
NEW EcoCooler 100-980
ECO – EcoCooler
ECX – EcoCooler with cooling recovery
Operation and maintenance instructions
THE NEW

Table of Contents
1 General
1.1 Intended use ...................................................................................................................2
1.2 Safety precautions......................................................................................................2
1.3 Manufacturer...................................................................................................................2
1.4 Designations ...................................................................................................................2
1.5 CE marking and EU Declaration of Conformity.....................................3
1.6 Maintenance....................................................................................................................3
1.7 Handling of refrigerant .............................................................................................4
1.8 Extended warranty......................................................................................................5
1.9 Spare parts.......................................................................................................................5
1.10 Dismantling and decommissioning ................................................................5
2 Technical description
2.1 Cooling unit, EcoCooler..........................................................................................6
3 Wiring instructions (US, MK)
3.1 Electrical connections, ECO and ECX cooling units.................... 10
3.2 Electrical connections, ECX rotary heat exchanger ..................... 10
3.3 Electrical connections, ECO and ECX electric heaters............... 10

Table of Contents, cntd
4 Operation
4.1 Commissioning rules .............................................................................................11
4.2 Check list for commissioning cooling unit .............................................11
4.3 Cooling status ............................................................................................................13
5 Maintenance instructions
5.1 General.............................................................................................................................15
5.2 Periodic inspection..................................................................................................16
6 Alarm management and troubleshooting
6.1 Troubleshooting in the event of an alarm................................................17
6.2 Troubleshooting via symptoms.......................................................................20
7 Technical data
7.1 EcoCooler without cooling recovery (code ECO)..............................21
7.2 EcoCooler with cooling recovery (code ECX)......................................22

Operation and Maintenance Instructions
NEW EcoCooler
DSKE180401.00.EN
Page 2
Continuous product development may give rise to specification changes without notice.
1 General
1.1 Intended use
The EcoCooler cooling unit is designed for cooling supply air in buildings (com-
fort cooling).
The cooling unit is designed to be installed together with IV Produkt AB air han-
dling units. The cooling unit should not be used as a standalone unit.
1.2 Safety precautions
Safety precautions for cooling units installed together with ventilation units can
be found in the Operation and Maintenance Instructions and the Assembly
Instructions for the relevant range of units.
1.3 Manufacturer
The cooling unit is manufactured by:
IV Produkt AB
Sjöuddevägen 7
SE-350 43 VÄXJÖ
1.4 Designations
The details of the cooling unit can be
found on the model identification label
placed on the front cover.
Kodnyckel
Code key
Beteckning
Project name
Ordernummer
Order number
Max. varv
Max. rev.
Tillv. ort
Made in
Tillv. månad
Manuf. month
YYMM
ENF-190-AA-00
Modell
Model Envistar Flex
TA1 FA1 POS 1
1234-567
– –
VÄXJÖ, SWEDEN
Max. temp. °Cr/m
1405
Art. Nr. 19121-1001
Typical model identification label

Operation and Maintenance Instructions
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1.5 CE marking and EU Declaration of Conformity
The cooling unit is CE-marked, which means that upon delivery, it conforms to
applicable provisions in EU Machinery Directive 2006/42/EC as well as to the EU
Directives applicable to the type of unit, e.g. Pressure Equipment Directive (PED)
2014/68/EU.
As certification confirming that the requirements have been met, we provide an
EU Declaration of Conformity, which is available at docs.ivprodukt.com.
The CE marking applies to units that IV Produkt AB manufactures and supplies
in the form of a unit without additional control equipment. For the CE marking of
IV products to apply, the applicable requirements of the EU Machinery Directive
2006/42/EC and related directives for control equipment shall be met when
installed for the unit.
0
1
Art. Nr. 19194-0001_01
12 3
180
s
Typical CE label for air handling units
0409
Cooling unit
Order number
Code Key
Model
Name of project
Date of manufacture
PS Max allowable pressure
PT Test pressure
TS Temperature range
Protection level - low
Protection level - high
Refrigerant / Fluid group
GWP
Refrigerant charge Circuit 1
Refrigerant charge Circuit 2
IV Produkt AB
VÄXJÖ, SWEDEN
Contains fluorinated greenhouse gases
covered by the Kyotot protocol.
bar (e)
bar (e)
°C
bar (e)
bar (e)
kg
kg
ton CO2e
ton CO2e
Typical CE label for cooling units
1.6 Maintenance
Regular maintenance of cooling units should be performed by a qualified cooling
engineer.

Operation and Maintenance Instructions
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Page 4
Continuous product development may give rise to specification changes without notice.
1.7 Handling of refrigerant
The following information summarises the requirements and guidelines for han-
dling the refrigerant used in cooling units. For further information, see the F-gas
Regulations (EU/517/2014) and the Refrigerant Regulations (SFS 2016:1128).
The purpose of the regulations is to contribute to achieving EU goals for reduced
climate impact in accordance with the Kyoto Protocol.
Operator responsibilities
Generally speaking, the unit operator must:
• Minimise and prevent leakage
• Take corrective action to remedy any leakage that arises
• Ensure that the service and repair of the refrigerant circuit is carried out by a
certified refrigeration technician
• Ensure that refrigerant is handled in an environmentally secure manner and
in accordance with national regulations.
By operator, we mean the European Parliament's definition: "...the natural or le-
gal person exercising actual power over the technical functioning of the equip-
ment and systems...".
The levels for the various actions to be taken for a system are calculated using
carbon dioxide equivalents, CO₂ e(tonnes). This figure is calculated by multiply-
ing the refrigerant’s GWP value (Global Warming Potential) by the filling amount
in kilos. GWP for R410a is 2088. A filling amount of 5.0 kg R410a therefore cor-
responds to (5.0×2088)/1000 = 10.44 CO₂ e(tonnes). The unit is marked with re-
frigerant quantity and carbon dioxide equivalent.
Leakage inspection and registration
The following applies for one-piece units with 5 CO₂e(tonnes) refrigerant content
or more per circuit:
• Leakage inspection must be carried out by a certified refrigeration techni-
cian:
– When installing/commissioning the unit
– Periodically at least once per 12 months,
i.e. no more than 12 months between inspections
– within one month of any work being performed (e.g. sealing a leak, replac-
ing a
component).
• The operator must record events, such as the volume and type of refrigerant
topped up, refrigerant taken into possession, results of inspections and work
done, person and company who carried out service and maintenance.
If the total refrigerant quantity below 5 CO₂ e(tonnes), no periodic leak detection
or record keeping is needed.
If the total refrigerant content of the ventilation system exceeds 14 CO2
e(tonnes), the result of the inspections (inspection report) must be sent to the
regulatory authorities and be in their possession no later than 31 March of the
following year.
For a unit that will contain 14 CO2e(tonnes) or more, the intended operator must
inform the supervisory authority of the installation well in advance.

Operation and Maintenance Instructions
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1.8 Extended warranty
In cases in which the equipment delivered falls under a 5-year warranty, in ac-
cordance with ABM 07 with supplement ABM-V 07 or in accordance with NL
09 with supplement VU13, the IV Produkt Service and Warranty Manual is sup-
plied with the product. In order to lay claim to an extended warranty, a complete,
documented and signed IV Produkt Service and Warranty Manual must be pre-
sented.
1.9 Spare parts
Spare parts and accessories for this unit are ordered from your nearest IV
Produkt sales representative. Always specify the product code when ordering.
The code is stamped on a separate data label, axed to each functional section.
A separate spare parts list is supplied with the unit.
1.10Dismantling and decommissioning
When an air handling unit is to be dismantled, separate instructions must be fol-
lowed, refer to Dismantling and decommissioning the AHU under Documenta-
tion at docs.ivprodukt.com.

Operation and Maintenance Instructions
NEW EcoCooler
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2 Technical description
2.1 Cooling unit, EcoCooler
EcoCooler is a range of integrated speed controlled cooling units with stepless
cooling power. The cooling units are designed for cooling supply air in buildings
(comfort cooling).
EcoCooler is designed to be installed together with IV Produkt AB air handling
units. The cooling unit should not be used as a standalone unit.
Two different versions of EcoCooler are available:
• ECO, without cooling recovery (no rotor)
• ECX, with cooling recovery (with rotor). Cooling recovery means that the
heat exchanger (rotary heat exchanger) starts up when the extract air/room
temperature drops below the outdoor temperature and cooling is required.
EcoCooler cooling unit (with
cooling recovery, code ECX)
Fan and filter section
(extract air fan)
Fan and filter section
(supply air fan)

Operation and Maintenance Instructions
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Cooling circuit function
Most cooling units operate according to the same principle. The cooling unit
moves the heat in the air from a location where the heat is unwanted or unneed-
ed, to another location where the heat can be emitted.
From the compressor (position 1) the refrigerant is pressed as hot gas to the
condenser (position 2) where heat is emitted. The refrigerant condenses from
gas to liquid when it is cooled by the extract air.
The refrigerant passes the pressure reducing expansion valve (position 7) and
undergoes a phase transformation in the evaporator (position 8) from liquid to
gas (the refrigerant evaporates).
Inside the evaporator (position 8), the refrigerant absorbs the heat required for
phase transformation. The heat is taken from the supply air which is thus cooled.
The cold refrigerant in gaseous form is drawn back into the compressor (position
1) where it is compressed and thus heated. The gas is also used for cooling the
compressor’s electric motor. The refrigerant now contains both the heat from the
supply air, the compressor’s motor heat and the compression heat.
14
12
13
8
39
15
10
411
1
7
5
6
2
Flow chart for EcoCooler refrigerant systems (for refrigerant volume, see the type label on the unit)
1 Compressor 9 Supply air fan
2 Condenser 10 Measurement outlets – low pressure
3 Extract air fan 11 Liquid line sensor
4 Pressure switch – high pressure 12 Control unit
5 Measurement outlet – high pressure 13 Temperature sensor suction gas
6 Drying filter 14 Pressure sensor – low pressure
7 Expansion valve 15 Hot gas sensor
8 Evaporator

Operation and Maintenance Instructions
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Compressor
The EcoCooler is fitted with a speed-controlled compressor. Depending on the
size, the EcoCooler can also be fitted with a switch controlled compressor.
When cooling is required, the frequency inverter increases the speed of the
compressor. When there is more than one compressor, they are activated in
fixed steps while the speed-controlled compressor is activated between steps.
The function is reversed where less cooling is needed.
Compressor protection
In the event of an alarm initiated by the control equipment or the safety circuit,
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 Climatix display.
In the event of an alarm, correct the fault and then reset the alarm. If the safety
circuit alarm trips repeatedly, an authorised refrigeration service company must
be called in.
The safety circuit consists of a high pressure switch with a manual reset button.
The safety circuit can trip in the event of high pressure in the system. 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 ventilation
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 con-
trolled 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.

Operation and Maintenance Instructions
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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 rec-
ommended 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 so the cursor starts flashing.
6. Press the up arrow to change “NO” to “YES”.
7. Press the enter arrow so 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.

Operation and Maintenance Instructions
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3 Wiring instructions (US, MK)
For MX and UC, see separate wiring diagram.
3.1 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~
3.2 Electrical connections, ECX rotary heat exchanger
+
–
33
34
36
37
41
42
43
L
N
PE
CONTROL
0-10 V DC
POWER SUPPLY
1×230 V AC
ALARM (CLOSES IN
EVENT OF ALARM)
COOLING RECOVERY
(CLOSED CONTACT
GIVES FULL SPEED)
3.3 Electrical connections, ECO and ECX electric heaters
201
202
203
204
101
N
PE
CONTROL SIGNAL 0-10 V
POWER SUPPLY
1×230 V AC
ALARM (CLOSES IN
EVENT OF ALARM)
SYSTEM NEUTRAL

Operation and Maintenance Instructions
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4 Operation
4.1 Commissioning rules
Commissioning may only be carried out by skilled personnel and according to
the following check list and commissioning record (supplied with the cooling
unit). A copy of the commissioning record, after being signed by the person who
commissioned the unit, must also be signed by the seller before it is sent to the
IV Produkt Ordering Department.
The validity of the product warranty is conditional on the system having been
correctly commissioned. No modifications to the cooling unit may be made dur-
ing the warranty period without the approval of IV Produkt.
Follow the troubleshooting instructions in the troubleshooting chart before con-
tacting a service representative for servicing a unit under warranty. This will pre-
vent any unnecessary service calls.
4.2 Check list for commissioning cooling unit
The cooling unit must not be put into operation until all the items in the check list
have been checked o.
1. Visually inspect the cooling unit for damage after transport and as-
sembly.
2. Check that the cooling unit is correctly positioned and that the open
space in front of the unit for servicing is sucient (1.5 x depth of the
unit, min. 1200 mm).
For more information, see the separate assembly instructions for each
unit series.
3. Check that the drain connection (evaporation water drainage) is con-
nected to a floor drain via a separate water trap. Check that the drain-
age pipe slopes correctly to the drain. For more information, see the
separate assembly instructions for each unit series.
4. Check that the incoming supply voltage, zero and earth are connect-
ed (see Section 3).
5. Check that control cables are connected (see chapter 3).
6. Check that the automatic circuit breakers are set to the ON position
and switch on the voltage.
7. It is important that the oil is warm inside the speed controlled com-
pressor crankcase before starting the cooling unit. The crankcase
heating must be switched on long enough before the unit begins op-
erating so that the oil maintains a temperature of at least 30ºC. The
maximum warm-up time is approximately 2–3 hours. The temperature
can be measured externally at the bottom of the compressor.
8. Start the air handling unit (supply and extract air fans).
9. Check that there are supply and extract air flows and that they have
been adjusted and recorded.

Operation and Maintenance Instructions
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10. Test all control functions according to the air handling unit’s func-
tional description.
11. Start the cooling unit via the control unit according to the following
menu sequence:
%
000
IV Produkt
Demand:
083%
Status: OFFbyKEY
Inv
OFF
%
087
IV Produkt
Unit On/Off
Demand:
083%
Status: UnitOn
Inv
ON
Unit On/Off
Main Menu
1×
1×
1×
2×
On/Off Unit
12. Check that the start and cooling signal is shown in the display. Status
should be
“UnitOn” and Demand should show a percentage value. If UnitOn
is not displayed and Demand is less than 10 per cent, the setpoint
should be temporarily changed to make start possible. Use Climatix
hand controller and go to Quick menu > Setpoints/Settings > Setp.
conf.heat. Adjust setpoint until the unit starts.
13. Check that the unit indicates a temperature change in the supply air,
note the operating data and check that no alarms are displayed.
14. Reset the setpoint and allow the unit to operate until it stops as per
the intended control function for the air handling unit.
NB: The time until restart is at least 10 minutes.
15. Make sure that an inspection to detect leakage is carried out and that
an inspection report is drawn up; see “1.7 Handling of refrigerant” on
page 4.

Operation and Maintenance Instructions
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4.3 Cooling status
Unit incl. control (Climatix code MX)
Status information can be read on the Climatix display (Main menu > Unit >
Cooling). The following will be presented:
Climatix Value Explanation
Cooling unit status UnitOn Status of cooling unit
Cooling x% Cooling load from Climatix cooling regu-
lator.
Freq. inv. output x.x% Frequency to the compressor.
Compr. no Comp1
Compr. Sum alarm Normal
Alarm management >The alarm is displayed if there is a fault
with the inverter or compressor. In the
event of an alarm, see “Alarm information
for inverter and compressor” page 18.
****************************************
Compressor C1 On/O Compressor operating mode.
Suction gas temp C1 x.x°C Measured suction gas temp.
Evaporation temp C1 x.x°C Calculated evaporation temp based on
low pressure.
Low pressure C1 x.x bar Relative pressure from low pressure sen-
sor.
Overheating C1 x.xK Measured overheating.
High pressure C1 x.x bar Relative pressure from high pressure sen-
sor.
Expansion valve 1 x.x% Expansion valve position.
Condensation temp C x.x°C
Hot gas temperature x.x°C Temperature of output from compressor
Liquid line tempera-
ture
x.x°C Temperature downstream of condenser
Supercooling x.x°C Measured supercooling

Operation and Maintenance Instructions
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Unit excl. control (Carel code UC, MK or US)
Status information can be read on the Carel display (Main menu/Status - I/O).
The following is presented:
Status A01 Value, example Explanation


IV Produkt
%FNBOE

4UBUVT0''CZ,&:
0''
*OW
0''

Operation and Maintenance Instructions
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5 Maintenance instructions
5.1 General
This part of the instructions is generic. It is designed to enable you to carry out a
simple periodic inspection of the unit and to show some simple checks you can
perform before calling in expert support in the event of a fault.
For those qualified to work on the unit, the attached connection and circuit dia-
grams and the control manual will provide the necessary information, or alterna-
tively at docs.ivprodukt.com.

Operation and Maintenance Instructions
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5.2 Periodic inspection
General
The IV Produkt cooling unit has been designed and fabricated along given op-
eration parameters that must be met in order for the unit to operate optimally
and provide good operating economy. The operation parameters must not be
changed unless a check is first made to ascertain that the changes will be within
the unit’s operating range.
Requirements and guidelines for handling refrigerant
For requirements and guidelines, see “1.7 Handling of refrigerant” on page
4.
Inspection
Check:
1. The fins on the condenser and evaporator to detect mechanical deforma-
tions
2. The drip tray and drain with water trap (clean if necessary)
3. That the water trap (without non-return valve) is filled with water.
Cleaning
If the fins on the condenser and evaporator are fouled, they should be vacuumed
from the inlet side. Alternatively, you can blow them clean with compressed air
from the outlet side. If they are severely fouled, you can clean them with warm
water mixed with dishwashing detergent that will not corrode aluminium.
Function
Check that the cooling unit is operating as it should by temporarily lowering the
temperature setting (setpoint).

Operation and Maintenance Instructions
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6 Alarm management and troubleshooting
6.1 Troubleshooting in the event of an alarm
The alarms for the cooling circuits are presented on the control unit display. To
ascertain what has caused the alarm, follow the procedure below.
Inspection Possible cause Corrective action
Is the alarm
“94 Drive oine”displayed?
YES ⇒The frequency inverter does not have
supply voltage 3×400V
Connect the supply voltage to the fre-
quency inverter
Check fuses
Check cabling for communication be-
tween frequency inverter and Carel
NO ⇓
Has the high pressure
switch tripped?
Is the alarm
“121 Compr 1, High
pressure switch”
or
“180 Compr 1,
High pressure switch”
displayed?
YES ⇒No or too low air flow across the con-
denser
Defective high pressure switch
Check the air flow across the condens-
er.
Reset the pressure switch manually
Check/replace
NO ⇓
Is the alarm
“118 Compr 1,
Low evaporation pres-
sure” or
“176 Compr 2, LowEvap-
Pressure” displayed?
YES ⇒Insucient refrigerant volume Look for leakage, seal the leak and top
up with refrigerant
No or too low air flow across the evap-
orator
Check/adjust the flow
Defective expansion valve or low pres-
sure control
Check/replace
NO ⇓
Is the LED flashing red on
the frequency inverter? YES ⇒Phase failure/voltage failure Check the 3-phase supply, measure the incoming voltage. Reset the frequency
inverter by switching o the voltage for
1 minute or more. Check that the com-
pressor is running without dissonance.
Overload/defective stepless compres-
sor
Reset the frequency inverter by switch-
ing o the voltage for 1 minute or more.
Check that the compressor is running
without dissonance.
Is the alarm
“189 Phase Rotation
order”displayed?
YES ⇒Incorrect phase sequence for supply
voltage on compressor 2
Shut o voltage and switch two of the
incoming phases
NO ⇓
Is the alarm
“AL 120 Compr 1
Low pressure di.” dis-
played?
YES ⇒No pressure dierence between the
high-pressure and low-pressure side
Contact service
NO ⇓
Is the alarm
“AL 59 Compr 1
Low Cond Temp” dis-
played?
YES ⇒Condensation temperature too low Contact service

Operation and Maintenance Instructions
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Page 18
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Alarm information for inverter and compressor
For unit incl. control (code MX), alarm information can be read on the Climatix
display (Main menu > Unit > Cooling > Alarms).
For unit excl. control (code UC, MK, US), alarm information can be read on the
Carel display. Press the alarm symbol to view alarms.
Climatix alarm (code MX) Explanation and corrective action
Cooling unit
Sum alarm Sum alarm, check alarm in Carel, see table below.
Alarm C1 R. pressure switch High pressure switch tripped or alarm for frequency inverter.
Alarm C1 EEV motor fault Fault on electrical connection to expansion valve.
Alarm C1 low pressure sensor Power cut or short circuit to low pressure sensor. Check EVD, cabling and sensor.
Alarm C1 suction gas sensor Power cut or short circuit to suction gas sensor. Check EVD, cabling and sensor.
Alarm C1 high pressure sen-
sor
Power cut or short circuit to high pressure sensor. Check EVD, cabling and sensor.
Alarm C1 low overheating Compressor stoppage caused by low overheating.
Alarm C1 LOP Compressor stoppage caused by low evaporation temperature.
Alarm C1 MOP Compressor stoppage caused by high evaporation temperature.
Alarm C1 communication EVD Fault on communication to EVD (expansion valve control).
Alarm C1 low suction gas
temp
Low suction gas temperature.