IV Produkt EcoHeater 060-1 Troubleshooting guide

Original instructions
Order number :
Project :
Extract Air Heat Pump
THE NEW EcoHeater 060-300
Operation and maintenance instructions
THE NEW

Table of Contents
1 General
1.1 Intended use ........................................................................................ 2
1.2 Safety precautions ........................................................................... 2
1.3 Manufacturer ........................................................................................ 3
1.4 Designations ........................................................................................ 3
1.5 CE marking and EU Declaration of Conformity .......... 3
1.6 Maintenance ......................................................................................... 4
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 Design ....................................................................................................... 6
2.2 Function ................................................................................................... 8
3 Wiring instructions and fuse protection
3.1 Recommended external fuse ................................................ 12
3.2 Power supply .................................................................................... 12
3.3 Wiring diagram ............................................................................... 13

4 Operation
4.1 Commissioning, general ........................................................... 14
4.2 Fan section, commissioning .................................................. 15
4.3 Heat pump section, commissioning ................................ 16
4.4 Combustion gas bypass, commissioning .................... 17
5 Maintenance instructions
5.1 General .................................................................................................. 18
5.2 Filters (code ELEF) ........................................................................ 20
5.3 Fan unit (code ENF) ...................................................................... 23
5.4 Damper (code EMT-01) ............................................................. 25
5.5 Combustion gas bypass (code EHP-B) ......................... 26
5.6 Sound attenuator (code EMT-02) ....................................... 27
5.7 Heat pump section (compressor part) ........................... 28
5.8 Evaporator (extract air coil) ..................................................... 30
6 Troubleshooting
6.1 Troubleshooting in the event of an alarm ..................... 31
6.2 Troubleshooting via symptoms and
status message ............................................................................... 32

Page 2
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
1 General
1.1 Intended use
The EcoHeater is a series of highly efficient extract air handling units with a
built-in, variable capacity-controlled heat pump. The EcoHeater is intended to
be used for heat recovery from comfort ventilation in energy-efficient apartment
blocks.
1.2 Safety precautions
Observe warning labels on the unit as well as the following safety precautions:
Lockable safety switch
WARNING!
High voltage and rotating fan impeller, risk of personal injury.
Before working on/servicing the unit –shut down the unit via
the control terminal, then turn the safety switch to the 0 position
and lock it.
NB:
The safety switch is not designed for starting/stopping the unit. Always
use the control equipment to start and shut down the unit.
Inspection doors
WARNING!
Positive pressure inside the unit, risk of personal injury. Allow
the pressure to drop before you open the inspection doors.
WARNING!
Rotating fan impeller, risk of personal injury. Shut down the air
handling unit and wait at least 3 minutes before you open the
inspection doors.
NB:
The doors in front of moving parts should normally be locked; there are
no safety guards. Before carrying out work, unlock the doors with the
key provided.
Electrical connection
WARNING!
Rotating fan impeller, risk of personal injury. 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.

Page 3
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
1.3 Manufacturer
The EcoHeater extract air heat pump is manufactured by:
IV Produkt AB
Sjöuddevägen 7
SE-350 43 VÄXJÖ
1.4 Designations
The EcoHeater extract air heat pump is comprised of two sections plus a
possible combustion gas bypass. Each section has a model identification label
placed on the front. All the necessary designations needed for identifying the
section appear on the label.
Kodnyckel
Code key
Beteckning
Project name
Ordernummer
Order number
Max. varv
Max. rev.
Tillv. ort
Made in Tillv. månad Manuf. month
YYMM
Modell
Model
– –
Max. temp. °Cr/m
Art. Nr. 19121-1001
Typical model identification label
1.5 CE marking and EU Declaration of Conformity
EcoHeater extract air heat pumps are CE marked, which means that upon
delivery, they conform to applicable provisions in EU Machinery Directive
2006/42/EC as well as to the EU Directives applicable to other types of air
handling units, e.g. the Pressure Equipment Directive 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.
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

Page 4
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
1.6 Maintenance
Continuous maintenance of this unit can be carried out either by the person
normally in charge of maintaining the building or through a contract with a well-
reputed service company.
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 refer to the European Parliament’s definition: “...the natural or
legal 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(ton). This figure is calculated by multiplying
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 corre-
sponds to
(5.0×2088)/1000 = 10.44 CO₂ e(tons). The unit is marked with refrigerant quan-
tity and carbon dioxide equivalent.

Page 5
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
Leakage inspection and registration
The following applies to one-piece units with 5 CO2e(ton) refrigerant content or
more per circuit (EcoHeater sizes 150 – 300):
• 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 content is below 5 CO2e (ton)
(EcoHeater sizes 060 – 100)
no periodic leak detection is needed, although an initial leak inspection should
be performed in conjunction with installation.
If the total refrigerant content of the ventilation system exceeds 14 CO2e(ton),
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(ton) or more, the intended operator
must inform the supervisory authority of the installation well in advance.
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 supplied
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 presented.
1.9 Spare parts
Spare parts and accessories for this unit are ordered from your nearest IV
Produkt sales representative. When ordering, state the order number and desig-
nation.
These are stated on a data label, affixed to each component.
A separate spare parts list is supplied with the unit.
1.10 Dismantling and decommissioning
When an air handling unit is to be dismantled, separate instructions must be
followed, refer to Dismantling and decommissioning the AHU under Documenta-
tion at docs.ivprodukt.com.

Page 6
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
2 Technical description
2.1 Design
The EcoHeater extract air heat pump consists of two sections; the fan section
and heat pump section.
Fan section Heat pump section
Heat pump section
The heat pump section comprises a DX heat recovery coil, electronic expan-
sion valve, a variable speed controlled compressor, fully soldered plate heat
exchanger (between refrigerant and the liquid side of the radiator circuit), frost-
protected evaporation water outlet for outdoor operation, and integrated control
equipment with electrical connection.
The cooling circuit is integrated in the heat pump section. The compressor and
control components are shielded from the extract air stream. The cooling circuit
is factory tested and built in accordance with PED 2014/68/EU, Module A2.
Designed in accordance with EN378.
The cooling circuit is supplied with a high pressure switch (manual reset), as well
as protection and alarm functions for high/low pressure. The cooling circuit is
controlled so freezing does not occur in the extract air coil. Refrigerant is R410a.
All piping and electrical connections are made via the front. Frost-protection
(heating wire) for the condensation outlet is a maximum of 1 metre from the heat
pump for outdoor operation.

Page 7
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
Fan section
The fan section has a direct driven chamber fan with an EC motor and deep-
ridged filter (filter class M5 as standard). EcoHeater sizes 240 and 300 have dou-
ble fans. The fan unit is withdrawable. Replace the filter from the front of the unit.
Variants and accessories
The unit can be delivered in the following configurations/variants:
•Indoor or outdoor configuration
•Extract air connection to the right or left
•Exhaust air connection can be either connected to the gable section or to
the ceiling (top) (not for outdoor operation).
•Combustion gas bypass
Optional accessories:
•Evacuation damper
•Duct damper
•Inspection window
•Light fitting
•Duct slide valve
•Filter manometer (U-tube, Kytölä or Magnehelic)

Page 8
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
EcoHeater with combustion gas bypass
2.2 Function
General
The EcoHeater is intended for energy recovery from the extract air of apartment
blocks.
Recovered energy is returned to the radiator circuit’s return line, see the circuit
diagram below. The function of the EcoHeater is designed for systems where the
secondary side temperature is at least 20°C (incoming water to the EcoHeater).

Page 9
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
max temp out = 60 ˚C
min temp in = 20 ˚C
max temp in = 53 ˚C
normal ∆t = 7 ˚CCP1
GT3
EcoHeater
Min 10 °C
Max 30 °C
Drain
CP2
GT5
GT6
GT7
GF1
F0
HP1
LT12
OP1
EV1
GT4 GT2 GP4
GP2
ET1
OT1
EP1
FF
C1 CT1
+2 °C
C1 Compressor, variable speed controlled GT2 Temperature sensor extract air
Drain Condensate drain, frost protected GT3 Temperature sensor outdoor air (north
east location)
EP1 Pressure sensor cooling circuit low
pressure
GT4 Temperature sensor exhaust air
ET1 Pressure sensor cooling circuit suction
gas
GT5 Temperature sensor water out (to radia-
tor circuit)
CT1 Temperature sensor compressor sump GT6 Temperature sensor water in (return)
LT12 Temperature sensor liquid line heating
mode
OT1 Temperature sensor hot gas
EV1 Expansion valve, electronic HP1 High pressure switch
F0 Frequency inverter for compressor OP1 High pressure sensor cooling circuit
EA Extract air fan, variable speed controlled CP2 Circulation pump radiator circuit
GF1 Water flow sensor CP1 Circulation pump heat pump
GP4 Pressure extract air duct GT7 Temperature sensor radiator circuit (for
internal control only, not used for exter-
nal control 0-10v).

Page 10
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
Control
The EcoHeater has a factory-set time programme for continuous operation at
one speed. The time programme can be changed in the processing unit for con-
trol at up to three fan speeds.
In case of malfunction of FF (extract air fan), an alarm sounds and the unit stops.
The EcoHeater must be interlocked via circulation pump CP1.
If GT6 (temperature sensor water in) registers a temperature that is too high, the
compressor stops. It restarts automatically when the temperature falls to the
permitted value.
If EP1 (pressure sensor cooling circuit) and/or GT4 (temperature sensor exhaust
air) register a temperature that is too low, the compressor’s speed is reduced
until the temperature reaches the permitted value.
If OP1 (high pressure sensor cooling circuit) registers a condensation tempera-
ture that is too high, the speed of the compressor is reduced.
If GT4 (temperature sensor exhaust air) is lower than 12 °C, the compressor can-
not be started.
If GT4 (temperature sensor exhaust air) is more than 3 °C lower than GT2 (tem-
perature sensor extract air), the compressor cannot be started.
If GF1 (water flow sensor) registers too low flow, the compressor cannot be
started.
Compressor protection
In case of an alarm from F0 (frequency inverter) or HP1 (high pressure switch),
the compressor stops. The high pressure switch is reset manually.
Temperature control
Heat demand from EcoHeater can be controlled via external control signal (0-
10 VDC from the district heating central unit) so that full capacity from the heat
pump is utilised before district heating is used.
Alternatively, EcoHeater can be controlled via an internal radiator curve or an
external tank temperature.
Pressure control
Pressure control can be used by GP4 maintaining a constant pressure in the
extract air duct.
If the duct pressure deviates from the setpoint after a set time, an alarm sounds.
The current air flow can be read from the hand-held terminal.
Smoke/fire
If GT2 (temperature sensor extract air) registers a temperature higher than the
set alarm limit, a smoke/fire alarm sounds.
Communication
Communication via Modbus TCP/IP and text-web included as standard.

Page 11
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
Current limiting
The control unit for EcoHeater is equipped with a function that measures the
heat pump’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
%
087
Demand:
083%
Status: UnitOn
Inv
ON
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. Reduce the value of the fans’
power consumption, see Product Selection Program IV Produkt Designer
(Technical data).
9. Press the enter arrow button.
10.Press the back arrow button twice to return to the start menu.

Page 12
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
3 Wiring instructions and fuse protection
3.1 Recommended external fuse
Recommended external fuse for the unit depends on size and fan
variant.
Size Fan variant
Rec. fuse protection at
(3×400V+N)
Fuses with type C character-
istics.
060-1 ELFF-025Z-EC01-0078-1-F-0, 1×230V 16A
100-1 ELFF-031Z-EC01-0135-1-F-0, 1×230V 16A
150-1
ELFF-035E-EC01-0110-2-F-0, 3×400V 16A
ELFF-040E-EC01-0250-2-F-0, 3×400V 20A
ELFF-040E-EC01-0335-2-F-0, 3×400V 20A
190-1
ELFF-035E-EC01-0110-2-F-0, 3×400V 32A
ELFF-040E-EC01-0250-2-F-0, 3×400V 32A
ELFF-040E-EC01-0335-2-F-0, 3×400V 32A
240-1 ELFF-035E-EC01-0190-2-F-0, 3×400V 32A
300-1 ELFF-035E-EC01-0190-2-F-0, 3×400V 40A
3.2 Power supply
Power supply 3x400V+N connected to the switch in the compressor
section.

Page 13
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
Option 3 – tank charging
208
207
221
222
226
225
209
210
224
223
N
L 1
PE
L 3
L 2
1
N
5
3
2
HB1
N
6
4POWER SUPPLY
3×400V~50Hz
OUTDOOR AIR SENSOR (GT3)
INTERLOCK FROM
CIRCULATION PUMP
GROUP ALARM
CENTRAL FIRE ALARM, WHERE
FITTED (OPEN CONTACT IN
THE EVENT OF ALARM)
TEMPERATUR SENSOR
ACCUMULATOR TANK (GT7)
3.3 Wiring diagram
See the order-unique wiring diagram supplied with the
unit, or at docs.ivprodukt.com.
Option 1 – external control of heat demand
(0–10 VDC)
208
207
221
222
226
225
209
210
224
223
N
L 1
PE
L 3
L 2
1
N
5
3
2
HB1
N
6
4POWER SUPPLY
3×400V~50Hz
SETPOINT HEATING 0-10V
SIGNAL GND (ACTUAL ZERO)
INTERLOCK FROM
CIRCULATION PUMP
CENTRAL FIRE ALARM, WHERE
FITTED (OPEN CONTACT IN
THE EVENT OF ALARM)
GROUP ALARM
OUTDOOR AIR SENSOR (GT3)
Option 2 – internal control of heat demand
(radiator curve)
208
207
221
222
226
225
209
210
224
223
N
L 1
PE
L 3
L 2
1
N
5
3
2
HB1
N
6
4
FLOW TEMP SENSOR (GT7)
POWER SUPPLY
3×400V~50Hz
OUTDOOR AIR SENSOR (GT3)
INTERLOCK FROM
CIRCULATION PUMP
GROUP ALARM
CENTRAL FIRE ALARM, WHERE
FITTED (OPEN CONTACT IN
THE EVENT OF ALARM)

Page 14
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
4 Operation
4.1 Commissioning, general
The EcoHeater extract air heat pump is a modular unit consisting of sections,
components for duct mounting, and accessories. The unit does not require spe-
cial commissioning by a certified technician, but leakage inspections need to
take place during installation, see "1.7 Handling of refrigerant" on page 4.
When commissioning the extract air heat pump for an occupied property, the fan
section must be started immediately after installation to avoid disruption to the
property’s ventilation. The heat pump section is then commissioned separately.
The commissioning must be carried out in accordance with a separate check
list;
EcoHeater, commissioning check list
and applicable sections in separate protocol;
EcoHeater, service protocol.
The validity of the product warranty is conditional on the system having been
correctly commissioned. No modifications to the refrigerant circuit may be made
during the warranty period without the approval of IV Produkt.
Follow the instructions under "6 Troubleshooting" on page 31 before
contacting a service representative for servicing a unit. This will prevent any
unnecessary service calls.

Page 15
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
4.2 Fan section, commissioning
Check list.
Check that the fan section is:
1. correctly set up on a waterproof, vibration-dampening plinth, that
there is sucient space for the backing and for servicing, and that
any supplementary material is removed from the unit
2. connected via sleeves to the exhaust air duct and the extract air duct
(via heat pump section)
3. connected to the power supply, contact a qualified electrician or ser-
vice technician if required
Fan start procedure (via Climatix):
A. set the main switch to ‘On’
B. check that no error messages are displayed, address any errors
C. Start by navigating to the menu line SERVICE SWITCH, press the
dial and select Auto.
1×
1×

Page 16
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
4.3 Heat pump section, commissioning
Check list.
Check that the heat pump:
1. can communicate with sub-central unit, via COM or signal cable, with one
of the following operating options:
- External control: Signal for required heat
- Internal control: Signal temperature sensor supply line
- Tank charging: Signal temperature sensor accumulator tank
Internal control or tank charging can be used even in those cases when
the option for communication with the sub-central unit is lacking or not to
be used. The temperature sensor is then connected directly to the Eco-
Heater.
2. receives a signal from the temperature sensor for outdoor air (via COM or
signal cable)
3. - is connected with flexible hoses (particle filter on inlet, possible safety
valve at heat pump side)
- is vented to the highest point of the liquid
- has the liquid flow adjusted to value according to Technical data
4. has condensation outlet connected to floor drain/sewer (outdoor not via
water trap, insulated pipe if in cold area)
5. for internal control: is aligned with parallel temperature curves for the
property (rec. 3 °C higher curve for supply temperature in Climatix than in
the property)
For detailed wiring instructions, refer to the Order specific Control Schedule, for
communication settings, refer to New EcoHeater, Quick Start Guide for Climatix,
and for connection instructions, refer to New EcoHeater Assembly Instructions at
docs.ivprodukt.com.
Heat pump start procedure (via CAREL):
A. IMPORTANT! The compressor’s crankcase must warm up before
being started. Heating takes place automatically using an in-built
heating coil when the compressor is connected to the power supply.
Heating time depends on the ambient temperature. Heating can take
several hours.
When the underside of the compressor feels warm, it may be started.
B. Allow the compressor to start as follows
Main Menu
1×
1× 1×
2×
On/Off Unit
IV Produkt
%
087
Demand:
083%
Status: UnitOn
Inv
ON
%
087
IV Produkt
Demand:
083%
Status: UnitOn
Inv
ON
Unit On/Off
Unit On/Off

Page 17
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
4.4 Combustion gas bypass, commissioning
Check list.
Check that the combustion gas bypass:
1. is connected to the unit’s fan section and wired according to the wir-
ing instructions, see Order specific wiring diagram.
2. shows Control Send and Return.open mode Yes in Climatix hand-held
unit (Main menu > Unit > Damper control > Fire damper). If error
messages are displayed, address any errors.
3. has a working end position function. Go to Start manual test on the
Climatix hand-held unit (Main menu > Unit > Damper control > Fire
damper - Start manual test). Select Active. If error messages are dis-
played, address any errors and restart the test.

Page 18
Operation and Maintenance Instructions
THE NEW EcoHeater
DSEH180401.00.EN
Continuous product development may give rise to specification changes without notice.
5 Maintenance instructions
5.1 General
Commissioning
See chapter "4.1 Commissioning, general" on page 14 and separate check list
EcoHeater, commissioning check list.
Daily inspection
EcoHeater requires no daily inspection.
Periodic service every six months.
It is recommended that EcoHeater undergo servicing every six months
in accordance with the service schedule (next page) and accompanying
instructions.
Periodic inspection at least once a year
EcoHeater in sizes 150 – 300 must be inspected by a certified refrigeration
technician at least once a year. This means that there may not be more than one
year between inspections. It is also advisable to inspect other sizes, but there
are no requirements.
Inspections include e.g. checking for leaks, reading the overheating status,
evaporation temperature and condensation temperature, and checking drainage.
The inspection points and other annual service are specified in a separate
protocol, see EcoHeater, service protocol.
After any work
Leakage inspection must be carried out by a certified refrigeration technician
within a month of any work (e.g. after any leaks are sealed, components
replaced).
Documenting events
The operator must document and record events such as the content 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.