System air Topvex TR Series Troubleshooting guide

Document in original language | 151620 · A002
Topvex SR 09, 11, Topvex TR 09-15
Compact Air Handling Units
Operation and Maintenance Instructions GB

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© Copyright Systemair AB
All rights reserved
E&OE
Systemair AB reserves the rights to alter their products without notice.
This also applies to products already ordered, as long as it does not affect the previously agreed specifications.

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Contents
1 Warnings.......................................................1
2 Product description..........................................2
2.1 Internal components Topvex SR 09,
11.......................................................2
2.2 Internal components Topvex TR 09-
15.......................................................3
2.3 Description of internal components ............4
2.3.1 Supply and extract air
fans ........................................4
2.3.2 Pressure sensor fans/
filter........................................4
2.3.3 Supply and extract air
filters.......................................4
2.3.4 Heat exchanger .........................4
2.3.5 Rotor motor ..............................4
2.3.6 Rotation guard...........................4
2.3.7 Switch module...........................4
2.3.8 Temperature sensor....................4
2.3.9 Water heating battery .................5
2.3.10 Electrical heater .........................5
2.4 Internal components electrical
connection box ......................................6
2.5 Free cooling description .... ... ... ... ... ...........7
3 Maintenance .. ... .............. ........... ....... ... ... ... ... .8
3.1 Important .............................................8
3.2 Maintenance intervals .............................8
3.3 Maintenance instructions .........................9
3.3.1 Changing supply/extract air
filter........................................9
3.3.2 Checking the rotating heat
exchanger ................................9
3.3.3 Checking the fans..................... 10
3.3.4 Checking the hot water
heating battery........................ 10
3.3.5 Checking the electrical heating
battery .................................. 10
3.3.6 Cleaning the extract louvres
and inlet diffusers..................... 10
3.3.7 Checking the outdoor air
intake .. ... ...... ....... .............. .... 10
3.3.8 Checking the duct
system .................................. 10
3.3.9 Changing the internal
battery .................................. 11
4 Troubleshooting............................................ 12
5 Service .......................................................12

Warnings |1
1 Warnings
The following admonitions will be presented in the different sections of the document:
Danger
• Indicates a potentially or imminently hazardous situation which, if not avoided, could result in death or
serious injury.
Warning
• Indicates a potentially hazardous situation that may result in minor or moderate injuries.
Caution
• Indicates a risk of damaging the product or prevent optimal operation.
Important
• This appliance can be used by children aged from 8 years and above and persons with reduced physical,
sensory or mental capabilities or lack of experience and knowledge if they have been given supervision
or instruction concerning use of the appliance in a safe way and understand the hazards involved.
• Children shall not play with the appliance. Cleaning and user maintenance shall not be made by children
without supervision.
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2| Product description
2 Product description
2.1 Internal components Topvex SR 09, 11
Fig. 1 Internal components with air connections symbols (Drawn as a left hand unit)
Position Description Symbol
AConnection supply air
BConnection exhaust air
CConnection outdoor air
D Connection extract air
1Fan supply air
2 Fan extract air
3Filter supply air
4Filter extract air
5Heat exchanger
6 Rotor motor
7Control heat exchanger
8Extra driving belt
9Pressure sensor supply air fan/extract air filter
10 Pressure sensor extract air fan/supply air filter
11 Temp sensor extract air
12 Electrical connection box
13 Electrical re-heater battery1
14 Temp sensor exhaust air
15 Temp sensor outdoor air
16 Air flow sensor 1
1Only valid for units with electrical re-heater battery
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Product description | 3
2.2 Internal components Topvex TR 09-15
Fig. 2 Internal components with air connection symbols (Drawn as a left hand unit)
Position Description Symbol
AConnection supply air
BConnection exhaust air
CConnection outdoor air
D Connection extract air
1Fan supply air
2 Fan extract air
3Filter supply air
4Filter extract air
5Heat exchanger
6 Rotor motor
7Control unit heat exchanger
8Extra driving belt
9Pressure sensor supply air fan/extract air filter
10 Pressure sensor extract air fan/supply air filter
11 Temp sensor extract air
12 Electrical connection box
13 Electrical re-heater battery1
14 Temp sensor exhaust air
15 Temp sensor outdoor air
16 Air flow sensor 1
1Only valid for units with electrical re-heater battery
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4| Product description
2.3 Description of internal components
2.3.1 Supply and extract air fans
The fans have external rotor motors of EC type which are steplessly controlled individually by setting the control signal
to a fixed value. It is possible to program the speed in 2 steps (normal/reduced) depending on the programming of the
week schedule. The motor bearings are life time lubricated and maintenance free. It is possible to remove the fans for
cleaning, see chapter 3 for more information.
2.3.2 Pressure sensor fans/filter
Two pressure sensors are installed (figure 1, figure 2), each of the sensors has two functions. One function is to meas-
ure the differential pressure over the inlet cone of the fan impellers to maintain the airflow at constant level (CAV func-
tion as standard). The other function, is to measure the differential pressure over the supply and extract air filters so
that when the pressure drop reaches the set value, an alarm is triggered in the main regulator, which indicates that the
filter needs to be replaced.
2.3.3 Supply and extract air filters
The filters are of bag filter type with filter quality ePM1 60% (F7) for the supply air filter and ePM10 60% (M5) for the
extract air filter. The filters need to be replaced when polluted. New sets of filters can be acquired from your installer or
wholesaler.
2.3.4 Heat exchanger
Topvex SR/TR models are equipped with a highly efficient, belt driven, rotating heat exchanger. Required supply air
temperature is therefore normally maintained without adding additional heat. The operation of the heat exchanger is
automatic and depends on the set temperature. An extra driving belt is included on the rotor on delivery (pos. 8 figure
1 ,figure 2).
The Topvex TR heat exchanger is removable for cleaning and maintenance, see chapter 3 for more information.
2.3.5 Rotor motor
The rotor motor drives the exchanger rotor with an infinitely rpm as long as there is a heat demand. The motor is con-
trolled by an analogue 0-10V control signal (pos.6 figure 1 and figure 2).
2.3.6 Rotation guard
A built-in rotation guard in the heat exchanger control registers the rotation of the heat exchanger rotor. If the heat ex-
changer stops when there is a heat/cooling demand the exchanger controller gives an alarm signal to the main
controller.
2.3.7 Switch module
A switch module with HMI and 2 TCP/IP connections is mounted in the heat recovery units. Connection is made through
the panel outlet in the air handling unit (see figure 4).
Note:
24V HMI connection dedicated for the display. The connection is only for HMI and no other
connections is permitted.
2.3.8 Temperature sensor
4 temperature sensors (PT1000) are included in the unit from factory. The sensors are as follows:
• Supply air sensor
• Extract air temperature sensor
• Outdoor air temperature sensor
• Efficiency temperature sensor
The supply air sensor is loosely delivered with the unit and needs to be installed in the supply air duct externally from
the unit. See Installation instructions for more information.
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Product description | 5
2.3.9 Water heating battery
In units with built in water heating battery the hot water coil is located next to the supply air connection. The hot water
coil can be either HWL (hot water coil, low power) or HWH (hot water coil, high power). The coil material is copper pip-
ing with a frame of galvanized sheet steel and aluminium fins. The coil is equipped with venting and immersion sensor
for frost protection.
2.3.10 Electrical heater
In units with built in electrical heater the heating rods are located after the supply air fan in the airflow direction. The
material is stainless steel. The electric heating coil has both automatic and manual overheating protection. The manual
overheat protection is reset by pushing the red button on the electrical heater frame (figure 3). The power demand of
the electric heating coil is controlled by the main regulator, which controls the heat steplessly by a TTC triac control ac-
cording to the desired supply/extract or room air temperature that is set in the control panel.
Danger
• Make sure that the mains power supply to the unit is disconnected before performing any maintenance
or electrical work!
• All electrical connections must be carried out by an authorized installer and in accordance with local rules
and regulations.
Fig. 3 Reset of the manual over heat protection in Topvex TR 09-15 and Topvex SR 09, 11
For removal of filter on TR 09-15 see chapter 3.3.1
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6| Product description
2.4 Internal components electrical connection box
Danger
• Make sure that the mains power supply to the unit is disconnected before performing any maintenance
or electrical work!
• All electrical connections must be carried out by an authorized installer and in accordance with local rules
and regulations.
Topvex SR/TR are equipped with a built in regulator and internal wiring (figure 4).
The figure shows the electrical connection box for the Topvex TR 09-15 units. The connection box for the SR 09, SR 11
has the same layout and components with the difference that the electrical heater is situated in a separate
compartment.
Fig. 4 Electric components
Position description
1Control unit CU283W-4
2Transformer 230/24V AC
3Terminals for internal and external components
4Terminals for internal wiring
5Terminals for mains power supply to the unit
6Contactor (K2) Pump control water (HW units
only, not used in EL-units)
7Automatic fuse
8Automatic fuse for EL heater
9Contactor (K3) EL heater
10 Automatic over heat protection (EL units)
11 Manual over heat protection reset (EL units)
12 TTC EL heater control (EL units)
13 Switch module
14 Panel outlet
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Product description | 7
2.5 Free cooling description
This function is used during the warm period to save energy by using cold outdoor air, e.g. during night time, to cool
down the building and thereby reducing the need for cooling during the day time.
Note:
The following is only valid if the free cooling function is activated in the program menu.
Free cooling is only activated when the following starting conditions are met.
Starting conditions:
• Less than 4 days have passed since the unit was last in running mode
• The outdoor temperature during the previous running period exceeded a set limit (+22°C)
• It is between 00:00 and 07:00:00 in the day (settable)
• The timer outputs for normal speed, Extended running normal and External stop are Off
• A time channel will be On sometime during the recently started 24 hours.
The unit checks the night temperature (indoor and outdoor temperature) during 3 minutes at the set starting hour when
the fans are started so that the sensors can perform a temperature measurement. If above conditions are met the free
cooling function is started, if not the unit goes back to OFF position.
If the outdoor sensor is not located in the outdoor air inlet duct and a room sensor has been selected, the unit will not
start free cooling as long as all the temperatures are not within the start and stop temperature intervals.
Stop conditions:
• Outdoor temp above the set max value (+18°C) or below the set min value (condensation risk, +10°C)
• The room temp/extract air temp is below the set stop value (+18°C)
• One of the timer outputs for normal speed, External stop or Extended running normal is On
• The time has past 07:00:00.
If any stop conditions is fulfilled after three minutes, the unit will stop again. Otherwise, operation will continue until a
stop condition is fulfilled.
When free cooling is active, the fans run at normal speed or the set value for pressure/flow control and the digital out-
put free cooling is active. The outputs block heating, cooling and heat exchanger. After free cooling has been activated,
the heating output is blocked for 60 minutes (configurable time). When using free cooling, an offset to normal fan con-
trol setpoint is adjustable.
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8|Maintenance
3 Maintenance
3.1 Important
Danger
• Make sure that the mains power supply to the unit is disconnected before performing any maintenance
or electrical work!
• All electrical connections must be carried out by an authorized installer and in accordance with local rules
and regulations.
Warning
• Although the mains power supply to the unit has been disconnected there is still risk for injury due to
rotating parts that have not come to a complete standstill.
• Beware of sharp edges during mounting and maintenance. Use protective clothing.
3.2 Maintenance intervals
The table below shows recommended maintenance intervals for the unit and the installation. To ensure a long opera-
tion lifetime for the unit it is important to perform maintenance according to below recommendations and that they are
performed according to the operation and maintenance instructions. A thorough and recurrent maintenance is a must
for a valid guarantee.
Type of maintenance Once a year When necessary
Cleaning the heat exchanger. X
Cleaning the fans. X
Cleaning extract louvres and supply
air diffusers.
X
Cleaning the outdoor air intake. X
Cleaning the duct system. X1
1Or in accordance with local rules and regulations
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Maintenance |9
3.3 Maintenance instructions
3.3.1 Changing supply/extract air filter
The bag filter cannot be cleaned and must be changed when necessary. New filters can be ordered from Systemair. Op-
eration time between filter changes depends on the air pollution at the installation site. A differential pressure switch
indicates when it’s time to change the filters. This will trigger an alarm in the control panel.
When this occurs do the following:
1. Replace the filters with new ones as described below.
2. Press on the alarm symbol on the control panel.
3. Choose Filter alarm and press acknowledge.
Fig. 5 Changing filters
3.3.2 Checking the rotating heat exchanger
After a long time of use dust may build up in the exchanger and block the airflow. It is important to clean the exchanger
regularly to maintain high efficiency. In Topvex TR the complete rotating heat exchanger block can be taken out of the
unit (figure 2.3.4) for cleaning and maintenance. Wash in hot soapy water or use pressure air. Topvex SR has a fixed
heat exchanger block and needs to be cleaned inside the unit. Use pressure air. Do not use detergent containing
ammonia.
Check at least once a year that the exchanger rotor rotates easily. Check this by removing the driving belt and move
the rotor by hand. Check also that the brushes are undamaged. The rotor bearings are permanently lubricated from fac-
tory and should not be re-greased.
Check 4 times per year that the driving belt is sufficiently tense, that it follows the tracks and that it is undamaged. If
the belt tension is too low it needs to be shortened.
Fig. 6 Dismounting the heat exchanger
Note:
Make sure that the rotor motor is not exposed to moisture.
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10 |Maintenance
3.3.3 Checking the fans
Even if the required maintenance, such as change of filters, is carried out dust and grease may slowly build up inside
the fans. This will reduce the efficiency.
The fans are easily taken out from the unit by loosening the 2 bolts (pos 1) on the rail (pos 2) and disconnecting the fast
couplings to the electric wires. The complete fan rack can then be pulled out (figure 7). The fans may be cleaned with a
cloth or a soft brush. Do not use water. White spirit can be used to remove accumulations which are otherwise difficult
to remove. Allow drying properly before remounting.
The fan motor bearings are life time lubricated and should not be re-greased.
Fig. 7 Dismounting the fans
3.3.4 Checking the hot water heating battery
After long periods of operation (usually several years) dust may have deposited on the surface of the battery. This may
reduce batteries capacity. The battery can be cleaned with a pressure washer with misting jets, or with compressed air.
Cleaning should be carried out carefully so as not to damage the batteries aluminium fins. Once a year the battery
water circuit needs to be vented to maintain the batteries capacity.
3.3.5 Checking the electrical heating battery
After long period of time dust and pollutants can build up on the heating rods. This can cause unpleasant odors and in
the worst case fire. Clean with compressed air, vacuum or brush. The automatic safety function needs to be tested and
verified.
3.3.6 Cleaning the extract louvres and inlet diffusers
The system supplies treated outdoor air to the building and extracts the used indoor air via the duct system and diffus-
ers/louvres. Diffusers and louvres are mounted in ceilings/walls in bedroom, living room, wet rooms, WC etc. Remove
diffusers and louvres and wash in hot soapy water if required. Diffusers/ louvres must be put back with their original
settings and positions in order not to unbalance the system.
The cleaning of these parts is done when necessary.
3.3.7 Checking the outdoor air intake
Leaves and pollution could plug up the air intake grille and reduce the unit’s capacity. Check the air intake grille at least
twice a year and clean if necessary.
3.3.8 Checking the duct system
Dust and grease settlements may build up in the duct system even if filters are changed regularly. This will reduce the
efficiency of the installation. The ducts should therefore be cleaned/changed when necessary. Steel ducts can be
cleaned by pulling a brush, soaked in hot soapy water through the duct via diffuser/louvre openings or special inspec-
tion hatches in the duct system (if fitted).
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Maintenance |11
3.3.9 Changing the internal battery
Note:
This procedure requires knowledge of proper ESD protection; i.e. an earthed wristband must be used!
When the alarm ”Internal Battery” is activated and the battery LED lights up red, the battery for backup of program
memory and real-time clock has become too weak. The battery is replaced as described below. A backup capacitor
saves the memory and keeps the clock running for at least 10 minutes after the power supply is removed. Therefore, if
the battery replacement takes less than 10 minutes, there will be no need to reload the program, and the clock will
continue to run normally.
The replacement battery must be of the type CR2032.
1 Remove the cover by pressing down the locking tor-
ques at the edge of the cover using a small screw-
driver, and at the same time pulling the edges
outwards.
2 Grip the battery firmly with your fingers and lift it up-
wards until it rises from its holder.
Press the new battery firmly down into place. Note
that to preserve correct polarity, the battery can only
be inserted the “right way round”.
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12 | Troubleshooting
4 Troubleshooting
Should problems occur, please check or correct the following before contacting your service representative. Always
check if there are any alarms active in the control panel.
1. Fan(s) do not start
• Check if there are any alarm messages
• Check that the fuses are not defect (figure 4)
• Check the settings in the control panel (times, week schedule, auto/manual operation etc.)
2. Reduced airflow
• Check the settings for medium and low fan speed
• Check that the outdoor/exhaust air damper (if used) opens
• Check if filters need changing
• Check if diffusers and louvres need cleaning
• Check diffuser/louvre openings
• Check if fans and exchanger block need cleaning
• Check if the roof unit or air intake is clogged
• Check ducts for visible damage and/or build up of dust/pollution
3. Cold supply air
• Check the control temperature on the control panel
• Check if the overheating thermostat has tripped. If necessary press the red button, on the electrical heater (figure
4).
• Check if the extract filter must be changed
• Check if the fans have stopped due to overheating. If so the thermal contact might have tripped (shows as fan
alarm in the control panel).
4. Noise/vibrations
• Check that the unit is completely levelled
• Clean the fan impellers
• Check that the screws holding the fans are tightened properly
5 Service
Before calling your service representative, make a note of the specification and production number from the type label
(figure 8)
230/400V 25 A 50Hz
Systemair Sverige AB
Industrivägen 3
SE-73930 Skinnskatteberg
Sweden
4016 W IP23 225kg
Ver. A
Serial. no: 1234/567891-0001/140214
Topvex XXXX
16kW 16kW
www.systemair.com
2 3 4
5
Fig. 8 Type label
Position Description
1Item number
2Production order number
3Consecutive number
4Production date
5Product code (product specification)
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Service |13
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14 |Service
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Topvex SR 09, 11, Topvex TR 09-15 · Operation and Maintenance Instructions · 151620 · en_GB · 2018-10-11 · A002
Systemair Sverige AB
Industrivägen 3
SE-739 30 Skinnskatteberg, Sweden
Phone [phone]
Fax [phone]
www.systemair.com