Topvex SX03, SX04, SX06 Compact Air Handling Unit

Topvex SX03, SX04, SX06 Compact Air Handling Unit
Topvex SX03, SX04, SX06
Compact Air Handling Unit
GB
Operation and maintenance instructions
Corrigo ver. no. 1.2-1-00
Introduction
This manual concerns air handling unit type Topvex SX, manufactured by Systemair AB. It consists of
basic information and recommendations concerning the design, installation, start-up and operation.
The key to proper and safe operation of the unit is to read this manual thoroughly, to use the unit
according to guidelines given and follow all safety requirements.
Table of contents
Introduction ....................................................................................................................................2 Table of contents............................................................................................................................2
Warning ..........................................................................................................................................2
Operation .......................................................................................................................................3 General ...................................................................................................................................................... 3 Free cooling ............................................................................................................................................... 3
Defrost function, general description..............................................................................................4 Defrost levels ............................................................................................................................................. 4 Shortcut to set the menu language ............................................................................................................ 5
Control panel ..................................................................................................................................5 How to operate ....................................................................................................................................... 5 Changing parameters ............................................................................................................................. 5 Navigating the menus ............................................................................................................................. 6 Alarms .................................................................................................................................................... 6 Alarms –Overview .................................................................................................................................. 6
Control unit, manual .......................................................................................................................7
Maintenance.................................................................................................................................12
Troubleshooting ...........................................................................................................................14
Service .........................................................................................................................................14
Commissioning record .................................................................................................................15 Warning
In order to avoid electrical shock, fire or other damage that might occur in the event of faulty use and
operation of the unit, it is important to consider the following:






The system must be installed according to the installation instructions
Disconnect mains supply before service or cleaning of components
Tumble dryer must not be connected directly to the ventilation system
Make sure that the filter is mounted in its place before running the system
Take care of sharp edges when removing parts for maintenance
Maintenance must be performed according to the instructions.
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Topvex SX03, SX04, SX06
Operation- and maintenance instructions
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Systemair AB
Operation
General
Topvex SX units with Electrical heater have 3 minutes of re-cooling after the unit has been turned off.
N.B. If the fire alarm is activated when the heater is in operation the fans stop immediately without recooling. This can cause the overheating protection to trip (see page 6 Alarms –Overview how to reset).
When changing a parameter in the control system it takes up to 1 minute for the change to be carried out.
Free cooling
The objective of the Free cooling function is to provide cool outdoor air if available during the night time
when the unit is in OFF position to cool down the interior of the building. During this time the heat
exchanger is by-passed.
NB the following is only valid if the free cooling function is set to Active in the program menu.
The fans are started at Start Cooling Hour if the following criteria are met simultaneously:
• all time channels are in OFF position and that the unit goes back to normal operation the following day
(set operation time during the following 24 hours) and
• the average outdoor temperature is higher than the outdoor temperature limit and
• the actual outdoor temperature is lower than the outdoor temperature set upper limit and
• the actual outdoor temperature is higher than the outdoor temperature set lower limit and
• the actual outdoor temperature is lower than the actual room temperature and
• the actual room temperature is higher than the set room temperature limit.
The fans are stopped at the Stop Cooling Hour or if the following conditions are met:
• the room temperature is lower than the set room temperature limit or
• the outdoor temperature exceeds the set outdoor temperature upper limit. or
• the outdoor temperature is lower than the lowest set outdoor temperature limit.
The unit checks the night temperature (indoor and outdoor temperature) during 3 minutes at 12.00 PM
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.
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Operation- and maintenance instructions
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Defrost function, general description
The need for defrosting of the heat exchanger block is determined by the outdoor temperature. There are
three possibilities for defrosting based on if you want to keep a balanced airflow or if you can accept an
unbalanced airflow during the defrost cycle. The unit can be programmed for how aggressive the
defrosting needs to be based on the estimated indoor humidity level. See table 1 below for explanations of
the different settable levels.
1. Reduction of the supply airflow (Unbalanced airflow):
Reduces the supply airflow up to 20% to allow the higher extract airflow to defrost the heat
exchanger. Starts, if activated, at a preset outdoor temperature and stays active as long as the
outdoor temperature stays below the set point. During this time the supply air fan operates at a
constant reduced speed
By even lower outdoor temperatures a stop defrosting sequence is started.
2. By-pass of the supply airflow (Balanced airflow):
Starts, if activated, when the outdoor temperature drops to a preset level, and keeps below that
level a preset number of minutes, the by-pass damper inside the unit opens to help reduce the
flow of the cold outdoor air through the heat exchanger block. As this cycle is initiated the set
supply air temperature is lowered 4K. If the set supply air temperature after the re-heater battery
still can’t be maintained both the supply air and exhaust air fan are reduced in order to maintain a
balanced indoor ventilation condition. If this is not enough to keep the set supply air temperature a
stop defrosting sequence will start that stops the supply air fan under a preset number of minutes.
3. Stop defrosting (Unbalanced airflow) (Default):
Starts when the outdoor temperature drops below the preset stop defrosting temperature or the
set supply air temperature during by-pass defrosting can’t be kept. Is active a preset number of
minutes based on the set defrost level (table 1). Stop defrosting is also automatically activated as
necessary if none of the above options are chosen.
Defrost levels
Defrost level
Indoor humidity level*
Description
1
Minimum <20%
Office with small amount of plants. Low physical activities.
Industrial building with processes that use no water.
2
Low 30%-40%
Office with normal amount of plants. Medium physical
activities.
3
Medium 40%-60%
Day care centre. High physical activities
4
High 60%-80%
Newly constructed buildings that need to dry out.
5
Extreme >80%
Greenhouse
Table 1.
*Relative humidity in extract air during cold season
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Shortcut to set the menu language
Press and hold the OK button while switching on the mains supply.
Press the OK button. Choose language with the UP/DOWN buttons. Confirm the choice with the OK
button. Press the LEFT button to step back in the menus. The language can also be set in the Language
menu (see Control unit manual, page 11).
Control panel
Description
1.
2.
3.
4.
5.
6.
Description
7.
7a.
7b.
7c.
7d.
7e.
Alarm button
Alarm LED
Write enable LED
OK button
Clearing button
Mounting holes
Connection block
Yellow cable
Orange cable
Red cable
Brown cable
Black cable
fig. 1
How to operate
The menus in the Corrigo E are organized in a horizontal tree structure. The UP/DOWN-buttons are used
to move between options in the present menu level. The RIGHT/LEFT buttons are used to move between
menu levels. When changing parameters the UP/DOWN buttons are used to increase or decrease the
value of the parameter and the RIGHT/LEFT buttons to move between digits within the parameter. The
OK button is used to confirm the choice of a parameter setting. The C button is used to abort an initiated
parameter change and restore the original value (press and hold). The ALARM button is used to access
the alarm list.
Changing parameters
In some menus there are parameters that can be set. This will be indicated by the LED flashing. To
change a parameter, first press the OK button, the LED changes to a steady light. A cursor will
appear at the first settable value. If you wish to change the value, do so by pressing UP/DOWN. In
numbers containing several digits you can move between the digits using LEFT/RIGHT. When the desired
value is displayed press OK. Settings outside the intervals are not registered (preceding values count). If
there are further settable values displayed the cursor will automatically move to the next one. To pass a
value without changing it, press RIGHT. To abort a change and return to the initial setting, press and hold
the C-button until the cursor disappears.
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Navigating the menus
The start display (the display normally shown) is at the root of the menu tree. Pressing DOWN will move
you through the menu options. UP will move you back through the options. To enter a higher menu level,
use UP or DOWN to place the cursor at the menu you wish to access and press RIGHT. If you have
sufficient log on privileges the display will change to the menu you have chosen.
At each level there may be several new menus which you move through using UP/DOWN.
Sometimes there are further submenus linked to a menu or menu item. This is indicated by an arrow
symbol at the right-hand side of the display. To enter a menu, press RIGHT again. To step back to
previous menu level, use LEFT.
Alarms
The alarm button (pos.1, fig. 1) opens the alarm queue. When pressing this button active and nonacknowledged alarms will be displayed in the menu window. The alarm-LED (pos. 2, fig. 1) is flashing if
there are non-acknowledged alarms and steady if the alarms are still active but have been acknowledged.
If there are multiple alarms, use UP/DOWN to move between them. An alarm can be acknowledged or
blocked by using OK and UP/DOWN. To abort and go back to start menu select Cancel and press LEFT.
Alarms –Overview
Alarm fan motor
DI1
Thermal contact in the fan motor has tripped. Reset in the control panel.
Overheat.
DI2
Thermal contact in the electric heater has tripped (auto. reset: 60°C, manual reset:
110°C). Manual reset is done by pressing the red button (RESET) In the electric
heater box.
Fire alarm
DI5
External fire alarm contact has tripped. Reset in the control panel.
Filter to be changed
-
Set time has expired. Reset in the control panel.
Alarm frost protect
-
Hot water heater outlet water below +7°C (temp. not changeable). Reset in the
control panel.
Sensor error supply
-
Supply air temperature sensor interruption.
Sensor error extract
Extract air temperature sensor interruption.
Sensor error outdoor
Outdoor air temperature sensor interruption.
Alarm output all alarms
Internal backup battery
error
DO5 Gives a 24V AC signal
Shows “Internal battery error” in the display
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Operation- and maintenance instructions
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Control unit, manual
Display shows
Description
Man/Auto:
Fan speed:
Show if the unit is running in Manual or Automatic mode.
Show if the fans are running on Low, Medium or High speed or if the unit
is stopped.
Extended/Forced
running
Activate extended/forced running. Extended/Forced running is the time
the unit goes from shut down mode, Low or Medium fan-speed to the fan
speed of your choice. OFF and ON times and fan-speeds are set at the
submenu Week program.
Control temp.
Running mode
Service
Time/Date
Week program
Set the desired control temperature value, 16-30 C.
Set the running mode of the unit. Choose between:
Auto, Manual high, Manual medium, Manual low or Manual shut off.
Login with 1111 to service level. Log’s out after 5 minutes of inactivity,
with main supply on.
Set the present time, date and weekday.
Set the units ON time for each week day, 2 periods/ day.
Preset time is Period 1. 07:00-16:00 Monday-Sunday and Period 2.
00:00-00:00 Monday-Sunday, 00:00-00:00 inactivates the period.
Set the fan-speed when the unit is ON to Low, Medium or High and the
fan-speed when the unit is OFF to shut off, Low, Medium or High.
Preset is: ON = Medium (75%) and OFF = Low (35%).
Extended/Forced
running
Set how many minutes (0-240) the unit should go to the desired fan
speed according to below setting.
Set the desired fan speed for the extended/forced running mode.
Choose between High, Medium or Low
Activating extended running can be done by pressing the OK button in
sub menu Extended/forced running (user level) or by using an external
Timer or a Push button. Set the minutes to 0 when using a Timer.
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Topvex SX03, SX04, SX06
Operation- and maintenance instructions
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Systemair AB
Display shows
Filter alarm
Description
Reset filter alarm by setting the Reset alarm to Yes.
Set the time until the filter alarm should be activated, 1-15 month.
Functions
Set the status for Cooling to Active or Not Active. Preset is: Not Active.
Function: Controls a cooling battery with a 0-10 V DC signal.
Set the status for Cool Recycling to Active or Not Active. Preset is: Not
Active.
Function: Closes the by-pass damper to allow recovery of the cold
extract air. Is activated when the extract air temperature is 3K lower than
the outdoor air temperature.
Set the status for Free cooling to Active or Not Active. Preset is: Not
Active
Function: Starts the fans and opens the by-pass damper under certain
conditions to use the cooler outdoor air to cool down the interior of the
building during night time between Start Cooling Hour (0:00) and Stop
Cooling Hour (06:00).
Free cooling active: Yes (changeable, Yes or No)
Outdoor temp activation 22°C (changeable, the average daytime temp.
needs to be over this value in order to start the function)
Outdoor temperature night
High: 15,0°C (changeable, Outdoor temp. needs to be below this value
to start the function)
Low: 5,0°C (changeable, Outdoor temp. needs to be over this value to
start the function)
Room temperature min: 18,0°C (changeable, Room temp. (extract air
temp. sensor) needs to be over this value to start the function)
Set the status for Fire function to Active or Not Active. Preset is: Not
Active.
Set how the unit should operate if the fire alarm function is activated, run
on High fan-speed or Shut off. Preset is: Shut off.
Function: Decides how the unit should operate at fire alarm.
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Display shows
Description
Set the Air control mode to:

Supply.

Supply & Outdoor compensation.

Set how much the control temp. should be compensated when the
out door temperature is –20°C and +15°C (the compensation will be
linear between these two points).
E.g. At –20 : 5°C.
E.g. At +15 : -2°C.
Control temp. = 18°C.
Outdoor temperature –20°C gives a Control temp. of 23°C (18+5).
Outdoor temperature +15°C gives a Control temp. of 16°C (18-2).
Extract.
Set the permitted maximum and minimum supply air temperature.
Set the Fan speed control for the supply air fan (SAF) in % of
maximum fan speed. Choose between: 0% to 100%.
All fan speeds LOW, MEDIUM & HIGH can be set in this interval
Set the Fan speed control for the exhaust air fan (EAF) in % of
maximum fan speed. Choose between: 0% to 100%.
All fan speeds LOW, MEDIUM & HIGH can be set in this interval
Defrost function
Set the By-pass function to “Yes” or “No” (preset is “No”)
Function: (enables the use of the by-pass damper for
defrosting. The set supply air temperature is reduced 4K during
defrost cycle. Reduction of both supply air fan and extract air
fan speed up to 20% if supply air temperature does not reach
reduced set point. If necessary the supply air fan is stopped
completely during the defrosting cycle (stop defrosting)).
Set the Reduced supply air to “Yes” or “No” (preset is “No”)
Function: Reduces the supply air fan speed up to 20%
whenever there is a frost risk of the plate heat exchanger.
Set the defrost level between 1 and 5 (preset is 3)
Function: Level 1 to 5 are depending on the estimated indoor
relative humidity level. See below table 1 on page 4 for a
description of the different levels.
Automatic summer/wintertime changeover
Choose between “Yes” and “No”, preset is “Yes”.
In-/Outputs
Show the Analogue inputs.
AI1: Show the actual temperature of the supply air.
AI2: Show the actual temperature of the exhaust air.
AI3 applies only to HW units.
AI3: Show the actual temperature of the return water in the hot water
battery (frost protection).
AI4: Show the actual outdoor temperature
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Operation- and maintenance instructions
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Systemair AB
Display shows
Description
Show the status and settings of the digital inputs.
DI1: Fan alarm. Connected to the thermal contact in the fan motor. Stops
the fan and disconnects the electrical heater when the alarm is activated.
DI2: applies only to EL units.
DI2: Overheating of the electrical heater. Connected to the thermal
contact in the heater. Disconnects the heater when the alarm is
activated.
DI3: Timer/P.B. Starts the Extended running when an external contact,
Timer or Push button, closes. Only when the unit is running in Off mode.
DI4: Not in use
DI5: Is only shown when the Fire function is activated.
DI5: Fire alarm. Connects to an external fire central. Stops the unit or
changes the fan speed to High if the alarm is activated.
Show and Set the Analogue outputs.
AO1: Heating battery, Electric or hot-water. Show the output signal, 010V. Set the status to: Auto, Manual or Off. In Manual status it is
possible to set the output signal within a range from 0 to10V, more than
2V activates the electrical re-heater (on/off function).
AO2 is shown only when the cooling function is activated.
AO2: Cooling battery, cold-water. Show the output signal, 0-10V. Set
the status to: Auto, Off or Manual. In Manual status it is possible to set
the output signal within a range from 0 to10V.
AO3: Control signal, 0-10V, to the extract air fan, Set Auto, Man or Off
AO4: Control signal, 0-10V, to the supply air fan, Set Auto, Man or Off
AO5: Control signal, 0-10V, to the by-pass damper, Set Auto, Man or
Off
Show and Set the digital outputs, output 24V AC.
DO1: Damper motor on/off. Opens the damper when the unit is started
DO2: Not in use
DO3: Not in use
DO4: Not in use
DO5: Alarm output. Show the status.
Version
Configuration
Show the program version
Present version 1.2-1-00
(Enter into the configuration menu using code 8642)
1. AHU type (Preset from factory is Topvex-X), should normally not
be changed
Fan speed control SAF (supply air fan)
High: 100% (changeable 0-100%)
Medium: 75% (changeable 0-100%)
Low: 35% (changeable 0-100%)
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Topvex SX03, SX04, SX06
Operation- and maintenance instructions
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Systemair AB
Display shows
Description
Fan speed control EAF (exhaust air fan)
High: 100% (changeable 0-100%)
Medium: 75% (changeable 0-100%)
Low: 35% (changeable 0-100%)
2. Type of heater (choose correct type of re-heater)
3. Control parameters
P-band: 30°C (changeable)
I-Time: 100s (changeable)
By-pass damper
P-band: 30°C (changeable)
I-Time: 100s (changeable)
4. Display unit type (E DSP preset)
5. Modbus Comm. (Not Active or Active, Preset is Not Active)
Modbus: Active
Modbus address: 7 (changeable)
Speed: 9600 bps (changeable)
Two stop bits: Yes (changeable)
Parity: No (changeable)
6. Address:
PLA: 254 (changeable)
ELA: 30 (changeable)
Language
Change codeword
Set the menu language.
Note: A short cut to the menu language is by pressing the OK button at
the same time as the main voltage is switched on.
Set a new code for Service level.
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Systemair AB
Maintenance
Maintenance of the Topvex SX should normally be carried out 3 – 4 times a year. Apart from general
cleaning the following should be observed:
Changing Supply/Extract air filter
Indicated as “filter to be changed” in the control panel, 1-2 times per year or when necessary (fig. 2)
The bag filter cannot be cleaned and must be changed when necessary. New filters can be ordered from
Systemair. Operation time between filter changes must be reset after filter change (see page 8, Filter
alarm). To change the alarm activating time see page 8, Filter alarm.
Initial pressure drop over the filter (Clean filters) is approx. 70 Pa and the final pressure drop is approx.
220 Pa.
fig. 2
Checking the 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 (once a year) to maintain high efficiency. The heat exchanger can be taken out of
the unit for maintenance (fig.3). Wash in hot soapy water or use pressure air. Do not use detergent
containing ammonia.
NB! The exchanger block is heavy. To take out the plate heat exchanger is normally a job for two
persons.
fig. 3
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Topvex SX03, SX04, SX06
Operation- and maintenance instructions
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Systemair AB
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 (fig 4) and may be cleaned with a cloth or a soft brush with a
recommended interval of once per year. Do not use water. White spirit can be used to remove obstinate
settlements. Allow drying properly before remounting.
fig. 4
Cleaning extract louvers and inlet diffusers
The system supplies treated outdoor air to the building and extracts the used indoor air via the duct
system and diffusers/louvers. Diffusers and louvers are mounted in ceilings/walls in bedroom, living room,
wet rooms, WC etc. Remove diffusers and louvers and wash in hot soapy water if required. Diffusers/
louvers 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.
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.
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/louver openings or special inspection hatches in the duct system (if fitted).
NB! Possible roof cowls must be checked once a year and cleaned when necessary.
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Systemair AB
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 that the fuses are not defect
Check the settings in the control panel (times, week schedule, auto/manual operation etc.)
Check if there are any alarm messages
2. Reduced airflow








Check the settings of Medium and Low fan speed
Check that the Outdoor/Exhaust air damper (if used) opens
Change of filters required?
Cleaning of diffusers/louvers required?
Cleaning of fans/exchanger block required?
Is the roof unit/air intake clogged?
Check ducts for visible damage and/or build up of dust/pollution
Check diffuser/louver openings.
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, marked
RESET, in the electric heater box, see fig.7 on page 13 in the installation description.
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). If necessary reset (see page 6 Alarms-overview)
4. Noise/vibrations


Clean the fan impellers
Pull the two fans out and check that the 2 screws holding the fans are tightened.
Service
Before calling your service representative, make a note of the specification and production number from
the type label (fig. 5).
1
2
3
4
5
Fig. 5
Code explanation
1: Item number
2: Production order number
3: Consecutive number
4: Production date
5: Product code (product specification)
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Systemair AB
Commissioning record
Company
Responsible
Customer
Date
Installation
Object/Unit
Item no.
Installation address
Model/size
Series no.
Filter replaces interval set.
Present time and date set.
Week scheduler settings
Preset On-time is:
Period 1. 07:00-16:00 Monday-Sunday, Medium fan-speed.
Period 2. 00:00-00:00 Monday-Sunday. 00:00-00:00 inactivates the period.
Preset Off time is:
Remaining time: Low fan-speed.
Weekday
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
Period
Running times (On)
1
:
-
:
2
:
-
:
1
:
-
:
2
:
-
:
1
:
-
:
2
:
-
:
1
:
-
:
2
:
-
:
1
:
-
:
2
:
-
:
1
:
-
:
2
:
-
:
1
:
-
:
2
:
-
:
Running mode On: Low , Medium , High
Running mode Off (remaining time): Shut off
, Low
, Medium
, High
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Operation- and maintenance instructions
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Systemair AB
Function
Preset value
Set value
Temperature
Control function Temp.
Control Temp.
Supply
Supply outdoor
Exhaust
Supply
Supply outdoor
18,0 °C
°C
Compensation: 20,0 °C
Compensation: 0,0 °C
12,0 °C
30,0 °C
°C
°C
°C
°C
35% of max. Fan speed
75% of max. Fan speed
100% of max. Fan speed
%
%
%
Exhaust
Outdoor compensating
Outdoor temp. -20,0 °C
+15,0 °C
Min. supply set point
Max. supply set point
Air flow
Fan speed Low
Fan speed Medium
Fan speed Maximum
Extended/Forced
running
Running time
240 Minutes
*)
Minutes
*)
Filter alarm
Replaces interval
6 Months
Months
Cooling
Status
Not active
Active
Not active
Active
Not active
22°C
High: 15°C Low: 5°C
18°C
Active
Cool Recycling
Status
Free Cooling
Status
Outdoor temp activation:
Outdoor temp night:
Room temp min:
High:
°C
°C
Low:
°C
°C
Fire function
Not active
Active
Unit shut off
High fan speed
By-pass
status
Not active
Active
Reduced supply airflow
status
Not active
Active
Status
Running mode at activated
fire alarm
Defrost function
Defrost level
3
Set defrost level
*) Set the minutes to 0 when using an external Timer.
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Topvex SX03, SX04, SX06
Operation- and maintenance instructions
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Systemair AB
Notes
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Systemair AB
Systemair AB reserves the right to make changes and improvements to the contents of this manual
without prior notice.
Systemair AB
Industrivägen 3
739 30 Skinnskatteberg, Sweden
Phone +46 222 440 00
Fax +46 222 440 99
www.systemair.com
205872 (26-01-2011)
10-03
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