Topvex FC Compact Air Handling Unit Installation

Topvex FC Compact Air Handling Unit Installation
Topvex FC
Compact Air Handling Unit
Installation instructions
Document in original language
125917-EN_GB
2015-03-16 A001
Contents
1 Declaration of Conformity ........................................................................................................... 1
2 Warnings................................................................................................................................... 2
3 Product information.................................................................................................................... 2
3.1 General ........................................................................................................................... 2
3.2 Technical data .................................................................................................................. 3
3.2.1 Dimensions and weight ........................................................................................... 3
3.2.2 Electrical data Topvex FC ........................................................................................ 5
3.3 Transport and storage....................................................................................................... 5
4 Installation................................................................................................................................. 7
4.1 Unpacking........................................................................................................................ 7
4.2 Where/how to install ......................................................................................................... 7
4.3 Condensation drain .......................................................................................................... 8
4.4 Installing the unit .............................................................................................................. 9
4.4.1 Installation procedure ..............................................................................................10
4.5 Supply air sensor..............................................................................................................11
4.6 Mounting the sliding door kit..............................................................................................12
4.7 Connections.....................................................................................................................14
4.7.1 Ducting...................................................................................................................14
4.7.2 Electric connections ................................................................................................15
4.8 Installing the Control Panel ...............................................................................................20
4.8.1 Dimensions ............................................................................................................20
4.8.2 General information.................................................................................................20
4.8.3 Installation ..............................................................................................................20
4.9 Additional Equipment........................................................................................................21
1 Declaration of Conformity
Manufacturer
Systemair AB
Industrivägen 3
SE-739 30 Skinnskatteberg SWEDEN
Office: +46 222 440 00 Fax: +46 222 440 99
www.systemair.com
hereby confirms that the following products:
Air handling units
Topvex FC02 EL
Topvex FC02
Topvex FC02 HWL
Topvex FC02 HWH
Topvex FC04 EL
Topvex FC04
Topvex FC04 HWL
Topvex FC04 HWH
Topvex FC06 EL
Topvex FC06
Topvex FC06 HWL
Topvex FC06 HWH
(The declaration applies only to product in the condition it was delivered in and installed in the facility in accordance
with the included installation instructions. The insurance does not cover components that are added or actions
carried out subsequently on the product)
Comply with all applicable requirements in the following directives
• Machinery Directive 2006/42/EC
• EMC Directive 2004/108/EC
• Low Voltage Directive 2006/95/EC
The following harmonized standards are applied in applicable parts:
EN ISO 12100:2010
Safety of machinery - General principles for design - Risk assessment and risk reduction
EN 13857
Safety of machinery – Safety distances to prevent hazard zones being reached by
upper or lower limbs
EN 60204-1
Safety of machinery – Electrical equipment of machines – Part 1: General requirements
EN 60335-1
Household and similar electrical appliances – Safety Part 1: General requirements
EN 60335-2-40
Safety of household and similar electrical appliances - Part 2-40: Particular requirements
for electrical heat pumps, air-conditioners and dehumidifiers
EN 50106:2007
Safety of household and similar appliances – Particular rules for routine tests referring to
appliances under the scope of EN 60 335-1 and EN 60967
EN 60529
Degrees of protection provided by enclosures (IP Code)
EN 62233
Measurement methods for electromagnetic fields of household appliances and similar
apparatus with regard to human exposure
EN 61000-6-2
Electromagnetic compatibility (EMC) – Part 6-2: Generic standards – Immunity for
industrial environments
EN 61000-6-3
Electromagnetic compatibility (EMC) – Part 6-3: Generic standards – Emission
standards for residential, commercial and light-industrial environments
The complete technical documentation is available.
Skinnskatteberg, 12-03-2015
Mats Sándor
Technical Director
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Installation instructions
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Systemair AB
2 Warnings
The following admonitions will be presented in the different sections of the document.
Danger
• Make sure that the Mains 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
• The door handles are only intended to be used during the installation and service. These must be
removed before the unit is put into operation to ensure the required level of safety for the unit.
The unit must be duct connected or in some other way provided with protection so that it is not
possible to come in contact with the fans through the duct connections
• The unit is heavy. Be careful during transport and mounting. Risk of injury through pinching. Use
protective clothing.
• Beware of sharp edges during mounting and maintenance. Make sure that a proper lifting device is
used. Use protective clothing.
• The units electrical connection to the mains supply must be preceded by an all pole circuit breaker
with a minimum 3 mm gap.
Caution
• If the unit is installed in a cold place make sure that all joints are covered with insulation, and tape well
• Duct connections/duct ends should be covered during storage and installation
• Do not connect tumble dryers to the ventilation system
• Take care not to damage the water battery when connecting water pipes to connectors. Use a
spanner to tighten the connection.
3 Product information
3.1 General
This installation manual concerns air handling unit type Topvex FC manufactured by Systemair AB. The
units include the following model options:
• Model: Topvex FC02, Topvex FC04, Topvex FC06
• Heating coil: EL (Electric), HWL (Water coil, low power), HWH (Water coil, high power) or None.
• Right or left models: R (Right) L (Left). The side where the supply air is located when facing the
electrical box when the unit is installed.
• Airflow control (as accessories): CAV – Constant Air Volume, VAV – Variable Air Volume = Constant
duct pressure control
This manual consists of basic information and recommendations concerning the design, installation,
start-up and operation, to ensure a proper fail-free operation of the unit.
The key to proper and safe operating of the unit is to read this manual thoroughly, use the unit according to
given guidelines and follow all safety requirements.
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3.2 Technical data
3.2.1 Dimensions and weight
D
148
J
I
70
A-A
F
H
E
A
øK
70
137
G
*1/2"
60
100
A-A
C
B
100
L
60
A-A
Fig. 1 Dimensions Topvex FC02 (mm) drawn as right hand unit
* = male
Model
Topvex FC02
Model
Topvex FC02
A
B
C
D
E
F
1500
2101
1919
1208
1577
1720
G
H
I
J
øK
L
Weight, kg
320
722
459
175
250
154
350
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D
148
J
70
A-A
F
I
H
E
A
□ K
70
C
C
60
100
A-A
B
G
136
*1/2"
100
L
60
A-A
Fig. 2 Dimensions Topvex FC04, Topvex FC06 (mm) drawn as right hand unit
* = male
Model
A
B
C
D
E
F
Topvex FC04
2024
2561
1190
1204
2098
2242
Topvex FC06
2214
2546
1182
1208
2288
2432
G
H
I
J
□K
L
Weight, kg
Topvex FC04
516
979
600
200
250x500
200
480
Topvex FC06
471
1073
671
250
300x600
300
550
Model
3.2.1.1 Space required
W
Image shows Topvex FC06
Model
W (mm)
Topvex FC02
644
Topvex FC04
774
Topvex FC06
765
In case the sliding door application is installed the required space corresponds to the height of the sliding
door support bars (60 mm).
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3.2.2 Electrical data Topvex FC
Model
Fans (W tot.) 230V 1~
and 400 V 3N~
El Heating battery (kW
tot.)
Fuse (mains) (A)
for 230 V 1~ and
400 V 3~
Topvex FC02
EL
1040
5
3x13
Topvex FC02
None, HWL, HWH
1040
-
10
Topvex FC04
EL
1536
10
3x25
Topvex FC04
None, HWL, HWH
1536
-
10
Topvex FC06
EL
5134
16
3x35
Topvex FC06
None, HWL, HWH
5134
-
3x10
3.3 Transport and storage
Topvex FC is delivered in one piece standing on a pallet for easy transportation using a forklift. The unit
should be stored and transported in such a way that it is protected against physical damage that can
harm panels, handles, display etc. It should be covered so that dust, rain and snow cannot enter and
damage the unit and its components. The appliance is delivered complete with all necessary components,
wrapped in plastic on a pallet for easy transportation.
At delivery the unit is fastened to the pallet with mounting brackets. Unscrew the brackets from the pallet
and fastened them on the units upper side for roof installation. Do not lift the unit in the mounting brackets,
they are only intended for mounting the unit in the roof.
When transporting the Topvex FC units use a forklift placed on the gable of the unit.
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Note:
Necessary parts like control panel, supply air sensor, handles, drainage pipe with drain trap and
electrical safety switch are placed loosely inside the unit. The unit must not be put into operation before
the enclosed parts are removed and installed properly.
Warning
The unit is heavy. Be careful during transport and mounting. Risk of injury through pinching. Use
protective clothing.
Be careful so the unit don't tip over.
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4 Installation
4.1 Unpacking
Verify that all ordered equipment are delivered before starting the installation. Any discrepancies from the
ordered equipment must be reported to the supplier of Systemair products.
4.2 Where/how to install
Topvex FC are meant for indoor installation. The electronic components should not be exposed to lower
temperature than 0° C and higher than +50° C.
If the unit is installed in a cold place it is important that the unit is not shut-off by the main switch. As long
as the main voltage is on the electrical cabinet will be kept warm also in cold climates. Although the unit is
turned off by the control system the current is on.
When choosing the location it should be kept in mind that the unit requires maintenance regularly and
that the inspection doors should be easily accessible. Leave free space for opening the doors and for
taking out the main components (chapter 3.2.1.1.)
Note:
If there is not sufficient space to open the inspection doors, it is possible to mount rails and use existing
doors as sliding doors (accessory) chapter 4.6.
The outdoor air intake of the building should if possible be put in the northern or eastern side of the building
and away from other exhaust outlets like kitchen fan outcasts or laundry room outlets.
Warning
• The door handles are only intended to be used during the installation and service. Handles must be
removed before the unit is put into operation to ensure the required level of safety for the unit.
• The unit must be duct connected or in some other way provided with protection so that it is not
possible to come in contact with the fans through the duct connections
Caution
Do not lift the unit in the mounting brackets. Only intended for mounting in roof.
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4.3 Condensation drain
The unit must be connected to the condensation drain. A transition, tube and drain trap are enclosed upon
delivery. Connect the drainage on the units extract side (pos 2, figure 3). The drainage on the supply side
(pos 1) must be connected if the unit will be used with cooling equipment or if it will run extensively where
the outdoor climate is very humid. On left hand units the positions of the connection are reversed.
See table 1 how the height “H” corresponds to different maximum negative pressures.
If the unit is mounted in a tight area that makes it difficult to have the appropriate height, a pump is
available as an accessory.
Note:
When installed in a non heated place the drain pipe and trap needs to be insulated well to prevent the
water from freezing.
185
H
2
Fig. 3 Drainage connection, right hand unit
Table 1:
H (mm)
Max. Negative
pressure (Pa)
65
300
951
600
135
1000
1.
Normal conditions
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4.4 Installing the unit
The units are design for ceiling installation. Left and right connections are possible.
Fig. 4 Installing position, left hand unit
Fig. 5 Installing position, right hand unit
Table 2: Symbol description
Symbol
Description
Supply air
Exhaust air
Outdoor air
Extract air
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4.4.1 Installation procedure
1
Prepare the surface where the unit is to be mounted. Make sure that the surface is flat, levelled and that
it carries the weight of the unit. Perform the installation in accordance with local rules and regulations.
Install the unit with 0-3° lean towards drainage connections.
2
Lift the unit in place.
Warning
Beware of sharp edges during mounting and maintenance. Make sure that a proper lifting device is
used. Use protective clothing.
3
Connect the unit electrically to the mains through
the all pole circuit breaker (safety switch), which
is enclosed inside the unit on delivery. The wiring
is led directly to the electrical connection box.
Consider that the electrical box can be tilted before
leading the wire.
See enclosed wiring diagram, and chapter 4.7.2.2
for more information.
Warning
The units electrical connection to the mains supply must be preceded by an all pole circuit breaker
with a minimum 3 mm gap.
Danger
• Make sure that the Mains 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.
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4.5 Supply air sensor
The supply air sensor is fitted in the duct ca. 3 m after the unit in the supply air duct (figure 6). See
table 3 to which terminals the sensor needs to be connected in the electrical connection box. All other
temperature sensors are built in to the unit from factory. The supply air sensor is enclosed in the unit
package on delivery.
Fig. 6 Installed supply air sensor (right hand connected unit)
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4.6 Mounting the sliding door kit
A sliding door kit for the inspections doors can be acquired as an accessory and can be mounted on the
units. The kit is installed according to below procedure.
1 Hinges
Close the hatch with all 4 or 6 handles (depending
on model) and unscrew the 2 hinges.
2 Repeat procedure
Repeat on the other hatch.
3 Mount the wheels
Mount the wheels in the prepared threaded
inserts on the side of the inspection hatch with the
enclosed screws and washers.
4 Sliding door support rails
Mount the sliding door rails on each side of the
unit. Fasten it to the casing with screws in the
prepared threaded inserts.
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5 Fasten with BSS screws
Fasten the rail to the side of the casing with the
enclosed BSS screws.
6 Open hatch
Open the hatch by unlocking the inner handles
(pos. 1) followed by the outer handles (pos. 2).
The hatch can now be pushed toward the centre of
the unit. Only one hatch at the time can be opened
like this.
7 Apply seal
Apply the enclosed self adhesive seal strip to the
inner frame of the unit casing.
8 Close hatch
Close the hatch with the handles. Make sure the hatch closes properly.
Repeat the procedure on the other hatch.
9 Remove Handles
After the hatch is closed, the handles need to be removed before the unit is put in operation.
Warning
The door handles are only intended to be used during the installation and service. Handles must be
removed before the unit is put into operation to ensure the required level of safety for the unit.
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4.7 Connections
4.7.1 Ducting
4.7.1.1 Air connections principles
Fig. 7 Connections and basic components in right hand connected units
Position
Description
A
Connection supply air
B
Connection exhaust air
C
Connection outdoor air
D
Connection extract air
1
Fan supply air
2
3
Fan extract air
Filter supply air
4
5
Filter extract air
Heat exchanger
6
7
Electrical connection box
Damper by-pass outdoor air
8
Pressure transmitter fans (accessory)
9
10
Pressure guard filter
Re-heater battery
11
Differential pressure sensor – airflow
Differential pressure sensor – deicing
12
Symbol
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4.7.1.2 Condensation and Heat Insulation
Outdoor air duct and discharge ducts must always be well insulated against condensation. Correct
insulation installation on ducts connected to the unit is especially important. All ducts installed in cold
rooms/areas must be well insulated. Use insulating covering (minimum 100 mm mineral wool) with plastic
diffusion barrier. In areas with extremely low outdoor temperatures during the winter, additional insulation
must be installed. Total insulation thickness must be at least 150 mm.
Caution
• If the unit is installed in a cold place make sure that all joints are covered with insulation, and tape well
• Duct connections/duct ends should be covered during storage and installation
• Do not connect tumble dryers to the ventilation system
4.7.1.3 Silencers
To avoid fan noise being transferred via the duct system, silencers should be installed both on supply and
extract air.
To avoid noise being transferred between rooms via the duct system and also to reduce noise from the
duct system itself, installation of silencers before every inlet diffuser is recommended.
4.7.2 Electric connections
All electric connections are made in the electrical connection box which can be found on the long side of
the unit. The electrical box can be tilted for easy access by loosening the grip screw (figure 8, pos 1). The
hatch is removed by unscrewing four screws (figure 8).
The unit must not be put into operation before all the electrical safety precautions have been read and
understood. See the enclosed wiring diagram for internal and external wiring.
All external connections to possible accessories are made to terminals inside the electrical connection
box (table 3).
Fig. 8
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Danger
• Make sure that the Mains 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
The units electrical connection to the mains supply must be preceded by an all pole circuit breaker
with a minimum 3 mm gap.
4.7.2.1 Electrical connection box, Components
Topvex FC is equipped with a built in regulator and internal wiring (figure 9).
Fig. 9 Electric components
Position
Description
1
Regulator E-28
2
Transformer 230/24V AC
3
Terminals for internal and external components
4
Terminals for internal wiring
5
Terminals for mains supply to the unit
6
Contactor (K2) On/Off Pump control water (HW units
only, not present in EL-units)
7
Automatic fuse
8
Automatic fuse for heater (EL units only)
9
Contactor (K3) EL heater (EL units only)
10
TTC El heater control (EL units only)
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4.7.2.2 Topvex FC02-06 External Connections
Table 3: Connections to external functions
Terminal
block
Description
Remark
PE
Ground
N
N
Earthed neutral (supply voltage)
L1
L1
Phase (supply voltage)
Used for phase 230V 1~
if the unit has this mains
supply
400V 3~
L2
L2
Phase (supply voltage)
400V 3~
L3
L3
Phase (supply voltage)
400V 3~
1
G
Mains supply (Water valve actuator)
24V AC
2
G0
Reference (Water valve actuator mains
supply)
24V AC
10
DO ref
DO reference
G (24V AC)
121
DO 2
Outdoor/Exhaust air damper
24V AC
Max. 2,0 A continuous load
WP
L1
Circulation pump hot water system
230V AC
141
DO 4
Cooling pump
24V AC
151
DO 5
DX Cooling step 1
24V AC
161
DO 6
DX Cooling step 2
24V AC
171
DO 7
Alarm output for DO signals
24V AC
30
AI Ref
Supply air sensor reference
neutral
31
AI 1
Sensor supply air
40
Agnd
UI reference
412
UAI 1/(UDI 1)
Pressure transmitter extract air
422
UAI 2/(UDI 2)
Pressure transmitter supply air
44
UAI 3/(UDI 3)
Frost protection sensor water heating
battery
Use terminal 40 as reference
43
DI ref
External function reference
+ 24V DC
50/60
B
Exo-line B
Modbus, Exo-line
connection
51/61
A
Exo-line A
Modbus, Exo-line
connection
52/62
N
Exo-line N
Modbus, Exo-line
connection
53/63
E
Exo-line E
Exo-line connection
743
DI 4
Extended running
Normally open contact
neutral
Use terminal 4 as reference
753
DI 5
Fire alarm
Normally open contact
Use terminal 4 as reference
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Connections to external functions cont'd
Terminal
block
763
DI 6
Description
Remark
External stop
Normally open contact
Use terminal 4 as reference
90
Agnd
AO Reference
neutral
93
AO 3
Control signal, Heating
0–10V DC
94
AO 4
Control signal, Cooling
0–10V DC
1.
2.
3.
Maximum current load for all DO combined: 8A
Connection to external pressure sensor in case of pressure controlled unit (VAV)
These inputs may only be wired to voltage free contacts
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4.7.2.3 BMS Connection
BMS Connection
Communication possibilities for controller E283 WEB.
•
RS485(Modbus): 50-51-52 or 60-61-62
•
RS485(Exoline): 50-51-52-53 or 60-61-62-63
• TCP/IP Exoline
• TCP/IP Modbus
•
TCP/IP WEB
•
BACnet/IP
Fig. 10 BMS connection on the controller
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4.8 Installing the Control Panel
4.8.1 Dimensions
Fig. 11 Control panel dimensions
Position
Dimensions (mm)
A
115.0
B
94.0
C
26.0
D
c/c 60.0
E
50.5
4.8.2 General information
The control panel is delivered connected to the Corrigo control unit situated in the electrical connection
box. Cable length is 10 m. In case the control panel needs to be detached from the signal cable it is
possible to loosen the wires on the back of the control panel (figure 12).
A set of self-adhesive magnet strips are included in the package to facilitate installation on a metal surface.
4.8.3 Installation
1
Find an appropriate place to install the control panel. Maximum length between control panel and
unit is 100 m.
2
If needed, drill two holes in the wall to hang the control panel (center to center: 60 mm) (pos.1, figure 12).
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Fig. 12 Control panel wire connections
Position
Description
1
Mounting holes
2
Connection block
3
Connection to brown cable
4
Connection to yellow cable
5
Connection to white cable
6
Connection to black cable
4.9 Additional Equipment
For information concerning additional external equipment such as valve actuators, motorized dampers,
E-tool, roof units, wall grilles etc. see technical catalogue and their enclosed instructions.
For electrical connections of external components see enclosed wiring chart.
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lastpage
Systemair AB reserves the right to make changes and improvements to the contents
of this manual without prior notice.
Systemair AB
Industrivägen 3
SE-739 30 Skinnskatteberg, Sweden
Phone +46 222 440 00
Fax +46 222 440 99
www.systemair.com
125917
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