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 Topvex FC 125917 Installation instructions 1 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. Topvex FC 125917 Installation instructions 2 Systemair AB 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 Topvex FC 125917 Installation instructions 3 Systemair AB 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). Topvex FC 125917 Installation instructions 4 Systemair AB 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. Topvex FC 125917 Installation instructions 5 Systemair AB 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. Topvex FC 125917 Installation instructions 6 Systemair AB 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. Topvex FC 125917 Installation instructions 7 Systemair AB 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 Topvex FC 125917 Installation instructions 8 Systemair AB 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 Topvex FC 125917 Installation instructions 9 Systemair AB 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. Topvex FC 125917 Installation instructions 10 Systemair AB 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) Topvex FC 125917 Installation instructions 11 Systemair AB 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. Topvex FC 125917 Installation instructions 12 Systemair AB 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. Topvex FC 125917 Installation instructions 13 Systemair AB 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 Topvex FC 125917 Installation instructions 14 Systemair AB 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 Topvex FC 125917 Installation instructions 15 Systemair AB 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) Topvex FC 125917 Installation instructions 16 Systemair AB 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 Topvex FC 125917 Installation instructions 17 Systemair AB 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 Topvex FC 125917 Installation instructions 18 Systemair AB 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 Topvex FC 125917 Installation instructions 19 Systemair AB 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). Topvex FC 125917 Installation instructions 20 Systemair AB 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. Topvex FC 125917 Installation instructions 21 Systemair AB 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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