Installation and maintenance instructions ECoCounter

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

INSTALLATION, COMMISSIONING, AND MAINTENANCE INSTRUCTIONS V.2.0

ECoCounter 1085 2185 3285 4385 6485

AIR CONDITIONING SYSTEM WITH A COUNTER-FLOW HEAT EXCHANGER © Oy Pamon Ab www.kair.fi

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ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

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V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Table of Content General ................................................................................................................................... 5 Operating Environment ..................................................................................................... 5 Automation ....................................................................................................................... 5 Standard and Optional Equipment .................................................................................... 5 Unit Delivery Documents .................................................................................................. 5 Product Identification Plate ................................................................................................... 6 AC Unit’s Identification Plate ............................................................................................. 6 Identification Plate of the Cooling System. ........................................................................ 6 Safety Instructions................................................................................................................. 7 Transport and Storage........................................................................................................... 8 Packaging ......................................................................................................................... 8 Parts Included in Delivery ................................................................................................. 9 Transport Dimensions and Weights .................................................................................. 9 Moving the Unit ................................................................................................................. 9 Lifting with slings............................................................................................................. 10 Installation ............................................................................................................................ 10 Installation site ................................................................................................................ 10 Adjustable Feet ............................................................................................................... 11 Outdoor and Exhaust Air Dampers ................................................................................. 11 Duct Connections ........................................................................................................... 12 Electrical System and Automation................................................................................... 12 Supply ..................................................................................................................... 12 Controller (FIM, OF, SI) ........................................................................................... 13 Automation Substation Connectivity......................................................................... 13 Condensate Drainage ..................................................................................................... 14 ECoCounter 1085 .................................................................................................... 14 ECoCounter 2185, 3285, 4385, and 6485 ................................................................ 15 Re-heating ...................................................................................................................... 17 Water Coil (VP / VPM) ............................................................................................. 17 Electric radiator (SP) ................................................................................................ 17 Cooling ........................................................................................................................... 17 Compressor Cooling System (CO) ........................................................................... 17 Water Coil Cooling (JP) ........................................................................................... 17 Direct Evaporation Coil (HP) .................................................................................... 18 Disassembly and assembly of the AC Unit...................................................................... 19 Commissioning .................................................................................................................... 21

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ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485 Maintenance ......................................................................................................................... 21 Maintenance Schedule ................................................................................................... 22 Inspection and maintenance procedures......................................................................... 22 Frame ...................................................................................................................... 22 Control devices ........................................................................................................ 22 Fans ........................................................................................................................ 22 Heat recovery element ............................................................................................. 23 Differential pressure transmitter ............................................................................... 23 Filters....................................................................................................................... 23 Water Coil (VP / VPM) (JP, optional) ....................................................................... 23 Control and adjustment kit of the re-heating system (VP / VPM, optional)................ 23 Electric radiator (SP) ................................................................................................ 24 Regular maintenance and inspection of the cooling system (HP / CO, optional) ...... 24 Outdoor and exhaust air dampers (optional equipment, outside the unit) HR and bypass dampers ........................................................................................................................ 24 Condensate drainage and ball-type water seal ........................................................ 24 Maintenance Card .......................................................................................................... 24 Unit Components and duct connections............................................................................ 26 Unit components – ECoCounter 1085............................................................................. 26 Other unit components – other ECoCounter models ....................................................... 27 Duct connections – ECoCounter 1085 ............................................................................ 28 Start-up sequence R ................................................................................................ 28 Start-up sequence L ................................................................................................ 28 Duct connections – other ECoCounter models................................................................ 29 Start-up sequence R ................................................................................................ 29 Start-up sequence L ................................................................................................ 29 Main dimensions of the units .............................................................................................. 30 ECoCounter 1085 ........................................................................................................... 30 ECoCounter 2185 ........................................................................................................... 30 ECoCounter 3285 ........................................................................................................... 31 ECoCounter 4385 ........................................................................................................... 31 ECoCounter 6485 ........................................................................................................... 32 Manual air-flow measurement ............................................................................................. 33 Output curves of the circulation pump (VP / VPM) ............................................................ 34

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V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

General These installation, commissioning, and maintenance instructions are applicable to the following air conditioning unit models: KAIR ECoCounter 1085, KAIR ECoCounter 2185, KAIR ECoCounter 3285, KAIR ECoCounter 4385, and KAIR ECoCounter 6485.

PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE USING THE UNIT. KEEP THE DOCUMENTS DELIVERED WITH THE UNIT AT HAND FOR SUBSEQUENT USE.

Operating Environment The KAIR ECoCounter air conditioning units with a heat recovery system (AC units) are suited for use in ventilation systems of, inter alia, kindergartens, schools, offices, care homes, restaurant, commercial premises, offices, industrial premises, social facilities, as well as apartment buildings.

AC units are installed in a semi-heated or heated room. IV units are not suited for use in ATEX premises.

The temperature of the processed air shall be below 40 °C. The air being processed must not be toxic or corrosive, and may not contain large concentrations of water vapour or large particles. The exhaust air temperature shall be below 25 °C, if the AC unit is equipped with a cooling system.

Automation The AC unit is controlled by the integrated controller, or with automatic substation connectivity (VAK). The units equipped with a controller are pre-assembled, parameterised, and tested. In VAK models the actuators have been pre-assembled, and factory-tested.

Standard and Optional Equipment The set of standard equipment of an AC unit includes supply and exhaust air fans (EC), a counterflow heat recovery element (HR element), supply and exhaust air filters, water seals, HR and bypass dampers, and a re-heating system. Re-heating is produced with the use of an integrated water, low temperature water, or electrical coil.

The range of potential optional equipment includes, inter alia, cooling and, alternatively, either a pre-heater or a section defroster unit. Cooling is produced with the use of an integrated cooling compressor system of the AC unit (ECoCounter 2185, 3285, 4385, and 6485), liquid cooling coil or a direct evaporation coil. Pre-heating is arranged with either an integrated electric pre-heating coil installed in the AC unit, or with a fluid coil installed in the exhaust channel of the AC unit.

Unit Delivery Documents For transportation the delivery documents are kept inside the electrical equipment section of the AC unit.

Documents: • • • • • • •

Installation, commissioning, and maintenance instructions Functional diagram, list of components, and circuit description (in units equipped with a controller) Electrical and Automation Diagrams Unit Card Data and Accessories’ Card Declaration of Conformity Warranty terms

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ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Product Identification Plate AC Unit’s Identification Plate The AC unit’s identification plate is attached to the door of the electrical and automation switchboard.

The Identification plate contains the following information: 1 2 3

4 5 6

Manufacturer’s details.

Model number.

Serial number. The serial number format is vvvkyyyyxxxx (vv = year, vk = week, yyyy = model, and xxxx= project number).

Year of manufacture.

Electrical details of the AC system.

Electrical data of the heating system.

Identification Plate of the Cooling System.

If the AC unit features a cooling system, then it has a separate identification plate. The identification plate is attached to the door of the electrical and automation switchboard.

The identification plate sets out the information concerning the pressure equipment and the refrigerant.

1 2 3

Refrigerant code.

Refrigerant capacities.

Refrigerant’s GWP value (Global Warming Potential).

4 5

Cooling power.

Min. and max. pressure.

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V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Safety Instructions •

When the unit is running the doors of the AC unit must be kept shut (Figure 1).

•

Use the master switch to turn off power supply to the unit before performing any maintenance or electrical work.

•

Before starting maintenance operations wait for 2 minutes for the heating resistors to cool down and the fans to stop.

•

Fan finger guards may be removed only for the duration of maintenance work. Put back the finger guards after the maintenance operations are completed (Figure 1).

•

Any electrical installation work on the unit may be performed only by a qualified electrician.

•

Maintenance of the cooling system may be performed only by a qualified cooling equipment service technician.

•

When performing any installation, dismantling, and maintenance work, always use personal protective gear (protective gloves, safety goggles, safety shoes). o

Beware of sharp edges, such as edges of coil fins and HR element fins.

o

Be careful when handling pressurised liquid and refrigerant contained in the heating and cooling system of the AC unit.

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ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485 o

Be careful when relocating the unit, or performing installation or maintenance operations, because the AC unit and the HR element are heavy. Use appropriate lifting units.

•

Do not walk on top of the AC unit.

•

Because of microbes replace the filters on the unit at least once a year.

DOORS CLOSED FAN FINGER GUARDS Figure 1 Doors of the AC unit. Fan finger guards

Transport and Storage NB! When handling the AC unit take care not to damage any components of the unit.

NB! Never stack packaged units on top of each other. A packaged unit must be protected against rain, direct sunlight, and dust.

Packaging The AC unit is delivered from the manufacturer packaged in plastic film. At the jobsite the AC unit may be disassembled into two smaller sections for ease of handling (Figure 2). See the instructions in section 5.9. Disassembly of the AC Unit into sections.

NB! The disassembly instructions apply to the ECoCounter models 3285, 4385, and 6485.

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V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Figure 2 Disassembly of the unit.

Parts Included in Delivery Any unattached parts delivered with the system, such as water seals and adjustable feet, are placed inside the unit for transportation.

If the delivery set of the system includes fresh and exhaust air dampers, the dampers and the damper actuators are packed on top of the unit.

Transport Dimensions and Weights Model

Hauling opening of the unit (mm)

Weight of the unit (kg)

1085 2185 3285 4385 6485

790 x 1450 910 x 1910 1130 x 1910 1630 x 1910 1830 x 2090

156 367 491 659 821

Weight of the AC unit with cooling (kg) --414 547 823 893

Hauling opening of the section (mm) ----910 x 1130 910 x 1630 1000 x 1830

Length of the unit (mm) 1350 2040 2300 2400 2800

Moving the Unit The AC unit may be moved with a pallet jack or a forklift. The tines are inserted under the unit at the side (Figure 3).

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ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485 Figure 3 Location of the tines under the unit

Lifting with slings Slings are passed from under the unit through the feet (Figure 4).

Figure 4 Location of the slings.

Installation NB! Any electrical installation work on the unit may be performed only by a qualified electrician.

NB! When installing the unit, use personal protective gear (protective gloves, safety goggles, safety shoes).

NB! Check with the construction designer to establish the floor structure at the installation site.

Installation site The AC unit is installed in the equipment room in a semi-heated or heated space. Leave some space in front and at the supply air side of the unit for installation and servicing the unit (see the table below and Figure 5). To avoid potential resonance leave a gap between the unit and the wall.

Installation and servicing space in front and at the side of the unit Unit Model ECoCounter 1085 ECoCounter 2185 ECoCounter 3285 ECoCounter 4385 ECoCounter 6485

10

S 700 mm 750 mm 1000 mm 1000 mm 1000 mm

L 1480 mm 2040 mm 2300 mm 2400 mm 2800 mm

Supply air side + 250 mm + 250 mm + 250 mm + 250 mm + 250 mm

V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Figure 5 Space to be left in front and at the side of the unit. The figure shows the start-up sequence R.

Adjustable Feet The adjustable feet of the AC unit are delivered inside the unit. Attach the feet to the unit. Adjust the height of the feet such as to ensure that the unit is stable. Check with a water level that the AC unit stands horizontally both sideways and depth-wise (Figure 6).

USING A WATER LEVEL CHECK THAT THE UNIT IS HORIZONTAL

ATTACH AND ADJUST THE FEET Figure 6. The horizontal position of the unit is checked with a water level

Outdoor and Waste Air Dampers The outdoor and waste air dampers are installed in the ducts in accordance with the HVAC design.

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ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Duct Connections The connector or the elbow between the outlet collar of the AC unit and the AC duct is attached to the collar with pop rivets or screws. The fastening is produced from inside of the connecting element.

Electrical System and Automation Supply 5.5.1.1 ECoCounter 1085 The bushing for the power supply cable is located on top of the unit (Figure 7). The cable is connected in accordance with the wiring diagram.

POWER SUPPLY TO THE UNIT

Figure 7 Power supply to the unit. The figure shows the start-up sequence R.

5.5.1.2 ECoCounter 2185, 3285, 4385, and 6485 The power supply point of the unit is on top of the unit (Figure 8). The bushings for the power supply cables of the electrical re-heater and pre-heater, as well as the compressor cooling system are located at the supply air side of the unit (Figure 8). The cables are connected in accordance with the wiring diagram.

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V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485 POWER SUPPLY TO THE UNIT

CONTROLLER (not for VAK models)

POWER SUPPLY FOR RE-HEATING (SP), PRE-HEATING, AND COMPRESSOR COOLING (CO) Figure 8 Power supply. The figure shows the start-up sequence R.

Controller (FIM, OF, SI) In AC units equipped with a controller, the damper actuators and accessories (humidity and CO2 sensors, etc.) are connected in accordance with the wiring diagram delivered with the unit. The controller is installed, and the functions are factory-tested. (Figure 8)

Automation Substation Connectivity The actuators of the AC unit have been factory pre-connected to the terminal blocks. The bushing for the cable between the ventilation unit and the VAK models is shown in Figure 8. The connection to the terminal blocks is shown in the wiring diagram delivered with the unit.

The damper actuators and accessories (humidity and CO2 sensors, etc.) are connected in accordance with the automation diagram.

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ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Condensate Drainage ECoCounter 1085 The condensate connections (2 pcs) are located on the bottom of the AC unit. (Figure 9). The water seals (2 pcs), delivered with the unit, are attached to the condensate connections (Figure 10).

CONDENSATE CONNECTIONS 2 x R ½” UK Figure 9 Condensate connections

Figure 10 Water seal

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V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

ECoCounter 2185, 3285, 4385, and 6485 The condensate connections (2 pcs) are located on the bottom of the AC unit. (Figure 11). The ball-type water seals (2 pcs) delivered with the unit are connected to the condensate pipes. When installing the water seals make sure to leave space for servicing the seals. The installation directions and heights of the condensate pipe and the water seal are shown in Figures 12, 13, and 14. After the water seals the condensate pipes can be connected into a single duct, which leads to the wastewater drain.

CONDENSATE CONNECTIONS Ø 32 mm Figure 11 Condensate connections

Figure 12 Installation height of the condensate pipe

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ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

INSTALLATION DIRECTION – UPWARD

Figure 13 Installation direction and principal dimensions of the ball-type water seal

CONDENSATE FROM AC UNIT DN32

CONDENSATE TO WASTEWATER DRAIN DN32

Figure 14 Installation direction of the ball-type water seal

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V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Re-heating Water Coil (VP / VPM) 5.7.1.1 ECoCounter 1085 The re-heating system is connected to the heating network according to the HVAC design. The water pipe connections of the re-heating system are located on top of the unit (Figure 15, and Table 1).

•

•

If the delivery set of the unit includes the controller and pump group, the supply water pipe is fitted with a shut-off valve, and the return water pipe is fitted with a shut-off valve and a line control valve. The line control valve is dimensioned according to the HVAC design. The controller and pump groups are inside the unit.

If the delivery set does not include a controller and pump group, it will be made outside the unit in accordance with the HVAC design. The heat duct connections are located outside the unit.

NB! If there are any air pockets left in the heat ducts leading to the unit, the ducts shall be fitted with an air vent.

5.7.1.2 ECoCounter 2185, 3285, 4385, and 6485 The re-heating system is connected to the heating network according to the HVAC design. The water pipe connections of the re-heating systems are on the supply air duct side, or on top of the unit, behind the supply air outlet (Figure 16 and Table 1).

•

•

If the delivery set of the unit includes the controller and pump group, the supply water pipe is fitted with a shut-off valve, and the return water pipe is fitted with a shut-off valve and a line control valve. The line control valve is dimensioned in accordance with the HVAC design. The controller and pump groups are inside the unit.

If the delivery set does not include a controller and pump group, it will be made outside the unit in accordance with the HVAC design. The heat duct connections are located outside the unit.

NB! If there are any air pockets left in the heat ducts leading to the unit, the ducts shall be fitted with an air vent.

Electric radiator (SP) See section 5.5.1

Cooling Compressor Cooling System (CO) See section 5.5.1.2

Water Coil Cooling (JP) 5.8.2.1 ECoCounter 1085 The cooling system of the AC unit is connected to the cooling network in accordance with the HVAC design. The water pipe connections of the water coil cooling system are located on top of the unit (Figure 15, and Table 1).

5.8.2.2 ECoCounter 2185, 3285, 4385, and 6485 The cooling system of the AC unit is connected to the cooling network in accordance with the HVAC design. The water pipe connections of the cooling system are on the supply air duct side, or on top of the unit, behind the supply air outlet. (Figure 16 and Table 1).

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ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Direct Evaporation Coil (HP) The direct evaporation coil is connected to the cooling network according to the design. The cooling systems are connected to the coil inside the unit.

WATER COIL – COOLING SYSTEM (JP) CONNECTIONS

WATER CONNECTIONS FOR THE RE-HEATING SYSTEM (VP / VPM)

Figure 15 Connections of the re-heating system and the water coil cooling system in model 1085. The figure shows the start-up sequence R.

WATER COIL – COOLING SYSTEM (JP) CONNECTIONS

WATER CONNECTIONS FOR THE RE-HEATING SYSTEM (VP / VPM)

Figure 16 Connections of the re-heating system and the water coil cooling system in models 2185, 3285, 4385, and 6485. The figure shows the start-up sequence R.

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V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Table 1 Dimensions of the external thread in the cooling and heating pipe connections Unit Model ECoCounter 1085 ECoCounter 2185 ECoCounter 3285 ECoCounter 4385 ECoCounter 6485

Re-heating pipe connection 2 x DN20 UK (2 x 3/4” UK) 2 x DN25 UK (2 x 1” UK) 2 x DN25 UK (2 x 1” UK) 2 x DN32 UK (2 x 1 ¼” UK) 2 x DN32 UK (2 x 1 ¼” UK)

Cooling pipe connection 2 x DN20 UK (2 x 3/4” UK) 2 x DN25 UK (2 x 1” UK) 2 x DN25 UK (2 x 1” UK) 2 x DN32 UK (2 x 1 ¼” UK) 2 x DN32 UK (2 x 1 ¼” UK)

Disassembly and assembly of the AC Unit.

NB! The disassembly and reassembly instructions apply to models 3285, 4385, and 6485.

NB! When disassembling or reassembling the unit, use personal protective gear (protective gloves, safety goggles, safety shoes).

The unit can be disassembled into two sections. The unit is assembled in the reverse order.

1. Remove the doors (Figure 17). Olen latches on the both sides of the door. The latches function both as hinges as well as latches.

Figure 17 Removal of the doors

2. Remove the central post (Figure 17). Release the fastener at the top of the central post by pressing on the barb in the hole with a screwdriver. While pressing with the screwdriver, push the top end of the post to the left, and then pull the post out (Figure 18).

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ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Figure 18 Removal of the central post

3. Remove the exhaust and supply air filters (Figure 19).

4. Remove the HR element (Figure 19). NB! Beware of sharp edges of the element. The element is heavy, and its fins are easily damaged, handle with care.

Figure 19 Removal of the HR element and the filters

5. Remove the electrical quick connectors between the sections.

6. Place the unit on its back.

7. Loosen the bolt and nut of the connecting parts between the sections (Figure 20). NB! Also loosen the pipe connections inside the unit, if the cooling/ heating pipes run from the top of the unit (Figure 20).

8. Pull the sections apart. NB! Also pull the pipes out from the top section, if the cooling/ heating pipes run from the top of the unit (Figure 20).

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V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

LOOSEN THE PIPE CONNECTIONS CONNECTING PARTS BETWEEN THE SECTION

IF THE COOLING AND HEATING PIPES RUN FROM THE TOP OF THE UNIT

PULL THE PIPES OUT FROM THE TOP SECTION

Figure 20 Separation of sections

Commissioning Commissioning Sequence: 1. Check that the AC unit has been installed correctly and connected to the ducts in accordance with the HVAC design.

2. Check that the filters are in place and that there are no foreign objects inside the unit.

Check that there are no protectors on the valves.

3. Check that the heat ducts are connected and that water circulates in the coils.

4. Turn on the power to the unit using the master switch.

5. Adjust the flow of water (VP and VPM) in accordance with the HVAC design. NB! See section 11. Circulation Pump (VP and VPM) Output Curves, if the delivery of the AC unit includes the controller and pump group for the re-heating system.

6. Start the UV unit. Check the functioning of the actuators (e.g. test the functioning of the outdoor and waste air dampers).

7. Adjust air flows. See section 10. Manual air-flow measurement 8. Set the filter alarm limit values according to the functioning of the unit, and the settings of the defrosting system. The unit running parameters are available at http://www.kair.fi/en/forlvisa-designer/selection-program.

9. Carry out the function tests prescribed by the designer.

Maintenance NB! Use the master switch to turn off power supply to the unit before performing any maintenance work.

NB! Before starting maintenance operations wait for 2 minutes for the heating resistors to cool down and the fans to stop.

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ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485 NB! Use personal protective gear (protective gloves, safety goggles, safety shoes) when performing maintenance work. Beware of sharp edges, such as edges of coil fins and HR element fins. Be careful when handling pressurised liquid and refrigerant contained in the heating and cooling system of the AC unit.

NB! Regular maintenance ensures trouble-free functioning of the AC unit.

The recommended intervals for inspection and maintenance of the AC unit are set out in section 7.1 Maintenance Schedule The guidelines for carrying out the operations can be found in section 7.2. Inspection and Maintenance Procedures.

The maintenance procedures performed shall be recorded in the maintenance card set out in section 7.3 or in another system.

Maintenance Schedule ITEM Check Frame

INTERVAL Clean

Replace

1a

when required

-

Control devices Fans

1a

-

-

1a

when required

when required

Heat recovery element Mechanical filters and the differential pressure transmitter Water coil (VP / VPM) 1) Water coil (JP) 2) Electric radiator (SP) 3) Regular maintenance of the cooling system (HP / CO) 4) Dampers

1a

2-3a

-

3kk

-

3-6kk

1a 1a 1a

2-3a 2-3a 2-3a

-

1a

2-3a

-

1a

1a

-

kk = month a = year 1) Units with a water-based reheating system 2) Units with a water-based cooling system 3) Units with electricity-based re-heating system 4) Units with integrated cooling

Inspection and maintenance procedures Frame • • •

Check that there are no air leaks through the doors. Check the condition of the door seals.

If necessary, clean the sealing surfaces of the doors.

If necessary, clean the inside surfaces of the AC unit’s walls.

Control devices • • •

Check the time control settings. The set times must match the operating times of the facility. (See the separate controller operating instructions.)

Check the time on the clock. (See the separate controller operating instructions.)

Make sure that no alarms are in the state of activation. (See the separate controller operating instructions.)

Fans •

22

NB! Fan finger guards may be removed only for the duration of maintenance work.

Put back the finger guards after the maintenance operations are completed (see section 3).

V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

• • • •

4385, 6485 Check the fan visually.

Check the fastening of the fans.

Rotate the impeller by hand and make sure that the fan rotates freely and emits no unusual noise.

If necessary, clean the fans. Do not remove the balancing elements of the fans.

Heat recovery element • • •

NB! Beware of sharp edges of the element. The element is heavy, and its fins are easily damaged, handle with care.

Check that the heat recovery element is clean and its seals are intact.

Wash the HR element with an aluminium safe detergent and finally flush with hot water. o To remove the element from the machine for washing, see section 5.9. Disassembly of the AC Unit into sections.

Before re-installing the element it is advisable to apply some silicone spray to the seals of the HR element. o The element may also be washed while it is installed in the unit. NB! Beware of electrical equipment!

Differential pressure transmitter •

Check the functioning of the differential pressure transmitter. When the unit is stopped the reading on the differential pressure transmitter should be zero. If the reading is not zero when the unit is not running, calibrate and check the hoses.

Filters • • •

Replace a filter when the filter alarm has activated. NB! Because of microbes hazardous to health the filters must be replaced at least once a year.

Check the model and the size of the filter on the Unit Card. NB! Only use original filters.

By using original filters you can ensure correct air flow rates and pressure ratios.

When installing a new filter make sure that it does not have any holes etc.

Water Coil (VP / VPM) (JP, optional) • • • • •

NB! Beware of sharp edges of the coil.

Make sure that there are no leaks of water.

Check that the fins of the coil are not dented. If necessary, comb the coil fins.

Be careful when cleaning the fins of the coil.

If necessary, bleed the air trapped in the coil.

Control group of the re-heating system (VP / VPM, optional) •

• •

Check the functioning of the control valves in the automatic or manual mode. The valve actuator features an automatic/ manual mode switch (Figure 21). NB! These inspection guidelines only apply to the valve actuators delivered with the unit. o In the automatic mode check that the handle of the valve actuator moves and the water flow rate changes when you use the control to change the setting. o In the manual mode check that the water flow rate changes when you turn the valve actuator handle (Figure 21). NB! Do not forget to return the valve actuator back to the automatic mode.

Make sure that there are no leaks of water.

Check the functioning of the circulation pump.

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ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485 HANDLE SWITCH

Figure 21 Valve actuator

Electric radiator (SP) • • • •

NB! Before starting maintenance operations wait for 2 minutes for the heating resistors to cool down.

Check that no dust or other foreign objects are stuck to the resistors. Clean them with compressed air or a brush.

Check the condition of the resistors and the overheat sensor visually for any wear, dents, etc.

Clean the probe of the overheat sensor (pulp). Be mindful of the capillary tubes of the overheat sensor.

Regular maintenance and inspection of the cooling system (HP / CO, optional) • • •

NB! Maintenance of the cooling system may be performed only by a qualified cooling equipment service technician.

Inspection is carried out in accordance with the standard SFS-EN-378-4.

Also check that there are not dents or foreign objects on the evaporator and condenser coil fins. Be careful when cleaning the fins.

Outdoor and exhaust air dampers (optional equipment, outside the unit) HR and by-pass dampers • • •

Check the condition of the seals.

Check the functioning of the heat recovery and by-pass dampers.

Clean if necessary.

Condensate drainage and ball-type water seal • •

Check that the condensate drain is not clogged. Clean if necessary.

Check that no dirt has accumulated in the ball-type water seal (applies to unit models 2185, 3285, 4385, and 6485). Clean if necessary.

Maintenance Card Record the maintenance operations performed in the maintenance card with codes: V = replacement, T = checking, P = cleaning.

24

V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

HR and by-pass dampers. Outdoor and waste air dampers 5)

(HP / CO)

Regular maintenance of the reheating system 4)

Electric radiator (SP) 3)

Water coil (JP) 2)

Control group of the re-heating system 1) (-VP / -VPM)

Water Coil (VP / VPM) 1)

Mechanical filter and the differential pressure transmitter

Heat recovery element

Fans

Control devices

Frame

4385, 6485 Item:

Unit type KAIR ECoCounter____________ Serial No.

Maintenance date

technician

signature

1) Units with a water-based re-heating system 2) Units with a water-based cooling system 3) Units with a water-based re-heating system 4) Units with integrated cooling 5) Outdoor and waste air dampers outside the unit, optional equipment

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25

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Unit Components and duct connections Unit components – ECoCounter 1085

1

Electrical and automation block + master switch

2

Exhaust air filter

3

Supply air filter

4

Exhaust air fan

5

Supply air fan

6

HR element (counter-flow)

7

HR and by-pass dampers + damper actuator

8

Foot (4 pcs)

9

Water seal (2 pcs)

10

Heater coil (VP / VPM / SP)

11

Heater control kit (if the unit is equipped with a heater coil (VP / VPM)

26

V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Other unit components – other ECoCounter models ECoCounter 2185, 3285, 4385, and 6485 The figure shows a right-handed model (start-up sequence R). In a left-handed model (start-up sequence L) the components 4–10, 13, 14 are in mirror-image position.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Electrical and automation block Master switch Controller (not for VAK models) Exhaust air filter Supply air filter Exhaust air fan Supply air fan HR element (counter-flow) Damper actuator (or optional damper actuators of the defrosting system, 4 pcs) HR and by-pass dampers (or optional dampers for the defrosting system) Foot (4 pcs) Ball-type water seal (2 pcs) Cooling coil (CO / JP / HP, optional) Heater coil (VP / VPM / SP)

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27

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Duct connections – ECoCounter 1085 Start-up sequence R Exhaust air on the right-hand side.

Exhaust air

Outdoor air

Waste air

Supply air

Start-up sequence L Exhaust air on the left-hand side.

Supply air

28

Exhau Outdoor air st air

Exractt air

V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Duct connections – other ECoCounter models Start-up sequence R ECoCounter 2185, 3285, 4385, and 6485 Exhaust air on the right-hand side.

Extract air

Outdoor air

Exhaust

Supply air

Outdoor air Extract air

Exhaust air Supply air

Start-up sequence L ECoCounter 2185, 3285, 4385, and 6485 Waste air on the left-hand side.

Outdoor air Exhaust air

Extract air

Supply air

Extract air Outdoor air Supply air Exhaust air

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29

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Main dimensions of the units ECoCounter 1085 Duct connection ⌀ 315 mm.

Adjustable foot 30-60

ECoCounter 2185 Duct connection ⌀ 315 mm.

Adjustable foot 35–100

30

V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

ECoCounter 3285 Duct connection ⌀ 400 mm.

Adjustable foot 35–100

ECoCounter 4385 Duct connection ⌀ 500 mm.

Adjustable foot 35–100

© Oy Pamon Ab www.kair.fi

31

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

ECoCounter 6485 Duct connection ⌀ 630 mm.

Adjustable foot 35–100

32

V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Manual air-flow measurement If the unit is not equipped with a flow meter, the flow rate qv (m3/h) can be calculated using the formula,

∗ ∆ , where k = fan k-value, see Table 2. ∆p = pressure difference (Pa) over the fan, see the section about differential pressure transmitter.

• •

Table 2 Fan k-value Unit Model

k-value

Fan

ECoCounter 2185 ECoCounter 3285 ECoCounter 4385 ECoCounter 6485

70 116 188 188

K3G250 K3G310 K3G400 K3G400

Calculation example for ECoCounter 4385: k-value = 188 measured differential pressure = 157 Pa

• •

188 ∗ √157 2355,6 / → conversion into l/s

, / ,

© Oy Pamon Ab www.kair.fi

654 l/s

33

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485

Output curves of the circulation pump (VP / VPM) NB! These guidelines apply to the controller and pump group (optional equipment) delivered with the unit.

Pump

Motor

EEI (Energy efficiency)

ALPHA2 (Grundfos)

Performance range 5 W – 45 W

50 Hz, 230 V

≤ 0,17

MAGNA1 (Grundfos)

8 W – 119 W

50/60 Hz, 230 V

0.21

Pump adjustment instructions: 1. Check the Q/H capacity curve of the pump (Figure 24 ja 25) to establish the standard pressure or the standard flow rate setting that matches the flow rate Q (l/s) and lifting height H (m) indicated in the HVAC design.

2. On the control panel set the standard pressure or the standard flow rate setting for the pump by pressing the selector switch repeatedly until the desired setting is activated and lights up green (Figure 22).

Power Off. The pump is not running “Display number”. Power On. The pump is running.

Alarm. The pump has stopped.

STANDARD FLOW RATE SETTINGS

STANDARD PRESSURE SETTINGS

Power Off. The pump is not running.

SETTING SELECTOR SWITCH

Power On. The pump is running.

Alarm. The pump has stopped.

Figure 22 Control panels of pumps ALPHA2 and MAGNA1

3. Adjust the fluid flow settings of the re-heating system in accordance with the HVAC design.

NB! The Relative Pressure and AUTOADAPT settings are not in use (Figure 23).

34

V.2.0

ECoCounter 1085, 2185, 3285

INSTALLATION, COMMISSIONING, AND MAINTENANCE

INSTRUCTIONS

4385, 6485 RELATIVE PRESSURE

AUTO ADAPT

Figure 23 Relative Pressure and AUTO ADAPT settings

ALPHA2 Capacity curves Q/H

standard pressure

Figure 24 ALPHA2 capacity curves MANGA1 Capacity curves Q/H

standard pressure Figure 25 MAGNA1 capacity curves

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35