FläktGroup EQKR ReCooler HP Generation 4 Installation and Maintenance Manual

FläktGroup
Brand
FläktGroup
Model
EQKR ReCooler HP Generation 4
Category
Split-system air conditioners
Type
Installation and Maintenance Manual
Content Page
2
3
3
3
4
7
7
9
10
15
16
17
1. Safety
2. Product description
– Generell information
– Overview
– ErP 2016/2018 compliance
3. Lifting and transport
4. Installation and jointing
5. Assembly instructions for split casing
6. Commissioning
7. Maintenance
8. Functional diagram
9. Alarm handling and troubleshooting
10. eQ with other AHU controller than FläktGroup 21
ReCooler HP, heat-pump with heat recovery
ReCOOLER® HP
INSTALLATION AND COMMISSIONING
FläktGroup DC_9567GB 20190820_R1Specifications are subject to change without further notice
ReCooler HP - Installation and commissioning
2
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
1. SAFETY
Important!
– The unit must NOT be used for purposes
other than as a reversible heat pump unit.
– The unit’s Installation and Commissioning
Instructions must be studied carefully
before starting/operating/servicing/
maintaining/scrapping the unit.
Keep these instructions in a safe place
for future reference!
– All service and maintenance must be
carried out by certified personnel.
Service/maintenance of the refrigerant
system must only be carried out by an
accredited company and certified
personnel wearing required protective
equipment (gloves and protective eye-
glasses).
– Lock and tag the heat pump prior to
performing service on the unit.
– Do NOT stand on the heat-pump unit!
– Use only genuine spare parts for
maintenance!
– Installation of units with split casing is
to be performed only by certified refri-
gerant technicians.
Failure to comply with above terms and conditions can
result in serious injury and will void the warranty.
ReCooler HP - Installation and commissioning 3
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
GENERAL INFORMATION
ReCooler HP is a module with rotary heat exchanger and rever-
sible heat pump included in the FläktGroup AHU range eQ.
ReCooler HP can be used in the modular range ”eQ Master”
and compact range ”eQ Prime”. This manual mainly focuses on
2. PRODUCT DESCRIPTION
1. Outdoor air
2. Supply air
3. Extract air
4. Exhaust air
5. Rotary heat exchanger - service hatch
6. Compressor
7. Frequency inverter for compressor
8. Drainage (Note: 2 drain connections)
9. Control system for the ReCooler HP
10. 4-way valve
11. Main switch disconnector
12. Optional – Electrical heater for defrost in exhaust air coil
13. Cable glands for incomming power
14. Electrical expansion valves
15. Handheld HMI for the ReCooler HP
3 4
5
13
11
14
14
10
12
15
1
2
6
7
9
8
8
The drawing shows a left hand version with supply air on top deck.
SIMPLIFIED OVERVIEW OF INSTALLED COMPONENTS
eQ Master, but most of the information is applicable to eQ Prime
and will give detailed info compared to the general eQ Prime
manuals.
ReCooler HP - Installation and commissioning
4
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
Roof top air
conditioner
Roof top air conditioner with
rotorary heat exchanger Roof top air conditioner with
rotorary heat exchanger Roof top air conditioner with
rotorary heat exchanger Roof top air conditioner with
rotorary heat exchanger Roof top air conditioner with
rotorary heat exchanger Roof top air conditioner with
rotorary heat exchanger Roof top air conditioner with
rotorary heat exchanger Roof top air conditioner with
rotorary heat exchanger
Model: EQKR 008 EQKR 011 EQKR 018 EQKR 023 EQKR 032 EQKR 041 EQKR 050 EQKR 072
Outdoor side heat
exchanger:
Air Air Air Air Air Air Air Air
Indoor side heat exchanger: Air Air Air Air Air Air Air Air
Type: Compressor driven vapour
compression
Compressor driven vapour
compression
Compressor driven vapour
compression
Compressor driven vapour
compression
Compressor driven vapour
compression
Compressor driven vapour
compression
Compressor driven vapour
compression
Compressor driven vapour
compression
Driver of compressor: Electric motor Electric motor Electric motor Electric motor Electric motor Electric motor Electric motor Electric motor
Rated cooling capacity, total
(Prated,c,tot)
14.71 20.29 33.3 42.4 59 75.4 92.4 132.4
Rated cooling capacity,
compressor, Prated,c,compr)
8.12 11.3 19 24 34.5 44.1 53.5 78
Seasonal space cooling
energy efficiency, total
(hs,c.tot)
192 194 225 203 215 204 213 206
Seasonal space cooling
energy efficiency, total (hs,c.
compr)
165 168 197 179 192 181 189 182
Supply temp 20 °C with
nominal air flow
Outdoor temperature (Tj) Cooling
cap. (kW)
EER Cooling cap.
(kW)
EER Cooling cap.
(kW)
EER Cooling cap.
(kW)
EER Cooling cap.
(kW)
EER Cooling cap.
(kW)
EER Cooling cap.
(kW)
EER Cooling cap.
(kW)
EER
Total Com-
p r.
Total Com
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
+35 °C 14.7 8.1 6.3 3.5 20.3 11.3 5.9 3.3 33.3 19.0 6.4 3.7 42.4 24.0 5.4 3.1 59.0 34.5 5.8 3.4 75.4 44.1 5.6 3.3 92.4 53.5 5.7 3.3 132.4 78.0 5.6 3.3
+30 °C 9.9 7.4 5.4 4.1 13.5 10.1 5.3 4.0 22.1 16.8 6.1 4.6 27.9 21.0 5.3 4.0 39.2 30.1 5.5 4.2 50.2 38.5 5.2 4.0 61.4 46.9 5.5 4.2 88.1 67.8 5.3 4.0
+25 °C 4.9 4.9 5.1 5.1 6.8 6.8 5.1 5.1 11.2 11.2 5.9 5.9 14.2 14.2 5.3 5.3 19.9 19.9 5.6 5.6 25.4 25.4 5.1 5.1 31.1 31.1 5.6 5.6 44.7 44.7 5.2 5.2
+21 °C 1.0 1.0 3.6 3.6 1.3 1.3 3.9 3.9 2.2 2.2 4.8 4.8 2.8 2.8 5.0 5.0 3.9 3.9 6.0 6.0 5.0 5.0 6.1 6.1 6.0 6.0 6.2 6.2 10.3 10.3 5.6 5.6
+20 °C 0.0 0.0 3.6 3.6 0.0 0.0 3.9 3.9 0.0 0.0 4.8 4.8 0.0 0.0 5.0 5.0 0.0 0.0 6.0 6.0 0.0 0.0 6.1 6.1 0.0 0.0 6.2 6.2 0.0 0.0 5.6 5.6
Degradation coefficient
(Cdc)
NA (variable speed
compressor)
NA (variable speed
compressor)
NA (variable speed
compressor)
NA (variable speed
compressor)
NA (variable speed
compressor)
NA (variable speed
compressor)
NA (variable speed
compressor)
NA (variable speed
compressor)
Power consumption
Off mode (POFF), Thermostat
off mode (PTO) and Standby
mode (PSB)
0.033 0.033 0.033 0.033 0.033 0.061 0.061 0.089
Crancase heater mode
(PCK)
0.028 0.045 0.045 0.045 0.045 0.09 0.09 0.135
Rotor mode (PR) 0.04 0.04 0.04 0.16 0.16 0.16 0.16 0.16
Cabinet fan mode (PFAN) 0.015 0.015 0.015 0.015 0.015 0.03 0.03 0.03
Capacity contol Variable speed Variable speed Variable speed Variable speed Variable speed Variable speed Variable speed Variable speed
Air flow rate outdoor
(Supply/Exhaust)
2880 3960 6480 8280 11520 14760 18000 25920
Sound power level See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification
Refrigerant R410A R410A R410A R410A R410A R410A R410A R410A
GWP value 2088 2088 2088 2088 2088 2088 2088 2088
ERP 2016/2018 COMPLIANCE
eQ with ReCooler HP is compliant with ErP 2016/2018
AHUs with an integrated heat pump (like eQ with ReCooler HP) are exempted from the normal ErP directive for Air Handling Units, ErP 1253/2014. However they fall under the ErP directive for air
conditioners, unit heaters, chillers etc. ErP 2016/2218 in case the AHU gives all the heating load for the building. eQ with ReCooler HP is compliant with this directive and the table below conta-
ins all compulsory information per AHU size required by the directive.
COOLING MODE
ReCooler HP - Installation and commissioning 5
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
HEATING MODE
Roof top heat
pump
Roof top heat pump with
rotorary heat exchanger
Roof top heat pump with
rotorary heat exchanger
Roof top heat pump with
rotorary heat exchanger
Roof top heat pump with
rotorary heat exchanger
Roof top heat pump with
rotorary heat exchanger
Roof top heat pump with
rotorary heat exchanger
Roof top heat pump with
rotorary heat exchanger
Roof top heat pump with
rotorary heat exchanger
Model: EQKR 008 EQKR 011 EQKR 018 EQKR 023 EQKR 032 EQKR 041 EQKR 050 EQKR 072
Outdoor side heat
exchanger:
Air Air Air Air Air Air Air Air
Indoor side heat exchanger: Air Air Air Air Air Air Air Air
Supplementary heater Option. Not needed for
Average climate
Option. Not needed for
Average climate
Option. Not needed for
Average climate
Option. Not needed for
Average climate
Option. Not needed for
Average climate
Option. Not needed for
Average climate
Option. Not needed for
Average climate
Option. Not needed for
Average climate
Type: Compressor driven vapour
compression
Compressor driven vapour
compression
Compressor driven vapour
compression
Compressor driven vapour
compression
Compressor driven vapour
compression
Compressor driven vapour
compression
Compressor driven vapour
compression
Compressor driven vapour
compression
Driver of compressor: Electric motor Electric motor Electric motor Electric motor Electric motor Electric motor Electric motor Electric motor
Rated heating capacity, total
(Prated,h,tot)
37.71 51.91 84.2 107.9 140.6 190.5 230.7 326.1
Rated heating capacity,
compressor, Prated,h,compr)
6.41 9.11 16.3 20.2 24.6 41.5 45.7 68.1
Seasonal space heating
energy efficiency, total
(hs,h.tot)
865 932 896 820 759 730 813 723
Seasonal space heating
energy efficiency, total (hs,h.
compr)
174 194 207 182 186 187 198 191
Supply temp at -15 °C
is 19.1 °C
Outdoor temperature (Tj) Heating cap.
(kW)
COP Heating cap.
(kW)
COP Heating cap.
(kW)
COP Heating cap.
(kW)
COP Heating cap.
(kW)
COP Heating cap.
(kW)
COP Heating cap.
(kW)
COP Heating cap.
(kW)
COP
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
Total Com-
p r.
-7 °C 28.2 5.3 19.1 3.6 38.5 7.3 18.9 3.6 62.5 13.1 18.0 3.8 80.2 16.3 16.5 3.4 110.1 25.9 14.1 3.3 141.8 33.8 13.7 3.3 173.3 39.3 15.0 3.4 247.9 60.9 13.3 3.3
+2 °C 18.5 3.8 27.3 5.6 25.4 5.3 28.0 5.9 41.9 9.8 23.5 5.5 53.2 11.8 23.3 5.2 74.5 19.1 19.7 5.1 94.4 23.6 20.6 5.1 115.2 27.4 22.9 5.5 166.6 43.6 19.2 5.0
+7 °C 13.7 3.0 36.3 7.9 18.8 4.2 41.3 9.2 30.9 7.7 29.9 7.4 39.7 9.7 29.0 7.1 54.6 14..5 26.5 7.0 70.1 18.8 26.6 7.1 85.2 21.7 29.7 7.6 122.7 33.5 25.7 7.0
+12 °C 8.8 2.2 31.5 7.9 12.0 3.1 30.4 7.7 19.7 5.4 38.5 10.5 25.2 6.7 40.4 10.8 35.6 10.9 37.6 11.5 45.1 13.5 19.6 5.9 55.2 16.1 20.8 6.1 80.1 25.1 22.8 7.2
-15 °C Bivalent temperature 37.7 6.4 15.7 2.7 51.9 9.1 15.0 2.6 84.2 16.3 15.0 2.9 107.9 20.2 13.5 2.5 140.6 24.6 16.7 2.9 190.5 41.5 11.4 2.5 230.7 45.7 13.3 2.6 326.1 68.1 12.5 2.6
-15 °C Operation limit
without electric heater (-20
°C with heater)
37.7 6.4 15.7 2.7 51.9 9.1 15.0 2.6 84.2 16.3 15.0 2.9 107.9 20.2 13.5 2.5 140.6 24.6 16.7 2.9 190.5 41.5 11.4 2.5 230.7 45.7 13.3 2.6 326.1 68.1 12.5 2.6
Degradation coefficient
(Cdc)
NA (variable speed
compressor)
NA (variable speed
compressor)
NA (variable speed
compressor)
NA (variable speed
compressor)
NA (variable speed
compressor)
NA (variable speed
compressor)
NA (variable speed
compressor)
NA (variable speed
compressor)
Power consumption
Off mode (POFF), Thermo-
stat off mode (PTO) and
Standby mode (PSB)
0.033 0.033 0.033 0.033 0.033 0.061 0.061 0.089
Crancase heater mode
(PCK)
0.028 0.045 0.045 0.045 0.045 0.09 0.09 0.135
Rotor mode (PR) 0.04 0.04 0.04 0.16 0.16 0.16 0.16 0.16
Cabinet fan mode (PFAN) 0.015 0.015 0.015 0.015 0.015 0.03 0.03 0.03
Drain pan heater
mode(PDP1)
0.05 0.05 0.075 0.075 0.075 0.1 0.1 0.125
Drain pan defrost
mode(PDP2)
0.45 0.49 0.57 0.65 0.693 0.771 0.894 1.02
Capacity contol Variable speed Variable speed Variable speed Variable speed Variable speed Variable speed Variable speed Variable speed
Air flow rate outdoor
(Supply/Exhaust)
2880 3960 6480 8280 11520 14760 18000 25920
Sound power level See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification See ACON specification
Refrigerant R410A R410A R410A R410A R410A R410A R410A R410A
GWP value 2088 2088 2088 2088 2088 2088 2088 2088
ReCooler HP - Installation and commissioning
6
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
TECHNICAL DATA
The charge is the same for eQ Master and eQ Prime but in eQ Prime there is only one common supply and the ReCooler gets the power from the AHU. Refrigerant charge
could be changed without notice. See EQKR data lable on delivered unit.
REFRIGERATION SYSTEM
The Reversible Heat-pump unit in the ReCooler HP is designed
at the following external air temperatures:
• For cooling from +20 °C to +40 °C (indoor unit)
• For cooling from +20 °C to +35 °C (outdoor unit)
• For heating from +20 °C to -15 °C with defrost system
• For heating from +20 °C to -20 °C with Integrated electrical
defrost heater.
• Temperature at installation site from -20 °C to +35 °C.
At temperatures below +10 °C ReCooler HP must be supplied
with crankcase heater on the compressor. An eQ for outdoor
installation is equipped with crankcase heater as default.
Indoor units that risk being in a room with less than +10 °C
at start up must be equipped with a crankcase heater which
needs to be ordered separately.
The ReCooler HP is also designed for extract air tempera-
tures of +16 to +28 °C.
ROTARY HEAT EXCHANGER
The rotor unit in the ReCooler HP is designed to recover heat energy
from the extract air. It operates in sequence with
the reversible heat pump unit to heat and cool the air using
as little electrical power as possible.
INTEGRATED ELECTRICAL DEFROST HEATER
The electrical defrost heater is mainly used to shorten defrost cycle
time. It’s also used to maintain the evaporating temperature at very
low external air temperature. At design temperatures below -15 °C
the heater is a requirement due to the limitations of the compressor.
The electrical heater includes two thermal protectors:
• An auto reset
• A manual reset
eQ
size
3x400 VAC
Operating current
(A) (without
electric heater)
3x400 VAC
Operating current
(A) (with
electric heater)
Refrigerant charge EQKR version 4
Oil/Circuit
(l)
Circuit 1 Circuit 2 Circuit 3 Total
kg R410A ton CO2ekg R410A ton CO2ekg R410A ton CO2ekg R410A
8 22.1 22.1 3.6 7.5 3.6 0.9
11 14.3 18.7 5.1 10.6 5.1 1.9
18 17.1 26.3 7.6 15.9 7.6 1.9
23 20.9 33.0 10.8 22.6 10.8 1.9
32 21.1 40.7 12.8 26.7 12.8 1.9
41 33.8 53.8 8.2 17.1 8.4 17.5 16.6 1.9
50 41.7 63.5 10.5 21.9 11.0 23.0 21.5 1.9
72 61.8 94 8.4 17.5 8.6 18.0 8.8 18.4 25.8 1.9
ReCooler HP - Installation and commissioning 7
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
3. LIFTING AND TRANSPORT
eQ size Weight (kg)
Non split version
Weight (kg)
Split version
008 500 522
011 570 700
018 680 763
023 900 909
032 990 1100
041 1230
050 1440
072 1590
Total weight (including casing and base frame).
L
L
L
L
Because of its design, the centre of gravity is offset towards
the inspection side. This must be taken into account when
lifting the unit. The unit should first be lifted slightly, and then
inspected to ascertain that it does not tilt or appear unstable
before being lifted higher.
The unit can be lifted usings its eye bolts if its weight does
not exceed 1.050 kg. If the unit weighs more than 1.050 kg,
it must be lifted by a forklift truck from below using the
specified holes. Lifting by any other means can cause the
unit to tip over due to the offset centre of gravity.
Important!
The unit’s centre of gravity is not in
the middle of the unit.
Take care when lifting.
WEIGHT
4. INSTALLATION AND JOINTING
REQUIREMENTS RELATED TO THE FLOOR
The floor must be level. This is to avoid torsional forces and
stresses which could damage the internal pipework in the re-
frigerant circuit. The base frame or thermal wheel must not be
removed.
REQUIREMENTS RELATED TO PLACEMENT
The unit must be installed in such a way that allows service in
accordance with this service manual.
INSTALLATION WITH ADDITIONAL EQEE/EQDE - COIL
(AIR HEATER FOR HOT WATER)
The coil should be designed for temperature lift from 0 °C up to
requested air supply temperature. (water/liquid flow must be
sufficient in defrost mode).
The coil should be provided with its own circulation pump. Hot
water from heat source must always be available at the heating
coil. More information about air heater for hot water is available in
document 8638GB.
DRAIN CONNECTIONS
The ReCooler HP has 2 drain connections (one for each coil). Both
must be connected to the drain with water traps. FläktGroup can
supply water trap with the AHU delivery, ordering code EQAZ-08.
If installed outdoors in cold climate the drains should be fitted with
heating cables for frost protection.
Heat source Heating coil
200 mm
ReCooler HP - Installation and commissioning
8
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
JOINTING – EXTERNALLY
JOINTING – INTERNALLY
AC
B
D
A
B, D
C
JOINTING
ReCooler HP - Installation and commissioning 9
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
The unit is tested at the factory and supplied with refrigerant
and closed valves (2). Most of the refrigerant is collected in the
large section and a small amount into the small section.
Other work required to disconnect large and small section
can be done by a ventilation installer.
Description for splitting of refrigerant circuit:
1. Remove the front panel on the small section of the Re-
cooler HP.
2. Remove the refrigerant from the small section with
recovery unit into a service cylinder using schrader
valve (1) (located under the ceiling in large section).
Use digital scale to weigh removed refrigerant amount
from the system.
3. Open the flare connectors (3) (located near the joint
between sections) and cover them.
4. The unit can now be split in two sections.
5. When the sections are assembled again, connect the
flare connectors.
6. Perform a leakage test of the flare connectors.
7. Evacuate the small section by using the schrader valve.
The pressure after evacuation shall be under 2 mbar.
8. Open the closed valves (2) (located under the ceiling in
large section).
9. Charge the circuit with refrigerant removed from the
small section.
10. The unit is ready to run.
NOTE: If the unit is not to be split, just open the closed valves (2)!
Important!
Please note that the work on the refrigerant
circuit must be done by a certified refrigeration
engineer according to description.
In accordance with F-GAS regulation 517/2014
(or later editions to that regulation).
CHECK THE POSITION ON THE SHUT-OFF VALVE
Fully closed Fully open
5. ASSEMBLY INSTRUCTIONS FOR SPLIT CASING SIZE 008–032
ReCooler HP - Installation and commissioning
10
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
6. COMMISSIONING
MAIN CONTROL COMPONENTS
A separate controller is installed in the service section of the
ReCooler HP and includes the following components:
– Main electrical panel disconnect switch
– Miniature circuit breaker
– Control unit with display
The controller is separate from the FläktGroup AHU control-
ler and is a microprocessor-based, programmable electronic
version.
MINIATURE CIRCUIT BREAKER
Automatically operated electrical switch designed to protect
an electrical circuit from damage caused overload or short
circuit.
MAIN ELECTRICAL PANEL DISCONNECT SWITCH
The disconnect switch is used to turn on/off power to the Re-
Cooler heat pump unit. If the ReCooler HP is included in an
eQ Prime with FläktGroup controller the disconnect switch
is combined for ReCooler HP and AHU. For eQ Master with
FläktGroup controller it is different switches for AHU part and
ReCooler HP.
Always lock and tag the unit prior to performing any mainte-
nance or servicing work.
TO SET THE SETPOINT FOR COOLING AND HEATING
The capacity of the ReCooler HP module is dependent on the
need for cooling or heating of the supply air. The temperature
set point that drives the capacity is defined by air handling
unit control, either via Modbus (Climatix only) or via analog
signals (0-10 V and potential free contacts) for other AHU
controllers than FläktGroup.
Important!
Check list
– Always read the safety work on the unit,
on page 2 before beginning work on
the unit.
– The air handling unit must not be com-
missioned until the installation has been
inspected according to the check list
below!
Before commissioning check the following:
– Condition on delivery - no transport
damage, installation site, (adequate
lighting, mounting surface etc.).
– No leakage of compressor oil.
– Proper connection of the supply power.
– Control signal.
– Energy recovery not disabled.
– Condensate drainage.
installation report submitted:
– There are no loose cables.
– Installation of units with split casing to
be carried out by a certified refrigerant
technician.
After commissioning check the following:
– Outdoor/supply air temperature.
– Condensing/evaporating temperature.
– Discharge gas temperature/subcooling/
superheating.
– Operating currents.
– Brief the operators of the unit.
– Complete the commissioning report
Warning!
The circuit breaker does NOT isolate
the power supply to the entire cooling unit!
Therefore always open and lock the main
switch before you begin any work on
the cooling unit.
eQ size Min. Design airflow
m3/s m3/h
008 0.4 1440
011 0.5 1800
018 0.9 3240
023 1.0 3600
032 1.5 5400
041 2.0 7200
050 2.5 9000
072 3.5 12600
MINIMUM DESIGN AIR FLOW RATE IN ACON
ReCooler HP - Installation and commissioning 11
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
eQ size Min. Design airflow
m3/s m3/h
008 0.24 864
011 0.36 1296
018 0.54 1944
023 0.69 2484
032 0.96 3456
041 1.00 3600
050 1.20 4320
072 1.50 5400
Min. air flows through the ReCooler HP are valid with:
1. Balanced air flows (supply/exhaust), large variation are not
allowed. Exhaust air flow must be higher, equal or max 20 %
lower than supply air flow.
2. AHU fans operation limits (min. airflow and pressure).
3. Correction of defrost factor (CAREL controller) under winter
conditions for EQKR size 041, 050 and 072, with CAREL soft-
ware up to version 5.0.
The ReCooler HP controller includes a protection that prevents
start of the compressor if the air flow of the eQ AHU is below the
minimum stated above.
MINIMUM AIR FLOW RATE AT TURN-DOWN
OPERATING MODE
Two operating modes are available: Economy and Comfort
mode.
Economy mode
In economy mode we prioritise energy recovery so the rotor is
operating at full speed while the compressor is operating in on-
off mode when there is a small re-heating demand. This means
there will be small temperature variations in the supply air.
Comfort mode
In comfort mode we prioritise a constant supply air temperature
so when the re-heating demand is small we reduce the speed of
the rotor so that the compressor can run continuously.
DEFROSTING
The ReCooler HP is equipped with a defrost system that uses
the pressure drop over the coils to decide if there is frost in the
extract coil. On detection of frost in the exhaust coil the circuit
is reversed to heat the extract coil. The rotor speed is reduced
and the electric heater in the exhaust side is started if present
in the unit.
Defrosting will run for a minimum time or as long as it takes to
reach a set condensing temperature. When those conditions
are met the unit reverts to normal operation by first reducing
the speed of the compressor and then reversing the circuit
followed by a return to the required compressor speed accor-
ding to the temperature control signal.
If there is a reheater in the AHU, it can be activated during
the defrost operation. Defrost operation can be detected on
terminals C1/NO1 if that has been selected in the Carel HMI by
means of the set up wizard. Those terminals can alternatively
be used as an alarm signal for the rotor.
RETURN AIR SECTION
The eQ air handling unit can be equipped with both a ReCooler
HP and a return air section for night heating. The AHU must
in this case be equpped with a separate reheater, since the
ReCooler HP shall be out of operation when the return air
damper is opened.
It is not possible to use ReCooler HP with mixing section where
extract and outdoor air is mixed.
ALARM
All the alarms are indicated on the display of the Carel control
unit. A global alarm is available on the terminal block from a
potential-free relay (normally open) (terminals 900, 901).
Most alarms are automatically reset 5 times within a 24 hour
period. If additional alarms are generated then a manual reset
will be necessary. To restart the unit in this case press the
alarm button for 5 seconds.
The controller in the unit checks that the correct mass of refrige-
rant is present in the circuit. A warning is issued from the control-
ler if the refrigerant quantity falls below the minimum limit.
Qualified refrigeration personnel can check the circuit opera-
tion by means of the data given in the controller HMI.
See page 16 of document for complete alarm list.
ReCooler HP - Installation and commissioning
12
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
PGD1 INSTRUCTIONS
The ENTER button is used to scroll through the list of
available languages and the ESC button is used to
confirm the users selection.
The home screen shows the following information:
– Circuit that the display is connected to
– Operating mode (Cooling/Heating)
Status:
– Standby
– Start phase
– Unit running
– Start delay
– Defrost
– Alarm
& etc.
The current example shows:
– Compressor speed demand sent from external
control system: 75 %
– Current rotation speed of the compressor: 35 %
– Current speed of Rotary Heat Exchanger: 100 %
This screen displays information related to the current
status (operating mode) of the coils (condensing /
evaporating ), position of the expansion valves and
whether the AHU is configured with supply air in the
upper or lower deck.
Temperature and pressure values.
Alarm button
Button for service mode
Esc Button
Button up
Enter button
Button down
HMI – DISPLAY
–+
Supply
FläktGroup
ReCooler HP - Installation and commissioning 13
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
Super-heat and sub-cooling.
Access to additional basic configuration settings.
Used to select the heat pump control method
(Analog/Modbus).
Analog - Third party.
Modbus - FläktGroup controls.
Activating quick start will bypass the normal
compressor start up sequence.
Valid for two and three circuits only.
ReCooler HP - Installation and commissioning
14
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
1. At start-up, the rotating heat exchanger speed will
be reduced when the demand compressor
speed is less than the actual compressor speed.
2. With low demand and the compressor at its lowest
speed, the rotating heat exchanger will reduce speed.
When the unit is running in economy mode, the rotating
heat exchanger is always first in the heating sequence and
only begins to decelerate when the compressor is off.
Software information of the system.
ReCooler HP - Installation and commissioning 15
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
COMPULSORY DECLARATION AND RECURRING INSPECTION
Compulsory declaration
The function of this product relies on the refrigerant R410A; which is
a fluorinated greenhouse gas.
The European Union is committed to reducing emissions of such
gases. Ensure that you are fully aware of your local regulations and
that they are complied with.
R410A has an equivalent mass of CO
2
of 2088 according to F-GAS
Regulation 517/2014. Global Warming Potential, GWP is 2088.
According to the F-Gas Regulation, ReCooler HP must be leak
tested once every 12 months. This is the responsibility of the end
user/operator. With a leakage detection system the frequency of
leak checks is 24 months.
Production of the ReCooler HP is carried out in accordance with
Commission Regulation 517/2014.
The ReCooler HP is an equipment in which all fluorinated green-
house gas containing parts are made tight by welding, brazing or a
similar permanent connection including capped valves and capped
service ports that allow proper repair or disposal.
Any service or repair work must be carried out by an authorised
person with the necessary training and certification in accord-
ance with the F-Gas Regulation and this instruction.
DUTY OF NOTIFICATION AND IN-SERVICE INSPECTION
Duty of notification
If the installation contains fluorinated greenhouse gases in quan-
tities of 14 tonnes of CO
2
equivalent or more the
supervisory authorities, generally the environmental health depart-
ment, must be informed. This information must be provided well in
advance of installation. For more information see local refrigeration
legislation.
INSPECTION/MAINTENANCE
Regular inspection and maintenace in accordance with legi-
slation in force must be carried out by a certified refrigeration technician.
INSPECTION
To be carried out by the owner/user once a week.
Check the following:
1. Indicated alarms
2. Abnormal noise/vibrations
3. Leakage
4. Corrosion, wear and tear
5. The interior of the unit, light fittings
MAINTENANCE
Check the following:
1. Electrical equipment
2. Coils, drip tray and the drainage system
3. Air filter-s on compressor cabinet
RECURRING CHECKS
Must only be carried out by a certified refrigeration technician.
Inspect the system at least once every 12 months and maintain
a journal. This is the responsibility of the end user/operator. With
a leakage detection system the frequency of leak checks is 24
months.
Check the following wherever applicable:
1. Piping and refrigerant components
2. Inspection to detect refrigerant leakage
3. Check for abnormal vibrations
4. Check to detect possible corrosion
5. Whether filling with additional refrigerant is needed
6. Check to detect possible oil leakage
7. Safety equipment
8. Connection joints/Seals
Important!
Always read the safety directions on page 2
prior to beginning any work!
7. MAINTENANCE
Leak testing minimum frequency
ReCooler HP
size
Without
Refrigerant charge detector
With
Refrigerant charge detector
81 test/12 months 1 test/24 months
11 1 test/12 months 1 test/24 months
18 1 test/12 months 1 test/24 months
23 1 test/12 months 1 test/24 months
32 1 test/12 months 1 test/24 months
41 1 test/12 months 1 test/24 months
50 1 test/12 months 1 test/24 months
72 1 test/12 months 1 test/24 months
Intake air hood with filter is located outside on lower deck of
compressor cabinet. To change the filter, pull back the filter
hood, insert new filter and put it back. Check filter inside in each
3 months. Filter is reusable and can be washed or vacuumed.
Otherwise order new one (AMIE-2598867) box with 3 new filters. If
filter is not clean ventilation in compressor cabinet can be reduced.
It will cause overheating of components and possible alarms from
speed drive.
AIR FILTER-S ON COMPRESSOR CABINET
ReCooler HP - Installation and commissioning
16
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
8. DESCRIPTION OF THE FUNCTIONS
Unit sizes 008-032 have 1 circuit
Unit sizes 041-050 have 2 circuits
Unit size 072 have 3 circuits
Pos Component
1:1-3 Supply air coil
2:1-3 Exhaust air coil
3:1-3 4 way valve
4:1-3 Compressor
5:1-3 Liquid separator
6:1-3 Reciever
7:1-3 Filter dryer
9:1-3 EEV 2 cooling
10:1-3 EEV 1 heating
11:1-3 High pressure sensor
12:1-3 Low pressure sensor
13:1-3 Suction gas sensor
14:1-3 Liquid temperature sensor
15:1-3 Discharge gas sensor
16:1-3 Low pressure service connector
17:1-3 High pressure service connector
18:1-3 High pressure service connector
18 Defrosting pressure sensor GP8
19 Rotor
20 Electrical heater
GT6 Automatic thermal protection
GT7 Manual thermal protection
18
Room
Cooling mode
Heating mode
20
19
VVX
GT6 GT7
2:1-3
1:1-3
3:1-3
11:1-3
18:1-3
S
15:1-3
12:1-3
13:1-3
16:1-3
4:1-3
5:1-3 9:1-3
7:1-3
14:1-317:1-3
6:1-3
10:1-3
Cooling mode
Heating mode
DISMANTLING
When dismantling (scrapping) this type of unit, the refrigerant and
compressor oil must unconditionally be collected and contained for
destruction/recycling.
SPARE PARTS
Spare parts can be bought via local refrigeration suppliers. Contact
your local FläktGroup office for information regarding components
that need to be replaced.
ReCooler HP - Installation and commissioning 17
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
9. ALARM HANDLING AND TROUBLESHOOTING
Alarm code Alarm displayed Alarm description/cause for alarm Possible solutions
AL01 Clock board fault or not connected Check connections. Contact FG CSS
control department.
AL02 Extended memory error Contact FG CSS control department.
AL03 High pressure alarm The high pressure sensor has detected max. working
pressure of 39 bar and the controller stops the compressor.
At 38 bar compressor start to ramp down. Cause: Extract air
flow is too low over condensing coil; overcharged system.
Check:
1. Air flow on extract side.
2. Min airflow rate over condensing coil
according FG.
3. Filter or coil (they need to be clean).
4. Refrigerant charge/subcooling.
AL04 Low pressure alarm The low pressure sensor has detected value under min.
allowed pressure of 1 bar. Cause: Start up without Rotor
running; At start up with low ambient temperature/conden-
sing temperature, several start attempts could be needed;
low air flow over evaporator; expansion valve is
in the wrong position; leakage in the system or Insufficient
refrigerant charge.
Check:
1. Rotor must be running before
compressor is started.
2. Min airflow rate over evaporating coil
according FG.
3. Refrigerant charge/superheat.
4. Search for possible leakage of
the system.
5. Allow the system to make several
attempts to start.
The alarm button is lit. At the bottom of the menu bar
information is shown regarding which circuit is
alerting(units with two or three circuits).
To check alarm-s of alerting circuit switch to the current
circuit by pressing the Enter button for 2-3s.
Press the alarm button to see the active alarm for the
selected ciruit. Follow instructions on the screen to get
to the Alarm log/Data logger.
The log shows information from the time when the alarm
was activated.
Alarm reset is possible only when the fault is remedied,
most alarms have automatic reset up to 5 times but can
be reset by pressing the alarm button for 5 sec. Some
alarms require a reboot.
FläktGroup
Off by low flow
Circuit 01
FläktGroup Circuit 01
Mode
Cooling
Control signal
000%
Off by low flow
%
535
000
%
000
ALARM LOG
Data logger E08
AL12 12:33 07/07/15
BMS offline
Low suction press
0: No alarm
Hi.Press 14.9 Comp031%
Lo.press 14.9 100-000
DiscTemp 081°c SSH 00.1
FläktGroup Circuit 01
If you contact Helpdesk at FläktGroup for support on your
ReCooler HP please take pictures of the ”Data logger” of
your last 10 alarms from alerting circuit and attach them
to the helpdesk request.
ALARM LIST
ReCooler HP - Installation and commissioning
18
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
Continued Alarm list
AL05 Frequency drive offline Check:
1. Cabel connection and 3-phase fuse
AL06 Power + alarms
0 - No alarm - -
1 - Overcurrent The drive has detected a current supplied that is too high
due to: too high load or sudden large load increase, wrong
parameter values or an inadequate motor.
Check the load, the dimension of the
motor and the cables.
2 - Motor overload The current supplied has exceeded the rated current over
the maximum time accepted.
3 - Overvoltage The DC voltage of the intermediate circuit has exceeded
the limits envisioned due to: deceleration that is too high
or high over-voltage peaks on the power supply network.
Check power supply voltage
4 - Undervoltage The DC voltage of the intermediate circuit is below the
limits envisioned due to: insufficient power supply voltage
or a fault inside the drive.
In the event of temporary cut-off of the
power supply, reset the alarm and re-
start the drive. Check the power supply
voltage. Check the 3-phase fuse and
power supply voltage
5 - Drive overtemperature The temperature inside the drive has exceeded the maxi-
mum level allowed.
Check that the flow of cooling air is correct.
Check filter and fans in cabinet.
Check thermostat for fan.
Check that there is not dust in the heat sink.
Check the enviroment temperature.
Ensure that the switching frequency is not
too high with respect to the enviroment
temperature and the motor load.
6 - Drive undertemperature The temperature inside the drive is less than the minimum
level allowed.
Check the enviroment temperature
7 - overcurrent HW The drive has detected an instataneous current supplied
that is too high due to: sudden strong load increase, motor
cables short circuit, wrong parameter values or inadequate
motor.
Check the load, the dimension of the
motor and the cables.
8 - Motor overtemperature The temperature detected by the PTC thermistor corresponds
to a resistance > 2600 ohm.
Reduce the motor load.
Check motor cooling.
9 - IGBT module error Internal fault Call FG CSS for assistance.
10 - CPU error Loss of data in memory Call FG CSS for assistance
11 - Parameter default Execution of reset parameter default command. -
AL36 Loss of communication
(Modbus J11 BMS2)
Control unit Circuit 1 is configured to communicate with
external control unit via modbus but is unable to establish
communication.
Confirm that the heat pump is to be
controlled via modbus signal and if not
select analog control. Check the wiring
and termination between the modbus
terminal of the external control signal
and the modbus terminal of the heat-
pump control unit (Circuit 1).
AL37 Gas detector sensor No power supply to gas detector sensor or sensor is faulty. Check power supply.
Replace gas detector
AL38 Gas detector alarm Gas detector is activated. Possible refrigerant leakage, make a
leakage check.
AL39 Gas detector off line No Modbus connection to gas detector. Check Modbusconnection to
Gas detector.
AL40 Gas detector service Service/test/calibration is needed for Gas detector. Contact FG CSS control department or
Refrigeration service company.
AL41 Low airflow supply Difference pressure sensor GP8 has indicated low supply
air flow.
Check supply air flow, fan, filter and
damper.
AL42 Low airflow exhaust Difference pressure sensor GP8 has indicated low exhaust
air flow.
Check exhaust air flow, fan, filter and
damper.
AL36 Loss of communication
(Modbus J11 BMS2)
Control unit Circuit 1 is configured to communicate with
external control unit via modbus but is unable to establish
communication.
Confirm that the heat pump is to be
controlled via modbus signal and if not
select analog control. Check the wiring
and termination between the modbus
terminal of the external control signal
and the modbus terminal of the heat-
pump control unit (Circuit 1).
ReCooler HP - Installation and commissioning 19
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
Continued Alarm list
AL37 Gas detector sensor No power supply to gas detector sensor or sensor is faulty. Check power supply.
Replace gas detector
AL38 Gas detector alarm Gas detector is activated. Possible refrigerant leakage, make a
leakage check.
AL39 Gas detector off line No Modbus connection to gas detector. Check Modbusconnection to
Gas detector.
AL40 Gas detector service Service/test/calibration is needed for Gas detector. Contact FG CSS control department or
Refrigeration service company.
AL41 Low airflow supply Difference pressure sensor GP8 has indicated low supply
air flow.
Check supply air flow, fan, filter and
damper.
AL42 Low airflow exhaust Difference pressure sensor GP8 has indicated low exhaust
air flow.
Check exhaust air flow, fan, filter and
damper.
AL36 Loss of communication
(Modbus J11 BMS2)
Control unit Circuit 1 is configured to communicate with
external control unit via modbus but is unable to establish
communication.
Confirm that the heat pump is to be
controlled via modbus signal and if not
select analog control. Check the wiring
and termination between the modbus
terminal of the external control signal
and the modbus terminal of the heat-
pump control unit (Circuit 1).
AL37 Gas detector sensor No power supply to gas detector sensor or sensor is faulty. Check power supply.
Replace gas detector
AL38 Gas detector alarm Gas detector is activated. Possible refrigerant leakage, make a
leakage check.
AL39 Gas detector off line No Modbus connection to gas detector. Check Modbusconnection to
Gas detector.
AL40 Gas detector service Service/test/calibration is needed for Gas detector. Contact FG CSS control department or
Refrigeration service company.
AL41 Low airflow supply Difference pressure sensor GP8 has indicated low supply
air flow.
Check supply air flow, fan, filter and
damper.
AL42 Low airflow exhaust Difference pressure sensor GP8 has indicated low exhaust
air flow.
Check exhaust air flow, fan, filter and
damper.
AL16 Rotor reference analog
input fault (U1) connected
with analog signal (0-10V)
Alarm is coming from CAREL controler because of in-
ter-ruption,short circuiting and if voltage is higher than 12V.
"Check:
1. If polarity is connected right
2. Check voltage
3. Input impedance is 20k ohm
4. With 10V current is 0,5mA
(theoretical) ”
AL17 Defrost temperature
probe fault (U2)
Check the defrost temperature sensor/
sensor wiring
AL18 Suction temperature
probe fault (U3)
Check the suction gas temperature
sensor/sensor wiring
AL19 Discharge temperature pro-
be fault (U4)
Check the discharge temperature sen-
sor/sensor wiring
AL20 Discharge pressure probe
fault (U5)
Check the high pressure sensor/sensor
wiring
AL21 Suction pressure
probe fault (U6)
Check the low pressure sensor/sensor
wiring
AL22 Electrical heater alarm Overheat protection is activated. Reset overheat protection
AL23 Maximum defrost duration
exceeded (defrost termi-
nated)
Too much ice on evaporater. In older softwares before 4.9
the 4-way valve is not activated and this alarm is coming.
Make manual defrost. Update softwa-
re to 5.0. Check timer/temperature
settings under M05/Df05/08/09/10.
Make a factory reset if anything has
been changed.
AL24 Compressor speed refe-
rence analog input fault
(U7) connected with analog
signal (0-10V)
Alarm is coming from CAREL controler because of inter-
ruption,short circuiting and if voltage is higher than 12V.
"Check:
1. If polarity is connected right
2. Check voltage
3. Input impedance is 20k ohm
4. With 10V current is 0,5mA (theoretical)
AL25 Inverter model not compra-
tible. Only power+ allowed
Check inverter model. Factory reset.
Make right selection for all parameters
in Wizard.
ReCooler HP - Installation and commissioning
20
FläktGroup DC_9567GB 20191030_R2Specifications are subject to change without further notice
Continued Alarm list
AL26 Compressor unable to start
due to excessive delta
pressure
Max allowed delta P for start of compressor is 9bar.
If this can't be reached in 300s alarm AL26 is activated.
Expansion valve is 32 % open to equalize pressure. Before
AL26 is coming the following information is shown on the
display: Pressure diff. limit. (in heating mode only)
Check that ROTOR is runing 100 %.
Activate cooling mode and back again to
heating mode.(directly in CAREL or from
external control). M03/Ma02 (Switch
compressor mode). For help please
contact FG CSS.
AL27 Rotor alarm Alarm present on the rotating heat exchanger. Check if ROTOR is runing. Check connec-
tions according installation manual.
When upgrading to software 5.0 please
change to NC in Parameters, M04/P05,
1. Rotor alarm. Contact FG CSS.
AL28 N/A N/A
AL29 Communication with slave
unit 1 is lost (J14 pLAN)
Circuit number 2 is offline. Check connections between master and
slave
AL30 Communication with slave
unit 2 is lost (J14 pLAN)
Circuit number 3 is offline. Check connections between master and
slave
AL31 Communication with the
master unit is lost (J14
pLAN)
Slave unit 1 (Circuit2) and/or slave unit 2 (Circuit 3) unable
to communicate with the master unit (Circuit 1).
Check the wiring and termination
between the pLan terminals (J14 pLAN).
Check that the master unit is not
powered OFF.
AL32 Liquid temperature sensor Check the liquid temperature sensor/
sensor wiring
AL33 Low refrigerant charge Warning level: valve 98%, superheat > 12, subcooling <3 at
the same time. Alarm level: valve 100%, superheat >
15, subcooling <2 at the same time.
Check:
1. Leakage
2. Charge refrigerant according to label
AL34 Pressure sensor across
the supply air coil
Check the pressure sensor across the
supply air coil/sensor wiring
AL35 Pressure sensor across
the exhaust air coil
Check the pressure sensor across the
exhaust air coil/sensor wiring
AL36 Loss of communication
(Modbus J11 BMS2)
Control unit Circuit 1 is configured to communicate with
external control unit via modbus but is unable to establish
communication.
Confirm that the heat pump is to be
controlled via modbus signal and if not
select analog control. Check the wiring
and termination between the modbus
terminal of the external control signal
and the modbus terminal of the heat-
pump control unit (Circuit 1).
AL37 Gas detector sensor No power supply to gas detector sensor or sensor is faulty. Check power supply.
Replace gas detector
AL38 Gas detector alarm Gas detector is activated. Possible refrigerant leakage, make a
leakage check.
AL39 Gas detector off line No Modbus connection to gas detector. Check Modbusconnection to
Gas detector.
AL40 Gas detector service Service/test/calibration is needed for Gas detector. Contact FG CSS control department or
Refrigeration service company.
AL41 Low airflow supply Difference pressure sensor GP8 has indicated low supply
air flow.
Check supply air flow, fan, filter and
damper.
AL42 Low airflow exhaust Difference pressure sensor GP8 has indicated low exhaust
air flow.
Check exhaust air flow, fan, filter and
damper.
Page is loading ...
Page is loading ...
Page is loading ...
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23

FläktGroup EQKR ReCooler HP Generation 4 Installation and Maintenance Manual

FläktGroup
Brand
FläktGroup
Model
EQKR ReCooler HP Generation 4
Category
Split-system air conditioners
Type
Installation and Maintenance Manual
Download PDF
report

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI

Related papers

Other documents