FläktGroup COM4plus Installation guide

Category
Split-system air conditioners
Type
Installation guide
OPERATION AND MAINTENANCE MANUAL
COM4plus
WITH ISYteq
We reserve the right to make changes without prior notice
FläktGroup DC-10619-GB 2021-10-20_R0
COM4plus – Operation and maintenance manual
1. Safety regulations ............................................................................4
Special warning and danger symbols ..................................................7
Function signs .............................................................................................. 8
2. Introduction ........................................................................................9
Document description ............................................................................... 9
Product description and intended use ................................................ 9
Control system .............................................................................................9
Environmental documentation ................................................................9
3. Unit overviews ................................................................................10
COM4plus with Rotary Heat Exchanger ............................................ 10
COM4plus with Counterflow Plate Heat Exchanger .......................11
COM4plus with Active mixing ............................................................... 12
4. Commissioning ............................................................................... 13
Prerequisites before commissioning ................................................. 13
List of steps ................................................................................................. 13
Setup wizard ............................................................................................... 13
Active mixing .............................................................................................. 15
CLOUD for ISYteq ....................................................................................... 15
5. Maintenance ....................................................................................16
Explanation of symbols ........................................................................... 16
Service schedule ....................................................................................... 16
To comply with VDI 6022 ventilation code of practice .................17
To clean the casing and the components .........................................17
Spare parts ...................................................................................................17
Warranty ........................................................................................................17
Casing ........................................................................................................... 18
CONTENTS
LIMITS OF RESPONSIBILITIES
Although FläktGroup has tested and reviewed the documentation contained in this manual, FläktGroup makes no warranty, neither expressed nor
implied, with respect to this manual, including its quality, performance, or fitness for a particular purpose. FläktGroup shall under no circumstances
be liable for direct, indirect, special, incidental or consequential damage arising from the use or the inability to use information contained in this
manual. FläktGroup reserves the right to revise this publication at any time and to make changes to its content without prior notice and has no
duty to provide notice to previous or current owners with respect to such revisions or changes.
Filter replacement ..................................................................................... 19
Fan ..................................................................................................................20
Coils ............................................................................................................... 21
Silencer .........................................................................................................22
Plate Heat Exchanger ..............................................................................22
Rotary Heat Exchanger ...........................................................................23
6. Alarms and troubleshooting ..................................................... 25
To reset alarms ..........................................................................................25
General troubleshooting ..........................................................................25
To read the alarm text correctly ..........................................................25
Alarm list ......................................................................................................26
7. Technical data ................................................................................ 34
Connection ................................................................................................... 34
Minimum mains supply ..........................................................................38
Fan data ......................................................................................................38
Control cabinet ...........................................................................................39
Energy recovery system ........................................................................39
EMC performance .....................................................................................39
8. FAQ ..................................................................................................... 40
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COM4plus – Operation and maintenance manual
WARNING!
Read and understand these instructions before operation or
maintenance of the air handling unit. The owner or installation
firm of the air handling unit is responsible for ensuring that
the applicable safety regulations are followed.
Do not discard this manual.
Before commissioning of the air handling unit, any open
connections must be protected with protective mesh.
The air handling unit must not be commissioned until all
electrical and mechanical safety devices are installed.
Be careful when opening the air purge connections for the hot
water supplied to the air heater. There is a risk of water hammer
or steam leakage.
If the unit is dismantled, FläktGroup will cease to be responsible
for its compliance with the specified tightness class.
The doors of the unit are equipped with lockable handles.
Always leave the unit locked and store the keys out of reach of
unauthorised persons.
ELECTRICAL HAZARD!
Main switch/Disconnector
The unit is equipped with a main switch in the electrical
enclosure. The unit should be equipped also with an external
disconnector.
Parts that are powered separately require a separate
disconnector.
Before service or inspection, disconnect the power from all
parts of the unit. Wait at least 1 minute before opening the
inspection doors. Close all inspections doors and restore
disconnectors before restarting the unit.
SAFETY REGULATIONS
Local rules and regulations must always be followed.
Do not let unauthorised persons operate the unit. Only let
qualified staff members operate the unit.
Make sure that all the included parts and tools used for
installing the unit are removed before operating the unit.
Drain coils if there is any risk of standing water at an air
temperature below the liquid freezing point in the circuit.
Do not use the disconnectors or main switch to start and stop
the unit.
Only let authorized personell open the electrical enclosure. Store
the key separately.
Before opening the electrical enclosure, the main switch must
be off.
Before electrical work, the entire electrical enclosure must be
disconnected.
DISPOSAL NOTES
The unit contains electrical components and must not
be disposed of together with household waste. Local
and currently valid legislation must be observed!
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PERSONAL INJURY!
No matter what kind of work is performed on the unit, there is
always a risk of cuts inflicted by the thin sheet metal and heat
exchanger fins.
This applies especially when carrying out maintenance and
cleaning work on the fin surfaces of heating and cooling coils.
Risk of impact from the opening doors fitted on the pressure
side.
Risk of crushing resulting from negative pressure applied to
the doors on the suction side.
Danger from the rotating parts such as fans etc.
Danger due to the hot surfaces and/or media.
The unit whose centre of gravity is located high up can tip over,
resulting in injury and material damage.
During transport, pay careful attention to the unit, observe its
behaviour and stay away from any potentially hazardous areas.
Make sure that no one is locked inside the unit. Walkable units
with a height clearance equal to or greater than 1,280 mm are
equipped with the emergency operating levers on the insides of
the doors for that purpose.
You must secure smaller units against a person being locked in
by mistake with a padlock e.g. on the door stop.
High concentration of refrigerant in the air can lead to death
or serious injury.
High concentrations of refrigerant in the air can numb the
senses and lead to loss of consciousness. Prolonged exposure
may cause irregular heartbeat and sudden death. Very high
concentrations can cause suffocation due to the resulting
reduced oxygen content of the ambient air.
Never stand beneath the suspended loads, since there is always
a risk that the lifting gear, tackle, ropes or slings are faulty
or damaged.
DAMAGE TO THE UNIT
If the dampers are abruptly shut during the unit operation,
the unit can be damaged beyond repair as a result of negative
pressure or overpressure.
Use only the lifting lugs provided by FläktGroup!
Make sure that the lifting lugs are firmly secured before lifting
the load.
DAMAGE TO THE ENVIRONMENT
Heavily contaminated filters may adversely affect production
processes. Depending on the filtered substances, contaminated
filters should therefore be treated as the special waste and
must be properly disposed of in an environmentally-friendly
manner in accordance with the current directives and laws.
Do not pollute the environment with the liquid products, refrigerants
or oils.
Dispose of the iquid products, refrigerants or oils in accordance
with the local laws and regulations to avoid harms to
the environment.
Ethylene glycol and propylene glycol are categorised as water
pollutants in the Catalogue. This also applies to the mixtures with
water.
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COM4plus – Operation and maintenance manual
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SHIPPING DAMAGE
Damaged outside packaging
Be careful to obey the following steps in case of the outside
packaging damage:
1. Unpack in the presence of the delivery truck driver and have
the damage certified on the shipping order.
2. Inform the FläktGroup Deutschland GmbH Sales Company
immediately before installation of the unit.
Claims cannot be processed unless the points above are
complied with.
Damaged contents if the packaging is OK
Be careful to obey the following steps in case of the contents
damage:
1. Once you have established the extent of the damage, report
the damage to the FläktGroup Deutschland GmbH Sales Company
in writing before installation of the unit.
2. Take the photographs of the damaged parts.
3. Possible shipping damage must be reported no later than 4 days
after delivery.
Claims cannot be processed unless the points above are
complied with.
STORAGE
Observe the permissible storage conditions between
-10 °C and +50 °C in dry, non-condensing atmosphere. Do not
remove the original packaging until just before installation.
The original packaging is designed for shipment and transportation,
but not for permanent storage. Take the appropriate measures.
Protect the unit up until commissioning from installation dust, dirt
and damage!
Protect the unit from UV radiation and adverse weather.
If units have been delivered without packaging or the packaging has
already been removed, take the appropriate measures to protect
them up until commissioning from installation dust, dirt and
the effects of weather.
If the unit has packaging added on-site, make sure that
condensate cannot form below the packaging (make sure that
there is a clearance between the packaging and the casing).
Always place the units on an even surface for storage or
temporary storage.
Protect the units against bumps and knocks to avoid damage
to the casing and protruding components.
If commissioning is not carried out within 3 months following
the delivery, the belt drive must be slackened off.
Rotate the motor axis and fan through at least 2 revolutions
every 3 months.
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COM4plus – Operation and maintenance manual
To connect - counter hold with a pipe wrench.
Attention: fire risk. Dust-laden filters are inflammable.
Before opening, use the main isolator to disconnect power.
Risk of injury. Wait until complete stop before opening.
Type sheet and assembly instructions attached to unit inside.
Remove these documents before the unit commissioning.
Do not start up the fan against closed dampers.
Potential equalisation.
To equalize potentials the unit must be connected to an external protective conductor
at the designated points on the base frame.
SPECIAL WARNING AND DANGER SYMBOLS
The following warning and instruction signs can be secured on the unit:
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COM4plus – Operation and maintenance manual
Fan or compressor,
generally with direction of airflow indicated
Unit heater/cooler for heat recovery
Air/water ECOFLOW
Noise attenuator in unit Unit heater/cooler for heat recovery
Air/steam ECOSTAT
Air filter, generally with
direction of airflow indicated
Unit heater/cooler for heat recovery
Air/air ECOPLAT
HEPA filter, with direction of airflow indicated Unit heater/cooler for heat recovery
Air/air ECOROT
Opposed-blade dampers General air humidifier
Unit heater air/water
General controller
Air cooler air/water Droplet separator
Air cooler
Air/steam/refrigerant
FUNCTION SIGNS
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COM4plus – Operation and maintenance manual
INTRODUCTION
DOCUMENT DESCRIPTION
This manual contains commissioning and maintenance instructions
for COM4plus air handling units with Rotary Heat Exchanger and with
Counterflow Plate Heat Exchanger.
Instructions for replacement of casing parts and components are
delivered separately and not included in this document.
Note: All screenshots and text references to screen items such as
search paths are in English in this manual. If you select a different
language in the Setup wizard, the texts on the screen will be in that
language.
WARNING!
Only let qualified personnel or persons with necessary knowledge do
the operation, commissioning and maintenance procedures described
in this manual. There is a risk of injury or damage to the product if
the procedures are not done correctly. Any work on the refrigeration
circuit may only be performed by certified and licensed personnel in
accordance with the current version of Regulation (EU) No 517/2014
and Regulation (EU) No 2015/2067.
PRODUCT DESCRIPTION AND INTENDED USE
The COM4plus air handling units are used for energy efficient
ventilation of normally contaminated air in for example offices,
residential buildings, schools, stores and industries.
The unit is not applicable for continuously humid environments, such
as indoor swimming facilities.
CONTROL SYSTEM
The ISYteq control system can be accessed through the touch display
or via a web browser.
ENVIRONMENTAL DOCUMENTATION
If you are not sure how to disassemble and recycle the product,
contact FläktGroup.
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COM4plus – Operation and maintenance manual
UNIT OVERVIEWS
COM4PLUS WITH ROTARY HEAT EXCHANGER
The pictured unit has the supply air at the bottom left-hand side. The
unit is available with the supply air either at the top or at the bottom,
and on the right or the left.
1. Outdoor air
2. Outdoor air damper with damper actuator
3. Outdoor air filter
4. Multifunction sensor (extract air flow, outdoor air filter pressure,
exhaust air temperature)
5. Rotary heat exchanger
6. Drive system rotary heat exchanger
7. Drive motor rotary heat exchanger
8. Extract air temperature sensor
9. Supply air fan with EC motor
10. Supply air
11. Extract air
12. Extract air filter
13. Multifunction sensor (supply air flow, extract air filter pressure,
supply air temperature)
14. Lockable main switch
15. Cable flanges
16. Touch display
17. Air handling unit controller
18. Exhaust air fan with EC motor
19. Exhaust air damper with damper actuator
20. Exhaust air
21. Base frame
22. Outdoor air temperature sensor
23. Extract air damper with damper actuator
24. Supply air damper with damper actuator
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31. Outdoor air
2. Supply air
3. Extract air
4. Exhaust air
5. Cable flanges
6. Lockable main switch
7. Air handling unit controller
8. Face and bypass damper
9. Damper actuator
10. Counterflow plate heat exchanger
11. Drain tray
12. Extract damper with damper actuator
13. Touch display
14. Multifunction sensor (extract air flow, outdoor air filter pressure,
exhaust air temperature)
15. Exhaust air fan with EC motor
16. Exhaust air damper with damper actuator
17. Outdoor air damper with damper actuator
18. Outdoor air temperature sensor
19. Outdoor air filter
20. Extract air filter
21. Extract air temperature sensor
22. Multifunction sensor (supply air flow, extract air filter pressure,
supply air temperature)
23. Supply air fan with EC motor
24. Base frame
25. Supply damper with damper actuator
COM4PLUS WITH COUNTERFLOW PLATE HEAT EXCHANGER
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Simplified overview of installed components
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1. Outdoor air
2. Supply air
3. Extract air
4. Exhaust air
5. Mixing damper
6. Return air
7. Outdoor air damper with damper actuator
8. Outdoor air filter
9. Multifunction sensor (extract air flow, outdoor air filter pressure,
exhaust air temperature)
10. Rotary heat exchanger
11. Drive system rotary heat exchanger
12. Drive motor rotary heat exchanger
13. Extract air temperature sensor
14. Supply air fan with EC motor
15. Extract air filter
16. Multifunction sensor (supply air flow, extract air filter pressure,
supply air temperature)
17. Lockable main switch
18. Cable flanges
19. Touch display
20. Air handling unit controller
21. Exhaust air fan with EC motor
22. Exhaust air damper with damper actuator
23. Base frame
24. Outdoor air temperature sensor
25. Extract air damper with damper actuator
26. Supply air damper with damper actuator
COM4PLUS WITH ACTIVE MIXING
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COM4plus – Operation and maintenance manual
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COMMISSIONING
PREREQUISITES BEFORE COMMISSIONING
Make sure that the unit and all components and accessories are
installed correctly.
Make sure that the unit is installed with the accessories necessary
to decrease transmission of sound and vibrations.
Make sure that the electrical connections are done correctly.
Use applicable personal protective equipment to prevent injury
during commissioning.
LIST OF STEPS
Follow the instructions below regarding any parts that are included in
your unit.
1. Make sure that the unit is electrically disconnected.
2. Check that the unit is horizontal.
3. Check that the inspection doors open and close smoothly. Adjust
the hinges if necessary.
4. Check that the unit is clean on the inside and on the outside.
5. Dampers with actuators – Check that the connected dampers are
in the closed position when the damper actuators are in their end
position.
6. Filter – Check that the filter cassettes are in place and the locking
system is closed.
7. Rotor (for COM4plus with Rotary Heat Exchanger only) – Check
that the rotary heat exchanger rotates easily when pushed
manually. If not, the rotor on the COM4plus can be adjusted.
8. Manometers and flow sensors – Check that the sensors are set
on 0 and connected correctly (+/–) to the test points.
9. For other functions, follow separate instructions.
10. Check that all the safety restraints have been removed.
11. Switch on disconnectors and turn on the main power switch.
12. The basic control system settings are factory configured, but
certain settings must be customised for each installation. Finish
configuring the control system by going through the setup wizard
on the touch display or via a web browser on your computer.
Refer to ”Setup wizard” on page 13 for details.
13. Set the operating mode to automatic.
a. Select Operating data > Unit Main Switch > On
b. Select the operating mode tile on the dashboard.
c. Select Automatic.
14. If the unit has active mixing, do a 0-calibration. Refer to ”To do a
0-calibration” on page 15 for instructions.
15. Adjust the duct system and the air terminal devices.
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SETUP WIZARD
The Setup wizard can be run on the touch display or via a web
browser on a computer with Ethernet connection to the unit. Type the
IP address 192.168.0.1 in the address bar of the web browser. In some
cases you might need to configure your LAN IPv4 address to static and
restart your computer before you can connect to the unit.
To log in and select language
Enter user name ”Admin” and password ”Admin” and select ”LOGIN”.
If the entered information is incorrect, a notification appears. If the
entered information is correct, the Setup wizard starts.
To navigate the Setup wizard
At the bottom of the screen there are four navigation icons.
A B DC
To confirm all settings in the current step of the Setup wizard and go
to the next step, select save (A).
To skip to the next step in the Setup wizard without saving any
changed settings, select skip (B). It is recommended to use the skip
function if you want to use the preconfigured settings and be sure
that you do not change anything.
To cancel the changes made in the current step of the Setup wizard
and restore the previous settings, select cancel (C).
As you go through the Setup wizard, the headings in the list on
the left side of the screen become green. To go back and change
already made settings, select a green heading.
To exit the Setup wizard, select exit (D).
Language settings
Select a flag to select the corresponding language and select save
to go to the next step.
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COM4plus – Operation and maintenance manual
Time, date and units
BA
The first tab (A) is selected automatically.
1. Select the dropdown menus to set the time zone.
2. Select the clock icon to set the time.
3. Select the calendar icon to set the date.
4. Select save or skip to go to the next tab (B).
5. Select the dropdown menus to set the applicable units.
6. Select save.
Edit profiles
You can configure up to five profiles. There are separate profiles for
Boost and Standby/Off. You can create individual time schedules for
each profile.
You can change the name on all profiles except the Boost profile.
The Boost profile starts the unit before the set start time to make
sure that the temperature is correct at the start time.
It is necessary to have a profile for night operation. In the night
profile, set the temperature control mode to Nightpurge and select to
enable the unit via temperature control.
The profile tab on the far right is for Standby/Off. To activate
room frost protection for Standby/Off, select to enable the unit via
temperature control.
1. Configure the profiles as is necessary for your unit application.
2. Select save.
Unit operation scheduler
This step lets you create a weekly schedule where you can select
different profiles for different time periods. The profile for unit off is
applied to the whole week until you add other profiles.
1. Select the week day for which you want to add a profile. A popup
with three icons appear.
A C
B
a. Select (A) to add a profile and select time period for that profile.
b. Select (B) to edit the profile.
c. Select (C) to close the icons popup without making any
changes.
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2. To edit an already added profile, select that profile. A popup with
six icons appear.
D E F G H J
a. Select (D) to add a different profile to the time period.
b. Select (E) to edit the currently selected profile.
c. Select (F) to copy the profile and apply it to another time period.
d. Select (G) to delete the profile from the weekly schedule.
e. Select (H) to change the start and stop time for the profile.
f. Select (J) to close the icons popup without making any changes.
3. Select the right tab (K) to set up exceptions for specific days,
weeks or months.
K
4. When the weekly schedule is finished, select save.
Start up settings
This step lets you configure how the unit starts depending if it is
summer or winter. You can set the temperature threshold, the startup
delays and the damper delay. Make sure that the settings are correct
for the local weather conditions.
When the start up settings are finished, select save.
If you are not sure how to do these settings correctly, select skip.
To set default page and finish the Setup wizard
1. Select Control schematics or Dashboard to set the default page
for the user interface.
2. Select save. A notification asks you to restart the unit to apply all
settings.
3. Select save to restart the unit and load the selected default page.
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ACTIVE MIXING
Active mixing is an energy recovery function using flow controlled
recirculation via dampers. The function is initialized with minimization
of the differential pressure over the mixing damper. This is done with
the extract air damper or the outdoor damper, depending on the
pressure setup of the installation. After that, the mixing damper and
the outdoor damper are controlled in parallel for mixing the air.
The exhaust fan is controlled to keep the flow balance in the unit. A
minimum level of fresh air can be set in each profile. If full recirculation
is allowed, the exhaust air fan is stopped and the mixing damper is
fully open.
To do a 0-calibration
For correct functioning of the active mixing, it is necessary to do a
0-calibration during commissioning. The unit shows a low level alarm
on the screen until the calibration is executed.
1. Set the operating mode to automatic.
a. Select Operating data > Unit Main Switch > On
b. Select the operating mode tile on the dashboard.
c. Select Automatic.
2. Select Operating data > Control > Damper > Calibration > Set
Damper Control ODA Amount Start Calibration > On.
The automatic calibration process starts. The unit runs the fans in
stable condition at maximum speed an then at 25% of maximum
speed.
CLOUD FOR ISYTEQ
CLOUD for ISYteq is a cloud service. The connection of the air handling
unit to CLOUD for ISYteq is done differently depending on the type of
internet access.
To connect with LAN
1. Make sure that the LAN firewall allows PPTP (port 1723) and GRE
(port 47) protocols.
2. Connect an Ethernet cable between the controller and the
assigned LAN network port.
3. Select Settings and device information in the menu bar.
4. Select Configuration > Network > TCP/IP > Interface.
5. Make sure that the row dyn_cloud under the section Dynamic has
green marks.
To connect with the built-in GSM modem
1. Put the GSM antenna in a position where the GSM signal can be
found.
2. Check the reported signal strength.
a. Select Settings and device information in the menu bar.
b. Select System > Diagnosis > Modem.
c. Read the value under Network state – Signal. The GSM signal is
sufficient if the level is green.
3. Select Settings and device information in the menu bar.
4. Select Configuration > Network > TCP/IP > Interface.
5. Make sure that the row dyn_cloud under the section Dynamic has
green marks.
Troubleshooting
Problem Solution
The row dyn_cloud does not have
green marks.
If connected with LAN, check
the LAN firewall settings.
If connected with the built-in
GSM modem, check the GSM
signal strength.
Check the factory loaded
parameter settings in the
controller.
The GSM signal is not sufficient. Move the GSM antenna to a
better position.
Use a longer antenna cable.
Max. length 15 m.
The firewall is blocking the used
protocols for LAN.
Contact the IT operations and
request openings in the firewall.
Contact FläktGroup for support.
The air handling unit does not
connect to CLOUD for ISYteq.
Check the internet settings.
Check the controller CLOUD
settings.
Check the CLOUD portal settings
Contact FläktGroup for support.
The air handling unit is connected
to CLOUD for ISYteq but not logged
in to the CLOUD portal.
Log in with the user account
credentials on the CLOUD Quick
Guide delivered with the air
handling unit.
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COM4plus – Operation and maintenance manual
MAINTENANCE
EXPLANATION OF SYMBOLS
Clean
according to
instructions
General
inspection
Hygiene
standard
according to
VDI 6022
Check
function
Replace
SERVICE SCHEDULE
Service schedule including intervals (month*) within the VDI ventilation
code of practice VDI 6022, Part 1 (**)
3* 6* 9* 12*
6* 12*
12*
**
Casing
Filter
Fan
Coils
Silencer
Plate heat
exchanger
Rotary heat
exchanger
Plastic tubes
and parts for
measurement
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COM4plus – Operation and maintenance manual
SPARE PARTS
Use only original FläktGroup spare parts. FläktGroup is not liable for
damages caused by spare parts that are not original.
WARRANTY
For warranty claims, a written and signed maintenance protocol and
commissioning protocol is necessary. FläktGroup will not be liable if
the product is not assembled, installed, commissioned or maintained
according to the instruction manuals included with the product.
TO COMPLY WITH VDI 6022 VENTILATION CODE OF PRACTICE
Use a full cover and protective gloves during service and
maintenance.
Clean all surfaces and components according to the instructions to
make sure that they are free from dirt and contaminant.
Note: We recommend that the system is never operated without
the filters. Keep a set of spare filters in stock as well.
TO CLEAN THE CASING AND THE COMPONENTS
CAUTION!
Do not use acetone, chlorine or other similar liquid solvents.
For disinfecting unit surfaces, use cleaning agents on the German
Society of Hygiene and Microbiology (DGHM) list, or which have
German Veterinary Medicine Society (DVG) or Association for Applied
Hygiene (VAH) certification. Ensure you comply with the concentrations
and exposure times specified there. Possible cleaning agents are e.g.
BODE Microbac or DESOMED Desotop. For the correct concentration,
refer to the data sheet provided by the manufacturer and/or select a
non-visible small surface to test the solution there beforehand.
The use of hydrogen peroxide H
2
O
2
or other oxidising agents for
disinfection purposes is not permitted.
Alcohol-based solutions are not permitted due to the risk of
explosion and fire.
Treat galvanised parts with protective spray.
Vacuum clean and dry off with a wet cloth.
Use dish soap to clean the casing. Rinse with clean water after
using detergent.
If necessary, disinfect the casing.
After cleaning make sure that all surfaces are dry.
Replace components that cannot be cleaned or have grown fungus
or mold.
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COM4plus – Operation and maintenance manual
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FläktGroup COM4plus Installation guide

Category
Split-system air conditioners
Type
Installation guide

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