Systemair Topvex SoftCooler SR09/SR11 Operation and Maintenance Instructions

1 Warnings

Danger

• Ensure the Mains supply is disconnected before performing maintenance or electrical work.
• All electrical connections must be carried out by an authorized installer according to local rules and regulations.
• Operation in the refrigerant circuit and handling refrigerants must be performed by certified personnel.

Warning

• Beware of sharp edges during mounting and maintenance; use protective clothing.
• Avoid skin contact with refrigerant; use protective equipment (goggles, gloves, suitable clothing) and ensure good ventilation.
• Seek medical attention for freezing injuries.
• Wash exposed skin contact areas carefully with water.
• In case of eye contact, flush with eyewash or lukewarm water for 20 minutes and consult a doctor.
• The unit's electrical connection must include an all-pole circuit breaker with a minimum 3 mm gap.
• This product is not intended for use by children or individuals with reduced physical/mental abilities or lack of experience/knowledge unless supervised or instructed by a responsible person. Supervise children to prevent them from playing with the product.

2 Product Description

2.1 Components

Diagram 1 shows the basic components of the left-hand unit. The numbered components are:

2.2 Electrical Cabinet

Diagram 2 illustrates the electrical cabinet. The numbered components are:

3 Installing the Unit

3.1 Installation

Diagram 3 depicts the installation process for the left-hand unit, indicating airflow directions and accessory connections. The numbered points represent:

• Supply Air
• Exhaust Air
• Outdoor Air
• Extract Air
• 1: VAV pressure transmitter supply air (accessories)
• 2: VAV pressure transmitter extract air (accessories)
• 3: Damper and motor exhaust air (accessories)
• 4: Damper and motor outside air (accessories)
• 5: Sensor supply air
• 6: Topvex SoftCooler SR

4 Refrigerant Control/Reporting

The Topvex SoftCooler SR units contain more than 3kg of refrigerants per circuit. Before commissioning, a control report regarding the installation must be established by a certified refrigeration technician. Leakage control with record-keeping is required annually. Reporting of the installation to the major inspection authority is necessary if the property/enterprise has a total refrigerant amount of 10 kg or more. Different regulations may apply in various countries; consult your local government.

5 Function Description

Diagram 4 illustrates the function of the left-hand unit. The components are:

5.1 General

The control unit (UC) monitors the extract temperature via the ETS sensor and maintains the set extract temperature by controlling the compressor (CPR), heat exchanger (HE), and hot water/electrical heater. The supply air temperature sensor (SS) provides minimum and maximum limits for the supply air temperature.

5.2 Power Control

The compressor (CPR) speed is steplessly controlled by the frequency converter (FC) within a set minimum and maximum frequency range.

5.3 Power Limitation

The programmable controller monitors the condensing pressure via the high pressure sensor (HPS). If the pressure exceeds a set limit, the compressor speed is reduced to prevent a high-pressure alarm.

Note: This manual covers functions for the Topvex SoftCooler SR. For a complete description, refer to the "SR 09,11, TR 09-15 Installation Instruction".

6 Cooling Flow Chart

6.1 The Cooling Function

Diagram 5 illustrates the cooling flow. The refrigerant circulates in a closed system through the Evaporator, Compressor, Condenser, and Expansion Valve. The compressor maintains low pressure in the evaporator, lowering the refrigerant's boiling point. Heat is absorbed from the supply air passing through the evaporator, reducing its temperature. The compressor increases refrigerant pressure, causing it to condense in the condenser, releasing heat to the exhaust air. The liquid refrigerant then passes through the expansion valve, which regulates its flow to the evaporator, completing the cycle.

Component Key for Diagram 5:

6.2 Components and Function

6.2.1 Compressor

The Topvex Soft Cooler uses a high-efficiency, variable-speed scroll compressor designed for speed control, requiring a frequency converter. Cooling capacity is regulated by changing operating frequency, with a working range of 20 to 120 rps. Maximum frequency may be limited by settings in the frequency converter. Compressor control is automatic, based on demand signals from the control unit.

6.2.2 Frequency Converter (FC)

The FC is located in the electrical cabinet. The programmable controller receives a 0-10V DC control signal for cooling load and uses the FC to regulate compressor speed. A high-pressure sensor (HPS) monitors system pressure. If pressure exceeds the set value, the FC reduces output frequency and compressor speed to prevent a high-pressure alarm. A 3-minute restart delay prevents rapid start/stop cycles.

6.2.2.1 Integrated Control, Quick Guide

FLSTDmCOMM is a CAREL solution for managing BLDC compressors via a Power+ inverter, featuring:

• Easy add-on for managing BLDC compressors via analogue signal (0-5V/0-10V) or Modbus serial communication.
• Full control of compressor working conditions, tested and approved by manufacturers.
• Electronic expansion valve management via EVD EVO on-board.
• No user interface (pGD1) needed when connecting to a BMS Modbus.
• Energy saving and cost reduction.
• Improved system management via a semi-graphic user interface (pGD1).

6.2.2.1.1 User Interface

The user interface provides:

• Bell symbol: Displays active alarms.
• Prg: Enters the main menu.
• Esc: Returns to the previous screen.
• Up arrow: Scrolls lists upwards or increases values.
• Enter arrow: Selects submenus or confirms values.
• Down arrow: Scrolls lists downwards or decreases values.

6.2.2.1.2 PGD1 Menu

Access to specific menus for Power+ inverter parameters, EVD Evo Parameters, manual controls, other parameters, defrost options, and BLDC compressor parameters is provided through various masks (e.g., Pa01, Ea01, Ma01, Ot01, Df01, Co01).

6.2.2.1.3 Pa Menu: Power+ Configuration

This menu is for Power+ inverter configuration (e.g., Compressor model). Generally, no access is needed as settings are pre-configured. It allows selecting the compressor model, setting defaults, saving custom configurations (by qualified personnel only), setting alarm delay times, and selecting speed units.

6.2.2.1.4 Pb Menu: Power+ Regulation

This menu is for Power+ inverter regulation and typically requires no user access. It displays frequency limits, allows setting skip frequencies to avoid mechanical resonance, and configures switching frequency. It also defines stopping modes, reverse speed, flying start, and relay/PTC input configuration.

6.2.2.1.5 Pc Menu: Power+ Custom

This menu is for Power+ custom settings and typically requires no user access. It includes parameters for motor control mode, base frequency/voltage, rated current, power factor, speed profile management (acceleration, deceleration, delays), motor electrical data, and PI regulation parameters.

6.2.3 Power Controlling

The control unit sends a demand signal (0-10V DC) proportional to the cooling demand. This signal, via a relay (R1), connects to the programmable controller, activating the compressor. The speed is controlled based on the demand signal, between a minimum frequency (20 rps) and a maximum frequency (up to 120 rps).

6.2.4 Compressor Protection

The compressor is protected by:

• Motor protection in the frequency converter (FC).
• High pressure switch (PSH) on the high-pressure side.
• Low pressure switch (PSL) on the low-pressure side.
• Hot gas thermostat (HGS) on the hot gas tube.

If any protection is triggered, the control unit displays "Malfunction cooling (SEQ-C)". Manual acknowledgment and reset are required before the compressor can restart.

6.2.5 Refrigerant

The system uses R410A refrigerant and is pre-filled and tested. High and low pressure measuring points are located on top of the unit. Refer to Chapter 4 for refrigerant installation control and reporting.

6.2.6 Condenser/Evaporator

The condenser and evaporator coils are constructed from copper tubes with aluminum fins.

6.2.7 Drip Tray

The drip tray is situated beneath the evaporator/brine coil to collect condensation. It is made of stainless steel with a 32 mm drain connection and includes an electrical heater to prevent freezing.

7 Maintenance

Caution

Regular maintenance of the Topvex SoftCooler is crucial for the installation's environmental impact, operating economy, durability, security, and functions. Consult Chapter 1 (Warnings) and Chapter 4 (Refrigerant Control/Reporting) before performing any work.

Maintenance should be performed twice a year, in addition to general cleaning. Key tasks include:

1. Leakage Control: Registration is required at least once a year, with varying regulations by country.
2. General Control: Listen for abnormal sounds/vibrations during operation. Inspect for oil leakage (potential refrigerant leak), corrosion, fretting damages, and loose pipe suspensions.
3. Cooling Coil (Evaporator/Condenser) Control: After extended use, coils may accumulate deposits obstructing heat transfer and airflow. Vacuum clean coils from the dirty side.
4. Drip Tray Control: Deposits can obstruct the drip tray and drain. Clean the drip tray, drain, water seal, and pipes.
5. Air Filter Control (Frequency Converter): The filter, located in the inspection door, can become clogged, reducing cooling airflow and causing overheating of the frequency converter. Clean or replace the filter (filter mat G5) if dirty.

8 Alarms

When an alarm is activated, a message is displayed, the corresponding LED illuminates, and the alarm relay may activate. Alarms are categorized as:

• Serious unit alarms (stop the compressor).
• Alarms that stop one or more system functions.
• Other alarms (warnings) that do not stop functions but indicate exceeded thresholds.

To view active alarms, press the bell symbol. Use the up/down arrow buttons to scroll through the list. To reset alarms, display them and press again. If the condition persists, the alarm will reappear.

Note: With automatic reset, the system resumes operation, but the alarm LED and warning string remain active until the bell symbol is pressed twice.

Table 1: Alarms