Komfovent PPU-LCHX Pipework Package Unit For Liquid Coupled Heat Exchanger Instruction Manual

Instruction Manual for Komfovent models including: PPU-LCHX Pipework Package Unit For Liquid Coupled Heat Exchanger, PPU-LCHX, Pipework Package Unit For Liquid Coupled Heat Exchanger, Package Unit For Liquid Coupled Heat Exchanger, Liquid Coupled Heat Exchanger, Coupled Heat Exchanger, Heat Exchanger, Exchanger

PPU-LCHX - Komfovent

6 UAB KOMFOVENT we reserve the right to make changes without prior notice PPU-LCHX 21-05 EN • Terminals L1, L2, L3, PE are for 3x400 V AC, 50 Hz electrical power connection. Connect power cable to the mains via 10A automatic circuit breaker (type C). • Terminals DIN and 10V are for inverter start/stop signal (open/close contact).If such signal is not needed, wire link must

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PPU-LCHX installation EN

PPU-LCHX
Pipework package unit for liquid coupled heat exchanger

EN
CONTENT
1. INTRODUCTION ...........................................................................................................................................................................................................3 2. ENCODING AND CONSTRUCTION ......................................................................................................................................................................3 3. MECHANICAL INSTALLATION...............................................................................................................................................................................4 4. ELECTRICAL INSTALLATION ..................................................................................................................................................................................5 5. FLOW RATE REGULATION .......................................................................................................................................................................................7 6. PERIODICAL MAINTENANCE.............................................................................................................................................................................. 10 7. TECHNICAL DATA ..................................................................................................................................................................................................... 10

UAB KOMFOVENT we reserve the right to make changes without prior notice PPU-LCHX_21-05

1. INTRODUCTION
This manual is intended for qualified technicians installing pipework package unit (PPU) for liquid coupled heat exchanger. Qualified professionals are persons with sufficient professional experience and knowledge of plumbing systems for heating/ cooling, their installation, knowledge of electrical safety requirements and ability to work without risk to themselves or others.
To avoid misunderstandings, read this manual carefully before installing the PPU, since ignoring the instructions not only shall invalidate the manufacturer's warranty but can also cause direct damage to property or human health.
· When performing installation works, make sure the frequency inverter and circulation pump are unplugged from electrical supply. Do not connect them to electrical power until all mechanical works on PPU are finished.
· Use caution when working near internal or external heaters of the airhandling unit (AHU), as their surfaces may be hot.
· Do not connect frequency inverter and circulation pump to the power supply network if there is visible damage that occurred during transportation.
· Use appropriate personal protective equipment (gloves, goggles) when installing or repairing · the PPU.
This sign means that the product may not be disposed of together with your household waste as defined in Directive (2002/96/EC) and national legislation on the management of WEEE. This product must be disposed of at an appropriate collection point or recycling facility for waste electrical and electronic equipment (WEEE). Improper handling of this type of waste due to hazardous substances inside electrical and electronic equipment can endanger the environment and human health. By helping to ensure proper disposal of this product, you will also contribute to the efficient use of natural resources. For more information on how to dispose of such waste for further recycling, contact your city authorities, waste management organisations, approved WEEE systems or your household waste management bodies representatives.
2. ENCODING AND CONSTRUCTION
PPU-LCHX is a pipework package unit for liquid coupled heat exchangers that are used for heat/cold recovery in the air handling units (AHU). PPU ensures proper circulation of thermal medium (usually mixture of glycol and water) throughout the piping circuit, regulates requperation efficiency and prevents coils from freezing.
11

2 FC

10 P

Fig. 1. PPU components and hydraulic diagram 1 Circulation pump; 2 Frequency inverter; 3 Thermometer; 4 Ball valve; 5 Water filter; 6 Expansion vessel; 7 Coil in the supply
airflow; 8 Safety valve; 9 Drain valve; 10 Manometer; 11 Coil in the extract airflow; 12 Balancing valve

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Encoding:

PPU - LCHX - FQ - L/R - 40 - WG2

1. PPU Pipework package unit 2. LCHX Liquid coupled heat exchanger 3. FQ with frequency inverter 4. L/R suitable for right (R) and left (L) inspection side AHU's 5. Connection pipe diameter (DN) 6. Type of circulation pump

3. MECHANICAL INSTALLATION
PPU-LCHX to be installed in technical room, where ambient temperature is 0..+40°C. Unit must be mounted on a flat and sturdy base or on a construction specially designed for mounting. If mounting base ins not flat, PPU can be leveled using adjustable feet at the bottom of the frame.
When selecting mounting location, you must foresee sufficient and secure access space for repair and maintenance operations. Also make sure PPU is not blocking access to the AHU and it's door can open freely.
Connect PPU to the heat exchanger coils of the AHU, following hydraulic diagram (see Fig. 1). It is important to ensure that fluid flow direction (marked on the arrow stickers of the PPU) is correct. For effective operation of liquid coupled heat exchanger, thermal medium flow direction should be against airflow direction. When fully assembled, all hydraulic circuit must be filled with glycol (not more than 40%) and water mixture. Pipes are filled through the drain valve until static pressure of 1.5 bar is reached. Do not use circulation pump of the PPU for filling the pipes additional equipment or pump must be used.

All piping between PPU and AHU coils should be thermally insulated after the works.

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4. ELECTRICAL INSTALLATION
Electrical work may only be carried out by a qualified electrician in accordance with the instructions given in this manual and in accordance with applicable legal requirements and safety requirements. Before performing electrical component installation:
· Check there is no mechanical damage on frequency inverter or circulation pump. · Check the insulation of the cable between frequency inverter and circulation pump is not
damaged. · Locate user manual for the frequency inverter. · If the PPU has been standing in an unheated room for a long time, make sure that electronic
parts and cable connectors were not affected by moisture.
Configure micro-switches, connect electrical power and control calbles to the frequency inverter (see Fig. 2):

COM

DIN

10V

U V W PE PE L1 L2 L3

AIN GND

OFF ON
1

Fig 2. Frequency inverter 1 Frequency inverter control terminals, 2 Pump connection terminals, 3 Main power terminals
4 Micro switch configuration, 5 Control panel connection (RJ9)

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EN
· Terminals L1, L2, L3, PE are for 3x400 V AC, 50 Hz electrical power connection. Connect power cable to the mains via 10A automatic circuit breaker (type C).
· Terminals DIN and 10V are for inverter start/stop signal (open/close contact). If such signal is not needed, wire link must be installed instead.
· Terminals AIN and GND is for inverter control signal (0..10V).
L1 L2 L3 PE DIN 10V AIN GND

4x1,5mm

2x0,5mm 2x0,5mm

3x400V AC

0..10V DC COM

Fig. 3. Frequency inverter connection diagram
· Connect the frequency inverter only to suitable power socket with appropriate earthing and meeting the electrical safety requirements.
· For information on how to connect frequency converter to the AHU automation control, please follow electrical wiring diagram of the AHU.

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5. FLOW RATE REGULATION

For circulation pump to run correctly, it is needed to set PPU flow rate according to designed flow rate stated in the technical printout of the liquid coupled heat exchanger. Flow rate of the PPU is set as follows:
1. Fully open balancing valve. 2. Connect differential pressure measuring equipment to the pressure measuring ports of the balancing valve. 3. Using flow rate diagram (Fig. 4), determine which differential pressure should be achieved, for PPU to reach the de-
signed flow rate.

kv 0,01 100

0,05

0,1

0,5

100

DN20

DN32

DN25

DN40

DN50 DN65

10
5

1
0,5

0,1
0,05

pressure drop p
[kPa]

0,01 10 [dm /h]
flow rate qm

100

500

1000

5000

10000

Fig. 4. Flow rate diagram of the balancing valves

4. Connect control panel of frequency inverter (see Fig. 2).

50000 100000

It is mandatory to turn OFF main power of the inverter, when connecting or disconnecting control panel cable, otherwise panel will be damaged.
5. Turn ON power of the inverter. Set initial frequency using control panel (20 Hz recommended) and start the inverter:

16:30
0.0 Hz Output setp. Output freq.
0.0 Hz
Page 1
0 - Stop

Output setpoint control, Hz 020.0

16:30
0.0 Hz Output setp. Output freq.
0.0 Hz
Page 1
0 - Stop

[1] Operation mode c... 9 - Analog control
0 - Stop
1 - Run

[1] Operation mode c... 0 - Stop
1 - Run
2 - Fire mode

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6. By increasing/decreasing inverter frequency, regulate pump speed until correct differential pressure will be reached. Memorize or write down operating frequency of the inverter at this pressure point.

16:30
20.0 Hz Output setp. Output freq.
20.0 Hz
Page 1
1 - Run

Output setpoint control, Hz

030.0

7. Stop the inverter:
16:30
30.0 Hz Output setp. Output freq.
30.0 Hz
Page 1
1 - Run

[1] Operation mode c... 0 - Stop
1 - Run
2 - Fire mode

[1] Operation mode c... 9 - Analog control
0 - Stop
1 - Run

8. Enter to the parameter 102 same frequency, under which correct differential pressure was reached (according step 6).

16:30
0.0 Hz Output setp. Output freq.
0.0 Hz
Page 1
0 - Stop

Overview

Motor

Configuration Op. settings

Operation settings
[100] Drive current limit, % 100 %
[101] Minimum output freq., Hz 4.0 Hz
[102] Maximum output freq., Hz 80.0 Hz
[103] Skip frequency 1, Hz 0.0 Hz
1 / 6

[102] maximum output freq...

030.0

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9. Enter to the parameter 306 same frequency, under which correct differential pressure was reached (according step 6).

16:30
0.0 Hz Output setp. Output freq.
0.0 Hz
Page 1
0 - Stop

Overview

Motor

Configuration Op. settings

Configuration
[300] Modbus ID
60 [301] Modbus baud rate
7 - 57600 baud [302] Modbus data format 2 - 8E1 [303] Output setpoint type 0 - Frequency, Hz
1 / 4

Configuration
[304] Modbus control timeout, sec 10.0 s
[305] AIN lowest level frequency, Hz 2.0 Hz
[306] AIN highest level frequency, Hz 80.0 Hz
[307] AIN lowest level, %
5.00 %
2 / 4

[306] AIN highest level fre...

030.0

10. Turn OFF power of the inverter. If control panel will not be used, disconnect it from the inverter. Also disconnect control panel in case if PPU is mounted in the unheated room..
It is mandatory to turn OFF main power of the inverter, when connecting or disconnecting control panel cable, otherwise panel will be damaged.
11. Turn ON main power of the inverter and start AHU. Check operation of the liquid coupled heat exchanger and PPU-LCHX.

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6. PERIODICAL MAINTENANCE
· Before starting any maintenance works, make sure that PPU and AHU are stopped. · If there is a need to perform any mechanical works on the piping circuit (for example to tighten
couplings or to clean water filter and etc.) disconnect PPU and AHU from the mains power.
It is recommended to carry out PPU-LCHX periodical maintenance at least once a year. If needed register performed works in the maintenance log.
Following to be checked during maintenance: · Piping circuit is tight, there are no leakage marks. · Circulation pump operates correctly. There are no big vibrations or unnecessary noise. · There are no alarms on the frequency inverter. · Signal and power cables are in good condition, there are no corrosion marks on the connectors and electrical terminals. · Measuring tools (manometer, thermometers) operates correctly. · Water filter is not clogged (clean the filter if necessary).

7. TECHNICAL DATA

Pipework package unit model

Filter and balancing
valve

Pipe connections
DN inch

Pump type

Pump power
kW

PPU-LCHX-FQ-L/R-20-WG1 PPU-LCHX-FQ-L/R-20-WG2 PPU-LCHX-FQ-L/R-25-WG1 PPU-LCHX-FQ-L/R-25-WG2 PPU-LCHX-FQ-L/R-32-WG2 PPU-LCHX-FQ-L/R-40-WG2 PPU-LCHX-FQ-L/R-40-WG3 PPU-LCHX-FQ-L/R-50-WG3 PPU-LCHX-FQ-L/R-50-WG4 PPU-LCHX-FQ-L/R-65-WG3 PPU-LCHX-FQ-L/R-65-WG4

DN20 DN20 DN25 DN25 DN32 DN40 DN40 DN50 DN50 DN65 DN65

20 3/4" WG1 0,55 20 3/4" WG2 0,55 25 1" WG1 0,55 25 1" WG2 0,55 32 1 1/4" WG2 0,55 40 1 1/2" WG2 0,55 40 1 1/2" WG3 1,1 50 2" WG3 1,1 50 2" WG4 2,2 65 2 1/2" WG3 1,1 65 2 1/2" WG4 2,2

Frequency inverter
DF2-551M0 DF2-551M0 DF2-551M0 DF2-551M0 DF2-551M0 DF2-551M0 DF2-112M0 DF2-112M0 DF2-222S0 DF2-112M0 DF2-222S0

Dimensions of the PPU frame (excluding
adjustable feet)

Expansion vessel volume

PPU weight

B, H, L, mm mm mm

Liters

500 867,5 650

550 867,5 700

550 1037,5 850

550 1037,5 900

670 1037,5 1000

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DN20-DN32
B DN40-DN65

867,5 867,5

42-92 L

1037,5 1037,5

42-92

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LITHUANIA
UAB KOMFOVENT
TECHNINS PRIEZIROS SKYRIUS / SERVICE AND SUPPORT Phone: +370 5 200 8000 Email: service@komfovent.com www.komfovent.com
RUSSIA
«» . . 16, . 1, 2 , 206 , , . +7 499 673 22 73 info.ru@komfovent.com www.komfovent.ru
«» , 20 , 6 390017 . , .: +7 491 255 95 71 info.ru@komfovent.com www.komfovent.ru
BELARUS
«» . 21 423, 220125 . , . +375 17 266 5297, 266 6327 info.by@komfovent.com www.komfovent.by
SWEDEN
Komfovent AB Ögärdesvägen 12B 433 30 Partille, Sverige Tel. +46 31 487 752 info_se@komfovent.com www.komfovent.se
FINLAND
Komfovent Oy Muuntotie 1 C1 FI-01 510 Vantaa, Finland Tel. +358 0 408 263 500 info_fi@komfovent.com www.komfovent.com

PARTNERS

AT J. PICHLER Gesellschaft m. b. H. Ventilair group
BE ACB Airconditioning
CZ REKUVENT s.r.o. WESCO AG
CH SUDCLIMATAIR SA CLIMAIR GmbH
DK Øland A/S EE BVT Partners FR ATIB HR Microclima
AIRVENT Légtechnikai Zrt. HU Gevent Magyarország Kft.
Merkapt IR Fantech Ventilation Ltd
Blikk & Tækniþjónustan ehf IS
Hitataekni ehf IT Icaria srl
Ventilair group NL DECIPOL-Vortvent
CLIMA DIRECT BV Ventilution AS NO Ventistål AS Thermo Control AS PL Ventia Sp. z o.o. SE Nordisk Ventilator AB SI Agregat d.o.o SK TZB produkt, s.r.o.

www.pichlerluft.at www.ventilairgroup.com www.acbairco.be www.rekuvent.cz www.wesco.ch www.sudclimatair.ch www.climair.ch www.oeland.dk www.bvtpartners.ee www.atib.fr www.microclima.hr www.airvent.hu www.gevent.hu www.merkapt.hu www.fantech.ie www.bogt.is www.hitataekni.is www.icariavmc.it www.ventilairgroup.com www.vortvent.nl www.climadirect.com www.ventilution.no www.ventistal.no www.thermocontrol.no www.ventia.pl www.nordiskventilator.se www.agregat.si www.tzbprodukt.sk

GERMANY
Komfovent GmbH Konrad-Zuse-Str. 2a, 42551 Velbert, Deutschland Tel. +49 0 2051 6051180 info@komfovent.de www.komfovent.de

LATVIA
SIA Komfovent Bukaisu iela 1, LV-1004 Riga, Latvia Tel. +371 24 66 4433 info@komfovent.lv www.komfovent.lv
Vidzemes filile Alejas iela 12A, LV-4219 Valmiermuiza, Valmieras pagasts, Burtnieku novads Tel. +371 29 358 145 kristaps.zaicevs@komfovent.com www.komfovent.lv

PPU-LCHX_21-05