Technical instructions - ETT · Technical instructions for Operation & Maintenance 4 07/2015 A....

E n e r g i e T r a n s f e r t T h e r m i q u e

Technical instructions for Operation & Maintenance

A different c l imateEnvironmental control solutions

Version 07/2015

IMPORTANTThe validity of our guarantee is conditional upon compliance with these technical instructions as stipulated in ETT General Terms of Sales.Maintenance shall be performed by a specialised company. Special attention shall be paid to cleaning and replacing filters regularly.We hope that you will enjoy your ETT equipment and trust that it will provide you total satisfaction.

E n e r g i eT r a n s f e r tThermique

ContentsA. Maintenance intervals ........................................................................................4

B. Specific recommendations ................................................................................5

C. Specific operational recommendations .........................................................10

D. Controller operation .........................................................................................12

E. Diagnostics and troubleshooting support ......................................................13

Appendix 1. HÉOLAIR unit (adiabatic air washer) ..............................................17


407/2015

A. Maintenance intervalsPlease remember:

> Use the unit maintenance book provided by ETT to follow up and keep track of the maintenance operations described hereafter.

> The validity of ETT guarantee is conditional upon strict compliance with operation and maintenance instructions presented in this document.

> The application of operation and maintenance recommendations is essential to ensure units efficiency and durability.

Maintenance intervals: Q (Quarterly), H (Half-yearly), A (Annually)Operations: Q H AGeneral control:Check casing XClean siphons and condensate drain XRead operating time XCheck securities XVentilation:Clean or replace filters (48 mm thickness filters) XClean or replace filters (96 mm thickness filters) XCheck servomotors and dampers XCheck and clean fans turbines XCheck and tighten fans and motors pulleys (if applicable) XCheck fans bearings (if applicable) XGrease fans bearings or change grease cartridges XCheck fans rotation speed and air flow rates XCheck ventilation motors XCheck belts and belts tension (if applicable) XReplace belts (if applicable) XRead fans motors currents XCheck propeller fans (if applicable) XRead propeller fans motor currents (if applicable) XRefrigeration circuits:Control circuit tightness (unit load >2kg "A" >30kg "H" >300 kg "Q") X X XCheck refrigerant load and adjust if necessary XCheck compressor XSet compressor(s) parameters XCheck compressor(s) currents XCheck pressures: HP and LP XCheck temperatures: gas and liquid XCheck and clean refrigerant-to-air exchangers XCheck expansion valves XCheck 4-way valve(s) XHeating (if applicable):Check hot water coil XCheck water quality in hot water coilCheck 3-way valve operation XCheck electric heaters XCheck warm air heaters (50 to 400 kW capacity) XCheck warm air heaters (over 400 kW) X

507/2015


Maintenance intervals: Q (Quarterly), H (Half-yearly), A (Annually)Operations: Q H AHeat pipe (if applicable):Check heat pipe efficiency by measuring temperatures XControl heat pipe tightness XCheck heat pipe jack operation (if applicable) XClean heat pipe XRotary exchanger (if applicable):Check heat exchanger efficiency by measuring temperatures XControl brushes / gaskets tightness XCheck and clean heat exchanger XCheck heat exchanger drive motor XCheck heat exchanger belt XCheck bearing greasing (if not life-time lubricated) XReplace heat exchanger belt Every 3 yearsReplace heat exchanger bearing Every 5 yearsElectricity/Control:Check controller XSet clock XCheck setpoints XTighten electrical connections XCheck temperature probes XClean smoke detector head XReplace smoke detector headNota: Maintenance intervals are given as an indication only. Replacement may be needed more regularly in polluted atmospheres.

Every 2 years

Replace smoke detection box battery Every 2 yearsReplace hygrometry probes (if applicable) Every 2 yearsReplace CO2 probes (if applicable) Every 2 years

B. Specific recommendations

1/ Heat exchangers cleaningIf necessary, clean the heat exchangers using a stiff bristle brush, a vacuum cleaner or a compressed air jet. Rinse with cold and low pressure water, avoid spattering water on the fan motor. Clean in counter flow of the air flow way.

2/ FiltrationPoor filtration or significant fouling can affect unit efficiency and damage the refrigeration circuit.

Nota:The filters referred to in the above table cannot be cleaned more than 2 or 3 times. Cleaning more times would dramatically reduce filtration performance.Filters should not be regenerated more than three times.If a filter cannot be regenerated, replace it.


607/2015

• Metal filters regeneration> Clean the filter with warm water and liquid detergent.> Rinse thoroughly and dry using compressed air or air current.> Re-treat filter media with "filter-coat" or a similar product, to restore original performance.> Check that filtering elements are correctly installed when reassembling.

• "Fabric" filters regeneration> Clean and dry as metal filters.> Reassemble in the support frame.

3/ Fan bearingsMost centrifugal fans in ETT units are equipped with life-time lubricated ball bearings which require no maintenance. However, bearings clearance must be checked.> For other fans equipped with lubricators, we advise you to check and add grease on a quarterly basis.> For your information, our fan bearings have an expected lifespan of 100,000 hours.

4/ Particularities of corrosive / saline atmospheres> Grease fan bearings and shaft monthly (whatever the type).> Check and clean fans monthly.> Clean heat exchangers with clear water

5/ Smoke detector head cleaningOperation must be controlled periodically, according to regulations applicable to the building. For type 1 detectors (S6), the secondary source must be controlled monthly by holding the "secondary source test" button for at least 5 seconds. The "power" indicator must remain switched on.

6/ Accessing the rotary exchanger (DX module and PACARE HPE+)The rotary exchanger is track-mounted to facilitate access.For interventions, open the access, dismount the angles and slide the rotary exchanger out.

! In accordance with installation instructions, The unit must be installed with sufficient lateral space to allow interventions.

707/2015


Rotary exchanger lateral space:

Loosen fixing angles

Teflon plate to slide the exchanger

Nota:Maintenance zone must be sufficient to fully slide out and access both sides of the heat exchanger. The following table indicates the minimum space required.

Unit Required lateral maintenance zone (in mm)CH 29-39-49 DX HPE+ 1350CH 59-69-79-99 DX HPE+ 1700CH 109-129-149 DX HPE+ 1850PACARE HPE+ 103 - 104 900PACARE HPE+ 203 - 204 1100PACARE HPE+ 207 - 208 1500PACARE HPE+ 210 - 225 1900PACARE HPE+ 260 - 285 2300PACARE HPE+ 2-235 - 2-295 2600


807/2015

7/ Condensing boiler module

1 - MaintenanceCorrect operation and regular maintenance (at least once a year) are the best way to ensure unit rational and efficient operation, low consumption and high durability.The unit must be cold and gas and power supplies must be cut before any maintenance operation. Maintenance operations must be performed by qualified personnel only.

Parts Maintenance operations

CC+ Module Control all securities operation and check all screws tightening.

Exhaust duct

Control fresh air intake ducts and smoke evacuation ducts.Ducts must be smoke-tight and corrosion-resistant.Water acidity after natural gas combustion is of 3.5-3.8 PH. The condensates neutralisation kit must be replaced yearly. ETT cannot be held responsible for any damage to equipment that has not been properly maintained.

Condensates evacuation (siphon) Check condensates evacuation siphon

Burner

Unplug electrodes, burner fan electrical connection, venturi tube / gas block.Dismount the gas injector from the gas block.Dismount the front plate / fan / combustion chamber venturi assembly.Clean the burner using a hand brush, a vacuum cleaner or a blow gun.Check the burner for damage or cracks on the surface. Replace the burner in case of damage.WARNING! Use a new gas gasket when reassembling the gas injector on the gas block.

Ignition / Ionisation

Control electrodes fouling and clean if necessary.Check the ignition electrode gap (4 +/- 0.5 mm) and the gap between the electrodes and the burner (8 +/- 1 mm).Check the sealing gasket. Replace if necessary.Check the ionisation current value. If ionisation current is lower than 3μA, check the ignition / ionisation electrode, the ignition line and earthing.

Heating element

Control the front plate gasket.Check the insulating part between the thermal exchanger front and back plates.Handle the plates with care.Any damaged or hard gasket must be replaced.Clean inside the heat exchanger using a hard brush (available as an option).

Expansion vessel

Do not open the expansion tank if it is still hot, severe burns may occur!Check level, with the unit stopped and cold!Fluid level should reach the cap.Fill with fluid with -20°C antifreeze, only if necessary.Warning: Use only antifreeze fluid specified by the manufacturer.

907/2015


Parts Maintenance operations

Pump

Control pump operation. Check the pressure sensor for potential pump fault.In a few cases of long-term interruption, the pump might need to be unjammed. In such case, switch off the unit, unscrew the pump cap, put a flat screwdriver through the hole and turn until completely unjammed.

Combustion

Measure O2/CO2 level and smoke temperature.Warning: regulations impose maximum values. Refer to your distributor or local organisations for more information.If the values indicated in the table below are not reached, the boiler requires complete maintenance

Type of gas Pressure when stopped

Pressure during operation

O2 with screw A high flow rate

O2 with screw B low flow rate

Maxi CO in PPMNG LPG

G20 (natural gas) 20 to 50 mBar mini 18 mBar 5% 6% 160 200G25 (natural gas) 25 to 50 mBar mini 20 mBar 5% 6% 160 200

G31 (LPG gas) 28 to 50 mBar mini 25 mBar 5% 6% 160 200

Control the flame through the lens. It must be stable, blue with orange particles around the burner (High Speed).During inspection, check that the analysis probe is hermetic at the sampling point, i.e. the probe end that is in the middle of the smoke evacuation flue.

2 - Recommendations to the user

2.1 - Safety rules- Never block smoke evacuation and fresh air suction.- Do not change the settings made by the qualified professional.- Do not touch hot and/or moving parts of the module.- Do not put any object on the unit or hang anything from it.- Power and gas supplies must be cut before any intervention on the unit.- Do not change the type of gas used, the unit settings, the security or control systems. It may

result in hazardous situations.- Contact the after-sales technician in case of change of gas, gas pressure or supply voltage.

2.2 - There is a problem. What should I do?Problem Solution

Gas smell Close the external gas valve and cut off the power supply.

Burner safety lock-outReset the burner from the control box.If the problem persists, please contact ETT Services.


1007/2015

C. Specific operational recommendations

1/ Refrigeration system logbook (EN 378-2):For equipment with refrigerant charges of 3 kg or over, the concerned party shall keep an up-to-date logbook of the refrigeration system.The logbook shall be prepared by the installer during installation. It shall be updated after every maintenance operation, as indicated in EN 378-4 standard.

The logbook shall include the following information:A. Detailed report of any maintenance or repair operationB. Quantity and nature (new, reused, recycled) of refrigerant added during the operation Quantity of

refrigerant transferred during the operation (see also EN 378-4 standard)C. Results of reused refrigerant analysis (if such analysis was performed)D. Reused refrigerant originE. System components replacement or modificationF. Routine or periodic tests resultsG. Significant non-use periods

2/ Refrigerant handlingRefrigerant handling must comply with French Decree no. 2007-737 and European legislation:- Operators must be trained and must hold the relevant F-gas qualification- The company employing the operator must hold an F-gas Company Certificate- Refrigerant leaks must be handled and declared according to the installation refrigerant charge

3/ Unit temporary shutdown

A. Stop the unit.B. If the unit is installed in an area where the temperature is likely to fall below 0°C, do not shut off power

to the evaporator crankcase heater (air-to-water, water-to-water heat pump) or to the line heaters. This operation may be handled automatically.

4/ Start-up after temporary shutdownNo special precautions are required. To start the unit, reverse the procedure outlined in paragraph "C3 Unit temporary shutdown".

! Caution: Special precautions must be taken for refrigerant handling. Please follow the recommendations of the refrigerant supplier.

1107/2015


5/ Unit seasonal shutdownA. If the heat pump includes water circuits, drain them. Also drain the connection lines if the unit is

installed in an area where the temperature is likely to fall below 0°C.B. Open the main power switch. Remove the fuse block or lock the main switch in opened position.C. If the heat pump is installed in an area subject to condensation, you may spray oil on mechanical

parts which are likely to rust (fan bearings, pulleys, etc.).

6/ Seasonal start-upA. Perform annual maintenance operations (refer to the table in paragraph A. Maintenance intervals).B. Fill the water circuits and bleed the air out as necessary.C. Fully open the compressor discharge valve.D. Open the liquid line stop valve (if applicable).E. Control refrigeration circuit tightness.F. Switch on the main power switch.G. Acknowledge faults on the detection station (if applicable).H. Allow the compressor crankcase heaters to preheat (72 hours).I. Start the system.J. Check operation of all interconnected devices.K. Check oil level and operating pressures after 15 to 20 minutes of operation. Make sure that refrigerant

flows in a steady stream with no bubbles.

7/ Generating set - EJP (peak load reduction)Equipment powered by a generating set must be correctly stopped. Refer to the procedure detailed in paragraph "C3. Unit temporary shutdown".This can be managed manually or by programming the BMS according to feedback from your energy supplier if you have a peak load reduction agreement.Failure to take this precaution could result major damage to the unit or cause components to break (electrical components, compressors). In such circumstances, components are not covered by ETT guarantee.


1207/2015

D. Controller operation

1/ Starting or stopping the unit

Esc

on-off

Prg

Set

Help

Menu

?

89

ONOFF

alarm

enter

prg Press and hold the ENTER key for 5 seconds.

2/ Acknowledging faultsEsc

on-off

Prg

Set

Help

Menu

?

89

ONOFF

alarm

enter

prg

Press the ALARM key to view the fault.

Correct the fault on the corresponding component (reset smoke detector, fire thermostat or freezestat, activate thermal protection, etc.).

Esc

on-off

Prg

Set

Help

Menu

?

89

ONOFF

alarm

enter

prg

Press and hold the ALARM key for 5 seconds to acknowledge the fault.

3/ Access level 0 - User settingsAccess to: - Setpoints - Operating schedule - Clock setting

Esc

on-off

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Set

Help

Menu

?

89

ONOFF

alarm

enter

prg

Hold the UP and DOWN arrow keys simultaneously for 2 seconds.Password = 0

Esc

on-off

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?

89

ONOFF

alarm

enter

prg

Use the arrow keys to scroll through menus.

Esc

on-off

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?

89

ONOFF

alarm

enter

prg Press the ENTRER key to enter the selected menu.

Esc

on-off

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89

ONOFF

alarm

enter

prg

Use the arrow keys to scroll through the masks.

Esc

on-off

Prg

Set

Help

Menu

?

89

ONOFF

alarm

enter

prg Press the ENTER key to access mask setpoints.

Esc

on-off

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Set

Help

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?

89

ONOFF

alarm

enter

prg

Use the arrow keys to select the setpoint to edit.

Esc

on-off

Prg

Set

Help

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?

89

ONOFF

alarm

enter

prg Press the ENTER key to access the setpoint.

Esc

on-off

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Set

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89

ONOFF

alarm

enter

prg

Use the arrow keys to adjust the setpoint.Esc

on-off

Prg

Set

Help

Menu

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89

ONOFF

alarm

enter

prg

Press the ESC key to return to the main mask

1307/2015


4/ Access level 1 - MaintenanceAccess to: - Maintenance - Communication - Alarms history - Energy meter - Inputs - Outputs - Meter reset

Esc

on-off

Prg

Set

Help

Menu

?

89

ONOFF

alarm

enter

prg

Hold the UP and DOWN arrow keys simultaneously for 2 seconds.Password = 1

Esc

on-off

Prg

Set

Help

Menu

?

89

ONOFF

alarm

enter

prg

Use the arrow keys to scroll through menus.

Esc

on-off

Prg

Set

Help

Menu

?

89

ONOFF

alarm

enter

prg Press the ENTRER key to enter the selected menu.

Esc

on-off

Prg

Set

Help

Menu

?

89

ONOFF

alarm

enter

prg

Use the arrow keys to scroll through the masks.

Esc

on-off

Prg

Set

Help

Menu

?

89

ONOFF

alarm

enter

prg Press the ENTER key to access mask setpoints.

Esc

on-off

Prg

Set

Help

Menu

?

89

ONOFF

alarm

enter

prg

Use the arrow keys to select the setpoint to edit.

Esc

on-off

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Set

Help

Menu

?

89

ONOFF

alarm

enter

prg Press the ENTER key to access the setpoint.

Esc

on-off

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Set

Help

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?

89

ONOFF

alarm

enter

prg

Use the arrow keys to adjust the setpoint.Esc

on-off

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Help

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ONOFF

alarm

enter

prg

Press the ESC key to return to the main mask

E. Diagnostics and troubleshooting support

1/ Smoke fault

Possible reasons Corrective actions

Smoke detection- Check for smoke or dust- Clean detector head- Replace detector head - Acknowledge the fault (see D.2)

Fouled detector head- Check for smoke or dust- Clean detector head- Replace detector head - Acknowledge the fault (see D.2)

Backup battery out of service - Replace battery


1407/2015

2/ Filter faultPossible reasons Corrective actions

Fouled filters - Clean filters- Replace filters

Fouled exchangers - Clean exchangers according to the recommendations

3/ Air flow faultPossible reasons Corrective actions


Leak on air network - Repair air distribution network

Transmission problem - Set transmissions

Fouled air network - Clean air distribution network

4/ Fire faultPossible reasons Corrective actions

Insufficient air flow - Check filters- Check fan and fan motor

Transmission problem - Check transmission

Faulty thermostat - Check thermostat

5/ Antifreeze faultPossible reasons Corrective actions

Insufficient air flow - Check filters- Check fan and fan motor

Transmission problem - Check transmission

Faulty thermostat - Check thermostat

Lack of hot water - Check boiler house and pump

6/ Drives faultPossible reasons Corrective actions

Current fault - Check power supply network for disturbances

1507/2015


7/ Low pressure faultPossible reasons Corrective actions

Poor air flow - Refer to E3. Air flow fault

Low pressure switch malfunction - Check pressure switch operation- Check pressure switch connections


Expansion valve malfunction - Check expansion valve (status, settings, operation)

Inefficient defrosting- Check refrigeration circuit probes- Check 4-way valve- Check defrost settings

Refrigerant charge problem - Check tightness

8/ High pressure faultPossible reasons Corrective actions

Poor air flow - Refer to E3. Air flow fault

High pressure switch malfunction - Check pressure switch operation- Check pressure switch connections


Outside T° out of application range - No action

Poor air distribution - Check air distribution network

9/ Refrigeration circuit fault

A. The compressor does not start.Possible reasons Corrective actions

Electrical protection fault - Check protections

Control security- Check control parameters- Check securities- Reset controller if authorised

Abnormal supply voltage- Check phases- Check voltage drop at unit start-up- Check power supply chain (wire, connections, contactor, etc.)

Propeller fault - Check propellers


1607/2015

B. The compressor stops.Possible reasons Corrective actions

Low pressure fault - Refer to E7. Low pressure fault

High pressure fault - Refer to E.8 High pressure fault

Ipsotherm fault- Check compressor cooling- Check ipsotherm probe- Check filters for fouling

Thermal fault - Check compressor's absorbed current- Check voltage drop at start-up

Power supply chain interruption Check power supply chain (wire, connections, contactors, etc.)

Propeller fault - Check propellers

C. The compressor is noisy.Possible reasons Corrective actions

Knocks - Check compressor suction pressure- Check valves status

Slugging - Check overheating- Check expansion valve bulb fixation

Grunts- Check supply voltage- Check phases- Galling => broken part

D. The compressor does not stop.Possible reasons Corrective actionsTemperature setpoint too far from recommended temperatures - Check temperature setpoints

Stuck contactor - Check contactor

E. Lack of capacity.Possible reasons Corrective actions

The expansion valve hisses - Check expansion valve settings- Check charge

Severe overheating - Check expansion valve settings- Check charge

Pre-expansion - Check drier filter

Wrong flow rates - Check flow rates

1707/2015


Appendix 1. HÉOLAIR unit (adiabatic air washer)Maintenance operations must comply with the following instructions from the supplier (MUNTERS).

1/ Dispensing orifices cleaning1- Before cleaning, shut off water supply and open the drain valve to empty the tank.

2- Remove the pipe connected to the distribution header.

3- Turn the distribution header lock a quarter turn to open it. This lock holds the header into position during operation.

4- Remove the distribution header from its support, on the front of the humidifier.


1807/2015

5- Clean the dispensing orifices as follows:Method 1: Connect the distribution pipe to a pressured tap water system and rince it. In most cases, the results are satisfactory.Method 2: Remove end caps. Turn the distribution tube to remove it. You can now see the dispensing orifices. Clean the orifices using a pointed tool and rince the inside of the distribution pipe.

6- Reverse this procedure to reassemble.

2/ Pump tank and filter cleaning1- Remove the end plate above the pump filter and take out the filter. Clean the filter.

2- Clean the bottom of the tank. Wash it and make sure that there is no dirt left.

1907/2015


3/ Restarting1- Close the bottom valve.

2- Check and adjust the tank water level by screwing the float. The level must be approximately 5 mm below the overflow protection.

3- Switch on the pump circuit breaker.4- Check that the distribution header's pressure locks are in the locking position. Press the locks to lock

them.

5- Check the drain rate.


2007/2015

4/ Cassettes and eliminator plate dismounting (during mat replacement only)1- Remove the distribution header as indicated in the pictures 9 to 11.2- If an eliminator plate is installed, remove it as indicated for cassettes in pictures 17 or 18. Handle the

cassettes with care to avoid damaging the GLASdek material. Use the metal frame to insert, remove or lift the cassette.

3 a- If you need to remove cassettes from the side, first lift the guillotine.

3 b- You may also remove cassettes from the back, in the air flow way.

www.ett.fr56 Route de Brest - BP26 - 29830 PLOUDALMEZEAU - FranceTel: +33 (0)2 98 48 14 22 - Fax: +33 (0)2 98 48 09 12Export Contact: +33 (0)2 98 48 00 70 - ETT Services: +33 (0)2 98 48 02 22

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A different c l imateEnvironmental control solutions

E n e r g i e T r a n s f e r t T h e r m i q u e

Technical instructions - ETT · Technical instructions for Operation & Maintenance 4 07/2015 A....

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