400895 Topvex FR Operation and Maintenance
Contents
1. Actual Only visible if the unit is Setp configured for Pressure control VAV Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 12 Systemair Inc Pressure Set the external pressure set control EAF point for normal speed 1 1 and reduced speed 1 2 for the Setp 1 1 1 0 supply air fan in wg Setp 1 2 0 4 in wg Outdoor Set the EAF pressure comp Setp 1 compensation for the settable outdoor temperature The 4 C 0 in wg outdoor compensation is linear and is set using two parameter 50 C 0 in wg pairs which give the value of the compensation at two different Act Comp 0 outdoor temperatures The in wg compensation can be positive or negative Shows The actual pressure compensation gt Timer normal Set week schedule Monday to speed Sunday Holiday for normal speed Possible to set 2 periods per day 00 00 24 00 for continuous running 00 00 00 00 inactivates the period Note the settings in the commissioning record gt Timer reduced Set week schedule Monday to speed Sub menu item 1 Sub menu item 2 Explanations 00 00 24 00 for continuous running 00 00 00 00 inactivates the period Note the settings in the commissioning record Sunday Holiday for reduced speed Possible to set 2 periods per day gt Extended Extended Set the time extended running running running Digital inputs can be used to force the unit to start or increas2. Cleaning extract louvers and X supply air diffusers 1 Or in accordance with local rules and regulations Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 22 Systemair Inc ee systemalr 5 3 Maintenance Instructions 5 3 1 Changing Supply Extract Air Filter The bag filter cannot be cleaned and must be changed when necessary New filters can be ordered from Systemair Operation time between filter changes depends on the air pollution at the installation site A differential pressure switch indicates when it s time to change the filters This will trigger an alarm in the control panel When this occurs do the following 1 Replace the filters with new ones as described below 2 Acknowledge the alarm by pressing the red button on the control panel pos 1 figure 4 followed by OK pos 4 figure 4 3 Choose sAcknowledge by pressing OK The filters are taken out according to the below procedure 1 Release the filter frame by pulling the filter support bars 2 Tilt the support bars to the back It is now possible to fold the filter and frame backwards This is especially important it there i is lack of space in front of the unit and the sliding door kit is used 1 The filter can now be taken out of the unit Topvex FR800 FR1600 FR3800 Operation
3. degrees above the set frost PDO alarm default alarm limit is 45 F P band active A 9 ier Fast stop Set the fast stop of the unit in aE FrOSE case of frost protection alarm to protection Yes OrNo alarm Mes Control flow Alternatively Pressure control is chosen in the configuration of the unit from factory Flow control Set P band l time and Min SAF output for the supply air fan when the unit comes configured P band as Flow control from 5885 8 GEM factory Alternatively Pressure control is that configuration is I time 10 0 chosen Sec IMBDUa s UnETSUIER 0 Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 16 Systemair Inc systemair Sub menu item 1 Sub menu item 2 Explanations Flow control EAF Domos 5885 8 CFM I time 10 0 sec IMGLigl XEUEISXPNE B Set P band l time and Min output for the Extract air fan when the unit comes configured as Flow control from factory Alternatively Pressure control is that configuration is chosen OS gt Alarm Alarm limits Set the alarm limits and allowed settings deviations for the different functions Save user settings No 5 Configuration Ee onis Controli function iEUIONEIE LOM Mode Room control gt Free cooling Free cool active No Outd temp activation TL Ge Alarm delays Set the alarm delays and allowed deviation delays for the different functions Restore factory In this
4. Description of electrical components Note For pre heater components please refer to the HWC EPH Installation Instructions manual 420353 Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 5 Systemair Inc e299 ts Systemalr 3 Interface Description 3 1 Control Panel The SCP control panel is delivered with a 32 ft 10 m cable that is connected to the panel and with a fast coupling contact connected to the Topvex unit The contact is connected to the Corrigo controller in the electrical connection box pos 1 figure 3 The cable can be unscrewed in the back of the control panel figure 4 3 1 1 Operating the control panel Fig 4 The control panel Table 3 Description of Control panel and wire connection Position Explanation Alarm button Gives access to the alarm list Alarm LED Indicates alarm by flashing red light Write LED Indicates by flashing yellow light that parameters can be set or changed 4 OK button Press this button to be able to change or set parameters whenever possible Also used to move between chargeable parameters in one dialogue window frame Cancel button Used to abort a change and return to the initial setting Right Left amp Up Down buttons Used to move up down left amp right in the menu tree Up Down buttons are also used to increase values when setting or changing parameters e conection bl
5. 1 Before starting the system 4 2 Initial setup of the nllo tee eret eet Al a it eae 4 3 Menu overview Operator Service level eerie etienne tinnitus etit thea pit nae D acad npe d 9 4 4 Free cooling description cocci trice Idee ee Ee eR SED eue dex Eo LE RU ee ee nee 20 AD CoolingTeCOVery ee tirer iE eid ite utet eed it v det etti erreichen 21 4 6 Exchanger frost preventi ssnin nce veta ee nbn ena an eo dr Lee eA aa Eai 21 ule 22 Bec L 22 5 2 Maintenance Ifitervals 2 ter tree EP haven eh Rene true iate Rene beside a per r EEEa 22 9 3 MainteManCe MSCONS T 23 5 3 1 Changing supply extract ali filter 12 tenia cce decet Litres ce bet hadi 23 5 3 2 Checking the heat exchanger uoo oen tinto itome ru tre t insandi aa ienke 24 99 9 CHECKING The Talis ino rote etre re De Ee En ree ici e t ee e Deren sd 26 5 3 4 Checking the hot water heating coil senem nennen 26 5 3 5 checking the electicalheater iiri iiia ide nde Ca e EORR FOE ER deed 26 5 3 6 Cleaning extract louvers and inlet diffusers sssssseee em 26 5 3 7 Checking the outdoor air Intake c eerte nente eret chr dnte nete eene iren 26 5 3 8 Checking the duct System cec ete erret reti te en ere Eee dr teet prep ae Rer Ee dede 27 5 3 9 Changing the internal battery in the corri
6. Active No EAF running during Support Gomer 3 Wes Min run time EON NN Serle 60 meim Set the upper outdoor night temperature limit for the activation of the free cooling function Set the lower outdoor night temperature limit for the activation of the free cooling function Set the lower room temperature limit The temperature needs to be above this value for the free cooling function to stay active Set the start and stop time for the free cooling function For example Start 0 and STOPLE means that the free cooling sequence is active between 00 00 and 06 00 h Set the delay in minutes from the time where the free cooling sequence has stopped until a possible heating sequence is initiated i e how long a cooler room temperature than set temperature can be accepted Set the fan speed in percentage of the normal speed for each fan individually during the free cooling sequence Set the outdoor sensor is placed in the intake duct or not Choose between No and Yes Preset is No When using the control function room control or extract air temperature control it is possible to utilize support heating and or support cooling Minimum running time is settable 0 720 minutes factory setting 20 minutes Choose between Active yes or No For start and stop E see the Temperature menu Set the minimum running time in minutes for support control Topvex FR800 FR1600 FR3800
7. Both electric heaters have automatic and manual overheating protection The manual overheat protection is reset by pushing the reset button on the electrical see figure 3 Both electric pre heater and re heater function outputs are modulated by the unit control in order to maintain their respective air temperature set points For Topvex FR800 1600 units without pre heater an electric heater can be equipped inside the unit See HWC EPH Installation Instructions manual 420353 for correct procedure Make sure that the Main power supply to the unit is disconnected before performing any maintenance or electrical work All electrical connections must be carried out by an authorized installer and in accordance with local rules and regulations Fig 2 Reset of the manual overheat protection in Topvex FR800 1600 Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 4 Systemair Inc ee systemalr 2 3 Internal components Electrical connection box Make sure that the Main power supply to the unit is disconnected before performing any maintenance or electrical work All electrical connections must be carried out by an authorized installer and in accordance with local rules and regulations Note Electric heater section Present in EL units Fig 3 Electrical components only Table 2
8. HW units E COT 2 Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 2 Systemair Inc ee systemalir 2 2 Description of Internal Components 2 2 1 Supply and Extract Air Fans The fans have external rotor motors of EC type which can be steplessly controlled individually 0 100 It is possible to program the speed in 2 steps normal reduced depending on the programming of the week schedule The motor bearings are life time lubricated and maintenance free It is possible to remove the fans for cleaning chapter 5 2 2 1 1 Pressure Transmitter Two pressure transmitters maintain the airflow at a constant level by measuring the differential pressure over the inlet cone of the fan impellers pos 11 figure 1 The pressure transmitters are installed from factory in all units with CAV control In VAV units the pressure transmitters will not be mounted in the unit from factory Instead they will be delivered with the unit to be mounted in the supply and extract air ducts see Installation instructions for more information concerning VAV installations 2 2 2 Outdoor and Extract Air Filters and Pre Filter only whit units with pre heater The filters are of bag filter type with filter quality MERV13 for the outdoor air filter and MERV9 for the extract air filter The filters need to be replaced when dirty New sets of filters can be acquired from your installer or wholesaler The pre filter s is of a
9. Noise vibrations Check if the unit is completely leveled Check if fans and or exchanger need to be cleaned Check if the screws holding the fans are tightened properly 5 4 1 Alarms The alarm button pos 1 figure 3 opens the alarm queue When pressing this button active and non acknowledged alarms will be displayed in the menu window The alarm LED pos 2 figure 4 will flash if there are non acknowledged alarms and be on but not flashing if the alarms are still active but have been acknowledged If there are multiple alarms use UP DOWN to move between them An alarm can be acknowledged or blocked by using OK and UP DOWN To abort and go back to start menu press cancel and then press LEFT See Commissioning record for an overview of possible alarms Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 28 Systemair Inc systema 6 Service Before calling your service representative make a note of the specification and production number from the type label figure 6 Ir Model TR1800EL 208 3 CA 460 Item 42680 e Serial 1234567 1234A 001 OA 2 Voltage 208 230 VAC 60 Hz 3 Phase M C 155865 Fan Motors 2 2 7A each Type TR1800EL MCA 348A MADE IN CANADA MOP 55A DOM Jan 09 2013 Systemair EPH TR1800 Preheater installed MCA wiPreheater 57 6A MOP wiPreheater 80A Maximum d inwg Minimum Airflo Operating Temperature Bt we ji 419 F 104F Minimum e minimum 1 inch 1
10. air is colder than the outdoor air and cooling is required the heat exchanger control is reversed in order to return the cool extract air Note The following is only valid if the cooling recovery function is set to Active inthe program menu 4 6 Exchanger Frost Prevention If the exhaust air temperature falls below the frost threshold of the unit the exchanger frost prevention function will be triggered and the unit will cycle between ventilation mode and the selected type of frost prevention mode in order to prevent any frost build up within the unit Types of frost prevention mode Exhaust only During exhaust only frost prevention the supply fan will shut down and the outdoor air damper will close interruption of the cold outdoor airflow The unit will keep extracting warm air for a defined period of time preventing any frost build up before going back to normal ventilation mode Recirculation There are 3 different recirculation configurations First is a 5th port configuration with continuous exhaust set to NO Second is a 5th port configuration with continuous exhaust set to YES in order to maintain an uninterrupted rate of exhaust The last option is an H Type configuration where the unit exhaust air is recirculated through the supply stream continuous exhaust has to be set to NO for this configuration These configurations require a dedicated recirculation damper interlocked with the outdoor air damper in order that a
11. and Maintenance Instructions 23 Systemair Inc e239 systemalr 4 Changing pre filter only when pre heater is installed A EL Pre Heater B HW Pre Heater 5 Insert the new filter and fasten it against the inlet seal with the filter support bars Make sure the filter is fitted tight all around the frame 5 3 2 Checking the Heat Exchanger After a long time of use dust may built up in the exchanger pos 5 figure 1 and block the air flow It is important to clean the exchanger regularly to maintain high efficiency The total heat exchanger in the Topvex FR800 3800 can be taken out of the unit Wash in hot soapy water or use pressurized air Do not use detergent containing ammonia Note Make sure that the rotor motor is not exposed to moisture 5 3 2 1 Dismounting the Heat Exchanger Block on Ceiling Mounted Units 1 Remove the exchanger cover plate in the centre of the unit by unscrewing the 4 screws in the corners of the plates Removing the plate is only possible after opening both inspection doors 2 There are 4 screws 2 on each side holding the heat exchanger block FR3800 model has 8 screws 4 on each side When removing the heat exchanger start with checking that the screw marked A is tightened properly Remove the screw marked B completely as shown in the figure after which the screw marked A is loosened carefully just enough to allow the exchang
12. po Thermally protected motors Moteurs muni de protection thermique For indoor use Pour utilisation interieur Reheater Capacity 9 0 kW 208 VAC 10 0 kW 230 VAC Preheater Capacity 9 0 kW 208 VAC 10 0 kW 230 VAC MFG BY Systemair Inc 50 Kanalflakt Way Bouctouche NB CANADA E4S 3M5 r QU anc N gt N ee Sore e ee Fig 6 Type label Table 5 Label description Model number Date of manufacturing DOM Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 29 Systemair Inc Systemair Inc reserves the right to make changes and improvements to the contents of this manual without prior notice systemair Systemair Inc 50 Kanalflakt Way Bouctouche NB E4S3M5 Canada Phone 1 519 550 3307 10048 Industrial Blvd KS 66215 United States Phone 1 517 648 3307 www systemair net
13. screen type and can be cleaned by using soap water or compressed air It can be acquired from installer or wholesaler 2 2 2 1 Pressure Guard Filters A pressure guard measures the differential pressure over the supply and extract air filters pos 10 figure 1 When the pressure drop reaches the set value an alarm is triggered in the main controller The differential pressure can be set between 0 2 in wg 40Pa and 1 2 in wg 300 Pa The pressure switch is preset from factory to 1 0 in wg 240 Pa 2 2 3 Heat Exchanger Topvex FR models are equipped with a highly efficient belt driven rotating heat exchanger Required supply air temperature is therefore normally maintained without adding additional heat The operation of the heat exchanger is automatic and depends on the set temperature The heat exchanger is removable for cleaning and maintenance Chapter 5 2 2 3 1 Rotor Motor The rotor motor drives the exchanger rotor with a constant rotational speed as long as there is a heat demand The motor is controlled by an on off control signal pos 6 figure 1 2 2 3 2 Rotation Sensor A sensor registers the rotation of the heat exchanger rotor It s connected to the main regulator which gives an alarm if the rotor stops while there is a heat demand pos 12 figure 1 2 2 4 Temperature Sensors 5 temperature sensors PT1000 are included in the unit from factory Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructio
14. there will be no need to reload the program and the clock will continue to run normally The replacement battery must be of the type CR2032 Danger e Make sure that the Main power supply to the unit is disconnected before performing any maintenance or electrical work 1 Remove the cover by pressing down the locking torques at the edge of the cover using a small screwdriver and at the same time pulling the edges outwards 2 Grip the battery firmly with your fingers and lift it upwards until it rises from its holder Press the new battery firmly down into place Note that to preserve correct polarity the battery can only be inserted the right way round Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 27 Systemair Inc 08 e ts Systemalr 5 4 Troubleshooting Should problems occur please check or correct the following before contacting your service representative Always check if there are any alarms active in the control panel See section 4 3 to learn how to navigate through the control panel menu For more information on the alarm designations go to the Systemair website www systemair com na North America and download the controller user manual 1 Fan s do not start Check if there are any alarm messages Check if the automatic fuse AS1 is tripped figure 3 pos 8 Check if fan s thermal contact is tripped due to overheating shows as Fan alarm in the contro
15. wash in hot soapy water if required Diffusers louvers must be put back with their original settings and positions in order not to unbalance the system 5 3 7 Checking the Outdoor Air Intake Leaves and other debris could plug up the air intake grille and reduce the unit s capacity Check the air intake grille at least twice a year and clean if necessary Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 26 Systemair Inc ee Systemair 5 3 8 Checking the Duct System Dust and grease settlements may build up in the duct system even if filters are changed regularly This will reduce the efficiency of the installation The ducts should therefore be cleaned changed when necessary Steel ducts can be cleaned by pulling a brush soaked in hot soapy water through the duct via diffuser louvre openings or special inspection hatches in the duct system if fitted 5 3 9 Changing the Internal Battery in the Corrigo Controller Note This procedure requires knowledge of proper ESD protection i e an grounded wristband must be used When the alarm Internal Battery is activated and the battery LED lights up red the battery for backup of program memory and real time clock has become too weak The battery is replaced as described below A backup capacitor saves the memory and keeps the clock running for at least 10 minutes after the power supply is removed Therefore if the battery replacement takes less than 10 minutes
16. 18 Operation and Maintenance Instructions Systemair Inc COZ NOE Control 2 Humidity Exchanger frost prevention ET Coolng recovery C02 VOC active Never type Fan Min time 60 min Activation level 1 2 speed ppm 800 1 2 speed 1000 ppm lu dE E Humidity control 160 ppm Not active Skar TE libb 15 Stoo ames 5 Mode OEE Type Recirculation Continue exhausting during recirculation NO Cooling recovery No Coolsing EE 35 669 Log on Enter password XXXX Actual level None In applications with varying occupancy the fan speeds can be controlled by the air quality as measured by C02 VOC sensor See encl corrigo manual CD for det explanation Setactive to Never Always OrIf time channel off Set what should be regulated Select type Fan Set the min time the unit is activated by the C02 VOC demand function Set the activation level as 1 2 speed Set the activation level as 1 1 speed Set allowed diff value Set the humidity control to Humid Dehumidification Dehumidification Humidification or Not active Set the start limit and stop limit in RH Applicable for external Humidification or Dehumidification device Set mode to ON or OFF Set Type to Recirculation or Exhaust Only Set exhaust air fan and exhaust air damper operation for recirculation to Yes or No Set the cooling recovery to Yes Or No Set the co
17. EL Start screen headline 2011 03 15 9 00 Can be set to 5 different layouts System Stopped Changeable at system level under the configuration menu Sp 18 0 Act F gt Running mode gt Running mode Running mode Set running mode to Auto On or Off Auto Running time Shows the time in hours that motor have been operating SAF 0 0 h SAF Supply air fan EAF 0 0 h EAF Exhaust air fan gt Selected Control Shows type of air temperature function function control the unit is configured for Extract air Shows type of fan speed control control the unit is configured for Fan control Flow control Heating Water Shows type of heating selected Exchanger Shows type of exchanger Rot Excha selected Cooling Water Shows type of cooling selected Free rca Shows the status of the free active cooling function control function Shows the status of the demand ventilation CO2 VOC function Fire damper Shows the status of the fire function damper function Not active Operation when Stopped Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 9 Systemair Inc Sub menu item 1 Sub menu item 2 Explanations Frost protection Active Cooling recovery o ot active mE a mE No External set point Shows the status of the frost protection function Shows the status of the cooling recovery function Shows the status of the external set poin
18. R3800 Operation and Maintenance Instructions 11 Systemair Inc Flow control Set the normal 1 1 and EAF reduced 1 2 airflow for the extract air fan Setp 1 1 647 4 CFM Setp 1 2 323 7 CFM Outdoor Set the EAF airflow comp Setp 1 compensation for the settable outdoor temperature The 4 F 5 9 CFM outdoor compensation is linear and is set using two parameter 32 F 0 CFM pairs which give the value of the compensation at two different Act Comp 0 outdoor temperatures The CFM compensation can be positive or negative Shows The actual airflow compensation Pressure Shows the actual external control SAF pressure and set point for the supply air fan Actual in wg Only visible if the unit is Setp in wg configured for Pressure control VAV Pressure Set the external pressure set control SAF point for normal speed 1 1 and reduced speed 1 2 for the Setp 1 1 0 6 supply fan in wg Setp 1 2 0 4 in wg Outdoor Set the SAF pressure comp Setp 1 compensation for the settable outdoor temperature The 4 F 0 in wg outdoor compensation is linear and is set using two parameter 50 C 0 in wg pairs which give the value of the compensation at two different Act Comp 0 outdoor temperatures The in wg compensation can be positive or negative Shows the actual pressure compensation Pressure Shows the actual external control 1 pressure and set point for the extract air fan
19. chedule for reduced speed It s possible to set 2 periods per day 7 Set the weekend and holiday schedule for reduced speed It s possible to set 2 periods per day 8 Select Yes or No systemalir ormal speed onday gt Friday 07 00 16 Per 1 Per 2 00 00 00 Normal speed Saturday gt Holiday 00 00 00 Per 1 Per 2 00 00 00 Reduced speed onday gt Friday 00 00 00 Per 1 Per 2 00 00 00 Reduced speed Saturday gt Holiday 00 00 00 Per 1 Per 2 00 00 00 End Wizard No After finishing the setup the menu system for Operator level will be available See below menu overviews that display the available menus in the Operator level followed by the Service level manual To enter Service level use code 2222 in the Access rights menu For Operator level use code 1111 Note To perform more advanced settings please see the enclosed CD where the Corrigo E manual can be found Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions Systemair Inc s Systemair 4 3 Menu overview OPERATOR SERVICE LEVEL The menu overview below shows both the Operator and Service level The overview of the parts unique to the Service level in the table below are marked with grey background color To logon to the Service level use code 2222 under Access rights Sub menu item 1 Sub menu item 2 Explanations FR 800
20. e 60 min to Normal running although the timer says the running mode Time in ext should be Off or Reduced running If the running time is set to 0 0 min the unit only runs as long as the digital input is closed The time the extended running is active is monitored in Time in ext Running It s also possible to set here as well in order to shorten the initial Set period Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 13 Systemair Inc Sub menu item 1 Sub menu item 2 Explanations gt Holidays Holidays mm dd 1 01 01 01 02 2 09 04 09 10 3 01 05 01 05 Set up to 24 separate possible holiday periods for a full year A holiday period can be any number of consecutive days from one and upwards The dates are in the format MM DD When the current date falls within a holiday period the scheduler will use the setting for the weekday Holiday gt Manual Auto In this menu the running mode of all the configured output signal and a number of control functions can be manually controlled The supply air controller s output signal can be manually set Manual Auto to any value between 0 and 10096 The temperature output signals will change accordingly if they are in Auto mode It is also possible to manually control each of the temperature output signals individually Since leaving any of the outputs in manual control will disrupt the normal control an alarm will be generated as
21. ed Extended running normal and External stop are off The timer channel will be On sometime during the recently started 24 hours The unit checks the night temperature indoor and outdoor temperature during 3 minutes at the set starting hour when the fans are started so that the sensors can perform a temperature measurement If above conditions are met the free cooling function is started if not the unit goes back to OFF position If the outdoor sensor is not located in the outdoor air inlet duct and a room sensor has been selected the unit will not start free cooling as long as all the temperatures are not within the start and stop temperature intervals Stop conditions Outdoor temp above the set max value 64 4 F 18 C or below the set min value condensation risk 50 F 10 C The room temp extract air temp is below the set stop value 64 4 F 18 C One of the timer outputs for normal speed External stop or External running normal is On The time has past 07 00 00 When free cooling is active the fans run at normal speed or the set value for pressure flow control and the digital output Free cooling is active The outputs Y1 Heating Y2 Heat exchanger and Y3 Cooling are shut down After free cooling has been activated the heating output is blocked for 60 minutes configurable time Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 20 Systemair Inc 4 5 Cooling Recovery If the extract
22. er frame to slide in the tracks Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 24 Systemair Inc 3 Slide out the exchanger block until the end of the tracks The heat exchanger block is heavy Use proper support device when taking out the heat exchanger block for maintenance 4 After finished cleaning maintenance push the heat exchanger block and fasten all screws tightly 5 3 2 2 Dismounting the Heat Exchanger Block on Floor Mounted Units 1 Loosen all screws completely holding the heat exchanger block 2 Remove the heat exchanger block completely by h lifting it straight up The exchanger block is heavy make sure to use B e proper support device or sufficient number of persons to lift the heat exchanger out of the unit Table 4 Weight of heat exchanger block Weight of heat exchanger block in Ibs kg FR800 66 30 FR1600 88 40 FR3800 146 66 Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 25 Systemair Inc 08 e ts Systemalr 5 3 3 Checking the Fans Even if the required maintenance such as change of filters is carried out dust and grease may slowly build up inside the fans pos 1 and 2 figure 1 This will reduce the efficiency The fans can be dismounted by loosening the 4 screws on the fan casing figure 5 Topvex FR1600 3800 have a fan support bracket that needs to be removed by loosen
23. go controller se 27 5 4 Troubleshoollilg 3 re te ertet Oden oerte Fete tpi e a aa a 28 E MENA LrtEM C 28 ISESI B E TRITT E E S E EAA E E E E E 29 1 Warning The following admonitions will be presented in the different sections of the document ONE Danger Make sure that the Main power supply to the unit is disconnected before performing any maintenance or electrical work All electrical connections must be carried out by an authorized installer and in accordance with local rules and regulations Although the Main power supply to the unit has been disconnected there is still risk for injury due to rotating parts that have not come to a complete standstill Beware of sharp edges during maintenance Use protective clothing This product is not intended to be used by children or people with reduced physical or mental ability or lack of experience and knowledge if no instruction concerning the use has been given by the person responsible for their safety or that this person is supervising the operation Children should be supervised so that they can not play with the product Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 1 Systemair Inc e239 t Systemalr 2 Product Description 2 1 Internal Components Topvex FR800 3800 OOOO Fig 1 Topvex FR components Table 1 Components descriptions EL and
24. he water heating coil Only visible for HW units Actual F Exhaust air Shows the actual exhaust air temp temperature Actual F Efficiency Shows the actual heat recovery efficiency Exchanger The function calculates the Actual heat exchangers temperature efficiency in when the output signal to the exchanger is higher than 98 and the outdoor temperature is lower than 50 F When the control signal is lower than 98 or the outdoor temperature is higher than 50 F the display will show 096 Air Control This menu option becomes visible if the unit is configured for Flow control or Pressure control Flow control Shows airflow for the supply air SAF fan constant airflow control Actual CFM Only visible if the unit is configured for Flow control Flow control Set the normal 1 1 and SAF reduced 1 2 airflow for the supply air fan Setp 1 1 647 4 CFM Setp 1 2 323 7 CFM Set the SAF airflow compensation for the settable outdoor temperature The outdoor compensation is linear and is set using two parameter pairs which give the value of the compensation at two different outdoor temperatures The compensation can be positive or negative Shows the actual airflow compensation Flow control Shows airflow for the extract air EAF fan constant airflow control Actual INF Only visible if the unit is CFM configured for Flow control Setp CFM Topvex FR800 FR1600 F
25. ing the 4 screws The fans may be cleaned with a cloth or a soft brush Do not use water A mild solvent can be used to remove obstinate settlements Allow drying properly before remounting Fig 5 Dismounting the fans 5 3 4 Checking the Hot Water Heating Coil After long periods of operation usually several years dust may have deposited on the surface of the coil This may reduce coil capacity The coil can be cleaned with a pressure washer with misting jets or with compressed air Cleaning should be carried out carefully so as not to damage the coil s aluminum fins Once a year the coil water circuit needs to be vented to maintain the coil capacity 5 3 5 Checking the Electrical Heater After a long period of time dust and pollutants can build up on the heating rods This can cause unpleasant odors and in the worst case fire Clean with compressed air vacuum or brush The heating power can be measured in the electrical connection box before the heating season The heater rods need to be measured to ensure there are no discrepancies in resistance between them The automatic safety function needs to be tested and verified 5 3 6 Cleaning Extract Louvers and Inlet Diffusers The system supplies treated outdoor air to the building and extracts the used indoor air via the duct system and diffusers louvers Diffusers and louvers are mounted in ceilings walls in bedroom living room wet rooms bathrooms etc Remove diffusers and louvers and
26. l panel Check the run status and the setting in control panel schedules auto manual operation airflow set points etc 2 Wheel motor does not start Check if there are any alarm messages Check if the automatic fuse AS1 is tripped figure 3 pos 8 Check if the fuses in the fuse holders F1 amp F2 are blown figure 3 pos 13 Check the run status and the setting in control panel schedule auto manual operation free cooling active etc 3 Reduced Airflow Check if there are any alarm messages Check the run status and the setting in control panel schedules auto manual operation airflow set points etc Check if outdoor exhaust air damper if used are opened Check if filters need to be changed Check if diffuser louvers are opened Check if diffusers louvers need cleaning Check if fans and or exchanger need to be cleaned Check for obstruction at the air inlets outlets Check ducts for visible damage and or buildup of dust and debris 4 Cold supply air Check if there are any alarm messages Check the supply air temperature set point on the control panel If electric re heater is equipped check if the automatic fuse AS2 is tripped figure 3 pos 9 If electric re heater is equipped check if the overheating thermostat is tripped If so see section 2 2 6 If hydronic re heater is equipped check if the valve s actuator s controlling the water flow are functioning properly Check if filters need to be changed 5
27. menu it is possible to restore all parameters to their settings No factory settings or to the user settings they were saved as Restore user earlier settings No Select Yes or No The current configuration can be saved in a separate memory area and can later be restored using the previous menu Restore user settings Select Yes Or No Set type of temperature control function you want the unit to operate under Choose between Hzerac otarre COMEZOIL Room control Outdoor Gio Suseillsy SUIgpls eave comeco Extract SUID V acus possible to switch between the two depending on outdoor temps Room supply air possible to switch between the two depending on outdoor temps Set free cooling active to Yes or No Set the lower outdoor day temperature limit for the activation of the free cooling function The temperature of the previous day needs to be over the set temperature in order activate the free cooling function Topvex FR800 FR1600 FR3800 17 Operation and Maintenance Instructions Systemair Inc Sub menu item 1 Sub menu item 2 Explanations pt E Support control Outd night temp aigas 59 07 kows 4 OF Room temp min 64 4 F Hour for start stop Free cooling Sear e a Stop Time to Block heat output after Free cooling 60 min Fan output when free cooling Outdoor sensor placed in intake channel intake duct No Support control
28. nctions fan control external control function etc How the unit is supposed to operate according to a weekly schedule normal and reduced speed 4 2 Initial setup of the unit On the first start up the controller will start a special program for setting language supply air temp set point Time amp Date and week schedule for normal speed Use the OK button to move between changeable parameters and the UP DOWN arrows to see the displayed alternatives Confirm by pressing OK once more Move on down in the menu structure by use of the UP DOWN arrows 1 Select language by pressing OK and then move between the alternatives with the UP DOWN buttons Confirm by pressing OK Move to the next level by pressing the DOWN button 2 Shows the supply air temperature setpoint Set the supply air setpoint Default is 64 F logon to service level needed code 2222 to change default setting 3 Ensure that correct time and date is displayed If not change the settings Choose Language English Supply Air Temp setp Time 12 46 Date 2010 03 12 Weekday Friday Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions Systemair Inc 4 Set the weekday Monday Friday schedule for normal speed It s possible to set 2 periods per day 5 Set the weekend and holiday schedule for normal speed It s possible to set 2 periods per day 6 Set the weekday Monday Friday s
29. ns 3 Systemair Inc Supply air sensor Extract air sensor Outdoor air sensor Exhaust air sensor Extra unit sensor 1 Only if pre heater is installed In Topvex FR800 3800 all temperature sensors are mounted and wired inside the unit except for the supply air sensor which is delivered uninstalled with the unit and needs to be installed in the supply air duct externally from the unit See Installation instruction for more detailed information 2 2 5 Hydronic Heater for FR800 3800 In units equipped with a hydronic pre heater the water coil is located next to the outside air connection The coil material is copper piping with a frame of galvanized sheet steel and aluminun fins Both pre heater amp re heater are equipped with a frost protection sensor Both hydronic pre heater and re heater function outputs are modulated by the unit control in order to maintain their respective air temperature set points For Topvex FR800 3800 units without pre heater and or re heater a heating water coil can be equipped inside the unit See HWC EPH Installation Instructions manual 420353 for correct procedure 2 2 6 Electrical Heater for FR800 1600 In unites equipped with an electric pre heater the heating rods are located next to the outdoor air connection In units equipped with a built in electric re heater EL units only the heating rods are located next to the supply air connection The heater material is stainless steel
30. ock 9 Connection oyelow able 3 1 1 1 Navigating the menus The start display the display normally shown is at the root of the menu tree Pressing DOWN will move you through the menu options UP will move you back through the options To enter a higher menu level Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 6 Systemair Inc use UP or DOWN to place the cursor at the menu you wish to access and press RIGHT If you have sufficient log on privileges the display will change to the menu you have chosen At each level there may be several new menus which you move through using UP DOWN Sometimes there are further sub menus linked to a menu or menu item This is indicated by an arrow symbol at the right hand side of the display To enter a menu press RIGHT again To step back to previous menu level use LEFT 4 Commissioning 4 1 Before Starting the System When the installation is finished check that The unit is installed in accordance with the installation instructions The unit is correctly wired Sound attenuators if used are installed and that the duct system is correctly connected to the unit Outdoor air intake is positioned with sufficient distance to pollution sources kitchen ventilator exhaust central vacuum system exhaust or similar All external equipment are connected The following data is available Intended configuration for example temperature control fu
31. oling limit the difference in temperature between extract air and outdoor air that activates the cooling recovery Log on to service level by entering a 4 digit code After reaching the desired level go back with LEFT arrow press 2 times on the control panel Standard code from factory to enter service level is 2222 Back to operator level 1111 Topvex FR800 FR1600 FR3800 19 Operation and Maintenance Instructions Systemair Inc Log off Log off from system level by changing No to Yes with the No OK and UP DOWN buttons Actual Automatic logoff after 6 minutes level None of inactivity gt Change Change password Set a new password for the level password for of your choice level None Can only be done once logged on to the service level New password XXXX 4 4 Free Cooling Description This function is used during the warm period to save energy by using cold outdoor air e g during night time to cool down the building Note The following is only valid if the free cooling function is set to Active in the program menu Free cooling is only activated when the following starting condition are met Starting conditions Less than 4 days have passed since the unit was last in running mode The outdoor temperature during the previous running period exceeded a set limit 71 6 F 22 C It is between 00 00 and 07 00 00 in the day settable The timer outputs for normal spe
32. per Outdoor air damper Set the outdoor damper to Auto Open orClose Auto Exhaust air damper Set the Exhaust air damper to Auto Open orClose Auto In this menu group the settings for the activated functions are available Depending on which choices have been made in the configuration menu some of the possible alternatives may not be displayed Fire damper Set the fire damper to Auto Open orClose Auto Note Needs to be activated in order Settings Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 15 Systemair Inc systemalir Sub menu item 1 Sub menu item 2 Explanations gt Control temp Supply air Set P band and l time for the control Supply air control function IP ISiumels Oz dE IT Note Iis 100 0 See Corrigo E ventilation sec manual for deeper explanation Room control Set P band and l time for the Room control function ie loxeunl Q2 Note I time 300 0 sec See Corrigo E ventilation manual for more info Shutdown mode Set P band and l time for the Shutdown function P lg eiiacl 3 91 4 F aaa Note I time 100 0 sec See Corrigo E ventilation manual for deeper explanation Eu ois P band active 41 F means that protection the frost protection controller will start overriding the heating Active output when the frost protection temperature is less than 41 Setp shutdown
33. s the outdoor air damper closes the recirculation path is opened and vice versa During recirculation frost prevention the outdoor air damper will close and the dedicated recirculation damper will open The unit will recirculate warm air for a defined period of time preventing any frost build up before going back to normal ventilation mode Note The following is only valid if the exchanger frost prevention function is set to Active in the program menu Topvex FR800 FR1600 FR3800 Operation and Maintenance Instructions 21 Systemair Inc 5 Maintenance 5 1 Important Make sure that the Main power supply to the unit is disconnected before performing any maintenance or electrical work All electrical connections must be carried out by an authorized installer and in accordance with local rules and regulations Although the Main power supply to the unit has been disconnected there is still risk for injury due to rotating parts that have not come to a complete standstill Beware of sharp edges during maintenance Use protective clothing 5 2 Maintenance Intervals The table below shows recommended maintenance intervals for the unit and the installation To ensure a long operation life of the unit it is important to perform maintenance according to recommendations below and that they are performed according to the operation and maintenance instructions A thorough and recurrent maintenance is a must for valid guarantee
34. set i 8 systemalr Topvex FR800 FR1600 FR3800 Compact Air Handling Unit Operation and Maintenance Instructions Item 400895 2015 06 23 Contents A MVEA Gis coast sctecsttaczeee cesntcacszeacthaas accteedsaiaceiseeecasecteqtagicascedceasacecad E E 1 2 Product descriptions sind ini pe nee eS ai Ae Ase ees 2 2 1 Internal components Topvex FR800 3800 ssssssssssesesseee neitsi Ea nre nennen nnne enne 2 2 2 Description of internal components 1i niic anae S reste d ae rec ER B DE cR Rn S 3 2 2 1 Supply and extract alt fans tacet tenant rane tuu aaa i aaraa aikani i Nia 3 2 2 2 Outdoor and extract aif filfers ci idest cere eer dene teet ee ee Dae rati bon 3 2 2 3 MEAL CX CAMO CM rcs 3 2 2 4 Temperat re Sensors uci rie dees tee te de EEEa eaaa cones sah e RA dE LA Eu ck eevee bo pret y gue 3 2 2 5 Hydronic MEAL Nessa m ccd eee rete ED Dt ciat te uice resin abet der tie mesEd 4 2 2 6 Electrical heater eerta dh bien code Pu S ue RR AU esp xe oe aed 4 2 3 Internal components electrical connection box ssssseeeene meme nnne 5 3 Interface GESCHPtlOM e ened 6 3 1 Controllipaneliza icin c A A a aE ERE 6 3 11 Operating the control panel 51 2 3 terne then eco eeceanbccachensasshectavitienycacapevaepeqndterpettheoestaed 6 4 COMMISSIONING SEE PME 4
35. soon as any output is set to a manual mode Supply Bliemio este CODES Auto Manual set omo Heating Auto anual set 100 0 SAF Auto anual set 0 0 EAF Auto anual set 0 0 Set the supply air temperature to Auto On or Off Set the output signal between 0 100956 The outputs Y1 Y2 and Y3 if in Auto mode will follow the signal according to the set split values Set the start signal for SAF supply air fan amp EAF exhaust airfan to Auto Manual full speed Manual half Speed orManual Set the heating to Auto Manual orOoff Set the manual output 0 100 Topvex FR800 FR1600 FR3800 14 Operation and Maintenance Instructions Systemair Inc systemair Sub menu item 1 Sub menu item 2 Explanations Exchanger Set the exchanger rotor control to Auto Manual orOff Auto Set the manual output 0 100 anual set 0 0 Cooling Set the cooling to Auto Manual OorOff Auto Set the manual output 0 100926 Manual set 0 0 Note Needs to be activated in order to be visible here Heating Set the pump control for the heating coil to Auto On or Auto ORE SE Pl Exchanger Set the pump control for a possible run around coil to Auto Auto On oroff Pl Coolingj Auto Set the pump control for the cooling coil to Auto On or OEE 5 to be visible here Configuration of fire damper functions are made at System level Fresh air dam
36. t Shows all registered alarms along with the time and date they occurred Move down and up in the list by pressing 1 5 Input Output Analogue Shows the status of the inputs Analogue inputs gt Digital Shows the status of the Digital inputs inputs Universal inputs Temperature Extract air temp e F Setp 64 4 F If cascade control Max min supply setp Outdoor temp F Supply air temp Actual F Setp 64 4 F Shows status of Universal Analogue inputs Shows status of Universal Digital inputs Analogue Shows the status of the outputs Analogue outputs Digital Shows the status of the Digital outputs outputs Shows the configured temperature control Default is Extract air temp Shows the actual temperature in the chosen control mode Shows the temperature for the chosen control mode Shows the maximum and minimum allowed supply air temperature in case of cascade control Login to service level needed to change settings Shows the actual outdoor air temperature Shows the actual supply air temperature Shows the calculated supply air set point The exhaust air controller output signal generates the supply air controller s set point value Topvex FR800 FR1600 FR3800 10 Operation and Maintenance Instructions Systemair Inc s Systemair Sub menu item 1 Sub menu item 2 Explanations Frost Shows the actual water protection temperature in t
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