SPC DERV Instructions de montage

QA/IOM/63 ISSUE 2 – DERV

INSTALLATION, OPERATING

AND MAINTENANCE INSTRUCTIONS

DERV(DX/CHW)

UNITS

C/W CHILLED WATER AND SPLIT SYSTEMDX COOLING

QA/IOM/63 ISSUE 2 - DERV Page 2 of 19

1 General Description

SPC DERV(DX/CHW) units are heat recovery ventilator units incorporating heat recovery heat

pipes, dehumidifier heat pipes and an active DX cooling coil or chilled water cooling coil. DX units

are supplied with a matched condensing unit for external mounting and for piping to the DERVDX

unit which acts as the indoor unit in the split system.

The units are intended to fully condition outside air by taking advantage of the cooling potential of

dirty extract air and the cooling and dehumidifying potential of a DX evaporator coil or chilled

water cooling coil.

The units are constructed in two halves; one half incorporating the extract fan(s) and extract

section of the heat recovery heat pipe, the other half contains the supply fan(s), supply section of

the heat recovery heat pipe plus chilled water/DX cooling coil c/w heat pipe wrapped around it.

The wrap around heat pipe precools the air prior to the cooling coil and reheats it after the cooling

and dehumidifying process to generate neutral ventilation air.

Units incorporate filtration on both the supply and extract side and are designed to be mounted

out of sight above false ceilings, suspended from the ceiling slab.

The supply and extract sections terminate in sheet metal flanges for the attachment of ducting.

Ducting design will be to suit the desired distribution within the premises and is largely beyond the

scope of this manual.

Units are supplied with an on/off and three speed controller to control the rotational speed of the

backward curved centrifugal fans and hence control the throughput of air on both the supply and

extract side. Further control of the air throughput must be made as part of the ducting design with

branch sizes matched to air volumes and manual volume control dampers fitted where

necessary. DX versions supplied with matched outdoor units incorporate a relay for switching of

the compressor and an additional temperature setting switch.

2 Technical Details

The table below gives details of the nominal operating characteristics of the DERV units along

with pertinent weights and dimensions. Operating limits for the units are as follows:

Maximum outside air temperature: 55°C

Minimum outside air temperature: 5°C

Maximum extract air temperature: 40°C

Minimum extract air temperature: 5°C

Units should be installed in a non-condensing environment.

Minimum outside air temperature for condensing unit operation of DX model: 20°C

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DERV chilled water units

Unit size 80 150 250 500

Nominal supply volume (litres/s) 107 155 236 473

Nominal extract volume (litres/s) 107 155 236 473

Nominal supply external static (Pa) 80 80 80 80

Nominal extract external static (Pa) 80 80 80 80

Total net cooling (W) 6375 9788 15127 30310

Sensible cooling (W) 3313 4929 7561 15155

Cooling coil total capacity (W) 5150 7779 11462 23970

Supply air dry bulb (°C) 20.2 19.5 19.3 19.3

Supply air wet bulb (°C) 17.1 16.0 15.7 15.7

Heat recovery heat pipe cooling load saving (W) 1225 2009 3665 6340

Wraparound heat pipe precool load saving (W) 622 1040 1660 3320

Wraparound heat pipe reheat load saving (W) 622 1040 1660 3320

Power supply (V/Ph/Hz) 230/1/50 230/1/50 230/1/50 230//1/50

Nominal current draw (A) 0.6 1.0 1.7 3.4

Nominal power draw (W) 138 230 391 782

Weight (kg) 75 100 130 190

Water flowrate (litres/s) 0.22 0.33 0.51 1.02

Water pressure drop (kPa) 10 9 18 19

Coil inlet connection size (mm) 15 22 22 28

Coil outlet connection size (mm) 15 22 22 28

The conditions upon which the above data is based are as follows:

Outside air @ 46/30°C

Extract air @ 25°C

CHW flow/return @ 7.2/12.8°C

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DERV DX version

Unit size 150 250 375 500

Nominal supply volume (litres/s) 155 236 358 473

Nominal extract volume (litres/s) 155 236 358 473

Nominal supply external static (Pa) 80 80 80 80

Nominal extract external static (Pa) 80 80 80 80

Total net cooling (W) 9788 15127 22907 30310

Sensible cooling (W) 4929 7561 11470 15155

Supply air dry bulb (°C) 19.5 19.3 19.3 19.3

Supply air wet bulb (°C) 16.0 15.7 15.7 15.7

Cooling coil total capacity (W) 7779 11462 18125 23970

Heat recovery heat pipe cooling load saving (W) 2009 3665 4782 6340

Wraparound heat pipe precool load saving (W) 1040 1660 2504 3320

Wraparound heat pipe reheat load saving (W) 1040 1660 2504 3320

Power supply (V/Ph/Hz) 230/1/50 230/1/50 230/1/50 230/1/50

Nominal current draw (A) 1.0 1.7 2.0 3.4

Nominal power draw (W) 230 391 460 782

Weight (kg) 100 130 170 190

Suction connection (“) 7/8 7/8 1,1/8 1,1/8

Liquid connection (“) 3/8 3/8 5/8 5/8

Outdoor unit power supply (V/Ph/Hz) 230/1/50 230/1/50 400/3/50 400/3/50

Outdoor unit nominal power draw (A) 13.1 18.0 8.4 8.4

Outdoor unit nominal power draw (W) 3013 4140 4143 4143

Compressor Reciprocating Reciprocating Scroll Scroll

Refrigerant R22 R22 R22 R22

Expansion device Capillary Capillary Valve Valve

Outdoor unit size WxHxD (mm) 1020x954x406 1020x954x406 1020x1270x406 1020x1270x406

Outdoor unit weight (kg) 80 90 110 120

The conditions upon which the above data is based are as follows:

Outside air @ 46/30°C

Extract air @ 25°C

Table1: Technical data

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Detailed unit dimensions and construction information is highlighted on the figure below:

Figure 1: Physical unit data

Outdoor unit sizes for DERVDX models are given in the performance table above.

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3 Reception & storage

DERV units are delivered in purpose made cardboard containers, if ordered as a DX version with

outdoor unit then this will be packaged separately. Upon receipt of the units the packaging should

be checked for any obvious damage and the labeling checked against the project requirement.

Any damage or delivery discrepancy should be reported to the SPC local office immediately. After

checking the packaging the units should be removed and a visual inspection carried out and any

damage reported immediately. If the units are not to be installed immediately then they should be

returned to the packaging for storage.

It is recommended that the units be stored in a safe location away from site activity and they must

not be exposed to the ambient. Units must be stored in non-condensing atmospheres where

temperatures cannot exceed 50°C.

4 Installation

4.1 Mounting of Indoor Unit

DERV and DERVDX indoor units must be installed horizontally and are intended to be fitted in a

concealed location, ideally above a false ceiling. The units must be suspended from the concrete

ceiling slab or other fixed and firm horizontal steelwork. Care must be taken to ensure that the

DERV(DX) unit is fixed to a structure that will accept the unit weight as shown in the above table

and that vibrations are not transmitted.

DERV(DX) units are supplied with 4-off robust fixing lugs at each of the corners of the unit (6-off

on the size 500). Each of these lugs incorporates a rubber bush to prevent unit vibrations being

directly transmitted to the mounting/support rods. The units should be mounted from the

ceiling/steelwork using threaded drop-rods. These drop-rods are not supplied with the units but

we recommend the use of M8 threaded rod.

The ceiling or support structure should first be marked out to match the position of the holes in

the DERV(DX) unit fixing lugs. The structure should then be drilled and fitted with suitable

anchors capable of accepting the weight of the DERV(DX) unit. Brackets can then be secured to

the ceiling anchors for securing the threaded drop rods. The rods should be cut to length and

secured to the ceiling bracket or supporting steelwork and the other end passed through the fixing

lugs on the DERV(DX) unit.

The drop-rods should be secured with suitable nuts on either side of the fixing lugs around the

anti-vibration bushes. It is important that the unit is fitted level in both directions so that correct

operation and drainage are ensured. A maximum deviation of 3mm from the horizontal should be

maintained and checked on installation using a spirit level and adjusted using the retaining nuts

on the fixing lugs.

4.2 Mounting/Location of Outdoor Unit (DERVDX only)

Outdoor units supplied with DERVDX are suitable for floor mounting and are side discharge

models. It is important that there is no obstruction on the air inlet and outlet sides of the unit and

that there is no possibility of hot discharge air being drawn back into the inlet.

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A minimum clearance of 600mm must be ensured on all sides of the unit except the air discharge

side where the clearance must be a minimum of 1500mm.

The unit must be located outside and must not be ducted. Ensure that the unit is not subject to

direct sunlight and cannot be subjected to any water run-off.

The unit must be mounted on a flat horizontal surface where vibrations cannot be transmitted to

the building structure and securely fixed.

A location should be found whereby the length of refrigerant pipes between the outdoor unit and

the indoor DERVDX unit is minimized.

4.3 Refrigerant Piping (DERVDX only)

The detailed instructions regarding the refrigerant piping given in the condensing unit IOM manual

should be followed. The text below gives general guidance. All refrigeration pipework should be

undertaken by a suitably qualified refrigeration engineer.

4.3.1 Liquid/Vapour lines

The table below identifies the recommended liquid and vapour line sizes based on the size of

DERVDX unit being installed. All refrigeration piping should be clean, dehydrated refrigeration

grade copper and should remain sealed until ready for use. A filter drier and liquid sight glass

may be installed in the liquid line upstream of the expansion device.

Unit size Liquid line OD

Vapour line OD

DERVDX 150

3/8” 5/8”

DERVDX 250

3/8” 7/8”

DERVDX 375

3/8” 7/8”

DERVDX 500

1/2” 1,1/8”

Table 2: Recommended refrigerant line sizes.

Both vapour and liquid lines should be insulated to prevent sweating and performance reduction.

A minimum of ½” thick pipe insulation should be used. In order to avoid any reduction in

performance it is recommended that the maximum distance between indoor and outdoor unit

(including any vertical lift) be limited to 15m.

Whenever tubing is cut it should be carefully deburred so as to prevent any chips falling into the

tubing to be used. Any bends in the pipework should be made using proper tube bending

equipment so as to prevent any kinking.

Wherever possible tube connections should be of the sweat type and made using copper brazing

material. For copper to copper brazing up to 5% silver content brazing rods should be used, for

copper to brass or steel then 35% silver content is recommended. Tubing and fittings should be

cleaned with wire wool prior to brazing and any debris prevented from entering the pipe. When

brazing at or near to the service valves the caps and Schraeder cores should be removed to

prevent damage and the valves themselves covered in wet rags. A flow of nitrogen should be

directed through a service port and tubing while brazing.

If flare joints are to be used these must be properly made ensuring the following:

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•No thinning of the flare tube material

•No cracked or split tubes

•No longitudinal scoring or tool marks

•Correct torque setting used to match diameter of nuts

After having completed the pipework the system should be pressure tested to ensure that there

are no leaks. Dry nitrogen up to a maximum pressure of 10 bar should be used and all joints

should be tested using leak detection spray or detergent.

4.3.2 Coil connections

For DERVDX size units 150 and 250 the evaporator coil in the indoor unit is equipped with a

capillary type expansion device. This device is factory brazed onto the coil within the casing of the

indoor unit. The liquid and vapour connections terminate outside the casing of the unit and are

sealed; the coil contains a holding charge of nitrogen which should be heard escaping when the

connections are opened with a hole cutter.

For unit sizes 375 and 500 the indoor units are supplied with a loose thermostatic expansion

valve. The valves must be fitted outside the casing of the unit and should be installed in line with

the instructions supplied with the device. When brazing the TEV into the liquid line it is important

that the valve is protected using wet rags so as to avoid any damage to same. The TEV should

be fitted as close as possible to the liquid connection on the coil.

4.3.3 Evacuation

After leak testing, the pipework should be evacuated before any of the valves are opened. The

vacuum pump should be connected to both the high and low side of the system and a deep

vacuum drawn to 500 microns. Triple evacuation is recommended if the vacuum pump cannot

achieve such deep vacuum levels.

4.3.4 Refrigerant charge

The outdoor unit is shipped with sufficient refrigerant for operation of the system with up to 5m

liquid line distance between the indoor and outdoor unit. The required system charge will be

indicated on the charging chart inside the access cover of the outdoor unit.

If the length of the liquid line exceeds 5m then additional charge should be added according to

the diameter of the liquid line. For 3/8” diameter pipe refrigerant should be added at a rate of 60

grams/metre and for ½” diameter pipe at a rate of 120 grams/metre.

If the unit is supplied without refrigerant or the refrigerant recovered and the whole system

evacuated then the full charge as shown on the charging table will need to be added.

4.3.5 Oil traps

To ensure adequate oil return to the compressor it is recommended that oil traps be fitted with at

least one trap for every 3m of vertical height. When the outdoor unit is above the indoor unit the

traps should be fitted in the suction line, if the indoor unit is above the outdoor unit then the traps

need to be fitted in the liquid line.

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4.4 Electrical connections

4.4.1 DERV units

DERV units are designed to allow simple operation with the minimum of electrical power and

control wiring required on site. A wiring diagram for the unit is attached to the unit next to the

terminal block. A copy of the wiring diagram is shown below.

Figure 2. Wiring details DERV units

For the size 500 unit the fuse rating is 5A not 2A as shown above.

Power supply to the units is single phase 230V/50Hz. A three wire supply is required (PH/N/E)

and this should be taken from a suitably isolated power supply. Maximum running current and

power drawn are given in the technical data table but minimum wire size for the power supply

should be 1mm2.

The terminal block is accessible on the side of the indoor unit. The 3-core power cable should be

connected to this terminal block as shown on the wiring diagram attached to the unit.

The DERV units incorporate a built-in controller allowing the speed to be changed (speed 1,2 & 3)

along with an on/off switch. Provision has also been made for remote control of the DERV units

via two volt free contacts. These contacts can be used to switch the units on and off remotely via

switches or relays attached to BEMS, occupancy sensors etc. The two remote contacts are wired

into terminals R1/R2 and R3/R4 respectively. Again wire should be a minimum of 1mm2 and

remote contacts should be rated at a minimum of 2A (5A, 500 unit).

If one or both of the remote contacts are not used then links must be fitted between R1/R2 and

R3/R4.

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4.4.2 DERVDX units

DERVDX units are designed to allow simple operation with the minimum of electrical power and

control wiring required on site. A wiring diagram for the indoor unit and interconnection to the

outdoor unit is attached to the indoor unit next to the terminal block. A copy of the wiring diagram

is shown below.

Figure 3. Wiring details DERVDX units

While all indoor units use a single phase supply the outdoor units for the larger models, size 375

and 500 are three phase as shown above.

For the smaller single phase units (150, 250) a three wire supply is required (PH/N/E) and this

should be taken from a suitably isolated power supply. Maximum running current and power

drawn are given in the technical data table but minimum wire size for the power supply should be

1mm2. Both the indoor and outdoor units must be earthed and the power cables should be taken

from the terminal block of the outdoor unit to the indoor unit terminal block.

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