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HHFlex HHFlex Air Handling Units Installation, operation

Contents

1. A 26 WE E E TEE 26 NEG ERE 27 6 11 Heat recovery EE 27 6 12 Plate Heat EE EE 27 6 13 Recirculation Ern eee ee d ad vt ie needed e enira ta dedecore delet edge Ne eve dentes 27 6 13 T General SEC AO Eege e a t E beoe EE NET EAR ERE s 27 6 13 24 Spray humdifler E 27 6 13 3 Infrasonic hu midirfication eR e GE ER E e e ER Cede SEGRE ADE 28 OH P B KC EE 28 OAT AAG ere r al no UD 28 LEER AIEO EE 28 NK D ebe EREM 28 ee EE 29 Abbreviations AHU Air handling unit ETA Extract air PED Pressure Equipment Directive ODA Outdoor air BMS Building Management System EHA Exhaust air SSR Solid state relay HMI Human Machine Interface SUP Supply air rh Relative humidity 1 SAFETY CONSIDERATIONS 1 1 General The 39SQ air handling units AHUs has been designed and manufactured in accordance with the CE machine directive In order to guarantee safe operation and use of the unit please carefully read and observe the instructions in this document and pay special attention to the warnings that apply to this unit Any modifications in the design and or installation of the AHU that are carried out without discussion with Holland Heating and without advance written agreement will result in the loss of the right to any warranty claims and any claim for injury to personnel as a result of these modifications All work must be carried out by sufficiently trained personnel All applicable personal sa
2. 13 4 2 2 Recirculation damper e The damper must always be closed during power cuts and when the unit has stopped e Ifa recirculation damper is used then both the outdoor intake and the exhaust opening must be fitted with a damper e Ifthe recirculation damper is used in a modulating manner the authority will have to be guaranteed depending on the external pressures on the other opening The authority of the recirculation damper can be increased by placing a perforated plate on the damper In the other case only using open closed control 4 3 Air filters Filter types Flat filter Bag filter Absolute filter Carbon filter Chemical filter Electrostatic filter ATTENTION When executing a test run of the AHU the air intake and exhaust side may never be blocked The fastening frame of the filter will fail if the pressure drop over the filter is excessive e Check if the correct filters have been installed air direction e Check if the filter bags have been installed correctly e Absolute filters are supplied separately in order to prevent contamination during transportation and commissioning Filters may only be fitted after the AHU has been completely cleaned e Set pressure switches or sensors if used e Close the inspection door e H desired a droplet eliminator can be fitted behind the outdoor air suction filter This drop eliminator catches droplets that fall off the filter The droplets conta
3. H2 Hi 75 Gauge pressure H1 gt maximum gauge pressure in the cooler section in mm WG 50 mm H2 50 mm Pressure in kPa 100 Pa 10 mm WG 4 5 2 Glycol in elements see 4 4 1 1 e Check if the droplet eliminator after the cooler has been correctly installed e Check if fins have been bent during transport e Correctly straighten the fins e The fins will only work correctly after several days in dehumidification mode e Start up the cooling coil by opening the shut off valves and switching on the controller After several days of cooling operation check the condensate drain and operation of the plastic siphon e If necessary clean the siphon AHU with control The first hot water coil without glycol in air flow direction is equipped with a frost protection thermostat This is set to a cut out temperature of 5 C the frost protection thermostat is also on a cooling coil that is used as a changeover coil 4 6 DX coils e The DX coils are supplied without refrigerant e The coils must never be pressurised with water They must be sealed and pressurised with a gaseous medium to prevent pollution of the coil e A qualified person should charge the coil and the rest of the system with a sufficient amount of the refrigerant specified in the technical specifications e When connecting the DX coil to the compressor condensing unit always follow the supplier specifications and the instructions of the qualified per
4. Remember to deenergise all components and to ensure that the fan has stopped rotating before the doors and access covers are opened before inspections and maintenance take place Check points and maintenance intervals Function Components Check points 1 month 3 months 6 months 12 months Depends on supplier and degree of contamination Casing general Indoor installation outdoor installation Internal and external panels Internal panels External panels Contamination corrosion and damage Joints Roof covering outdoor installation Seams and cracks watertight Doors access covers Hinges Correct operation Locks Door closure check bolt tightening Door seal Cracks Flexible connections Cracks Dampers Damper blades Sealing Bearings Damper drive Actuator Outdoor air intake Air intake cover grille Check for obstruction air velocity Floor condensate pan if used Contamination corrosion Droplet eliminator if used Contamination corrosion Filters Flat filter Bag filter Check pressure drop across filter Carbon filter check for damage and check SE sealing Electrostatic filter Pressure differential gauge Operation Pressure differential switch Operation drip tray dirt corrosion droplet eliminator if used dirt siphon dirt and
5. 3 kW 400 V 690 V should be started with the star delta switch 21 Connection diagrams connection of the power supply cable and of the terminals on the terminal strip Motor with the name plate data 230 V 400 V Y A Direct mains connection with a voltage between two phases of Indirect mains connection Y A with a 230 V 400 V voltage between two phases of 230 V Winding connection diagram ut ut we Ut e U2 we wi il wi v2 vi L3 L2 L2 L2 v2 vi DELTA STAR Connection method of the W2 9 U2 o V2 TENET Np conductors to the motor 90 0 D a O9 OQ terminals ut Pv Pw ut 9vi9w9 u Mumm wi 9 Y A switch DG 03 DG B DG B Motor with the name plate data 400 V 690 V Y A Direct mains connection with a voltage between two phases Indirect mains connection Y A with a of voltage between two phases of 690 V 400 V Li 690 V L1 Winding connection diagram w2 Ut u u2 w2 wi ye Wi v2 vi L3 L2 L2 L2 v2 vi DELTA STAR Connection method of the W2 Q U2 Q V2 w uU wv w uU wv conductors to the motor GO D o O OQ terminals u Pv Pw u Nu Pw ut Mim lun 9 Y A switch U 2 L83 D 03 U 2 B 4 11 1 Plug fans Where Plug fans are fans without a scroll that are directly driven by V actual air flow rate in m h the motor To get the correct operating point for this
6. amp holland heating HHFlex a systemair compan a HHFlex Air Handling Units EU cee GERTIFETE D PERFORMANCE Installation operation and maintenance instructions www eurovent oortilicatien cam CONTENTS 1 SAFETY CONSIDERATIONS ccccscscscssssscscecscesssscsensnsessssesencncossescsenensosocsesenensosscscsenensossesescncnsocoescsenensossssesensnsosscsceenensesees 4 SE SIE ME CHEER 4 UE ee e EE 4 1 3 Instruction typ6es deco teet ente aee deelgehol events 4 1 4 Disposal Of EE EE 6 2 TRANSPORT AND LIFTING INSTRUCTIONS eese e reete sesta en en stata enne tain nenas sensns tatnen ene teen tne tasses en as en en enean 6 ESI LL sus chee T OA A dutexeveguse EN 6 2 2 Transport and SOTA GE ee eie er ee eH vr ere le NE De ATASE Aa A ERENER EERE EE 6 2 3 Roof edge protection during transport outside installation sessi tenete tentent tenent 6 2 4 Offloading and le EE 7 2 5 ee Ee Ee EN en GE z PA ENIO E11 ERE Ep 7 pug E 7 3 CHECKLIST OF START UP CHECK POINTS sssssssssssssscsssssssssssessscsssvesessssscssesessscesessssssvosssessssssesosssossesossscasesesess 9 3 1 Checklist of start up check points iis seoseis rettet tnrba baec EAKA a NEATE a eas iara ieis 9 KEES AH BWINKOC IRAK 11 enge EE 11 41 1 Casing EE 11 ME Doors RE 11 4 1 3 Elexible connections eet teo ertt Ne enero ee E oe ee D Read ei cots redes e
7. corrosion Motor larger types Lubrication Belt Wear tension Vibration dampers Fixings Flexible connections Cracks Pressure switch sensor Operation Silencer Dirt deposit Damage t top layer Controller Alarms Check alarm history Sensors General Chck operation of all sensors Pressure sensors Zero Calibration 6 MAINTENANCE AND OPERATING INSTRUCTIONS 6 1 General e The smooth inside and outside finish of the panels makes maintenance very simple e For dry sections twice a year thoroughly check the inside and outside of the AHU casing For maintenance of wet sections coolers please refer to the air handling section concerned e All work must be carried out by sufficiently trained personnel e All applicable personal safety devices must be used to ensure safe working conditions Safety gloves and glasses must be worn for all maintenance operations A respiratory protection mask must be worn when changing the filters e No holes must be drilled into the AHU to prevent leakage from the AHU cooling coils and heating coils and damage to the wiring 6 2 Casing panels 6 2 1 Inside installation a Internal inspection of the casing of double skin panels and of all dry parts Remove contamination with water and a mild pH neutral household soap solution Where damage of the paint finish has occurred if necessary remove rust and touch up with good quality anti corrosive primer and paint The outdoor air intake
8. dimensions and weights of the sections as well as the installation sequence The weight is given on each transport section Each transport section is equipped with a subframe with four lifting points These points are marked by the label shown below o For offloading as well as hoisting lifting cables can be attached to the lifting bars Evenly positioned spacer bars should be used between the lifting cables to prevent damage to the top of the unit and ensure that no excess pressure is applied to the side panels For hoisting please ensure that the weight is evenly distributed The AHU must not be raised under the cross beams during lifting or moving operations This is indicated by the label below 2 5 Horizontal transport For horizontal movement pallet lifters or transport skids can be placed under the installation frame or under the lifting bars It is important that these support the lifting points At no time should the cross beams at the ends of the unit sections be used for jacking or tracking the AHU FOR HORIZONTAL TRANSPORT ALWAYS PROVIDE SUPPORT UNDER THE LIFTING POINTS The use of bars as rollers can result in damage to the installation frame 2 6 Storage The packaging in which the AHU is supplied can cause condensation to be formed between the packaging and the AHU if the unit is stored in an unconditioned place If the AHU is not immediately used it is recommended to store it in a conditioned lo
9. for 10 minutes When entering the steam function and touching the steam generato distribution pipe and pipes you must be sure that the machine is no longer producing steam Entering the steam function and touching the team generator distribution pipe and pipes can cause burn injuries The surface temperature of the steam generator distribution pipe and pipes and the steam can reach 100 C or more Steam generators that are connected to the pipes must always be compression tested by sufficiently trained personnel and comply with the PED guideline Compression testing is the responsibility of the installer Always de aerate the system Pipes must always be insulated and are the responsibility of the installer Consult the documentation supplied in the case of faults in the system The operation of the steam generator must be linked to the operation of the fan If the fan de activates supply to the steam generator must be stopped For all types of humidifiers it is important that a maximum hygrostat is placed so that interventon takes place in the case of excessive humidification 4 8 2 Steam humidification direct 18 Check the fastening of the steam container Check the steam supply and the condensate exhaust Fit an extra condensate container boiler in accordance with the supplier s instructions for longer pipes Check that the dirt collector has been placed Condensate drainage may be executed without pressure depending on
10. freezing point e Avoid excessive vibration caused by external devices and transmitted through the pipes e The flangers of the collectors must be removed from the pipes Voltage free e The maximum operating pressure may never be exceeded Check the connections on the dimensional drawing Ensure that the coil has been fully purged Check connections for leakage Ensure that the frost protection thermostat has been correctly connected and set up e Itis possible that the coil is the last or second last component in the AHU The frost protection thermostat must be made accessible by providing a field installed inspection hatch in the supply air duct e Ensure that the heater can supply heat to prevent frost formation when the fan is started CAUTION When the coils are drained no water must remain in the circuits to prevent freezing at temperatures below zero 4 4 1 1 Coils containing glycol If coils are filled with a water glycol mixture this requires extra attention e Glycol can react violently with strong oxidation solutions e When working on the coil always check which medium is used Before adding anything to the heat exchange medium always check with the installer e Always wear safety glasses and gloves e Do not smoke or use an open flame e When sizing the expansion tank take the higher heat transfer coefficient into account 25 larger e Watertight seals are not always tight for water glycol mixture
11. sections can show signs of corrosion as they contain wet parts and are affected by mist rain and air pollutants b Outside inspection of the coating If damage to the paint treatment has occurred remove the rust if necessary and touch up with good quality anti corrosive primer and paint 6 2 2 Outside installation Check the sealed joints of AHUS installed outside and if required seal with a UV resistant and paintable kit Repair damage as described for inside installation Check the roof for leaks and if necessary repair these 6 3 Doors and access covers Check locks and hinges of all doors and access covers Check that the bolt of the internal roller is still correctly tightened 6 4 Flexible connections Check the flexible connections for damage 6 5 Earthing Ensure that the unit is earthed and installed in the correct manner 6 6 Dampers ATTENTION es When working on damper registers it is possible for fingers to become trapped During cleaning of the damper fins the AHU must be Voltage free in order to prevent unexpected closing of the dampers e During repairs to the servo the AHU must be made Voltage free in order to prevent the connection cables being live e Lubrication of the dampers is not required Remove excess contamination by cleaning with compressed air and possible cleaning with water and a mild household soap solution Ensure that the damper blades run free in the casing 6 7 Ou
12. shown in the drawing below BH Legend 1 AHU 2 Flexible connection or damper 3 Duct connection single skin flexible connection x 30 mm press fit The combination of flexible connections and dampers extends beyond the external AHU dimension as shown in the drawing below 500 mm Legend 1 AHU 2 Duct connection PDH Legend Connecting outside air suction duct to a unit without a 1 CAHU damper register 2 Damper p g 3 Flexible connection 4 Ductconnection e Connection a fittign piece with a length of van 500mm to single skin flexible connection x 30 mm press fit the corner window of the air handling unit e Insulate the complete fitting piece internally up to the panel of the unit e Insulate the fitting piece externally until there is a 250 mm overlap between the internal and external insulation e The exterior of the rest of the fitting piece must not be insulated Fig 2 Unit without damper register 500 mm Legend 1 AHU 2 Duct connection Connecting the outdoor air intake in one of the manners depicted above prevents condensation from occuring on the corner framework 4 1 7 Assembly and placement of the air handling unit e Ensure that the floor in the room where the unit is installe
13. the EMC directives are observed and pay attention to the shielded cables The frequency converter must always be correcly set to suit the motor and type installed Observe the instructions of the supplier of the frequency converter Special attention should be given to the following parameters e Correct application of the general motor data Pay special attention to the motor frequency For subsynchronous operation lower than the network frequency it must be set in accordance with the motor nameplate Forsupersynchronous operation higher than the network frequency it must be set for the maximum admissible frequency of the motor impeller assembly this applies above all to plug fans Operating type square variable connection It is recommended to cut out so called overmodulation Setting of the normal start up shut down times Check for possible condensate moisture Condensate may form in the period before the first start up of the AHU as a result of weather change and or humid air from the building Remove all condensate from the construction components and dry the electrical components using warm dry air e g with a hair drier 4 12 Silencers The silencers for the 39SQ are supplied separately on a pallet as duct silencers The duct silencer must be installed on site at the correct opening For this use the connection profiles supplied and use the method described in chapter in 4 1 5 Duct connections The
14. the entire section and repair any damage After cleaning refill the reservoir with water Check that the float seal fills the container up to the mark stripe and then start the pump If any of the sprayers are blocked unscrew the spray head after which it can be cleaned 27 e Outside the humidification season and during long periods of stoppage we recommend that the pump be operated for several minutes every week in order to prevent scaling on the bearings and the axle seal of the pump e During this period of long term stoppage replace the water in good time in order to prevent health risks and unpleasant odours e N B We recommend carrying out a monthly check of the conductivity of the water in the reservoir of every humidifier in the building This may prompt an alteration of the thickening factor See 4 10 3 6 14 3 Infrasonic humidification The following points deserve extra attention e Check the correct operation of the drain e Check the connection of the high pressure hose for tears and leaks e Check that the sprayers produce mist effectively e Check the operation of the pressostats and the pressure e Check the water quality See 4 10 3 e H the humidifier is not in operation for a long period of time and must be started again the following must be carried out check the set up of the humidifier e Switching the humidifier on and off can produce scaling in the spray pipes which may affect their operati
15. typeof k specific fan coefficient fan a frequency converter is required The maximum frequency at which the plug fan can rotate depends on the motor impeller assembly and should normally be higher than 50 Hz The maximum frequency is given on the fan name plate Plug fans are equipped with a pressure measurement point in the intake cone of the fan By measuring the pressure drop between the pressure for the fan and the pressure in the intake cone the actual air flow can be calculated using the following formula V k VAp 22 Ap pressure differential cone air intake section in Pa The k value depends on the fan size used This value can be found in the table below k values Fan size Plug fan 225 47 250 60 280 75 315 95 355 121 400 154 450 197 500 252 560 308 630 381 710 490 4 11 2 Frequency converters It is recommended to install a frequency converter with an integrated operating switch If a separate operating switch is installed on the unit and near the frequency converter this can be located in the supply voltage for the frequency converter If the frequency converter is not isnstalled near the unit operating switch the operating switch can be placed in the control power circuit that switches the supply voltage to the frequency converter via a relay To connect the frequency converter please refer to the wiring diagram for the converter installed Ensure that
16. y humidi e s nde deste e e P ORI NR Cola ar raa a sp o doin oi deine ee Gee a rera i gu aS 19 4 10 3 Determining the quantity of spray water and the condensation factor EE 19 4 10 4 Infr asonic humidification citri citer rie ttbi E UR USERS EH EHI IS EIE HEEL GEHE Pe Heb le ri tende dudes 19 ALTA SIR AI M AA 20 ATT T PIug fans nan pi re pbi dio pd n iat es sene e bo deett septo tear iet tidal es 22 4 11 2 Frequency Converters E 23 cu m 23 cURESPIdUUDERC UPC M 23 FESUEY UD VOD TI 24 5 1 Checklist of check points and maintenance intervals EEN 24 6 MAINTENANCE AND OPERATING INSTRUCTIONS eere esee esent tenants en an stato ente tatnen sensn ones enata en en ane tn naa 25 SERE EE 25 E CASING panels iis roi n T 25 6 2 T Inside amstallations EE 25 6 22 Outside installation EE 25 6 3 Doors ANd access EE 25 6 4 Plexible connections uiii EH PRO RD e ere PER EUER UR RR AOERE GEHEN ese IER edo LARA OR ROI adi 25 6a RATTAN Gives C 25 6 6 Dampers rrr D 25 6 7 Qutdoor air EE 25 E qu 25 P ENILIC E DI 26 69 1 Hot water coil MT
17. 4 9 2 Steam humidifier electric Check the fastening of the steam generator Check the steam supply and condensate drainage pipes Condensate drainage may be executed without pressure depending on the manufacturer Refer to the supplier s instructions In the case of under pressure in the AHU place a special siphon for condensate drainage Check the Voltage and measure the total power consumption Connect the humidifier in accordance with the supplier s instructions The following warning sticker is applied to the panel Hot Surface A maximum hygrostat must be fitted in order to prevent excessive humidification in the AHU See 4 8 1 4 10 Water humidifiers 4 10 1 General It is possible for bacteria to grow in open water Include Legionaire s Disease in the building prevention programme e The connection of the suppletion water and the drainage of the condensed water must comply with the local regulations e The circulation pump of the humidifier may only be started when the fan is in operation It will not function or function insufficiently without an air flow thereby causing other parts of the cabinet to become wet Start the humidification pump and check the direction of rotation in accordance with the arrow applied Water must be emitted from the sprayers immediately after the pump is started Stop immediately if necessary The circulation pump has water lubricated bearings and a water lubricated axle s
18. OUR vind eee elut ieeus 11 LM EN Se HT N 11 41 5 Connected duets og eo o e bp n emnt dieit ied euin 11 41 6 ee 12 4 1 7 Assembly and placement of the air handling unt 13 ELES Adr contaminatlOn oid iaa dor o D da e RR EURO Nr bb Ret m edi eebe 13 4 1 9 Condensation in or on the AH seen 13 A D DAM PETS n a eerta UOI CDI DIT QI LL LIT LLLI T UTTT 13 A De Dampers ices TEE 14 4 22 Recirculation dampers EE 14 43 AAP E 14 EE D EE 14 AAs Hot Water coll Cuotas RUNE OON 14 4A Na EEN EE 15 AAD BIC CHHiC i ORE E 15 444 Steam Heaters eoe et ee pa tbe deis eei ueste tend oes eet c dee Pe EROR e dee e i np be etes 15 AVS COQIETS e 16 E E I IERI IE 16 AS 2 Glycolimelenmients see4 4 101 EE 17 LED CUI P H 17 4 6 Heat recovery wee ee eet rep e epe eire cete e d e ee bush depen ere reed ee ier epe abe ient 17 4 7 Plate heat exchanger rete e p te eee etre teste ee e cs ove ee dee EE E ete doce eie er ete ieri 18 4 8 Steam humidific ation direct erioch e elei tede d e e deeper UE ere reed ee ier EE 18 4 9 Steam H ue EE 18 4 10 Water hiumidifiers 2e e tp eee tire inei ates e e bush dee Ree ede ite oreet iens 19 410 1 General enoue iens i E E M 19 4 10 2 Spr
19. alled Ensure that there is a watertight connection at the angle bend of the condensate pan tap by using PTFE tape Leave approximately 32 mm WITHOUT tape between the siphon casing and the connection to the pipe as this part is sealed by the rubber ring provided The negative pressure siphon supplied by Holland Heating is suitable for a negative pressure of up to 800 Pa in the associated section Check if siphon cover and ball have been correctly installed The gauge pressure siphon supplied by Holland Heating is suitable for a gauge pressure of up to 1200 Pa in the associated section i ee Hc ELLUL Check that the negative or gauge pressure corre sponds to the siphon type installed The outlet of the siphon trap connected to the drain must not be under pressure It is not recommended to connect a siphon in a negative pressure section and a siphon in a gauge pressure section via a manifold that is not under pressure to the drain Instead two separate manifolds should be used If the field prepared siphon is used follow the instruc tions in the drawing below Fill siphon with water if the fan is switched off Ht H2 ce Negative pressure H1 maximum negative pressure in the cooler section in mm WG 50 mm H2 gt 1 2 x H1
20. an must continue to run for at least 5 minutes Gefahr Nach Abschalten der Elektroheizung muss der Ventilator noch mindestens 5 Minuten weiterlaufen attention Apr s la d connexion de la r sistance lectrique le venti lateur doit continuer tourner pendant au moins 5 minutes 200034908 CAUTION All doors and access covers must be closed before starting up the AHU Lifting and transport An instruction is attached to the AHU that describes the procedures that must be followed for lifting and transport The following chapter contains further details 1 4 Disposal of parts materials e The packaging material must be disposed of in a respon sible manner and in accordance with local regulations e Components that are replaced must be disposed of as described above 2 TRANSPORT AND LIFTING INSTRUCTIONS 2 1 General e Transport and lifting of the AHU must always be in accor dance with the instructions below If these instructions are not observed the unit may be irreparably damaged and people in the immediate vicinity of the unit are endangered Holland Heating does not accept any responsibility if these instructions are not observed Transport and lifting must be carried out by qualified personnel The AHU must only be lifted with lifting bars supplied by Holland Heating box profile 30 x 30 x 4 mm quality 52 e In special cases lifting is executed by means of a base or Ifiting f
21. are opened before inspections and maintenance take place 6 16 Silencers It is recommended to check the splitters of the silencers periodically for possible damage and loosening of the fibres to prevent dirt deposits in the system 29 holland heating a systemair company Holland Heating B V Zanddonkweg 7A 5144 NX Waalwijk The Netherlands Postbus 159 5140 AD Waalwijk The Netherlands Tel 31 0 416 68 55 55 Fax 31 0 416 34 17 95 www hollandheating nl Holland Heating B V participates in the Eurovent Certification program Products are as listed in the Eurovent Directory of Certified Products Order no HHFlex IOM UK 07 2013 The manufacturer reserves the right to change the specification without prior notice The front cover photos are for illustration purposes only and not contractually Manufactured by Holland Heating Waalwijk The Netherlands Printed in the Europian Union
22. cation on site If the AHU is kept outside for a short period direct sun radiation must be avoided If the fans are shut down for a longer period longer than three months bearing damage can occur To prevent this it is recommended to loosen the belt tension or to temporarily remove the fan belts When the fans are re started the belt tension must be reset to the specified tension Controlled rotation of the fan impeller can also prevent this type of damage This is also recommended for direct drive fans 2 7 Assembly For the assembly of our units please refer to our instruction manual Assembly Example configuration of 39HQ with heat recovery wheel KKKKLELIZL MI LMMLMMU MMdBIzaRaRM Mah MMMM MM hhhhhhbahbhhiltihidfilddldllilillhith EE GE Cl H ZZ Y Section bottompart D om O Ml lt gt l 4 p m 4 1 b A i vm og 7 n m J 4 ea e LI 4 4 i Section frontpart A MA 12 t fF 6 H O WR Legend Legend Dimensions A Exhaust air damper 1 Actuator outdoor air damper W breedte unit n x 160498 B Outdoor ai
23. conection to the rest of the duct system can also be made in this way as shown in the drawing below Please ensure that the duct silencers are always correctly supported on the floor or suspended from the ceiling Make sure that the following weights are taken into consideration Duct silencers Unit type Weight kg 0405 30 0506 35 0606 45 0707 50 0808 70 0909 75 1010 105 1111 110 1212 135 The duct silencer can also be used for units installed outside After installation they must always be insulated on the outside to ensure that they are water and steam tight The pre installed air intake and discharge hood if used must be removed first Install the corner frame supplied separately at the opening of the silencer before installing the silencer Finally replace the air intake and discharge hood at the opening of the silencer Here too the duct silencer must be sufficiently supported as shown in the drawing below 4 13 Lighting e Check the connection voltage e Check the operation of the switch The switch must be connected in accordance with local regulations 23 5 MAINTENANCE CHECKLIST 5 1 Checklist of check points and maintenance intervals The checklist contains a general overview of a planning that facilitates the inspections and maintenance of the AHU On the following pages there is a more detailed description of the individual components WARNING
24. d is even and waterproof The joints between the parts must be covered with the sealing tape provided The sections can then be placed in the correct order Place the sections as close as possible together and ensure that they can be moved Using a support pull the sections towards each other with a pull rope Check if all parts are water tight and if necessary slide spacers under the support where required see also chapter 2 Then attach the profiles supplied to the joint The roof of units installed outside must be sealed so that no water can leak to the inside Always attach a unit installed outside to the floor of the support frame to ensure that the unit cannot move or fall take the force of the wind into account For units installed inside please make sure that the unit cannot move from its support points If necessary the unit must be attached to the support e Fora detailed description of the assembly please refer to the instruction manual Assembly 4 1 8 Air contamination If the exhaust and outdoor air intake openings are close to each other there is a risk of air contamination To reduce contamination the air must be rarefied To do this correctly the air volume the horizontal and vertical distance to the two openings and the position of the two openings in relation to each other must be taken into consideration is the outdoor air intake lower or higher than the exhaust air opening It may be necessary to position
25. d rotation of the fan impeller This is recommended for direct drive fans e Check if the flexible connection is correctly installed e fused check the pressure switch and set the correct pressure e Check the operation of the main switch 20 CAUTION While working on the fan the switch has to be locked open e The warning pictograms on rotating parts electrical voltage and opening doors are attached to the door Q waarschuwing Voor openen deuren ventilator uitschakelen spanningsloos maken en uit laten lopen minimaal 2 minuten warning Before opening the doors switch off and deenergise the fan and allow it to run down minium 2 minutes Transport brackets Remove transport brackets before starting up the fan Transportbeugels Verwijder transportbeugels voor opstarten ventilator Gefahr Vor ffnen der T ren den Ventilator abschalten span nungslos machen und zum Stillstand kommen lassen mindestens 2 Minuten warten attention Avant ouverture des portes le ventilateur doit tre d connect et avoir eu le temps de s arr ter completement 2 minutes minimum Fixations de transport Retirer les fixations de trans port avant la mise en route Transportsicherungen Transportsicherungen vor der Inbetriebnahme demontieren 200034906 If the machine has stopped due to an unexpected power supply failure sudden re starting of the machine m
26. e air flow or clean the air intake with a vacuum cleaner e Checking the heaters Check the operation of the frost protection thermostat and check the correct control sequence when the themostat trips e For coils filled with glycol please check if the mixture has the correct glycol concentration by weight e While working on the heaters gloves must be worn that offer protection against temperatures of 70 C The piping outside the air handling unit must be insulated The water temperature in the pipes can be 120 C maximum 26 The following sticker is shown to warn that there is a hot surface 6 9 2 Electric heater e Once a year check the air inlet and air outlet of the coil for contamination If they are polluted clean them with a vacuum cleaner Safety gloves and safety glasses must be worn while working on the heater The coil surface temperature can reach 600 C If access to the heater is possible a safety screen must protect the operator against direct contact es ATTENTION When you switch on the electric heater the fan must always be activated in order to prevent overheating of the inside of the cabinet The fan must continue to operate for a minimum of 5 minutes after switching off the electric heater This is necessary in order to allow the spirals to cool down e The following label is attached to indicate a hot surface e The warning label for electrical voltage is attached to the inspection hatc
27. eal fitted with 2 hard metal rings e In the case of the danger of freezing always check that the heater functions correctly e The operation of the water humidifier must be linked to the operation of the fan If the fan stops the supply to the water humidifier must also be stopped immediately e A maximum hygrostat must be fitted in order to prevent excessive humidification in the AHU See 4 8 1 4 10 2 Spray humidifier e norder to measure the quantity of spray water the siphon must be disconnected and the quantity of water must be measured on site with the aid of a measuring jug and a stopwatch The required quantity of spray water must be immediately determined for every cabinet in advance Check that the float seal in the water reservoir is set to the correct height 4 10 3 Determining the quantity of spray water and the condensation factor e The constant evaporation of water increases the salt concentrations and thereby the concentration of the other constituents in the reservoir When the air is humidified a portion of the water evaporates while the remaining water falls back into the reservoir The salts and other undissolved substances that are always present in pipe water or softened water remain in the water that falls back into the water reservoir while the evaporated portion does not contain any solids e Evaporation should make the level in the reservoir drop This is prevented by the automatic addition of fresh
28. eel Check the rotor once a year for contamination and if necessary clean with compressed air Check the rotor speed and compare it with the design data Check the operation of the rotation monitor Depending on the rotor material the wheel can absorb moisture When stationary the wheel will become moist on one side and therefore heavier The rotor speed can be set to intermittent in the controller so that the wheel will rotate x times per time unit The rotor bearings are lubricated for life and do not require maintenance The drive motor is accessible via an inspec tion cover The V belt is automatically tensioned by a spring loaded rocking base on which the motor is installed New belts expand a lot in the beginning Check after two days if the belt still has enough tension After this check the belt tension weekly during the first month and then check it once a month For further operation and maintenance details on the heat recovery wheel controller refer to the documentation provided by the supplier The following warning pictogram is located on the panel Rotating parts 6 12 Plate heat exchanger CAUTION The cleaning agent may not affect the heat exchanger Check the plate heat exchanger once a year for contamination and if necessary clean with compressed air against the direction of the air flow If dampers are used follow the instructions in section 6 6 Check condensate pan for contamination and clean if nec
29. em 28 The following points require extra attention e Check for vibration e Check the rotation direction e Avoid unnecessary stops and rapid start ups of the fan 6 15 3 Transmission After starting up the unit and after replacing the belts the belt tension must be checked within one week and then after two weeks and further tensioned if required After that check the belt tension and inspect the condition of the belts every three months The CORRECT BELT TENSION depends on e the belt type number of belts smallest pulley diameter power to be transmitted belt velocity The belt tension is calculated for each transmission If the belt tension is too high this can result in bearing wear and vibration if it is too low this can result in belt slippage and pulley and belt wear Sequence for installation of new belts e Ensure that the pulleys are correctly aligned If necessary re align e Position all belts loosely on the pulleys do not pull tensioned belts over the pulleys e Tension the belts and check the tension with a Sonic Tension Meter e Re check the alignment If the fan speed changes or if a motor with different power specifications and or speed is installed this must be discussed in advance with the manufacturer The supplier must re calculate the bearing load as well as the impeller load If this is not done irreparable damage to the fan may incur The supplier does not accept any responsibil
30. ess covers or panels that If the AHU consists of several parts each part must have include rotating parts and pose a potential risk this is also a label with the required data indicated by this pictogram C Holland Heating bv Order no C Zanddonkweg 7a ut 8144 NX Waalwijk POS NO o The Netherlands Q Type HHFlex Se Jaar Year Jahr Ann e 2 C Part a Gewicht Weight Poids Kg VM Hot surfaces s Code This pictogram indicates that there are components behind this access cover door or panel that can cause serious burns when touched Opening the fan door This pictogram is positioned on the outside of the door or The surfaces that may be hot are the heater surfaces If access cover of the fan assembly This pictogram warns that there are special special customer specific components the fan must have been switched off and deenergised for a behind doors access covers or panels that have hot surfaces minimum of two minutes before the door or access cover is and pose a potential risk this is also indicated by this opened This pictogram also indicates that transport pictogram brackets must be removed before the fan is started up Q AM waarschuwing warning Electrical voltage Voor openen deuren ventilator Before opening the doors This pictogram indicates that there are electrical components uitschakelen spanningsloos switch off and deenergise the behind
31. essary Check the droplet eliminator fins in the condensate pan if installed 6 13 Recirculation damper For maintenance of this damper refer to chapter 6 6 6 14 Water humidifiers 6 14 1 General see 4 10 1 Thickening factor see 4 10 3 6 14 2 Spray humidifier Check the correct functioning of the float seal for supplemental water every week Scaling and sludge formation can have a detrimental effect on the operation of the float tap The water level in the water container must be kept at the correct level in all circumstances without water overflowing into the funnel shaped overflow When the circulation pump is stopped the level is 5mm under the overflow Check the spray water quantity every week during the humidification season The salt concentration thickening in the reservoir is directly dependent on the effective operation of the spray tap Regularly check the quality of the water in the reservoir This must take place monthly during the humidification season Inspect the flexible connection between the pump and cabinet wall for leaks every week The interior of the reservoir of the humidification section must be cleaned twice per year The water reservoir must be drained and then cleaned with a water jet and soft brush and then flushed with water Do not use sharp or hard objects during cleaning in order to prevent damage to the protective layer and or thermal insulation Carefully inspect the surface in
32. evented by j 2 installing rain protec tion air intake grilles Caution ERE The maximum air velocity for the grille is as given by the supplier The rear air intake duct must be sized to E avoid higher than allowable air velocities in the grille High air velocities in the openings can also be caused by wind attacks at one of the openings If these can be expected for the installation or geographical location try to minimise them with partitions If there is any possibility that rain water can be drawn in droplet eliminators are fitted with a suction grille in the outside The flexible connection protrudes beyond the external air duct AHU dimension as shown in the drawing below e A pre heater for the filters can be installed to prevent that mist causes the filters to become too wet The pre heater will reduce the relative humidity of the air Connection of the outdoor air intake duct If the heater is not fitted in AHU it must be fitted in the outside air duct To connect the outdoor air intake duct to a unit that is installed inside we recommend the following procedure e Connect a 500 mm long adapter piece to the corner frame of the air handling unit e Insulate the inside of the complete adapter piece up to the unit panel e Insulate the outside of the adapter piece so that there is a 250 mm overlap between inside and outside insulation e The remainder of the adapter piece needs to be insulated on the outside as
33. fety devices must be used to ensure safe working conditions Safety gloves and glasses must be worn for all maintenance operations A respiratory protection mask must be worn when changing the filters The A weighted equivalent continuous sound pressure level can be above 80 dB A depending on the motor size fan size fan speed and the location where the AHU is installed This means that ear defenders must be worn when the fan is running All doors and hatches must have at least one lock that can only be opened with a special device Heating and cooling coils are manufactured and supplied in accordance with guidelines of the Pressure Equipment Directive PED Do not walk on the roof panels of units installed inside or outside Only sufficiently qualified personel is allowed to work on electrical components All power supplies to the unit must be disconnected before any work can be carried out Switch off the supply voltage using the main disconnect switch CAUTION In general electric heaters have a separate supply and must be switched off separately If work lighting is required use only lighting with 24 V maximum Use of electical equipment with a voltage above 48 V is only permitted if an earth leakage switch is installed that complies with local and national regulations 1 2 Applications The AHU is designed for the movement and conditioning of air unless otherwise agreed during the design stage 1 3 Instr
34. h The earth warning label is attached to the inside of the heater and the inspection hatch The warning label for the procedure to switch off the heater is located on the door or hatch of the fan assembly elektrische verwarmer moet de ventilator nog minimaal 5 waarschuwing Na het uitzetten van de warning After switching off the electric heater the fan must continue to run for at least 5 minutes minuten draaien Apr s la d connexion de la ventilateur doit continuer Gefahr Nach Abschalten der Elektroheizung muss der Ventilator noch mindestens 5 attention r sistance lectrique le tourner pendant au moins 5 Minuten weiterlaufen minutes 200034908 6 10 Coolers 6 11 Contamination of the finned surface reduces the capacity of the cooler Check once a year for contamination and if necessary clean with compressed air against the direction of the air flow or clean with a vacuum cleaner Check the coil and the connections for leaks For coils filled with glycol please check if the mixture has the correct glycol concentration by weight DX coolers may never be cleaned with steam Check the fins of the droplet eliminator after the coil Clean the siphon and check it for correct operation Check the condensate pan for contamination and clean if necessary Heat recovery wheel Contamination on the finned surface reduces the capacity of the heat recovery wh
35. has been earthed correctly and in accordance with local regulations A label on the support frame indicates where the unit should be earthed 4 1 5 Connected ducts There are corner frames attached to all openings to be connected These corner frames allow connection of the air duct to the AHU e It is recommended to use Europrofile connections type E30 at the corner frame as well as at the duct to be connected 30 The Europrofile connections are available in fixed lengths and can be cut to the required length with a saw These profiles can easily be placed over the corner frame Allow for a maximum profile height of 30 mm so that ducts that are positioned one above the other can be installed correctly e The four corners between the profiles can be completed with a corner piece type H30 27 e The profile at the corner frame can be attached to the profile on the duct using a drive slip type SR e Attaching self adhesive tape between the two profiles ensures an air tight seal as shown in the drawing below l N Z7 TE J Legend WD 1 AHU Q 2 Duct connection 11 The corner frame has a length of 32 or 72 mm and 4 1 6 Outdoor air intake extends 22 or 62 mm beyond the external AHU e Ensure that the air intake duct is correctly connected dimension as shown in the drawing below High air velocities must be avoided and no rain drops should get into the duct This can be pr
36. he supplied diagram Check the correct connection of the drain Check the connection of the high pressure hose After commissioning check that the hoses do not rub against any surface Check that the sprayers produce an effective mist Check the operation of the pressostats and the pressure Check the water quality In terms of adjustment technology the humidifier must be fitted with a safety feature for overheating and running dry The air flow over the humidifier may not exceed 5 5 m s Optimum operation is at 4 m s The only humidification medium that may be used is demineralised water with a conductivity to 20 microsiemens cm and an ambient temperature of 2 C to 30 C Adjustment must be made so that the air flow gradually decreases for another 20 minutes after the de activation of the humidification pump This is in order to allow the AHU to dry completely and prevent microbiological contamination After 50 operating hours the oil in the pump must be replaced We recommend that you use synthetic oil SAE 20W50 A maximum hygrostat must be fitted in order to prevent excessive humidification in the AHU See 4 8 1 The following sticker is applied to the control box 19 4 11 Fan CAUTION The air flow may cause stationary parts to move even a fan that is switched off e Remove the transport brackets This is indicated by a label on the door e Check if the fan can move freely without obstructing the fra
37. ins substances that are extremely corrosive and can cause corrosion damage to the filter function and functions behind the filter A stainless steel drip tray is mounted under the filter e Check that the fins of the droplet eliminator are straight and secured in position e Check the operation of the siphon see 4 5 1 14 4 4 Heaters 4 4 1 Hot water coil e Using gloves in order to prevent cutting wounds is compulsory while executing maintenance or repairs on the heater element e Safety glasses must be worn while working on the heater element e The fins and the pipes may reach temperatures that can cause burn wounds Wearing gloves that provide protection against temperatures of a minimum of 70 C is compulsory during maintenance work e It is forbidden to drill holes in the AHU in order to prevent damage to pipes and the heater e When the system is compression tested some water can remain in the element The system must comply with the PED guideline Compression testing is the responsibility of the installer Always de aerate the system If the cabinet is temporarily not in use the remnant water must be removed in order to prevent the danger of freezing e Only use the medium for which the element was designed If the medium consists of a mixture of water glycol you must take account of the fact that glycol is a strong oxidising agent e If only water is used as a medium the element must be drained if the air reaches
38. ion testing is the responsibility of the installer Pipes must always be insulated and are the responsibility of the installer The operation of the steam heater must be connected to the operation of the fan If the fan stops the supply to the steam heater must be stopped immediately Steam heaters have surface temperatures that exceed 100 C The entry of the steam must be done by expert personnel in a controlled manner The steam heater may only be switched on if a minimum specified quantity of air is flowing over the heater Check whether there are any objects in the heating function The temperature can rise so high that plastics may melt The steam heater must be switched off a minimum of 5 minutes before the AHU is switched off The following warning pictogram is applied to the panel of the LBK Hot surface 4 5 Coolers 4 5 1 General Using gloves in order to prevent cutting injuries during maintenance or repairs of the cooling element is compulsory Safety glasses must be worn while working on the cooling element Gloves must be worn during maintenance work It is forbidden to drill holes in the AHU in order to prevent damage to pipes and the cooling element Water may remain in the element during compression testing The system must comply with the PED 15 16 guideline Compression testing is the responsibility of the installer Always de aerate the system If the cabinet is temporarily out of use all of
39. ity for modifications that have not been approved See chapter 1 1 After changing the motor transmission or frequency converter settings e Check the fan rotation direction e Check the power input CAUTION While working on the fan the switch has to be locked open ae Q waarschuwing Voor openen deuren ventilator uitschakelen spanningsloos maken en uit laten lopen minimaal 2 minuten Transportbeugels Verwijder transportbeugels voor opstarten ventilator warning Before opening the doors switch off and deenergise the fan and allow it to run down minium 2 minutes Transport brackets Remove transport brackets before starting up the fan attention Avant ouverture des portes le ventilateur doit tre d connect et avoir eu le temps de s arr ter completement 2 minutes minimum Fixations de transport Retirer les fixations de trans port avant la mise en route Gefahr Vor ffnen der T ren den Ventilator abschalten span nungslos machen und zum Stillstand kommen lassen mindestens 2 Minuten warten Transportsicherungen Transportsicherungen vor der Inbetriebnahme demontieren 200034906 The warning pictograms indicating rotating parts electrical voltage and opening of doors are attached to the door WARNING Remember to deenergise all components and to ensure that the fan has stopped rotating before the doors and access covers
40. led description of the individual components CAUTION Before starting up the AHU ensure that the components have the correct connection voltage and connect them in accordance with the regulations The doors and access covers must be closed and the AHU must be earthed Start up check points Function Components Check points Start up General All functions Remove obstacles and loose debris from compartment All functions Check for possible condensate and if necessary dry the parts Indoor installation Internal and external panels Damage outdoor installation Internal and external panels Damage Joints Cracks Doors access covers Must be closed and locked before start up Flexible connections Correct installation Earthing Correct earthing in accordance with regulations Roof covering outdoor installation Check if roof is completely watertight Dampers Correct operation Blades fully closed and at zero position Actuators Correct operation Check rotation direction Actuator end position same as damper end position Filters Correct filter type Are the filters correctly installed Pressure differential gauge Correct operation Pressure differential switch Correct operation set up droplet eliminator bent fins siphon correct connection Start up check points Function Components Check points Start up Heaters Hot water coil Correct connections Air
41. me flexible connection or wiring e Check for possible condensate moisture Condensate may form in the period before the first start up of the AHU as a result of weather change and or humid air from the building Remove all condensate from the construction components and dry the electrical components using warm dry air e g with a hair drier This applies to both motor and frequency converter e Check the connection voltage e Check and or connect the motor in accordance with local instructions and the data of the supplier e Check the direction of rotation of the impeller The direction is indicated on the fan by an arrow e Separately measure the current draw of the electric motor for all phases The current draw of all phases must be approximately the same and agree with the data on the name plate Set the motor protection device to the nominal value e The motor data shown is for an altitude above sea level of up to 1000 m and an ambient temperature of 40 C maximum e The data for belt type belt tension number of belts size and type of pulley is given on a sticker on the fan housing e Ifthe fans are shut down for longer periods longer than three months the bearings may be damaged To prevent this it is recommended to reduce the fan belt tension or to remove the fan belts temporarily When the fans are restarted the belt tension has to be reset to the specified value This type of damage can also be prevented by controlle
42. ommended to insulate all ducts from and to the building to minimise heat transfer and to ensure good control e After connecting the ducts to the building immediately connect the unit to the power supply switch it on and start it up If this is not done moisture will move from the building ducts to the AHU causing an increase of the relative humidity in the AHU At low outdoor temperatures if the AHU is not operating this can lead to condensation in the AHU and at the control panel This must always be prevented 4 2 Dampers When working on damper registers it is possible for your fingers to become trapped The AHU must be Voltage free while cleaning the damper blades in order to prevent unexpected closing of the dampers While connecting the cabling of the servo the AHU must be Voltage free in order to prevent the connection cables from being live e Check if the actuator motor is installed in accordance with the supplier s instructions Check if the correct angle has been set Check if the dampers close properly Check if the damper can be set to the fully open position Check operation and damper position of the spring return after a power cut Some dampers must be open others must be closed e Ensure that the end position of the damper is the same as the end position of the actuator so that the drive lever of the damper is unloaded in the end position Actuator assisted operation
43. on It is therefore necessary to regularly check and clean these spray pipes 6 15 Fan 6 15 1 General e CAUTION The air flow may cause stationary parts to move even a fan that is switched off e CAUTION While working on the fan the switch has to be locked open Before switching off the fan always check if an electric heater is installed If this is the case the electric heater must always be switched off first The fan must continue to run for at least five minutes to cool down the heater coils e The data for belt type belt tension number of belts size and type of pulley is indicated on the fan housing 6 15 2 Bearings The bearings of the smaller fan types cannot be lubricated If the larger fans are of the re lubricated type they should be lubricated every six months For higher temperatures and increased contamination the lubrication interval should be adjusted as required The standard lubricant is Shell Alvania R3 For higher temperatures and a higher degree of humidity use a lubricant recommended by the supplier The electric motors are equipped with roller bearings Depending on the motor size the bearings are lubricated for life or equipped with a grease nipple The lubrication interval and type of lubricant are as above It is recommended to check the motor and fan bearings for excessive vibration This can be a sign of bearing wear but also of incorrect operation of the transmission or an unbalanced syst
44. operation Heaters Hot water coil Contamination corrosion Air vent the coil Leakage Glycol Check glycol concentration Frost protection thermostat Operation Electric heater Contamination of heating coils Loose wiring Thermostat operation Steam heater Contamination corrosion Leakage Coolers Chilled water coil Contamination corrosion Air vent the coil Leakage Condensate pan Contamination corrosion Droplet eliminator if used Contamination Drain trap Contamination and operation Glycol Check glycol concentration Heat recovery wheel Rotor Contamination Seal Cracks position Motor Operation Belt Tension wear Electrical components Operation Fins Contamination Damper if used Sealing Bearings Actuator Condensate pan Contamination corrosion Water trap Contamination and operation steam humdification direct connection and appendages leakage operation servo operation steam humidification electric connection and appendages leakage operation electric components operation boiler scaling on the electrodes spray humidification sprayers operation Infrasonic humidifier hoses connections tears sprayers operation pressostat operation max pressure 24 coil filter contamination operating pressure Fan Bearings larger types Lubrication wear Impeller Contamination
45. ositioned and have been pushed well against each other from below When replacing built in filters you must ensure that the filter has been pushed well against the sealant Filters must be replaced at the required intervals The timing of the replacement depends on the filter quality and the degree of contamination of the air The pressure loss across the contaminated filter can be measured with a pressure differential gauge e Filter functions that are fitted with droplet eliminators stainless steel drip tray and stainless steel inner plates must be cleaned completely All dirt must be removed from the walls drip tray and fins Flush the drip tray and siphon with clean water e A respiratory protection mask type P2 and safety gloves must be worn when changing the filters Open flames are forbidden while changing the filters to prevent setting fire to the filter medium This is indicated by a sticker on the door or hatch waarschuwing warning Vervuilde filters zijn brandbaar Polluted filters are inflammable attention Gefahr Les filtres encrass s peuvent Verschmutzte Filter sind leicht tre inflammables entflammbar 200034907 6 9 Heaters 6 9 1 Hot water coil ATTENTION For general comments see 4 1 1 e Dirt on the finned surface reduces the capacity of the heater e Check the air intake once a year for contamination and if necessary clean with compressed air against the direction of th
46. r Jahr Ann e Part j Gewicht Weight Poids Kg hls S Code 4 1 1 Casing panels Check the AHU panels for any damage Any dirt or stains must be removed from the surface to prevent possible long term damage Building debris left on the roof of units installed inside and outside must be removed Dirt can be removed with water and a mild household soap solution Damage can be repaired by thoroughly cleaning the affected surface then treat and paint as necessary If applicable check the sealing joints and repair if required 4 1 2 Doors and access covers Check the operation of door handles locks and movement of the hinges Check if the door closure on the inside of the door is tightly fitted so that there are no excessive air leaks at the doors For outside installation of the AHU check the storm cord For the sections that are under pressure it is recommended to order a door lock with an pressure safety device CAUTION Doors and access covers must always be closed before starting the unit 4 1 3 Flexible connections e Check that all flexible connections are firmly attached to the AHU If necessary tighten loose screws e The stretched length of a single skin flexible connection is 130 mm but a flexible connection must NOT be installed stretched between the AHU and the duct Once installed the operating length of the flexible connection must be 100 mm 4 1 4 Earthing Ensure that the AHU
47. r intake damper 2 Pressure sensor extract air fan H hoogte unit n x 160 98 C Anti corrosion screen 3 Main switch supply air fan H1 hoogte ondersteuning in mm D Supply air filter 4 Actuator recirculation air damper E Extract air fan 5 Frequency converter supply air fan The gray areas in the table indicate F Control panel 6 Pressure sensor supply air fan standardized units G Motor heat recovery wheel 7 Main switch supply air fan H Heatrecovery wheel 8 Main disconnect switch supply electric heater Custom sizes are possible L Steam humidifier 9 Pressure sensor extract air fan J Supply air fan 10 Servo exhaust damper The service area for the exchange of K Extract air filter 11 Pressure switch supply air filter components such as elements and L Electric reheater hot water 12 Frost protection thermostat heater ventilators depending on the cabinet M Cooling coil with changeover 13 Pressure switch extract filter width and at least equal to the cabinet N Supply air damper width O Extract air damper 18 16 14 12 10 8 6 4 2 5 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 w 5 3 CHECKLIST OF START UP CHECK POINTS Before commissioning the unit all functions below and the associated components must be checked using the check list below The table below shows a general overview of the operations required to facilitate the installation of the AHU The following pages give a more detai
48. r pulse pause must be activated or the quantity of air supply must be reduced 4 7 Heat recovery wheel e Ensure that the heat exchanger face area is not damaged e Check that the wheel is rotating in the correct direction This is indicated by an arrow on the casing e Check if the wheel seals are fitting correctly e Check if belt tension is correct e Check if the motor and the rotation monitor have been correctly connected 5 mm play between sensor and detection point on the wheel e Check if the controller has been correctly connected and set in accordance with the supplier instructions The instructions for the controller supplier apply e Ensure that the rotor speed has been correctly set The 39SQ condensation rotor must have a maximum speed of 10 min a sorption rotor must have a maximum speed of 20 mn Refer to the user manual for the heat recovery wheel controller e Ifthe air intake temperature is below 15 C a pre heater is recommended for the heat recovery wheel to prevent freezing e The following warning sign is shown on the panel Rotating parts AHU with control If the heat recover wheel is supplied including a rotor controller this must be included in the central control panel The rotation sensor of the rotor is pre fitted and must be connected If it is necessary to protect the heat recover wheel against frost damage the heat recovery wheel must be fitted with a pressure sensor or pulse pause m
49. rame fitted with lifting plates with holes for the fastening of D D sluitingen e Lifting must be carried out in accordance with local regulations and with the help of certified lifting aids e Only one set of lifting bars is supplied per order position number per unit width if ordered These lifting bars are suitable for single use and only for the parts of this order position number The lifting bars are certified by an authorised person using a type test 2 2 Transport and storage During transport and storage the air handling unit must only be supported under the designated lifting points Supporting and lifting under the cross beams is prohibited This is indicat ed on the cross beam with the following label 2 3 Roof edge protection during transport outside installation Roof edge transport protection During transport by truck the units are attached to the loading surface with tie ropes pulled across the unit towards the side edges of the truck To protect the roof edge on outside units that are wider than 1500 mm protection plates are added in place of the tie ropes to prevent distortion of the roof edge 2 4 Offloading and hoisting Depending on the dimensions of the AHU and the situation on site the AHUs are supplied in previously agreed trans port sections Before proceeding with the transport and installation of the casing sections always consult the applicable dimensional drawing that give the
50. s check the atomization Check the pressostats Fan Transport protection brackets Remove Fan housing and fan compartment Remove obstacles and loose debris from the fan and fan compartment Fan compartment fan motor frequency converter Check for possible condensate and if necessary dry the parts Impeller Check rotation direction Motor Check connection voltage Correct connection Check current in all phases Drive belt Check tension Flexible connections Correct installation Operating switch Check connection Ensure switch is locked off during checks Pressure switch sensor Operation Silencer duct silencer Damage of the top layer Check for air tight connection at the correct opening Is the duct silencer sufficiently supported Frequency converter Connections Correct connection complies with EMC Frequency converter Check for possible condensate and if necessary dry the converter Voltage Check connection voltage Settings Check correct settings Phases Check voltage in all phases Lighting Lamp Check connection voltage Switch Check connection 10 4 START UP INSTRUCTIONS 4 1 Casing The unit data such as order number position number etc is given on the nameplate C Holland Heating bv Order no C Zanddonkweg 7a uz to 814 NX Waalwijk POS no d The Netherlands Type HHFlex o d Jaar Yea
51. s It is therefore better to use weld solder connections e Water glycol causes increased sludge formation Always observe the instructions of the right glycol manufacturer Check the mixture to ensure that the glycol concen tration by weight is correct 4 4 2 Electric heater ATTENTION The electric heater must be connected on the basis of the technical data and the connection diagram supplied It is important that the requested capacities of the machine correspond with the thickness of the chosen connection cable and fuses of the power grid The installer is responsible for the connection and correct operation of the machine It is forbidden to enter the AHU if the electric heater is switched on In the adjustment include that the fan must first be rotating before the heater may be switched on After switching the heater off the fan must continue to rotate for a minimum of 5 minutes If not all of the steps of the electric heater are variably controlled ensure that the minimum speed over the heater is 2m s If all steps are variably controlled the air speed over the element can be reduced to 1 5m s Check and or connect the heater in accordance with local regulations and the data from the manufacturer Ensure that the terminal strip earth and the inspection hatch earth have been connected Check for possible condensate moisture Condensate may form in the period before the first start up of the AHU as a result of wea
52. sonnel e It is not recommended to connect several DX coils to one compressor condensing unit e tis best to use an infinitely variable controller for the compressor condensing unit If the condensing unit has infinitely variable control one of the temperature controls in the controller can be selected e Ifthe condensing unit does not have infinitely variable control set the AHU control for supply air tempera ture control and connect the DX entering temperature sensor instead of the supply air sensor The desired room temperature must then be controlled by a separate controller at the condensing unit If a changeover coil is supplied by a heat pump the installa tion must be designed to compensate for the required heat during the system heat pump defrost cycle and the heat cannot be drawn from the supply air Otherwise the supply air temperature cannot be achieved During the heat pump defrost cycle it must be possible to add so much heat into the system that the desired entering temperature heater design capacity as well as the required heat for heat pump defrosting can be guaranteed AHU with control If the heat recover wheel is supplied including a rotor controller this must be included in the central control panel The rotation sensor of the rotor is pre fitted and must be connected If it is necessary to protect the heat recover wheel against frost damage the heat recovery wheel must be fitted with a pressure sensor o
53. tdoor air intake The outdoor air intake is contaminated by pollution taken in with the air The maintenance interval must be observed as irreparable damage of the panels might otherwise occur Clean the outdoor air intake well and repair damage as described in point 6 2 1 Ensure that no moisture droplets is taken in If there is still moisture ensure that this is corrected by changing the outdoor air intake duct 6 8 Filters ATTENTION es When changing the filter there is a danger of viral and bacteriological contamination Use of suitable gloves face masks and safety glasses is compulsory Wearing safety glasses is compulsory The face mask must be minimum P2 The gloves must be liquid tight es The filters must be fitted in the correct manner air direction es The bottom under the filter may be highly contaminated This dirt must removed during every inspection Any corrosion of the bottom must be removed immediately and repaired with an anti corrosion agent and or coating 25 Filters that are too dirty also increase the resistance pressure differential of the filter and can increase power consumption The fastening frame of the filter may fail if the pressure differential over the filter is excessive e The filters must be inspected once a month for excess pollution pressure loss damage and seating of the slide in filters or built in frames With slide in filters ensure that the filters have been correctly p
54. the manufacturer Refer to the supplier s instructions In the case of under pressure in the AHU place a special siphon for condensate drainage To commission the steam humidifier the steam must be introduced into the system and the humidifier must be brought operating temperature slowly When the condensate pipe has reached operating temperature switch on the adjustment motor electrically or pneumatically and set the desired humidity level Refer to the supplier s instructions Clean the seive of the dirt collector and check the conensate ahaust several days after commissioning the machine In the case of cabinets with underpressure the operation of the underpressure siphon must be checked with a non return valve A maximum hygrostat must be fitted in order to prevent excessive hmidification in the AHU See 4 8 1 The connection of the steam pipe to the pipe must be Voltage free in order to prevent distortion of the steam pipe and generator The following warning sticker I applied to the panel Hot surface 4 9 Steam humidifier electric 4 9 1 General see 4 8 1 The electric humidifier must be connected on the basis of the technical data and the supplied connection diagram It is important that the requested capacities of the machine correspond with the thickness of the chosen connection cable and the fuses on the electricity grid The installer is responsible for the connection and good operation of the device
55. the remnant water must be removed in order to prevent the danger of freezing Only use the medium for which the element was designed If the medium consists of a mixture of water glycol you must take account of the fact that glycol is a strong oxidising agent Remove any remnants of liquid immediately If only water is used as a medium drain the elements if the air starts to approach freezing point lt lt lt Indien mengsel van water en glycol moe gt gt Avoid excessilve vibrations caused by external devices that are transmitted through the pipes The flanges of the headers must be mounted on the pipes Voltage free The maximum operating pressure may never be exceeded Check the connections on the dimensional drawing Ensure that the coil has been fully purged Control the connections for leaks If a changeover coil is supplied by a heat pump the installation must be designed to compensate for the required heat during the system heat pump defrost cycle and the heat cannot be drawn from the supply air Otherwise the supply air temperature cannot be achieved During the heat pump defrost cycle it must be possible to add so much heat into the system that the desired entering temperature heater design capacity as well as the required heat for heat pump defrosting can be guaranteed Ensure that the AHU is installed high enough to enable the siphon trap to work correctly Check that the siphon trap option has been correctly inst
56. the two openings further apart using an extra piece of duct at the outdoor air intake opening If the units are installed outside this piece of duct should be placed between the air handling unit and the pre installed suction cap if used The piece of ducting must always be supported in an appropriate way 4 1 9 Condensation in or on the AHU Condensation can form on the inside and outside the AHU This depends on the installation location indoor or outdoor temperature and relative humidity inside and outside the AHU and the thermal bridge factor theTB value of the AHU Always select an AHU with a thermal bridge factor that will not lead to condensation at the indoor and outdoor conditions For units installed inside the following points must be considered e Open water collection tanks e g vapour condensate collection tank These must always be unpressurised and covered so that the relative humidity in the plant room is minimised e Sufficiently insulate the cold water and condensate lines up to the AHU e Sufficiently insulate air ducts with a possible air temperature below the dew point of the air in the plant room as described earlier For units that are installed outside the following points must be considered e Always insulate air ducts with a possible air condition temperature and relative humidity with a dew point above the expected outdoor air condition to prevent condensate formation in the duct It is rec
57. ther change and or humid air from the building Remove all condensate from the construction components and dry the electrical components using warm dry air e g with a hair drier Check the connection voltage Check the existing amperage on all phases The values must agree with the data on the heater name plate To ensure safe operation of the heater it is equipped with a thermostat with auto reset 80 C and a high limit thermostat with manual reset 128 C The warning label for electrical voltage is attached to the inspection hatch The earth warning label is attached to the inside of the heater and the inspection hatch The warning label for the procedure to switch off the heater is found on the door or hatch of the fan assembly elektrische verwarmer moet de minimaal 5 minuten draaien waarschuwing Na het uitzetten van de warning After switching off the electric heater the fan must continue to ventilator nog run for at least 5 minutes ventila teur doit continuer tourner pendant au moins 5 Gefahr Nach Abschalten der Elektroheizung muss der Ventilator noch mindestens 5 Minuten weiterlaufen attention Apr s la d connexion de la r sistance lectrique le minutes 200034908 4 4 4 Steam heaters ATTENTION Steam heaters that are connected to the pipes must always be compression tested by trained personnel and comply with the PED guideline Compress
58. this access cover door or panel that may be dan maken en uit laten lopen fan and allow it to run down gerous for the user installer Only qualified personnel is minimaal 2 minuten minium 2 minutes permitted to carry out work on these components For this work the regulations of the applicable international a o Transportbeugels Lien uuu Os TEC 61557 EN 50110 and ES 59009 and national e g BS n e nee eee 7671 standards must be observed The pictogram is attached E SE to the access cover for the electric heater control box attention _ Gefahr Avant ouverture des portes le Vor Offnen der Tiiren den ventilateur doit tre d connect Ventilator abschalten span et avoir eu le temps de nungslos machen und zum s arr ter completement Stillstand kommen lassen 2 minutes minimum mindestens 2 Minuten warten Fixations de transport Transportsicherungen Retirer les fixations de trans Transportsicherungen vor der port avant la mise en route Inbetriebnahme demontieren 200034906 Other warning labels waarschuwing Vervuilde filters zijn brandbaar warning Polluted filters are inflammable attention Gefahr Les filtres encrass s peuvent Verschmutzte Filter sind leicht tre inflammables entflammbar 200034907 waarschuwing Na het uitzetten van de elektrische verwarmer moet de ventilator nog minimaal 5 minuten draaien warning After switching off the electric heater the f
59. uction types The following warning pictograms and labels with text are used Lifting point This pictogram shows where the AHU must be lifted and is positioned on the support beam o Lifting prohibited This pictogram shows that no horizontal transport devices must be placed under this frame section such as pallet lifters or the forks of fork lift trucks It is also forbidden to place lifting devices for transport and storage under this frame element Earthing This pictogram indicates where the AHU can be earthed andis on one of the support beams beneath the casing in the fan section If a unit consists of several sections only one section needs to be earthed provided the sections are connected in the correct way e The electrical components in the AHU must be earthed except for components with double insulation and or components with a supply voltage below 50 V e The electrical components must be installed in accordance with national and local regulations Rotating parts Central data This pictogram indicates that there are rotating parts behind This label contains the data for the AHU such as order this access cover door or panel which may cause injury The number position number etc The label is normally located components that include rotating parts are the fan and heat on the access cover or the door of the fan assembly recovery wheel If there are special customer specific components behind doors acc
60. ust be avoided The control system must include an appropriate protection device General data fan motor Insulation class motor DOE PTC trip temperature 155 C Connection voltage 3 x 230 V 50 Hz 3 x 400 V 50 Hz 3 x 690 V 50 Hz The fan motor must have a power supply of 230 V 3 ph 50 Hz or 400 V 3 ph 50 Hz The connection must be made with short circuit protection fuses and a thermal motor safety switch matched to the nominal current of the motor The motor can also be protected against overheating by three series connected PTC thermistor fuses installed in the windings If a frequency converter is used the thermistors must be connected to the converter PTC PTC PTC Thermal motor fuse Before connecting the power supply please check the diagrams on the next page to ensure that they agree with the data on the motor name plate and the data in the technical documentation The disconnect switch is located on or near the fan section When working on the unit the switch must be turned off and secured with a padlock Switching off the disconnect switch must be done when the unit is not energised Before opening the door or inspection hatch of the fan section failure maintenance service the AHU must be de energised CAUTION Motors with a power output of up to 2 2 kw 230 V 400 V can have across the line starting Motors with a power output of
61. ust be activated or the quantity of air supply must be reduced 4 8 Plate heat exchanger Ensure that the face area of the heat exchanger is not damaged 17 If dampers are installed also check if the actuator motor has been installed in accordance with the instructions of the supplier Check if the correct angle has been set Check if the dampers close correctly Check if the dampers can reach the fully open position Before connecting the siphon trap and checking the droplet eliminator if installed see chapter 4 5 If the air intake temperature at the is below 10 C ina cross flow plate heat exchanger a pre heater is recom mended for the plate heat exchanger to prevent freezing In a counter flow plate heat exchanger a pre heater is recommended for the plate heat exchanger if the air intake temperature is below 5 C to prevent freezing If desired necessary the heat recovery wheel is fitted with a sensor that protects the exchanger from freezing If dampers present the control system must open and close the dampers at the correct time in order to prevent freezing of the plate exchanger 4 8 Steam humidification direct 4 8 1 General First read the documentation supplied Connect the steam generator in accordance with the documentation supplied Wearing safety gloves and glasses is compulsory Entering an active steam generator is forbidden Entry is only permitted after the steam generator has been inactive
62. vent the coil Leakage Frost protection thermostat connected Electric heater Check heater earth Check hatch earth Correct fuse size Check wiring diagram Check for possible condensate and if necessary dry the heater steam heater correct connections completely water free leakage heater and pipework Testing heater and pipework Leakage Droplet eliminator Correct alignment Drain trap Correct connection Heat recovery wheel Rotor Check rotation direction Seal Correct seal towards wheel Drive Check connection voltage Correct connection Check current in all phases Drive belt Check tension Rotation monitor Correct connection Controller Correct connection Plate heat exchanger Damper if used Correct operation Actuator if used Correct operation Syphon trap Correct connection Droplet eliminators if used Bent fins steam humidification direct connections and appendages see supplied documentation test humidifier and pipes leakage servo check connection and operation steam humidification electric connections and appendages check connection Voltage check connection and operation water humidifiers spray humidifiers see supplied documentation Infrasonic humidifiers see supplied documentation check connection Voltage check exhaust check hose
63. water through the float seal However this does contain more salts and other solids so that they become increasingly concentrated in the reservoir which is indicated by the term thickening Constantly spraying a certain quantity of water can limit the concentration in the container We control this limit by determining the quantity of spray water required e Determination of the quantity of spray water with a known maximum of water to be evaporated and a selected thickening factor Os SC qt qv qs l In which i thickening factor see below qt supply water quantity qy quantity of water to be evaporated qs spraywater quantity The Ph value of the spray water may not be lower than 5 or higher than 10 The choice of thickening factor and therefore of the spray water quantity is an important factor If the thickening factor chosen is too low the costs of water consumption will be unnecessarily high If the thickening factor is too high extreme scaling and contamination of the wet parts of the humidifier takes place This causes high maintenance costs A maximum hygrostat must be fitted in order to prevent excessive humidification in the AHU See 4 8 1 4 10 4 Infrasonic humidification Read the instructions supplied by the supplier carefully The following points deserve extra attention Check whether the connection Voltage corresponds with the Voltage of teh machine Connect the machine in accordance with t

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