cobra2 compact units

COMPACT UNITS

CompAir CF CompAir RW CompAir CF FREE

INSTRUCTIONS FOR: TRANSPORT

INSTALLATION COMMISSIONING

OPERATION TESTING

MAINTENANCE

COMPACT AIR HANDLING UNITS 2

INSTRUCTIONS FOR TRANSPORT, INSTALLATION, COMMISSIONING, OPERATION, TESTING AND MAINTENANCE 2

0 GENERAL During the transport, installation, commissioning, operation, testing and maintenance of the air handling units, please observe the following:

Prior to any work on the unit, please study carefully the instructions in full.

The airhandling unit may only be installed, checked, commissioned and maintained by trained personnel, which shall, in their operations, observe the statutorily provided engineering standards and local safety regulations applicable at the time of the unit installation.

In installing, commissioning and maintenance of functional elements produced by

The instructions and electrical diagrams shall be stored and kept available to the person operating the unit.

The airhandling unit shall only be used for the purpose and under the operating conditions specified in the confirmation of order under which the unit has been manufactured. Any other use deviating from the intended use relieves the manufacturer from any obligation.

The unit manufacturer shall not be kept liable in the cases of failure to observe the information provided in these instructions during the airhandling unit installation, commissioning, testing and maintenance, or in the cases of alterations of electrical or mechanical unit components without a prior specific approval by the manufacturer. Any unauthorised intervention into the unit also voids the warranty.

ADDRESSES OF THE MANUFACTURER AND AUTHORISED

SERVICES

Lindab IMP Klima d.o.o. Godovič 150, 5275 Godovič, SLOVENIA

Tel.: +386 (0)5 3743 000 E-mail: [email protected]

www.lindab.si

Authorised service: Lindab IMP Klima d.o.o.

Godovič 150, 5275 Godovič, SLOVENIA Tel.: +386 (0)5 3743 000

E-mail: [email protected] www.lindab.si

manufacturers other than Lindab, the manufacturer’s instructions shall be followed.

http://www.lindab.si/



1 DESCRIPTION A CompAir compact air handling unit model essentially consists of a housing with installed different functional elements as required, constituting, in combination with the housing, the functional sections the designations of which are listed in the following table.

1.1 TYPES OF FUNCTIONAL SECTIONS

Designation Description

VF Fan section – EC Radial fan backwards curved without housing

EW Heater section with water heater

FR Section with anti-freezing protection

KW Cooling section with water cooler

FK Cartridge filter section

RPDG Recuperation section with counter flow plate recuperator – diagonal design

RRG Regeneration section with rotary wheel

ST Flexible connection

H Protection hood

EE Heater section with electrical heater

FREE Unit with an inverter compressors driven reversible cooling system

1.2 FUNCTIONAL ELEMENTS

Figure 1 Functional elements of full optional inside CF monoblock unit

Counterflow plate recuperator

Drain pan

Inlet fan

After heater

Cooler Siphon

Inlet air flexible connection

Handle

Outlet air flexible connection

Outlet fan Electro control cabinet

By-pass damper

By-pass damper drive

Preheater Fresh air filter

Fresh air flexible connection

Fresh air damper

Outlet flexible connection

Outlet air damper

Outlet air filter

Feet



Figure 2 Functional elements of full optional outside CF monoblock unit

Figure 2a Functional elements of FREE outdoor CF compact unit with a cooling system

Inlet fan


Handle

Protection hood outlet


By-pass damper

By-pass damper drive

Preheater Fresh air filter

Protection hood fresh air

Fresh air damper


Outlet air damper

Outlet air filter

Counterflow plate recuperator Drain pan

After heater

Cooler Siphon

Roof

Integrated cooling system

Condenser Droplet eliminator

Droplet eliminator Compressor

Evaporator



Figure 3 Functional elements of full optional inside RW monoblock unit

Figure 4 Functional elements of full optional outside RW monoblock unit

Rotary wheel

Inlet fan

After heater Cooler


Handle



Preheater

Fresh air filter

Fresh air flexible connection

Fresh air damper


Outlet air damper

Outlet air filter

Feet

Rotary wheel

Inlet fan

After heater Cooler


Handle



Preheater

Fresh air filter

Protection hood fresh air

Fresh air damper

Protection hood outlet air

Outlet air damper

Outlet air filter



1.3 AIR HANDLING UNIT HOUSING CompAir air handling unit model housing consists of a thermally and sound insulated aluminium frame, thermally and sound insulated sheet metal bottom, top and side covers, and the servicing door on the servicing side, and a structural steel frame fitted, as required, with rubber-base legs. The unit housing wall thickness is 50 mm. 1.3.1 HOUSING PANEL MATERIALS As standard, the external and internal panels are available in painted sheet steel, on special request, or stainless sheet steel 1.4301. 1.3.2 SOUND INSULATION

(Hz) 125 250 500 1000 2000 4000 8000

De (dB) 10,6 13,9 13,2 16,2 21,4 25,3 35,2

1.3.3 THERMAL INSULATION Heat transfer coefficient: T3 or T2 according to EN 1886. Thermal bridge coefficient: TB3 or TB2 according to EN 1886. 1.3.4 MECHANICAL STABILITY Conforms to class 2A according to EN 1886. 1.3.5 HOUSING AIR-TIGHTNESS Air-tightness class A according to EN 1886. 1.3.6 FILTER INSTALLATION TIGHTNESS Conforms to filter installation class F7 according to EN 1886. 1.3.7 HOUSING CHECKING AND MAINTENANCE The checking and maintenance shall be done according to the schedule set out in the following table.

Inspect for water formation within the housing x

Check the hygiene condition x

Air handling unit housing checking and maintenance schedule

Action

Time interval (months)

1 3 6 12 24 According to the hygiene inspection

Inspect for contamination, damage and corrosion of the housing interior

x



2 AIRHANDLING UNIT TRANSPORT Protect individual compact sections (shipment units) so as to prevent, during loading, ride or unloading, their damaging due to tumbling, sliding or uncontrolled release from the transport vehicle, and to prevent any safety or health hazards to exposed persons. Until the delivery to the installation site, the individual compact sections of the air handling unit are to remain secured with all guards and protective means (diagonal restraints, wooden supports – pallets under the structural frame, protective foil etc.). During the transport, any handling of the device shall be carried out via the structural frame – no pressure on the housing! Any crane hoisting of the airconditioning compact sections is to be done only via the structural frame provided underneath the section. Insert appropriate tubes (thick wall tube of outside diameter ø 48.3 mm and wall thickness of 10 mm) through the circular leads in the structural frame. For lifting, apply steel hoisting ropes or chains; in all cases, apply two spacer supports (Figure 5, detail A). The tubes shall be provided with appropriate guards at both ends (Figure 5, detail B).

Figure 5 Allowed transport Figure 6 Not allowed transport

Hoisting without spacer supports (Figure 6) is not allowed, since this might damage the housing. In the cases of some functional units, such as heat exchanger section and similar, or of standalone rotational regenerators or heat exchangers, short and disproportionately high section combinations may be encountered. In such cases, be extra careful to avoid transport hazards. To this end, the packaging of such sections is constructed so as to prevent the hazard of tumbling during transport or storage, to add to the safety of exposed persons. The shipment units of this kind are factory protected in the following ways (Figure 7):

wooden pallets or support beams exceed, in length, the section length by H1/4 (H1 = total section height) to prevent unit tumbling (the wooden support beam depends on the shipment unit length and height);

on their sides, the units are propped with extra diagonal supports, fixed to the woodenpallet or beam on one end and to the unit itself on the other end (the length of these props depends on the length of the support beams and on the shipment unit height);

A

DETAIL A

B

DETAIL B



the base (structural frame) is provided with hoisting holes on the longer (transversal) sections, too (observed from the front);

Figure 7 Shipment of high units

Always place the shipment unit on even ground. Always lift the shipment unit applying the hoisting procedure described in this chapter paragraph three. No stripping of props or aids is allowed during transport; in an event of such stripping, the person having carried it out is held fully liable for any adverse consequences. Remove the props only before the installation on site. Until installation, store the air handling units in a roofed and dry area. Any handling by means forklift is only allowed using the wooden transport pallet which is always provided under the compact shipment unit. Always observe the weight and the position of the centre of gravity of the compact shipment unit.

3 AIRHANDLING UNIT MOUNTING

3.1 SERVICING AREA To allow maintenance interventions and operation (e.g. withdrawal of a heat exchanger), always provide a clear area of a minimum width of 1.3 x unit width on the airhandling unit servicing side. To facilitate the installation, a clearance area of a minimum width of 0.5 m should be provided on the non-servicing side as well (Figure 8).



Figure 8 Servicing area

In the case of an airhandling unit mounting on an elevated platform, provide safe access to the platform and the necessary servicing area on the platform. Also provide appropriate guards for the maintenance technician, in accordance with applicable regulations on safety at work. In the design and construction of electric installation and piping connections to the functional sections, the designer and the constructing contractor shall refrain from leading such installations and connections through servicing doors or servicing hatches. Failure to observe this requirement may render the servicing of airhandling unit functional sections impracticable.

3.2 CONSTRUCTION OF AN AIRHANDLING UNIT FOUNDATION Mount the airhandling unit onto an appropriately high and level concrete or steel foundation (or base). Level out any irregularities in the foundation surface. The minimum foundation height is determined by the elevation of the drain siphon in the section set and shall be 150 mm.



Figure 9 Unit on foundation

In acoustically demanding applications, separate the foundation plate from the rest of the building structure by means of a structural noise insulation layer of appropriate thickness, depending on the airhandling unit mass and excitation frequency and the natural frequency of the insulation material (Figure 9).

3.3 MOUNTING OF AN AIRHANDLING UNIT WITHOUT A FOUNDATION The foundation may be substituted by the mounting the unit onto HIDRIA type base legs fitted with a structural noise and vibration insulation bolt, allowing the levelling within a range of 30 mm (Figure 10).

Figure 10 Unit on legs

Figure 11 Leg in the unit corner Figure 12 Leg in the unit centre

Structural noise insulation

Air conditioning unit Drain siphon

Fundation

Legs



3.4 AIRHANDLING UNIT MOUNTING PROCEDURE The airhandling unit mounting and assembling procedure is as follows:

Transport the unit to the place of installation.

Remove protective screening and guards (diagonal restraints, wooden supports – pallets under the structural frame, protective foil etc.).

Check the evenness and levelness of the foundation. The section front faces shall be exactly perpendicular to the foundation and parallel one to another.

Apply self-adhesive EPDM rubber sealing tape of 19 x 5 mm cross-section (supplied with the unit) onto the contact front faces (housing frame).

Draw the individual sections together by means of the tightening clamps, which you have mounted into the structural frame openings.

Having drawn the sections together, join them by means of eccentric clamps fitted on the section frames. The eccentric clamps are fitted on both vertical and horizontal sides either outside or inside on the frame, depending on the unit type (parallel, two-stage, horizontal).

In case of TopAir housing, on vertical and horizontal plates are mounted clamps (Figure 14) , which are connected with M8x40 screw.

Figure 13 Joining section for Klimair2 type Figure 14 Joining section for TopAir type

3.5 INSTALLATION PROCEDURE FOR AN OUTDOOR INSTALLATION AIRHANDLING UNIT

Mount the airhandling unit on a foundation of adequate height. In specifying the foundation height, take into account all factors that may potentially affect the unit operation: mounting location, depth of snow cover, requirements regarding the quality of suction of outside air, position of intake and exhaust air duct connections, design of heat exchanger piping connections, installation of power cables etc. The foundation height should not be less than 500 mm. Construct the foundation so as to protect the unit or its components against sliding or tumbling over under wind gusts. Check the wind strength for this purpose.

SEALING TAPE 19x5 ISOWA



Following the attaching and joining of the airhandling unit compact sections, mount the roof sections onto the outer frame ceiling side according to the unit design specification, and seal the roof joints watertight. Roof is mounted in the shop, no mounting on the site is necessary, however, seal the section joints watertight and mount ridge as it shown on figure 15.

Figure 15 Ridge mounting

Check whether the protection grilles and hoods are properly mounted on the air suction and exhaust openings. If not, install them according to the unit design specification. Seal watertight all the vertical joints between compact sections. All the joints between the connections and the intake and outflow air ducts shall be watertight. If the suction air and exhaust air run to/from the unit through ducts, the joints between the connections and the ducts shall be watertight as well. In the case of installing of the unit on the roof or at an elevation, arrange for safe access to the unit and construct a thread-on platform as required. The thread-on platform on the unit servicing side or around the unit should be designed so as to prevent the build-up of snow on the platform in front of the air suction opening, which might result in heavy suction of snow into the unit interior. The platform shall be fitted with a safe ascend and descend footpath and shall ensure safe operation and maintenance of the unit.

4 FUNCTIONAL SECTIONS

4.1 FAN SECTION

Ridge Rivet 4,8x10



4.1.1 SECTION DESCRIPTION

4.1.1.1 Plug fan The fan (Figure 16), without a spiral housing, is driven by an electric motor directly, via a shaft. The electric motor is installed mounted on the fan frame via a base plate. The fan structural frame is mounted to the section housing by means of vibration insulators. A flexible connection prevents the propagation of vibrations from the fan pressure flange to the airhandling unit housing.

Figure 16 Fan unit

4.1.2 ELECTRIC MOTOR CONNECTION Prior to commissioning, check the conformity of the connection parameters specified on the electric load nameplates or in the a/c installation control cabinet with the site power mains parameters. The electric motor connection (figure12) shall be carried out by a properly qualified technician in accordance with the technical regulations and standards, in accordance with the electric design specifications for the building in which the airhandling unit with the fan section is to be installed, and following the electric motor manufacturer's instructions. The electric motor grounding is mandatory.

Figure 17 Motor

Fan motor

Fan impeller

Base frame



connection

Each electronic commutation electric motor is supplied with two connection cables, namely a three-lead power cable for the motor power supply, and a five-lead cable for the position transducer and the motor temperature protection (the temperature protection function being an option). 4.1.3 COMMISSIONING Prior to the fan startup, remove the mechanical blocks of the vibration insulators. The blocks consist of red colour joint brackets screwed on the bottom to the housing structural frame and on the top to the fan-electric motor assembly section. Following the checking and the unblocking of the vibration insulators, remove any tools and other material from the section, check the tightness of screw joints and the condition of electric connections, mount all covers and wall panels removed during the intervention into the section, and close the servicing door and secure them against any unauthorised opening by means of the mechanical lock. The fan should not be operated with the fan section door open. The procedures of accessing into the fan section and of the preparation of the section for the startup, described in paragraphs one and two of this section, are mandatory for any subsequent accessing and intervention into the section as well. Check:

the fastening of the fan to the frame

fastening of the rotor and its uninterrupted rotation in the housing;

fastening of the vibration insulator;

correct grounding;

correct electric connections and their function (proper fuse, contactor and thermal protection sizing);

presence of any tools or other materials in the housing;

fastening of all covers and doors. After the first switching on, measure the electric motor current. If the current is less or equal to the rated current, proceed with the setting of the air volume flow rate. The air volume flow rate is carried out by means of appropriate adjustment (opening or closing) of the control louvres. Upon the completion of the setting of the air volume flow rate, measure the electric motor current again. If the current is less or equal to the rated current, the fan section operation is appropriate. If the measured current exceeds the specified rating, switch the electric motor off and establish the cause of improper operation. The possible causes include: incorrect electric motor connection, incorrect power supply voltage, incorrect power supply frequency, inadequate power leads, improperly sized electric motor (of inadequate capacity), incorrect pressure drops, excessive air volume flow rate. Correct the air volume flow rate by means of reducing the electric motor speed, by changing the electric motor and/or fan pulleys. Correct the pressures by adjusting the



control louvres. Upon the remedying of all causes of improper operation, measure the electric motor current again. If the current is less or equal to the rated current, the fan section operation is appropriate. 4.1.4 SAFE OPERATION, TESTING AND MAINTENANCE Prior to any intervention into the fan section, switch off the repair switch of the fan section being the subject of the check, and lock it in the off state to disconnect the power supply to the drive electric motor. Following the works, remove any tools and other material from the section, check the tightness of screw joints and the condition of electric connections, mount all covers and wall panels removed during the intervention into the section, and close the servicing door and secure them against any unauthorised opening by means of the mechanical lock.During the section operation, all the covers and servicing doors shall be closed at all times. The fan should not be operated with the fan section door open. Proper maintenance is also a guarantee for the safe operation of the unit. Regularly check the tightness of all screw joints, electric connections, grounding and section housing sealing. Observe the electric motor manufacturer's instructions for the motor maintenance. Once a month, check:

tightness of all screw joints;

impeller run;

fan – electric motor assembly vibration insulators;

flexible connections

The checking and maintenance shall be done according to the schedule set out in the following table.

Cleaning of parts of the fan in contact with air and also the water drain to maintain functioning

x


4.2 HEATER SECTION WITH WATER HEATER 4.2.1 SECTION DESCRIPTION The heater section with water heater consists of a section housing, a water heater and anti-freezing protection section (FR) is installed on it. The principal diagram of a water heater section complete with all pertaining safety elements is provided in Figure 18, and applies to all the water heater variants.

Fan section checking and maintenance schedule

Action



Inspect for contamination, damage and corrosion x



4.2.2 WATER HEATER

Figure 18 Water heater unit

4.2.2.1 Description The water heater consists of a frame, fin package, a collection and a distribution pipe (Figure 18). The fin package consists of copper pipes fitted with aluminium fins. The aluminium fins are mounted on the copper tubes by means of mechanical expansion. The collection and distribution pipes interconnecting the fin package tubes are fitted with a bleeding and draining valve. The frame protects the piping elbows and serves for the mounting of the exchanger in the unit. The collection and distribution pipe and soldered joints are anti-corrosion protected by means of a temperature resistant paint coat. Each water heater is submitted to a tightness test in a water bath at the test pressure corresponding to the operating pressure. 4.2.2.2 Installation and commissioning The water heater is mounted in the housing by means of guides allowing its removal from the section in cases of fault or damaging. For this purpose, the A/C unit shall be installed so as to allow a free area at least 1.3 times the width of the A/C unit external width. The heating circuit piping and the heater connections shall not impede the withdrawal of the antifreezing section frame from the air-handling unit housing. Depending on the working medium, the heater connection piping and the collector and distribution manifold may reach high surface temperatures; therefore, take care not to touch these surfaces when working close to the heater, or wear personal protection means (leather gloves), or stop the airhandling unit and shut off the supply of hot water and let the heater and the piping cool down prior to any work. The method of connecting the piping to the heating circuit depends on the piping diameter, as follows:

Anti freezing protection thermostat

Heater connection

Water heater

Capillary tube

Intermediate guide



- with piping diameters of 3/4" up to and including 2", by means of threaded (Holland) nuts. With outdoor installation airhandling units, install the piping circuit in the void chamber downstream the water heater. In this way, it is protected against freezing in the winter period. When installing the water heater, make sure to properly connect the piping installation (Figure 19) and observe the following:

Provide the transfer medium / air counterflow configuration.

Connect the piping and fittings so as to allow unobstructed access to and drawing out of the heat exchanger for revision and maintenance works, without obstructing access to the adjacent sections.

When tightening threaded joints, apply counterforce with an appropriate tool (pipe wrench – padded), to avoid damaging the heater piping circuit.

For easier dismounting, connect the heater by means of two pairs of flanges. Do not weld the connection.

Arrange the two piping connections to the water heater observing the air flow direction, so that the air inflow to the heater is closer to the return pipe, to ensure medium/air counterflow. This applies for either horizontal or vertical air flow configuration.

The pump may be installed in either the horizontal or in the vertical piping leg, provided that the pump shaft is horizontal.

The control/distribution or mixing valve may be installed in either the supply or return pipe; the distance between the supply and return pipe and the distance between the control valve and the bypass pipe should not be less than 500 mm.

Upstream the heater intake, install a dirt trap in the supply pipe to protect the control valve and the circulation pump.

In the supply pipe downstream the connection stop valve, at the heater intake and outlet, install thermometers.

At the lowest point of the piping installation, provide drain cocks for the transfer medium, to allow the heat exchanger draining.

At the highest point of the piping system, provide a bleeding device to ensure uninterrupted flow of the medium through the heater (as a rule, the heaters are supplied already fitted with the bleeding valve and drain cock at the highest / lowest point of the collector / distribution pipe).

Clean the piping system of filings and other debris.



Figure 19 Water heater installation

Prior to the commissioning, check:

the tightness of different screw joints; tighten them as required;

proper operation of the heater automatic anti-freezing protection – prior to the filling of the heater with the circulation medium;

tightness of piping connections;

proper operation of the automatic heating medium supply shut-off function, designed to protect the electric motor against overheating, at the heating medium temperature exceeding 70 °C.

4.2.2.3 Filling and draining procedure – transfer medium: warm, hot water Filling:

partly open the transfer medium supply valve; let the fin register to heat up or cool down uniformly to avoid thermal stresses;

fully open the transfer medium supply valve;

bleed the system to ensure its achieving the full rated thermal capacity;

switch the fan on.

Draining:

close the transfer medium supply valve;

slowly open the drain cock until the heat exchanger is depressurised; then full open both the bleeding valve and the drain cock.

4.2.2.4 Operation In the event of the air temperature falling below the set value, the thermostat and the automatic controller shall carry out the following operations:



switch the fan off;

close the fresh air control louvres;

fully open the heating medium valve;

switch on the circulation pump if not already on.

The heating medium return line thermostat shall function combined with the freezing thermostat. Namely, with only the air flow thermostat installed, under certain conditions, even with the air heated to 5 °C, freezing in the return line might still develop. With the sections consisting of a cooler, heater and preheater, it is sufficient to provide the anti-freezing protection only at the preheater. In an event of a prolonged power blackout, the unit shutdown or interruption of the heating medium supply, drain the heater to avoid its freezing. To further eliminate the risk of freezing, blow the pipe register with compressed air after draining. With the airhandling unit supplied with the controls or automatic controls by HIDRIA, the unit comes with the anti-freezing protection function already fitted; in the case of the controls provided by the customer or a third person, make sure to provide the heater with the anti-freezing protection function. 4.2.2.5 Maintenance Prior to any intervention in the water heater, shut the entire airhandling unit down by switching off the main switch on the electric control cabinet. Lock the switch in the off position. Prior to the startup, clean the device interior and firmly attach and seal all air joints (covers, duct flanges, guards etc.). To ensure proper functioning, regularly carry out the following operations:

Check the tightness of all water connections and air joint tightness.

Check the operation of the bleeding valve. In an event of disturbed medium flow through the exchanger, or presence of air in the circuit, bleed the piping system.

Check the proper operation of the heater automatic anti-freezing protection.

Periodically, check the proper operation of the heating medium supply automatic shut-off upon the unit shutdown.

To prevent the electric motor overheating, check the fan prolonged operation (at least 3 minutes). following the unit shutdown.

Regularly check any dust build-up on the heater fins. Dust or scale build-up on the fins result in a reduced heat exchanger capacity. Periodically – approximately every 500 hours of operation – clean the fins. Clean the fins by blowing compressed air in the direction opposite to the air flow direction. If this cleaning method is not sufficient, dismount the heater and wash it with low pressure water or steam. Do not use high pressure water or steam, to avoid deforming the aluminium fins. When washing with water, the water pressure shall not exceed 15 bar, and the water jet shall be strictly perpendicular to the fin surfaces. Water jet at an angle will damage the fins. This applies in particular for the fins along the edges, which are more sensitive. Never use any hard object for cleaning.





4.2.3 ANTI-FREEZING PROTECTION (FR)

Figure 20 Antifreezing protection

4.2.3.1 Description Anti-freezing protection is fitted with a frost sensor. A capillary tube 2 to 6 m in length is laid on the water heater frame evenly distributed across the entire unit cross-section (Figure 20). 4.2.3.2 Connection, operation and maintenance The type, connection, operation and maintenance specifications for the frost sensor are provided in the electric control cabinet instructions, irrespective of the supplier of the airhandling unit controls (the customer or a third person).

4.3 HEATER SECTION WITH ELECTRIC HEATER 4.3.1 SECTION DESCRIPTION Heating unit with electric heater consists of a unit housing unit, electric air heaters and cabinets with the associated control elements. Example electric heater is shown in Figure 21. 4.3.2 ELECTRIC HEATER 4.3.2.1 Description The casing is made of Aluzinc-coated sheet steel, AZ 185, that conforms to the requirements for corrosivity class C4. The heater elements are made of stainless steel to EN 1.4301. The junction box includes the terminal blocks necessary for the electrical connections.

Water heater section checking and maintenance schedule

Action




Anti freezing protection thermostat

Capillary tube

Electrical connection



Figure 21 Electric heater

4.3.2.2 Installation and commissioning

The electric heater is mounted in the housing by means of guides allowing its removal from the section in cases of fault or damaging. For this purpose, the A/C unit shall be installed so as to allow a free area at least 1.3 times the width of the A/C unit external width.

Connection of the electric heater to the mains shall be done by a properly qualified electrician, in conformance with the applicable regulations.

The terminals in the electric heater junction box can be accessed from the outside on the unit servicing side.

Connect electric cables through cable sleeves in the junction box wall; make sure that their laying does not obstruct the servicing of the adjacent functional sections of the air handling unit.

Heating elements are connected to a 3x220 V or 3x380 V power supply; during operation, their surface reaches temperatures up to ~ 350 °C.

Any air handling unit comprising an electric air heater shall also be fitted with an air flow rate monitoring device.

Air flow velocity across the heater shall not be less than 1,5 m/s; the air flow shall be evenly distributed across the entire cross section.

Any functional section comprising temperature sensitive components shall be separated from the electric heater section with a void section no less than 600 mm in length.

Where the electric air heater section is installed on the fan section (fan blowing the air into the electric heater), a void section should be installed between these sections; its length should be L=(H+B)/2, where H is the height and B the width of the A/C unit, but in no case less than 600 mm.

The electric air heater shall start only with the fan already running and an adequate air flow volume established.

Upon the heater switching off, the fan shall continue to operate for another at least 3 minutes to cool down the heater coils.

The electric air heater is not of a water-tight construction; hence the electric heater section shall not be installed so as to be exposed to water or steam.

Electrical heater housing

Heaters elements

Junction box



4.3.2.3 Maintenance Prior to any intervention in the electric air heater, shut the entire air handling unit down by switching off the main switch on the electric control cabinet. Lock the switch in the off position. Prior to the startup, clean the device interior and firmly tighten all electric connections, seal all air joints and attach guards (covers, duct flanges, protection grilles etc.). Once a month, check:

tightness of electric connections and joints;

operation of the air flow rate monitoring device;

operation of the relays for the early switching on of the fan and the delayed switching off of the electric heater;

proper and secure attachment of the guards (servicing cover, connection box cover, protection grilles etc.).

4.4 COOLING SECTION WITH WATER COOLER 4.4.1 SECTION DESCRIPTION A water cooler section consists of a section housing, a water cooler, a condensate collection pan, and a negative pressure siphon to drain the condensate from the pan. The principal diagram of a water cooler section complete with all pertaining safety elements is provided in Figure 22, and applies to all the water cooler variants.

Figure 22 Water cooler unit

4.4.2 WATER COOLER 4.4.2.1 Description The water cooler consists of a frame, an aluminium fin package with inserted copper pipes, a collection and a distribution pipe. The aluminium fins are mounted on the copper tubes by means of mechanical expansion. The collection and distribution pipes interconnecting the fin package tubes are made of steel and are fitted a threaded or flange connection, and with a bleeding and draining valve. The frame protects the piping elbows and serves for the mounting of the water cooler in the unit. The water cooler is mounted in the section housing by means of guides, to facilitate its withdrawal. The collection and distribution pipe and soldered joints are anti-corrosion protected by means of a temperature resistant paint coat. Each water cooler is submitted to a

Stoppers

Water cooler

Drain pan

Water cooler cover

Handle

Siphon



tightness test in a water bath at the air test pressure corresponding to the operating pressure. 4.4.2.2 Installation and commissioning The water cooler is mounted in the housing by means of guides allowing its removal from the section in cases of fault or damaging. For this purpose, the airhandling unit shall be installed so as to allow a free area at least 1.3 times the width of the airhandling unit external width. Make sure an adequately sized siphon is installed in the condensate collection pan drain line. The method of connecting the piping to the heating circuit depends on the piping diameter, as follows: - for piping diameters of 3/4" up to and including 3", by means of threaded (Holland) nuts When installing the water cooler, make sure to properly connect the piping installation and observe the following:


Connect the piping and fittings so as to allow unobstructed access to and drawing out of the heat exchanger for revision and maintenance works, without obstructing access to the adjacent sections.

When tightening threaded joints, apply counterforce with an appropriate tool (pipe wrench – padded), to avoid damaging the cooler piping circuit.

For easier dismounting, connect the water cooler by means of two pairs of flanges. Do not weld the connection.

Arrange the two piping connections to the water cooler observing the air flow direction, so that the air inflow to the cooler is closer to the return pipe, to ensure medium / air counterflow. This applies for either horizontal or vertical air flow configuration.

The pump may be installed in either the horizontal or in the vertical piping leg, provided that the pump shaft is horizontal.

The distribution or mixing control valve, if specified, may be installed in either the supply or the return line. The distance between the supply and return pipe and the distance between the control valve and the bypass pipe should not be less than 500 mm.

Upstream the cooler intake, install a dirt trap in the supply pipe to protect the control valve and the circulation pump.

In the supply pipe downstream the connection stop valve, at the cooler intake and outlet, install thermometers.

Install the transfer medium drain cocks at the lowest point of the piping installation. This enables the draining of the heat exchanger.

At the highest point of the piping system, install a bleeding device to ensure uninterrupted fluid flow through the cooler. As a rule, the water cooper is delivered with the bleeding / draining valves already installed at the highest / lowest point of the distribution / collection pipe.

Clean the piping system of filings and other debris.



An example of proper connection is illustrated in Figure 23.

Figure 23 Water cooler installation


the tightness of different screw joints; tighten them as required;

proper operation of the cooler automatic anti-freezing protection – prior to the filling of the cooler with the circulation medium;

tightness of piping connections;

cleanliness of the piping system and the installation of the dirt trap. 4.4.2.3 Filling and draining procedure: Filling:

fully open the transfer medium supply valve;

bleed the system to ensure its achieving the full rated cooling capacity;

switch the fan on. Draining:

close the transfer medium supply valve;

slowly open the drain cock until the cooler is depressurised; then full open both the bleeding valve and the drain cock.

4.4.2.4 Protection of the cooler against freezing a) Cooling circuit filled with water:

anti-freezing protection by means of the anti-freezing protection function of the heater section which shall be installed upstream the cooler section;

anti-freezing protection is provided by fully draining the system before the cold (winter) period of non-operation.



b) Cooling circuit filled with glycol and water mixture:

anti-freezing protection is provided with an appropriate concentration of the glycol and water mixture. In handling glycol, observe the glycol filling safety sheet.

In an event of a prolonged power blackout, the unit shutdown or interruption of the cooling medium supply, drain the cooler to avoid its freezing. To further eliminate the risk of freezing, blow the pipe register with compressed air after draining. 4.4.2.5 Maintenance

Prior to any intervention in the water cooler, shut the entire airhandling unit down by switching off the main switch on the electric control cabinet. Lock the switch in the off position. Prior to the startup, clean the device interior, firmly attach and seal all air and water joints (covers, duct flanges, guards etc.) and install the drain siphon and connect it to the sewage system. To ensure proper functioning of the heat exchangers, regularly carry out the following operations:

Check the tightness of all water connections and air joint tightness.

Check the operation of the bleeding valve. In an event of disturbed medium flow through the cooler, or presence of air in the circuit, bleed the piping system.

Check the proper operation of the cooler anti-freezing protection.

Regularly check any dust build-up on the cooler fins. Dust or scale build-up on the fins result in a reduced heat exchanger capacity. Periodically – approximately every 500 hours of operation – clean the fins. Clean the fins by blowing compressed air in the direction opposite to the air flow direction. If this cleaning method is not sufficient, dismount the cooler and wash it with water or low pressure steam. Do not use high pressure water or steam, to avoid deforming the aluminium fins. When washing with water, the water pressure shall not exceed 15 bar, and the water jet shall be strictly perpendicular to the fin surfaces. Water jet at an angle will damage the fins. This applies in particular for the fins along the edges, which are more sensitive. Never use any hard object for cleaning.


Functionally test the siphon x

CIean wet cooler, demister and condensate tank x


Water cooler section checking and maintenance schedule

Action


1 3 6 12 24

According to the

hygiene inspection


Inspect wet coolers, condensate tanks and demisters for contamination, corrosion and functioning

x



4.4.3 DIRECT EVAPORATOR 4.4.3.1 Description The direct evaporator (DUF) consists of a frame, an aluminium fin package with inserted copper pipes, a collection and a distribution pipe. The aluminium fins are mounted on the copper tubes by means of mechanical expansion. The collection and distribution pipes interconnecting the fin package tubes are made of steel and are fitted a threaded or flange connection, and with a bleeding and draining valve. The frame protects the piping elbows and serves for the mounting of the direct evaporator in the unit. The direct evaporator is mounted in the section housing by means of guides, to facilitate its withdrawal. The collection and distribution pipe and soldered joints are anti-corrosion protected by means of a temperature resistant paint coat. Each DUF section is submitted to a tightness test in a water bath at the air test pressure corresponding to the operating pressure. DUF may be divided into two or more cooling circuits and cools the air by means of a freon based cooling medium R 407c or R 410a). 4.4.3.2 Installation and commissioning The DUF is mounted in the housing in drain pan by means of allowing its removal from the section in cases of fault or damaging. For this purpose, the A/C unit shall be installed so as to allow a free area at least 1.3 times the width of the A/C unit external width. The cooling system piping and the direct evaporator connections shall not impede the withdrawal of the antifreeze protection frame from the unit housing, in case these are installed in the immediate vicinity. Make sure an adequately sized siphon is installed in the condensate collection pan drain line. See following section for the instructions for the construction, installation and connection of siphons. When installing a DUF section, make sure to properly connect the piping installation and observe the following:


Connect the piping and fittings so as to allow unobstructed access to and drawing out of the cooler for revision and maintenance works, without obstructing access to the adjacent sections.

When tightening threaded joints, apply counterforce with an appropriate tool (pipe wrench – padded), to avoid damaging the DUF piping circuit.

Arrange the two piping connections to the DUF observing the air flow direction, so that the air inflow to the DUF is closer to the return pipe, to ensure medium / air counterflow. This applies for either horizontal or vertical air flow configuration.

The most common joining method consists of soldering; connection by means of fast joints is even more preferable, since this method saves operational costs associated with blade cleaning. The evaporator outlet pipe should be thermally insulated with the insulation fitted with vapour stopping according to applicable standards.



Install the thermostat expansion valve following the manufacturer's instructions, to a horizontal piping leg as close as practicable to the DUF, upstream the pressure equalisation equipment and at a proper angle according to the pipe thickness. The sensor shall be insulated to avoid the ambient air interference with the measurement. The same applies to the pressure equalisation valve sensor. Application of external pressure equalisation valves is recommended, to avoid the interference of the pressure drop across the evaporator.

The distribution head should be mounted vertical; if this is not practicable, make sure to install Venturi head.

Since the air handling unit evaporator is not fitted with blade defrosting, arrange the electric connection so as to prevent the compressor from operating with the DUF fan not in operation. If larger inlet air temperature variations (higher share of outside air) are expected during the DUF operation, i.e. the DUF operation at loads lower than the rated load, we recommend the installation of a cooling capacity controller with a hot DUF bypass line to prevent blade freezing.

Clean the piping system of filings and other debris. In the connection of a DUF to a compressor-condenser section, the required accessories include, in addition to a thermal expansion valve:

a drying cartridge;

a solenoid valve (high-low pressure boundary);

inspection opening;

collection pan, in particular in cases of long piping installations. In the laying of pipelines, pay attention to oil return and other freon flow associated phenomena (see instructions for the layout of pipelines with AIR HANDLING UNITS comprising a direct evaporator). An example of proper connection is illustrated in Figure 54.

9109 8 67

3

4

5

2 1

1. distribution head 2. thermostat expansion valve 3. temperature sensor 4. TEV capillary

5. pressure equalisation line 6. moisture indicator 7. solenoid valve

8. drying cartridge 9. collection pan Rotolock valve 10. collection pan

Figure 24



The cooling system connection and filling with the cooling medium may only be carried out by a qualified person. Apply copper pipes for the connection, the pipes having been cleaned, dried, purged with dry nitrogen and sealed on both ends. Observe the following points during the installation:

the maximum allowable distance of the DUF to the other cooling circuit part is 25 m;

the condenser may be located maximum 2 m below the compressor;

the outlet piping layout should be along the shortest practicable route, with the minimum number of bends (bend radius R > 3.5 times pipe diameter).

In selecting the combination, pay attention to the compatibility of the compressor, the DUF and other cooling circuit components. Prior to the commissioning, check:

the conformance of the electric connection with the electrical switching diagram;

the condensate outlet;

the successful completion of the freon line testing, drying, connection to an air cooled condenser and filling with cooling medium;

proper setting of the cooling circuit protection elements, such as the high/low pressure protection switch. The same applies to the condensation pressure control switch.

During the commissioning, check:

tightness of the soldered joints;

adequate quantity of freon (no droplets in the inspection opening);

dryness of the equipment (inspection opening – colour indicator; dry – moist; following the manufacturer's instructions);

achievement of the proper evaporation and condensation pressures. During the commissioning, make sure that the sump heater heats freon enough to ensure the evaporation of any accumulated liquid freon (continuous operation during the unit shutdown or switching on preceding the unit startup). DUF filling Prior to the filling, vacuum the system. The vacuuming should continue until the piping system is dry and a proper vacuum is established (see instructions for the filling of cooling systems). Normally, the system is filled through the compressor suction connection – larger compressors are fitted with special connectors. Having opened the freon cylinder valve to admit the gas to the system, start the compressor and continue the filling until the specified evaporation pressure is achieved and no more bubbles are seen in the inspection opening. DUF evacuation Shut off the compressor-condensation section isolation valves and exhaust freon from the DUF section through a valve fitted specifically for this purpose (employing an environment compliant exhaust equipment according to the Montreal protocol). Next, disassemble the thermostat valve insert. In the case of fast joint connections, release them; otherwise, desolder the DUF assembly to allow its dismounting.



4.4.3.3 Operation Observe the instructions for safe operation, starting and maintenance of cooling equipment, which are included in these instructions. 4.4.3.4 Maintenance Prior to any intervention in the DUF, shut the entire air handling unit down by switching off the main switch on the electric control cabinet. Lock the switch in the off position. Prior to the startup, clean the device interior, firmly attach and seal all air and water joints (covers, duct flanges, guards etc.) and install the drain siphon and connect it to the sewage system. To ensure proper functioning of the DUF, regularly carry out the following operations:

check the condition of the soldered joints;

periodically, check the inspection opening for bubbles and humidity;

check the cooling circuit protection elements – mechanical and electrical;

in a case of a prolonged shutdown, check the operation of the compressor sump heater;

check the DUF fan operation;

regularly check dust build-up on the DUF fins. Dust or scale build-up on the fins results in a reduced heat exchanger capacity. Periodically – approximately every 500 hours of operation – clean the fins. Clean the fins by blowing compressed air in the direction opposite to the air flow direction.

If this cleaning method is not sufficient, dismount the heat exchanger and wash it with water or low pressure steam. Do not use high pressure water or steam, to avoid deforming the aluminium fins. When washing with water, the water pressure shall not exceed 15 bar, and the water jet shall be strictly perpendicular to the fin surfaces. Water jet at an angle will damage the fins. This applies in particular for the fins along the edges, which are more sensitive. Never use any hard object for cleaning.



Ciean wet direct evaporator, demister and condensate tank

x


Direct evaporator section checking and maintenance schedule

Action


1 3 6 12 24

According to the

hygiene inspection


Inspect wet direct evaporator, condensate tanks and demisters for contamination, corrosion and functioning

x



4.4.4 OUTLET SIPHON 4.4.4.1 Description The outlet siphon is a device allowing the outflow of condensate in the conditions of negative pressure, and prevents air leakage from the unit through the outlet pipe in the conditions of positive pressure in the airhandling unit or its particular section. It is made of plastics. 4.4.4.2 Sizing and installation

Difference between the pressure inside the section and the atmospheric pressure p (Pa):

p = pn – pz pn = pressure in the section pz = atmospheric pressure The following cases are possible:

p < 0 – negative pressure in the unit

p = 0 – pressure in the section equal to the atmospheric pressure

p > 0 – positive pressure in the unit An undersized siphon leads to jerky outflow of air and water. If the available height difference from the drain pipe connection point to the machine room floor is less than the required siphon height, lead the condensate outlet deep into an outlet funnel. Do not connect the negative pressure and positive pressure siphon drain pipe directly to the sewage system piping. The outflow of condensate from the siphon to the sewage piping shall be free, through an open funnel. Never connect a positive pressure siphon and a negative pressure siphon to a common drain pipe. Mount the siphon on the section outside. Otflow piping should be laid at a minimum 2% inclination in the outflow direction.

Figure 25 Negative pressure siphon



The measure "A" corresponds to the total pressure drop in the section, specified in the section nameplate or in the fan nameplate. Divide the nameplate readout value (in Pa) by 10 to obtain the measure "A" in mm. C* Required foundation height for proper operation of the siphon. Prior to the airconditioning startup, make sure to flood the siphon with water. Flood it every beginning of the summer season, prior to the startup of the airhandling unit.

115

385

maks. 285

75 80 230

Figure 26 Negative pressure siphon with ball

The negative pressure siphon (Figure 26) does not require flooding with water, since the siphon automatically fills up with condensate as this starts to accumulate.

Slika 27 Positive pressure siphon

The measure "A" corresponds to the total pressure drop in the section, specified inthe section nameplate or in the fan nameplate. Divide the nameplate readout value (in Pa) by 10 to obtain the measure "A" in mm. C* Required foundation height for proper operation of the siphon. Prior to the airconditioning startup, make sure to flood the siphon with water. Flood it every beginning of the summer season, prior to the startup of the air handling unit.



Figure 28 Positive pressure siphon

The positive pressure siphon HIDRIA (Figure 28) does require flooding with water. 4.4.5 SIPHON TRACING 4.4.5.1 Description Siphon tracing is self regulated cable, which prevents spihon against freezing in winter time. 4.4.5.2 Installation Cable is connect in electrical box and it's pull to siphon through the structural frame. Electrical box is connected to electro control cabinet. Cable (heating element) is activated, when the temperature drops below +4°C, so as to prevent the condensed water from freezing (figure 24).

Figure 29 Siphon tracing



4.5 UNIT WITH A COOLING SYSTEM 4.5.1. DESCRIPTION OF UNIT WITH A COOLING SYSTEM Caution ! Any intervention into the cooling system may only be undertaken by an authorised service technician qualified for handling cooling systems and Freons! During the works, observe safety limits for handling Freons and the requirements of applicable regulations, norms and guidelines (example: DIN EN 378, EU regulation on handling Freon). The unit with cooling system is made in one piece, which contains the entire Freon installation, an evaporator, a condenser, a compressor and all the elements necessary for proper functioning of the cooling system (pressure gauges,pressure controls, an inspection glass, a filter driers, a Freon reservoir, a four-way winter/summer shunt valve). Each unit is also fitted with its own electric-control cabinet containing a frequency inverter for the compressor that ensures smooth operation of the cooling system and is linked to the main electric-control cabinet of the compact air-handling unit. The Freon installation is dispatched from the factory fully tested, vacuumed and filled with Freon. The type of Freon in the system and the system parameter settings are indicated in the specification accompanying the compressor. 4.5.1.1 Installation and commissioning Prior to commissioning the cooling system, the Freon installation, evaporator and condenser shall be inspected for any Freon leakage. The commissioning shall be done by a service technician authorised for cooling systems. Caution ! Initial startup of the compressor, i.e. of the cooling system, shall not be attempted with the rotalok valves closed or with nitrogen present in the system or with the system under vacuum or with the entire installation not finalised and still open to the atmosphere. Such a startup would destroy the compressor! In case the compressor is destroyed due to improper startup or improper handling of the cooling system, the damages to the cooling system are not covered by the guarantee. The evaporator and the condenser are mounted in the unit housing in a pan and, in case of defect or damage, can be withdrawn from the unit complete with the pan. For this purpose, the air handling unit shall be installed so as to allow a free area on the servicing side, at least 1.3 times the width of the air handling unit external width. Make sure an adequately sized siphon is installed in the condensate collection pan drain line. See the section on siphons for the instructions on the construction, installation and connection of siphons.




the conformance of the electric connection with the electrical switching diagram;

the condensate outlet;

proper setting of the cooling circuit protection elements, such as the high/low pressure protection switch. The same applies to the condensation pressure control switch.

During the commissioning, check:

tightness of the soldered joints;

adequate quantity of Freon (no droplets in the inspection glass);

dryness of the equipment (inspection glass – colour indicator; dry – moist; following the manufacturer's instructions);

achievement of the proper evaporation and condensation pressures. During the commissioning, make sure that the sump heater heats Freon enough to ensure the evaporation of any accumulated liquid Freon (continuous operation during the unit shutdown or switching on preceding the unit startup). Filling the Cooling System Prior to filling, vacuum the system. Vacuuming should continue until the piping system is dry and adequate vacuum is established (see instructions for the filling of cooling systems). The system is filled through a port on the suction side. Having opened the Freon cylinder valve to admit the gas into the system, start the compressor and continue filling until the specified evaporation pressure is achieved and no more bubbles are seen in the inspection glass. This operation shall only be performed by a service technician authorised for cooling systems. Evacuation of the Cooling System Shut off the compressor-condensation section isolation valves, if installed, and evacuate Freon from the cooling system through a valve fitted specifically for this purpose (employing environmentally compliant Freon evacuation equipment according to the Montreal protocol). 4.5.1.2 Operation Observe the instructions for safe operation, starting and maintenance of cooling equipment that are included in these instructions. 4.5.1.3 Maintenance Prior to any intervention in the cooling system, shut the entire air handling unit down by switching off the main switch on the electric-control cabinet. Lock the switch in the off position. Prior to startup, clean the unit interior, firmly attach and seal all air and water joints (covers, duct flanges, guards, etc.) and install the drain siphon and connect it to the sewage system. To ensure proper functioning of the cooling system, regularly carry out the following operations:

check the condition of the soldered joints;

periodically, check the inspection glass for bubbles and humidity;



check the cooling circuit protection elements – mechanical and electrical;

in case of a prolonged shutdown, check the operation of the compressor sump heater;

check the operation of the fan downstream of the evaporator and downstream of the condenser;

regularly check any build-up of dust on evaporator and condenser fins. Dust or scale build-up on the fins results in a reduced heat exchanger capacity. Periodically – approximately every 500 hours of operation – clean the fins. Clean the fins by blowing compressed air in the direction opposite the air flow direction. If this cleaning method is not sufficient, dismount the heat exchanger and wash it with water or low pressure steam. Do not use high pressure water or steam to avoid deforming the aluminium fins. When washing with water, water pressure shall not exceed 15 bar, and the water jet shall be strictly perpendicular to the fins. Water jet at an angle will damage the fins. This applies in particular to the fins along the edges, which are more sensitive. Never use any hard object for cleaning.


Testing of the operation of the siphon x Cooling of the wet cooler, condensate pan and eliminator

x

Checking of the hygienic condition x

4.6 CARTRIDGE FILTER SECTION 4.6.1 SECTION DESCRIPTION A filter section consists of a section housing and a cartridge filter of filtration class G4 and F7. The cartridge filter section principal diagram is shown in Figure 25.

Checking and maintenance schedule for a unit with cooling system

Activity



Checking of soiling, damages and corrosion x Checking of soiling, damages and corrosion of the wet evaporator, condenser, condensate pan and eliminator

x

Checking of the inspection glass and protection elements

x

Overall checking of the cooling system – by a service technician

x



4.6.2 CARTRIDGE FILTER DESCRIPTION A cartridge filter – filter cartridge consists of a frame 100 mm in width, made of galvanized sheet steel. The frame holds synthetic resin reinforced synthetic fibre filter medium arranged in a ZIG-ZAG pattern and armoured with galvanized steel wire mesh. Cartridge filters are mounted to the structural frame by means of dismountable joints and sealed with sealant band. The structural frame is mounted to the section housing by means of a fixed joint and sealed with permanently elastic putty. The filter medium is

temperature resistant up to 90 or 100 C; the exact temperature range is declared by the particular medium manufacturer.

Figure 25 Cartridge filter unit 4.6.3 INITIAL AND RECOMMENDED FINAL PRESSURE DROPS

Filtration class

L (mm)

vn (m/s)

Am (%)

pz (Pa)

pk (Pa)

G4 100 3,7 94 62 150

F7 94 2,4 99 94 200

TABLE LEGEND: vn - inflow air velocity

pz - initial pressure drop L - cartridge length Am - average rate of synthetic dust arresting

pk - recommended final pressure drop

cartridge filter

guide

limiter

sealing tape

lock section

pressure differencial sensor



4.6.4 NUMBER OF FILTER CELLS PER UNIT CROSS SECTION, BY UNIT SIZES

Filter cell dimensions

Airhandling unit size

10

20

30

40

60

80

10

0

592 x 490 1

592 x 592 1 2 2 2 3 3

592 x 287 1 1 3 4

287 x 287 1

4.6.5 INSTALLATION AND COMMISSIONING If not already installed, insert the filter cartridges into the structural frame, according to the following procedure:

insert the filter cartridges into the structural frame;

with a layer (across the entire unit cross section) filled up with filter cartridges, push the filter cartridges by means of the lock section against the guide with the sealing tape applied;

repeat the procedure to fill up the entire section volume;

make sure that sealing tape is applied to the L section against which the door will lean, and apply the tape onto the door as well if required.

remove any tools and other solid particles from the section;

close the servicing door, and

check the connection of pressure gauge pipes to the pressure measurement outlets and connect as required.

Set the air-handling unit control system so as to prevent the relative humidity within the second stage filter section from exceeding 90 % and the relative humidity of air within the first stage filter section or within the unit upstream the filter section from exceeding 80 % in three consecutive days. 4.6.6 MAINTENANCE Prior to any intervention in the cartridge filter section, shut the entire airhandling unit down by switching off the main switch on the electric control cabinet. Lock the switch in the off position. Prior to the startup, clean the device interior and firmly attach and seal all air joints (covers, duct flanges etc.). The filter shall keep its efficiency throughout its service lifetime. To ensure its functionality regarding the hygiene of the handled air, periodically check filters in each filter stage for:

pressure drop;

operating hours;

visual appearance (check any cracks in the filter material, leakage between the filter and its frame).



In a case of any contamination, cracks in the filter material or leakage between the filter and its frame, replace the filter regardless of the actual pressure drop or lifetime stage. Replace a filter in the following cases:

the allowable pressure drop has been reached;

the service lifetime has been reached;

the filter performance is inadequate, in mechanical or hygienic terms;

during the installation or modification of the air-handling unit, the filter has been contaminated;

the replacement is ordered by the hygiene inspection. All the filters of a filter stage or filter section shall be replaced at the same time. Replacing of only one filter of a filter stage is allowable only in a case of damage and provided that the time since the last replacement does not exceed 6 months. Prior to installing new filters, always check the complete, uniform and air-tight mounting of the sealing tape on the sealing seat between the filter and its frame. Make sure the filter cartridge is not damaged upon installation in the filter frame. When replacing filters, protect the new filters from contamination by dust from old filters or in any other way. Store new filters in dust-free rooms and protected from damages. Do not use filters with the expired shelf life, as declared by the filter manufacturers. Only use filters declared conformant with the SIST EN 779 standard by their manufacturers. Handle the contaminated filters in compliance with applicable environment protection regulations. With outdoor installation airhandling units, there is a risk of the first filter stage (prefilter) clogging with snow in extreme climatic conditions. There is also a risk of filters freezing. In such an event, immediately clean the filters of snow or replace. Possible pressure measuring instruments for include: U tube, inclined manometer or a electronic manometer with acoustic or visual indicator. Connect the pressure gauge to the measurement outlets upstream and downstream of the filter, provided on the outside of the unit servicing side, except in the case of outdoor installation units, where the outlets are provided inside the housing. The filter cartridge change procedure is as follows:

open the servicing door;

loosen the lock section(s);

withdraw the contaminated filter cartridges;

clean the section housing as required,

check the condition of the sealing tape on the sealing seat and repair or replace it as required;

always install fresh and undamaged filter cartridges only; and

close the servicing door. The checking and maintenance shall be done according to the schedule set out in the following table.



Cartridge filter section checking and maintenance schedule

Action


1 3 6 12 24

According to the

hygiene inspection

Inspect for impermissible contamination and damage (Ieaks) – Replace the defective air filter if

the most recent filter stage replacement look place not more than 6 months ago, otherwise replace the complete filter stage

x

Check the differential pressure x

First filter stage x

Second filter stage x


4.7 RECUPERATOR SECTION

4.7.1 SECTION DESCRIPTION A recuperator section consists of a section housing, a counterflow plate recuperator, a bypass control louvre.The recuperator is mounted in the section housing diagonally. At the housing bottom, a condensate outlet connection is provided on the section servicing side.Recuperator fouling build-up increases air pressure drop and decreases efficiency. 4.7.2 COUNTERFLOW PLATE RECUPERATOR 4.7.2.1 Description Counterflow plate recuperators are heat exchangers in which heat from the waste air flow is transferred to the fresh air flow directly through a separation wall, i.e. without an intermediate heat transfer medium. The consist of flat aluminium plates, which make the entire construction sturdy. The fresh and waste air pass through the recuperator in counterflow. Figure 31 presents an installation plate recuperator.

Figure 31 Counterflow plate recuperator unit

Plate recuperator

By-pass damper

Motor drive

Internal partition walls

Condensate collection and draining pan

By-pass

Electro control cabinet



The plate recuperator ensures a full transfer of condensation (latent) heat from the exhaust to the fresh air without directly transferring the humidity. In dry operation, heat

recover efficiency is up to 2 = 84 %; with the recovery of condensation heat, is up to 2

= 90 %, even higher efficiencies are achievable. The maximum allowable recuperator operation temperature is +120 °C. For the purposes of control and anti-freezing protection, the recuperator is fitted with an air bypass installed within the airhandling unit proper. The bypass is located on the fresh air side and is fitted with counter-direction operated louvres. The heating capacity control in transitional seasons is available, as well as summer season cooling capacity control, and anti-freezing protection. The anti-freezing protection is achieved through the reducing of the fresh air flow through the recuperator to prevent the cooling of the waste air flow below the freezing point and thus prevent the formation of ice which would in turn increase the pressure drop and reduce the device efficiency. 4.7.2.2 Installation and Commissioning A plate recuperator section shall be mounted on a foundation prepared in advance. Prior to the commissioning, check the tightness of different screw joints and tighten them as required. Also check the fitting and linking of the control louvre to the electric motor drive and its operation. Make sure an adequately sized siphon is installed in the condensate collection pan drain line. 4.7.2.3 Maintenance Prior to any intervention in the plate recuperator section, shut the entire airhandling unit down by switching off the main switch on the unit panel. Lock the switch in the off position. Prior to the startup, clean the device interior and firmly attach and seal all air joints (covers, duct flanges etc.). Regularly clean the plate recuperator. Recuperator insert fouling build-up increases air pressure drop and decreases efficiency. An easy way to check the plate recuperator fouling is to remove the covers on the section servicing side, visually check the insert face surfaces, and, with aid of a lamp, also the fouling of the air channels through the insert. In a case of fouling with dry dust, the insert can be cleaned without dismounting, by blowing it with compressed air with a pressure up to 10 bar maximum through the servicing openings; always wear personal protection equipment during such an operation. If fouled with greasy or sticky debris, the insert shall be withdrawn from the recuperator section housing and cleaned by means of a hot water jet (temperature up to 90 oC, pressure up to 6 bar) with appropriate cleaning detergent added. Dirt can alternatively be removed by soaking in a warm water bath with cleaning detergent added. Since the insert filler is made of very thin aluminium foil, be careful not to damage the insert face surface during dismounting. The sequence of dismounting an insert from the section housing is as follows – Figure 27:



remove the servicing covers at backside

remove the partition sections on the backside side, by unscrewing the fixing screws

remove the rubber seal;

unscrew the top guide section fixing screws, loosen the side guide section screws and remove the top guide section;

draw the insert out of the section housing;

after cleaning, install the inserts back in the section in the opposite order.

Figure 32 Counterflow plate recuperator removing

As a part of any maintenance or checking operation, also clean the condensate outlet at the pool bottom and top up the siphon with water. Check the drive and operation of control louvres. Exchanger can be remove from unit on access side (Figure 32). The checking and maintenance shall be done according to the schedule set out in the following table.


CIean the wet cooler, demister and condensate tank

x


Plate recuperator section checking and maintenance schedule

Action


1 3 6 12 24

According to the

hygiene inspection


Check the seal between the incoming air and outgoing air

x

Inspect the condensate tank and demister for contamination, corrosion and functioning

x



4.8 ROTATIONAL REGENERATOR SECTION

4.8.1 SECTION DESCRIPTION The rotational regenerator section is available in casing design. The casing design section consists of a section housing and a rotational regenerative heat exchanger (Rototherm). The rotational regenerator is mounted in the section housing and can be drawn out of it in one piece or, in the case of larger sections, by segments. 4.8.1.1 Installation and Commissioning A rotational regenerator is designed for vertical mounting in two-stage air handling units. An example of mounting a two-stage unit, in Figure 33.

Figure 33

Mount and install the regenerator in accordance with the manufacturer's instructions, attached to these instructions. Prior to the commissioning, check:

proper mounting of the Rototherm in the casing or between the flanges;

proper tightness of screw joints;

free rotation of the rotor;

proper tension of the drive belt;

air-tightness;

operation of the electric motor drive, control and protection functions (fuses, thermal protection);

clean the device of any debris



All electrical installation and connection shall only be carried out by an authorised professional in accordance with the regenerator manufacturer's instructions and applicable regulations.

4.8.1.2 Maintenance Prior to any intervention in the rotational regenerator section, air handling unit down by switching off the main switch on the Lock the switch in the off position. Prior to the startup, clean firmly attach and seal all air joints (covers, duct flanges etc.). The rotational regenerator is self-cleaning, therefore no filtering needed, except in the case of contamination with extremely particles. The regenerator honeycomb structure may be cleaned by means water, steam or special cleaning agents. Cleaning may be manual cleaning nozzles provided. Pressures up to 150 bar are allowable. Humidity transfer rotors shall not be cleaned by means of water washing off of lithium chloride particles (LiCl) which facilitate the Check the operation of the drive and control unit. Observe the rotational regenerator manufacturer's instructions.

4.9 ROOF WALLEYS 4.9.1 DESCRIPTION Roof walleys are elements which are used for protection of rain water, which could flow to canal net on roof and then to building. They are made of 0,6 mm sheet metal and used for outdoor units. 4.9.2 INSTALLATION Roof walleys are fitted on basic profile with self drill screws (figure 34) and connect together with rivets (figure 35). Under connections of two walleys is mounted plate which is hold them with rivets.

Slika 34 Roof walley innstallation Slika 35 Roof walley connecting



5 COMPAIR UNIT CONTROL

5.1 FUNCTIONAL DIAGRAM WITH COUNTERFLOW HEAT EXCHANGER

Position Description Type Pcs.

N1 Controller DDC Carel pCO3S 1

B1 Duct temperature sensor – fresh air NTC 1

B2 Duct temperature sensor - inlet NTC 1

B4 Duct temperature sensor - outside NTC 1

B9 Antifrost thermostat TF30 1

B5 Duct temperature sensor - outlet NTC 1

B8 Electrical heater sensor AtHF 170/g 1

P1 Pressure difference sensor - fresh air filter BK 930.84 1

P2 Pressure difference sensor - outlet filter BK 930.84 1

Y1 Heating valve with 24V actuator H512B + NVD24 - SR 1

Y2 Cooling valve with 24V actuator H525B + NVD24 - SR 1

Y3 Modulating air dampers by-pass NM24A - SR 1

Y4 Preheating valve 24V actuator H512B + NVD24 - SR 1

Y5, Y6 Modulating air dampers fresh/exhaust air NM24A on-off 2 ! Valve size depends on unit size.

5.1.1 FUNCTIONAL DESCRIPTION The duct temperature sensor B1 measured air temperature in the room by the controller N1 compared to the desired value. In the case of a downward deviation (heating) followed by control output signals for controlling the bypass dampers plate recuperator (el. actuator Y3), opening the valve heater (el. actuator Y1) and turn on water heater pump (M3). The pump runs for 2 minutes after the valve closure. In derogation of upward (cooling) is activated plate Heat exchanger (opens blind or recuperator by-pass, depending on the ambient temperature and outside temperature) and cooling valve (el. actuator Y2). The duct temperature sensor B4 measured value of the supply air temperature and the controller N1 compared to the desired value. In the event that the measured supply temperature is lower or higher than the lower or upper limit values set in the controller N1, get switch to control the supply air temperature (limiting temperature between puffs



set Tmin - 16 ° C and T max - 40 ° C). B4 channel temperature sensor is used for the collection of the outside temperature state .

5.2 FUNCTIONAL DIAGRAM OF A UNIT WITH A COUNTER-FLOW RECUPERATOR AND INTEGRATED COOLING SYSTEM

5.2.1 FUNCTIONAL DESCRIPTION OF A UNIT WITH AN ADDED COOLING SYSTEM MODULE

An existing or a new unit can be augmented with an integrated compressor heat pump. The compressor is driven by a frequency inverter to achieve a higher efficiency level. Air handling unit operation is the same as described above, except that, in winter mode, with heating demand present, the heat pump starting and control sequence follows the signal from the plate recuperator. In summer mode, the cycle is reversed and the heat pump operates as a cooling aggregate. It serves for space cooling. Excess heat is dissipated with exhaust air.

5.3 FUNCTIONAL DIAGRAM WITH ROTARY WHEEL



Position Description Type Pcs.

N1 Controller DDC Carel pCO3S 1

B1 Duct temperature sensor - outlet NTC 1

B2 Duct temperature sensor - inlet NTC 1

B4 Duct temperature sensor - fresh air NTC 1

B3 Antifrost thermostat TF30 1

P1 Pressure difference sensor - fresh air filter BK 930.84 1

P2 Pressure difference sensor - outlet filter BK 930.84 1

Y1 Heating valve with 24V actuator H512B + NVD24 - SR 1

Y2 Cooling valve with 24V actuator H525B + NVD24 - SR 1

Y5, Y6 Modulating air dampers fresh/exhaust air NM24A on-off 2

! Valve size depends on unit size.

5.3.1 FUNCTIONAL DESCRIPTION The duct temperature sensor B1 measured air temperature in the room by the controller N1 compared to the desired value. In the case of a downward deviation (heating) followed by the output control signals for sequential control of a rotary heat recovery (rotary wheel - M4), opening the valve of the heater (or electric powered Y1) and turn on water heater pump (M3). The pump runs for 2 minutes after the valve closure. In derogation of upward (cooling) is activated rotary wheel (speed of rotation depends on the spatial temperature and ambient air) and opens the valve (el. actuator Y2). The duct temperature sensor B2 measure the value of the supply air temperature and the controller N1 compared to the desired value. In the event that the measured supply temperature is lower or higher than the lower or upper limit values set in the controller N1, get switch to control the supply air temperature (limiting temperature between puffs set Tmin - 16 ° C and T max - 40 ° C).B4 channel temperature sensor is used for the collection of the outside temperature state.

5.4 FUNCTIONAL ELEMENT REGULATION 5.4.1 ELECTRICAL HEATER REGULATION: Electrical heater is used to preheat outside air to specific value (setpoint). Setpoint (it can be set from 5°C to 30°C) can be set in controller, then it is compared with sensor B8 value (sensor measures temperature behind preheater). If temperature is too low, electrical heater is turned ON and works for a while, until setpoint is reached. Safety thermostat is used to prevent damage from overheating. First point of safety thermostat is set to 80°C, second on 110°C. 5.4.2 HEAT EXCHANGER REGULATION: Outside temperature is measured with ntc sensor B4. Exhaust/outlet temperature is measured with ntc sensor B1. Both sensors send signal to controler in which both values are compared. By this, energetic value of outside and outlet air is estimaded. Regarding this estimation, output signal is lead to actuator of plate heat exchanger. Maximum of disposable energy (of outside or outlet air) is used by this. In case of insufficient enery additional signal is lead to electric preheater and/or water heater (if electric/water heaters are instaled into unit).



5.4.3 FILTERS: Filters are used as protection against dirt in inside of air-handling unit and as assurance of clean air. Filter supervising is doing by pressure switches on them or Alarm »check filters« is shown every 1000 working huors. When changing the filters you must be careful on direction of air through filters. Air-handling unit must be turned off at the time when filters are changed! 5.4.4 HEATER FROST PROTECTION: Freeze protection thermostat measure temperature after water heater. If at any point of the capillary falls below the set value (5 ° C), the controller reports an error, the valve is fully open heater, pump heater is turned on, turned of both fans, dampers are closed. When the error is gone, the air conditioning switched on automatically, the error is automatically reset. 5.4.5 FROST PROTECTION OF PLATE EXCHANGER: Frost protection sensor (B5) is designed to give temperature value behind recuperator. If the temperature falls below set value, controller will close recuperator dampers and open by-pass dampers so cold outside air will go directly into room and warmer inside air will defrost recuperator dampers. 5.4.6 INLET AND OUTLET FAN: Fans are driven with the help of electronics, which are taken as a reference signal (0-10V), which sends it to the controller. The controller is set two desired value (set point I speed and speed setpoint II), then the choice of (I or II speed) send this to the electronics. Fans can also be driven by CO2 sensor (mounted in duct or room) or by pressure sensors (constant pressure or airflow in duct) Figure 36 Temperature sensor NTC060HP00 Figure 37 Pressure sensor

Figure 38 Duct CO2 sensor Figure 39 Directly driven



5.4.7 INTEGRATED COMPRESSOR CIRCUIT CONTROL The compressor is inverter driven. The controller transmits the control signal according to heating and cooling demands and according to the cooling circuit parameters so as to keep the compressor in its optimal operating range at all times. These parameters are factory set according to the compressor type.

5.5 MANAGING WITH AIR HANDLING UNIT Main switch on the front side of electro cabinet must be always in ON position, because only in that case you may be assured that controller and all safety functions works correctly. FOR SERVICE ON WHICHEVER PART OF AIR-HANDLING UNIT SUITABLE FUSE MUST BE TURNED OFF (check wiring diagram)! 5.5.1 DISPLAYS: Controller has display on it as a standard, so all parameters can be monitored/changed with it. Figure 40 Controler Figure 41 PGD remote display

This remote display can be mounted somewhere in room, so user can easily check and set all parameters of compact air handling unit. Screen on PGD is copy of screen, mounted in controller. It can be connected through 6wire telephone cable (3x2x0,6mm2)

Figure 42 PGD touchscreen

Touchscreen can be used as remote display. BMS of 30 compact/air handling units can be prepared on it. It's used for local monitoring and control of the main functions of the installation.



5.5.2 CONNECTION TO EXTERNAL UNITS: Standard unit has no card mounted in controller so connection to external unit is not possible. Cards can be ordered additionaly. Available protocols: Modbus RS485 Lonworks TCP/IP LAN TCP/IP modbus TCP/IP bacnet PcoWEB card is mostly used. It works like a web server (BMS) and it has it's own IP address. Air handling unit can be monitored and configured through this card. It can be connected to local area network (LAN) or through router on internet, so IP address can be reached worlwide through external PCs. You only need PC and web browser (Mozilla Firefox, Internet Explorer or something else). Web server is password protected, separately for different web pages (for different users).

Figure 43 PcoWEB connection

Figure 44 PcoWEB net



How BMS on pcoWEB looks like?

Figure 45 PcoWEB face



HOW TO MANAGE WITH CAREL PCO3 REGULATOR OR PGD DISPLAY

Instructions for moving through menu and value setting: For moving through menu use buttons up and down . This will move from one mask (mask is page on display) to another, cursor will be on the left upper corner (base

position). If we press enter button, then cursor move to next changeable variable. If cursor doesn't move to another variable that means the following parameters could not be set. Way to change the parameters: move to desire parameter which you want to

change it and press on the button enter . Than use buttons up and down to set desire

value. Any change must be confirmed with button enter , at the same time cursor go

to the next variable. If we want to move on the beginning of the mask, button enter must be pressed so many times that cursor move back to base position and now we can move to another mask. In case that we done mistake we go back to the base point

with pressing on the button ESC, but only in case we didn't pressed the button before.

In case any alarm occurs, red LED starts to blink. If button (bell) is pressed, active alarm will be shown on display. Active alarm can be reset with bell button (press and hold down it for 10 seconds.

Main screen, when controller in powered ON.

If ENTER button is pressed, two new things shows up. One is temperature corrector (so you don't need to change setpoints in ECON CO, HE or COMF CO, HE). Other parameter shows working regime (OFF, AUTO, SPEED I, SPEED II) and can be changed. It's the same as parameters on last screen.

OFF - unit is off completely SPEED 1 - unit works continuously in the first speed until withdrawal (OFF or AUTO) SPEED 2 - unit works in the second speed until withdrawal (OFF or AUTO) AUTO - air conditioning works on pre-set schedule or by CNS



To see this screen, press buttons UP and DOWN at the same time. All mesured temperatures are shown here.

ECON CO – limit (economical mode) of cooling setpoint

COMF CO – limit (comfort mode) of cooling setpoint

COMF HE – limit (comfort mode) of heating setpoint

ECON HE – limit (economical mode) of heating setpoint

If the room temperature under COMF HE, heat will work. If the ambient temperature of COMF CO cooling will work. The difference between COMF CO and comf COMF HE must be at least 1 ° C for the proper functioning of the control of heating and cooling.

Maximum and minimum inlet temperatures can be set on this screen. If heating is needed (room temperature is quite lower than setpoint ), maximum temperature of inlet air will be 40°C, so room temperature setpoint will be achieved in a short time. It's the same for cooling. COM T INLET will be shown only if compensation of minimum inlet regarding outside temperature will be ACTIVE. If not, this text won't appear on the screen.

If temperature of inlet air drops below MIN T INLET – DELTA T (16°C – 2°C), Y4 signal (fan speed) drops on MIN SPEED (30%). So, if inlet temperature is 14°C, fans will work on 30% and then continuously to speed, set as setpoint at 16°C or above.



This screen displays the current speed of supply and exhaust fan.

Speed setpoints for supply fan (speed regulation) for SPEED I and SPEED II mode can

be set separately on this screen, from 30% (minimum – can be set in other screen) to

100% (max speed).

Speed setpoints exhaust fan (speed regulation) for SPEED I and SPEED II mode can

be set separately on this screen, from 30% (minimum – can be set in other screen) to

100% (max speed).

Momentaly setpoint is shown here.

Speed regulation

E

S

Supply

Exhaust



Temperature behind plate exchanger (antifrosting function) is shown on this screen. If temperature is too low, frost protection will be ACTIVE.

Analog 0-10VDC outputs: Controller pco3S has four analog outputs. If value near Y1, Y2, Y3 or Y4 is 000.0%, output is INACTIVE. If value is 100.0%, output send 10VDC to valves/actuators. Y1 – heater valve, Y2 – cooler valve, Y3 – recuperation, Y4 – fan speed.

Digital outputs: if square is black, digital output ia ACTIVE. If square is empty, digital output is INACTIVE. Check wiring diagram, which digital output is used for turning ON heating pump, electrical heater etc.

Screen shows day and time (this must be set correctly because of schedule settings). If it's not set correctly, scheduler won't work properly.

Screen with schedule settings. H = Hours, M = minutes, MON = Monday etc. Time (when unit start/stop working) and temperature/speed regime (economic/comfort) can be set. This is weekly schedule so six different times and regimes can be set for each day in week. For the scheduled operation mode should be AUTO.



Days: Regimes:

MON = Monday OFF = unit turned OFF

TUE = Tuesday EC1 = economic regime (temperature) and speed I (55%)

WED = Wednesday EC2 = economic regime (temperature) and speed II (90%)

THU = Thursday CO1 = comfort regime (temperature) and speed I (55%)

FRI = Friday CO2 = comfort regime (temperature) and speed II (90%)

SAT = Saturday

SUN = Sunday

EXAMPLE:

AHU will start to work at 7.00 AM in comfort regime (fan speed will be 95% of max. speed, temperature setpoint is between 22 and 24°C). Regime will be changed at 11.00, to economic (fan speed will be 95% of max. speed, temperature setpoint is between 20 and 26°C). Unit will turn off at 19.00. CO1 = comfort regime (temperature) and speed I (55%) EC2 = economic regime (temperature) and speed II (90%)

Screen shows operation time of the unit in speed I and speed II.



Hand forced start and changing temperature regimes can be done here.

Manual: AUTO - working by schedule.

SPEED I - working in speed I (55% or set)

SPEED II - working in speed II (95% or set)

OFF - turned OFF unit

Regime: CO - comfort temperature regime

EC - economic temperature regime

5.5.3 ALARM LIST

In case any alarm occurs, BELL button will light in red color. If button (bell) is pressed, active alarm will be shown on display. Active alarm can be reset with bell button (press and hold down it for 10 seconds.

FIRE - If the signal from fire central is not present any more, fire alarm shows on display and AHU will STOP. ROTARY WHEEL ERROR - In case of rotary wheel error frequency converter give signal to main controller. When error is occure, air conditioning does not stop! NO AIRFLOW - differential pressure switch on fans close/open relay contact, if fan doesn't work. This alarm is not used on COMPAIR2 projects! OVERLOAD MOTOR FAN – this error is recieved from fan electronics or fuse. It might be something wrong with the fan, maybe overheating. OVERLOAD HEATING PUMP – this alarm is shown if the fuse is turned OFF by overcurrent! It's probably something wrong with pump!



FROST PROTECTION ACTIVE – if temperature behind heater drops below 5°C, this alarm will be shown, fans will stop working, heating valve will be open 100%, heating pump will start to work and fresh air damper will close. DIRTY FILTER – in case of this alarm AHU will continue to work – filter needs to be changed or cleaned. FROST PROTECTION OF PLATE EXCHANGER (this alarm is not shown) – Frost protection sensor (B5) is designed to give an information of the temperature behind exchanger. If the temperature drops below set value (5°C), controller will close exchanger dampers and open by-pass dampers so the cold outside air will go directly into room and warmer inside air will defrost exchanger dampers. 5.5.3.1 Electrical board Electrical board is mounted (inserted) on the top of the unit (for unit sizes 1000 – 4000) and on the front side (for bigger units). Electrical board can be taken out, but not completely.

Figure 46 ECC cabinet

Wires

Power supply, clams

Fuses

Controller

24 VAC

Relay

Transformer

Socket 230V



The heat pump electric-control cabinet is installed on a segment of the compressor circuit.

Figure 46a Heat pump electric-control cabinet

CAUTION: there is a stick HIGH VOLTAGE on the front of electrical board so when taking it out, be aware of high voltage! Board should be taken out only 15cm max, so only controller could be seen and parameters could be changed.

Figure 47 Warning sticker



5.5.3.2 PGD connecting PGD screen is a copy of the screen on the controller and is used to facilitate the managing of air handling unit just because the controller itself is usually hidden and sometimes hard to achieve. The black connector for PGD is ready in dose. Connection between the connector and PGD is done by the customer! Use only the UTP cable and two 6-pin connector, which are tied 1 to 1 (same color in the same places on both sides). If PGD connect directly to cable ready (that is, to remove the black connector), the board will not work!

Figure 48 PGD connection

5.5.3.3 Electrical connection in splitted units If the air condition unit consists of 3 parts is necessary for proper operation before unit assembling to connect connectors which are connected to motors, sensors, etc.. Connect the connectors to each other with the same numbers as shown in Figure 49th

Figure 49 Connector connection in splitted units



Connected connectors must be inserted in a dose, as shown in Figure 50.

Figure 50 Connectors in dose



5.5.3.4 Standard wiring diagram (CF)

IMPORTANT THING FOR CUSTOMER!



Wiring diagram is standard until unit has electrical heater installed in it or pressure sensors. In that case, wiring diagram is different and is always attached with the unit. It can also be sent via e-mail. Standard wiring diagram is always the same, customer must just check the main supply cable and fuses, which are different and depends on unit size.



5.5.3.5 Standard wiring diagram (RW)



6 MEANING OF SYMBOLS APPLIED

RADIAL FAN SECTION WATER HEATER SECTION WATER COOLER SECTION PLATE RECUPERATOR

SECTION

SECTION WITH ANTIFREEZING PROTECTION

FILTER SECTION FILTRATION CLASS G4

FILTER SECTION FILTRATION CLASS F7

ELECTRIC-CONTROL CABINET SECTION

CONTROL LOUVRE HANDLE OPEN POSITION HANDLE CLOSED

POSITION

CONDENSATE DRAINING SIPHON SIZING

HEATING FUNCTION COOLING FUNCTION

MEDIUM ENTRY RED COLOUR

MEDIUM EXIT BLUE COLOUR

MEDIUM ENTRY BLUE COLOUR

MEDIUM EXIT RED COLOUR

AIR FLOW DIRECTION MEDIUM FLOW DIRECTION CONTROL LOUVRE OPEN

CONTROL LOUVRE CLOSED



7 TABLE OF CONTENTS

0 General .................................................................................................................................................2 1 Description ............................................................................................................................................3

1.1 Types of functional sections .........................................................................................................3 1.2 Functional elements .....................................................................................................................3 1.3 Aircondition UNIT housing ...........................................................................................................6

1.3.1 Housing panel materials ..........................................................................................................6 1.3.2 Sound insulation ......................................................................................................................6 1.3.3 Thermal insulation ...................................................................................................................6 1.3.4 Mechanical stability ..................................................................................................................6 1.3.5 Housing air-tightness ...............................................................................................................6 1.3.6 Filter installation tightness .......................................................................................................6 1.3.7 Housing checking and maintenance ........................................................................................6

2 Airhandling unit transport ......................................................................................................................7 3 Airhandling unit mounting .....................................................................................................................8

3.1 Servicing area ..............................................................................................................................8 3.2 Construction of an airhandling unit foundation ............................................................................9 3.3 Mounting of an airhandling unit without a foundation ............................................................... 10 3.4 Airhandling unit mounting procedure ........................................................................................ 11 3.5 Installation procedure for an outdoor installation airhandling unit ............................................ 11

4 Functional sections ............................................................................................................................ 12 4.1 Fan section ................................................................................................................................ 12

4.1.1 Section description ............................................................................................................... 13 4.1.1.1 Plug fan ........................................................................................................................ 13

4.1.2 Electric motor connection ..................................................................................................... 13 4.1.3 Commissioning ..................................................................................................................... 14 4.1.4 Safe operation, testing and maintenance ............................................................................. 15

4.2 Heater section with water heater .............................................................................................. 15 4.2.1 Section description ............................................................................................................... 15 4.2.2 Water heater ......................................................................................................................... 16

4.2.2.1 Description ................................................................................................................... 16 4.2.2.2 Installation and commissioning .................................................................................... 16 4.2.2.3 Filling and draining procedure – transfer medium: warm, hot water ............................ 18 4.2.2.4 Operation ..................................................................................................................... 18 4.2.2.5 Maintenance ................................................................................................................. 19

4.2.3 Anti-freezing protection (FR) ................................................................................................. 20 4.2.3.1 Description ................................................................................................................... 20 4.2.3.2 Connection, operation and maintenance ..................................................................... 20

4.3 Heater section with electric heater ............................................................................................ 20 4.3.1 Section description ............................................................................................................... 20 4.3.2 Electric heater ....................................................................................................................... 20

4.3.2.1 Description ................................................................................................................... 20 4.3.2.2 Installation and commissioning .................................................................................... 21 4.3.2.3 Maintenance ................................................................................................................. 22

4.4 Cooling section with water cooler ............................................................................................. 22 4.4.1 Section description ............................................................................................................... 22 4.4.2 Water cooler .......................................................................................................................... 22

4.4.2.1 Description ................................................................................................................... 22 4.4.2.2 Installation and commissioning .................................................................................... 23 4.4.2.3 Filling and draining procedure: ..................................................................................... 24 4.4.2.4 Protection of the cooler against freezing ...................................................................... 24 4.4.2.5 Maintenance ................................................................................................................. 25

4.4.3 Direct evaporator .................................................................................................................. 26 4.4.3.1 Description ................................................................................................................... 26 4.4.3.2 Installation and commissioning .................................................................................... 26 4.4.3.3 Operation ..................................................................................................................... 29 4.4.3.4 Maintenance ................................................................................................................. 29

4.4.4 Outlet Siphon ........................................................................................................................ 30 4.4.4.1 Description ................................................................................................................... 30



4.4.4.2 Sizing and installation .................................................................................................. 30 4.4.5 Siphon tracing ....................................................................................................................... 32

4.4.5.1 Description ................................................................................................................... 32 4.4.5.2 Installation .................................................................................................................... 32

4.5 Cartridge filter section ............................................................................................................... 33 4.5.1 Section description ............................................................................................................... 35 4.5.2 Cartridge filter description ..................................................................................................... 36 4.5.3 Initial and recommended final pressure drops ...................................................................... 36 4.5.4 Number of filter cells per unit cross section, by unit sizes .................................................... 37 4.5.5 Installation and commissioning ............................................................................................. 37 4.5.6 Maintenance ......................................................................................................................... 37

4.6 recuperator section ................................................................................................................... 39 4.6.1 Section description ............................................................................................................... 39 4.6.2 Counterflow Plate Recuperator............................................................................................. 39

4.6.2.1 Description ................................................................................................................... 39 4.6.2.2 Installation and Commissioning ................................................................................... 40 4.6.2.3 Maintenance ................................................................................................................. 40

4.7 Rotational regenerator section .................................................................................................. 42 4.7.1 Section description ............................................................................................................... 42

4.7.1.1 Installation and Commissioning ................................................................................... 42 4.7.1.2 Maintenance ................................................................................................................. 43

4.8 Roof walleys .............................................................................................................................. 43 4.8.1 Description ............................................................................................................................ 43 4.8.2 Installation ............................................................................................................................. 43

5 Compair unit control ........................................................................................................................... 44 5.1 Functional diagram with counterflow heat exchanger ............................................................... 44

5.1.1 Functional description ........................................................................................................... 44 5.2 Functional diagram with rotary wheel ....................................................................................... 45

5.2.1 Functional description ........................................................................................................... 46 5.3 Functional element regulation ................................................................................................... 46

5.3.1 Electrical heater regulation: .................................................................................................. 46 5.3.2 Heat exchanger regulation: ................................................................................................... 46 5.3.3 Filters: ................................................................................................................................... 47 5.3.4 Heater frost protection: ......................................................................................................... 47 5.3.5 Frost protection of plate exchanger: ..................................................................................... 47 5.3.6 Inlet and outlet fan: ............................................................................................................... 47

5.4 Managing with air handling unit ................................................................................................ 48 5.4.1 Displays: ............................................................................................................................... 48 5.4.2 Connection to external units: ................................................................................................ 49 5.4.3 How to manage with Carel pCO3 regulator or PGD display ................................................ 51 5.4.4 Alarm list .............................................................................................................................. 56

5.4.4.1 Electrical board ............................................................................................................ 57 5.4.4.2 PGD connecting ........................................................................................................... 59 5.4.4.3 Electrical connection in splitted units ........................................................................... 59 5.4.4.4 Standard wiring diagram (CF) ...................................................................................... 61 5.4.4.5 Standard wiring diagram (RW) ..................................................................................... 65

6 Meaning of symbols applied .............................................................................................................. 70 7 Table of contents ............................................................................................................................... 71

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