SystemAir HHFlex Installation, Operation And Maintenance Instructions

Brand
SystemAir
Model
HHFlex
Category
Split-system air conditioners
Type
Installation, Operation And Maintenance Instructions
HHFlex Air Handling Units
Installation, operation and maintenance instructions
Content
Safety considerations
4 1.1 - General
4 1.2 - Applications
4 1.3 - Instruction types
6 1.4 - Disposal of parts/materials
Transport and lifting instructions
6 2.1 - General
6 2.2 - Transport and storage
6 2.3 - Roof edge protection during transport (outside installation)
7 2.4-Ofoadingandhoisting
7 2.5 - Horizontal transport
7 2.6 - Storage
7 2.7 - Assembly
Checklist of start-up check points
9 3.1 - Checklist of start-up check points
Start-up instructions
11 4.1 - Casing
11 4.1.1 - Casing panels
11 4.1.2 - Doors and access covers
11 4.1.3 - Flexible connections
11 4.1.4 - Earthing
11 4.1.5 - Connected ducts
12 4.1.6 - Outdoor air intake
13 4.1.7 - Assembly and placement of the air handling unit
13 4.1.8 - Air contamination
13 4.1.9 - Condensation in or on the AHU
13 4.2 - Dampers
13 4.2.1 - Dampers
14 4.2.2 - Recirculation dampers
14 4.3-Airlters
14 4.4 - Heaters
14 4.4.1 - Hot water coil
15 4.4.1.1 - Coils containing glycol
15 4.4.2 - Electric heater
16 4.4.3 - Steam heaters
16 4.5 - Coolers
16 4.5.1 - General
17 4.5.2 - Glycol in elements, see 4.4.1.1
17 4.5.3 - DX-coils
17 4.6-Heatrecoverywheel
18 4.7-Plateheatexchanger
18 4.8-Directsteamhumidication
18 4.8.1 - General
18 4.8.2 - Direct steam humidication
19 4.9-Electricsteamhumidier
19 4.9.1 - General, see 4.8.1
19 4.9.2 - Electric steam humidier
19 4.10-Waterhumidiers
19 4.10.1 - General
19 4.10.2 - Spray humidier
19 4.10.3 - Determining the quantity of spray water and the condensation factor
20 4.10.4 - Infrasonic humidication
20 4.11 - Fan
22 4.11.1 - Plug fans
23 4.11.2 - Frequency converters
23 4.11.3 - Plug fans with integrated EC motors
23 4.12 - Silencers
23 4.13-Lightning
Maintenance checklist
25 5.1-Checklistofcheckpointsandmaintenanceintervals
Maintenance and operating instructions
26 6.1 - General
26 6.2 - Casing panels
26 6.2.1 - Inside installation
26 6.2.2 - Outside installation
26 6.3 - Doors and access covers
26 6.4-Flexibleconnections
26 6.5-Earthing
26 6.6 - Dampers
27 6.7-Outdoorairintake
27 6.8 - Filters
27 6.9 - Heaters
27 6.9.1 - Hot-water coil
27 6.9.2 - Electric heater
28 6.10 - Coolers
28 6.10.1 - Chilled-water coil
28 6.11-Heatrecoverywheel
28 6.12-Plateheatexchanger
28 6.13 - Recirculation damper
28 6.14-Waterhumidiers
28 6.14.1 - General
29 6.14.2 - Spray humidier
29 6.14.3 - Infrasonic humidication
29 6.15 - Fan
29 6.15.1 - General
29 6.15.2 - Bearings
29 6.15.3 - Transmission
30 6.16 - Silencers
Abbreviations
AHU - Air Handling Unit
PED - Pressure Equipment Directive
BMS - Building Management System
SSR - Solid-state Relay
SUP - Supply Air
ETA -ExtractAir
ODA - Outdoor Air
EHA -ExhaustAir
HMI -Human-MachineInterface
RH - Relative Humidity
VU - Ventilation Unit
NRVU - Non-Residential Ventilation Unit
BVU - Bidirectional Ventilation Unit
UVU - Unidirectional Ventilation Unit
4 | HHFlexAirHandlingUnits
Safety Considerations
1.1 - General
TheHHFlexairhandlingunits(AHUs)havebeendesigned
andmanufacturedinaccordancewiththeCEmachine
directive. In order to guarantee safe operation and use of
theunit,pleasecarefullyreadandobservetheinstructions
inthisdocumentandpayspecialattentiontothewarnings
thatapplytothisunit.Anymodicationsinthedesign
and/orinstallationoftheAHUthatarecarriedoutwithout
priordiscussionwithSystemairB.V.andwithoutadvance
writtenagreementwillresultinthelossoftherighttoany
warranty claims and any claim for injury to personnel as a
resultofthesemodications.Allworkmustbecarriedout
bysufcientlytrainedpersonnel.
All applicable personnel safety devices must be used
toensuresafeworkingconditions.Safetyglovesand
glasses must be worn for all maintenance operations. A
respiratoryprotectionmaskmustbewornwhenchanging
thelters.TheA-weightedequivalentcontinuoussound
pressurelevelcanbeabove80dB(A),dependingonthe
motor size, fan size, fan speed andtheAHUinstallation
location.Thismeansthateardefendersmustbeworn,
whenthefanisrunning.
Alldoorsandhatchesmusthaveatleastonelockthatcan
onlybeopenedwithaspecialdevice.Heatingandcooling
coilsaremanufacturedandsuppliedinaccordancewith
guidelinesofthePressureEquipmentDirective(PED).
Donotwalkontheroofpanelsofunitsinstalledinsideor
outside.Onlysufcientlyqualiedpersonnelisallowed
toworkon(electrical)components.Allpowersuppliesto
theunitmustbedisconnected,beforeanyworkcanbe
carriedout.Switchoffthesupplyvoltageusingthemain
disconnectswitch.
CAUTION:Generalelectricheatershaveaseparatesupply
andmustbeswitchedoffseparately.
Ifworklightingisrequired,useonlylightingwith24V
maximum.Useofelectricalequipmentwithavoltage
above48Visonlypermittedifanearthleakageswitchis
installedthatcomplieswithlocalandnationalregulations.
1.2 - Applications
TheAHUisdesignedforthemovementandconditioning
ofair,unlessotherwiseagreedduringthedesignstage.
FromJanuary1st,2016AHUsmustcomplywithEU
regulation 1253/2014 implementing ErP directive
2009/125/EC,iftheyarewithinthescopeofthe
regulationandthedirective.
EUregulation1253/2014ispartoftheCE-marking.
Thisregulationappliesfor:
• ‘ventilation unit (VU)’ means an electricity driven
applianceequippedwithatleastoneimpeller,one
motor and a casing and intended to replace utilised
air by outdoor air in a building or a part of a building.
WhereanAHUisregardedasa:
• ‘non-residential ventilation unit’ (NRVU) means a
ventilationunitwherethemaximumowrateofthe
ventilationunitexceeds250m
3
/h,and,wherethe
maximumowrateisbetween250and1000m
3
/h,
themanufacturerhasnotdeclareditsintendeduseas
beingexclusivelyforaresidentialventilationapplication.
Theregulationdenestwotypesofventilationunits.
Thesemustbeplacedonthemarketorputintoservice,in
accordancewiththerequirementsofthisregulation.
• ‘unidirectional ventilation unit’ (UVU) means a ventila-
tionunitproducinganairowinonedirectiononly,
eitherfromindoorstooutdoors(exhaust)orfromout-
doorstoindoors(supply),wherethemechanically
producedairowisbalancedbynaturalairsupplyor
exhaust
• ‘bidirectional ventilation unit’ (BVU) means a
ventilationunitwhichproducesanairowbetween
indoorsandoutdoorsandisequippedwithboth
exhaustandsupplyfans
ThefollowingunitcombinationsareconsideredasaBVU:
• TwoormoreunitscombinedwithaRACheatrecovery
system
• Twoormoreunitsdirectly(withoutbuilding-side
ductwork)connectedwithamixingchamber.
If two or more units are combined as described above
on-siteinthebuildingbyathirdparty(forexampleinstaller),
aBVU(basedonCE-markedUVUs)willbe“putintoservice”.
Thismeansthethirdpartyhastodeclareproductconformity
withtherequirementsofaBVUandCEmarking.
Unitscanbesuppliedwithoutaccessoriesthatareindicated
asmandatoryinregulation1253/2014.Theseaccessories
mustbesuppliedandinstalledbyathirdparty.Theaccesso-
riesthatarenotsuppliedbutmandatoryareindicatedin
thetechnicalspecicationoftheAHU,e.g.fanswithvariable-
speeddrive,thermalbypassdevice,heatrecovery,visual
signalingoralteralarm(2018regulation).
1.3 - Instruction types
Thefollowingwarningpictogramsandlabelswithtextareused.
Lifting point
ThispictogramshowswheretheAHUmustbeliftedand
ispositionedonthesupportbeam.
HHFlexAirHandlingUnits | 5
Lifting prohibited
Thispictogramshowsthatnohorizontaltransportdevices
mustbeplacedunderthisframesection,suchaspallet
liftersortheforksofforklifttrucks.Itisalsoforbiddento
placeliftingdevicesfortransportandstorageunderthis
frame element.
Earthing
ThispictogramindicateswheretheAHUcanbeearthed
andisononeofthesupportbeamsbeneaththecasingin
thefansection.Ifaunitconsistsofseveralsections,only
onesectionneedstobeearthed,providedthesections
areconnectedinthecorrectway.
• TheelectricalcomponentsintheAHUmustbeearthed,
exceptforcomponentswithdoubleinsulationand/or
componentswithasupplyvoltagebelow50V.
• Theelectricalcomponentsmustbeinstalledin
accordancewithnationalandlocalregulations.
Rotating parts
Thispictogramindicatesthattherearerotatingparts
behindthisaccesscover,doororpanelwhichmaycause
injury.Thecomponentsthatincluderotatingpartsare
thefanandheatrecoverywheel.Iftherearespecial
customer-speciccomponentsbehinddoors,access
coversorpanelsthatincluderotatingpartsandposea
potentialrisk,thisisalsoindicatedbythispictogram.
Hot surfaces
Thispictogramindicatesthattherearecomponents
behindthisaccesscover,doororpanelthatcancause
seriousburnswhentouched.Thesurfacesthatmaybe
hotaretheheatersurfaces.Iftherearespecialcustomer-
speciccomponentsbehinddoors,accesscoversor
panelsthathavehotsurfacesandposeapotentialrisk,
thisisalsoindicatedbythispictogram.
Electrical voltage
Thispictogramindicatesthatthereareelectrical
componentsbehindthisaccesscover,doororpanel
thatmaybedangerousfortheuser/installer.Only
qualiedpersonnelispermittedtocarryoutworkon
thesecomponents.Forthisworktheregulationsofthe
applicable international (e.g. IEC 61557, EN 50110 and
ES 59009) and national (e.g. BS 7671) standards must be
observed.Thepictogramisattachedtotheaccesscover
fortheelectricheatercontrolbox.
Central data
ThislabelcontainsthedatafortheAHU,suchasorder
number,positionnumberetc.Thelabelisnormallylocated
ontheaccesscoverorthedoorofthefanassembly.Ifthe
AHUconsistsofseveralparts,eachpartmusthavealabel
withtherequireddata.
Opening the fan door
Thispictogramispositionedontheoutsideofthedoor
oraccesscoverofthefanassembly.Thispictogram
warnsthatthefanmusthavebeenswitchedoffand
deenergisedforaminimumoftwominutesbeforethe
doororaccesscoverisopened.Thispictogramalso
indicatesthattransportbracketsmustberemovedbefore
thefanisstartedup.
6 | HHFlexAirHandlingUnits
! Waarschuwing !
Voor openen deuren, ventilator
uitschakelen, spanningsloos
maken en uit laten lopen
(minimaal 2 minuten).
Transportbeugels
Verwijder transportbeugels voor
opstarten ventilator.
! Warning !
Before opening the doors, switch
off and deenergise the fan and
allow it to run down
(minimum 2 minutes)
Transport brackets
Remove transport brackets before
starting up the fan.
! Attention !
Avant ouverture des portes, le
ventilateur doit être déconnecté
et avoir eu le temps, de s’arrêter
completement
(2 minutes minimum)
Fixations de transport
Retirer les xations de transport
avant la mise en route.
! Gefahr !
Vor Öffnen der Türen den
Ventilator abschalten, span-
nungslos machen und zum
Stillstand kommen lassen
(mindestens 2 Minuten warten).
Transportsicherungen
Transportsicherungen vor der
Inbetriebnahme demontieren.
200034906
Other warning labels
! Waarschuwing !
Vervuilde lters zijn brandbaar.
! Warning !
Polluted lters are inammable.
! Attention !
Les ltres encrassés peuvent être
inammables.
! Gefahr !
Verschmutzte Filter sind leicht
entammbar.
200034907
! Waarschuwing !
Na het uitzetten van de
elektrische verwarmer moet de
ventilator nog
minimaal 5 minuten draaien.
! Warning !
After switching off the electric
heater the fan must continue to
run for at least 5 minutes.
! Attention !
Après la déconnexion de la
résistance électrique, le venti-
lateur doit continuer à tourner
pendant au moins 5 minutes.
! Gefahr !
Nach Abschalten der
Elektroheizung muss der Ventilator
noch mindestens 5 Minuten
weiterlaufen.
200034908
CAUTION: All doors and access covers must be closed
beforestartinguptheAHU.
Lifting and transport
AninstructionattachedtotheAHUdescribestheprocedures
thatmustbefollowedforliftingandtransport.The
followingchaptercontainsfurtherdetails.
1.4 - Disposal of parts/materials
• Thepackagingmaterialmustbedisposedofina
responsiblemannerandinaccordancewithlocal
regulations.
• Componentsthatarereplaced,mustbedisposedof
as described above.
Transport and lifting instructions
2.1 - General
• TransportandliftingoftheAHUmustalwaysbein
accordancewiththeinstructionsbelow.Ifthese
instructionsarenotobserved,theunitmaybe
irreparablydamaged,andpeopleintheimmediate
vicinityoftheunitareendangered.SystemairB.V.does
notacceptanyresponsibilityiftheseinstructionsare
not observed. Transport and lifting must be carried out
byqualiedpersonnel.TheAHUmustonlybeliftedwith
liftingbarssuppliedbySystemairB.V.(boxprole30x
30x4mm,quality52ortube48.3x6.3quality52).
• In special cases, lifting can be done using a base or
liftingframettedwithliftingplateswithfastening
holesthatuseabowanchorshackleandascrew
collar pin.
• Liftingmustbecarriedoutinaccordancewithlocal
regulationsandwiththehelpofcertiedliftingaids.
• Only one set of lifting bars is supplied per order/
positionnumberperunitwidth(ifordered).These
liftingbarsaresuitableforsingleuseandonlyforthe
partsofthisorder/positionnumber.Theliftingbarsare
certiedbyanauthorisedpersonusingatypetest.
2.2 - Transport and storage
Duringtransportandstoragetheairhandlingunitmust
onlybesupportedunderthedesignatedliftingpoints.
Supportingandliftingunderthecrossbeamsisprohibited.
Thisisindicatedonthecrossbeamwiththefollowinglabel.
2.3 - Roof edge protection during transport (outside
installation)
Duringtransportbytrucktheunitsareattachedtothe
loadingsurfacewithtieropes,pulledacrosstheunit
towardsthesideedgesofthetruck.
HHFlexAirHandlingUnits | 7
Toprotecttheroofedgeonoutsideunitsthatarewider
than1500mm,protectionplatesareaddedinplaceof
thetieropestopreventdistortionoftheroofedge.
2.4 - Ofoading and hoisting
DependingonthedimensionsoftheAHUandthe
situationonsite,theAHUsaresuppliedinpreviously
agreed transport sections.
Beforeproceedingwiththetransportandinstallation
ofthecasingsections,alwaysconsulttheapplicable
dimensionaldrawingsthatgivethedimensionsand
weightsofthesections,aswellastheinstallation
sequence.
Theweightisgivenoneachtransportsection.Each
transportsectionisequippedwithasubframewithfour
liftingpoints.Thesepointsaremarkedwiththelabel
shownbelow.
Forofoadingaswellashoistingliftingcablescanbe
attachedtotheliftingbars.Evenlypositionedspacerbars
shouldbeusedbetweentheliftingcablestoprevent
damagetothetopoftheunitandensurethatnoexcess
pressureisappliedtothesidepanels.Forhoistingplease
ensurethattheweightisevenlydistributed.
TheAHUmustnotberaisedunderthecrossbeamsduring
liftingormovingoperations.Thisisindicatedbythelabel
below.
2.5 - Horizontal transport
Forhorizontalmovementpalletliftersortransportskids
canbeplacedundertheinstallationframeorunderthe
liftingbars.Itisimportantthatthesesupportthelifting
points.Atnotimeshouldthecrossbeamsattheendsof
theunitsectionsbeusedforjackingortrackingtheAHU.
FOR HORIZONTAL TRANSPORT ALWAYS PROVIDE SUPPORT
UNDER THE LIFTING POINTS.Theuseofbarsasrollerscan
resultindamagetotheinstallationframe.
2.6 - Storage
ThepackaginginwhichtheAHUissuppliedcancause
condensationtoformbetweenthepackagingandthe
AHU,iftheunitisstoredinanunconditionedplace.
IftheAHUisnotimmediatelyuseditisrecommendedto
storeitinaconditionedlocationon-site.IftheAHUiskept
outsideforashortperioddirectsunradiationmustbe
avoided.
Ifthefansareshutdownforalongerperiod(longerthan
threemonths)bearingdamagecanoccur.Toprevent
thisitisrecommendedtoloosenthebelttensionorto
temporarilyremovethefanbelts.Whenthefansare
re-startedthebelttensionmustberesettothespecied
tension.Controlledrotationofthefanimpellercanalso
preventthistypeofdamage.Thisisalsorecommended
for direct-drive fans.
2.7 - Assembly
Fortheassemblyofourunitspleaserefertoour
instructionmanual“Mountinginstructions”.
8 | HHFlexAirHandlingUnits
Example conguration of HHFlex with heat recovery wheel
D2
T1
D1
M2
X1
X1
M2
M1
T1
X1
X1
M1M1
M1
D2
T1
D1
M2
X1
X1
M2
M1
T1
X1
X1
M1M1
M1
D2
T1
D1
M2
X1
X1
M2
M1
T1
X1
X1
M1M1
M1
HHFlexAirHandlingUnits | 9
Legend
A. Outdoorairintakedamper
B. Supplyairlter
C. Anti corrosion screen
D. Pre-heater
E. Supply air fan
F. Heater(hot-water)
G. Cooling coil
H. Droplet eliminator
I. Steamhumidier
J. Supply air damper
K. Extractairdamper
L. Extractairlter
M. Extractairfan
N. Heatrecoverywheel
O. Exhaustairdamper
Legend
1. Actuator, outdoor air damper
2. Frequency converter, supply air fan
3. Mainswitchsupplyairfan
4. Pressure sensor, supply air fan
5. Actuator, supply air damper
6. Actuator,extractairdamper
7. Mainswitchextractairfan
8. Frequencyconverter,extractairfan
9. Pressuresensor,extractairfan
10. Actuator,exhaustairdamper
11. Pressureswitch,supplyairlter
12. Frostprotectionthermostat,heater
13. Pressureswitchextractairlter
Dimensions
W=widthunitnx160+98
H=heightunitnx160+98
H1=heightbaseframeinmm
Thegreyareasinthetableindicate
standardised units.
Custom sizes are possible.
Theserviceareaforreplacementofcomponentssuchas
coilsandfansdependsonthecabinetwidthandmust
beatleastequaltothecabinetwidth.
H
18
16
14
12
10
8
6
4
2.5
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
W
Checklist of start-up check points
3.1 - Checklist of start-up check points
Beforecommissioningtheunit,allfunctionsbelowand
theassociatedcomponentsmustbechecked,usingthe
checklistbelow.Thetableonthenextpageshowsa
generaloverviewoftheoperationsrequiredtofacilitate
theinstallationoftheAHU.Thefollowingpagesgivea
moredetaileddescriptionoftheindividualcomponents.
CAUTION:BeforestartinguptheAHUensurethatthe
componentshavethecorrectconnectionvoltageand
connecttheminaccordancewiththeregulations.The
doorsandaccesscoversmustbeclosedandtheAHU
mustbeearthed.
Start-up check points
Function Components Check points Start-up
General All functions Remove obstacles and loose debris from compartment
All functions Check for possible condensate and if necessary dry the parts
Indoor installation/
outdoor installation
Internal and external panels Damage
Internal and external panels Damage
Joints Cracks
Doors/access covers Must be closed and locked before start-up
Flexible connections Correct installation
Earthing Correct earthing in accordance with regulations
Roof covering (outdoor installation) Check if roof is completely watertight
Dampers Correct operation
Blades fully closed and at zero position
Actuator Correct operation
Check rotation direction
Actuator end position same as damper end position
Filters Correct lter type
Are the lters correctly installed
Pressure differential gauge Correct operation
Pressure differential switch Correct operation/set-up
Droplet eliminator Bent ns
Siphon Correct connection
10 | HHFlexAirHandlingUnits
Start-up check points
Function Components Check points Start-up
Heaters Hot-water coil Correct connections
Air vent the coil
Leakage
Frost protection thermostat connected
Electric heater Check heater earth
Check hatch earth
Correct fuse size
Check wiring diagram
Check for possible condensate and if necessary dry the heater
Steam heater Correct connections
Completely drain water
Leakage heater and pipework
Testing heater and pipework
Coolers Chilled-water coil Correct connections
Air vent the coil
Leakage
Droplet eliminator Correct alignment
Drain trap Correct connection
Heat recovery wheel Rotor Check rotation direction
Seal Correct seal towards wheel
Drive Check connection voltage
Correct connection
Check current in all phases
Drive belt Check tension
Rotation monitor Correct connection
Controller Correct connection
Plate heat exchanger Damper (if used) Correct operation
Actuator (if used) Correct operation
Siphon trap Correct connection
Droplet eliminators (if used) Bent ns
Direct steam
humidication
Connections and attachments See documentation supplied
Test humidier and pipes
Leakage
Actuator Check connection and operation
Electric steam
humidication
Connections and attachments Check connection voltage
Check connection and operation
Water humidiers Spray humidiers See documentation supplied
Infrasonic humidiers See documentation supplied
Check connection voltage
Check exhaust
Check hoses
Check atomisation
Check pressostats
Fan Transport protection brackets Remove
Fan housing and fan compartment Remove obstacles and loose debris from the fan and fan compartment
Fan compartment, fan, motor,
frequency converter
Check for possible condensate and if necessary dry the parts
Impeller Check rotation direction
Motor Check connection voltage
Correct connection
Check current in all phases
Drive belt Check tension
Flexible connections Correct installation
Operating switch Check connection
Ensure switch is locked off during checks
Pressure switch/sensor Operation
Silencer (duct silencer) Damage of the top layer
Check for air-tight connection at the correct opening
Is the duct silencer sufciently supported
Frequency converter Connections Correct connection/complies with EMC
Frequency converter Check for possible condensate and if necessary dry the converter
Voltage Check connection voltage
Settings Check correct settings
Phases Check voltage in all phases
Lighting Lamp Check connection voltage
Switch Check connection
Control panel Components Check for possible condensate and if necessary dry the components
Power supply Check power supply voltage
Check neutral
Correct earthing in accordance with regulations
Power supply with correctly sized fuses
External sensors/control devices Connect according to wiring diagram
Alarms Connect to BMS or external panel
Controller Parameters Set all specic project parameters
HHFlexAirHandlingUnits | 11
Start-up instructions
4.1 - Casing
Theunitdata,suchasordernumber,positionnumberetc.
isgivenonthenameplate.
4.1.1 - Casing panels
ChecktheAHUpanelsforanydamage.Anydirtorstains
mustberemovedfromthesurfacetopreventpossible
long-termdamage.Buildingdebrisleftontheroofof
units installed inside and outside must be removed. Dirt
canberemovedwithwaterandamildhouseholdsoap
solution.Damagecanberepairedbythoroughlycleaning
theaffectedsurface,thentreatandpaintasnecessary.If
applicablecheckthesealingjointsandrepairifrequired.
4.1.2 - Doors and access covers
Checktheoperationofdoorhandles,locksandmovement
ofthehinges.Checkifthedoorclosure(ontheinsideof
thedoor)istightlytted,sothattherearenoexcessive
airleaksatthedoors.ForoutsideinstallationoftheAHU
checkthestormcord.Forthesectionsthatareunder
pressureitisrecommendedtoorderadoorlockwithan
pressure safety device.
CAUTION: Doors and access covers must always be closed
beforestartingtheunit.
4.1.3 - Flexible connections
• Checkthatallexibleconnectionsarermlyattached
totheAHU.Ifnecessary,tightenloosescrews.
• Thestretchedlengthofasingle-skinexible
connectionis130mm,butaexibleconnection
mustNOTbeinstalledstretchedbetweentheAHU
andtheduct.Onceinstalledtheoperatinglengthof
theexibleconnectionmustbe100mm.
4.1.4 - Earthing
EnsurethattheAHUisearthedcorrectlyandinaccordance
withlocalregulations.Alabelonthesupportframe
indicateswheretheunitshouldbeearthed.
4.1.5 - Duct connections
Therearecornerframesattachedtoallopeningstobe
connected.Thesecornerframesallowconnectionofthe
airducttotheAHU.
• ItisrecommendedtouseEuroproleconnections
(typeE30)atthecornerframeaswellasattheduct
to be connected.
• Europroleconnectionsareavailableinxedlengths
andcanbecuttotherequiredlengthwithasaw.
Theseprolescaneasilybeplacedoverthecorner
frame.Allowforamaximumproleheightof30mm,
sothatductsthatarepositionedoneabovethe
othercanbeinstalledcorrectly.
• Thefourcornersbetweentheprolescanbecompleted
withacornerpiece(typeH30).
• Theproleatthecornerframecanbeattachedto
theproleontheductusingadriveslip(typeSR).
• Attachingself-adhesivetapebetweenthetwo
prolesensuresanairtightseal,asshowninthe
drawing below.
Legend
1. AHU
2. Duct connection
12 | HHFlexAirHandlingUnits
• Thecornerframehasalengthof40mmandextends
32mmbeyondtheexternalAHUdimension,asshown
inthedrawingbelow.
• Theexibleconnectionprotrudesbeyondthe
externalAHUdimension,asshowninthedrawing
below.
Legend
1. AHU
2. Flexibleconnectionordamper
3. Duct connection
(single-skinexibleconnection-±30mmpresst)
• Thecombinationofexibleconnectionsanddampers
extendsbeyondtheexternalAHUdimension,as
showninthedrawingbelow.
Legend
1. AHU
2. Damper
3. Flexibleconnection
4. Duct connection
(single-skinexibleconnection-±30mmpresst)
4.1.6 - Outdoor air intake
• Ensurethattheairintakeductiscorrectlyconnected.
Highairvelocitiesmustbeavoided,andnoraindrops
shouldgetintotheduct.Thisispreventedbyinstalling
rainprotectionairintakegrilles(Caution:themaximum
airvelocityforthegrilleisasgivenbythesupplier).
Therearairintakeductmustbesizedtoavoidhigher
thanallowableairvelocitiesinthegrille.Highair
velocitiesintheopeningscanalsobecausedby
windattacksatoneoftheopenings.Ifthesecanbe
expectedfortheinstallationorgeographicallocation,
trytominimisethemwithpartitions.Ifthereisany
possibilitythatrainwatercanbedrawnin,droplet
eliminatorsarettedwithasuctiongrilleinthe
outside air duct.
• Apre-heaterforthelterscanbeinstalledtoprevent
mistcausingthelterstobecometoowet.The
pre-heaterwillreducetherelativehumidityoftheair.
Connectionoftheoutdoorairintakeduct
Connectionoftheoutdoorairintakeducttoaunitwith
damper register:
• Connecta500mmlongadapterpiecetothecorner
frameoftheairhandlingunit.
• Insulatetheinsideofthecompleteadapterpieceup
totheunitpanel.
• Insulatetheoutsideoftheadapterpiecesothat
thereisa250mmoverlapbetweeninsideand
outside insulation.
• Theremainderoftheadapterpieceneedstobe
insulatedontheoutside,asshowninthedrawing
below.
Connectionoftheoutdoorairintakeducttoaunitwithout
damper register:
• Connecta500mmlongadapterpiecetothecorner
frameoftheairhandlingunit.
• Insulatetheinsideofthecompleteadapterpieceup
totheunitpanel.
• Insulatetheoutsideoftheadapterpiecesothat
thereisa250mmoverlapbetweeninsideand
outside insulation.
• Theremainderoftheadapterpieceneedstobe
insulatedontheoutside.
Legend
1. AHU
2. Duct connection
HHFlexAirHandlingUnits | 13
Connectingtheoutdoorairintakeinoneoftheways
depictedabovepreventscondensationonthecorner
framework.
4.1.7 - Assembly and placement of the air handling unit
• Ensurethattheoorintheroomwheretheunitis
installedisevenandwaterproof.Thejointsbetweenthe
partsmustbecoveredwiththesealingtapeprovided.
Thesectionscanthenbeplacedinthecorrectorder.
Placethesectionsascloseaspossibletogetherand
ensurethattheycanbemoved.Usingasupport,pull
thesectionstowardseachotherwithapull-rope.
Checkifallpartsarewater-tightandifnecessaryslide
spacersunderthesupportwhererequired(seealso
chapter2).Thenattachtheprolessuppliedtothe
joint.Theroofofunitsinstalledoutsidemustbesealed
sothatnowatercanleaktotheinside.Alwaysattacha
unitinstalledoutsidetotheoorofthesupportframe,
toensurethattheunitcannotmoveorfall(takewind
force into account). For units installed inside please
makesurethattheunitcannotmovefromitssupport
points.Ifnecessary,attachtheunittothesupport.
• Foradetaileddescriptionoftheassemblyplease
refertotheinstructionmanual“Mountinginstructions”.
4.1.8 - Air contamination
Iftheexhaustandoutdoorairintakeopeningsareclose
toeachotherthereisariskofaircontamination.To
reducecontaminationtheairmustberareed.Todo
thiscorrectly,theairvolume,thehorizontalandvertical
distancetothetwoopeningsandthepositionofthetwo
openingsinrelationtoeachothermustbetakeninto
consideration(istheoutdoorairintakelowerorhigher
thantheexhaustairopening).
Itmaybenecessarytopositionthetwoopeningsfurther
apart,usinganextrapieceofductattheoutdoorair
intakeopening.Iftheunitsareinstalledoutside,thispiece
ofductshouldbeplacedbetweentheairhandlingunit
andthepre-installedsuctioncap(ifused).Thepieceof
ducting must always be supported in an appropriate way.
4.1.9 - Condensation in or on the AHU
Condensationcanformontheinsideandoutsideofthe
AHU.Thisdependsontheinstallationlocation(indooror
outdoor),temperatureandrelativehumidityinsideand
outsidetheAHUandthethermalbridgefactor(theTB
value)oftheAHU.AlwaysselectanAHUwithathermal
bridgefactorthatwillnotleadtocondensationatthe
indoor and outdoor conditions. For units installed inside
thefollowingpointsmustbeconsidered:
• Openwatercollectiontanks(e.g.vapour/condensate
collectiontank).Thesemustalwaysbeunpressurised
andcoveredsothattherelativehumidityintheplant
room is minimised.
• Sufcientlyinsulatethecoldwaterandcondensate
linesuptotheAHU.
• Sufcientlyinsulateairductswithapossibleair
temperaturebelowthedewpointoftheairinthe
plant room, as described earlier.
Forunitsthatareinstalledoutside,thefollowingpoints
must be considered:
• Alwaysinsulateairductswithapossibleaircondition
(temperatureandrelativehumidity)withadewpoint
abovetheexpectedoutdooraircondition,toprevent
condensateformationintheduct.Itisrecommended
toinsulateallductsfromandtothebuildingto
minimiseheattransferandtoensuregoodcontrol.
• Afterconnectingtheductstothebuilding
immediatelyconnecttheunittothepowersupply,
switchitonandstartitup.Ifthisisnotdone,
moisturewillmovefromthebuildingductstothe
AHU,causinganincreaseoftherelativehumidityin
theAHU.Atlowoutdoortemperatures(iftheAHUis
notoperating)thiscanleadtocondensationinthe
AHUandatthecontrolpanel.Thismustalwaysbe
prevented.
4.2 - Dampers
4.2.1 – Dampers
Whenworkingondamperregistersitispossibleforyour
ngerstobecometrapped.TheAHUmustbedeenergised
whilecleaningthedamperbladesinordertoprevent
unexpectedclosingofthedampers.Whileconnectingthe
cablingoftheactuator,theAHUmustbedeenergisedin
ordertopreventtheconnectioncablesfrombeinglive.
• Checkiftheactuatormotorisinstalledinaccordance
withthesupplier’sinstructions.
• Checkifthecorrectanglehasbeenset.
• Checkifthedamperscloseproperly.
• Checkifthedampercanbesettothefullyopen
position.
• Checkoperationanddamperpositionofthespring
return after a power cut. Some dampers must be
open,othersmustbeclosed.
•Ensurethattheendpositionofthedamperisthe
sameastheendpositionoftheactuatorsothatthe
driveleverofthedamperisunloadedintheend
position.
Manual operation Actuator-assisted operation
14 | HHFlexAirHandlingUnits
4.2.2 – Recirculation damper
• Thedampermustalwaysbeclosedduringpower
cutsandwhentheunithasstopped.
• Ifarecirculationdamperisused,thenboththe
outdoorintakeandtheexhaustopeningmustbe
ttedwithadamper.
• Iftherecirculationdamperisusedinamodulating
manner,theauthoritymustbeguaranteeddepending
ontheexternalpressuresontheotheropening.The
authorityoftherecirculationdampercanbeincreased
byplacingaperforatedplateonthedamper.Other-
wise only use open/closed control.
4.3 - Air lters
Filter types:
• Flatlter
• Baglter
• Absolutelter
• Carbonlter
• Chemicallter
• Electrostaticlter
ATTENTION: When carrying out a test run of the AHU the
air intake and exhaust side must never be blocked. The
fastening frame of the lter will fail if the pressure drop
across the lter is excessive.
• Checkifthecorrectltershavebeeninstalled.(air
direction)
• Checkifthelterbagshavebeeninstalledcorrectly.
• Absoluteltersaresuppliedseparatelyinorderto
prevent contamination during transportation and
commissioning.Filtersmayonlybettedafterthe
AHUhasbeencompletelycleaned.
• Setpressureswitchesorsensors,ifused.
• Closetheinspectiondoor.
• Ifdesired,adropleteliminatorcanbettedbehind
theoutdoorairsuctionlter.Thisdropleteliminator
catchesdropletsthatfalloffthelter.Thedroplets
containssubstancesthatareextremelycorrosiveand
cancausecorrosiondamagetothelterfunctionand
functionsafterthelter.Astainlesssteeldriptrayis
mountedunderthelter.
• Checkthatthensofthedropleteliminatorare
straightandsecuredinposition.
• Checktheoperationofthesiphon,see4.5.1.
4.4 - Heaters
4.4.1 - General
• Alwaysusegloveswhilecarryingoutmaintenanceor
repairsontheheaterelementtopreventcuts.
• Alwayswearsafetyglasseswhileworkingonthe
heaterelement.
• Thensandthepipescanreachtemperaturesthat
cancauseburns.Duringmaintenanceworkalways
wearglovesthatprovideprotectionagainsttempera-
tures up to at least 70°C.
• ItisforbiddentodrillholesintheAHUtoprevent
damagetopipesandheater.
• Ifthesystemiscompressiontested,somewatercan
remainintheelement.Thesystemmustcomplywith
thePEDguideline.Compressiontestingistheresponsi-
bilityoftheinstaller.Alwaysde-aeratethesystem.If
thecabinetistemporarilynotinuse,theremaining
water must be removed to prevent freezing.
• Onlyusethemediumforwhichtheelementwas
designed.Ifthemediumconsistsofamixtureof
water/glycoltakeaccountofthefactthatglycolisa
strongoxidisingagent.
• Ifonlywaterisusedasamedium,theelementmust
bedrained,iftheairreachesfreezingpoint.
• Avoidexcessivevibrationcausedbyexternaldevices
andtransmittedthroughthepipes.
• Theunitmustbede-energisedwhenthecollector
angesareremovedfromthepipes.
• Neverexceedthemaximumoperatingpressure.
• Checktheconnectionsonthedimensionaldrawing.
• Ensurethatthecoilhasbeenfullypurged.
• Checkconnectionsforleakage.
• Ensurethatthefrostprotectionthermostathasbeen
correctly connected and set up.
• Thecoilcanbethelastorsecondlastcomponentin
theAHU.Provideaccesstothefrostprotection
thermostatviaaeld-installedinspectionhatchin
thesupplyairduct.
• Ensurethattheheatercansupplyheattoprevent
frostformationwhenthefanisstarted.
CAUTION:Whenthecoilsaredrained,nowatermust
remaininthecircuitstopreventfreezingattemperatures
below zero.
HHFlexAirHandlingUnits | 15
4.4.1.1 - Coils containing glycol
Ifcoilsarelledwithawater/glycolmixture,thisrequires
extraattention.
• Glycolcanreactviolentlywithstrongoxidationsolutions.
• Whenworkingonthecoil,alwayscheckwhich
mediumisused.Beforeaddinganythingtotheheat
exchangemedium,alwayscheckwiththeinstaller.
• Always wear safety glasses and gloves.
• Donotsmokeoruseanopename.
• Whensizingtheexpansiontanktakethehigherheat
transfercoefcientintoaccount(±25%larger).
• Watertightsealsarenotalwaystightforwaterglycol
mixtures.Itisthereforebettertouseweld/solder
connections.
• Water/glycol causes increased sludge formation.
• Alwaysobservetheinstructionsoftheglycol
manufacturer.
• Checkthemixturetoensurethattheglycolconcen-
tration(byweight)iscorrect.
4.4.2 - Electric heater
• Theelectricheatermustbeconnectedasdescribed
inthetechnicaldataandshownintheconnection
diagramsupplied.Itisimportantthattherequired
machinecapacitiescomplywiththethicknessofthe
chosenconnectioncableandfusesofthepowergrid.
Theinstallerisresponsibleforthecorrectconnection
andmachineoperation.
• DonotentertheAHU,iftheelectricheaterisswitched
on.
• Beforeswitchingontheheaterensurethatthefan
rotates.Afterswitchingtheheateroff,thefanmust
continue to rotate for a minimum of 5 minutes.
• Ifnotallthestepsoftheelectricheaterhaveinnitely
variablecontrol,ensurethattheminimumspeed
overtheheateris2m/s.Ifallstepshaveinnitely
variablecontrol,theairspeedovertheelementcan
be reduced to 1.5 m/s.
• Checkand/orconnecttheheaterinaccordancewith
localregulationsandthedatafromthemanufacturer.
• Ensurethattheterminalstripearthandtheinspection
hatchearthhavebeenconnected.
• Checkforpossiblecondensate/moisture.Condensate
mayformintheperiodbeforetherststart-upofthe
AHUasaresultofweatherchangeand/orhumidair
fromthebuilding.Removeallcondensatefromthe
constructioncomponentsanddrytheelectricalcompo-
nentsusingwarm(dry)air(e.g.withadrier).
• Checktheconnectionvoltage.
• Checktheexistingamperageonallphases.Thevalues
mustagreewiththedataontheheaternameplate.
• Toensuresafeoperation,theheaterisequippedwith
athermostatwithautoreset(80°C)andahighlimit
thermostatwithmanualreset(128°C).
• Thewarninglabelforelectricalvoltageisattachedto
theinspectionhatch.
• Theearthwarninglabelisattachedtotheinsideof
theheaterandtheinspectionhatch.
• Thewarninglabelfortheproceduretoswitchoffthe
heaterisfoundonthedoororhatchofthefan
assembly.
! Waarschuwing !
Na het uitzetten van de
elektrische verwarmer moet de
ventilator nog
minimaal 5 minuten draaien.
! Warning !
After switching off the electric
heater the fan must continue to
run for at least
5 minutes.
! Attention !
Après la déconnexion de la
résistance électrique, le ventila-
teur doit continuer à tourner
pendant au moins 5 minutes
! Gefahr !
Nach Abschalten der
Elektroheizung muss der Ventilator
noch mindestens 5 Minuten
weiterlaufen.
200034908
16 | HHFlexAirHandlingUnits
4.4.3 - Steam heaters
ATTENTION:
• Steamheatersconnectedtothepipesmustalways
be compression-tested by trained personnel and
complywiththePEDguideline.Compressiontestingis
theresponsibilityoftheinstaller.Pipesmustalways
beinsulatedandaretheresponsibilityoftheinstaller.
• Theoperationofthesteamheatermustbecon-
nectedtotheoperationofthefan.Ifthefanstops,
stopthesupplytothesteamheaterimmediately.
• Steamheatershavesurfacetemperaturesthat
exceed100°C.Thesteamintakemustbedoneby
expertpersonnelinacontrolledmanner.
• Thesteamheatermayonlybeswitchedonifa
minimumspeciedairquantityisowingoverthe
heater.
• Checkifthereareanyobjectsintheheatingfunction.
Thetemperaturemaybehighenoughforplasticsto
melt.
• Thesteamheatermustbeswitchedoffatleast5
minutesbeforetheAHUisswitchedoff.
• Thefollowingwarningpictogramisappliedtothe
paneloftheAHU:Hotsurface
4.5 - Coolers
4.5.1 - General
• Alwaysusegloveswhilecarryingoutmaintenanceor
repairsonthecoolingelementtopreventcuts.
• Alwayswearsafetyglasseswhileworkingonthe
cooling element.
• Alwayswearglovesduringmaintenancework.
• ItisforbiddentodrillholesintotheAHUinorderto
preventdamagetopipesandthecoolingelement.
• Ifthesystemiscompression-tested,somewatercan
remainintheelement.Thesystemmustcomplywith
thePEDguideline.Compressiontestingistheresponsi-
bilityoftheinstaller.Alwaysde-aeratethesystem.If
thecabinetistemporarilynotinuse,theremaining
water must be removed to prevent freezing.
• Onlyusethemediumforwhichtheelementwas
designed.Ifthemediumisamixtureofwater/glycol
takeaccountofthefactthatglycolisastrongoxidis-
ing agent. Remove any remaining liquid immediately.
• Ifonlywaterisusedasamedium,theelementmust
bedrained,iftheairreachesfreezingpoint.
• Avoidexcessivevibrationcausedbyexternaldevices
andtransmittedthroughthepipes.
• Theunitmustbede-energisedwhenthecollector
angesareremovedfromthepipes.
• Neverexceedthemaximumoperatingpressure.
• Checktheconnectionsonthedimensionaldrawing.
• Ensurethatthecoilhasbeenfullypurged.
• Checkconnectionsforleakage.
CAUTION:Whenthecoilsaredrained,nowatermust
remaininthecircuitstopreventfreezingattemperatures
below zero.
• Ifachangeovercoilissuppliedbyaheatpump,the
installationmustbedesignedtocompensateforthe
requiredheatduringthesystemheatpumpdefrost
cycleandtheheatmustnotbedrawnfromthe
supplyair.Otherwisethesupplyairtemperature
cannotbeachieved.Duringtheheatpumpdefrost
cycleitmustbepossibletoaddenoughheatintothe
systemtoguaranteethedesiredentering
temperature(heaterdesigncapacity)aswellasthe
requiredheatforheatpumpdefrosting.
• EnsurethattheAHUisinstalledhighenoughto
enablethesiphontraptoworkcorrectly.
• Ensurecorrectinstallationofthesiphontrap(option).
UsePTFEtapetomakesurethattheconnectionat
theanglebendofthecondensatepantapis
watertight.Leaveapproximately32mmWITHOUT
tapebetweenthesiphoncasingandtheconnection
tothepipe,asthispartissealedbytherubberring
provided.
• ThenegativepressuresiphonsuppliedbySystemair
B.V. is suitable for a negative pressure of up to 800 Pa
intheassociatedsection.
• Checkifsiphoncoverandballhavebeencorrectly
installed.
• ThegaugepressuresiphonsuppliedbySystemairB.V.
is suitable for a gauge pressure of up to 1200 Pa in
theassociatedsection.
HHFlexAirHandlingUnits | 17
• Checkthatthe(negativeorgauge)pressurecorres-
pondstothesiphontypeinstalled.
• Theoutletofthesiphontrapconnectedtothedrain
must not be under pressure.
• Itisnotrecommendedtoconnectasiphonina
negativepressuresectionandasiphoninagauge
pressuresectionviaamanifoldthatisnotunder
pressuretothedrain.Insteadtwoseparatemanifolds
shouldbeused.
• Iftheeld-preparedsiphonisused,followthe
instructionsinthedrawingbelow.
• Fillsiphonwithwater,ifthefanisswitchedoff.
Negative pressure:
H1 = maximum negative pressure in the cooler section (in mm WG) + 50 mm.
H2 = >1/2 x H1
Gauge pressure:
H1 = >maximum gauge pressure in the cooler section (in mm WG) + 50 mm.
H2 = 50 mm
Pressure in kPa (100 Pa = 10 mm WG)
• Checkifthedropleteliminatorafterthecoolerhas
been correctly installed.
• Checkifnshavebeenbentduringtransport.
• Correctlystraightenthens.
• Thenswillonlyworkcorrectlyafterseveraldaysin
dehumidicationmode.
• Startupthecoolingcoilbyopeningtheshut-off
valvesandswitchingonthecontroller.Afterseveral
daysofcoolingoperationcheckthecondensatedrain
andoperationoftheplasticsiphon.
• Ifnecessarycleanthesiphon.
4.5.2 - Glycol in elements, see 4.4.1.1
4.5.3 - DX-coils
• TheDX-coilsaresuppliedwithoutrefrigerant.
• Thecoilsmustneverbepressurisedwithwater.They
mustbesealedandpressurisedwithagaseous
mediumtopreventpollutionofthecoil.
• Aqualiedpersonshouldchargethecoilandtherest
ofthesystemwithasufcientamountofthe
refrigerantasspeciedinthetechnicalspecications.
• WhenconnectingtheDX-coiltothecompressor/
condensingunitalwaysfollowthesupplierspecica-
tionsandtheinstructionsofthequaliedpersonnel.
• ItisnotrecommendedtoconnectseveralDX-coilsto
one compressor/condensing unit.
• Itisbesttouseaninnitelyvariablecontrollerforthe
compressor/condensingunit.Ifthecondensingunit
hasinnitelyvariablecontrol,oneofthetemperature
controlsinthecontrollercanbeselected.
• Ifthecondensingunitdoesnothaveinnitelyvariable
control,settheAHUcontrolforsupplyairtemperature
controlandconnecttheDXenteringtemperature
sensorinsteadofthesupplyairsensor.Thedesired
(room)temperaturemustthenbecontrolledbya
separatecontrolleratthecondensingunit.
Ifachangeovercoilissuppliedbyaheatpump,the
installationmustbedesignedtocompensateforthe
requiredheatduringthesystemheatpumpdefrostcycle
andtheheatmustnotbedrawnfromthesupplyair.
Otherwisethesupplyairtemperaturecannotbeachieved.
Duringtheheatpumpdefrostcycleitmustbepossibleto
addenoughheatintothesystemtoguaranteethedesired
enteringtemperature(heaterdesigncapacity)aswellas
therequiredheatforheatpumpdefrosting.
4.6 - Heat recovery wheel
• Ensurethattheheatexchangerfaceareaisnot
damaged.
• Checkthatthewheelisrotatinginthecorrect
direction.Thisisindicatedbyanarrowonthecasing.
• Checkifthewheelsealsarettingcorrectly.
• Checkifthebelttensioniscorrect.
18 | HHFlexAirHandlingUnits
• Checkifthemotorandtherotationmonitorhave
been correctly connected (5 mm play between
sensoranddetectionpointonthewheel).
• Checkifthecontrollerhasbeencorrectlyconnected
andsetinaccordancewiththesupplierinstructions.
Theinstructionsfromthecontrollersupplierapply.
• Ensurethattherotorspeedhasbeencorrectlyset
TheHHFlexcondensationrotormusthavea
maximumspeedof10min
-1
; a sorption rotor must
haveamaximumspeedof20min
-1
.Refertothe
usermanualfortheheatrecoverywheelcontroller.
• Iftheairintaketemperatureisbelow-15°C,a
pre-heaterisrecommendedfortheheatrecovery
wheeltopreventfreezing.
• Thefollowingwarningsignisshownonthepanel.
Rotating parts
Rotor controller
Iftheheatrecoveywheelissuppliedwitharotor
controller,thismustbeincludedinthecentralcontrol
panel.Therotationsensoroftherotorispre-ttedand
must be connected.
Ifitisnecessarytoprotecttheheatrecoverywheel
againstfrostdamage,itmustbettedwithapressure
sensororpulse/pausemustbeactivatedortheairsupply
volume must be reduced.
4.7 - Plate heat exchanger
• Ensurethatthefaceareaoftheheatexchangeris
not damaged.
• Ifdampersareinstalled,alsocheckiftheactuator
motorhasbeeninstalledinaccordancewiththe
supplier instructions.
• Checkifthecorrectanglehasbeenset.
• Checkifthedampersclosecorrectly.
• Checkifthedamperscanreachthefullyopen
position.
• Beforeconnectingthesiphontrapandcheckingthe
dropleteliminator(ifinstalled),seechapter4.5.
• Iftheairintaketemperatureinacross-owplate
heatexchangerisbelow-10°C,apre-heateris
recommendedfortheplateheatexchangerto
prevent freezing.
• Iftheairintaketemperatureinacounter-owplateheat
exchangerisbelow-5°C,apre-heaterisrecom-
mendedfortheplateheatexchangertoprevent
freezing.
Ifdesired/necessary,theheatrecoverywheelistted
withasensortoprotecttheheatexchangeragainst
freezing.Ifdampersarepresent,thecontrolsystem
mustopenandclosethedampersatthecorrecttimeto
preventfreezingoftheplateheatexchanger.
4.8 - Direct steam humidication
4.8.1 - General
• Firstreadthedocumentationsupplied.
• Connectthesteamgeneratorinaccordancewiththe
documentation supplied.
• Wearing safety gloves and glasses is compulsory.
• Do not enter an active steam generator. Entry is only
allowedifthesteamgeneratorhasbeeninactivefor
10minutes.Whenenteringthesteamsectionand
touchingthesteamgenerator,distributionpipeorpipes
makesurethattheunitisnolongerproducingsteam.
• Enteringthesteamfunctionandtouchingthesteam
generator, distribution pipe and pipes can cause
burns.Thesurfacetemperatureofthesteam
generator,distributionpipeandpipesandthesteam
canreach100°Cormore.
• Steamgeneratorsthatareconnectedtothepipes
mustalwaysbecompressiontestedbysufciently
trainedpersonnelandcomplywiththePEDguideline.
Compressiontestingistheresponsibilityoftheinstaller.
Alwaysde-aeratethesystem.Pipesmustalwaysbe
insulatedandaretheresponsibilityoftheinstaller.
• Consultthedocumentationsuppliedinthecaseof
faultsinthesystem.
• Theoperationofthesteamgeneratormustbelinked
totheoperationofthefan.Ifthefanisde-activated,
supplytothesteamgeneratormustbestopped.
• Foralltypesofhumidiersamaximumhygrostat
must be installed to allow intervention in case of
excessivehumidication.
4.8.2 - Direct steam humidication
• Checkthefasteningofthesteamcontainer.
• Checkthesteamsupplyandthecondensateexhaust.
• Forlongerpipestanextracondensatecontainer
boilerinaccordancewiththesupplier’sinstructions.
• Checkthatthedirtcollectorhasbeeninstalled.
• Condensatedrainagemaybeexecutedwithout
pressure,dependingonthemanufacturer.Referto
thesupplier’sinstructions.
• Incaseofunder-pressureintheAHU,placeaspecial
siphonforcondensatedrainage.
• Tocommissionthesteamhumidier,thesteammust
beintroducedintothesystemandthehumidier
mustslowlybebroughttotheoperatingtemperature.
Whenthecondensatepipehasreachedtheoperating
temperature,switchontheadjustmentmotorelectri-
callyorpneumaticallyandsetthedesiredhumidity
level.Refertothesupplier’sinstructions.
HHFlexAirHandlingUnits | 19
• Cleanthedirtcollectorsieveandcheckthecondensate
exhaustseveraldaysaftercommissioningtheunit.In
caseofcabinetswithunder-pressure,theoperation
oftheunder-pressuresiphonmustbecheckedwith
a non-return valve.
• Amaximumhygrostatmustbettedinordertoprevent
excessivehumidicationintheAHU.See4.8.1.
• Theconnectionofthesteampipetothepipemust
betension-freeinordertopreventdistortionofthe
steam pipe and generator.
• ThefollowingwarningstickerIappliedtothepanel.
Hot surface.
4.9 – Electric steam humidier
4.9.1 - General - see 4.8.1
• Theelectrichumidiermustbeconnectedbasedon
thetechnicaldataandthesuppliedconnection
diagram.Itisimportantthattherequiredcapacities
ofthemachinecorrespondwiththethicknessofthe
chosenconnectioncableandthefusesonthe
electricitygrid.Theinstallerisresponsibleforthe
connectionandgoodoperationofthedevice.
4.9.2 – Electric steam humidier
• Checkthefasteningofthesteamgenerator.
• Checkthesteamsupplyandcondensatedrainage
pipes.
• Condensatedrainagemaybeexecutedwithout
pressure,dependingonthemanufacturer.Referto
thesupplier’sinstructions.
• Incaseofunder-pressureintheAHU,installaspecial
siphonforcondensatedrainage.
• Checkthevoltageandmeasurethetotalpower
consumption.
• Connectthehumidierinaccordancewiththe
supplier’sinstructions.
• Thefollowingwarningstickerisappliedtothepanel:
Hot surface.
• Amaximumhygrostatmustbettedinorderto
preventexcessivehumidicationintheAHU.See
4.8.1.
4.10 - Water humidiers
4.10.1 - General
• Bacteria may grow in open water. Ensure correct
maintenancetopreventLegionaire’sDisease.
• Theconnectionofthereplenishmentwaterandthe
drainageofthecondensatewatermustcomplywith
local regulations.
• Thecirculationpumpofthehumidiercanonlybe
startedwhenthefanisinoperation.Itwillnot
functionorfunctioninsufcientlywithoutanairow,
therebycausingotherpartsofthecabinettobecome
wet.Startthehumidicationpumpandcheckthe
directionofrotationinaccordancewiththearrow
shown.Watermustbeemittedfromthesprayers
immediatelyafterthepumpisstarted.Stop
immediatelyifnecessary.Thecirculationpumphas
water-lubricatedbearingsandawaterlubricatedaxle
seal,ttedwithtwohardmetalrings.
• Incaseofdangeroffreezing,alwayscheckthatthe
heaterfunctionscorrectly.
• Theoperationofthewaterhumidiermustbelinkedto
theoperationofthefan.Ifthefanstops,thesupplyto
thewaterhumidiermustalsobestoppedimmediately.
• Amaximumhygrostatmustbettedtoprevent
excessivehumidicationintheAHU.See4.8.1.
4.10.2 - Spray humidier
• Inordertomeasurethequantityofspraywater,the
siphonmustbedisconnectedandthequantityof
watermustbemeasuredonsitewiththeaidofa
measuringjugandastopwatch.Immediately
determinetherequiredquantityofspraywaterfor
everycabinetinadvance.Checkthattheoatsealin
thewaterreservoirissettothecorrectheight.
4.10.3 - Determining the quantity of spray water and
the condensation factor
• Theconstantevaporationofwaterincreasesthesalt
concentrationandtherebytheconcentrationofother
constituentsinthereservoir.Whentheairishumidied
aportionofthewaterevaporates,whiletheremaining
waterreturnstothereservoir.Saltsandotherundis-
solvedsubstancesthatarealwayspresentinpipe
waterorsoftenedwaterremaininthewaterthat
returnsintothewaterreservoir,whiletheevaporated
portion does not contain any solids.
• Evaporationlowersthelevelinthereservoir.Thisis
preventedbytheautomaticadditionoffreshwater
throughtheoatseal.However,thiscontainsmore
saltsandothersolidsandbecomesincreasingly
concentratedinthereservoir.Thisisdescribedbythe
term‘thickening’.Constantlysprayingacertain
amountofwatercanlimittheconcentrationinthe
container.Thislimitcanbecontrolledbydetermining
thequantityofspraywaterrequired.
20 | HHFlexAirHandlingUnits
• Determinethespraywateramountwithaknown
maximumofwatertobeevaporatedandaselected
thickeningfactor.
Qs = qv  qt=qv+qs
i-1
where:
i = thickening factor (see below)
qt = supply water amount
qv = quantity of water to be evaporated
qs = spray water amount
The pH value of the spray water must not be lower than 5
or higher than 10.
• Selectionofthethickeningfactor(andthereforethe
spraywateramount)isimportant.Ifthefactorchosenis
toolow,thewaterconsumptioncostwillbeunneces-
sarilyhigh.Ifthefactoristoohigh,extremescaling
andcontaminationofthewetpartsofthehumidier
willoccurandleadtohighmaintenancecosts.
• Amaximumhygrostatmustbettedtoprevent
excessivehumidicationintheAHU.See4.8.1.
4.10.4 - Infrasonic humidication
• Carefullyreadthesupplier’sinstructions.The
followingpointsdeserveextraattention.
• Ensurethattheconnectionvoltagecorrespondsto
theunitvoltage.
• Connecttheunitinaccordancewiththediagram
supplied.
• Checkthecorrectconnectionofthedrain.
• Checktheconnectionofthehigh-pressurehose.
Aftercommissioning,checkthatthehosesdonot
rub against any surface.
• Checkthatthesprayersproduceaneffectivemist.
Checkoperationofthepressostatsandpressure.
• Checkthewaterquality.
• Thehumidiermustbettedwithasafetyfeatureto
preventoverheatingandrunningdry.
• Theairowoverthehumidiermustnotexceed5.5
m/s.Optimumoperationisat4m/s.Theonly
humidica-tionmediumthatmaybeusedis
demineralisedwater,withaconductivityupto20
microsiemens/cm and an ambient temperature
between+2°Cand+30°C.
• Ensurethattheairowgraduallydecreasesforanother
20minutesafterde-activationofthehumidication
pumptoallowtheAHUtodrycompletelyandprevent
microbiological contamination.
• After50operatinghours,theoilinthepumpmust
bereplaced.Werecommendthatyouusesynthetic
oil SAE 20W50.
• Amaximumhygrostatmustbettedtoprevent
excessivehumidicationintheAHU.See4.8.1.
• Thefollowingstickerisappliedtothecontrolbox.
4.11 - Fan
CAUTION:Theairowmaycausestationarypartstomove
(evenafanthatisswitchedoff)!
• Removethetransportbrackets.Thisisindicatedbya
labelonthedoor.
• Checkifthefancanmovefreelywithoutobstructing
theframe,exibleconnectionorwiring.
• Checkforpossiblecondensate/moisture.Condensate
mayformbeforetheAHUrststart-updueto
changingweatherand/orhumidairfromthebuilding.
Removeallcondensatefromtheconstruction
componentsanddrytheelectricalcomponentsusing
warm(dry)air(e.g.withadrier).Thisappliestoboth
motor and frequency converter.
• Checktheconnectionvoltage.
• Checkand/orconnectthemotorinaccordancewith
localinstructionsandthedataofthesupplier.
• Checkthedirectionofrotationoftheimpeller.The
directionisindicatedonthefanbyanarrow.
• Separatelymeasurethecurrentdrawoftheelectric
motorforallphases.Thecurrentdrawofallphases
mustbeapproximatelythesameandagreewiththe
dataonthenameplate.Setthemotorprotection
devicetothenominalvalue.
• Themotordatashownisforanaltitudeofupto
1000 m above sea level and an ambient temperature
of40°Cmaximum.
• Thedataforbelttype,belttension,numberofbelts,
pulleysizeandtypeisgivenonastickeronthefan
housing.
• Ifthefansareshutdownforlongerperiods(longer
thanthreemonths),thebearingsmaybedamaged.
Topreventthis,itisrecommendedtoreducethefan
Remove after
transport
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SystemAir HHFlex Installation, Operation And Maintenance Instructions

Brand
SystemAir
Model
HHFlex
Category
Split-system air conditioners
Type
Installation, Operation And Maintenance Instructions
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