ATTACHMENT 1

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 - Offloading 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 filters
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 humidification
18 4.8.1 - General
18 4.8.2 - Direct steam humidification
19 4.9 - Electric steam humidifier
19 4.9.1 - General, see 4.8.1
19 4.9.2 - Electric steam humidifier
19 4.10 - Water humidifiers
19 4.10.1 - General
19 4.10.2 - Spray humidifier
19 4.10.3 - Determining the quantity of spray water and the condensation factor
20 4.10.4 - Infrasonic humidification
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 Abbreviations
27 6.9.1 - Hot-water coil AHU - Air Handling Unit
27 6.9.2 - Electric heater PED - Pressure Equipment Directive
28 6.10 - Coolers BMS - Building Management System
28 6.10.1 - Chilled-water coil SSR - Solid-state Relay
28 6.11 - Heat recovery wheel SUP - Supply Air
28 6.12 - Plate heat exchanger ETA - Extract Air
28 6.13 - Recirculation damper ODA - Outdoor Air
28 6.14 - Water humidifiers EHA - Exhaust Air
28 6.14.1 - General HMI - Human-Machine Interface
29 6.14.2 - Spray humidifier RH - Relative Humidity
29 6.14.3 - Infrasonic humidification VU - Ventilation Unit
29 6.15 - Fan NRVU - Non-Residential Ventilation Unit
29 6.15.1 - General BVU - Bidirectional Ventilation Unit
29 6.15.2 - Bearings UVU - Unidirectional Ventilation Unit
29 6.15.3 - Transmission
30 6.16 - Silencers
 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 modifications 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 modifications. All work must be carried out
by sufficiently 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 filters. The A-weighted equivalent continuous sound
pressure level can be above 80 dB(A), depending on the
motor size, fan size, fan speed and the 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 sufficiently qualified 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 flow rate of the
ventilation unit exceeds 250 m3/h, and, where the
maximum flow rate is between 250 and 1 000 m3/h,
the manufacturer has not declared its intended use as
being exclusively for a residential ventilation application.
The regulation defines 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 flow in one direction only,
either from indoors to outdoors (exhaust) or from out-
doors to indoors (supply), where the mechanically
produced air flow is balanced by natural air supply or
exhaust
• ‘bidirectional ventilation unit’ (BVU) means a
ventilation unit which produces an air flow 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 specification of the AHU, e.g. fans with variable-
speed drive, thermal bypass device, heat recovery, visual
signaling or a filter 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.

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-specific components behind doors, access
covers or panels that include rotating parts and pose a
potential risk, this is also indicated by this pictogram.
HHFlex Air Handling Units | 5
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-
specific 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
qualified 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

Transport and lifting instructions

! Waarschuwing !
Voor openen deuren, ventilator
uitschakelen, spanningsloos
maken en uit laten lopen
(minimaal 2 minuten).
Transportbeugels
Verwijder transportbeugels voor
opstarten ventilator.
! 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 fixations de transport
avant la mise en route.
Other warning labels
! Waarschuwing !
Vervuilde filters zijn brandbaar.
! 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.
! 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
! Warning !
Polluted filters are inflammable.
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 qualified personnel. The AHU must only be lifted with
lifting bars supplied by Systemair B.V. (box profile 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 fitted 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 certified 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
certified by an authorised person using a type test.

! Attention ! ! Gefahr ! 2.2 - Transport and storage

Les filtres encrassés peuvent être
inflammables.
! Waarschuwing !
Na het uitzetten van de
elektrische verwarmer moet de
ventilator nog
minimaal 5 minuten draaien.
Verschmutzte Filter sind leicht
entflammbar.
During transport and storage the air handling unit must
200034907
only be supported under the designated lifting points.
Supporting and lifting under the cross beams is prohibited.
! Warning ! This is indicated on the cross beam with the following label.
After switching off the electric
heater the fan must continue to
run for at least 5 minutes.

! Attention ! ! Gefahr !
Après la déconnexion de la Nach Abschalten der
résistance électrique, le venti- Elektroheizung muss der Ventilator
lateur doit continuer à tourner noch mindestens 5 Minuten
pendant au moins 5 minutes. weiterlaufen.
200034908

CAUTION: All doors and access covers must be closed 2.3 - Roof edge protection during transport (outside
before starting up the AHU. installation)

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. During transport by truck the units are attached to the
loading surface with tie ropes, pulled across the unit
towards the side edges of the truck.

To protect the roof edge on outside units that are wider
than 1500 mm, protection plates are added in place of
the tie ropes to prevent distortion of the roof edge.
2.4 - Offloading and hoisting
Depending on the dimensions of the AHU and the
situation on site, the AHUs are supplied in previously
agreed 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 offloading as well as hoisting lifting cables can be
attached to the lifting bars. Evenly positioned spacer bars
should be used between the lifting cables to prevent
damage to the top of the unit and ensure that no excess
pressure is applied to the side panels. For hoisting please
ensure that the weight is evenly distributed.
The AHU must not be raised under the cross beams during
lifting or moving operations. This is indicated by the label
below.
HHFlex Air Handling Units | 7
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 specified
tension. Controlled rotation of the fan impeller can also
prevent this type of damage. This is also recommended
for direct-drive fans.
2.7 - Assembly
For the assembly of our units please refer to our
instruction manual “Mounting instructions”.
 8 | HHFlex Air Handling Units

Example configuration of HHFlex with heat recovery wheel

M1 M1 M1
M2

M1 M1 M1
M2

M1 M1 M1
M2

M1
M2

M1
M2

M1
M2

D1
X1

X1

D1
X1

X1
X1

D1
X1

X1

D2
X1

T1 T1

D2
X1

D2 T1 T1
X1

T1 T1
X1
X1
 HHFlex Air Handling Units | 9

Legend Legend Dimensions

A. Outdoor air intake damper 1. Actuator, outdoor air damper W = width unit n x 160+98
B. Supply air filter 2. Frequency converter, supply air fan H = height unit n x 160+98
C. Anti corrosion screen 3. Main switch supply air fan H1 = height base frame in mm
D. Pre-heater 4. Pressure sensor, supply air fan
E. Supply air fan 5. Actuator, supply air damper The grey areas in the table indicate
F. Heater (hot-water) 6. Actuator, extract air damper standardised units.
G. Cooling coil 7. Main switch extract air fan
H. Droplet eliminator 8. Frequency converter, extract air fan Custom sizes are possible.
I. Steam humidifier 9. Pressure sensor, extract air fan
J. Supply air damper 10. Actuator, exhaust air damper The service area for replacement of components such as
K. Extract air damper 11. Pressure switch, supply air filter coils and fans depends on the cabinet width and must
L. Extract air filter 12. Frost protection thermostat, heater be at least equal to the cabinet width.
M. Extract air fan 13. Pressure switch extract air filter
N. Heat recovery wheel
O. Exhaust air damper

18
16
14
12
10
H

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/ Internal and external panels Damage
outdoor installation Internal and external panels Damage
Joints Cracks
Doors/access covers Must be closed and locked before start-up
Flexible connections Correct installation
Earthing Correct earthing in accordance with regulations
Roof covering (outdoor installation) Check if roof is completely watertight
Dampers Correct operation
Blades fully closed and at zero position
Actuator Correct operation
Check rotation direction
Actuator end position same as damper end position
Filters Correct filter type
Are the filters correctly installed
Pressure differential gauge Correct operation
Pressure differential switch Correct operation/set-up
Droplet eliminator Bent fins
Siphon Correct connection
 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 fins
Direct steam Connections and attachments See documentation supplied
humidification
Test humidifier and pipes
Leakage
Actuator Check connection and operation
Electric steam Connections and attachments Check connection voltage
humidification
Check connection and operation
Water humidifiers Spray humidifiers See documentation supplied
Infrasonic humidifiers 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, Check for possible condensate and if necessary dry the parts
frequency converter
Impeller Check rotation direction
Motor Check connection voltage
Correct connection
Check current in all phases
Drive belt Check tension
Flexible connections Correct installation
Operating switch Check connection
Ensure switch is locked off during checks
Pressure switch/sensor Operation
Silencer (duct silencer) Damage of the top layer
Check for air-tight connection at the correct opening
Is the duct silencer sufficiently supported
Frequency converter Connections Correct connection/complies with EMC
Frequency converter Check for possible condensate and if necessary dry the converter
Voltage Check connection voltage
Settings Check correct settings
Phases Check voltage in all phases
Lighting Lamp Check connection voltage
Switch Check connection
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 specific project parameters
 HHFlex Air Handling Units | 11

Start-up instructions • It is recommended to use Europrofile connections

(type E30) at the corner frame as well as at the duct
to be connected.
4.1 - Casing
The unit data, such as order number, position number etc.
is given on the nameplate.

• Europrofile connections are available in fixed lengths

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.
and can be cut to the required length with a saw.
These profiles can easily be placed over the corner
frame. Allow for a maximum profile height of 30 mm,
so that ducts that are positioned one above the
other can be installed correctly.
• The four corners between the profiles can be completed
with a corner piece (type H30).

4.1.2 - Doors and access covers

Check the operation of door handles, locks and movement
of the hinges. Check if the door closure (on the inside of
the door) is tightly fitted, so that there are no excessive
air leaks at the doors. For outside installation of the AHU
check the storm cord. For the sections that are under
pressure it is recommended to order a door lock with an
pressure safety device. • The profile at the corner frame can be attached to
the profile on the duct using a drive slip (type SR).
CAUTION: Doors and access covers must always be closed
before starting the unit.

4.1.3 - Flexible connections

• Check that all flexible connections are firmly attached
to the AHU. If necessary, tighten loose screws.
• The stretched length of a single-skin flexible • Attaching self-adhesive tape between the two
connection is 130 mm, but a flexible connection profiles ensures an airtight seal, as shown in the
must NOT be installed stretched between the AHU drawing below.
and the duct. Once installed the operating length of
the flexible connection must be 100 mm.

4.1.4 - Earthing
Legend
Ensure that the AHU is earthed correctly and in accordance 1. AHU
2. Duct connection
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.
 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 flexible 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 flexible connection - ± 30 mm press fit)
• The combination of flexible 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 flexible connection - ± 30 mm press fit)
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 fitted with a suction grille in the
outside air duct.
• A pre-heater for the filters can be installed to prevent
mist causing the filters 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

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 floor 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 other with a pull-rope.
Check if all parts are water-tight and if necessary slide
spacers under the support where required (see also
chapter 2). Then attach the profiles supplied to the
joint. The roof of units installed outside must be sealed
so that no water can leak to the inside. Always attach a
unit installed outside to the floor of the support frame,
to ensure that the unit cannot move or fall (take 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 rarefied. To do
this correctly, the air volume, the horizontal and vertical
distance to the two openings and the position of the two
openings in relation to each other must be taken into
consideration (is the outdoor air intake lower or higher
than the exhaust air opening).
It may be necessary to position 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.
HHFlex Air Handling Units | 13
• Sufficiently insulate the cold water and condensate
lines up to the AHU.
• Sufficiently insulate air ducts with a possible air
temperature below the dew point of the air in the
plant room, as described earlier.
For units that are installed outside, the following points
must be considered:
• 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
fingers 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
fitted 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 filters
Filter types:
• Flat filter
• Bag filter
• Absolute filter
• Carbon filter
• Chemical filter
• Electrostatic filter
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 filter will fail if the pressure drop
across the filter is excessive.
• Check if the correct filters have been installed. (air
direction)
• Check if the filter bags have been installed correctly.
• Absolute filters are supplied separately in order to
prevent contamination during transportation and
commissioning. Filters may only be fitted after the
AHU has been completely cleaned.
• Set pressure switches or sensors, if used.
• Close the inspection door.
• If desired, a droplet eliminator can be fitted behind
the outdoor air suction filter. This droplet eliminator
catches droplets that fall off the filter. The droplets
contains substances that are extremely corrosive and
can cause corrosion damage to the filter function and
functions after the filter. A stainless steel drip tray is
mounted under the filter.
• Check that the fins 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 fins 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 comply with
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 only water 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
flanges 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 field-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
• The warning label for electrical voltage is attached to
4.4.1.1 - Coils containing glycol
the inspection hatch.
If coils are filled 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 flame. • The earth warning label is attached to the inside of
• When sizing the expansion tank take the higher heat the heater and the inspection hatch.
transfer coefficient 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. • The warning label for the procedure to switch off the
heater is found on the door or hatch of the fan
4.4.2 - Electric heater assembly.
• The electric heater must be connected as described
in the technical data and shown in the connection ! Waarschuwing ! ! Warning !
diagram supplied. It is important that the required Na het uitzetten van de After switching off the electric
elektrische verwarmer moet de heater the fan must continue to
machine capacities comply with the thickness of the ventilator nog run for at least
chosen connection cable and fuses of the power grid. minimaal 5 minuten draaien. 5 minutes.

The installer is responsible for the correct connection ! Attention ! ! Gefahr !

Après la déconnexion de la Nach Abschalten der
and machine operation. résistance électrique, le ventila- Elektroheizung muss der Ventilator
• Do not enter the AHU, if the electric heater is switched teur doit continuer à tourner noch mindestens 5 Minuten
pendant au moins 5 minutes weiterlaufen.
on.
200034908
• 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 infinitely
variable control, ensure that the minimum speed
over the heater is 2 m/s. If all steps have infinitely
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 first start-up of the
AHU as a result of weather change and/or humid air
from the building. Remove all condensate from the
construction components and dry the electrical 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).
 16 | HHFlex Air Handling Units

• Never exceed the maximum operating pressure.

4.4.3 - Steam heaters
• Check the connections on the dimensional drawing.
ATTENTION:
• Ensure that the coil has been fully purged.
• Steam heaters connected to the pipes must always
• Check connections for leakage.
be compression-tested by trained personnel and
comply with the PED guideline. Compression testing is CAUTION: When the coils are drained, no water must
the responsibility of the installer. Pipes must always remain in the circuits to prevent freezing at temperatures
be insulated and are the responsibility of the installer. below zero.
• The operation of the steam heater must be con-
nected to the operation of the fan. If the fan stops, • If a changeover coil is supplied by a heat pump, the
stop the supply to the steam heater immediately. installation must be designed to compensate for the
• Steam heaters have surface temperatures that required heat during the system heat pump defrost
exceed 100°C. The steam intake must be done by cycle and the heat must not be drawn from the
expert personnel in a controlled manner. supply air. Otherwise the supply air temperature
• The steam heater may only be switched on if a cannot be achieved. During the heat pump defrost
minimum specified air quantity is flowing over the cycle it must be possible to add enough heat into the
heater. system to guarantee the desired entering
• Check if there are any objects in the heating function. temperature (heater design capacity) as well as the
The temperature may be high enough for plastics to required heat for heat pump defrosting.
melt. • Ensure that the AHU is installed high enough to
• The steam heater must be switched off at least 5 enable the siphon trap to work correctly.
minutes before the AHU is switched off. • Ensure correct installation of the siphon trap (option).
• The following warning pictogram is applied to the Use PTFE tape to make sure that the connection at
panel of the AHU: Hot surface 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.
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 comply with • Check if siphon cover and ball have been correctly
the PED guideline. Compression testing is the responsi- installed.
bility of the installer. Always de-aerate the system. If • The gauge pressure siphon supplied by Systemair B.V.
the cabinet is temporarily not in use, the remaining is suitable for a gauge pressure of up to 1200 Pa in
water must be removed to prevent freezing. the associated section.
• 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 only water 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
flanges are removed from the pipes.

• 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 field-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)
HHFlex Air Handling Units | 17
• Check if the droplet eliminator after the cooler has
been correctly installed.
• Check if fins have been bent during transport.
• Correctly straighten the fins.
• The fins will only work correctly after several days in
dehumidification 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 qualified person should charge the coil and the rest
of the system with a sufficient amount of the
refrigerant as specified in the technical specifications.
• When connecting the DX-coil to the compressor/
condensing unit always follow the supplier specifica-
tions and the instructions of the qualified personnel.
• It is not recommended to connect several DX-coils to
one compressor/condensing unit.
• It is best to use an infinitely variable controller for the
compressor/condensing unit. If the condensing unit
has infinitely variable control, one of the temperature
controls in the controller can be selected.
• If the condensing unit does not have infinitely variable
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 fitting 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 recovery wheel 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-fitted and
must be connected.
If it is necessary to protect the heat recovery wheel
against frost damage, it must be fitted 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-flow 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-flow 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 fitted
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 humidification
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 sufficiently
trained personnel and comply with the PED guideline.
Compression testing is the responsibility of the installer.
Always de-aerate the system. Pipes must always be
insulated and are the responsibility of the installer.
• Consult the documentation supplied in the case of
faults in the system.
• The operation of the steam generator must be linked
to the operation of the fan. If the fan is de-activated,
supply to the steam generator must be stopped.
• For all types of humidifiers a maximum hygrostat
must be installed to allow intervention in case of
excessive humidification.
4.8.2 - Direct steam humidification
• Check the fastening of the steam container.
• Check the steam supply and the condensate exhaust.
• For longer pipes fit 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 humidifier, the steam must
be introduced into the system and the humidifier
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.

• 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 fitted in order to prevent
excessive humidification 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 humidifier
4.9.1 - General - see 4.8.1
• The electric humidifier 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 humidifier
• 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 humidifier in accordance with the
supplier’s instructions.
• The following warning sticker is applied to the panel:
Hot surface.
• A maximum hygrostat must be fitted in order to
prevent excessive humidification in the AHU. See
4.8.1.
HHFlex Air Handling Units | 19
4.10 - Water humidifiers
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 humidifier can only be
started when the fan is in operation. It will not
function or function insufficiently without an air flow,
thereby causing other parts of the cabinet to become
wet. Start the humidification pump and check the
direction of rotation in accordance with the arrow
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, fitted with two hard metal rings.
• In case of danger of freezing, always check that the
heater functions correctly.
• The operation of the water humidifier must be linked to
the operation of the fan. If the fan stops, the supply to
the water humidifier must also be stopped immediately.
• A maximum hygrostat must be fitted to prevent
excessive humidification in the AHU. See 4.8.1.
4.10.2 - Spray humidifier
• 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 float seal in
the water reservoir is set to the correct height.
4.10.3 - Determining the quantity of spray water and
the condensation factor
• The constant evaporation of water increases the salt
concentration and thereby the concentration of other
constituents in the reservoir. When the air is humidified
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 float 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 spray water 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
spray water 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 humidifier
will occur and lead to high maintenance costs.
• A maximum hygrostat must be fitted to prevent
excessive humidification in the AHU. See 4.8.1.
4.10.4 - Infrasonic humidification
• 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 humidifier must be fitted with a safety feature to
prevent overheating and running dry.
• The air flow over the humidifier must not exceed 5.5
m/s. Optimum operation is at 4 m/s. The only
humidifica-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 flow gradually decreases for another
20 minutes after de-activation of the humidification
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 fitted to prevent
excessive humidification in the AHU. See 4.8.1.
• The following sticker is applied to the control box.
4.11 - Fan
Remove after
transport
CAUTION: The air flow 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, flexible connection or wiring.
• Check for possible condensate/moisture. Condensate
may form before the AHU first 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
 HHFlex Air Handling Units | 21
belt tension or to remove the fan belts temporarily.
The fan motor must have a power supply of 230 V, 3
When the fans are restarted, the belt tension has to
ph, 50 Hz or 400 V, 3 ph, 50 Hz. The connection must be
be reset to the specified value. This type of damage
made with short circuit protection (fuses) and a thermal
can also be prevented by controlled rotation of the
motor safety switch, matched to the nominal current
fan impeller. This is recommended for direct-drive
of the motor. The motor can also be protected against
fans.
overheating by three series-connected PTC thermistor
• Check if the flexible connection is correctly installed.
fuses, installed in the windings. If a frequency converter is
• If used, check the pressure switch and set the correct
used, the thermistors must be connected to the converter.
pressure.
• Check the operation of the main switch.

CAUTION: While working on the fan the switch has to be

locked open.

• The warning pictograms on rotating parts, electrical

voltage and opening doors are attached to the door.
Thermal motor fuse

Before connecting the power supply please check the

! 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.
diagrams on the next page to ensure that they agree with
the data on the motor name plate and the data in the
technical documentation.
The disconnect switch is located on or near the fan
section. When working on the unit, the switch must be
turned off and secured with a padlock. Switching off the
disconnect switch must be done when the unit is not
energised.

! Attention !
Avant ouverture des portes, le
ventilateur doit être déconnecté
et avoir eu le temps, de s’arrêter
completement
(2 minutes minimum)
! Gefahr ! Before opening the door or inspection hatch of the fan
Vor Öffnen der Türen den
Ventilator abschalten, span- section (failure, maintenance, service) the AHU must be
nungslos machen und zum
Stillstand kommen lassen de-energised.
(mindestens 2 Minuten warten).

Fixations de transport Transportsicherungen CAUTION: Motors with a power output of up to 2.2 kW

Retirer les fixations de transport
avant la mise en route.
Transportsicherungen vor der
Inbetriebnahme demontieren.
200034906
(230 V/400 V) can have across-the-line starting. Motors
with a power output of 3 kW (400 V/690 V) should be
started with the star/delta switch.

If the unit has stopped due to an unexpected power

supply failure, sudden re-starting of the unit must be
avoided. The control system must include an appropriate
protection device.

General data, fan motor

Insulation class motor : F
PTC trip temperature : 155°C
Connection voltage : 3 x 230 V/50 Hz
3 x 400 V/50 Hz
3 x 690 V/50 Hz
 22 | HHFlex Air Handling Units

Connection diagrams: connection of the power supply

cable and of the terminals on the terminal strip.

Motor with the name plate data: 230 V/400 V - Y/Δ

Direct mains connection with a voltage between two phases of: Indirect mains connection Y/Δ with a
230 V 400 V voltage between two phases of: 230 V
L1 L1
Winding connection diagram L1 L1
U1
W2 U1 U1
W2 U1

U2
U2
W2
W2
W1 U2
W1 U2 W1 V2 V1
W1 V2 V1
L3 L2 L2 L2
L3 L2 L2 L2
V2 V1
V2 V1
DELTA STAR
Connection method of the con-
ductors to the motor terminals W2 U2 V2 W2 U2 V2 W2 U2 V2
W2 U2 V2 W2 U2 V2 W2 U2 V2

U1 V1 W1 U1 V1 W1 U1 V1 W1
U1 V1 W1 U1 V1 W1 U1 V1 W1

Y/Δ switch
L1 L2 L3 L1 L2 L3
L1 L2 L3 L1 L2 L3

L1 L2 L3
L1 L2 L3

Motor with the name plate data: 400 V/690 V - Y/Δ

Direct mains connection with a voltage between two phases of: Indirect mains connection Y/Δ with a
400 V L1 690 V L1 voltage between two phases of: 690 V
L1
L1 W2 L1
L1 U1
Winding connection diagram U1
U1
U1
W2
W2 U1
U1
U2
W2
U2
U2
W1 U2 W2
W2
W1 V2 V1
W1
W1 U2
U2
L3 L2 W1
W1 L2 V2
V2 V1
V1 L2
L3
L3 V2 L2V1
L2 L2
L2 L2
L2
V2
V2 DELTA V1
V1 STAR
Connection method of the con-
ductors to the motor terminals W2 U2 V2 W2 U2 V2 W2 U2 V2
W2
W2 U2
U2 V2
V2 W2
W2 U2
U2 V2
V2 W2
W2 U2
U2 V2
V2

U1 V1 W1 U1 V1 W1 U1 V1 W1
U1
U1 V1
V1 W1
W1 U1
U1 V1
V1 W1
W1 U1
U1 V1
V1 W1
W1

Y/Δ switch
L1 L2 L3 L1 L2 L3
L1
L1 L2
L2 L3
L3 L1
L1 L2
L2 L3
L3

L1 L2 L3
L1
L1 L2
L2 L3
L3

4.11.1 - Plug fans Where

Plug fans are fans without a scroll that are directly driven V = actual air flow rate in m3/h
by the motor. To get the correct operating point for k = specific fan coefficient
this type of fan a frequency converter is required. The ∆pst = pressure differential cone/air intake section in Pa
maximum frequency at which the plug fan can rotate
depends on the motor/impeller assembly and should The k-value depends on the fan used. This value can be
normally be higher than 50 Hz. The maximum frequency requested.
is given on the fan name plate.

Plug fans are equipped with a pressure measurement

point in the intake cone of the fan. By measuring the
pressure drop between the pressure for the fan and the
pressure in the intake cone the actual air flow can be
calculated using the following formula: V = k ·√∆pst

4.11.2 - Frequency converters
It is recommended to install a frequency converter with an
integrated operating switch. If a separate operating switch
is installed on the unit and near the frequency converter,
this can be located in the supply voltage for the frequency
converter. If the frequency converter is not installed near
the unit/operating switch, the operating switch can be
placed in the control power circuit, that switches the
supply voltage to the frequency converter via a relay.
To connect the frequency converter, please refer to the
wiring diagram for the converter installed. Ensure that
the EMC directives are observed and pay attention to the
shielded cables.
The frequency converter must always be correctly set to
suit the motor and type installed. Observe the instructions
of the supplier of the frequency converter. Special
attention should be given to the following parameters:
• Correct application of the general motor data
- Pay special attention to the motor frequency.
- For subsynchronous operation (lower than the
network frequency) it must be set in accordance
with the motor nameplate.
- For supersynchronous operation (higher than the
network frequency) it must be set for the maxi-
mum admissible frequency of the motor/impeller
assembly (this applies above all to plug fans.)
• Operating type, square variable connection
• It is recommended to cut out so-called overmodu-
lation
• Setting of the normal start-up/shut-down times.
• Check for possible condensate/moisture. Condensate
may form in the period before the first start-up of
the AHU as a result of weather change and/or humid
air from the building. Remove all condensate from
the construction components and dry the electrical
components using warm (dry) air (e.g. with a drier).
HHFlex Air Handling Units | 23
4.11.3 - Plug fans with integrated EC motors
For EC motors both electronic commutation and speed
control are integrated in the motor as standard. The motor
protection class is IP54 and the thermal class is THCL155.
The motors can be single-phase 230 V or three.phase 400 V.
To achieve the correct motor speed a 0-10 V control
signal should be supplied to the motor. The technical
specification of the unit shows the exact value (in V) to
reach the correct motor speed.
As an option the motor can be factory set so that 10 V is
the motor speed at the actual point of operation.
A second option is to use a motor with an integrated
Modbus module. In this case the motor can be externally
set or controlled via an RS485 or wifi connection (the EC
090 motor has an RS485 Modbus module as standard).
The wiring diagrams for EC motors can be found on the
next page.
AHU with control
The optional Modbus module is not possible for units with
controls. The control signal for the motor is managed by
the control, and the motor is factory set.
4.12 - Silencers
Check the splitters for damage.
4.13 - Lighting
• Check the connection voltage.
• Check the operation of the switch. The switch must
be connected in accordance with local regulations.
 24 | HHFlex Air Handling Units

To connect a single-phase 230 V or the three-phase 400 V motor the following connection diagram is applicable.

ECblue Basic (_ _ _ _ _-_I_.D_._ _ _ _), (_ _ _ _ _-_I_.G_._ _ _ _)

Contact rating
Kontaktbelastung
2 Contact rating
(Imax = 70 mA)

(Imax = 10 mA)
max AC 250 V2A

Analog In 1
Digital In 1
max. AC 250 V 2 A
DC Out

DC Out
L1 N

24V 10V GND D1 E1 11 14 L1 L2 L3

K1

PE PE L1 L2 L3/N
Line voltage g ratingLeistungsschild
Netzspannung plate
Externe Drehzahlvorgabe 10 kΩ
External speed Line voltage Rating-plate
External speed setting
setting3 3 ~ Typ nur in Sonderausführung
für IT-System geeignet
+ 3 ~ type only in special version
suitable for IT-System
InputEingang
0-10 V
4 Input 1
0...10 V

Except for an EC 090 motor the following diagram is applicable.

E1
10 V

GND

ECblue10(_kΩ_ _ _ _-_I_.B_._ _ _ _) (_ _ _ _ _-_I_.D_._ _ _ _)

Open-Collector Out

Contact rating
max AC 250 V 2 A
max. AC 250 V 2 A
MODBUS
Analog In

PWM
(RS-485)
Digital In

E1
24 V
DC Out

f = 1...10 kHz
5 K1 MOEA03K0
08.03.2011
A B
10V GND E1 D1 A1 (D+) (D-) 11 14 PE N L1
E1
GND

- +

15...28 V 9
GNYE
WH

WH

WH
GN
RD

BU

BN

BU

BN
YE

BK

7 6 5

10 kΩ

+ 4 3 2
Signal
0...10 V

Netzspannung Leistungsschild
Line voltage g rating plate
E1
10 V

GND

Line voltage Rating-plate

GND - EI 10 kΩ
0-10 V control signal 1
11 - 14 Alarm relay (or no motor power)
DI Motor release 24 V DC (except EC 090: 10 V DC)

Signal PWM
E1
10 V

f = 1...10 kHz
8
 HHFlex Air Handling Units | 25

Maintenance Checklist
5.1 - Checklist of check points and maintenance
intervals
The unit data, such as order number, position number etc. description of the individual components.
is given on the nameplate.
WARNING: Remember to de-energise all components and
The checklist contains a general overview of a planning to ensure that the fan has stopped rotating, before the
that facilitates the inspections and maintenance of the doors and access covers are opened before inspections
AHU. On the following pages there is a more detailed and maintenance take place.

Check points and maintenance intervals

Depends on

3 months

6 months
1 month
supplier and

months
degree of

12
Function Components Check points contamination
Casing general
Internal and external panels
Indoor installation/ Contamination/corrosion and
Internal panels
outdoor installation damage
External panels
Joints
Roof covering (outdoor Seams and cracks (watertight)
installation)
Doors/access covers Hinges Correct operation
Locks Door closure (check bolt
tightening)
Door seal Cracks
Flexible connections Cracks
Dampers Damper blades Sealing
Bearings
Damper drive Actuator
Outdoor air intake Air intake cover/grille Check for obstruction/air velocity
Floor, condensate pan (if used) Contamination/corrosion
Droplet eliminator (if used) Contamination/corrosion
Filters Flat filter
Check pressure drop across filter,
Bag filter
check for damage and check
Carbon filter
sealing
Electrostatic filter
Pressure differential gauge Operation
Pressure differential switch Operation
Drip tray Dirt/corrosion
Droplet eliminator (if used) Dirt
Siphon Dirt and operation
Heaters Hot-water coil Contamination/corrosion
Air vent the coil
Leakage
Glycol Check glycol concentration
Frost protection thermostat Operation
Electric heater Contamination of heating coils
Loose wiring
Thermostat operation
Steam heater Contamination/corrosion
Leakage
Coolers Chilled-water coil Contamination/corrosion
Air vent the coil
Leakage
Condensate pan Contamination/corrosion
Droplet eliminator (if used) Contamination
Drain trap Contamination and operation
Glycol Check glycol concentration
Heat recovery wheel Rotor Contamination
Seal Cracks/position
Motor Operation
Belt Tension/wear
Electrical components Operation
Fins Contamination
Damper (if used) Sealing
Bearings
Actuator
Condensate pan Contamination/corrosion
Water trap Contamination and operation
Steam humdification direct Connection and appendages Leakage/operation
Actuator Operation
 26 | HHFlex Air Handling Units

Steam humidification electric Connection and appendages Leakage/operation

Electric components Operation
Boiler Scaling on the electrodes
Spray humidification Sprayers Operation
Infrasonic humidifier Hoses Connections/tears
Sprayers Operation
Pressostat Operation/max. pressure
Coil filter Contamination
Operating pressure
Fan Bearings (larger types) Lubrication/wear
Impeller Contamination/corrosion
Motor (larger types) Lubrication
Belt Wear/tension
Vibration dampers Fixings
Flexible connections Cracks
Pressure switch/sensor Operation
Silencer Dirt deposit
Damage to top layer
Controller Alarms Check alarm history
Sensors General Check operation of all sensors
Pressure sensors Zero calibration

Maintenance and operating

Instructions

6.1 - General 6.2.2 - Outside installation

• The smooth inside and outside finish of the panels
makes maintenance very simple.
• For dry sections: twice a year thoroughly check the
inside and outside of the AHU casing. For maintenance
of wet sections (coolers) please refer to the air
handling section concerned.
• All work must be carried out by sufficiently 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 filters.
• No holes must be drilled into the AHU, to prevent
leakage from the AHU, cooling coils and heating coils
and damage to the wiring.
Check the sealed joints of AHUs installed outside and if
required seal with a UV-resistant and paintable kit. Repair
damage as described for inside installation. Check the roof
for leaks and if necessary, repair these.
6.3 - Doors and access covers
Check locks and hinges of all doors and access covers.
Check that the bolt of the internal roller is still correctly
tightened.
6.4 - Flexible connections
Check the flexible connections for damage.
6.5 - Earthing
Ensure that the unit is earthed and installed in the correct
manner.

6.2 - Casing panels 6.6 - Dampers

6.2.1 - Inside installation
a) Internal inspection of the casing of double-skin
panels and of all dry parts.
Remove contamination with water and a mild (pH
neutral) household soap solution. Where damage of
the paint finish has occurred, if necessary remove
rust and touch up with good quality anti-corrosive
primer and paint. The outdoor air intake sections can
show signs of corrosion as they contain wet parts
and are affected by mist, rain and air pollutants.
b) Outside inspection of the coating.
If damage to the paint treatment has occurred,
remove the rust (if necessary), and touch up with
good quality anti corrosive primer and paint.
ATTENTION
• When working on damper registers it is possible for
fingers to become trapped.
• During cleaning of the damper fins the AHU must be
de-energised to prevent unexpected closing of the
dampers.
• During repairs to the actuator, the AHU must be
de-energised to ensure the connection cables are
not live.
• Lubrication of the dampers is not required. Remove
excess contamination by cleaning with compressed
air and possible cleaning with water and a mild
household soap solution. Ensure that the damper
blades run free in the casing.
 HHFlex Air Handling Units | 27

6.7 - Outdoor air intake 6.9 - Heaters

The outdoor air intake is contaminated by pollution taken
in with the air. Observe the maintenance interval to avoid
irreparable damage of the panels. Clean the outdoor air
intake well and repair damage as described in point 6.2.1.
Ensure that no moisture (droplets) is taken in. If there is
still moisture, ensure that this is corrected by changing the
outdoor air intake duct.
6.8 - Filters
ATTENTION
• When changing the filter there is danger of viral and
bacteriological contamination. Always use of suitable
gloves, face masks and safety glasses. The face mask
must be minimum P2. The gloves must be liquid-tight.
• The filters must be fitted in the correct manner (air
direction).
• The base under the filter may be highly contaminated.
Remove this dirt during every inspection. Any corrosion
of the base must be removed immediately and
repaired with an anti-corrosion agent and/or coating.
• Filters that are too dirty also increase the resistance
(pressure differential) of the filter and can increase
power consumption. The fastening frame of the filter
may fail if the pressure differential over the filter is
excessive.
• The filters must be inspected once a month for
excess pollution, pressure loss, damage and seating
of the slide-in filters or built-in frames. With slide-in
filters ensure that the filters have been correctly
positioned and have been pushed well against each
other from below. When replacing built-in filters you
must ensure that the filter has been pushed well
against the sealant. Filters must be replaced at the
required intervals. The timing of the replacement
depends on the filter quality and the degree of air
contamination. The pressure loss across the
contaminated filter can be measured with a pressure
differential gauge.
• Filters that are fitted with droplet eliminators,
stainless steel drip tray and stainless steel inner
plates must be cleaned completely. All dirt must be
removed from the walls, drip tray and fins. Flush the
drip tray and siphon with clean water.
• A respiratory protection mask, type P2 and safety
gloves must be worn when changing the filters.
Open flames are forbidden while changing the filters
to prevent setting fire to the filter medium. This is
indicated by a sticker on the door or hatch.
6.9.1 - Hot-water coil
ATTENTION: For general comments, see 4.4.1
• Dirt on the finned surface reduces the capacity of the
heater.
• Check the air intake once a year for contamination,
and if necessary clean with compressed air against
the direction of the air flow or clean the air intake
with a vacuum cleaner.
• Checking the heaters: Check the operation of the
frost protection thermostat and check the correct
control sequence when the thermostat trips.
• For coils filled with glycol please check if the mixture
has the correct glycol concentration (by weight).
• While working on the heaters, gloves must be worn
that offer protection against temperatures of 70°C.
The piping outside the air handling unit must be
insulated. The water temperature in the pipes can be
120°C maximum.
The following sticker is shown to warn that there is a hot
surface.
6.9.2 - Electric heater
• Once a year, check the air inlet and air outlet of the
coil for contamination. If they are polluted, clean
them with a vacuum cleaner.
• Safety gloves and safety glasses must be worn while
working on the heater. The coil surface temperature
can reach 600°C. If access to the heater is possible, a
safety screen must protect the operator against
direct contact.
ATTENTION: If you switch on the electric heater the fan
must always be activated in order to prevent overheating
of the inside of the cabinet. The fan must continue to
operate for a minimum of 5 minutes after switching off
the electric heater. This is necessary to allow the coils to
cool down.

! Waarschuwing !
Vervuilde filters zijn brandbaar.
! Attention !
Les filtres encrassés peuvent être
inflammables
! Warning !
Polluted filters are inflammable.
! Gefahr !
Verschmutzte Filter sind
leicht entflammbar.
200034907
 28 | HHFlex Air Handling Units

• The following label is attached to indicate a hot surface.

6.11 - Heat recovery wheel
• Contamination on the finned surface reduces the
capacity of the heat recovery wheel.
• Check the rotor once a year for contamination, and if
necessary clean with compressed air. Check the rotor
speed and compare it with the design data.
• Check the operation of the rotation monitor. Depending
on the rotor material the wheel can absorb moisture.
• The warning label for electrical voltage is attached to When stationary the wheel will become moist on
the inspection hatch. one side and therefore heavier. The rotor speed can
be set to intermittent in the controller so that the
wheel will rotate “x” times per time unit.
• The rotor bearings are lubricated for life and do not
require maintenance. The drive motor is accessible
via an inspection cover.
• The V-belt is automatically tensioned by a spring
loaded rocking base on which the motor is installed.
• The earth warning label is attached to the inside of New belts expand a lot in the beginning. Check after
the heater and the inspection hatch. two days if the belt still has enough tension. After
this check the belt tension weekly during the first
month and then check it once a month.
• For further operation and maintenance details on the
heat recovery wheel/controller refer to the
documentation provided by the supplier.

The following warning pictogram is located on the panel:

• The warning label for the procedure to switch off the Rotating parts
heater is located on the door/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 ! ! Gefahr !
Après la déconnexion de la Nach Abschalten der
résistance électrique, le ventilateur Elektroheizung muss der Ventilator
doit continuer à tourner pendant noch mindestens 5 Minuten 6.12 - Plate heat exchanger
au moins 5 minutes weiterlaufen.
CAUTION:
200034908
• The cleaning agent may not affect the heat exchanger.
• Check the plate heat exchanger once a year for
6.10 - Coolers contamination and if necessary clean with compressed
6.10.1 - Chilled-water coil air against the direction of the air flow. If dampers
ATTENTION: For general comments, see 4.5.1 are used, follow the instructions in section 6.6.
• Check the condensate pan for contamination and
• Contamination of the finned surface reduces the clean if necessary.
cooler capacity. • Check the droplet eliminator fins in the condensate
• Check once a year for contamination and if necessary pan (if installed).
clean with compressed air against the air flow direction
or clean with a vacuum cleaner. Check coil and connec- 6.13 - Recirculation damper
tions for leaks. For coils filled with glycol check if the For maintenance of this damper refer to chapter 6.6.
mixture has the correct glycol concentration (by weight).
• DX coolers must never be cleaned with steam. 6.14 - Water humidifiers
• Check the fins of the droplet eliminator after the coil. 6.14.1 - General, see 4.10.1 Thickening factor,
Clean the siphon and check it for correct operation. see 4.10.3
Check the condensate pan for contamination and
clean if necessary.

6.14.2 - Spray humidifier
• Check the correct functioning of the float seal for the
replenishment water every week. Scaling and sludge
formation can have a detrimental effect on the opera-
tion of the float tap. The water level in the water
container must always be kept at the correct level
without water overflowing into the funnel-shaped
overflow. When the circulation pump is stopped, the
level is 5 mm under the overflow. Check the spray
water amount every week during the humidification
season. The salt concentration (thickening) in the
reservoir depends directly on the effective operation
of the spray tap. Regularly check the quality of the
water in the reservoir. During the humidification
season this check must be made monthly.
• Inspect the flexible connection between the pump
and cabinet wall for leaks every week.
• The interior of the reservoir of the humidification
section must be cleaned twice per year.
• The water reservoir must be drained, cleaned with a
water jet and soft brush and then flushed with water.
• Do not use sharp or hard objects during cleaning in
order to prevent damage to the protective layer and/
or thermal insulation. Carefully inspect the surface in
the entire section and repair any damage.
• After cleaning, refill the reservoir with water. Check
that the float seal fills the container up to the mark
and then start the pump.
• If any of the sprayers are blocked unscrew the spray
head and clean it.
• Outside the humidification season and during long
shut-down periods we recommend that the pump is
operated for several minutes every week to prevent
scaling on the bearings and the axle seal of the pump.
• During long shut-down periods replace the water in
good time to prevent health risks and unpleasant
odours.
• N.B. We recommend carrying out a monthly check of
the water conductivity in the reservoir of every
humidifier in the building. This may prompt a change
of the thickening factor. See 4.10.3.
6.14.3 - Infrasonic humidification
The following points deserve extra attention.
• Check the correct operation of the drain.
• Check the connection of the high pressure hose for
tears and leaks.
• Check that the sprayers produce mist effectively.
• Check the operation of the pressostats and the
pressure.
• Check the water quality. See 4.10.3.
• If the humidifier is not in operation for a long period
of time and must be started again, the following
steps must be carried out. Check the set-up of the
humidifier.
HHFlex Air Handling Units | 29
• Switching the humidifier on and off, can produce
scaling in the spray pipes which may affect their
operation. It is therefore necessary to regularly check
and clean these spray pipes.
6.15 - Fan
6.15.1 - General
CAUTION: The air flow may cause stationary parts to move
(even if the fan is switched off)!
CAUTION: While working on the fan, the switch must be
locked open.
Before switching off the fan always check if an electric
heater is installed. If this is the case, the electric heater
must always be switched off first. The fan must continue
to run for at least five minutes to cool down the heater
coils. The data for belt type, belt tension, number of belts,
size and type of pulley is indicated on the fan housing.
6.15.2 - Bearings
The bearings of the smaller fan types cannot be lubricated.
If larger fans are of the re-lubricated type, they should be
lubricated every six months. For higher temperatures and
increased contamination adjust the lubrication interval as
required. The standard lubricant is Shell Alvania R3. For
higher temperatures and a higher degree of humidity use a
lubricant recommended by the supplier. The electric motors
are equipped with roller bearings. Depending on motor size,
the bearings are lubricated for life or have a grease nipple.
The lubrication interval and type of lubricant are as above.
Check the motor and fan bearings for excessive vibration.
This can be a sign of bearing wear, but also of incorrect
operation of the transmission or an unbalanced system.
The following points require extra attention:
• Check for vibration.
• Check the rotation direction.
• Avoid unnecessary stops and rapid start-ups of the
fan.
6.15.3 - Transmission
After starting up the unit and after replacing the belts, the
belt tension must be checked within one week and then
after two weeks and further tensioned if required. After
that check the belt tension and inspect the condition of
the belts every three months.
The CORRECT BELT TENSION depends on:
• the belt type
• number of belts
• smallest pulley diameter
• power to be transmitted
• belt velocity.
 30 | HHFlex Air Handling Units

The belt tension is calculated for each transmission. If the WARNING: Remember to de-energise all components and
belt tension is too high it can result in bearing wear and to ensure that the fan has stopped rotating, before the
vibration. If it is too low it can result in belt slippage and doors and access covers are opened before inspections
pulley and belt wear. and maintenance take place.

Sequence for installation of new belts: 6.16 - Silencers

• Ensure that the pulleys are correctly aligned. If It is recommended to check the splitters of the silencers
necessary re-align. periodically for possible damage and loosening of the
• Position all belts loosely on the pulleys, do not pull fibres, to prevent dirt deposits in the system.
tensioned belts over the pulleys.
• Tension the belts and check the tension with a Sonic
Tension Meter.
• Re-check the alignment.

If the fan speed changes or if a motor with different

power specifications and/or speed is installed, this must
be discussed in advance with the manufacturer. The
supplier must re-calculate the bearing load as well as the
impeller load. If this is not done the fan may be irreparably
damaged. The supplier does not accept any responsibility
for modifications that have not been approved. See
chapter 1.1.

After changing the motor, transmission or frequency

converter settings:
• Check the fan rotation direction.
• Check the power input.

CAUTION: While working on the fan the switch has to be

locked open.

The warning pictograms indicating rotating parts, electrical

voltage and opening of doors are attached to the door.

! Waarschuwing !
Voor openen deuren, ventilator
uitschakelen, spanningsloos
maken en uit laten lopen
(minimaal 2 minuten).
! Warning !
Before opening the doors, switch
off and deenergise the fan and
allow it to run down
(minimum 2 minutes)

Transportbeugels Transport brackets

Verwijder transportbeugels voor Remove transport brackets before
opstarten ventilator. 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)
! Gefahr !
Vor Öffnen der Türen den
Ventilator abschalten, span-
nungslos machen und zum
Stillstand kommen lassen
(mindestens 2 Minuten warten).

Fixations de transport Transportsicherungen

Retirer les fixations de transport Transportsicherungen vor der
avant la mise en route. Inbetriebnahme demontieren.
200034906
 Holland Heating_IOM HHFlex_EN_ June 2017_Version 04

Systemair B.V.
Zanddonkweg 7A
5144 NX, Waalwijk
P.O. Box 159, 5140 AD Waalwijk

Tel. +31 (0) 416 685555

Fax +31 (0) 416 341795

www.systemair.nl

Systemair B.V. participates in the Eurovent Certification programme. Products are as listed in the Eurovent Directory of Certified Products.

The manufacturer reserves the right to change the specification without prior notice. Manufactured by: Systemair B.V., Waalwijk, The Netherlands.
The front cover photos are for illustration purposes only and not contractually binding. Printed in the European Union.
Installation and maintenance manual
Manuel d’installation et de maintenance ATTACHMENT 2
Installations- und Wartungshandbuch
Manuale di installazione e di manutenzione
Manual de instalación y de mantenimiento

SyScrew Air CO/TR

English Français Deutsch Italiano Español

366 Air Cooled Water Chillers with Screw Compressors


1320 kW
Refroidisseurs de liquide à condensation par air avec compresseurs à vis
Luftgekühlte Wasserkühler mit Schraubenkompressoren
Refrigeratori d’Acqua Raffreddati ad Aria con compressori a vite
Enfriadores de Agua Condensadas con Aire con compresores a tornillo

Part number / Code / Code / Codice / Código: 363112/C

Supersedes / Annule et remplace / Annulliert und ersezt / Annulla e sostituisce /
Anula y sustituye:363112/B
Notified Body /Organisme Notifié / Benannte Zertifizierungsstelle /
Organismo Notificato / Organismo Notificado N°. 1115 ”

ISO 9001:2008 certified management system

 Table of Contents
1 - FOREWORD
1.1 Introduction...........................................................................2
1.2 Warranty...............................................................................2
1.3 Emergency stop/Normal stop................................................2
1.4 An introduction to this manual...............................................2
2 - SAFETY
2.1 Foreword...............................................................................3
2.2 Definitions.............................................................................4
2.3 Access to the unit ................................................................4
2.4 General precautions..............................................................4
2.5 Precautions against residual risks..........................................4
2.6 Precautions during maintenance operations...........................5
2.7 Safety labels.................................................................. 6 & 7
2.8 Safety regulations......................................................... 8 to 10
3 - TRANSPORT, LIFTING AND POSITIONING
3.1 Inspection...........................................................................11
3.2 Lifting.................................................................................11
3.3 Anchoring...........................................................................12
3.4 Storage...............................................................................12
4 - INSTALLATION
4.1 Positioning of the unit..........................................................13
4.2 Spring isolator installation....................................................13
4.3 External hydraulic circuit............................................. 14 & 15
4.4 Hydraulic connections ........................................................15
4.5 Power supply......................................................................16
4.6 Electrical connections.........................................................17
4.7 Connection of water temperature sensors
(on shell and tube evaporator) ............................................18
5 - START-UP
5.1 Preliminary check................................................................19
5.2 Start-up..............................................................................19
5.3 Checking the operation........................................................19
5.4 Delivery to the customer......................................................19
6 - CONTROL
6.1 Display................................................................................21
6.2 Setpoint..............................................................................23
6.3 Protection and Safety Equipment.........................................24
6.4 HPF version configuration....................................................25
1
English
7 - PRODUCT DESCRIPTION
7.1 Introduction.........................................................................26
7.2 General specifications.........................................................26
7.3 Compressors......................................................................26
7.4 Refrigeration circuits...........................................................26
7.5 Water heat exchanger..........................................................27
7.6 Air heat exchanger...............................................................27
7.7 Fans....................................................................................27
7.8 Electrical power supply and control system.........................27
7.9 Accessories........................................................................27
8 - TECHNICAL DATA
8.1 Pressure drops....................................................................30
8.2 Technical data............................................................ 31 to 42
8.3 Unit electrical data...................................................... 43 to 45
8.4 Hydraulic Features...................................................... 46 to 49
8.5 Position of shock adsorbers
and weight distribution on supports.....................................50
8.6 Dimensional Drawings................................................ 51 to 57
8.7 Service spaces....................................................................58
9 - MAINTENANCE
9.1 General requirements..........................................................59
9.2 Planned maintenance..........................................................59
9.3 Refrigerant charge...............................................................60
9.4 Compressor........................................................................60
9.5 Condenser..........................................................................60
9.6 Fans....................................................................................60
9.7 Dehydrating filter.................................................................60
9.8 Sight glass..........................................................................61
9.9 Electronic expansion valve...................................................61
9.10 Evaporator..........................................................................61
10 - TROUBLESHOOTING........................................... 62
11 - SPARE PARTS
11.1 Spare part list.....................................................................63
11.2 Oil for compressors.............................................................63
11.3 Wiring diagrams..................................................................63
12 - DISMANTLING, DEMOLITION AND SCRAPPING
12.1 Generalities.........................................................................64
 11--Introdução
Foreword

1.1 Introduction 1.3 Emergency stop / Normal stop

Units, manufactured to state-of-the-art design and implementation
standards, ensure top performance, reliability and fitness to any type
of air-conditioning systems.
These units are designed for cooling water or glycoled water (and for
water heating in heat pump models) and are unfit for any purposes
other than those specified in this manual.
This manual includes all the information required for a proper
installation of the units, as well as the relevant operating and
maintenance instructions.
It is therefore recommended to read this manual carefully before
installation or any operation on the machine. The chiller installation
and maintenance must be carried out by skilled personnel only
(where possible, by one of Authorised Service Centers).
The emergency stop of the unit can be enabled using the master
switch on the control panel (move down the lever).
For a normal stop, press the relevant push-buttons.
To restart the appliance, follow the procedure detailed in this manual.
1.4 An introduction to the manual
For safety reasons, it is imperative to follow the instructions given in
this manual. In case of any damage caused by non-compliance with
these instructions, the warranty will immediately become null and
void.
Conventions used throughout the manual:

The manufacturer may not be held liable for any damage to people or The Danger sign recalls your attention to a
property caused by improper installation, start-up and/or improper certain procedure or practice which, if not
use of the unit and/or failure to implement the procedures and followed, may result in serious damage to
instructions included in this manual. DANGER people and property.

1.2 Warranty
These units are delivered complete, tested and ready for being The Warning sign precedes those procedures
operated. Any form of warranty will become null and void in the event that, if not followed, may result in serious
that the appliance is modified without manufacturer’s preliminary WARNING
damage to the appliance.
written authorisation.

This warranty shall apply providing that the installation instructions

have been complied with (either issued by manufacturer, or deriving
from the current practice), and the Form 1 (“Start-up”) has been
The Notes contain important observations.
filled-in and mailed to manufacturer (attn. After-Sales Service).
NOTE

In order for this warranty to be valid, the following conditions shall be

met:

n The machine must be operated only by skilled personnel from

Authorised After-Sales Service. The Useful Tips provide valuable information
that optimises the efficiency of the appliance.
n Maintenance must be performed only by skilled personnel - from USEFUL TIPS

one of Authorised After-Sales Centers.

n Use only original spare parts. This manual and its contents, as well as the documentation which
n Carry out all the planned maintenance provided for by this manual accompanies the unit, are and remain the property of manufacturer,
in a timely and proper way. which reserves any and all rights thereon. This manual may not
be copied, in whole or in part, without manufacturer’s written
Failure to comply with any of these conditions will automatically void authorization.
the warranty.

2
 2 - Safety

2.1 Foreword
These units must be installed in conformity with the
provisions of Machinery Directive 2006/42/EC, Pressure
Equipment Directive 2014/68/EU, Electromagnetic
Compability Directive 2014/30/EU, as well as with other
regulations applicable in the country of installation. If these
provisions are not complied with, the unit must not be
operated.
The unit must be grounded, and no
installation and/or maintenance operations
may be carried out before deenergising the
DANGER electrical panel of the unit.
Failure to respect the safety measures mentioned above may result
in electrocution hazard and fire in the presence of any short-circuits.
English
The guards of the fans (only for units provided
with air heat exchangers) must be always
mounted and must never be removed before
DANGER de-energising the appliance.
It is the User’s responsibility to ensure that
the unit is fit for the conditions of intended use
and that both installation and maintenance are
carried out by experienced personnel, capable
of respecting all the recommendations
provided by this manual.
DANGER
It is important that the unit is adequately
supported, as detailed in this manual. Non-
compliance with these recommendations may
create hazardous situations for the personnel.

Inside the heat exchangers, the compressors
and the refrigeration lines, this unit contains
liquid and gaseous refrigerant under
pressure. The release of this refrigerant may
DANGER
be dangerous and cause injuries.
The unit must rest on a base which meets the
characteristics specified in this manual; a
base with inadequate characteristics is likely
DANGER to become a source of serious injury to the
personnel.

The units are not designed to be operated with

natural refrigerants, such as hydrocarbons.
Manufacturer may not be held liable for any
problems deriving from the replacement
DANGER of original refrigerant or the introduction of
hydrocarbons.
WARNING
Units are designed and manufactured according to the requirements
of European Standard PED 2014/68/EU (pressure vessels directive).
The unit has not been design to withstand
loads and/or stress that may be transmitted by
adjacent units, piping and/or structures.
Each external load or stress transmitted to the
unit may break or cause breakdowns in the
unit’s structure, as well as serious dangers to
people. In these cases, any form of warranty will
automatically become null and void.

n The used refrigerants are included in group II (non-hazardous

fluids).

n The maximum working pressure values are mentioned on the The packaging material must not be disposed of
unit’s data plate. in the surrounding environment or burnt.
WARNING
n Suitable safety devices (pressure switches and safety valves)
have been provided, to prevent any anomalous overpressure
inside the plant.

n The vents of the safety valves are positioned and oriented in such
a way as to reduce the risk of contact with the operator, in the
event that the valve is operated. Anyway, the installer will convey
the discharge of the valves far from the unit.

n Dedicated guards (removable panels with tools) and danger signs

indicate the presence of hot pipes or components (high surface
temperature).

3
 2 - Safety (continued)
2.2 Definitions
OWNER: means the legal representative of the company, body or
individual who owns the plant where unit has been installed; he/she
has the responsibility of making sure that all the safety regulations
specified in this manual are complied with, along with the national
laws in force.
INSTALLER: means the legal representative of the company who has
been given by the owner the job of positioning and performing the
hydraulic, electric and other connections of unit to the plant: he/she
is responsible for handling and properly installing the appliance, as
specified in this manual and according to the national regulations in
force.
OPERATOR: means a person authorised by the owner to do on unit
all the regulation and control operations expressly described in this
manual, that must be strictly complied with, without exceeding the
scope of the tasks entrusted to him.
ENGINEER: means a person authorised directly by manufacturer or,
in all EC countries, excluding Italy, under his full responsibility, by
the distributor of product, to perform any routine and extraordinary
maintenance operations, as well as any regulation, control, servicing
operations and the replacement of pieces, as may be necessary
during the life of the unit.
2.3 Access to the unit
The unit must be placed in an area which can be accessed also
by OPERATORS and ENGINEERS; otherwise the unit must be
surrounded by a fence at not less than 2 meters from the external
surface of the machine.
OPERATORS and ENGINEERS must enter the fenced area only
after wearing suitable clothing (safety shoes, gloves, helmet etc.).
The INSTALLER personnel or any other visitor must always be
accompanied by an OPERATOR.
For no reason shall any unauthorised personnel be left alone in
contact with the unit.
2.4 General precautions
The OPERATOR must simply use the controls of the unit; he must not
open any panel, other than the one providing access to the control
module.
The INSTALLER must simply work on the connections between plant
and machine; he must not open any panels of the machine and he
must not enable any control.
When you approach or work on the unit, follow the precautions listed
below:
n do not wear loose clothing or jewellery or any other accessory tat
may be caught in moving parts
n wear suitable personal protective equipment (gloves, goggles
etc.) when you have to work in the presence of free flames
(welding operations) or with compressed air
n if the unit is placed in a closed room, wear ear protection devices
n cut off connecting pipes, drain them in order to balance the
pressure to the atmospheric value before disconnecting them,
4
disassemble connections, filters, joints or other line items
n do not use your hands to check for any pressure drops
n use tools in a good state of repair; be sure to have understood the
instructions before using them
n be sure to have removed all tools, electrical cables and any other
objects before closing and starting the unit again
2.5 Precautions against residual risks
Prevention of residual risks caused by the control
system
n be sure to have perfectly understood the operating instructions
before carrying out any operation on the control panel
n when you have to work on the control panel, keep always the
operating instructions within reach
n start the unit only after you have checked its perfect connection to
the plant
n promptly inform the ENGINEER about any alarm involving the unit
n do not reset manual restoration alarms unless you have identified
and removed their cause
Prevention of residual mechanical risks
n install the unit according to the instructions provided in this
manual
n carry out all the periodical maintenance operations prescribed by
this manual
n wear a protective helmet before accessing the interior of the unit
n before opening any panelling of the machine, make sure that it is
secured to it by hinges
n do not touch air condensation coils without wearing protective
gloves
n do not remove the guards from moving elements while the unit is
running
n check the correct position of the moving elements’ guards before
restarting the unit
Prevention of residual electrical risks
n connect the unit to the mains according to the instructions
provided in this manual
n periodically carry out all the maintenance operations specified by
this manual
n disconnect the unit from the mains by the external disconnecting
switch before opening the electrical board
n check the proper grounding of the unit before start-up
n check all the electrical connections, the connecting cables, and in
particular the insulation; replace worn or damaged cables
 2 - Safety (continued)
n periodically check the board’s internal wiring
n do not use cables having an inadequate section or flying
connections, even for limited periods of time or in an emergency
Prevention of other residual risks
n make sure that the connections to the unit conform to the
instructions provided in this manual and on the unit’s panelling
n if you have to disassemble a piece, make sure that it has been
properly mounted again before restarting the unit
n do not touch the delivery pipes from the compressor, the
compressor and any other piping or component inside the
machine before wearing protective gloves
n keep a fire extinguisher fir for electrical appliances near the
machine
n on the units installed indoor, connect the safety valve of the
refrigeration circuit to a piping network that can channel any
overflowing refrigerant outside
n remove and leak of fluid inside and outside the unit
n collect the waste liquids and dry any oil spillage
n periodically clean the compressor compartment, to remove any
fouling
n do not store flammable liquids near the unit
n do not disperse the refrigerant and the lubricating oil into the
environment
n weld only empty pipes; do not approach flames or other sources
of heat to refrigerant pipes
n do not bend/hit pipes containing fluids under pressure
2.6 Precautions during maintenance operations
Maintenance operations can be carried out by authorised technicians
only.
Before performing any maintenance operations:
n disconnect the unit from the mains with the external disconnecting
switch
5
English
n place a warning sign “do not turn on - maintenance in progress”
on the external disconnecting switch
n make sure that on-off remote controls are inhibited
n wear suitable personal protective equipment (helmet, safety
gloves, goggles and shoes etc.)
To carry out any measurements or checks which require the
activation of the machine:
n work with the electrical board open only for the necessary time
n close the electrical board as soon as the measurement or check
has been completed
n for outdoor units, do not carry out any operations in the presence
of dangerous climatic conditions (rain, snow, mist etc.)
The following precautions must be always adopted:
n do not scatter the fluids of the refrigeration circuit in the
surrounding environment
n when replacing an eprom or electronic cards, use always suitable
devices (extractor, antistatic bracelet, etc.)
n to replace a compressor, the evaporator, the condensing coils or
any other weighty element, make sure that the lifting equipment is
consistent with the weight to be lifted
n in air units with independent compressor compartment, do not
access the fan compartment unless you have disconnected the
machine by the disconnecting switch on the board and you have
placed a warning sign “do not turn on - maintenance in progress”
n contact manufacturer for any modifications to the refrigeration,
hydraulic or wiring diagram of the unit, as well as to its control
logics
n contact manufacturer if it is necessary to perform very difficult
disassembly and assembly operations
n use only original spare parts purchased directly from manufacturer
or the official retailers of the companies on the recommended
spare parts list
n contact manufacturer if it is necessary to handle the unit one year
after its positioning on site or if you wish to dismantle it.
 2 - Safety (continued)

2.7 Safety labels

Identification of the refrigerant - External door Identification of the unit - Outside, on the right-hand front column
CODICE PRODOTTO NEUTRO
PRODUCT CODE
RECUPERARE FLUIDO - NON DISPERDERE NELL’AMBIENTE - REGOLAMENTO CEE N° 3093/94

USARE SOLO MODELLO

MODEL

RECOVER - DO NOT VENT - EEC REGULATION N° 3093/94

R134a
1115

MO.NO

MATRICOLA
SERIAL NO.

E ANNO DI COSTRUZIONE
SPECIAL ESTER OIL
Manuf. Year
CIRCUIT 1 2 3 4
REFR. GWP CHARGE (Kg)

USE ONLY PS (LATO ALTA / LATO BASSA)

PS (HIGH / LOW SIDE)

TS (ALTA / BASSA)
bar

°C
TS (HIGH / LOW)

ALIM. POTENZA V / PH / Hz
MAIN SUPPLY
Electrical warning - Adjacent to the master switch CORRENTE DI SPUNTO (max) A
LRA

CORRENTE A PIENO CARICO (max) A

FLA
ATTENZIONE ! ATTENTION ! POTENZA ASSORBITA (max) Kw
POWER INPUT
Prima di Enlever PRESS. MAX ESERCIZIO ACQUA bar
aprire togliere l’alimentation MAX WATER OPERATING PRESSURE
tensione electrique MASSA Kg
avant d’ouvrir MASS

ACHTUNG ! CAUTION ! ATENCION ! SYSTEMAIR S.r.l. Via XXV Aprile 29 20825 BARLASSINA MB ITALIA
MADE IN ITALY COD.NO: P35952

Vor offnen des Disconnect Cortar la MODELLO:

MODEL
gehauses electrical corrente antes
hauptschalter supply before de abrir MATRICOLA:
ausschalten opening el aparato SERIAL NO.

CODICE: ANNO DI COSTRUZIONE

PRODUCT CODE Manuf. Year

MODELLO:
Read the instruction on the electrical board MODEL
MATRICOLA:
SERIAL NO.

CODICE: ANNO DI COSTRUZIONE

PRODUCT CODE Manuf. Year

MODELLO:
MODEL
MATRICOLA:
SERIAL NO.

CODICE: ANNO DI COSTRUZIONE

Manuf. Year
PRODUCT CODE

Gravity centre - Base

On the compressor box

GANCIO DI SOLLEVAMENTO
TENERE SU QUESTA LINEA

KEEP LIFT HOOK

ON THIS LINE

DO NOT OPEN THE PANEL

WHILE UNIT IS RUNNING
WARNING

Circuit drain - Outside, on the right-hand front column Grounding connection on the electrical board, adjacent to the connection

ATTENTION! Don’t leave the unit with water inside hydraulic circuit during
winter or when it is in stand by.
ATTENZIONE! Non lasciare l’unità con acqua nel circuito idraulico durante
l’inverno o quando non è funzionante.
ATTENTION! Ne laissez pas l’unitè avec de l’eau dans le circuit hydraulique
pendant l’hiver ou quand elle ne travaille pas.
WARNUNG! Lassen Sie nicht das Wasser in die Schaltung während des
Winters oder wenn es nicht funktionient.
¡ATENCÍON! No deje el agua en el circuito hidráulico durante el invierno o
cuando no esta trabajando.

6
 2 - Safety (continued)

English
Start-up warning - Outside the door Final Test Certificate - Inside the external door
of the electrical board

ATTENZIONE
INSERIRE LE RESISTENZE DI RISCALDAMENTO OLIO ALMENO 12
ORE PRIMA DI OGNI AVVIAMENTO (SE PREVISTE)
PRIMA DELLA MESSA IN TENSIONE ASSICURARSI CHE LE VITI DEI
CIRCUITI ELETTRICI SIANO SERRATE COMPLETAMENTE

WARNING
ENERGIZE THE CRANCKCASE HEATER FOR AT LEAST 12 HOURS
BEFORE EACH STARTING (IF FITTED)
BEFORE TIGHTENING-UP, TO TIGHTEN ALL TERMINAL SCREWS
ESPECIALLY THOSE IN MAIN CIRCUIT

WARNUNG
OLSUMPFHEIZUNG (FALLS VORHANDEN) 12 STUNDEN VOR DEM
START EINSCHALTEN
VOR INBETRIEBNAHME ALLE SCHRAUBENVERBINDUNGEN
NACHZIEHEN, BESONDERS DIE ELEKTRISCHEN ANSCHLUSSE

ATTENTION
ALIMENTER ELECTRIQUEMENT LA RESISTANCE DE CARTER AU
MOINS 12 HEURES AVANT CHAQUE DEMARRAGE (SI MONTE SUR
LE PRODUIT)
AVANT DE DEMARRER LA MACHINE, VERIFIER LE SERRAGE DE
TOUTES LES BORNES A VIS, SPECIALEMENT DANS LE BOITIER
ELECTRIQUE

ATENTION
ATENCIÓN ALIMENTAR ELÉCTRICAMENTE LA RESISTENCIA DE
CARTER AL MENOS 12 HORAS ANTES DE CADA PUESTA EN
MARCHA (SI ESTA EQUIPADA EN LA UNIDAD)
ANTES DE LA PUESTA EN MARCHA, COMPROBAR QUE LOS
BORNES ESTAN BIEN APRETADOS, ESPECIALMENTE EN EL
CUADRO ELÉCTRICO
035B00057-000 MADE IN ITALY

Instruction for the lifting

On the coil

ATTENZIONE! BORDI TAGLIENTI

VORSICHT! SCHARFE RÄNDER
CAUTION! SHARP EDGES
ATTENTION! BORDS COUPANTS
ATENCION! PERFIL AFILADO
Fitting identification - Adjacent to fittings
Warning - High temperature
Warning - Safety valve vents zone adjacent to hot pipes or
components
EIN - INLET
ENTRÉE - ENTRATA
AUS - OUTLET
SORTIE - USCITA

7
 2 - Safety (continued)

2.8 Safety regulations

REFRIGERANT DATA SAFETY DATA: R134a

Toxicity Low

If sprayed, the refrigerant is likely to cause frost burns. If absorbed by the skin, the danger is very limited;
it may cause a slight irritation, and the liquid is degreasing. Unfreeze the affected skin with water.
Contact with skin Remove the contaminated clothes with great care - in the presence of frost burns, the clothes may stick
to the skin. Wash with plenty of warm water the affected skin.
In the presence of symptoms such as irritation or blisters, obtain medical attention.

Vapours do not cause harmful effects. The spraying of refrigerant may cause frost burns.
Contact with eyes Wash immediately with a proper solution or with tap water for at least 10 minutes, and then obtain
medical attention.

Very unlikely - should something happen, it will cause frost burns.

Ingestion Do not induce vomiting. Only if the patient is conscious, wash out mouth with water and give some
250 ml of water to drink. Then, obtain medical attention.

R134a: remarkable concentrations in the air may have an anaesthetic effect, up to fainting.
The exposure to considerable amounts may cause irregular heartbeat, up to the sudden death of the
patient. Very high concentrations may result in the risk of asphyxia, due to the reduction in the oxygen
Inhalation percentage in the atmosphere. Remove the patient to fresh air and keep warm and at rest.
If necessary, give oxygen. In case of breathing difficulties or arrest, proceed with artificial respiration.
In case of cardiac arrest, proceed with cardiac massage. Then, obtain medical attention.

Semiotics or support therapy is recommended. Cardiac sensitisation has been observed that, in
Recommendations the presence of circulating catecholamines such as adrenalin, may cause cardiac arrhythmia and
accordingly, in case of exposure to high concentrations, cardiac arrest.

R134a: a study on the effects of exposure to 50,000 ppm during the whole life of rats has identified the
development of benign testicle tumour.
Prolonged exposure
This situation should therefore be negligible for personnel exposed to concentrations equal to or lower
than professional levels.

Professional levels R134a: Recommended threshold: 1000 ppm v/v - 8 hours TWA.

Stability R134a: Not specified

Conditions to avoid Do not use in the presence of flames, burning surfaces and excess humidity.

May react with sodium, potassium, barium and other alkaline metals.
Hazardous reactions
Incompatible substances: magnesium and alloys with magnesium concentrations > 2%.

Hazardous decomposition R134a: Halogen acids produced by thermal decomposition and hydrolysis.
products

8
 2 - Safety (continued)

English
2.8 Safety regulations (continued)

REFRIGERANT DATA SAFETY DATA: R134a

Do not inhale concentrated vapours. Their concentration in the atmosphere should not exceed the
minimum preset values and should be maintained below the professional threshold. Being more weighty
General precautions than the air, the vapour concentrates on the bottom, in narrow areas. Therefore, the exhaust system must
work at low level.

If you are in doubt about the concentration in the atmosphere, it is recommended to wear a respirator
Respiratory system protection approved by an accident-prevention
Authority, of the independent or oxygen type.

Cylinders must be stored in a dry and fresh place, free from any fire hazard, far from direct sunlight or
Storage other sources of heat, radiators etc.
Keep a temperature below 45 °C.

Protective clothing Wear overalls, protective gloves and goggles or a mask.

It is important to wear protective clothing and a respirator.

Stop the source of the leak, if you can do this without danger. Negligible leaks can be left evaporating
under the sun, providing that the room is well ventilated.
Accidental release measures
Considerable leaks: ventilate the room. Reduce the leak with sand, earth or other absorbing substances.
Make sure that the liquid does is not channelled into gutters, sewers or pits where the vapours are likely
to create a stuffy atmosphere.

The best method is recovery and recycling. If this method is not practicable, dispose according to an
Disposal approved procedure, that shall ensure the absorption and neutralization of acids and toxic agents.

Fire fighting information R134a: Not flammable in the atmosphere.

Cylinders The cylinders, if exposed to fire, shall be cooled by water jets; otherwise, if heated, they may explode.

Protective fire fighting equipment In case of fire, wear an independent respirator and protective clothing.

9
 2 - Safety (continued)

2.8 Safety regulations (continued)

LUBRICANT OIL DATA SAFETY DATA: POLYESTER OIL (POE)

Classification Not harmful.

May cause slight irritation. Does not require first aid measures. It is recommended to follow usual
Contact with skin personal hygiene measures, including washing the exposed skin with soap and water several times a day.
It is also recommended to wash your overalls at least once a week.

Contact with eyes Wash thoroughly with a suitable solution or tap water.

Ingestion Seek medical advice immediately.

Inhalation Seek medical advice immediately.

Strong oxidising substances, caustic or acid solutions, excess heat.

Conditions to avoid
May corrode some types of paint or rubber.

Protection of the Use in well ventilated rooms.

respiratory system

Always wear protective goggles or a mask. Wearing protective gloves is not mandatory, but is
Protective clothing recommended in case of prolonged exposure to refrigerant oil.

It is important to wear protective clothing and, especially, goggles.

Accidental release measures Stop the source of the leak. Reduce the leak with absorbing substances (sand, sawdust or any other
absorbing material available on the market).

The refrigerant oil and its waste will be disposed of in an approved incinerator, in conformity with the
Disposal provisions and the local regulations applicable to oil waste.

In the presence of hot liquid or flames, use dry powder, carbon dioxide or foam. If the leak is not burning,
Fire fighting information use a water jet to remove any vapours and to protect the personnel responsible for stopping the leak.

Cylinders The cylinders exposed to a fire will be cooled with water jets in case of fire.

Fire fighting protective equipment In case of fire, wear an independent respirator.

10
 3 - Transport, Lifting and Positioning

English
Refrigerators are supplied assembled (apart from standard It is recommended to use a spacer to prevent cables from
antivibrating rubber supports, that will be installed on site). The damaging the unit (see the figure).
equipment are full of refrigerant and oil, in the quantity required for a
proper operation.

3.1 Inspection
When the unit is delivered, it is recommended to check it carefully
and to identify any damage occurred during transportation. The
goods are shipped ex-factory, at the buyer’s risk. Check that the
delivery includes all the components listed in the order.

In case of damage, note it down on the carrier’s delivery note and

issue a claim according to the instructions provided in the delivery
note.

In the presence of any serious damage, that does not affect the
surface only, it is recommended to inform manufacturer immediately.

Please note that manufacturer may not be held liable for any damage
to the equipment during transportation, even though the carrier has
been appointed by the factory.

3.2 Lifting
Before positioning the unit, make sure that the place of installation is
The unit must be lifted by using the hooks inserted into the relevant appropriate and sturdy enough to hold the weight and to withstand
eyebolts (see the figure). the stress caused by the operation of the whole assembly.

Do not displace the unit on rollers, and do not

lift it with a lift truck.
Unit must be lifted carefully.
WARNING
To lift unit slowly and regularly.

To lift and displace the unit:

n Insert and secure eyebolts into the holes marked on the frame.

n Insert spacer between cables.

n Hook near the barycentre of the unit.

n The cables must be long enough to form, if tensioned, an angle

of at least 45° with respect to the horizontal plane.

For lifting operations, use only tools and

material fit for this purpose, in accordance with
WARNING accident-prevention regulations.

11
 3 - Transport, Lifting and Positioning (continued)
During the lifting and handling of the unit, be
careful not to damage the finned pack of the
coils positioned on the sides of the unit.
WARNING The sides of the unit must be protected by
cardboard or plywood sheets.
It is recommended not to remove the protective
plastic envelope, that should prevent scraps
from penetrating into the appliance and any
WARNING damage to the surfaces, until the unit is ready
for operation.
The lifting eyebolts protrude from the base
of the unit; it is therefore recommended to
remove them once the unit has been lifted and
positioned, if in your opinion they are likely to
WARNING
become a source of hazard and injury.
12
The eyebolts must be mounted on the unit whenever it shall be
displaced and then lifted again.
3.3 Anchoring
It is not essential to secure the unit to the foundations, unless in
areas where there is a serious risk of earthquake, or if the appliance
is installed on the top of a steel frame.
3.4 Storage
When the unit is to be stored before installation, adopt a few
precautions to prevent any damage or risk of corrosion or wear:
n plug or seal every single opening, such as water fittings
n do not store the appliance in a room where the temperature
exceeds 50 °C for the units using R134a and, if possible, do not
expose to direct sunlight
n minimum storage temperature is -25 °C
n it is recommended to store the unit in a roof where traffic is
minimized, to prevent the risk of accidental damage
n the unit must not be washed with a steam jet
n take away and leave to the site manager all the keys providing
access to the control board
Finally, it is recommended to carry out visual inspections at regular
intervals.
 4 - Installation

English
4.1 Positioning of the unit 4.2 Spring Isolator Installation
n Prepare the base, that must be flat and plane.
Before installing the unit, make sure that the
structure of the building and/or the supporting n Lift the appliance and insert shock absorbers as follows:
surface can withstand the weight of the
DANGER appliance. The weights of the units are listed in
Chapter 8 of this manual.

These units have been designed for outdoor installation on a solid

surface. Standard accessories include antivibrating rubber supports,
that must be positioned under the base.

When the unit is to be installed on the ground, it is necessary to

provide a concrete base, to ensure a uniform distribution of the
weights.

As a general rule, no special sub-bases are required. However, if the

unit is to be installed on the top of inhabited rooms, it is advisable
to rest it on spring shock absorbers (optional), that will minimise the
transmission of any vibration to the structures.

To choose the place of installation of the unit, bear in mind that:

n the longitudinal axis of the unit must be parallel to the direction of

prevailing winds, so as to ensure a uniform distribution of the air
on finned exchangers

n the unit must not be installed near boilers’ vent pipes

n the unit must not be installed leeward with respect to sources of

air contaminated by greases, such as, for example, the outlets
to kitchen exhaust hoods into the atmosphere. Otherwise,
the grease is likely to deposit on the fins of the refrigerant /air
exchangers, and would fix every type of atmospheric impurity,
resulting in the quick clogging of the exchangers

n the unit must not be installed in areas subject to considerable

snow falling

n the unit must not be installed in areas subject to flooding, under

gutters etc.

n the unit must not be installed in air shafts, narrow courts or other
small places, where the noise may be reflected by the walls or
the air ejected by fans may short-circuit itself on refrigerant/air
heat exchangers or condenser

n the place of installation must be have all the necessary spaces

for air circulation and maintenance operations (see Chapter 8).

13
 4 - Installation (continued)

4.3 External Water Circuit
The flow switch and the filter water, although not included in the
supply, must always be fitted such as plant components.
Their installation is mandatory for warranty.
The external hydraulic circuit must ensure the
water flow to the evaporator under any working
or adjustment conditions.
WARNING
A flow switch will stop the unit when the water is not circulating or a
flow rate problem occurs.
To install the flow switch, follow the manufacturer’s instructions.
As a general rule, the flow switch shall be mounted on a horizontal
pipe, at a distance from the curves equal to 10 times the diameter
of the pipe and far from valves or other components that are likely
to hinder the water flow upstream of or downstream from the flow
switch.

n The bleed valves must be mounted on the highest point of the

piping.
The circuit shall be composed by the following elements:
n The stop valves must be mounted on the piping of the water ente-
n A circulation pump which can ensure the necessary capacity
ring/leaving the evaporator.
and discharge head.
n The drain points (provided with plugs, cocks etc.) must be arran-
n The capacity of the primary hydraulic circuit should not be less
ged in the lowest point of the piping.
than 7.5 litres/KW of cooling capacity, in order to prevent the
repeated start-up of the compressor and any damage to it. If
the water capacity in the primary piping of the circuit and in the
evaporator is lower than this value, an insulated storage tank The flow switch must be connected (terminals
shall be installed. 1-2) as shown in the wiring diagram of the
WARNING “User’s Terminal Box”.
n A membrane expansion vessel provided with safety valve with
vent, that must be visible.

RECOMMENDED WATER COMPOSITION

The capacity of the expansion vessel must allow PH 7,5 - 9
for an expansion of at least 2% of the volume of
Electrical conductivity 10 - 500 μS/cm
the fluid in the circuit (evaporator, piping, user
Total hardness 4,5 - 8,5 dH
circuit and standby tank, if any). The expansion
Temperature < 60 [°C]
NOTE
vessel needs not be isolated, because no water
Alkalinity (HCO3-) 70-300 ppm
can circulate inside it.
Alkalinity / Sulphates (HCO3-/ SO42-) >1 ppm
Sulphates (SO42-) < 70 ppm
Chlorides (Cl-) < 50 ppm
Free Chlorine < 0,5 ppm
Phosphates (PO43-) <2 ppm
Ammonia (NH3) < 0,5 ppm
Ammonium Ion (NH4+) <2 ppm
Manganese Ion (Mn2+) < 0,05 ppm
Free Carbon Dioxide (CO2) <5 ppm
Hydrogen Sufide (H2S) < 0,05 ppm
Oxygen Content < 0,1 ppm
Nitrates (NO3-) < 100 ppm
Manganese (Mn) < 0,1 ppm
Iron (Fe) < 0,2 ppm
Aluminium (Al) < 0,2 ppm

Caution
If the water circuit is to be drained for a time exceeding one month, the
circuit must be fully charged with nitrogen to prevent any risk of corrosion
by differential venting

14
 4 - Installation (continued)

English
Then:

n Provide the evaporator with a by-pass circuit equipped with a

valve to wash the plant.

n Insulate the piping, to prevent the risk of heat loss.

n Position a filter on the suction side of the evaporator of the heat

recovery condenser.

Standard hydraulic circuit

Unit External water circuit

Connection Diagram

COMPONENTS
I Pressure gauge connection R Drain cock
S Gate valve T Thermometer
F1 Flow Switch F Filter
GA Flexible hoses I1/I2 Pressure gauge connection to measure pressure drop or head pressure

4.4 Hydraulic connection

Before filling the circuit, it is important to check
that it is free from any foreign matter, sand, The water inlet/outlet fittings shall conform to the instructions
gravels, rust, welding deposits, waste and other provided by the plates affixed near the connection points.
WARNING
materials that may damage the evaporator.

When cleaning the lines, it is recommended to create a circuit by-

pass. It is important to mount a filtering medium (30 mesh) upstream
of the chiller.

If necessary, the water required to fill the circuit

must be treated to obtain the requested pH.
NOTE

15
 4 - Installation (continued)

4.5 Connection of water temperature sensors

(on shell and tube evaporator)
The units are provided with fittings for hydraulic connections between Each fitting is complete with sensor well to fasten temperature
heat exchangers and plant. sensor (BT-IN and BT-OUT). Fittings are supplied separate and must
be mounted during the installation of the unit.

BT OUT

BT IN

VICTAULIC JOINT

OUT
FITTING

VICTAULIC JOINT

IN FITTING

16
 4 - Installation (continued)

English
4.6 Power supply 4.7 Electrical connections
The unit must be installed on site according to the Machinery
Before carrying out any operations on the Directive 2006/42/EC, Electromagnetic Compatibility Directive
electrical system, make sure that the unit is 2014/30/EU and the usual procedures and standards applicable
DANGER deenergised. in the place of installation.

The unit must not be operated if its installation has not been
carried out according to the instructions provided in this manual.

The power supply lines must consist of insulated copper

It is important that the appliance is grounded. conductors, dimensioned for the maximum absorbed current.
DANGER
Connection to terminals must be performed according to the diagram
of connections (User’s Terminal Box) provided in this manual and
according to the wiring diagram which accompanies the unit.

The company in charge of the installation shall

conform to the standards applicable to outdoor Before connecting the power supply lines, check
electrical connections. that the available voltage value does not exceed
DANGER
the range specified in the Electric Data (Chapter
WARNING 8).
The manufacturer may not be held liable for any damage and/or
injury caused by failure to comply with these precautions.
For 3-phase systems, check also that the unbalance between the
The unit conforms to EN 60204-1. phases does not exceed 2%. To perform this check, measure the
differences between the voltage of each phase couple and their mean
The following connections shall be provided:
value during operation.
n A 3-phase and grounding connection for the power supply
circuit. The maximum % value of these differences (unbalance) must not
exceed 2% of the mean voltage.
n The electrical distribution system shall meet the power absorbed
by the appliance. If the unbalance is unacceptable, contact the Energy Distributor to
solve this problem.
n The disconnecting and magnetothermal switches must be sized to
control the starting current of the unit.
n The power supply lines and the insulation devices must be Supplying the unit through a line whose
designed in such a way that every line independent. unbalance exceeds the permissible value will
n It is recommended to install differential switches, to prevent any WARNING automatically void the warranty.
damage caused by phase drops.
n The fans and compressors are supplied through contactors
controlled from the control panel.
n Each motor is provided with an internal safety thermal device
and external fuses.
n The power supply cables must be inserted into dedicated
openings on the front of the unit, and the will enter the electrical
board through holes drilled on the bottom of the board.

17
 4 - Installation (continued)

Electrical connections - Units with standard step and stepless type compressors

18
 5 - Start-Up
The unit must be started for the first time by
personnel suitably trained by one Authorised
Service Centre. Failure to meet this requirement
WARNING will immediately void the warranty.
The operations carried out by authorised
personnel are limited to the start-up of the unit,
and do not include any other operation on the
plant, such as, for example, electrical and
hydraulic connections etc.
NOTE
All the other operations before start-up, including
oil pre-heating for at least 12 hours, must be
performed by the Installer.
5.1 Preliminary check
The checks listed below shall be performed before starting the unit
and before the arrival of the personnel authorised.
n Check the section of power supply and grounding cables; make
sure that terminals are tightened and check the correct operation
of contactors, with the main switch open.
n Check that any voltage and phase variation in the power supply
does not exceed the prefixed thresholds.
n Connect the contacts of the flow switch and the thermal relay of
the pump and of the other devices (if any), to terminals 1-2 and
3-4, respectively.
n Check that the components of the external water circuit (pump,
user equipment, filters, power supply tank and reservoir, if any)
have been installed properly, and according to the manufacturer’s
instructions.
n Check the filling of the hydraulic circuits, and make sure that
the fluid circulation is correct, without any trace of leaks and air
bubbles. If you use ethylene glycol as antifreeze, check that its
percentage is correct.
n Check that the direction of rotation of the pumps is correct, and
that fluids have been circulating for at least 12 hours for both
pumps. Then, clean the filters on the suction side of the pumps.
n Adjust the liquid distribution network in such a way that the flow
rate is within the specified range.
n Check that the water quality is up to the specifications.
n Check that oil heaters, if any, have been turned on at least 12
hours before.
5.2 Start-up
Start-up sequence:
n Turn on the Main switch (at least 12 hours before).
n Check that the oil in the compressor has reached the requested
temperature (the minimum temperature outside the pan must be
approx. 40°C) and that the auxiliary control circuit is energised.
n Check the operation of all the external equipment, and make sure
that the control devices of the plant are properly calibrated.
19
English
n Start the pump and check that the water flow is correct.
n Set the desired fluid temperature on the control board.
n Start the appliance (see Chapter 6).
n Check the correct direction of rotation of compressors. Scroll
compressors cannot compress the refrigerant when they rotate
in the opposite direction. To make sure that they are rotating in
the correct direction, simply check that, just after the start-up
of the compressor, the pressure drops on the LP side and rises
on the HP side. Furthermore, if a scroll compressor rotate in
the opposite direction, there is a considerable rise in the sound
level of the unit, as well as in a dramatic reduction of current
absorption compared to normal values. In case of wrong
rotation, the scroll compressor can be definitely damaged. Phase
monitor is assembled in the unit as a standard to prevent wrong
compressors rotation.
n After about 15 minutes of operation check that there are no
bubbles, through the sight glass on the liquid line.
The presence of bubbles may indicate that a
part of the refrigerant charge has been released
in one or more points. It is important to remove
WARNING these leaks before proceeding.
n Repeat the start-up procedure after removing the leaks.
n Check the oil level in the compressor’s sight glass.
5.3 Checking the operation
Check the following:
n The temperature of the water entering the evaporator.
n The temperature of the water leaving the evaporator.
n The level of the water flow rate in the evaporator, if possible.
n The current absorption upon the start of the compressor and in
case of stabilised operation.
n The fan’s current absorption.
Check that the condensing and evaporation temperatures, during
operation at high and low pressure detected by the pressure gauges
of the refrigerant, are within the following range:
(On the units not provided with HP/LP pressure gauges for the
refrigerant, connect a pressure gauge to the Shrader valves on the
refrigeration circuit).
HP side
Approx. 15 to 21 °C above the temperature of
the air entering the condenser, for R134a units.
Approx. 2 to 7 °C below the temperature of the
LP side
leaving chilled water, for R134a units.
5.4 Delivery to the customer
n Train the user according to the instructions provided in Section 6.
 6 - Control

6 General information The control system consists of:

a) Main Board. The units are provided with a microprocessor card

Introduction which is fully programmed by default for the control of a chiller
This document contains the information and the operating instructions of cold only type with 2 circuits, 1 compressor for circuit, a HP
for screw compressors of step type. transducer and a LP transducer for Circuit.

This information is for the after-sales service and the production b) EEV controllers (two separate drivers) to the management of the
operators, for the end-of-line testing. electronic expansion valves.

C) Keyboard & Display Terminal.

Main characteristics
– Microprocessor control

– User-friendly keyboard

– Proportional and integral control of the return water temperature

(RWT)

– Hysteresis control of the leaving water temperature (LWT)

– Access code to enter the Manufacturer’s Level

– Access code to enter the Assistance Level

– Alarm and LED

– Backlighted LCD

– Pump-Down logic The terminal makes it possible to carry out the following operations:
– Rotation of the compressor operation – the initial configuration of the machine
– Oil return function – the change of all the main operating parameters
– Night mode (or Low Noise) control – the display of the detected alarms
– Counting of the pump/compressors’ hours of operation – the display of all the measured quantities
– Display of discharge and suction pressure values The terminal and the card are connected by a 6-way phone cable.
– Display of temperature sensor
The connection of the terminal to the basic card is not essential for
– History of stored alarms (option) the normal operation of the controller.

– 
Built-in serial Communication RS485 Card; to connect the
“Chiller Control” to a BMS network

The following accessories can be also connected:

– Remote Display Terminal

– Wire Remote Control.

20
 6 - Control (continued)

English
6.1 Display/Keyboard
Esc key: allows you to move from one mask to another.

Alarm key: used to display the alarms, to reset them in

alarm
manual.
Press it one to display the mask of the activated alarm,
press it again to reset the alarm signal.

Prg+Esc keys: Pressing these keys at the same

+
time,allows you to turn the unit on/off.

Up-down keys: allows you to set the control parameters’

values and to move from one mask to another (not
backlighted).
enter
Enter key: used to move the cursor inside the masks and
to save the values of the set parameters.
The display is an LCD 8 lines x 22 columns. The quantities and the
information about the operation of the unit are alternated in the form
of subsequent screens, named “masks”.
It is possible to move inside the masks with the terminal keys as
described below.

Arrows key - Up/Down/Enter

alarm enter Alarm+Enter keys: press these keys at the same time
+ to enter the "storical alarm" after 1’ come back at status
machine menu. If the cursor is in the top left-hand corner (Home), press the UP/
DOWN keys to access the subsequent masks associated to the
selected branch. If a mask includes some value setting fields and
you press the ENTER key, the cursor will reach these fields.

Once you have reached the quantity setting field, you can modify any
value (within the expected limits) by pressing the UP/DOWN keys.

After you have selected the desired value, press the ENTER key again
to store it.

21
 6 - Control (continued)

Alarms

Alarm code Description Notes

1 Main board - EPROM Failure
2 Main board - Clock card Failure
3 Main board - External air temperature sensor fault
4 Main board - Return Water temperature sensor fault
5 Main board - Leaving Water temperature sys 1 sensor fault
6 Main board - Leaving Water temperature sys 2 sensor fault
7 Main board - Low pressure sys 1 sensor fault
8 Main board - Low pressure sys 2 sensor fault
9 Main board - High pressure sys 1 sensor fault
10 Main board - High pressure sys 2 sensor fault
11 Main board - Discharge temperature sys 1 sensor fault
12 Main board - Discharge temperature sys 2 sensor fault
13 Main board - Coil Temperature sys 1 sensor fault
14 Main board - Coil Temperature sys 2 sensor fault
15 Flow switch / Interlock / Serious alarm (SQZ)
16 Serious alarm (SQZ)
17 Flow switch / Interlock
18 Oil Safety Sys 1 manual reset
19 Oil Safety Sys 2 manual reset
20 High pressure switch Sys 1
21 High pressure switch Sys 2
22 Low pressure Sys 1 switch manual reset
23 Low pressure Sys 2 switch manual reset
24 Thermal protection compressor 1 Sys 1 manual reset
27 Thermal protection compressor 1 Sys 2 manual reset
30 Fan Thermal protection manual reset
31 Fan Thermal protection Group 1 Sys 1 manual reset
32 Fan Thermal protection Group 2 Sys 1 manual reset
33 Fan Thermal protection Group 1 Sys 2 manual reset
34 Fan Thermal protection Group 2 Sys 2 manual reset
35 Low refrigerant cutout Sys 1 manual reset
36 Low refrigerant cutout Sys 2 manual reset
37 Low pressure alarm Sys 1 manual reset
38 Low pressure alarm Sys 2 manual reset
39 Out of envelope Sys 1 manual reset
40 Out of envelope Sys 2 manual reset
41 High pressure Sys 1 manual reset
42 High pressure Sys 2 manual reset
43 High limit discharge temperature Sys1 manual reset
44 High limit discharge temperature Sys2 manual reset
45 ∆T Water Too High
47 Wrong Water Trend
49 Antifreeze alarm manual reset
51 Antifreeze alarm Recovery manual reset
52 Pump maintenance
53 Compressor 1 Sys 1 maintenance
56 Compressor 1 Sys 2 maintenance
59 Driver 1 LAN disconneted
60 Driver 2 LAN disconneted
61 EPROM Error Driver 1
62 EPROM Error Driver 2
63 Driver 1 S1 Sensor fault
64 Driver 1 S3 Sensor fault
65 Driver 1 S2 Sensor fault
66 Driver 1 S4 Sensor fault
67 Driver 2 S1 Sensor fault
68 Driver 2 S3 Sensor fault
69 EEV motor Error (Check viring) Sys 1
70 EEV motor Error (Check viring) Sys 2
71 Driver 1 Battery alarm

22
 6 - Control (continued)

English
Alarm code Description Notes
72 Driver 2 Battery alarm
73 Autotune alarm Sys 1
74 Autotune alarm Sys 2
75 Low suction alarm Sys 1
76 Low suction alarm Sys 2
77 Driver 1 Regulation Alarm
78 Driver 2 Regulation Alarm
79 Expansion board 1 OFF LINE
80 Expansion board 2 OFF LINE
81 Expansion board 1 - Sensor 1 fault
82 Expansion board 1 - Sensor 2 fault
83 Expansion board 1 - Sensor 3 fault
84 Expansion board 1 - Sensor 4 fault
85 Safety Extra Heater
86 Recovery Flow switch
87 Low delta pressure Sys 1 manual reset
88 Low delta pressure Sys 2 manual reset
118 Oil Safety Sys 1 auto reset
119 Oil Safety Sys 2 manual reset
122 Low pressure Sys 1 switch auto reset
123 Low pressure Sys 2 switch auto reset
124 Thermal protection compressor 1 Sys 1 auto reset
127 Thermal protection compressor 1 Sys 2 auto reset
130 Fan Thermal protection auto reset
131 Fan Thermal protection Group 1 Sys 1 auto reset
132 Fan Thermal protection Group 2 Sys 1 auto reset
133 Fan Thermal protection Group 1 Sys 2 auto reset
134 Fan Thermal protection Group 2 Sys 2 auto reset
135 Low refrigerant cutout Sys 1 auto reset
136 Low refrigerant cutout Sys 2 auto reset
137 Low pressure alarm Sys 1 auto reset
138 Low pressure alarm Sys 2 auto reset
139 Out of envelope Sys 1 auto reset
140 Out of envelope Sys 2 auto reset
141 High pressure Sys 1 auto reset
142 High pressure Sys 2 auto reset
143 High limit discharge temperature Sys1 auto reset
144 High limit discharge temperature Sys2 auto reset
187 Low delta pressure Sys 1 auto reset
188 Low delta pressure Sys 2 auto reset

6.2 Setpoint
Pressing the Set key allows you to enter the Set point level accessible to the user. The parameters that can be set are listed below, along with the
limit values and the default values (standard shop settings):

User parameters Control mode Min value Max value Default

RWT Return Control 9 15 10
Cooling Setpoint
LWT Leaving Control 6 15 8
RWT Return Control -5 15 10
Cooling Setpoint - glycol water
LWT Leaving Control -8 15 8
Proportional band RWT Return Control 1 10 5
Neutral band LWT Leaving Control 1 6 2
Languages —— ITA ENG FRE GER SPA ITA
System On/Off
System 1 # —— OFF ON OFF
System 2 # —— OFF ON OFF
Unit management Cooling

23
 6 - Control (continued)

6.3 Protection and Safety Equipment Electrical flow switch

Refrigeration system A electrical flow switch must be installed, to prevent the unit working
in case of insufficient circulation of the chilled fluid.
The units are filled with R134a refrigerant fluid of non hazardous type
(group II). Safety device (pressure switch and safety valves) with the
sets below indicated are provided on the discharge and suction line The electrical flow switch must be carefully
of each circuit. installed, according to the instructions given by
WARNING the Manufacturer.
Discharge Line
Pressure relief valve 21 bar.
Pressure switch 19 bar.
The electrical flow switch must be installed on the pressing side
Suction line
of the circulation pump for the fluid, just upstream of the heat
Pressure relief valve 14.5 bar.
exchanger’s inlet. The electrical flow switch must be installed in a
Pressure switch 0.5 bar. horizontal straight length of piping, in a position reasonably far (both
upstream and downstream) from localized pressure drops (curves,
Frost Protection for the Chilled Fluid valves etc.).
These units are provided with frost protection for the chilled fluid. This
Continuous Regulation of the Fan Speed
protection consists of an electrical resistor positioned in contact with
the coolant/circulating fluid exchanger, which is activated (although The fans’ speed regulator, if installed, allows the unit to work at an
the unit is off) when the temperature of the fluid drops below 5 °C - ambient temperature down to -10 °C.
the standard value for a non-glycol unit.

If the leaving water temperature drops below 4 °C (standard value for

a non-glycol unit) the machine’s antifreeze alarm is activated. If the
circulating fluid is water, before the beginning of the cold season it is
advisable to drain the circuit to prevent water frosting.

If the circuit cannot be drained, it is essential to avoid de-energizing

the unit, so as to permit the activation, when necessary, of the frost
protection.

Compressor protection
Compressors are equipped with a heating element to prevent
oil dilution, which may result in remarkable risks of failure of
compressors.

The windings of the compressors’ motors are provided with a

thermal protection.

An accessory kit for thermal protection (ACB) is available, for any

overcurrent of compressors, which shall be shop-mounted.

24
 6 - Control (continued)

English
6.4 HPF version configuration
Units equipped with High pressure fan (HPF) can be set-up on the
field to give the unit a specific static pressure.

By entering parameter in service level - Max Speed (Vdc) - it is

possible to modify high static pressure. The table below shows
the correspondance between chiller model, fan RPM, high static
pressure (approximate values).

Parameter in Service Level:

Model Fan Static Pressure (Pa) Fan RPM
Max Speed (Vdc)
0 900 8,1
30 950 8,5
360-1300 70 1.000 9,0
100 1.050 9,4
120 1.100 10,0

25
 ATTACHMENT 3

T
AIR DUCT

HANGER EXPANSION SLEEVE

R0D/ANGLE ANCH0R B0LT
NUT & SPRING WASHER

SUPP0RT NUT
RIGID DUCT
INSULATI0N �--- STEEL ANGLE

RECOMMENDED HANGER SIZES FOR RECTANGULAR DUCT

LONGER DUCT STEEL ANGLE HANGER MAXIMUM HANGER
DIMENSI0N SiZE R0D SPACING ANGLE
UP THRU 914 25x25x3 6 * 1.17 M 25x25x3
940 THRU 1370 38x38x5 6 * 1.17 M 38x38x5
1400 THRU 1524 50x50x5 8 * 1.17 M 50x50x5
ATTACHMENT 4
 ATTACMENT 5

5 5

2 2

A
Pos. Name

B
4 1 Rod M12

2 U Profile support

3 Anchor screw-bolt M12

4 Nut M12
1 3
5 Cable tray

6 Concrete beam

Cable trays ceiling mounting details

02 1:5

Signal Cables Power Cables

Name
Pos.

A B

1 Floor support

2 L Profile support

3 Anchor screw-bolt M12

4 Bolt Nut M12

5 Cable tray

6 Concrete beam

Cable trays floor mounting details

03 1:5