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Denco HyCassette-Geko Operation Manual

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OPERATION MANUAL
Fan-Coil Units
HyCassette-Geko
®
– Hygiene Version
Quality in Detail - Effective and Quiet

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Summary of Contents for Denco HyCassette-Geko

  • Page 1 OPERATION MANUAL Fan-Coil Units HyCassette-Geko ® – Hygiene Version Quality in Detail - Effective and Quiet...
  • Page 2 HyCassette-Geko DencoHappel product range PR-2015-0159-GB • Subject to modifications • R1-11/2015...
  • Page 3 A = Speed 1, 2, 3 Metal-sheet electric switch cabinet with ter- Unit type minal block or for integrated control sys- C = HyCassette-Geko K = Speed stage 1, 2, 3 L = Speed stage 2, 3, 4 M = Speed stage 3, 4, 5 O = Speed stage 1, 3, 5 S = Min...Max (EC motor)

  • Page 4: Table Of Contents

    Table of Contents HyCassette-Geko 1 Safety and User Instructions ..........9 1.1 Symbols used ................9 1.2 Safety instructions: warning and danger symbols ......9 1.3 Safety-conscious work procedures ..........10 1.4 Personnel selection and qualification ..........11 1.5 Proper use ..................11 1.6 Improper use ..................12 1.7 Safety regulations and codes ............13...
  • Page 5 HyCassette-Geko Table of Contents 3.3 Weight and packaging ..............35 3.4 Handling ..................36 3.5 Temporary storage ................ 36 3.6 Disposal ..................36 4 Mounting .................37 4.1 Installation site ................37 4.2 Recommended service opening for maintenance work ....37 4.3 Pre-installation work ..............
  • Page 6 Table of Contents HyCassette-Geko 6.6 Connecting electric heater (for units without MATRIX 3500) ..70 6.6.1 Connection value of electric heating and fusing ......71 6.7 Connection of staged motors (AC motors) with control by others ..71 6.8 Connection of EC motors with control by others ......72 6.8.1 Actuation of EC motor in units with an electric heater ....73...
  • Page 7 HyCassette-Geko Table of Contents 7.2.1 Checking the control valves ............103 7.2.2 Shut-off valve settings (variants) 7.2.3 Shut-off valve for control valves up to 1.6 kvs (1/2") value for fan coil units 7.2.4 Shut-off valve for control valves from to 2.5 kvs (3/4") to 4.0 kvs (3/4") value for fan coil units...
  • Page 8 Table of Contents HyCassette-Geko 8 Maintenance and Troubleshooting ........121 8.1 Maintenance ..................121 8.2 Technical Maintenance ..............122 8.2.1 List of regular technical maintenance work ........122 8.2.2 Check condensate drain ............122 8.2.3 Check screw connections of medium connections ....122 8.2.4 Check electrical connections and earthing ........123 8.2.5 Cleaning the lateral condensate pan .........123...

  • Page 9: Safety And User Instructions

    EC Directive on Machinery. HyCassette-Geko fan coil units are reliable in operation and satisfy strict quality standards. Future-oriented technology and pronounced operator and mainte- nance friendliness were combined in this product series.

  • Page 10: Safety-Conscious Work Procedures

    Safety and User Instructions HyCassette-Geko respective steps. The following warnings are used: HAZARDOUS VOLTAGE! This symbol indicates a risk of electrical shock that can result in serious injury, death and material damage. DANGER OF SCALDING! This symbol indicates a risk of scalding from leaking hot liquids that can result in personal injury, including death and material damage.

  • Page 11: Personnel Selection And Qualification

    – Proper use Fan coil units of the HyCassette-Geko series are exclusively designed for heat- ing, filtering and cooling purposes. As medium water or water/glycol solution (max. 50 %) may be used. The following limit values apply to the medium for oper-...

  • Page 12: Improper Use

    Also ensure that the unit is protected from dust and other substances that can cause acidic or alkaline reaction with water (aluminum corrosion). It is not allowed to use HyCassette-Geko units, in particular with a cooling func- tion, for the extraction of kitchen exhaust air containing organic acids, e.g. vin- egar.

  • Page 13: Safety Regulations And Codes

    1.10 Selection and qualification of personnel NOTE! Ensure that every person working on the HyCassette-Geko fan coil unit has read and understood the entire operation manual. Please read this document fully before com- mencing any work, and not while performing a task.

  • Page 14: Technical Description

    Technical Description HyCassette-Geko Technical Description Unit Components Pos. 1: Suction grille Pos. 2: Filter G1 Pos. 3: Design panel Pos. 4: Adapter for design panel Pos. 5: Main condensate pan Pos. 6: Fan with casing Pos. 7: Heat exchanger (optional electric heater included) Pos.
  • Page 15 The adapter for the design panel transfers the filtered and conditioned air to the design panel air outlets. Main condensate pan (pos. 5) The main condensate pan is used to collect condensate from HyCassette-Geko and as an intake nozzle for the fan. Fan with casing (pos. 6) The fan consists of a centrifugal fan and is equipped with low-noise, mainte- nance-free ball bearings.

  • Page 16: Material Specification

    Technical Description HyCassette-Geko Lateral condensate pan (pos. 10) The condensate pan is used to collect condensate forming on valves and connec- tion fittings and draining it into the main drain. Suspension brackets (pos. 11) The suspension lug is integrated in the base of the basic casing.

  • Page 17: Range Of Application

    Range of Application 2.3.1 Ambient conditions The air temperature inside the intake area of HyCassette-Geko (centered in the inlet area of the intake nozzle) must be kept between +6° and 40°C (in heating mode max 30°C), higher or lower temperatures are not permissible. It is only allowed to operate the unit with a relative humidity according to Fig.

  • Page 18: Unit And Heat Exchanger

    Technical Description HyCassette-Geko 2.3.3 Unit and heat exchanger Unit and heat exchanger Values Max. operating pressure/temperature 1.6 MPa (16 bar) / 82 °C (70°C)* Min. cooling medium temperature 6 °C Ambient conditions see Chapter 2.3.1 Operating voltage 230 V ~...

  • Page 19: Valves With Thermoelectric Actuators

    HyCassette-Geko Technical Description Valves with modulating actuators 230 V Values and 2 floating auxiliary switches Max. operating pressure/inlet temperature 1.6 MPa (16 bar) / 110 °C Max. allowed ambient temperature 60 °C Operating voltage 230 V AC, 50/60 Hz Power consumption/protection class...

  • Page 20: Dimensions

    1) Dimension depends on type of installation (see Chapter 4.3) 2) External dimension mounting plate 3) External dimension basic casing Fig. 2-3: Dimensions unit type HyCassette-Geko with 4-way outlet (GCF#.###.###) Unit type SWIRL® 2) External dimension mounting plate 3) External dimension basic casing Fig.

  • Page 21: Unit Data

    HyCassette-Geko Technical Description Unit data 2.5.1 Unit weight and water charge of heat exchanger Unit type Capacity Weight [kg] Water charge[l] size 2-pipe 4-pipe 2-pipe 4-pipe Heating Cooling ® SWIRL 4-way 1) without electric heater with electric heater Tab. 2-8: Unit weight and water charge of heat exchanger 2.5.2 air volume flow...

  • Page 22: Electrical Data

    Technical Description HyCassette-Geko 2.5.3 Electrical data The supply voltage is the mains supply voltage 230 V ~ 50 Hz. Electrical data of fan motors Unit Motor design Capacity stage Current consumption Power consumption [W] type 2-pipe 4-pipe 0.18 0.22 0.22 ®...

  • Page 23: Condensate Pump

    HyCassette-Geko Technical Description Electrical data of valve actuators 2- and 3-way valves 2- and 3-way valves 2- and 3-way valves on/off control mode modulating operation continuous operation (thermoelectric actuator) (modulating actuator) (continuous actuator) Starting cur- Operating Power con- Current con-...

  • Page 24: Technical Data And Capacity Of Condensate Pump

    Tab. 2-14: Max. hose length Control variants and supported functions The HyCassette-Geko with 4-way outlet is provided with the following control system. The MATRIX 3500 control system is the premium solution based on a BUS system. It is possible to operate with a building management system. The CET controllers are electronic miniature switches for easy temperature and fan regulation.

  • Page 25: Quick Guide Matrix Control Panel With Display (Opxx)

    HyCassette-Geko Technical Description Type MATRIX 3500 Miniature switch Via con- trols by oth- OP30 OP31 OP50 OP51 CET.AC CET.EC 4-way Fan control 1-2-3 1-2-3 1-2-3 1-2-3 1-2-3 1-2-3 1-2-3 (AC motor) auto auto auto auto auto auto auto mute mute...

  • Page 26: Overview Of The Operating Elements

    Technical Description HyCassette-Geko Overview of the operating elements The MATRIX OP5xx control panel is divided into three segments: (1) Display (2) Buttons (3) Navigator (rotation switch) Display The MATRIX control panel is equipped with a monochrome graphic LCD display (1) featuring a resolution of 128 x 64 pixels.

  • Page 27: The Menus In Overview

    HyCassette-Geko Technical Description 2.9.1 The menus in overview NOTICE! The selectable menus depend on the unit version. The menus and their struc- ture can differ depending on the configuration of HVAC equipment and possibly other connected units. 2.9.1.1 Select menu In stand-by mode, the MATRIX control panel with display shows the home screen.

  • Page 28: Setting Room Temperature-Setpoint

    Technical Description HyCassette-Geko 2.9.2 Setting room temperature-setpoint • Select a menu, e.g. “Setpoint room temperature”. • Press the key "SET". The current room temperature setpoint value is displayed inversely. • Turn the navigator to the left (decrease value) or right (increase value) until the required new setpoint value is displayed.

  • Page 29: Fan Mode" Menu Setting

    HyCassette-Geko Technical Description “Fan mode” menu setting 2.9.3 Four menu items can be selected in the menu "Fan mode". The menu is preas- Fan mode signed with “automatic” as factory setting. This menu item appears when using the control panel at decentralized devices or if "Temperature controlled" was Automatic selected at central units for the fan-controlled variable.

  • Page 30: Operating Mode" Menu Setting

    Technical Description HyCassette-Geko 2.9.4 “Operating mode” menu setting Four menu options are available in the "Operating mode" menu. The menu is pre- Operating mode set with "normal mode” as factory setting. Normal mode Economy mode Menu Display Explanation Clock timer...

  • Page 31: Controller Mode" Menu Setting

    HyCassette-Geko Technical Description 2.9.5 “Controller mode” menu setting The following menu options are available in the “controller mode” menu. Controller mode The menu is preassigned with “automatic” as factory setting. Heating only Cooling only Automatic Menu Display Explanation option Heating only The control system works exclusively in the heating mode.
  • Page 32 Technical Description HyCassette-Geko 2.9.6.2 Operation mode "Manuel" In "Manual" mode the user can change the direction of discharge and air throw of Room air flow cold or warm air independently of the HVAC mode (heating or cooling). The air Automatic...

  • Page 33: Menu "Additional Menus

    HyCassette-Geko Technical Description 2.9.6.4 "Breath" operating mode The option for the "Breath" operating mode is only displayed on the home screen Room air flow when the plant is designed for cooling function. The operating mode Automatic The "Breath" operating mode is only available in normal operation for a limited Manual time.

  • Page 34: Hygiene Control Functions

    Technical Description HyCassette-Geko 2.10 Hygiene control functions 2.10.1 Hygiene control functions of the condensate pump Via MATRIX 3500 regulation (control code D5.###.## on name plate) the conden- sate pump pumps residual water out of the condensate pan every 24 hours for 15 seconds whether or not the unit is switched on or off, but not if the unit is in heating mode.

  • Page 35: Shipping And Storage

    HyCassette-Geko Shipping and Storage Shipping and Storage Transport safety DANGER DUE TO OVERHEAD LOADS! It is extremely dangerous to stand under overhead loads. • Make sure there are no persons below an overhead load! RISK OF DAMAGE TO THE UNIT! Improper shipping can cause damage to the fan coil unit.

  • Page 36: Handling

    Shipping and Storage HyCassette-Geko Handling RISK OF EQUIPMENT DAMAGE AND PERSONAL INJURY! • Always wear protective gloves to prevent injury caused by sharp edges. • To prevent injury ensure that at least two people carry the HyCassette- Geko. • When delivering on pallets, use only lifting gear and transport vehicles with sufficient load-bearing capacity.

  • Page 37: Mounting

    HyCassette-Geko Mounting Mounting HAZARDOUS VOLTAGE! Before drilling, ensure that the drilling area is free from electrical cables and pipes. PERSONAL INJURY! Injury may be caused by falling parts and sharp edges! Wear a helmet, safety boots and protective gloves when installing the unit. Ceil- ing installations should always be performed by two persons.
  • Page 38 Mounting HyCassette-Geko Fig. 4-1: Dimensions of service opening - rectangular-grid ceiling Fig. 4-2: Dimensions of service opening - closed ceiling PR-2015-0159-GB • Subject to modifications • R1-11/2015...

  • Page 39: Pre-Installation Work

    The electric wiring is prepared and ready for connection in the false ceiling. – 4.3.1 Ceiling opening - 4-way The HyCassette-Geko design panel offers different model variants for an optical adaptation of the ceiling underside depending on the size of the ceiling opening. Model variant 1 (only for 4-way outlet) –...
  • Page 40 Mounting HyCassette-Geko Model variant 2 (only for 4-way outlet) The mounting is the same as in variant 1, except that the shadow joint is closed by sticking in a sealing strip. The strip is provided by the factory (see Fig. 4-4, for sizes see Tab. 4-1; see also chapter 4.6.3 "Mounting the design panel"...

  • Page 41: Ceiling Opening - Swirl

    Primary air supply HyCassette-Geko has a primary air connection placed in a corner on the side of the unit that enables the addition of primary air to the supply air within the unit.

  • Page 42: Position Of Connection

    Furthermore, depending on the operating point, there is a risk of condensation on the external sides of the on-site ductwork. 4.4.1 Position of connection With the HyCassette-Geko, such a primary air supply is possible on one unit – corner (Fig. 4-6, Pos. 1).

  • Page 43: Mounting Primary Air Ducts

    HyCassette-Geko unit. The same applies for the last meters of the primary air duct connected on-site .

  • Page 44: Air Volume Flow Primary Air

    The air volume flow of the supplied primary air depends on the nominal volume flow rate of the HyCassette-Geko (see Tab. 2-9on page 20) and on the pressure drop of the primary air connection (see Fig. 4-9 and Fig. 4-10).

  • Page 45: Fixation

    HyCassette-Geko Mounting Pos. 1: 1st speed stage (210 m ® SWIRL Pos. 2: 2nd speed stage (250 m Pos. 3: 3rd speed stage (360 m Pos. 4: 4th speed stage (500 m Pos. 5: 5th speed stage (670 m Primary air flow volume [m³/h] ®...

  • Page 46: Fixation With Mounting Bracket

    Mounting HyCassette-Geko Pos. 1: Outline of design panel Pos. 2: Outline of basic unit Pos. 3: Mounting drill holes Fig. 4-11: Drilling pattern for direct fixation 4.5.2 Fixation with mounting bracket The threaded rods are fixed with additional mounting brackets directly on the mounting bracket of the unit (see Fig.

  • Page 47: Unit Mounting

    HyCassette-Geko Mounting Pos. 1: Outline of design panel Pos. 2: Outline of basic unit Pos. 3: Mounting drill holes Fig. 4-12: Drilling pattern for fixation with mounting bracket Unit mounting Mount the unit on-site under the true ceiling with a provided threaded rod. In gen-...
  • Page 48 Mounting HyCassette-Geko • Fix the threaded rods to the ceiling. The length of the threaded rod results from Fig. 4-13. For easy installation, the threaded rods should not be any longer than this. • Push the unit with the cable box ahead and at an angle into the opening of the false ceiling.
  • Page 49 HyCassette-Geko Mounting 4.6.2 Mounting with mounting bracket (accessory set ZGC 0112) Fasten the threaded rods provided on-site to the ceiling with the accessory set ZGC0112. The set consists of: 4 pcs. Mounting brackets (see Fig. 4-13) – 8 pcs. Nuts M8 –...
  • Page 50 Mounting HyCassette-Geko Fig. 4-14: Mounting brackets • Determine the position of the mounting drill holes (see chapter 4.5.2 "Fixation with mounting bracket" on page 46). • Fasten the mounting bracket below the true ceiling using suitable tools. • Fasten the mounting bracket below the ceiling.

  • Page 51: Mounting The Design Panel

    HyCassette-Geko Mounting Pos. 1: Mounting brackets Pos. 2: Nut M8 with washer Pos. 3: Mounting bracket Fig. 4-15: Fixation of threaded rod with mounting bracket 4.6.3 Mounting the design panel The 4-way design panel with air filter is not delivered pre- mounted.
  • Page 52 Mounting HyCassette-Geko NOTE ABOUT SHADOW JOINT! Depending on the chosen ceiling opening and mounting variant and in order to compensate an uneven ceiling surface, the design panel uses a run-around shadow joint of approximate 4 mm to the suspended ceiling - see chapter°4.3.1 "Ceiling opening - 4-way"...
  • Page 53 HyCassette-Geko Mounting Mounting design panel SWIRL® • Mount the cover using the snares on the basic unit the way that the cover hangs down vertical. The snares are important for subsequent cleaning work! • Thread both cover cables through the ceiling opening and stick them in sideways into the switch box.

  • Page 54: Hydraulic Connection

    Hydraulic Connection General DANGER OF SCALDING BY ESCAPING HEATING MEDIUM! Before the on-site piping and hydraulic connections of the HyCassette-Geko are set up, the heating/cooling medium must be shut off and secured against inadvertent opening. Fan coil units with a cooling function are equipped with a lateral condensate pan.
  • Page 55 HyCassette-Geko Hydraulic Connection With a 2-way valve, control is carried out by throttling the medium supply (see Fig. 5-2). Fig. 5-2: Motor actuated 2-way valve Valves with thermoelectric actuator 2-point operation (open/close) is possible with these valves. If 3-way valves are fitted by the manufacturer, control is carried out via a distributor circuit (refer to Fig.

  • Page 56: Heating And Cooling Connections For Units Without Valves Or With On-Site Valves Provided By Others

    Hydraulic Connection HyCassette-Geko Heating and cooling connections for units without valves or with on-site valves provided by others 5.3.1 Mounting connections • At the beginning of the fitting procedure, remove caps on the water inlet and outlet pipes. • Fit the connections while ensuring they are free of mechanical stress.

  • Page 57: Medium Connection In A 4-Pipe System

    HyCassette-Geko Hydraulic Connection 2-pipe system Pos. 1: Inlet line Pos. 2: Return line Pos. 3: Opening for conden- sate hose Fig. 5-5: Pipe connection in a 2-pipe system NOTICE! The given dimensions are only "approximated values". Due to adding toleranc- es there can be differences up to 10 mm (in individual cases beyond that).

  • Page 58: Heating And Cooling Connections For Units With On-Site Mounted Dencohappel Valve Equipment

    Hydraulic Connection HyCassette-Geko Four-pipe system Pos. 1: Water inlet cooling Pos. 2: Cooling outlet Pos. 3: Inlet line heating Pos. 4: Return line heating Pos. 5: Opening for conden- sate hose Fig. 5-6: Pipe connection in a 4-pipe system NOTICE! The given dimensions are only "approximated values".

  • Page 59: Medium Connection In A 2-Pipe System

    HyCassette-Geko Hydraulic Connection 5.4.2 Medium connection in a 2-pipe system • At the beginning of the fitting procedure, remove caps on the water inlet and outlet pipes. • Fit the connections while ensuring they are free of mechanical stress. •...
  • Page 60 Hydraulic Connection HyCassette-Geko NOTICE! Ensure a correct position of inlet line and return line when installing medium connection (Fig. 5-7 and Fig. 5-8). The pipe connections of the heat exchanger always have the internal screw thread size R1/2". 2-pipe, 2-way valve Fig.
  • Page 61 HyCassette-Geko Hydraulic Connection NOTICE! The given dimensions are only "approximated values". Due to adding toleranc- es there can be differences up to 10 mm (in individual cases beyond that). 2-pipe, 3-way valve Fig. 5-10: Dimension pipework, 2-pipe, 3-way valve Pos. 1: Inlet line Pos.

  • Page 62: Medium Connection In A 4-Pipe System

    Hydraulic Connection HyCassette-Geko Circuit Valve code Dimen- Control valve diameter sion DN 15 (½") DN 20 (¾") Cooling or VGC.####.0C heating VGC.####.1C KH2=KH3 VGC.####.2C KH2=KH3 VGC.####.3C KH2=KH3 VGC.####.4C VGC.####.4C VGC.####.5C VGC.####.5C Dimension pipework, 2-pipe, 3-way valve Tab. 5-3: NOTICE! The given dimensions are only "approximated values". Due to adding toleranc- es there can be differences up to 10 mm (in individual cases beyond that).
  • Page 63 HyCassette-Geko Hydraulic Connection 4-pipe system with 3-way valve Pos. 1: Valve actuator motor Pos. 2: Supply line cooling Pos. 3: Return line cooling Pos. 4: Supply line heating Pos. 5: Return line heating Pos. 6: Shut-off valve or ball valve (optional, de- pends on unit version) Pos.
  • Page 64 Hydraulic Connection HyCassette-Geko Circuit Valve code Dimen- Control valve diameter sion DN 15 (½") DN 20 (¾") Cooling VGC.####.0C VGC.####.1C VGC.####.2C VGC.####.3C VGC.####.4C VGC.####.5C VGC.####.0C Heating VGC.####.0C VGC.####.1C VGC.####.2C VGC.####.3C VGC.####.4C VGC.####.5C VGC.####.0C Tab. 5-4: Dimension pipework, 4-pipe, 2-way valve NOTICE! The given dimensions are only "approximated values".

  • Page 65: Mounting Lateral Condensate Pan

    HyCassette-Geko Hydraulic Connection Circuit Valve code Dimen- Control valve diameter sion DN 15 (½") DN 20 (¾") Cooling VGC.####.0C VGC.####.1C K2=K3 VGC.####.2C K2=K3 VGC.####.3C K2=K3 VGC.####.4C VGC.####.4C VGC.####.5C VGC.####.5C Heating VGC.####.0C VGC.####.1C H2=H3 VGC.####.2C H2=H3 VGC.####.3C H2=H3 VGC.####.4C VGC.####.4C VGC.####.5C VGC.####.5C...

  • Page 66: Connection Of Condensate Drain

    Hydraulic Connection HyCassette-Geko • Turn the lateral condensate pan back to the horizontal position so that the pan is locked under the two connecting plates (Fig. 5-16, pos 2). • Push the plastic rivet in the provided drilling hole to fix the lateral condensate pan next to the lower connecting plates (Fig.
  • Page 67 HyCassette-Geko Hydraulic Connection • Insulate the condensate hose in the false ceiling to prevent condensation. • Ensure that the condensate hose is installed along the shortest path. Cut off any surplus hose length • Do not install any grinds or waves, i.e. no local low points. Install the hose at a constantly incline until the high point (see Fig.

  • Page 68: Electrical Connection

    The PCB provides the power supply for the miniature switch (separate fuse on the PCB). Electric switch cabinet HyCassette-Geko units are delivered with: metal-sheet electric switch cabinet - type A or – metal-sheet electric switch cabinet - type K and S.
  • Page 69 HyCassette-Geko Electrical Connection Metal-sheet electric switch cabinet The interior comprises (depending on type): Various terminal blocks and, depending on unit type, additional electrical – parts. A PCB – Control/power electronics (MATRIX 3500). – PCB IR-receiver – Metal-sheet electric switch cabinet - type A Metal-sheet electric switch cabinet - type K and S Fig.

  • Page 70: Electric Switch Cabinet With Controls By Others

    Electrical Connection HyCassette-Geko Electric switch cabinet with controls by others HyCassette-Geko is delivered with a metal-sheet electric switch cabinet. The interior comprises (depending on type): Various terminal blocks and, depending on unit type, additional electrical – parts. A PCB –...

  • Page 71: Electric Switch Cabinet With Matrix 3500

    HyCassette-Geko Electrical Connection Electric switch cabinet with MATRIX 3500 HyCassette-Geko is delivered with a metal-sheet electric switch cabinet. The interior comprises (depending on type): Various terminal blocks and, depending on unit type, additional electrical – parts. Control/power electronics (MATRIX 3500).

  • Page 72: Connecting Mains Supply Voltage With Controls By Others (No Miniature Switch Control)

    Electrical Connection HyCassette-Geko Connecting mains supply voltage with controls by others (no miniature switch control) Pos. 1: Power supply 230 V AC/ 50 Hz fusing by others max. B 16 A ensure an on-site all-pole disconnect switch is provid- ed by others Pos.

  • Page 73: Connecting Electric Heater (For Units Without Matrix 3500)

    HyCassette-Geko Electrical Connection Connecting electric heater (for units without MATRIX 3500) The supply voltage for all types is 230 V. It is always connected to terminal L.1- N.1-PE on the terminal block in the electric switch cabinet. Pos. 1: Safety-temperature limiter with reset button Pos.

  • Page 74: Connection Of Staged Motors (Ac Motors) With Control By Others

    Electrical Connection HyCassette-Geko 6.6.1 Connection value of electric heating and fusing Unit type Fan type Capacity stage Recommended on-site Power fusing [kW] B10A 0.75 B10A 0.75 4-way B10A B10A ® SWIRL B10A 0.75 B10A B10A Tab. 6-2: Electric heater data...

  • Page 75: Connection Of Ec Motors With Control By Others

    Connection of EC motors with control by others EC motors require a 0-10 V DC signal for RPM regulation. HyCassette-Geko unit type "single" and "double" can also be regulated by a PWM signal. DAMAGE TO THE UNIT! The error signal is ground-referenced and a serial interconnection of multiple outputs can cause motor damage.

  • Page 76: Actuation Of Ec Motor In Units With An Electric Heater

    DAMAGE TO THE UNIT! If minimum control signal size is not maintained, units can sustain damage. DencoHappel HyCassette-Geko with SWIRL® outlet controls by others is not pro- vided. If the unit is equipped with electric heating and a SWIRL® outlet, use the MATRIX 3500 controller.

  • Page 77: Dencohappel Matrix Control Electronics

    HyCassette-Geko Electrical Connection DencoHappel MATRIX control electronics The DencoHappel MATRIX control electronics are built into the electric switch cabinet. For each connectable component an individual table indicates possi- bilities of connecting electric equip- ment to the supplied controller hardware. Fig. 6-9: Overview controller type 6.10...

  • Page 78: Electrical Connection With Dencohappel Matrix

    Electrical Connection HyCassette-Geko Fig. 6-10: Mounting the control panel and room temperature sensor * recommended installation height To install your control panel on the wall or in flush-mounted sockets (in the wall), refer to the relevant operation manual for the respective control panel. There you will also find the right drill template.

  • Page 79: Connecting Control Cables

    HyCassette-Geko Electrical Connection NOTICE! According to the relevant regulations, an all-pole isolating device must be pro- vided by others on site! If an earth leakage circuit breaker is used, all-current sensitive types (type B) must be used. Power supply for slave units can be provided by the master unit (refer to Fig. 6- 11, Pos.

  • Page 80: Connecting Supply-Air Sensor (For Subsequent Retrofitting)

    Electrical Connection HyCassette-Geko Connecting master unit with slave units If units are fitted with MATRIX 3500 controllers, a 2-core bus line must be used. • Connect the control cables in accordance with the wir- ing diagram. Individual units are fitted with MATRIX 3000.

  • Page 81: Connecting Room Sensor/Return-Air Sensor (Option)

    HyCassette-Geko Electrical Connection 6.11.5 Connecting room sensor/return-air sensor (option) MATRIX 3500 ✓ Pos. 1: Connection cable (see bottom note on Page 76) • Connect the room or return-air sensor according to the wiring diagram. Fig. 6-15: Connecting room sensor/return-air sensor 6.11.6...

  • Page 82: Connecting Function Input

    Electrical Connection HyCassette-Geko 6.11.8 Connecting function input MATRIX 3500 ✓ In closed condition, the function input 1 switches to auton- omous operating mode. In closed condition, the function input 2 switches to unit OFF with/without indoor anti-freeze protection (depending on configuration).

  • Page 83: Valve Connection 230 V Valve

    HyCassette-Geko Electrical Connection 6.11.9 Valve connection 230 V valve Function Heating - Cooling, Heating - Cooling; 2-pipe system MATRIX 3500 ✓ Unit with 230 V AC / MATRIX 50Hz 3500 2-point modulating actuators (valve code VT...) Valve Kl. 103 Kl. N...
  • Page 84 Electrical Connection HyCassette-Geko MATRIX 3500 ✓ Unit 230 V AC / with 50Hz MATRIX 3-point modulating actuators (valve code VR..., VC..., 3500 V5...) Valve Kl. 102 Kl. 103 Kl. 104 Kl. 105 Kl. N 2-way brown black brown black blue Fig.

  • Page 85: Valve Connection 24 V Valve

    HyCassette-Geko Electrical Connection 6.11.10 Valve connection 24 V valve Heating, cooling, heating or cooling function; 2-pipe system MATRIX 3500 ✓ Unit with 2-point modulating actuators (valve code VQ...) MATRIX 3500 Valve Kl. 103 Kl. STV 2-way brown blue 3-way brown blue Pos.
  • Page 86 Electrical Connection HyCassette-Geko Cooling and heating function; 4-pipe system MATRIX 3500 ✓ Unit with 2-point modulating actuators (valve code VQ...) MATRIX 3500 Valve Kl. 102 Kl. 103 Kl. STV 2-way brown brown blue 3-way brown brown blue Fig. 6-27: Valve connection 4-pipe system, 2-point modu- Pos.

  • Page 87: Network And Shielding Connection Matrix.net

    HyCassette-Geko Electrical Connection MATRIX 3500 ✓ Unit with MATRIX 3-point modulating actuators (cooling) - 2-point 3500 modulating actuators (heating) (valve code V4...) Valve Kl. 102 Kl. 103 Kl. 105 Kl. STV 2-way brown green brown blue Fig. 6-30: Valve connection 4-pipe system, 3- and 2-point...
  • Page 88 Electrical Connection HyCassette-Geko Group structure with MATRIX 3500 and/or MATRIX 3000/4000 system A group may be formed using the MATRIX 3500 and MATRIX 3000/4000 sys- tems. The Fig. 6-31 shows an example of a network consisting of a control panel, MATRIX 3500/3000/4000 system and various global modules.

  • Page 89: Network Structure Matrix.net

    HyCassette-Geko Electrical Connection 6.12.2 Network structure MATRIX.Net A network can consist of one or several (up to 16) groups. Global modules can also be integrated into the network. The network structure/network topology of MATRIX.Net must be performed linearly – See “Topologies of network MATRIX.Net”...

  • Page 90: Topologies Of Network Matrix.net

    Electrical Connection HyCassette-Geko 6.12.3 Topologies of network MATRIX.Net The MATRIX.Net can be set in a line structure and a line structure with branch feeder. All units equipped with DencoHappel MATRIX system can access this data bus. The data bus must be terminated at both physical ends to avoid reflections, which can interfere with data transfer.

  • Page 91: Line Structure With Branch Feeder

    HyCassette-Geko Electrical Connection 6.12.5 Line structure with branch feeder The illustration Fig. 6-34 shows the setup of the MATRIX.Net as line with branch feeder structure. A sample connection of a control panel via a branch feeder in multiple groups is illustrated. The maximum allowed branch feeder length is 25 m.

  • Page 92: Network Set Up Matrix.net

    Electrical Connection HyCassette-Geko 6.12.6 Network set up MATRIX.Net Data transfer cable When building up the MATRIX.Net, only use data transfer cables according to DIN 19245 T3, with twisted wires pairs and with braided shielding. (See tab. 6-4) We recommend the following data transfer cable: Total max.

  • Page 93: Electrical Connection For Staged Motors (Ac Motor) With Dencohappel Miniature Switches/Relay Cet.ac/Pcb

    6.13 Electrical connection for staged motors (AC motor) with DencoHappel miniature switches/relay CET.AC/PCB The DencoHappel HyCassette-Geko units with 4-way can be easily controlled using the CET.AC switches. According to unit model the following operating modes are possible: Operating mode Only Heating (2-pipe system) –...
  • Page 94 Electrical Connection HyCassette-Geko Only terminals for wiring control and steering system as well as supply voltage are pre- sented. Fig. 6-35: Terminal block basic PCB/relay PCB Pos. 1: Internal safety fuse 6.3 A Pos. 2: Basic PCB power supply 230 V AC ensure all-pole disconnect switch and fusing are provided on-site by others ! Pos.

  • Page 95: Connection With Staged Motors (Ac Motors) With And Without Pcb

    HyCassette-Geko Electrical Connection 6.13.1 Connection with staged motors (AC motors) with and without PCB Unit without relay PCB Unit with relay PCB 2nd unit 2nd unit 1st unit 1st unit Fig. 6-36: Connecting terminals 1) = put jumper between terminal 814 and 815 on last unit and jumper between 806/L and 816 on first unit.

  • Page 96: Operating Mode Only Heating (2-Pipe System)

    Electrical Connection HyCassette-Geko 6.13.2 Operating mode Only Heating (2-pipe system) Parameter 3: SEL0 = 14 and SEL2 = auto (2-pipe system) Parameter 4: SEL0 = 16 and SEL2 = auto / SEL2 = OFF (fan continuous operation or On/Off) Parameter 5: SEL0 = 18 and SEL2 = auto...

  • Page 97: Electrical Connection For Ec Motors With Dencohappel Miniature Switches Cet Ec

    HyCassette-Geko Electrical Connection 6.14 Electrical connection for EC motors with DencoHappel miniature switches CET EC The DencoHappel HyCassette-Geko units with 4-way can be easily controlled using the CET.EC switches. According to unit model the following operating modes are possible: Operating mode Only Heating (2-pipe system) –...

  • Page 98: Operating Mode Only Heating (2-Pipe System)

    Electrical Connection HyCassette-Geko • Connect only in accordance with the unit-specific wiring diagram. 6.14.1 Operating mode Only Heating (2-pipe system) Parameter 3: SEL0 = 14 and SEL2 = auto (2-pipe system) Parameter 4: SEL0 = 16 and SEL2 = auto / SEL2 = OFF...

  • Page 99: Operating Mode Heating And Cooling (4-Pipe System)

    HyCassette-Geko Electrical Connection 6.14.4 Operating mode Heating and Cooling (4-pipe system) Parameter 2: SEL0 = 12 and SEL2 = 1 Parameter 3: SEL0 = 14 and SEL2 = OFF (4-pipe system) Parameter 4: SEL0 = 16 and SEL2 = auto / SEL2 = OFF...
  • Page 100 Electrical Connection HyCassette-Geko NOTICE! The installation site of the room temperature sensor is crucial for the precise control of room temperature. Therefore avoid mounting the sensor in the following locations (refer to Fig. 6-48): Not next to doors, windows, hatches etc., as intense movement –...

  • Page 101: Miniature Switch Cet

    HyCassette-Geko Electrical Connection Input enabling This input is used to enable the controller. For this purpose an external contact must be open. If enabling was not initiated (contact closed), then only the room frost protection function is active in order to open the heating valve and activate fan at temperatures below 4°C.
  • Page 102 Electrical Connection HyCassette-Geko Perform configuration: To change parameters proceed as follows: Set SEL0 button to 10°C – Set SEL2 button to position A – Press both SEL1 and SEL3 buttons simultaneously for more – than 5 seconds If the LED H/C has flashed and changed red and green for 3 –...
  • Page 103 HyCassette-Geko Electrical Connection Setpoint Description Fan speed selection switch (SEL2) rame- (SEL0) Comfort setpoint range 10-30°C 12-28°C 13-27°C 14-26°C 15-25°C Dead band System type (2 or 4-pipe) Fan operating mode Continuou On/Off Continuou Continuo operation operation operation cooling heating Enabling active =...
  • Page 104 Electrical Connection HyCassette-Geko Fan speed configuration for automatic mode Perform configuration To change parameters proceed as follows: Set SEL0 button to 10 C – Set SEL2 button to stage 1,2 or 3 – Press both SEL1 and SEL3 buttons simultaneously for more –...

  • Page 105: Commissioning

    Safety check 7.1.1 Pre-commissioning checklist The entire facility comprising HyCassette-Geko units has been installed both – mechanically and electrically. The system and HyCassette-Geko units are disconnected from the power –...

  • Page 106: Checking The Control And Shut-Off Valves

    Commissioning HyCassette-Geko Checking the control and shut-off valves Check all on-site valves according to the regulations of the manufacturer. 7.2.1 Checking the control valves 2- or 3-way valves with modulating actuators or 2- and 3-way valves with thermoelectric actuators. Actuators of 2- and 3-way valves have a position indicator shaped like a red plas- tic nose that is placed in the relevant slots, guided above the coupling nut or vis- ible behind a sight window (see tab.

  • Page 107: Shut-Off Valve Settings (Variants)

    HyCassette-Geko Commissioning 7.2.2 Shut-off valve settings (variants) Check if shut-off valves are open: • Unscrew the protective cap (Fig. 7-1, pos. 2). • Close the valve by tightening the internal flow-control screw (Fig. 7-1, pos. 3) using a 4-mm hex key until the stop position on the right side.

  • Page 108: Shut-Off Valve For Control Valves Up To 1.6 Kvs (1/2") Value For Fan Coil Units

    Commissioning HyCassette-Geko 7.2.3 Shut-off valve for control valves up to 1.6 kvs (1/2") value for fan coil units Pre-setting Flow Rate Fig. 7-2: Flow rate diagram V9400 1 1/2 Pre-setting values 0.07 0.13 0.22 0.32 0.43 0.65 0.85 1.10 1.25 1.40...

  • Page 109: Shut-Off Valve For Control Valves From To 2.5 Kvs (3/4") To 4.0 Kvs (3/4") Value For Fan Coil Units

    HyCassette-Geko Commissioning 7.2.4 Shut-off valve for control valves from to 2.5 kvs (3/4") to 4.0 kvs (3/4") value for fan coil units Pre-setting Flow Rate Fig. 7-3: Flow rate diagram V9441 1 1/2 2 1/2 Pre-setting values Tab. 7-3: Pre-setting = turns of the pre-setting screw from the right stop position...

  • Page 110: Vent The Unit

    Commissioning HyCassette-Geko Vent the unit To ensure that the exchanger is charged with heating/cooling medium, it must be air vented. NOTICE! Protect electrical hardware and furniture from escaping splash water. • Open all shut-off and control valves. • Use the air vent key to open the first air vent screw (see Fig. 7-4).

  • Page 111: Terminating Resistors

    HyCassette-Geko Commissioning Terminating resistors MATRIX 3500 ✓ Unit printed circuit boards of the MATRIX 3500 control system and MATRIX OP5X control panels are equipped with terminating resistors. Terminating resistors are placed at line start and end (Fig. 7-5): Turn the DIP switch of both users (e.g. control panels, unit MCBs or modules) •...

  • Page 112: Address Setting

    Set address on the control panel Pos. 1: Control panel, HyCassette-Geko(s) Group 0 (Address 0) Pos. 2: Control panel, HyCassette-Geko(s) Group 1 (Address 1) Pos. 3: Control panel, HyCassette-Geko(s) Group 2 (Address 2), etc PR-2015-0159-GB • Subject to modifications • R1-11/2015...

  • Page 113: Setting Limitation Functions

    HyCassette-Geko Commissioning Setting limitation functions MATRIX 3500 ✓ Limit values of the supply air temperature can be set for heating and cooling oper- ation. Heating operation: – Minimum and maximum limitation (limitation type: rigid or variable) Cooling operation: – Minimum limitation These limitation values and the limitation type can be set via the “MATRIX.PC”...

  • Page 114: Switch On Unit

    Commissioning HyCassette-Geko Minimum heating limitation (variable): Value can fall below the set minimum temperature value if the current room tem- perature value exceeds the setpoint by a value that is calculated as room temper- ature difference multiplied by effective factor.

  • Page 115: Checking Data Connection

    HyCassette-Geko Commissioning • Apply mains supply voltage. The unit is switched on via a MATRIX control panel, a miniature switch of CET series or a controller supplied by others. For instructions, refer to the operation manual enclosed with the relevant con- trol panel.

  • Page 116: Checking Control Cables

    Commissioning HyCassette-Geko 7.9.1 Checking control cables MATRIX 3500 ✓ The data/commands are communicated via control cables. Depending on the unit equipment, these should be connected or checked in accordance with the wiring diagram affixed to the unit connection box ( seeConnecting control cables on page 76).

  • Page 117: Functional Input

    HyCassette-Geko Commissioning 7.10.1 Functional input MATRIX 3500 ✓ Depending on the control system, the input can be assigned with the following functions as required: Window contact • Couple input terminals. • Turn the unit on and change the setpoint as required to activate the fan.

  • Page 118: Functional Characteristics For The Use Of Dencohappel Matrix

    Commissioning HyCassette-Geko ✓ After a short period, when the water is drained off, the pump must switch off again. 7.13 Functional characteristics for the use of DencoHappel MATRIX 7.13.1 Fan MATRIX 3500 ✓ Fan control depends on the configured control type and selected operating mode on the control panel.

  • Page 119: Valves

    HyCassette-Geko Commissioning Manual The fan is operated at the pre-set fan speed or rotational speed. Settings can be entered via control panel There are further possibilities via building services or via external modules. Air change function This function enables the fan to operate irrespective of the selected control sys- tem and regardless if the setpoint temperature is reached.

  • Page 120: Indoor Anti-Freeze Protection

    Commissioning HyCassette-Geko range. The MATRIX.PC service software makes it possible to change this set- point. The standby mode is activated if a room temperature sensor is connected but no room temperature setpoint, i.e. no control panel, is available (e.g. during con- struction phase and drying of building).

  • Page 121: Filter Replacement Indication

    HyCassette-Geko Commissioning 7.13.7 Filter replacement indication MATRIX 3500 ✓ This function calculates the filter contamination level using the operation times of the respective fan speeds. The necessary filter replacement message is dis- played and entered as a warning only on the MATRIX OP50 or MATRIX OP51 control panel.
  • Page 122 Commissioning HyCassette-Geko In preparation for calibration, switch the unit to cooling mode. Pay attention to achieving the maximum possible cooling performance. We recommend to calibrate using a low fan speed, i.e. for units with 3 speed stages use stage 1, or for continuously variable units use 35%. Make sure to adjust the fan before starting the calibration.

  • Page 123: Default Setting

    HyCassette-Geko Commissioning 7.14.2 Default setting This menu enables you to reset the determined data of the calibration process Default setting back to the default setting (factory setting) (described in chapter chapter 7.14.1) Really? To prevent an unintentional resetting of data, it is coupled with a confirmation prompt.

  • Page 124: Maintenance And Troubleshooting

    Maintenance The HyCassette-Geko unit is a high-quality, reliable unit. In order to guarantee the durability and trouble-free performance of the HyCassette-Geko unit, regular maintenance and inspection must be performed by technical experts.

  • Page 125: Technical Maintenance

    HyCassette-Geko Maintenance and Troubleshooting Technical Maintenance 8.2.1 List of regular technical maintenance work The following technical maintenance must be carried out annually by technical experts. Components Checking condensate drain Checking screw connections of pipes * Checking electrical connections Checking earthing...

  • Page 126: Check Electrical Connections And Earthing

    Maintenance and Troubleshooting HyCassette-Geko Fig. 8-1: Check screw connections 8.2.4 Check electrical connections and earthing HAZARDOUS VOLTAGE! Before completing the following work, ensure that the unit is isolated and secured against being energized at an appropriate point of the on-site power supply.

  • Page 127: Disinfection

    HyCassette-Geko Maintenance and Troubleshooting following table. For use in medical areas observe the cleaning intervals according to the specified cleaning and disinfection schedules. NOTICE! For units with electric heating it is obligatory to clean the filters every 4 months. The manufacturer’s warranty will become void if unit damage is attributed to non-observance of this measure.
  • Page 128 Maintenance and Troubleshooting HyCassette-Geko Required materials • Ladder • Flat-headed screwdriver and Phillips screwdriver • Disposable gloves • Protective goggles • Disinfectant • Water • Spray bottle • Cloth (e.g. KIMTECH Prep 7622, company Kimberly-Clark) • Vacuum cleaner with brush nozzle (e.g. Miele SHB 30 or Numatic angle- rubber nozzle with brush 601179) 8.3.1 Disinfection...

  • Page 129: Annual Random Sampling Contamination Audit According To No. A

    HyCassette-Geko Maintenance and Troubleshooting 8.3.2 Annual random sampling contamination audit according to No. A A step-by-step instruction is presented below. Stop the unit by switching the control panel "off" (Fan mode --> "OFF"). Please wait for 3 minutes. During this time, the valves close and the fans coast to a stop.
  • Page 130 Maintenance and Troubleshooting HyCassette-Geko ® SWIRL 4-way Fig. 8-3: Remove filter If contaminated: Clean both sides of the filter under lukewarm water (< 38 °C) to remove dust particles and fluff. Disinfect the filter on both sides according to the notice with the recommended disinfectant as mentioned above.
  • Page 131 HyCassette-Geko Maintenance and Troubleshooting ® SWIRL 4-way Fig. 8-4: Dismantling the design panel 4-way : The 4-way cover is completely removable from the basic unit, since there is no electric connection. Remove the 4-way adapter from the condensate pan (see arrows in Fig. 8-5).
  • Page 132 Maintenance and Troubleshooting HyCassette-Geko cover can only be cleaned with a dry cloth. Then disinfect by using a cloth that is sprayed with disinfectant and wipe the parts of the cover. RISK OF DAMAGE TO THE UNIT! Do not spray disinfectant or other liquids on cover.
  • Page 133 HyCassette-Geko Maintenance and Troubleshooting Check fan impeller for dirt and remove dirt by wiping if required. Disinfect fan impeller with a cloth. Turn the impeller to reach certain parts easier. RISK OF DAMAGE TO THE UNIT! Do not spray disinfectant or other liquids on the fan.

  • Page 134: Filter Replacement According To No. B (Every 24 Months)

    Maintenance and Troubleshooting HyCassette-Geko 8.3.3 Filter replacement according to No. B (every 24 months) Follow the points 1-6; 8-11; 33-37 from Chapter 8.3.2. 8.3.4 Cleaning and repairing according to No. C (every 3 or rather 6 months Follow the points 1-15; 23-26; 28-37 from Chapter 8.3.2.

  • Page 135: Remove Fan In The Event Of Critical Contamination According To No. E

    HyCassette-Geko Maintenance and Troubleshooting 8.3.6 Remove fan in the event of critical contamination according to No. E Follow the steps 1-15 from Chapter 8.3.2. HAZARDOUS VOLTAGE! Disconnect the unit from the power supply (point 3)! Make sure that the intercon- nection cables between unit and cover are secured against being electrically alive before installation.

  • Page 136: Troubleshooting

    Maintenance and Troubleshooting HyCassette-Geko Fig. 8-8: Provisional fastening of the fan Loosen the four nuts of the fan suspension with a socket set, one by one and crosswise. They are located above the fan impeller. You get access to the nuts through the assembly holes in the fan impeller. Spin the impeller to the right position.
  • Page 137 HyCassette-Geko Maintenance and Troubleshooting Check the lateral casing walls and clean or disinfect them as described above. RISK OF PERSONAL INJURY! Take care not to injure yourself on the sharp cutting edges of heat exchanger fins. This position enables a better accessibility to the inside of the heat exchanger and therefore an easier cleaning.
  • Page 138 Maintenance and Troubleshooting HyCassette-Geko Fasten the cable(s) on the inside of the heat exchanger connection sheet using a cable strap with plug-in peg to prevent cable dragging against the impeller in operating mode. Thread the cable sleeve back into the connec- tion sheet.

  • Page 139: Troubleshooting

    8.4.1 Enable safety temperature limiter of the electric heater This point applies only for units with electric heater. The HyCassette-Geko electrical heating elements are monitored by a tempera- ture-dependent switch. In case of failure, limiting switches are activated and the electric heater is shut down.

  • Page 140: Breakdowns

    Maintenance and Troubleshooting HyCassette-Geko Breakdowns Deviations from normal operating conditions of fan coil units indicate malfunctions that must be investigated by the maintenance personnel. The following table should serve as a starting point for maintenance personnel regarding possible causes of malfunctions and their remedy.
  • Page 141 HyCassette-Geko Maintenance and Troubleshooting Fault Possible Cause Action/remedy Unit does not heat Fan not switched on Switch on fan /heats insufficiently Heating medium is not hot Switch on the heating system (boiler) (hot water) Switch on the circulating pump Vent the unit...
  • Page 142 Maintenance and Troubleshooting HyCassette-Geko Fault Possible Cause Action/remedy Unit leaks in cooling op- Condensate pan dirty Clean condensate pan eration Chilled water lines not (correctly) insu- Correctly insulate chilled water lines lated Unit is not hung horizontally Align the unit and hang it horizontally...

  • Page 143: Ec Declaration Of Conformity

    HyCassette-Geko Unit type GC XX.XXX.XXX including accessories ® Fan coil unit HyCassette-Geko is equipped with a control system MATRIX 3500 and thermostat/miniature switches CET of type GC XX.XXX.XXX including accessories. Unit is designed for heating, ventilating, cooling and filtering of indoor and outdoor air.
  • Page 144 DencoHappel is a global company with expertise in air treatment, air conditioning and air filtration. Our nearest sales and service teams will be glad to discuss ideas and develop creative and effective solutions with you. www.dencohappel.com...

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