Page 1 OPERATION MANUAL Decentral Systems Comfort - Fan Coil Units ® Flex-Geko Flexible Solutions for all Demands...
Page 2: Table Of Contents
Table of Contents Flex-Geko Fan Coil Unit 1 Safety and User Instructions ........5 1.1 Symbols used .
Page 3 6.4 Connection with controls by others ....... 67 6.4.1 Overview of DencoHappel MATRIX control electronics ..71 6.4.2 Mounting control panel .
Page 4 ..........122 7.6.1 DencoHappel MATRIX functions ......124 8 Maintenance and Troubleshooting .
Page 5: Safety And User Instructions
Flex-Geko Fan Coil Unit Safety and User Instructions Safety and User Instructions This is an original operation manual verified by the manufacturer. Flex-Geko fan coil units are developed and manufactured in accordance with the state-of-the-art technological standards, established technical safety codes and EC Directive on Machinery.
Page 6: Safety-Conscious Work Procedures
Safety and User Instructions Flex-Geko Fan Coil Unit 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 through running hot liquids that can result in personal injury including death and material damage.
Page 7: Personnel Selection And Qualification
Flex-Geko Fan Coil Unit Safety and User Instructions DANGER DUE TO OVERHEAD LOADS! Wear a helmet and safety boots to prevent injury from falling components, especially when fitting the unit to the ceiling. Ceiling installations should always be performed by two persons. PERSONAL INJURY! Always wear protective gloves when shipping or installing the unit to prevent injury caused by sharp edges.
Page 8 The operator is responsible for proper use. Proper use also stipulates the observance of the operation manual and the in- spection and maintenance conditions defined by DencoHappel. PR-2011-0115-GB • Subject to modifications • R4-12/2015...
Page 9: Improper Use
Changes or modifications of the Flex-Geko unit will invalidate the CE conformity and render all warranty claims null and void. Spare parts Only original DencoHappel spare parts are allowed, since DencoHappel is not lia- ble if third-party spare parts are used. 1.10 Selection and qualification of personnel...
Page 10: Technical Description
Safety and User Instructions Flex-Geko Fan Coil Unit Technical Description Components of the unit Fig. 2-1: Unit components (depending on unit model) 1: Holding plate 14: Mixed-air box with actuator 2: Heat Exchanger 15: Unit foot on left side for recirculating-air unit 3: Control panel 16: Unit foot on right side for recirculating-air unit 4: Metal sheet electric control box...
Page 11 Flex-Geko Fan Coil Unit Safety and User Instructions Various unit parts indicated in Fig. 2-1 are specified in detail as follows. Holding plate (Pos. 1) The mounting panel is used to support the heat exchanger. Heat exchanger (Pos. 2) The heat exchanger for chilled and warm water has a connection fitting with 1/2" internal thread as well as air vents and drain valves.
Page 12: Material Specification
Safety and User Instructions Flex-Geko Fan Coil Unit Unit foot cover, right/left (Pos. 20/Pos. 21) Unit foot cover panels are used as a casing for unit feet (Pos. 15/Pos. 16) or mixed-air box (Pos. 14) and are connected with the unit casing (Pos. 19). Mixed-air box with actuator (Pos.
Page 13: Range Of Application
Flex-Geko Fan Coil Unit Safety and User Instructions Range of Application 2.3.1 Medium inlet temperature To prevent condensate from forming on non-insulated casing parts when the tem- perature falls below the dew point during cooling operation, certain minimum water inlet temperature or evaporating temperature must be maintained. These temperatures depend on ambient temperature and indoor relative humidity and are specified in the following diagram.
Page 14 Safety and User Instructions Flex-Geko Fan Coil Unit 2.3.3 Unit and heat exchanger Unit and heat exchanger Values Max. operating pressure/temperature 1.6 MPa (16 bar)/90 °C Max. allowed ambient temperature 40 °C Min. allowed ambient temperature 2 °C Operating voltage 230 V AC, 50 Hz Power consumption/protection class Refer to identification plate...
Page 15 Flex-Geko Fan Coil Unit Safety and User Instructions 2.3.4 Valves with modulating actuators Valves with modulating actuators Values 230 V/24 V 230 V 24 V Max. operating pressure/inlet temperature 1.6 MPa (16 bar)/110 °C Max. allowed ambient temperature 60 °C Operating voltage 230 V AC 24 V AC...
Page 16 Safety and User Instructions Flex-Geko Fan Coil Unit 2.3.6 Valves with continuous actuators Valves with continuous actuators Values Max. operating pressure/inlet temperature 1.6 MPa (16 bar)/110 °C Max. allowed ambient temperature 55 °C Operating voltage 24 V AC, 50/60 Hz Analog control signal 0 ...
Page 17: Dimension
Flex-Geko Fan Coil Unit Safety and User Instructions Dimension 2.4.1 Basic unit * Space need for field-provided piping on site ** only with frontal air intake *** possibly additional space need of 5 mm (unit height) with cooling units for pitched mounting for condensate connection side Fig.
Page 18 Safety and User Instructions Flex-Geko Fan Coil Unit 2.4.2 Unit casing Air intake grille (opt.) Pos. 1: Casing design 01, 02, 03, 04, 13, 23 Discharge grille (opt.) Pos. 2: Relevant for the following casing types: Comfort Economy ZGF.1Cxx# ZGF.1Exx# ZGF.2Cxx# ZGF.2Exx# ZGF.3Cxx#...
Page 19: Unit Data
Flex-Geko Fan Coil Unit Safety and User Instructions 2.4.3 Intake sound attenuator for mixed-air units Unit casing (mixed-air) Pos. 1: Sound attenuator Pos. 2: Relevant for the following casing types: ZGF.##07# (or ZGF.##08#) Can also be used without casing. Fig. 2-6: Dimension of casing All other sizes are the same as with a wall unit (refer to Chapter 2.4.2).
Page 20 Safety and User Instructions Flex-Geko Fan Coil Unit 2.5.2 Air volume flow Model size Motor design Air volume flow [m Fan stages AC (5-stages/series resistor) AC (3-stages) AC (5-stages/series resistor) AC (3-stages) AC (5-stages/series resistor) AC (3-stages) AC (5-stages/series resistor) AC (3-stages) AC (5-stages/series resistor) 1010...
Page 21 Flex-Geko Fan Coil Unit Safety and User Instructions 2.5.3 Electrical data Electrical data of fan motors Model size Motor design Current consumption [A] Power consumption [W] AC (5-stages) 0,28 AC (series resistor) 0,32 AC (3-stages) 0,27 0,34 AC (5-stages) 0,29 AC (series resistor) 0,32 AC (3-stages)
Page 22 Safety and User Instructions Flex-Geko Fan Coil Unit Electrical data for electric heater and full electric heater (maximum values) Model size Electric heater Full electric heater (230 V, 50 Hz) (400 V, 50 Hz) Current Power Current Power consumptio consumption consumptio consumption n [A]...
Page 23: Condensate Pump
Flex-Geko Fan Coil Unit Safety and User Instructions Condensate pump In cooling units condensate can form and is collected in the lateral drain pan. If a slope for condensate drainage is not fitted, a condensate pump must be installed. This pump drains condensate into higher placed upstream drainage pipework. 2.6.1 Function of condensate drain A separate level sensor is installed on the side of the unit at the additional con- densate tray other than the condensate pump, which performs the following func-...
Page 24 Safety and User Instructions Flex-Geko Fan Coil Unit Technical data of condensate pump Technical Data Values Operating voltage 230 V AC/50 Hz Starting current max. 0.07 A Operating current 0.02 A Power consumption 4.7 W Protection class IP 64 Max. pump head Max.
Page 25: Air Side Accessories
Flex-Geko Fan Coil Unit Safety and User Instructions Air side accessories The following accessories can be supplied for the Flex-Geko fan coil unit. Designation Order No. Type Transition piece ZGF.#A131 Galvanized metal sheet for flexible intake connector Flexible connection ZGF.#A112 discharge Fire classification B1, mounting on discharge sideIntake-side ZGF.#A111 intake mounting only with recirculating-air units with a transition piece...
Page 26: Shipping And Storage
Safety and User Instructions Flex-Geko Fan Coil Unit 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! DAMAGE TO THE UNIT! Improper shipping can cause damage to the fan coil unit.
Page 27 Flex-Geko Fan Coil Unit Safety and User Instructions 3.4.1 Shipping without unit casing Vertical transport Horizontal transport Fig. 3-1: Transport without unit casing, vertical/horizontal • When shipping the Flex-Geko secure the unit on both sides on frame top (refer to Fig. 3-1). 3.4.2 Shipping with unit casing •...
Page 28: Temporary Storage
Safety and User Instructions Flex-Geko Fan Coil Unit Temporary storage When storing the unit for a temporary period, the following aspects must be con- sidered: Store the fan coil unit in its original packing. – The storage location must be protected from the elements, dry and dust-free –...
Page 29: Assembly
Flex-Geko Fan Coil Unit Safety and User Instructions Assembly 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! Put on Personal Protective Equipment (PPE) such as helmet, safety boots and protective gloves when installing the unit.
Page 30: Recommended Service Opening For Maintenance Work On The Basic Unit
Safety and User Instructions Flex-Geko Fan Coil Unit Recommended service opening for maintenance work on the basic unit In order to carry out all necessary service and maintenance work on the basic unit it is recommended that a service opening with minimum dimensions of W x 620 mm is provided in the false ceiling (refer to Fig.
Page 31: Removing Unit Casing
Flex-Geko Fan Coil Unit Safety and User Instructions Removing unit casing If the unit is ordered with a casing the latter must be removed before the actual unit installation. Remove styrofoam protective blocks used for shipping safety. NOTICE! With already assembled units and casing make sure to follow instructions on securing casing in section 4.11.
Page 32: Pre-Installation Work
Safety and User Instructions Flex-Geko Fan Coil Unit Pre-installation work Depending on the model, the pipes may be connected from left or right. The fol- lowing installation clearances must be observed: Position No., Unit Type Reason Installation refer to Fig. 4- clearance [mm] with all units for unobstructed air supply:...
Page 33: Unit Mounting
Flex-Geko Fan Coil Unit Safety and User Instructions Unit mounting 4.5.1 Installation on wall/stand-alone on floor NOTICE! In order to ensure complete removal of condensate from condensate trays in cooling units according hygiene regulations (VDI 6022, SWKI VA 104-01), the units must have a 5 mm pitch mounted towards connection side of condensate drainage and 0-2 mm towards unit front side (refer to Fig.
Page 34 Safety and User Instructions Flex-Geko Fan Coil Unit The unit can be secured vertically or suspended on the wall. With suspended units without feet at least four mounting elements are needed – (on both side on top and bottom) With upright units with feet two mounting elements are sufficient (on both top –...
Page 35 Flex-Geko Fan Coil Unit Safety and User Instructions * Space need for field-provided piping on site ** only with frontal air intake Fig. 4-5: Sizes and mounting dimensions of the Flex-Geko with ceiling installation Model size Width w [mm] 1010 1160 1310 1460...
Page 36: Installing Mixed-Air Units On The Wall With Fresh Air Intake From The Rear
Wall installation without air intake sound attenuator See „Installation on wall/stand-alone on floor“ on page 33 and 39. NOTICE! We recommend DencoHappel accessories for fresh air connection (see Fig. 4- 6) for reasons of size compatibility). 4.6.2 Wall opening for units with air intake sound attenuators Fig.
Page 37 Flex-Geko Fan Coil Unit Safety and User Instructions 4.6.3 Installing air intake sound attenuator Installing air intake sound attenuator The air intake sound attenuator is fitted on the wall in an upright position. Keyholes are provided on the side of the rear panel for securing the air intake sound attenuator (2 for each side, refer to Fig.
Page 38: Intake From The Rear
Safety and User Instructions Flex-Geko Fan Coil Unit Installing stand-alone mixed-air units on the wall with fresh air intake from the rear 4.7.1 Floor opening To avoid draughts, the size of floor openings and air intake connectors must be matched exactly. Besides, the connecting surfaces must be sealed. NOTICE! When using the weather protection grille, the opening can be made as shown in Fig.
Page 39: Above (Vertical)
Pos. 5: Fig. 4-12: Fresh air intake design Installation on ceiling: See „Installation on ceiling“ on page 34 NOTICE! We recommend DencoHappel accessories for fresh air connection (see Fig. 4- 12) for reasons of size compatibility. Model size Width d [mm]...
Page 40: Setting Mixed-Air Rate
Spring return of the servo-motor switches the unit over to only recirculating air mode. If the DencoHappel MATRIX controller is used, the heating valve is opened, the fan is switched off and the extract fan is disabled.
Page 41: Installing Unit Casing
Flex-Geko Fan Coil Unit Safety and User Instructions 4.11 Installing unit casing NOTICE! Do not mount the casing if there is other outstanding installation or commission- ing that has to be carried out on the unit. NOTICE! In units where the casing is supplied separately or if the casing is mounted on units subsequently, the mounting hooks (refer to Fig.
Page 42 Safety and User Instructions Flex-Geko Fan Coil Unit You have the following possibilities to balance the slope with cooling units: - Wall installation: Secure the spacer ring (refer to Fig. 4-14, Pos. 3) between basic unit (refer to Fig. 4-14, Pos. 4) and unit casing (refer to Fig.
Page 43: Mounting Field-Provided Ductwork
Flex-Geko Fan Coil Unit Safety and User Instructions 4.12 Mounting field-provided ductwork Ductwork by others can be connected woth the basic unit in the following way: 4.12.1 Mounting field-provided ductwork on the discharge side Ductwork by others can only be mounted on the discharge side of basic units with direction of airflow "A"...
Page 44 Safety and User Instructions Flex-Geko Fan Coil Unit 4.12.3 Mounting field-provided ductwork on the intake side (mixed-air units) In units with an air-mixing facility ductwork by others can only be connected directly to the intake fitting for outside air. For dimensions see Fig. 4-17 Fig.
Page 45: Hydraulic Connection
Flex-Geko Fan Coil Unit Safety and User Instructions Hydraulic Connection General If units are not fitted with valves or have been fitted with valves on-site by others, the installation of the supply and return lines depends on how the on-site medium connections are run and/or the valve types used.
Page 46: Overview Of Valves
Safety and User Instructions Flex-Geko Fan Coil Unit Overview of valves Various circuit configurations can be used for the supply of both heating and cool- ing medium. The only exception is presented by the thermostatic expansion valve fitted in the direct expansion coil. NOTICE! The correct direction of medium flow is marked on the valves by an arrow and/ or a letter.
Page 47 Flex-Geko Fan Coil Unit Safety and User Instructions 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 performed via a distributor circuit (refer to Fig. 5-3). Fig. 5-3: 3-way valves with thermoelectric actuator With a 2-way valve control is carried out by throttling the medium supply (refer to Fig.
Page 48 Safety and User Instructions Flex-Geko Fan Coil Unit Shut-off valve The shut off valve is used to limit or shut off the medium flow (refer to Fig. 5-6). Fig. 5-6: Shut-off valve Ball valve The ball trap is used to limit or shut off the medium flow (refer to Fig. 5-7). Fig.
Page 49: Heating And Cooling Connections For Units Without Valves Or With On-Site Valves Provided By Others
Flex-Geko Fan Coil Unit Safety and User Instructions Heating and cooling connections for units without valves or with on-site valves provided by others 5.3.1 Mounting connections DAMAGE TO THE UNIT! During installation, the connecting nut on the heat exchanger must be countered using a suitable tool.
Page 50: Heating And Cooling Connections For Units With Factory Mounted
Safety and User Instructions Flex-Geko Fan Coil Unit Heating and cooling connections for units with factory mounted valves 5.4.1 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. DAMAGE TO THE UNIT! During installation, the connecting nut on the heat exchanger must be coun- tered using a suitable tool.
Page 51 Flex-Geko Fan Coil Unit Safety and User Instructions 5.4.2 Medium connection in a 2-pipe system Wall and ceiling unit, 2-way valve Wall unit Ceiling unit Fig. 5-10: Wall and ceiling unit, piping connection in a 2-pipe system Wall and ceiling unit, 3-way valve Wall unit Ceiling unit Fig.
Page 52 Safety and User Instructions Flex-Geko Fan Coil Unit 5.4.3 Medium connection in a 4-pipe system Wall and ceiling unit, 2-way valve Wall unit Ceiling unit Fig. 5-12: Wall and ceiling unit, piping connection in a 4-pipe system Wall and ceiling unit, 3-way valve Wall unit Ceiling unit Fig.
Page 53: Coil Connections With Units Fitted With Dx Evaporator (Refrigerant)
Flex-Geko Fan Coil Unit Safety and User Instructions Coil connections with units fitted with DX evaporator (refrigerant) 5.5.1 Mounting connections PERSONAL INJURY! Risk posed by a refrigeration unit: Ensure that only specialised personnel can access the unit (e.g. refrigeration engineer). REFRIGERATION SYSTEM! For all jobs on the direct evaporator ensure that all relevant codes and reg- ulations like DIN norms, VDI guidelines, VDMA codes as well as country-spe-...
Page 54 Safety and User Instructions Flex-Geko Fan Coil Unit 5.5.2 Coil connections with 2-pipe system (refrigerant cooling) Without expansion valve Wall unit Ceiling unit Fig. 5-14: Wall and ceiling unit, 2-pipe system, without expansion valve, refrigerant connections With expansion valve Wall unit Ceiling unit Fig.
Page 55 Flex-Geko Fan Coil Unit Safety and User Instructions 5.5.3 Coil connections with 4-pipe system (refrigerant cooling, warm water heating) Heat exchanger connections for warm water circuit are performed with 1/2" inter- nal screw thread with a flat gasket. The position of supply and return lines depends on the field-provided valve type and pipework.
Page 56 Safety and User Instructions Flex-Geko Fan Coil Unit 5.5.4 Coil connections with 4-pipe system (refrigerant cooling, warm water heating) Without expansion valve/with 2-way heating valve Wall unit Ceiling unit Fig. 5-18: Wall and ceiling unit, 4-pipe system, without expansion valve, with 2-way heating valve, refrigerant and heating circuit connections Without expansion valve/with 3-way heating valve Wall unit...
Page 57 Flex-Geko Fan Coil Unit Safety and User Instructions With expansion valve/with 2-way heating valve Wall unit Ceiling unit Fig. 5-20: Wall and ceiling unit, 4-pipe system, with expansion valve, with 2-way heating valve, refrigerant and heating circuit connections With expansion valve/with 3-way heating valve Wall unit Ceiling unit Fig.
Page 58: Connecting Condensate Drain
Safety and User Instructions Flex-Geko Fan Coil Unit Connecting condensate drain In order for the condensate to be drained off properly, the condensate drain by others must be connected to the lateral drain pan. • Condensate drain line must be run with a slope. •...
Page 59: Connecting Condensate Pump
Flex-Geko Fan Coil Unit Safety and User Instructions Drain connection of the main drain Pos. 1: Ceiling unit Positions of fixing screws Pos. 2: Auxiliary drain pan Pos. 3: Drain connection of auxiliary drain Pos. 4: pan (diameter 20 mm, length l = 25 Screws (2 pieces) for securing Pos.
Page 60 Safety and User Instructions Flex-Geko Fan Coil Unit 5.7.1 Connecting condensate pump (wall units) Connect the end of the condensate pump pressure hose to the field-provided con- densate drainage pipework (see Fig. 5-25, Pos. 3) with consideration of instruc- tions specified in section 5.7. Condensate pump Pos.
Page 61 Flex-Geko Fan Coil Unit Safety and User Instructions Mounting of the auxiliary drain pan for ceiling units with condensate pump. • Apply some grease on the drain connection of the main drain pan of the basic unit (see Fig. 5-23, Pos. 1) and insert the auxiliary drain pan as far as possible. •...
Page 62: Electrical Connection
Safety and User Instructions Flex-Geko Fan Coil Unit Electrical Connection DANGER OF ELECTRICAL CURRENT! The electrical installation of the fan coil unit may only be carried out by qualified licensed electricians in observance of this operation manual and the following regulations: VDE regulations, including safety regulations –...
Page 63: Fan Speed
Flex-Geko Fan Coil Unit Safety and User Instructions Plastic terminal box Metal sheet electric control box Fig. 6-1: Open terminal box / electrical control box Fan Speed 6.3.1 3-speed motor The fan motor is fitted with three controllable speeds set by the manufacturer (see unit-specific wiring diagram).
Page 64 Safety and User Instructions Flex-Geko Fan Coil Unit wired to undocumented terminals. In such a way it is possible to assign different RPM combinations to the three speed stages (see Tab. 6-3). NOTICE! The factory performed assignment of the terminals depends on the speed com- bination selected by the customer.
Page 65 Flex-Geko Fan Coil Unit Safety and User Instructions 6.3.3 Fan with series resistor (stand-alone unit) DAMAGE TO THE UNIT! For units fitted with an electric heater or DX evaporator the factory-set speed must not be changed! A series resistor is used for speed control of fan motors. Three fixed speed stages are pre-set by the factory using the series resistor.
Page 66 Safety and User Instructions Flex-Geko Fan Coil Unit NOTICE! The clearance between adjustable clips should amount to at least 10 mm. The following setting limits apply to the 3 possible series resistor types (see Tab. 6- ΔR (between clips) Resistance type [Ω] [Ω] [Ω]...
Page 67: Connection With Controls By Others
Flex-Geko Fan Coil Unit Safety and User Instructions 6.3.4 Fan with EC motors The EC motor has continuously variable speed control. For this purpose a 0-10 V control signal is required. An alarm signal can be tapped off as a grounded signal. DAMAGE TO THE UNIT! If multiple motors are installed in one unit, alarm signals must be tapped off for each motor separately if a control system provided on-site is used.
Page 68 Safety and User Instructions Flex-Geko Fan Coil Unit HAZARDOUS VOLTAGE! Controllers may only be installed in units with casing that are installed with a rear side towards wall or ceiling. The installer must ensure that interfering with controllers or contacting basic insulation of wiring is prevented. •...
Page 69 Flex-Geko Fan Coil Unit Safety and User Instructions Connecting multiple Flex-Geko units with relay PCB Fan control (terminal 110/1 = speed Pos. 1: 111/2 = speed 2; 112/3 = speed 3) Power supply 230 V AC; Pos. 2: fusing by others max. 6 A Connecting terminals for valves Pos.
Page 70 Safety and User Instructions Flex-Geko Fan Coil Unit Model size Number of motors Tab. 6-5: Number of motors Only connecting terminals for motor(s) are shown. Refer to the unit-specific wiring diagram for wiring other connecting terminals. If a unit is fitted with one motor, an alarm signal is conducted to the terminals 11.1.
Page 71: Overview Of Dencohappel Matrix Control Electronics
Flex-Geko Fan Coil Unit Safety and User Instructions Overview of DencoHappel MATRIX control electronics The MATRIX control electronics are built into the electrical control box. The following table illustrates dif- ferent controller circuit boards. In order to enable necessary con-...
Page 72: Mounting Control Panel
Safety and User Instructions Flex-Geko Fan Coil Unit Mounting control panel All IP20 control panels have an integrated room temperature sensor. The latter can be used when the control panel is mounted at an optimum indoor location for regulating temperature. All IP54 control panels are supplied with a separate exter- nal room temperature sensor.
Page 73 Flex-Geko Fan Coil Unit Safety and User Instructions 6.6.1 Mounting control panel on Flex-Geko NOTICE! Completely assembled control panel can be mounted on the basic unit. The fol- lowing installation manual is only valid for a subsequent retrofitting of a control panel.For this purpose an additional room or return air sensor is required.
Page 74 Safety and User Instructions Flex-Geko Fan Coil Unit Fig. 6-11: Connecting cable and terminal block NOTICE! Depending on the MATRIX control system, different cables types with different number of wires is used. For unit-related assignment of terminals as well as data on cable type refer to section „Electrical connection with MATRIX"...
Page 75 Flex-Geko Fan Coil Unit Safety and User Instructions Fig. 6-12: Fixation of the control panel Front plate of control box Pos. 1: Cable Pos. 2: Fixation sheet Pos. 3: Mounting plate of control panel Pos. 4: Front panel of control panel Pos.
Page 76: Electrical Connection With Matrix
Safety and User Instructions Flex-Geko Fan Coil Unit Electrical connection with MATRIX 6.7.1 Connecting mains supply voltage for controller MATRIX 2001 3001 4001 4001+IO Power supply 230 V AC / 50 Hz, Pos. 1: on-site fusing by others max. B 10 A Connection to first unit Pos.
Page 77 The maximum total line length must not exceed 50 m. – DencoHappel does not assume any liability in regard to meeting the require- – ments of the Declaration of Conformity if other cable types, like foil-type shielding, are used. Likewise, DencoHappel cannot make statements regarding the suitability of such cable types.
Page 78 Safety and User Instructions Flex-Geko Fan Coil Unit NOTICE! Likewise only one external room sensor or one return air sensor or only one inlet sensor per unit group and control panel can be connected. MATRIX 2001 3001 4001 4001+IO Connecting control panel – unit - other slave units Control panel MATRIX OP21 can only be connected to units equipped with MATRIX 2000.A maximum of 16 units can be connected to OP21.
Page 79 Flex-Geko Fan Coil Unit Safety and User Instructions NOTICE! Likewise only one external room sensor or one return air sensor or only one inlet sensor per unit group per control panel can be connected. MATRIX 2001 3001 4001 4001+IO Connecting master unit MATRIX 3000 – slave units MATRIX 2000 Units with MATRIX 3000 can be operated with units fitted with MATRIX 2000.
Page 80 Safety and User Instructions Flex-Geko Fan Coil Unit 6.7.3 Completing bus connection MATRIX 2001 3001 4001 4001+IO Connecting control panel – network participant When connecting control panel MATRIX OP21 to MATRIX.Net network, 2-wire bus line should be used. '& • Connect the control cables in accordance with the wiring diagram.
Page 81 Flex-Geko Fan Coil Unit Safety and User Instructions Connecting master unit with slave units If units are fitted with MATRIX 3000 controllers a 2-core bus line must be used. • Connect the control cables in accordance with the wiring diagram. Individual units can be fitted with MATRIX 3000.
Page 82 Safety and User Instructions Flex-Geko Fan Coil Unit 6.7.5 Connecting mains supply voltage for full electric heater MATRIX 2001 3001 4001 4001+IO Power supply 400 V AC / 50 Hz, fusing by others Pos. 1: max. B 20 A Connection on terminal block Pos.
Page 83 Flex-Geko Fan Coil Unit Safety and User Instructions MATRIX 2001 3001 4001 4001+IO Connecting cable (refer to notice on Page 77) Pos. 1: • Connect the inlet sensor according to the wiring diagram. • Connect the shielding of the sensor line with grounding clamps to a large ground area! Fig.
Page 84 Safety and User Instructions Flex-Geko Fan Coil Unit 6.7.9 Connecting supply-air sensor (for subsequent retrofitting) MATRIX 2001 3001 4001 4001+IO Connecting cable (refer to notice on Page 77) Pos. 1: • Connect the supply-air sensor according to the wiring diagram. Fig.
Page 85 Flex-Geko Fan Coil Unit Safety and User Instructions 6.7.11 Connecting alarm signal MATRIX 2001 3001 4001 4001+IO The controller PCB enables to tap fault messages using a floating volt free contact. The contact load at 230 V AC amounts to a maximum of 4 A ohmic / 2 A inductive. •...
Page 86 Safety and User Instructions Flex-Geko Fan Coil Unit 6.7.14 Connecting function inputs and outputs MATRIX 2001 3001 4001 4001+IO Function input can be assigned with different functions depending on the supplied control equipment. To activate the function the contact must be: closed for economy mode operation –...
Page 87: Network And Shield Connection Matrix.net (Not For Matrix 500)
This section contains information about the MATRIX.Net and the correct network setup. The MATRIX.Net is a network for connecting various components of the DencoHappel control system (network users) in one data bus. The bus enables the exchange of all information required for control and regulation between the users.
Page 88 MATRIX 3000 The group address is assigned: via the group address switch on the control panel – refer to the “Commission- – ing and Testing” section in the relevant operation manual for DencoHappel MATRIX ® control panels. – on the printed circuit board of the MATRIX 3000 controller – refer to the unit’s operation manual.
Page 89 The group address is assigned: via the group address switch on the control panel – refer to the “Commission- – ing and Testing” section in the relevant operation manual for DencoHappel ® MATRIX control panels.
Page 90 Safety and User Instructions Flex-Geko Fan Coil Unit 6.8.2 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 91 6.8.3 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 92 Safety and User Instructions Flex-Geko Fan Coil Unit 6.8.5 Line structure with branch feeder The illustration 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.
Page 93 Flex-Geko Fan Coil Unit Safety and User Instructions 6.8.6 Network set up MATRIX.Net Data transfer cable For setting up the MATRIX.Net use only data transfer cable certified according to DIN 19245 T3 and EN 50170 as twisted-pair wire with braided shield. We recommend the following data transfer cable: Total max.
Page 94 *Contains 2 wires for the voltage supply of the control panels or modules Shielding / Earthing • Install the data transfer cable (MATRIX.Net) on one side in the DencoHappel air treatment unit using shielding clips to ensure the best possible electrical contact.
Page 95: For Units With Ac Fans
Flex-Geko Fan Coil Unit Safety and User Instructions Electrical connection of DencoHappel miniature switches/relay PCB for units with AC fans The Flex-Geko units can be easily controlled using the CMS, CMT or CET switches. According to unit model the following operating modes are possible: Operating mode only heating (2-pipe system) –...
Page 96: Connecting Miniature Switches Cms And Cmt
Safety and User Instructions Flex-Geko Fan Coil Unit 6.10 Connecting miniature switches CMS and CMT 6.10.1 Unit connecting terminals for configurations with terminal block and relay PCB Unit with terminal Unit with relay PCB Fig. 6-43: Connecting terminals N-jumpers must be set by others Connect valves, if these are available in the unit configuration.
Page 97 Flex-Geko Fan Coil Unit Safety and User Instructions 6.10.2 Operating mode only heating – only cooling – heating or cooling (2-pipe system) Fig. 6-44: Manual fan control 6.10.3 Operating mode only heating (2-pipe system) CMT 2D CMT 2Z Fig. 6-45: Fan continuous mode and valve control Fan control or fan and valve control 6.10.4 Operating mode only cooling (2-pipe system)
Page 98: Connecting Miniature Switches Cet
Safety and User Instructions Flex-Geko Fan Coil Unit 6.11 Connecting miniature switches CET 6.11.1 Sensors and control inputs Room or return air sensor connection (option) or inlet sensor Connecting cable (refer to top note on Page 77) – Room or return air sensor Pos.
Page 99 Flex-Geko Fan Coil Unit Safety and User Instructions Control inputs enable or H/C-change-over Connecting cable (refer to top note on Page 77) – Input H/C change-over (instead of inlet sensor Fig. 6-49, Pos 2) Pos. 3: Presence input (absent = contact closed) Pos.
Page 100 Safety and User Instructions Flex-Geko Fan Coil Unit 6.11.2 Unit connecting terminals for configurations with terminal block and relay PCB Unit with terminal block Unit with relay PCB 3 3 L L N N N 3 3 L L N N N L PE L PE A B C...
Page 101 Flex-Geko Fan Coil Unit Safety and User Instructions 6.11.3 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 Parameter 7: SEL0 = 22 and SEL2 = Auto Parameter 8: SEL0 = 24 and SEL2 = 2 (without sensor)
Page 102 Safety and User Instructions Flex-Geko Fan Coil Unit 6.11.7 Configuration Perform configuration To change parameters proceed as follows: set button SEL0 to 10°C – set button SEL2 to position A – press both bottons SEL1 and SEL3 simultaneously for – more than 5 seconds if the LED H/C has flashed and changed red and green –...
Page 103 Flex-Geko Fan Coil Unit Safety and User Instructions Set- Description Fan speed selection switch (SEL2) rame- point (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 Continuous On/Off Continuous Continuous operation operation operation...
Page 104: Commissioning
Safety and User Instructions Flex-Geko Fan Coil Unit Commissioning HAZARDOUS VOLTAGE! Before performing any work on the unit, ensure that the unit is de-energized. Ensure that the unit is secured against subsequent switch-on at a suitable loca- tion in the area of the on-site electrical power supply. DANGER OF SCALDING! Before completing any kind of job on fan coil units: Seal off the supply of heating medium before performing work on the valves or...
Page 105: Checking The Control And Shut-Off Valves
Flex-Geko Fan Coil Unit Safety and User Instructions 7.1.2 Pre-commissioning checks: • Check that the Flex-Geko is properly secured (on the wall, ceiling or floor). • Manually check the mounting of actuators (Fig. 7-1, Pos. 1 sample). • Tighten all screw connections on medium connections (Fig. 7-1, Pos. 2). •...
Page 106 Safety and User Instructions Flex-Geko Fan Coil Unit 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 in the form of a red plas- tic nose that is placed in the relevant slots.
Page 107 Flex-Geko Fan Coil Unit Safety and User Instructions 7.2.2 Shut-off valve settings (variants) Check if shut off valves are open: • Unscrew the protective cap (Fig. 7-2, Pos. 2). • Close the valve by tightening the internal flow-control screw (Fig. 7-2, Pos. 3) using a 4 mm hex key until the stop position on the right side.
Page 108 Safety and User Instructions Flex-Geko Fan Coil Unit 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. 7-3: Flow rate diagram V9400 Pre-setting 1 1/2 values 0,07 0,13 0,22 0,32 0,43 0,65...
Page 109 Flex-Geko Fan Coil Unit Safety and User Instructions 7.2.4 Shut off valve for control valves from to 2.5 k (3/4") to 4.0 k (3/4") value for fan coil units Pre-setting Flow Rate Fig. 7-4: Flow rate diagram V9441 Pre-setting 1 1/2 2 1/2 values Tab.
Page 110: Vent The Unit
Safety and User Instructions Flex-Geko Fan Coil Unit Vent the unit This checkpoint is only relevant for units equipped with an electric heater or DX evaporator. 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.
Page 111: Checking The Condensate Drain
Flex-Geko Fan Coil Unit Safety and User Instructions Checking the condensate drain This checkpoint only applies to cooling units without condensate pump! Condensate forms as a result of unit operation in cooling mode, the same applies to non-insulated pipes. ‚Ä¢Check that the connection of the lateral wall or ceiling drain pan (Fig. 7-6, Pos. 1 or Fig.
Page 112: Terminating Resistors
Safety and User Instructions Flex-Geko Fan Coil Unit Terminating resistors MATRIX 2001 3001 4001 4001+IO Unit printed circuit boards of the MATRIX 2000 control system are not equipped with terminating resistors. Terminating resistors of the MATRIX OP21 control panel have to be switched on or off only if this network is established with other unit groups or additional mod- ules, such as a clock module, or to input and output modules through the MATRIX.Net.
Page 113 Flex-Geko Fan Coil Unit Safety and User Instructions MATRIX 2001 3001 4001 4001+IO Unit printed circuit boards of the MATRIX 3000 control system and MATRIX OP3X/44/5X control panels are equipped with terminating resistors. Terminating resistors are placed at line start and end (Fig. 7-9): •...
Page 114: Setting Address
Safety and User Instructions Flex-Geko Fan Coil Unit Setting address MATRIX 2001 3001 4001 4001+IO The unit PCBs of the MATRIX 2000 control system are not fitted with address selection switches. The relevant group address must be assigned on the control panel. Single group (without networking multiple unit groups) •...
Page 115 Flex-Geko Fan Coil Unit Safety and User Instructions MATRIX 2001 3001 4001 4001+IO The corresponding group address must be assigned to the control panels and units in a group. Single group (without networking multiple unit groups) • On the control panel, set the address “0” (manufacturer's default setting). •...
Page 116: Setting Limitation Functions
Safety and User Instructions Flex-Geko Fan Coil Unit Setting limitation functions MATRIX 2001 3001 4001 4001+IO 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: –...
Page 117 Flex-Geko Fan Coil Unit Safety and User Instructions Minimum heating limitation (rigid): The set minimum temperature value is maintained (value does not fall below limit). Advantage: Air draughts are largely avoided. – Disadvantage: The room can become slightly overheated, particularly if the –...
Page 118: Switch On Unit
Safety and User Instructions Flex-Geko Fan Coil Unit Switch on unit HAZARDOUS VOLTAGE! The electrical control box is open. Direct interventions in the electrical control box are not permitted! Before completing work on the air treatment unit, ensure that the electrical con- trol box is properly closed (refer to ""...
Page 119: Checking Data Connection
Flex-Geko Fan Coil Unit Safety and User Instructions Checking data connection HAZARDOUS VOLTAGE! Before correcting an error in the data connection, de-energize and isolate the entire facility. Ensure that the unit is properly secured against subsequent switch-on at an appropriate point of the on-site power supply. 7.9.1 Checking control cables MATRIX 2001...
Page 120: Checking Control Inputs And Outputs
Safety and User Instructions Flex-Geko Fan Coil Unit 7.10 Checking control inputs and outputs The MATRIX 500/3000/4000 control systems are fitted with inputs and/or out- puts.Consider the factory-performed configuration for checking control inputs and outputs.Refer to the unit connection diagram (attached to the connection box) for the relevant controller function.
Page 121: Checking Electric Heater (Only Or Units With Electric Heating)
Flex-Geko Fan Coil Unit Safety and User Instructions 7.10.2 Operating programs MATRIX 2001 3001 4001 4001+IO Using 4 additional inputs and 2 outputs the following operating programmes can be activated: Procedure for activating „normal mode“: • Switch the unit on. •...
Page 122: Checking Frost Protection (Only With Mixed-Air Units)
Safety and User Instructions Flex-Geko Fan Coil Unit 7.12 Checking frost protection (only with mixed-air units) Units with a connection for outside air are fitted with a frost protection thermostat that cuts off power supply to the motor actuator of the outside air damper, if the temperature falls below 5 °C.
Page 123 Flex-Geko Fan Coil Unit Safety and User Instructions 7.13.1 Checking condensate pump with wall and ceiling units Condensate forms as a result of unit operation in cooling mode, the same applies to non-insulated pipes. • Check that, that the coil drip tray is properly secured and stable. –...
Page 124: Dencohappel Matrix Functions
Safety and User Instructions Flex-Geko Fan Coil Unit 7.14 DencoHappel MATRIX functions 7.14.1 Fans with MATRIX 2001 to 4001 MATRIX 2001 3001 4001 4001+IO Fan control depends on the configured control type and selected operating mode on the control panel. The following fan modes can be set: Manual fan control –...
Page 125 Standby mode is only available with room temperature control option. This does not regulate the temperature to a fixed setpoint, but instead to a pre-set setpoint range. The DencoHappel MATRIX.PC service software enables to change this setpoint. The standby mode is activated if a room temperature sensor is connected but no room temperature setpoint, i.e.
Page 126 Safety and User Instructions Flex-Geko Fan Coil Unit 7.14.6 Indoor Anti-Freeze Protection MATRIX 2001 3001 4001 4001+IO NOTICE! This note is only valid for units with a heating function. This function ensures a frost-free condition when the unit is switched off. At room temperatures <...
Page 127: Maintenance And Troubleshooting
Flex-Geko Fan Coil Unit Safety and User Instructions Maintenance and Troubleshooting NOTICE! Maintenance may only be performed by qualified licensed staff in observance of this operation manual and current regulations. WARNING: RISK OF ROTATING COMPONENTS! Risk of injury because of rotating fan! Before performing any work on the unit, ensure that the unit is de-energized.
Page 128 Safety and User Instructions Flex-Geko Fan Coil Unit List of regular maintenance work The following maintenance tasks must be performed at the indicated time inter- vals. Maintenance frequency Components Checking filter Check the air intake grille * Checking air discharge grille * Variant: checking intake sound attenuator * Checking fan and fan section * Fan section: cleaning and checking fan...
Page 129: Quarterly Maintenance
Use sales number ZGF.#A813 (G1), ZGF.#A823 (G2), ZGF.#A833 (G3) to order a DencoHappel spare filter set (5 pieces). Spare filter sets of classes G1 and G2 include 5 filter elements fitted with a plastic frame, a spare filter set of class G3 includes 5 filter hoses (for retrofitting a wire frame is required).
Page 130: Semi-Annual Maintenance
Safety and User Instructions Flex-Geko Fan Coil Unit Semi-annual maintenance 8.3.1 Cleaning air intake/discharge grille Suction grille • Clean air intake grille and remove foreign matter from the latter. Air intake grille in all variants is secured by 2 cam locks (see Fig. 8-1, Pos. 2). •...
Page 131 Flex-Geko Fan Coil Unit Safety and User Instructions 8.3.3 Cleaning fan section Unit casing has been removed (see Fig. 4- 14 - for this purpose follow all steps specified in section 4.11 in reverse order). • Disassemble the cover sheet of fan sec- tion (Fig.
Page 132: Annual Maintenance
Safety and User Instructions Flex-Geko Fan Coil Unit Annual maintenance 8.4.1 Check screw connections of medium lines Unit casing has already been removed (refer to Chapter 4.3). • Check that all screw pipework connections of medium lines are securely fixed (Fig.
Page 133 Flex-Geko Fan Coil Unit Safety and User Instructions Maintenance for a ceiling unit should be performed in an analogous way. • Remove the cover plate of the fan chamber (see Fig. 8-4, Pos. 1, 1 screw per each right and left side) or remove the filter with front-side intake (see Fig. 8- 2, Pos.
Page 134: Checking Heat Exchanger And Main Drain Pan For Dirt
Safety and User Instructions Flex-Geko Fan Coil Unit 8.4.3 Checking heat exchanger and main drain pan for dirt/mould and, if necessary, cleaning and disinfecting PERSONAL INJURY! Always wear protective gloves to prevent injury caused by sharp edges! In order to meet the hygienic requirements (VDI 6022, SWKI VA 104-01) the heat exchanger and main drain pan must be checked for dirt and mould and, if required, cleaned and disinfected.
Page 135 Flex-Geko Fan Coil Unit Safety and User Instructions tilt the small additional tray upwards Pos. 1: Push in the small additional tray in- Pos. 2: wards into the unit Fig. 8-9: Push in the small additional tray inwards • Remove the cover plate of the heat exchanger (see Fig. 8-10, Pos. 3, 2 screws on each right and left side) •...
Page 136: Checking Internal Insulation For Dirt And Mould And, If
Safety and User Instructions Flex-Geko Fan Coil Unit 8.4.4 Checking internal insulation for dirt and mould and, if necessary, cleaning and disinfecting In order to meet the hygienic requirements (VDI 6022, SWKI VA 104-01) internal unit insulation must be checked for dirt and mould and, if required, cleaned and disinfected.
Page 137 Flex-Geko Fan Coil Unit Safety and User Instructions 8.4.7 Cleaning coil drip tray This section is not relevant for only heating units or units with electric heater. Unit casing has already been removed (refer to Chapter 4.3). • Clean the lateral condensate pan (Fig. 8-11, Pos. 1). •...
Page 138: Before Cooling Season
Safety and User Instructions Flex-Geko Fan Coil Unit Before cooling season 8.5.1 Cleaning humidity sensors Only applicable to units with an integrated condensate pump. Unit casing has already been removed (refer to Chapter 4.3). NOTICE! Protect the humidity sensors from dust and aggressive liquids. Never use hard/sharp tools or aggressive detergents to clean contact surfaces.
Page 139: Break-Downs
Flex-Geko Fan Coil Unit Safety and User Instructions 8.5.2 Checking condensate pump Only applicable to units with an integrated condensate pump. Unit casing has already been removed (refer to Chapter 4.3). • Check proper operation of condensate pump as specified in Chapter 7.13. •...
Page 140: Before Heating Season
Safety and User Instructions Flex-Geko Fan Coil Unit Before heating season 8.6.1 Checking antifreeze agent This section is not relevant for units with only electric heater. Unit casing has already been removed (refer to Chapter 4.3). HAZARDOUS VOLTAGE! Risk of escaping splash water. Protect electrical devices and furniture from es- caping splash water.
Page 141: Troubleshooting
Flex-Geko Fan Coil Unit Safety and User Instructions Troubleshooting Deviations from normal operating conditions of fan coil units testify to malfunc- tions 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: Fault Possible Cause...
Page 142 Safety and User Instructions Flex-Geko Fan Coil Unit Fault Possible Cause Action/remedy Unit fails to heat/heats Very low setpoint temperature selected Increase setpoint temperature on con- insufficiently on control panel/miniature switch trol panel/miniature switch (pumped warm water) Control panel/miniature switch or sen- Place control panel/miniature switch or sor is located above a heat source or sensor in proper position (technical per-...
Page 143 Flex-Geko Fan Coil Unit Safety and User Instructions Fault Possible Cause Action/remedy Unit does not cool/cools Water flow rate too low Check pump capacity insufficiently (chilled (technical personnel only) water) Check pipe run balance and adjust us- ing calculated pressure drop (technical personnel only) Very high setpoint temperature set on Decrease setpoint temperature on con-...
Page 144 Safety and User Instructions Flex-Geko Fan Coil Unit Fault Possible Cause Action/remedy Controller switches on Control panel/miniature switch or sen- Fit control panel or miniature switch in continuously sor fitted in improper location (e.g. adja- proper location where room tempera- cent to an open door or close to Flex- ture can be measured representatively Geko discharge grille)
Page 145 Flex-Geko Fan Coil Unit Safety and User Instructions Fault Possible Cause Action/remedy Condensate pump Condensate pump does Pump fuse is faulty Replace fuse (technical personnel only) not run Pump humidity sensor is faulty Replace humidity sensor (techn. person) Pump thermal contact is faulty Replace pump ( technical personnel only ) Pump coil is faulty Replace pump ( technical personnel only )
Page 146: Declaration Of Conformity
EC Declaration of Conformity pursuant to Directive 2006/42/EC of the European Parliament and of the Council (original EC Declaration of Conformity) Manufacturer: D encoHappel CZ a.s., Slovanská 781, 463 12 Liberec XXV-Vesec, Czech Republic, ID No.: 46708375 Entity authorized to compile technical documentation: D encoHappel CZ a.s., Slovanská...
Page 147 Flex-Geko Fan Coil Unit Safety and User Instructions PR-2011-0115-GB • Subject to modifications • R4-12/2015...
Page 148 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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DencoHappel ZGF.1E series Operation Manual

2 Technical Description

3 Shipping and Storage

4 Assembly

5 Hydraulic Connection

6 Electrical Connection

7 Commissioning

8 Maintenance and Troubleshooting

9 Declaration of Conformity

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