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Table of Contents
Related Manuals for SystemAir HHCompact Series
Summary of Contents for SystemAir HHCompact Series
- Page 1 HHCompact Air Handling Units Installation, operation and maintance instructions...
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Page 2: Table Of Contents
HHCompact Air Handling Units Content Safety considerations 1.1 - General 1.2 - Applications 1.3 - Instruction types 1.4 - Disposal of parts/materials Transporting and lifting constructions 2.1 - General 2.2 - Transport and storage 2.3 - Roof edge protection during transport (outside installation) 2.4 - Offloading and hoisting 2.5 - Horizontal transport 2.6 - Storage... -
Page 3: General
HHCompact Air Handling Units 4.10 - Fan 4.10.1 - Plug fans 4.10.2 - Frequency converter 4.10.3 - Plug fans with built-in EC motors 4.11 - Silencer 4.12 - Lightning 4.13 - Control panel 4.14 - Installation of external sensors included 4.15 - Sensor replacement Maintenance checklist 5.1 - Checklist of check points and maintenance intervals Maintenance and operating instructions 6.1 - General 6.2 - Casing panels 6.2.1 Inside installation... -
Page 4: Applications
Where an AHU is regarded as a: instructions in this document and pay special attention to • ‘non-residential ventilation unit’ (NRVU) means a the warnings that apply to this unit. Any modifications in ventilation unit where the maximum flow rate of the the design and/or installation of the AHU that are carried ventilation unit exceeds 250 m3/h, and, where the out without prior discussion with Systemair B.V. and maximum flow rate is between 250 and 1 000 m3/h, without advance written agreement will result in the loss of the right to any warranty claims and any claim for injury the manufacturer has not declared its intended use as to personnel as a result of these modifications. being exclusively for a residential ventilation application. All work must be carried out by sufficiently trained The regulation defines two types of ventilation units. personnel. All applicable personal safety devices must be These must be placed on the market or put into service, in used to ensure safe working conditions. Safety gloves and... - Page 5 • The electrical components in the AHU must be earthed, except for components with double insulation and/or components with a supply voltage below 50 V. • The electrical components must be installed in accordance with national and local regulations. Central data This label contains the data for the AHU, such as order number, position number etc. The label is normally located on the access cover or the door of the fan assembly. If the AHU consists of several parts, each part must have a label with the required data. Systemair B.V. Zanddonkweg 7a 5144 NX Waalwijk The Netherlands HHCompact Rotating parts This pictogram indicates that there are rotating parts behind this access cover, door or panel which may cause injury. The components that include rotating parts are the fan and heat recovery wheel. If there are special customer-specific components behind doors, access covers or panels that include rotating parts and pose a potential risk, this is also indicated by this pictogram. Opening the fan door This pictogram is positioned on the outside of the door or access cover of the fan assembly. This pictogram...
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Page 6: Disposal Of Parts/Materials
Voor openen deuren, ventilator Before opening the doors, switch uitschakelen, spanningsloos off and deenergise the fan and unit are endangered. Systemair B.V. does not accept maken en uit laten lopen allow it to run down any responsibility if these instructions are not observed. (minimaal 2 minuten). -
Page 7: Offloading And Hoisting
HHCompact Air Handling Units 2.4 - Offloading and hoisting Depending on the dimensions of the AHU and the situation on site, the AHUs are supplied in previously agreed transport sections. Before proceeding with the transport and installation of the casing sections, always consult the applicable dimensional drawings that give the dimensions and weights of the sections, as well as the installation sequence. The weight is given on each transport section. Each transport section is equipped with a subframe with four lifting points. Thesepoints are marked by the label shown below. 2.6 - Storage The packaging in which the AHU is supplied can cause condensation to be formed between the packaging and the AHU, if the unit is stored in an unconditioned place. For offloading as well as hoisting lifting cables can be If the AHU is not immediately used it is recommended to attached to the lifting bars. Evenly positioned spacer bars store it in a conditioned location on-site. If the AHU is kept should be used between the lifting cables to prevent outside for a short period direct sun radiation must be damage to the top of the unit and ensure that no excess avoided. pressure is applied to the side panels. For hoisting please ensure that the weight is evenly distributed. If the fans are shut down for a longer period (longer than three months) bearing damage can occur. To prevent this it is recommended to loosen the belt tension or to temporarily remove the fan belts. When the fans are re-started the belt tension must be reset to the specified... - Page 8 HHCompact Air Handling Units HHCompact C with high-efficiency counter-flow plate heat exchanger - Sizes 0405, 0506 and 0606 Legend A. Exhaust air damper Legend B. Outdoor air intake damper 1. Actuator, outdoor air damper C. Electric pre-heater (hot water) 2. Pressure sensor, extract air fan D. Supply air filter 3. Frequency converter, extract air fan E. Extract air fan 4. Actuator, face/bypass damper, plate heat exchanger Control panel 5. Frequency converter, supply air fan Face/bypass damper 6. Pressure sensor, supply air fan...
- Page 9 HHCompact Air Handling Units HHCompact R with high-efficiency heat recovery wheel - Sizes 0606, 0707, 0808, 0909, 1010, 1111, 1212, 1412 and 1416 Legend Legend A. Exhaust air damper 1. Actuator, outdoor air damper B. Outdoor air intake damper 2. Pressure sensor, extract air fan C. Electric pre-heater (hot water) 3. Frequency converter, extract air fan D.
- Page 10 10 | HHCompact Air Handling Units HHCompact P with cross-flow plate heat exchanger - Sizes 0405, 0506, 0606, 0707, 0808, 0909 and 1010 Relay Legend Pro-Dialog control A. Outdoor air intake damper 15. Main supply connection, control panel B. Extract air damper 16. Main disconnect switch, AHU (excl. electric heater) C. Electric pre-heater (hot water) Connection terminals D. Supply air filter Reset button E. Extract air filter...
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Page 11: Checklist Of Start-Up Check Points
| 11 HHCompact Air Handling Units Checklist of start-up check points The following pages give a more detailed description of the individual components 3.1 - Checklist of start-up check points Before commissioning the unit, check all functions and CAUTION: Before starting up the AHU ensure that the associated components, using the checklist below. components have the correct connection voltage and The table shows a general overview of the operations connect them in accordance with the regulations. The required to facilitate the installation of the AHU. doors and access covers must be closed and the AHU must be earthed. Start-up check points Function Components Check points Start-up General All functions Remove obstacles and loose debris from compartment All functions Check for possible condensate and if necessary dry the parts... -
Page 12: Start-Up Instructions
12 | HHCompact Air Handling Units Start-up instructions • It is recommended to use Europrofile connections (type E30) at the corner frame as well as at the duct 4.1 - Casing to be connected. The unit data, such as order number, position number etc. is given on the nameplate. Systemair B.V. Zanddonkweg 7a 5144 NX Waalwijk HHCompact The Netherlands • Europrofile connections are available in fixed lengths and can be cut to the required length with a saw. 4.1.1 - Casing panels These profiles can easily be placed over the corner Check the AHU panels for any damage. Any dirt or stains frame. Allow for a maximum profile height of 30 mm, must be removed from the surface to prevent possible so that ducts that are positioned one above the other long-term damage. Building debris left on the roof of... -
Page 13: Duct Connections
| 13 HHCompact Air Handling Units • To be able to make two openings one above the • The combination of flexible connections and dampers, other the corner frames of the two openings have a including the installed corner frame, extends 252 different length so that there is always enough space or 292 mm beyond the external AHU dimension, as to place and attach the profiles. Using the drive slip shown in the drawing below. means that there is no need to use screws in the limited space between the two ducts that are one above the other, as shown in the drawing below. above the other, as shown in the drawing below. Legend Legend Damper Flexible connection Duct connection Duct connection • The corner frame has a length of 32 or 72 mm and (single-skin flexible connection - ± 30 mm press fit) extends 22 or 62 mm beyond the external AHU dimension, as shown in the drawing below. 4.1.6 - Outdoor air intake • Ensure that the air intake duct is correctly connected. High air velocities must be avoided, and no rain drops should get into the duct. This is prevented by installing rain protection air intake grilles (Caution:... -
Page 14: Assembly And Placement Of The Air Handling Unit
14 | HHCompact Air Handling Units • The remainder of the adapter piece needs to be 4.1.9 - Condensation in or on the AHU insulated on the outside, as shown in the drawing Condensation can form on the inside and outside of the below. AHU. This depends on the installation location (indoor or outdoor), temperature and relative humidity inside and outside the AHU and the thermal bridge factor (theTB value) of the AHU. Always select an AHU with a thermal bridge factor that will not lead to condensation at the indoor and outdoor conditions. For units installed inside the following points must be considered: • Open water collection tanks (e.g. vapour/condensate collection tank). These must always be unpressurised Legend and covered so that the relative humidity in the plant Duct connection room is minimised. -
Page 15: Dampers
| 15 HHCompact Air Handling Units Unit length: 4.3 - Air filters ATTENTION: When executing a test run of the AHU, the air intake and exhaust side may never be blocked. The fastening frame of the filter will fail if the pressure drop over the filter is excessive. • Check if the correct filters have been installed. (air direction) • Check if the filter bags have been installed correctly. 4.2 - Dampers • Set pressure switches or sensors, if used. When working on damper registers it is possible for your • Close the inspection door. fingers to become trapped. The AHU must be de- energised while cleaning the damper blades in order to prevent unexpected closing of the dampers. While connecting the cabling of the servo, the AHU must be de- energised in order to prevent the connection cables from being live. • Check if the actuator motor is installed in accordanc with the supplier’s instructions. • Check if the correct angle has been set. -
Page 16: Coils Containing Glycol
16 | HHCompact Air Handling Units • Check the connections on the dimensional drawing. values must agree with the data on the heater • Ensure that the coil has been fully purged. nameplate. • Check connections for leakage. • To ensure safe operation, the heater is equipped with • Ensure that the frost protection thermostat has been a thermostat with auto reset (80°C) and a high limit correctly connected and set up. thermostat with manual reset (128°C). • The coil can be the last or second last component in the AHU. Provide access to the frost protection CAUTION: thermostat via a field-installed inspection hatch in the • The electric heater must be connected as described supply air duct. in the technical data and shown in the connection • Ensure that the heater can supply heat to prevent diagram supplied. It is important that the required frost formation when the fan is started. machine capacities comply with the thickness of the chosen connection cable and fuses of the power grid. -
Page 17: Electric Heaters In Combination With Changeover Coil
• Check if siphon cover and ball have been correctly corresponds to a cycle ON – OFF – ON installed. • For an interval period of 50 seconds • The gauge pressure siphon supplied by Systemair B.V. • Power supply 400 V is suitable for a gauge pressure of up to 1200 Pa in • Safety margin 15% the associated section. •... -
Page 18: Dx-Coils
• Check that the siphon trap (option) has been correctly Negative pressure: installed. Ensure that there is a watertight connection H1 = maximum negative pressure in the cooler section (in mm WG) + 50 mm H2 = >1/2 x H1 at the angle bend of the condensate pan tap by using PTFE tape. Leave approximately 32 mm WITHOUT tape between the siphon casing and the connection to the pipe, as this part is sealed by the rubber ring provided. • The negative pressure siphon supplied by Systemair B.V. is suitable for a negative pressure of up to 800 Pa in the associated section. Gauge pressure: H1 = >maximum gauge pressure in the cooler section (in mm WG) + 50 mm H2 = 50 mm Pressure in kPa (100 Pa = 10 mm WG) • Check that the (negative or gauge) pressure corresponds to the siphon type installed. • The outlet of the siphon trap connected to the drain must not be under pressure. -
Page 19: Heat Recovery Wheel
| 19 HHCompact Air Handling Units specifications and the instructions of the qualified The following warning sign is shown on the panel: personnel. Rotating parts • It is not recommended to connect several DX-coils to one compressor/condensing unit. • It is best to use an infinitely variable controller for the compressor/condensing unit. If the condensing unit has infinitely variable control, one of the temperature controls in the controller can be selected. • If the condensing unit does not have infinitely variable control, set the AHU control for supply air temperature control, and connect the DX entering AHU with control temperature sensor instead of the supply air sensor. The heat recovery wheel is supplied with rotor control, The desired (room) temperature must then be included in the central control panel. The rotation monitor controlled by a separate controller at the condensing for the rotor is pre-installed and connected. - Page 20 20 | HHCompact Air Handling Units • The AHU with recirculation damper is therefore NOT belt tension or to remove the fan belts temporarily. suitable for modulating operation of the recirculation When the fans are restarted the belt tension has to damper. This is due to the non-guaranteed damper be reset to the specified value. This type of damage authority and the fan position in the AHU relative to can also be prevented by controlled rotation of the the recirculation damper. fan impeller This is recommended for direct-drive fans. AHU with control • Check if the flexible connection is correctly installed. • If used, check the pressure switch and set the correct The recirculation damper is supplied with an open/closed actuator with spring return (24 V). The control used for • pressure. the recirculation damper is an open/closed control. • Check the operation of the main switch. 4.10 - Fan CAUTION: While working on the fan the switch has to be locked open. • The warning pictograms on rotating parts, electrical Remove after voltage and opening doors are attached to the door.
- Page 21 | 21 HHCompact Air Handling Units used the thermistors must be connected to the converter. The disconnect switch is located on or near the fan section. When working on the unit the switch must be turned off and secured with a padlock. Switching off the disconnect switch must be done when the unit is not energised. Before opening the door or inspection hatch of the fan section (failure, maintenance, service) the AHU must be de-energised. Thermal motor fuse CAUTION: Motors with a power output of up to 2.2 kW Before connecting the power supply please check the (230 V/400 V) can have across-the-line starting. Motors diagrams on the next page to ensure that they agree with a power output of 3 kW (400 V/690 V) should be with the data on the motor nameplate and the data in the started with the star/delta switch. technical documentation. Connection diagrams: connection of the power supply cable and of the terminals on the terminal strip. Motor with the name plate data: 230 V/400 V - Y/Δ...
- Page 22 22 | HHCompact Air Handling Units 4.10.1 - Plug fans The frequency converter must always be correcly set to Plug fans are fans without a scroll that are directly driven suit the motor and type installed. Observe the instructions by the motor. To get the correct operating point for of the supplier of the frequency converter. this type of fan a frequency converter is required. The Special attention should be given to the following maximum frequency at which the plug fan can rotate parameters: depends on the motor/impeller assembly and should • Correct application of the general motor data normally be higher than 50 Hz. The maximum frequency - Pay special attention to the motor frequency. is given on the fan name plate. - For subsynchronous operation (lower than the network frequency) it must be set in accordance with Plug fans are equipped with a pressure measurement the motor nameplate. point in the intake cone of the fan. By measuring the - For supersynchronous operation (higher than the pressure drop between the pressure for the fan and the network frequency) it must be set for the maximum pressure in the intake cone the actual air flow can be admissible frequency of the motor/impeller assembly calculated using the following formula: V = k ·√∆p (this applies above all to plug fans.) • Operating type, square variable connection Where •...
- Page 23 | 23 HHCompact Air Handling Units To connect a single-phase 230 V or the three-phase 400 V motor the following connection diagram is applicable. ECblue Basic (_ _ _ _ _-_I_.D_._ _ _ _), (_ _ _ _ _-_I_.G_._ _ _ _) Contact rating Kontaktbelastung max AC 250 V 2 A Contact rating max. AC 250 V 2 A 24V 10V GND D1 L3/N Line voltage g rating plate Netzspannung...
- Page 24 24 | HHCompact Air Handling Units 4.11 - Silencers The duct silencer can also be used for units installed The silencers for the HHCompact are supplied separately outside. After installation they must always be insulated on a pallet as duct silencers. The duct silencer must on the outside to ensure that they are water- and be installed on site at the correct opening. For this use steamtight. The pre-installed air intake and discharge the connection profiles supplied and use the method hood (if used) must be removed first. Install the corner described in chapter in 4.1.5 - “Duct connections”. The frame, supplied separately, at the opening of the silencer, conection to the rest of the duct system can also be made before installing the silencer. Finally replace the air intake in this way, as shown in the drawing below. and discharge hood at the opening of the silencer. Here too the duct silencer must be sufficiently supported, as shown in the drawing below. Legend Duct connection Please ensure that the duct silencers are always correctly supported on the floor or suspended from the ceiling. Make sure that the following weights are taken into Legend consideration: Duct silencer Discharge hood Support (to be field-supplied) Duct silencers Unit type Weight, kg 0405...
- Page 25 | 25 HHCompact Air Handling Units • If required include alarms, release signals and similar Duct pressure sensor elements in the BMS or on the external panel. The active sensor (24 V) has a maximum measurement • Set the controller for the specific project parameters, range of up to 2500 Pa and can be set to the desired such as operating times, holidays etc. Follow the range, using jumpers. Before the sensor is used, zero instructions given in the operating instructions for the calibration must be carried out (keep the button in the “Pro Dialog AHU control”. sensor pressed for 4 seconds). It is recommended to set • The control panel is ventilated using exhaust air. To the response time to 4 seconds. ensure the air flow there is a grille in the control panel hatch. This must not be covered. • The hatch locks for the control panel must always be locked when the AHU is started. CAUTION: If the AHU includes an electric heater, the heater needs to have a separate power supply.
- Page 26 26 | HHCompact Air Handling Units This sensor (if required) is supplied separately and must 4.15 - Sensor replacement be connected to the control panel after the unit has been • If sensors are replaced, ensure that the new sensor installed. In the control diagram this sensor is shown as is the same type as the installed sensor and of a 25QT23 (QT). Systemair B.V. authorised replacement type. • Before connecting the ducts and completing the other Thermostat, cooling coil with changeover function installation procedures ensure that all sensors are still The chilled-water coil can be set by the controller to accessible for maintenance in their final location. This can be achieved by installing inspection hatches in operate as a cooling coil, or a heating coil, if warm water is available for this coil. The controller needs to know if the ducts to be connected. warm or chilled water is available. The passive thermostat supplied for this purpose must be installed on a supply water pipe after this coil. Position the thermostat in a place in the piping system where continuous flow and a temperature for the medium can be guaranteed that is independent of the control damper position. If the sensor is installed in the wrong position in the water piping, the system will not work.
- Page 27 | 27 HHCompact Air Handling Units Maintenance Checklist 5.1 - Check points and maintenance intervals WARNING: Remember to deenergise all components and The checklist contains a general overview of a planning to ensure that the fan has stopped rotating, before the that facilitates the inspections and maintenance of the doors and access covers are opened before inspections AHU. On the following pages there is a more detailed and maintenance take place. description of the individual components. Check points and maintenance intervals Depends on supplier and degree Function...
- Page 28 28 | HHCompact Air Handling Units Maintenance and Operation 6.6 - Dampers Instructions CAUTION: • When working on damper registers it is possible for 6.1 - General fingers to become trapped. The smooth inside and outside finish of the panels makes • During cleaning of the damper fins the AHU must be maintenance very simple. de-energised to prevent unexpected closing of the dampers. • During repairs to the servo, the AHU must be For dry sections: twice a year thoroughly check the inside and outside of the AHU casing. For maintenance of wet deenergised to ensure the connection cables are not sections (coolers) please refer to the air handling section live. concerned. All work must be carried out by sufficiently • Lubrication of the dampers is not required. Remove trained personnel. excess contamination by cleaning with compressed air and possible cleaning with water and a mild All applicable personal safety devices must be used...
- Page 29 | 29 HHCompact Air Handling Units • The timing of the replacement depends on the filter safety screen must protect the operator against direct quality and the degree of contamination of the air. contact. The pressure loss across the contaminated filter can be measured with a pressure differential gauge. ATTENTION: If you switch on the electric heater the fan • A respiratory protection mask, type P2 and safety must always be activated in order to prevent overheating gloves must be worn when changing the filters. of the inside of the cabinet. The fan must continue to Open flames are forbidden while changing the filters operate for a minimum of 5 minutes after switching off to prevent setting fire to the filter medium. This is the electric heater. This is necessary in order to allow the indicated by a sticker on the door or hatch. spirals to cool down. • The following label is attached to indicate a hot surface. ! Waarschuwing ! ! Warning ! Vervuilde filters zijn brandbaar. Polluted filters are inflammable. ! Attention ! ! Gefahr ! Les filtres encrassés peuvent être...
- Page 30 30 | HHCompact Air Handling Units 6.10 - Coolers 6.12 - Plate heat exchanger 6.10.1 - Chilled-water coil • The cleaning agent must not affect the heat ATTENTION: For general comments, see 4.5.1 exchanger. • Check the plate heat exchanger once a year • Dirt on the finned surface reduces the cooler capacity. for contamination and if necessary clean with • Check once a year for contamination, and if necessary compressed air against the direction of the air flow. If clean with compressed air against the direction of the dampers are used, follow the instructions in section 6.6. air flow or clean with a vacuum cleaner. Check the coil and the connections for leaks. For coils filled with • Check condensate pan for contamination and clean if glycol please check if the mixture has the correct necessary. glycol concentration (by weight). •...
- Page 31 | 31 HHCompact Air Handling Units • Avoid unnecessary stops and rapid start-ups of the fan. The warning pictograms on rotating parts, electrical voltage and opening doors are attached to the door. 6.14.3 - Transmission After starting up the unit and after replacing the belts, the belt tension must be checked within one week and then after two weeks, and further tensioned if required. After that check the belt tension and inspect the condition of the belts every three months. ! Waarschuwing ! ! Warning ! The CORRECT BELT TENSION depends on: Voor openen deuren, ventilator Before opening the doors, switch uitschakelen, spanningsloos off and deenergise the fan and •...
- Page 32 Systemair B.V. participates in the Eurovent Certification program. Products are as listed in the Eurovent Directory of Certified Products. The manufacturer reserves the right to change the specification without prior notice. Manufactured by: Systemair B.V., Waalwijk, The Netherlands.
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