DencoHappel ZGF.1E series Manual de usuario

OPERATION MANUAL

Decentral Systems Comfort - Fan Coil Units

Flex-Geko®

Flexible Solutions for all Demands

Table of Contents Flex-Geko Fan Coil Unit

2PR-2011-0115-GB • Subject to modifications • R4-12/2015

1 Safety and User Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.1 Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.2 Safety instructions: warning and danger symbols . . . . . . . . . . . . . . . . . . . .5

1.3 Safety-conscious work procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.4 Personnel selection and qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.5 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.6 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.7 Safety regulations and codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.8 Modifications and changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.9 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.10 Selection and qualification of personnel . . . . . . . . . . . . . . . . . . . . . . . . . .9

2 Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.1 Components of the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.2 Material specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.3 Range of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.3.1 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.4 Unit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

2.4.1 Condensate pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

2.4.2 Air side accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

3 Shipping and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

3.1 Transport safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

3.2 Packaged content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

3.3 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

3.4 Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

3.5 Temporary storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

3.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

4.1 Installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

4.1.1 Recommended service opening for maintenance work on the

basic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

4.1.2 Removing unit casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

4.1.3 Pre-installation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

4.2 Unit mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

4.3 Installing mixed-air units on the wall with fresh air intake from the rear . . .36

4.3.1 Installing stand-alone mixed-air units on the wall with fresh air

intake from the rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

4.3.2 Installing mixed-air units on the ceiling with fresh air intake from

above (vertical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

4.4 Installing mixed-air units on the ceiling with fresh air intake

from rear (horizontal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Flex-Geko Fan Coil Unit Table of Contents

PR-2011-0115-GB • Subject to modifications • R4-12/2015 3

4.5 Setting mixed-air rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

4.6 Installing unit casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

4.7 Mounting field-provided ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5 Hydraulic Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

5.1.1 Overview of valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

5.1.2 Heating and cooling connections for units without valves or with

on-site valves provided by others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

5.1.3 Heating and cooling connections for units with factory mounted

valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

5.1.4 Coil connections with units fitted with DX evaporator (refrigerant) . .53

5.1.5 Connecting condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

5.2 Connecting condensate pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

6 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

6.1 Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

6.2 Terminal box or electrical control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

6.3 Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

6.4 Connection with controls by others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

6.4.1 Overview of DencoHappel MATRIX control electronics . . . . . . . . . .71

6.4.2 Mounting control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

6.4.3 Electrical connection with MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . .76

6.4.4 Network and shield connection MATRIX.Net (not for MATRIX 500) . 87

6.4.5 Electrical connection of DencoHappel miniature switches/relay PCB

for units with AC fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

6.5 Connecting miniature switches CMS and CMT . . . . . . . . . . . . . . . . . . . . . .96

6.6 Connecting miniature switches CET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Table of Contents Flex-Geko Fan Coil Unit

4PR-2011-0115-GB • Subject to modifications • R4-12/2015

7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

7.1 Safety check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

7.2 Checking the control and shut-off valves . . . . . . . . . . . . . . . . . . . . . . . . . . .105

7.2.1 Vent the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

7.2.2 Checking the condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

7.3 Terminating resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

7.3.1 Setting address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

7.4 Setting limitation functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

7.4.1 Switch on unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118

7.4.2 Checking data connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

7.4.3 Checking control inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . .120

7.5 Checking electric heater (only or units with electric heating) . . . . . . . . . . . .121

7.5.1 Checking frost protection (only with mixed-air units) . . . . . . . . . . . . .122

7.6 Checking condensate pump (applies only to cooling units

with condensate pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122

7.6.1 DencoHappel MATRIX functions . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

8 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

8.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

8.1.1 Quarterly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

8.1.2 Semi-annual maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

8.1.3 Annual maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132

8.1.4 Before cooling season . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

8.2 Before heating season . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

8.2.1 Break-downs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

8.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

9 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Flex-Geko Fan Coil Unit Safety and User Instructions

PR-2011-0115-GB • Subject to modifications • R4-12/2015 5

1 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.

The Flex-Geko fancoil unitsare reliable in operation and satisfystrictqualitystan-

dards. Future-oriented technology and pronounced operator and maintenance

friendliness were combined in this product series.

Nevertheless, all fan coil units could pose unavoidable residual risk of injury or

risk of equipment or property-damage only accidents. Therefore your personal

safety and the proper operation of the unitdepend on the strict observance of the

safety instructions. Failure to follow the safety precautions could result in death,

serious injury, environmental damage and/or considerable property damage.

Observing the safety instructions in the current operation manual will help avoid

the risks, ensure economical operation of the unit and let you enjoy the full bene-

fits of the product. The safety aspects covered by this chapter are valid for the

entire operation manual.

1.1 Symbols used

The following symbols are used to highlight particular text sections:

–This symbol is used to indicate lists.

•This symbol indicates handling instructions.

9This symbol indicates the result of an action.

1.2 Safety instructions: warning and danger symbols

Allinformationinthischapter is importantand relevantfor your safety.That is why

not all of the information contained in the present chapter is labelled with special

danger pictograms.

In subsequent chapters of this manual, warning notes are indicated by picto-

grams. General safety instructions are listed at the beginning of the respective

chapter and special safety instructions on specific jobs are listed along with the

respective steps. The following warnings are used:

USER INSTRUCTIONS

User instructions provide optimal, efficient and environmentally friendly meth-

ods for using and handling the units.

RECYCLING

This symbol is used to highlight instructions on proper reuse of packaging ma-

terial and disused components (separated according to recyclable materials,

e.g. metal, plastic, etc.).

Safety and User Instructions Flex-Geko Fan Coil Unit

6PR-2011-0115-GB • Subject to modifications • R4-12/2015

1.3 Safety-conscious work procedures

To ensure your own safety consider the following safety instructions:

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.

WARNING: RISK OF ROTATING COMPONENTS!

This symbol indicates a hazardous location with a risk of personal injury includ-

ing death and material damage.This symbol indicates a hazardous location

with a risk of personal injury including death and material damage.

DANGER DUE TO OVERHEAD LOADS!

This symbol indicates a hazardous location with a risk of personal injury includ-

ing death and material damage.This symbol indicates a hazardous location

with a risk of personal injury including death and material damage.

PERSONAL INJURY!

This symbol indicates (different from the above-mentioned danger types) a

hazardous location with a risk of personal injury including death and material

damage.

DAMAGE TO THE UNIT!

This symbol indicates a hazardous location with a risk of material damage that

can also lead to personal injury.

ENVIRONMENTAL DAMAGE!

This symbol warns about damage to the environment.

HAZARDOUS VOLTAGE!

Before carrying out any jobs on the unit, power the unit down to prevent injury

from electrical current. Ensure that the unit is secured against being energised

again at an appropriate point of the on-site power supply.

DANGER OF SCALDING!

Before performing work on the valves or the inlet or outlet pipes, seal off the

heating or cooling medium inlet to prevent scalding. Commence work only after

the heating medium has cooled down.

WARNING: RISK OF ROTATING COMPONENTS!

The rotating fanwheel poses a risk of injury!Beforeperformingany work on the

unit, ensure that the unit is de-energized. Ensure that the unit is secured

against being switched on again at an appropriate point of the on-site power

supply.

Flex-Geko Fan Coil Unit Safety and User Instructions

PR-2011-0115-GB • Subject to modifications • R4-12/2015 7

The following accident prevention regulations apply (VBG1, BGV A2 (previously:

VBG4), VBG7w, VBG9a) and generally recognized codes for machinery and prin-

ciples of engineering, particularly DIN VDE 0100, DIN VDE 0105.

1.4 Personnel selection and qualification

The unit may be installed, operated and maintained only by qualified, specially

trained and authorized staff. The following tasks described in the operation man-

ual may only be performed by qualified personnel:

–Shipping and storage

–Assembly

–Hydraulic Connection

–Electrical connection

–Commissioning

–Maintenance

1.4.1 Chiller

Units that are equipped witha direct evaporator are considered as a refrigeration

system in technical terms.

1.5 Proper use

Fan coil units of the Flex-Geko series are exclusively designed for ventilating,

heating, filtering and cooling purposes. As medium water, water/glycol solution

(max. 50 %) or different refrigerants (direct evaporator) may be used.

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.

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-

cific accident prevention regulations are adhered to.

DAMAGE TO THE UNIT!

During the installation it must be ensured that no condensation or splash water

penetrates into electric units in case of unit/installation damage.

Safety and User Instructions Flex-Geko Fan Coil Unit

8PR-2011-0115-GB • Subject to modifications • R4-12/2015

The following limit values apply to medium for operating Cu/Al heat exchangers:

The Flex-Geko may only be operated indoors.

The Flex-Geko units are designed for wall and ceiling installation.

Parameter Unit Value

pH-value (at 20 °C) 7.5 - 9

Conductivity (at 20 °C) μS/cm < 700

Oxygen content O2mg/l < 0.1

Total hardness °dH 1 - 15

Dissolved sulphur S not detectable

Sodium Na+mg/l < 100

Iron Fe2+, Fe3+ mg/l < 0.1

Manganese Mn2+ mg/l < 0.05

Ammonium content NH4+mg/l < 0.1

Chloride Cl-mg/l < 100

Sulphate SO42- mg/l < 50

Nitrite NO2-mg/l < 50

Nitrate NO3-mg/l < 50

Tab. 1-1: Limit values for medium in closed heating and cooling circuits

EQUIPMENT DAMAGE!

In open systems (e.g. when using well water consider limit values from table

from Tab. 1-1), used water should additionally be cleansed of suspended mat-

ter using a filter to be installed at the inlet. Failure to do so could result in a risk

of erosion by suspended matter.

It must also be ensured that the unit is protected from dust and other sub-

stances that can cause acidic or alkaline reaction with water (aluminium corro-

sion).

It is not allowed to use Flex-Geko units, in particular with a cooling function, for

suction of kitchen exhaust air containing organic acids, e.g. vinegar. Besides, it

isnotallowedtousecleaningagents,containingvinegarorotherorganicacids,

to clean rooms where such units are installed due to a substantial risk of acid-

related corrosion of aluminium fins!

The unit is considered to be used inan improper manner if it is applied for other

purposes or a purpose that is not covered by the scope of the given operation

manual.The manufactureror supplier is notliablefor any resultingdamage:the

user alone bears the full risk.

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.

Flex-Geko Fan Coil Unit Safety and User Instructions

PR-2011-0115-GB • Subject to modifications • R4-12/2015 9

1.6 Improper use The Flex-Geko may not be operated:

–Outdoors

–In areas subject to explosion risk

–In wet areas

–In locations with high dust levels or aggressive air

–In open systems (e.g. well water) in combination with a supply line without a

filter

1.7 Safety regulations and codes

When carrying out installation, commissioning, maintenance and service of Flex-

Geko units, all local safety regulations and codes aswell as generally established

technical practices must be followed.

1.8 Modifications and changes

No changes, add-ons or modifications may be performed on the Flex-Geko air

treatment unit or its components.

Changes or modifications of the Flex-Geko unit will invalidate the CE conformity

and render all warranty claims null and void.

1.9 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

PERSONAL INJURY AND EQUIPMENT DAMAGE!

Improper use can cause personal injury and material damage.

NOTICE!

It must be ensured that every person working on the Flex-Geko fan coil unit has read

and understood entire operation manual. Please read this document fully before

commencing any work, and not while performing a task.

Electrical and water connections must be established by qualified licensed staff or

other individuals with proper professional training and experience in the following

areas:

– Occupational health and safety regulations

– Relevant accident prevention regulations

– Directives and recognized codes of practice

All skilled staff must be able to assess the entrusted work and be able to recognize

and avoid all associated dangers.

Safety and User Instructions Flex-Geko Fan Coil Unit

10 PR-2011-0115-GB • Subject to modifications • R4-12/2015

2 Technical Description

2.1 Components of the unit

Fig. 2-1: Unit components (depending on unit model)

1: Holding plate

2: Heat Exchanger

3: Control panel

4: Metal sheet electric control box

5: Basic casing (rear wall with lateral sheet steel panels)

6: Cover sheet at discharge on front side

7: Bottom panel at intake on front side

8: Filter element

9: Main drain pan

10: Fan with casing

11: Suction side front panel at bottom/rear intake

12: Pressure side front panel with frontal discharge

13: Pressure side front panel with top/frontal discharge

14: Mixed-air box with actuator

15: Unit foot on left side for recirculating-air unit

16: Unit foot on right side for recirculating-air unit

17: Lateral ceiling drain pan

18: Lateral wall drain pan

19: Unit casing

20: Unit foot cover, left side

21: Unit foot cover, right side

22: Suction grille

23: Front casing for front side discharge

24: Front casing for front side intake

25: Front casing for front side intake and discharge

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