INCORPORATION & INSTALLATION INSTRUCTIONS. For incorporating a heat pump control system by others

Transcription

1 HX2 DX HEAT PUMP AIR CURTAINS NO CONTROLS INCORPORATION & INSTALLATION INSTRUCTIONS For incorporating a heat pump control system by others PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE INCORPORATING CONTROLS AND CARRYING OUT THE INSTALLATION Thermoscreens Ltd. St. Mary s Road, Nuneaton, Warwickshire, UK, CV11 5AU sales@thermoscreens.com Tel: +44 (0) English T UK (DRAFT - 14 Sept 2016) Page 1 of 30

2 Thermoscreens HX2 DX Heat Pump Air Curtains No Controls CONTENTS Important Information 3 Warranty Conditions 3 Air Curtain System Schematic 4 Design Information 5 Unpacking the Air Curtain 9 Page INSTALLATION Installation of the Air Curtain 11 Figure 6 Dimensions of HX2 DX Air Curtain 12 Refrigerant Pipework 13 To gain access inside the Air Curtain 14 Electrical Supply and Wiring to the Air Curtain 15 Wiring Diagram 1, HX2-S (AC Fans) 16 Wiring Diagram 2, HX2-M (EC Fans) 17 Fitting the Optional Service Covers 18 COMMISSIONING Air Curtain Checks 19 Selecting the Fan Speeds of the HX2-S Air Curtain (AC Fans) 20 Setting the Fan Speeds of the HX2-M Air Curtain (EC Fans) 21 Starting the Heat Pump System 22 Adjusting the optional Side-Guard Airstream Vanes 23 Final Check of the Unit 24 Hand-over to End-User 24 SERVICING Weekly Vacuum Clean the Air Filters 25 6 Monthly Full Service of the Heat Pump Air Curtain 26 If the Air Curtain has seen significant condensate in the drip tray 27 Fault Finding 29 EC Declaration of Incorporation 30 T UK (DRAFT - 14 Sept 2016) Page 2 of 30

3 IMPORTANT INFORMATION This air curtain is supplied without controls to a third party who will incorporate their own heat pump control system into the air curtain. As supplied to the third party the air curtain will not function but requires the third party to incorporate controls to make it function as a heat pump air curtain. The air curtain is delivered without any heat pump system controls. All controls, internal wiring and connections for the operation of the air curtain with a manufacturer s heat pump system needs to be designed and fitted by others. Whilst we provide guidance within these instructions for how to incorporate controls, Thermoscreens Ltd. cannot be held responsible for how the heat pump system controls are incorporated into the air curtain, how they function and any safety aspects associated with the operation of the unit. The work to design and incorporate a heat pump control system into the air curtain must be done by a competent person having knowledge of refrigeration systems and heat pump control systems. This air curtain is designed for heating and ambient operation only, it is not designed for cooling. A drip tray is fitted under the DX heating coil in case of unintentional condensate formation such as with Multi-Split VRF systems where the LEV may let-by, or during a defrost cycle. Warranty conditions Thermoscreens warranty only covers the basic air curtain without controls which is: Fan motors if wired correctly by the third party. DX coil if incorporated into the heat pump system correctly by the third party. Air curtain casing, air filters and drip tray for unintentional cooling. If any problems are encountered with the heat pump air curtain please contact the Service Agent of the heat pump system first as it is more than likely the fault is with the heat pump system or with the incorporation of heat pump system controls into the basic air curtain. Care has been taken in compiling these instructions to ensure they are correct, although Thermoscreens Ltd. disclaims all liability for damage resulting from any inaccuracies and/or deficiencies in this documentation. Thermoscreens Ltd. retain the right to change the specifications stated in these instructions. Thermoscreens Ltd St. Mary s Road Nuneaton Warwickshire England CV11 5AU sales@thermoscreens.com Tel: + 44 (0) Fax: + 44 (0) T UK (DRAFT - 14 Sept 2016) Page 3 of 30

4 Thermoscreens HX2 DX Heat Pump Air Curtains No Controls (controls are supplied and fitted by others before installing on site) Figure 1 shows a typical schematic for a heat pump air curtain installation: Permanent electrical supply (from local switched spur) 1-phase electrical power alternative 1-phase electrical supply (from local switched spur) communication link LEV multisplit only Heat Pump Air Curtain Outdoor Unit BMS Control Remote 3-Speed Fan Switch (Option, if end user requires this) Remote Controller Suggested Door Switch used to change fan speeds, Door open - High; Door shut - Low Refrigeration pipework Electrical cables Control cables BMS Control Figure 1 The HX2-DX Heat Pump Air Curtain consists of :- Sheet metal casing fitted with inlet air grilles, air filters, patented discharge air diffuser, access panels and decorative plastic end caps. Fans fitted with either AC motors (HX2-S) or EC motors (HX2-M). A DX heat pump condensing (heating) coil. Condensate drip tray for unintentional cooling. IMPORTANT: The air curtain is delivered without any heat pump system controls. All controls, internal wiring and connections for the operation of the air curtain with a manufacturer s heat pump system needs to be designed and fitted by others. Whilst we provide guidance within these instructions for how to incorporate controls, Thermoscreens Ltd. cannot be held responsible for how the heat pump system controls are incorporated into the air curtain, how they function and any safety aspects associated with the operation of the unit. T UK (DRAFT - 14 Sept 2016) Page 4 of 30

5 DESIGN INFORMATION The work to design and incorporate a heat pump control system into the air curtain must be done by a competent person having knowledge of refrigeration systems and heat pump control systems. The heat pump air curtain should be seen as the indoor unit of a heat pump system. Most heat pump manufacturers have an interface controller that fits inside their indoor unit and this switches fans, measures air and coil temperatures using sensors, and on multi split systems, controls the LEV that adjusts the heat output of the air curtain. There is space inside the left hand end of the air curtain where an interface controller can be located and internal wiring and terminals can be fitted to a DIN rail, see an example of this in Figure 2 below. There is also a mounting plate that slides in and out and will accommodate a control board pcb of maximum dimensions 240mm x 150mm x 40mm, see an example of this in Figure 3 below. If this mounting plate is not the right size for the interface controller being fitted then it can be modified or you will need to manufacture your own mounting system to incorporate your interface controller. Figure 2 Figure 3 If your interface controller is too big to be fitted inside the air curtain it will have to be incorporated into its own enclosure and positioned adjacent to the left hand end of the unit. Electrical and controls wiring can then be connected to the unit during installation. There is a bracket fitted at the air inlet of one of the fans where an air inlet sensor from the heat pump control system can be located, an example of this is shown in the picture. T UK (DRAFT - 14 Sept 2016) Page 5 of 30

6 For Multi-Split systems it is normal to fit the Liquid Expansion Valve (LEV) or Electronic Expansion Valve (EEV) in the liquid line adjacent to the air curtain, see Schematic Figure 1. Do this in accordance with the instructions of the heat pump control manufacturer as they will state a maximum distance that the LEV has to be from the air curtain pipe connections. The air curtain fans operate from a 230v, 1 phase, 50Hz electrical supply (1L+N+E) and need to be connected to the fan output of the heat pump interface controller. Wiring Diagram 1 shows the electrical connections for an air curtain fitted with fan decks that have the 5 speed AC tap-wound motor (HX2-S). Wiring Diagram 2 shows the electrical and speed control connections for an air curtain fitted with EC motor fan decks (HX2-M). Air performance details for the air curtains are given in Table 1. Table 1 Air Curtain Max. Air Volume Flow Rate (m 3 /h) AC fans EC fans (HX2-S) (HX2-M) Air Curtain Parameters Maximum Noise Level AC fans EC fans (HX2-S) (HX2-M) Effective Width of Airstream (m) HX DX HX DX HX DX HX DX Air volume flow rate performance figures derived from independent testing by UK test house BSRIA in accordance with test standard ISO Noise testing carried out at Sound Research Laboratories to ISO3741 and BS See Table 6 & 7 for more details of air volume flow rates and noise levels. The DX heating coil in the heat pump air curtain is designed to be used with R410A refrigerant at a condensing temperature of 49 C. The coil has been designed for optimal performance in condensing mode (heating). Coils are manufactured from: 9.52mm (3/8inch) diameter x 0.3mm (0.012 inch) wall thickness, smooth copper tubing 0.12mm thick corrugated, uncoated aluminium fins at 2.1mm fin pitch (12 fins per inch) 2mm thick aluminium end plates Further details of the DX heating coils for each size of air curtain are given in Table 2. Table 2 Air Curtain Internal HEX Volume (cm 3 ) Finned Length Finned Height Number of Circuits Header Diameter (inch) Gas Liquid Maximum heating output (kw) (mm) (mm) HX DX /8 1/ HX DX /8 1/ HX DX /8 5/ HX DX /8 5/ Heating Outputs based on:- Indoor air temperature = 20ºC. Outdoor condition = 7/6 db/wb ºC. Performance figures derived from independent testing by UK test houses BRE and BSRIA in accordance with test standard EN All coils are 3 rows deep and 9 tubes high. Gas and Liquid header diameters are sized for the correct flow of refrigerant in and out of the individual coil circuits, these sizes are not necessarily what the site installation gas and liquid pipework sizes should be. The manufacturer of the heat pump system will advise on site installation pipework sizes. T UK (DRAFT - 14 Sept 2016) Page 6 of 30

7 Coils are thoroughly cleaned after manufacture so that no flux remains inside, chemical cleansers that contain chloride have not been used during manufacture and contamination levels are lower than the following values: Water 0.6mg/m, Oil 0.5mg/m, Solid Particles 1.8mg/m Coils are pressure tested to 40 bar during manufacture and come with a holding charge of 0.35 bar (5 PSI) Oxygen Free Nitrogen (OFN) It should be noted that during heating mode, if the outdoor unit goes into its defrost cycle during cold weather, the temperature of the discharge air from the air curtain can be low during the defrost cycle period that may occur every few hours under particular outdoor weather conditions. We recommend that the air curtain fans continue to operate however during the defrost cycle to maintain the all-important air stream across the doorway. It is this air stream, particularly towards the top of the doorway, which is so effective at stopping buoyant warm air from inside the building escaping to outside and wasting energy and also in reducing airborne contamination. The temperature of the discharge air can be low during the defrost cycle period that may occur every few hours under particular outdoor weather conditions but this has rarely become an issue with the end user and we have found it is really only a perceived problem. There are three temperature probe pockets located on the DX heating coil suitable for thermistor type sensors. Figures 4 & 5 show the location of these probe pockets. T4 sensor pocket, mid way down 1 st circuit used for some Single-Split systems hot gas sensor pocket on top of unit, for Multi-Split systems liquid line sensor pocket, for all systems Figure 5 Figure 4 This air curtain is designed for heating and ambient operation only; it is not designed for cooling. A drip tray is fitted under the DX heating coil in case of unintentional condensate formation such as during a winter defrost cycle or with Multi-Split VRF systems where the LEV may let-by in cooling during summer operation. A condensate drainage system could be considered if thought necessary for these unintentional condensate situations especially in extreme climates. T UK (DRAFT - 14 Sept 2016) Page 7 of 30

8 The condensate drip tray for unintentional condensate situations has a 15mm outlet pipe at the right hand side of the air curtain. Suitable condensate hose can be fitted to the outlet pipe (see picture) and fed through a 20mm hole at the back of the unit, see Figure 6, so condensate will gravity drain away. Means of condensate disposal must then be provided at the rear of the air curtain. If it is not practical to gravity drain from the air curtain a suitable condensate pump (not supplied with the unit) can be supplied and fitted by the installer to remove unintentional condensate directly from the unit. There is space inside the air curtain at the right hand end of the unit to mount a condensate pump. There are two 20mm condensate outlet holes in the casing, one at the top of the unit and a lower one at the rear, both fitted with rubber plugs (see Figure 6). These can be used to feed a hose from the condensate pump to a remote condensate drain. Condensate drain hose should be pushed through either of the two condensate outlet holes after removing the plug and connected to the condensate pump using the adapter supplied with the pump. It may be necessary to extend the hose if the pump is remotely located. Whether a gravity drain system or a condensate pump is used to remove the unintentional condensate there should be an alarm system with appropriate sensor fitted in the drip tray that will give an alarm signal to stop the air curtain if the condensate drip tray is in danger of flooding. There is a fixing bracket with 8mm diameter hole attached to the drip tray inside the air curtain so a condensate alarm sensor can be fixed in the tray by the installer. Hinge the drip tray down to gain better access to the fixing bracket (see picture and Section, Servicing). Enlarge the hole if necessary to suit the type of sensor being used so it is located in the tray at the appropriate position. If a condensate pump is being used see the manufacturers instructions that come with the pump for further information. In case of extreme weather conditions or blockage of the drip tray, it is vital that the design of the floor beneath the air curtain and the surface of the floor is such that it will not become slippery or damaged if it became wet. This is similar to the conditions that might be experienced with heavy rainfall in at an open doorway or wet pedestrian foot traffic, so careful consideration must be paid to the design of the floor and its surface finish. Persons using the air curtain must be given adequate instruction and supervision concerning the use of the appliance by a person responsible for their safety. The air curtain is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities. These instructions must be read in conjunction with the separate manufacturers instructions that come with the heat pump Outdoor Unit. All instructions should be kept by the building facilities manager for future reference. T UK (DRAFT - 14 Sept 2016) Page 8 of 30

9 UNPACKING THE AIR CURTAIN The following items are supplied and packaged within the air curtain box :- HX2 DX Heat Pump Air Curtain Wall Brackets and Fixing Bolts * * * * Please note, Inlet Plenum and optional Service Covers* are supplied loose to be fitted during installation for if air curtain is to be wall mounted The installer may also need to supply and/or install the following items:- Door Switch for energy efficient, noise reducing, fan speed control, Door open Higher fan speed Door shut Lower fan speed Example Switch only Optional Remote 3-Speed Fan Switch Optional from Thermoscreens Supplied by Installer Gives industry standard fan speed control see wiring diagrams for more information If remote fan speed control is required by the end user NB Industry standard is to have High/Low fan speed control via a door switch or single speed set at commissioning Service Covers Optional from Thermoscreens T UK (DRAFT - 14 Sept 2016) Page 9 of 30

10 If anything is missing or damaged please contact your place of purchase immediately. IMPORTANT This Heat Pump Air Curtain is intended only for use with a heat pump system operating on R410A. These instructions must be read in conjunction with the separate manufacturer s instructions that come with the heat pump Outdoor Unit. All instructions should be kept by the building facilities manager for future reference. (All documentation supplied with each unit should be stored and kept for future reference.) For your records: Date of Purchase.. Place of Purchase. Serial Number For warranty purposes proof of purchase is necessary so please keep a copy of your invoice. T UK (DRAFT - 14 Sept 2016) Page 10 of 30

11 B A INSTALLATION OF THE AIR CURTAIN The air curtain is designed to be surface mounted inside a building and located horizontally over a doorway. It must not be installed on the outside of the building, or built into a cabinet or recessed in anyway. Location The air curtain must be mounted so the discharge grille is up to 3.2m (AC Fans HX2-S), 3.5m (EC Fans HX2-M) maximum above floor level and as close to the doorway as possible. It must be installed level. It is recommended to leave a gap of 250mm minimum above the air curtain to allow for pipework brazing operations. Beware of doorway top edges, structural beams, door opening/closure devices, etc. which may interfere with the air stream and affect the location of the unit. Ceiling Suspension Table 3 Air Curtain D C 250mm B D 3200mm HX2-S 3500mm HX2-M Refer to Figure 6 for positions and secure M10 threaded hanging rods A (not provided) onto a suitable structure that can support the weight of the unit * (see Table 3 below). All suspension points must be used. Secure each hanging bracket B to two hanging rods A using (x4) M10 nuts and washers C, make sure bracket B is the right way around. Lift the air curtain into position and hook each bracket B into bracket D as shown and fit locking angle E. Level the air curtain using the M10 nuts. Weight (kg) HX DX 85 HX DX 125 HX DX 160 HX DX 211 If fitting Service Covers, DO NOT fit them yet! Install all services now. Fit Service Covers later. E A C Wall Fixing Refer to Figure 6 for positions and fix the Wall Brackets to the wall using suitable wall fixing bolts (not supplied) taking into account the type of wall and the weight of the unit *, see Table 3. Use all the wall brackets supplied. Suspend the air curtain from the wall brackets using short lengths of M10 threaded hanging rod A (not supplied) and the hanging bracket system B C D E as described above in section Ceiling Suspension. Level the air curtain using the M10 nuts. 250mm B A D C 3200mm HX2-S 3500mm HX2-M E * It is the sole responsibility of the installer to ensure that the building fixing locations and suspension system used are suitable for the air curtain being installed. T UK (DRAFT - 14 Sept 2016) Page 11 of 30

12 Liquid Line Refrigerant Connection (L) Gas Line Refrigerant Connection (G) Covers AIR IN Recommend 250 minimum for pipes Covers Hanging Brackets for M10 drop rods Use all drop rod holes! 90 M10 drop rods 306 AIR OUT Filter 20mm hole for gravity or pumped condensate disposal (for if there is unintentional condensate) 592 Gas Line Refrigerant Connection (G) 734 Electrical Supply and Control Wiring Inlets (M20) Liquid Line Refrigerant Connection (L) A B HX DX HX DX HX DX A (mm) F D C B (mm) C (mm) D (mm) E (mm) F (mm) in in. 5 8 in. 7 8 in. 5 8 in. 1 2 in in. 8 in. G L H 45 Hanging Brackets for M10 drop rods Use all drop rod holes! 213 M10 x4 x6 x6 x6 E HX DX Covers H (mm) 130 Weight (kg) FIGURE 6 DIMENSIONS OF HX2 DX SURFACE MOUNTED AIR CURTAIN 20mm hole on top for pumped condensate disposal (for if there is unintentional condensate) T UK (DRAFT - 14 Sept 2016) Page 12 of 30

13 Refrigerant Pipework This must be carried out before connection of any electrical and controls cables and in accordance with the Instructions that come with the heat pump outdoor unit. This work must only be undertaken by an approved refrigeration Contractor. Contact the manufacturer of the outdoor unit for recommended pipework sizes, pipework lengths, numbers of fittings, etc. The refrigerant pipework installation must be carried out in accordance with the Installation Manual that comes with the heat pump outdoor unit. Refrigerant pipe connections should be brazed to the air curtain and this must be carried out in a professional and safe manner. If installation pipe sizes for the discharge (gas) line and liquid line are different from the pipe connection sizes on the air curtain (see Figure 6) suitable pipe reducers must be used for the connection. R410A refrigerant systems can operate at pressures up to 610 psi (c. 42 Bar). These brazed joints may well be located in a public area and a weakness leading to an explosion could be extremely dangerous. For Multi-Split systems it is normal to fit the Liquid Expansion Valve (LEV) or Electronic Expansion Valve (EEV) in the liquid line adjacent to the air curtain, see Schematic Figure 1. Do this in accordance with the instructions of the heat pump controls manufacturer as they will state a maximum distance that the LEV has to be from the air curtain pipe connections. The air curtain with its DX heating coil is manufactured in accordance with the Pressure Equipment Directive (PED) and the installation must be carried out to a good standard of workmanship. Remove the protective plastic film on top of the air curtain before starting work and protect the top surface of the air curtain. Use a heat sink on the copper pipes during brazing to reduce the transfer of heat to the inside of the air curtain where sensitive components are located. T UK (DRAFT - 14 Sept 2016) Page 13 of 30

14 To gain access inside the Air Curtain Slide open the access panels underneath the unit. Remove the hexagon headed M6 screws using a 10mm nut driver. Support the bottom access panel and hinge it open. Please note: All the panels of the air curtain are covered in a protective plastic film which should now be removed. T UK (DRAFT - 14 Sept 2016) Page 14 of 30

15 Electrical Supply and Wiring to the Air Curtain This must be carried out AFTER the connection of the refrigerant pipework. All electrical wiring and connections MUST be carried out by a competent qualified electrician in accordance with the latest edition of the IEE wiring regulations and/or local statutory regulations. (see also Wiring Diagrams 1 and 2) If the air curtain needs a separate electrical supply a local isolator having a contact separation of at least 3mm on all poles must be fitted in the 1 phase electrical supply (1L + N + E) curtain and located in an accessible position adjacent to the unit. The appliance must be connected using cables having an appropriate temperature rating (heat resistant). Ensure that the supply cables, circuit breakers and other electrical installation equipment are correctly sized for the air curtain being installed. See Table 4. A 25mm size cable gland or conduit connector should be used for the Electrical Supply into the air curtain. See Figure 6 showing where the electrical supply enters the unit. This appliance must be Earthed. Table 4 Air Curtain Rated Electrical Power Input (kw) Rated Current (A) AC Fans (HX2-S) EC Fans (HX2-M) AC Fans (HX2-S) EC Fans (HX2-M) HX DX HX DX HX DX HX DX As supplied the only electrical components in the air curtain are fan motors which require a 230v, 1-phase, 50Hz electrical supply. The fan motors are wired to a loose terminal block inside the unit to help the technician integrate the fans to their heat pump control system. Wiring Diagram 1 shows how to wire to AC fans (HX2-S) if these are fitted. AC fan motors have 5 speed tappings on the motor; if there are two fan motors in the unit make sure the same speed tappings are used on both fan motors. Wiring Diagram 2 shows how to wire to EC fans (HX2-M) if these are fitted. EC fan motors are supplied with a Speed Control PCB that has 3 speed control adjusters to set the HIGH, MEDIUM and LOW fan speeds. It is possible to wire in a Door-Switch which can switch the unit between a Higher fan speed - Door Open and a Lower fan speed - Door Closed. This is both energy efficient and reduces noise levels in the building. An alternative is to use the optional Thermoscreens 3- speed fan switch to manually switch the fan speed between HIGH, MEDIUM and LOW. See Section, Commissioning; Selecting the fan speeds of the air curtain which gives details as to how the different fan motor speeds can be set to suit outdoor environmental conditions and indoor noise levels. Make sure the fan speeds selected suit the operation of the heat pump system, it is possible to set EC fans (HX2-M) to a very low speed which is unsuitable for an air curtain and could cause problems with the heat pump system. T UK (DRAFT - 14 Sept 2016) Page 15 of 30

16 Fan motor 1 1~ Blue (Neutral) Brown (High) Grey Violet Orange Red (Low) 1~ Blue (Neutral) Brown (High) Grey Violet Orange Red (Low) Fan motor 2 (2m & 2.5m unit only) White Black Blue Yellow N High Med Low N L 230V/1ph/50Hz Electrical Supply HX2-1000DX = 0.8A HX2-1500DX = 1.2A HX2-2000DX = 1.4A HX2-2500DX = 1.9A N High Med Low Carries 230v AC N Door-Switch White Black Door-Switch option:- Door Open - Higher speed Door Closed - Lower speed Blue Yellow Black, Blue & Yellow speed tappings on Fan motor 2 must be the same as on Fan motor 1 N High Med Low Carries 230v AC N L Thermoscreens 3-Speed Fan Switch WIRING DIAGRAM 1 HX2-S DX AIR CURTAIN (with AC Fan Decks) L T UK (DRAFT - 14 Sept 2016) Page 16 of 30

17 N N Carries 230v AC L High Door-Switch L Med Low Blue Brown Green/Yellow Door-Switch option:- Door Open - Higher speed Door Closed - Lower speed Blue Brown Green/Yellow ECDC SPEED ADJUST PCB 230V AC Relays 230V/1ph/50Hz Electrical Supply N N L HX2-1000DX = 1.1A HX2-1500DX = 1.5A HX2-2000DX = 1.9A HX2-2500DX = 2.5A 10V High Black 3 Red Orange White EC L Med Low Yellow 2 CONT GND A/T Red 1 White N High Med Low Fan motor 1 Speed Adjust Red Orange White EC L N N L High Med Low Fan motor 2 (2m & 2.5m unit only) Carries 230v AC Thermoscreens 3-Speed Fan Switch WIRING DIAGRAM 2 HX2-M DX AIR CURTAIN (with EC Fan Decks) EC Fan Decks T UK (DRAFT - 14 Sept 2016) Page 17 of 30

18 Fitting the Optional Service Covers For units using Ceiling Suspension service covers can be fitted after all the services have been installed, (i.e. refrigeration pipework, electrical wiring, controls wiring, condensate drain pipe). Fix the support plate to the hanging rods as shown in the picture. Bend the service cover to clip into the support plate. Ensure all services go inside the service cover. Fit the other service cover into the support plate. The services cover is now complete, repeat for all hanging rods, remove the protective plastic film. Fitting the Air Inlet Plenum Attach the air inlet plenum to the M6 fixing studs using M6 nuts. The open inlet can be upwards or downwards. T UK (DRAFT - 14 Sept 2016) Page 18 of 30

19 COMMISSIONING THE AIR CURTAIN Ensure that the electrical supply to the heat pump outdoor unit and, if applicable, the local electrical supply to the heat pump air curtain, are switched OFF. Air Curtain Checks Check that all components inside the heat pump air curtain are fitted and wired up as they should be. The responsibility of this rests on the Technician integrating the heat pump control system into the heat pump air curtain and making sure the wiring of fan outputs to the fan motors in the air curtain are properly engineered as per Wiring Diagrams 1 or 2. Things to check are: Internal wiring has been done in accordance with the heat pump system wiring diagram. Any dip switch settings are correctly set, slide out interface controller pcb for access if necessary, see Figure 2 and 3. The heat pump refrigeration system is fully installed, gassed-up and ready to operate. If there is a likelihood of significant condensate forming in the drip tray (Multi-Split LEV by-pass) and this could leak out, that a proper condensate drainage system is installed. That all air filters are correctly fitted and clean. T UK (DRAFT - 14 Sept 2016) Page 19 of 30

20 Selecting the Fan Speeds of the HX2-S Air Curtain AC Fan Decks The AC fan motor(s) in the HX2-S heat pump air curtain is a 5-speed motor and fan speeds can be re-selected at commissioning to suit the installation, both to suit the outdoor environmental conditions and for indoor noise levels. As delivered, the 3 fan speeds available are wired as follows (see Wiring Diagram 1) HIGH fan speed (black wire) is wired into motor tapping 1 (highest motor speed tapping), MEDIUM fan speed (blue wire) is wired into motor tapping 3, LOW fan speed (yellow wire) is wired into motor tapping 5 (lowest motor speed), motor tapping: Table 6 provides guidance for how the fan speeds can be set. Table 6 Fan Speed (air curtain as delivered) Motor Speed Tapping (see Wiring Diagram 1) Maximum air curtain mounting height (m) HIGH (black wire) 1 (Highest speed) MEDIUM (blue wire) LOW (yellow wire) 5 (Lowest speed) 1.8 Sound Pressure Level of air curtain [db(a) at 3m] HX2-S 1000DXE 53 HX2-S 1500DXE 53 HX2-S 2000DXE 54 HX2-S 2500DXE 54 HX2-S 1000DXE 52 HX2-S 1500DXE 52 HX2-S 2000DXE 53 HX2-S 2500DXE 53 HX2-S 1000DXE 51 HX2-S 1500DXE 51 HX2-S 2000DXE 52 HX2-S 2500DXE 52 HX2-S 1000DXE 49 HX2-S 1500DXE 49 HX2-S 2000DXE 50 HX2-S 2500DXE 50 HX2-S 1000DXE 45 HX2-S 1500DXE 45 HX2-S 2000DXE 46 HX2-S 2500DXE 46 Air Volume Flow Rate (m 3 /h) Sound pressure levels db(a) at 3m distance are for a single air curtain mounted at its maximum mounting height, operating in a room with average acoustic characteristics as defined in CIBSE Guide B5 (reverberation time 0.7s at 1kHz) and a room size equivalent to 8 air changes per hour (ac/h). Care needs to be taken when selecting air curtains for an installation as noise levels can be several db higher if the mounting height is reduced, if the room is more live (i.e. hard surfaces, no furnishings or absorbent materials), if the room is smaller than 8 ac/h equivalent or a combination of these factors. Noise levels will also increase if more than one air curtain is installed at the same doorway (e.g. +3dB(A) for 2 equal point sources: direct field). T UK (DRAFT - 14 Sept 2016) Page 20 of 30

21 Setting the Fan Speeds of the HX2-M Air Curtain EC Fan Decks EC fans are fitted in the HX2-M air curtain and there is a speed control PCB fitted inside the unit with adjuster knobs to set the High, Medium and Low fan speeds (see Wiring Diagram 2). _ 10v Speed Control PCB Speed Control Adjusters LOW MEDIUM HIGH The speed control adjusters can be set between 0 and 10(High), check with a voltmeter to set the speed accurately. The 3 fan speeds are factory set but can be re-adjusted at commissioning to suit the installation, both for the outdoor environmental conditions and for indoor noise levels. Make sure fan speeds selected suit the operation of the heat pump system, it is possible to set EC fans to a very low speed which is unsuitable for an air curtain and could cause problems with the heat pump system. Factory settings are 9.5v HIGH; 7.5v MEDIUM; 5.5v LOW. Table 7 provides guidance for setting the fan speeds. Table 7 Fan Speed Voltage Maximum air curtain mounting height (m) Sound Pressure Level of air curtain [db(a) at 3m] Air Volume Flow Rate (m 3 /h) HX2-M.. DXE HX2-M.. DXE v v (High) v v v v v (Medium) v v v v (Low) v Sound pressure levels db(a) at 3m distance are for a single air curtain mounted at its maximum mounting height, operating in a room with average acoustic characteristics as defined in CIBSE Guide B5 (reverberation time 0.7s at 1kHz) and a room size equivalent to 8 air changes per hour (ac/h). Care needs to be taken when selecting air curtains for an installation as noise levels can be several db higher if the mounting height is reduced, if the room is more live (i.e. hard surfaces, no furnishings or absorbent materials), if the room is smaller than 8 ac/h equivalent or a combination of these factors. Noise levels will also increase if more than one air curtain is installed at the same doorway (e.g. +3dB(A) for 2 equal point sources: direct field). T UK (DRAFT - 14 Sept 2016) Page 21 of 30

22 Starting the Heat Pump System Carry out a final inspection to ensure that all wiring is in accordance with Wiring Diagrams and that all connections have been properly made. Ensure that the refrigerant system is complete, there are no leaks and there is sufficient charge of refrigerant R410A. Switch on electrical power to the heat pump outdoor unit and if applicable the local electrical supply to the air curtain. WARNING! The Interface Controller PCB inside the air curtain will have 230 volts on it. The system will boot-up and the screen on the Remote Controller will become active. DANGER: Beware of Fans Starting! Turn the air curtain on using the Remote Controller and the air curtain fans will start straight away. If a door switch has been installed to change fan speeds from High (door open) to Low (door closed) check this operates correctly. If the Thermoscreens 3-Speed fan switch has been installed check that the fans run at HIGH speed, MEDIUM speed and LOW speed by operating the slider switch. Whatever the means of control of the fan speeds check there is no mechanical noise coming from the fans at any of the fan speeds and that all fans are working. Operate the air curtain in Heating mode using the Remote Controller and adjust the target temperature to the maximum setting. Check that the air stream from the discharge grille warms up across the whole length of the air curtain after approximately 10 minutes of operation from cold and that the air stream reaches right down across the doorway with the door open or closed. Operate the air curtain in Fan only mode (Ambient) using the Remote Controller and check the air stream still reaches right down across the doorway with the door open or closed. To conserve energy and carbon resources it is recommended to set the Remote Controller, BMS System or Centralised Controller so it operates in HEAT Mode at a target temperature of 24 C. This is the normal mode of operation for a heat pump air curtain and it should run in this set-up with no further adjustments, automatically heating as required. If the target temperature is reached the air curtain fans will still operate but the air stream is then not heated (ambient air curtain). T UK (DRAFT - 14 Sept 2016) Page 22 of 30

23 Adjusting the optional Side-Guard Airstream Vanes :- If fitted, adjust the airstream vanes at each end of the discharge grille as shown in the diagrams. Adjustable Airstream Vanes Standard outlet grille projects main airstream straight down Main airstream Adjustable Airstream Vanes at each end of the standard outlet grille Angled airstreams project into un-protected gap at end of air curtain Angled airstreams project into un-protected gap at end of air curtain Switch off the electrical power to the heat pump Air Curtain and the heat pump outdoor unit. T UK (DRAFT - 14 Sept 2016) Page 23 of 30

24 Final Check of the Unit Replace the air filters if removed and the bottom access panel (see Section To gain access inside the Air Curtain ). Power-up both the Outdoor Unit and the heat pump Air Curtain and re-check the operation of the unit. Hand-over to End-User Before leaving site it is important that there is a 'Hand-Over Meeting' to hand-over the heat pump system and air curtain installation to the end user or their representative. This should include a full and clear explanation of how the system operates with User Instructions and a demonstration showing the air curtain running. Be sure to explain that the air inlet grilles and air filters must be regularly vacuum cleaned and the unit serviced at regular intervals. See Section Servicing the Air Curtain. Explain how the fan speeds operate if there is a door operated fan speed switch, Thermoscreens remote 3-speed fan switch or some other type of fan speed control. That the air curtain should be operated in FAN (Ambient) mode or in Heating mode with a fixed target temperature of, say, 24 C. It is vital they understand that the air curtain must not be run in Cooling mode if it is possible to so with the heat pump controls. Explain to the end user that the doorway should be closed whenever possible but that during times of high pedestrian use it will become effectively open doorway. The air curtain serves an essential purpose by saving energy and providing comfort to the occupants when compared to an open doorway with no air curtain fitted. Ensure that all instructions and manuals are handed to the end user or their representative. T UK (DRAFT - 14 Sept 2016) Page 24 of 30

25 SERVICING THE AIR CURTAIN Weekly - Vacuum Clean the Air Filters With the air curtain switched OFF, slide open the access panels underneath the air curtain. Release the quarter-turn fasteners. Remove the air filters from the air curtain. Clean the air filters with a vacuum cleaner. This is important to minimise the build-up of dust and lint on the air filters which will affect the performance of the air curtain. This is a simple service task that can be carried out by the Cleaner or Janitor on a weekly basis from floor level without having to access the air curtain at high level. This should be done weekly as a regular service task. T UK (DRAFT - 14 Sept 2016) Page 25 of 30

26 6 Monthly Full Service of the Heat Pump Air Curtain Before servicing, maintaining or repairing the Air Curtain always isolate the local electrical supply to the heat pump outdoor unit and to the Air Curtain if it has a local electrical supply. Note: All servicing, maintenance and repairs to the air curtain must be carried out by an approved Service Agent. Keep any loose fixings for re-assembly. Open the bottom access panel underneath the air curtain, See To gain access inside the Air Curtain Vacuum clean and remove any build-up of dust, dirt and debris inside the air curtain especially on the fans. Note: Fan motors are permanently lubricated and do not need additional lubrication. Check all electrical connections inside the air curtain are tight. Do not adjust the fan speeds, these were set during commissioning. T UK (DRAFT - 14 Sept 2016) Page 26 of 30

27 If the Air Curtain has seen significant condensate in the drip tray:- (because of unintentional condensate formation such as with Multi-Split VRF systems where the LEV may let-by) Remove the bottom access panel Unscrew M6 nut, then M6 screw. Remove condensate hose from the drip tray outlet pipe. Remove the screws that fix the outlet grille to the unit. Remove the outlet grille from the unit. Remove the M5 screws that fix the drip tray to the underside of the unit. On 1500, 2000 and 2500 units there are M5 screws in the air outlet to remove as well. T UK (DRAFT - 14 Sept 2016) Page 27 of 30

28 Remove M6 screws at each end of the drip tray. Remove the drip tray from the unit. Remove all debris and deposits from the coil face, drip tray, outlet pipe, condensate hoses and the condensate disposal system if fitted. Check there are no kinks in condensate hoses. If fitted, if the condensate pump is a peristaltic type change the rubber pump head tube. Refit drip tray opposite to removal. Replace all components and access panels and fully test unit in accordance with Section Commissioning T UK (DRAFT - 14 Sept 2016) Page 28 of 30

29 Fault Finding If the Thermoscreens Heat Pump Air Curtain System does not operate as expected refer to the fault finding table below: Symptom Possible Cause Action Required Air curtain fans do not operate or they run too slow Air curtain discharge air stream is not heating when required Heat pump system is indicating an error code Electrical power is not switched on at the Air Curtain or Outdoor Unit Air curtain is not switched On Air Curtain fans are not wired correctly to heat pump interface controller in air curtain, 3-Speed fan switch or Door Switch Problem with air curtain fan motor(s), internal wiring, controls or fan speed door switch if fitted AC fan motor tapping set too low or EC fan speed adjusters set too low Air curtain has been running for less than 10 minutes and is still warming up Target temperature is set incorrectly, i.e. too low for heating The operating mode is set incorrectly, i.e. set on FAN ONLY when heating is required, or vice versa Air curtain will not operate if there has been significant condensate in drip tray Air Curtain filters and/or coil is dirty Heat pump system has a fault A variety of error codes can occur because of a heat pump system fault Error Code indicating condensate alarm from condensate pump alarm system If there has been condensate in drip tray Switch on power to Air Curtain and/or Outdoor Unit and wait for system to boot-up Switch on air curtain using Remote Controller, BMS System or Centralised Controller Wire correctly to interface controller, 3-speed fan switch or door switch see Wiring Diagrams 1 or 2 Use wiring diagram from heat pump system manufacturer to investigate possible cause of fault See Selecting or Setting the Fan speeds of the air curtain Give system sufficient time to reach operating condition Adjust the target temperature on the Remote Controller, BMS System or Centralised Controller Select the correct mode for the conditions on the Remote Controller, BMS System or Centralised Controller Check condensate alarm circuit which may have tripped Service air curtain as described in Section Servicing the Air Curtain Refer to manufacturer of heat pump system Refer to heat pump system Service Manual to understand fault, then inspect and repair air curtain if there is a fault Inspect air curtain condensate drip tray and condensate pump, service or repair if necessary If the Heat Pump Air Curtain system is still not operating correctly call for assistance from the Service Agent of the heat pump system. T UK (DRAFT - 14 Sept 2016) Page 29 of 30

30 Thermoscreens Ltd St. Mary s Road Nuneaton Warwickshire CV11 5AU United Kingdom Telephone: +44 (0) Fax: +44 (0) EC DECLARATION OF INCORPORATION as defined by the EC Council Directive on Machinery 2006/42/EC, the Low Voltage Directive 2014/35/EU, Electromagnetic Compatibility Directive 2014/30/EU, the Pressure Equipment Directive 97/23/EC, the Energy related Products Directive 2009/125/EC Herewith we declare that the air movement equipment designated below, on the basis of its design and construction as supplied by us to a third party for them to incorporate their own controls is in accordance with the relevant safety, health and performance requirements of the Machinery. If heat pump controls are incorporated into the air curtain by a third party not in accordance with these instructions, or alterations are made to the machinery without prior consultations with us, this declaration becomes invalid. Designation of Equipment : Series Type : Relevant EC Council Directives : THERMOSCREENS HEAT PUMP AIR CURTAINS, BASIC UNIT WITH NO CONTROLS FITTED - heat pump controls to be fitted by a third party HX2-S 1000 DX; HX2-S 1500 DX; HX2-S 2000 DX, HX2-S 2500 DX HX2-M 1000 DX; HX2-M 1500 DX; HX2-M 2000 DX, HX2-M 2500 DX the Machinery Directive (2006/42/EC) the Low Voltage Directive (2014/35/EU) the Electromagnetic Compatibility Directive (2014/30/EU) the Pressure Equipment Directive (97/23/EC) the Energy related Products Directive (2009/125/EC) Applied Harmonised Machinery - BS EN ISO 12100:2010, BS EN ISO 13857:2008 Standards : LVD - EN :2012+A11:2014, EN :2009+A11:2012, EN :2003+A13:2012 EMC - EN :2007, EN :2007+A1:2011, EN :2014, EN :2013 PED - EN 13133:2000, EN 13134:2000 ErP - ISO 5801:2007, ISO 12759:2010 Basis of Self Attestation : Quality Assurance to BS EN ISO 9001 : 2008 B.S.I. Registered Firm Certificate Number FM SGS Test Report DUR 43908/2/R/RG/05; GL Test Report TR/09/149; Wemtech Test Report 6620 Responsible Person : Mr. J.Rogers, Managing Director, Thermoscreens Ltd. Date : 30 th June 2016 Signed : T UK (DRAFT - 14 Sept 2016) Page 30 of 30