OPERATION INSTRUCTIONS MANUAL DUCTED FAN COILS UNIT FUN I / FUN U FUN I MCP / FUN U MCP FUN V / FUN V MCP 1
CONTENTS 1. GENERAL... 3 2. INSTALLATION... 4 3. AIR CONNECTIONS... 5 4. WATER CONNECTIONS... 8 5. ELECTRICAL CONNECTIONS... 9 6. DIMENTION & WEIGHT... 13 7. MAINTENANCE... 18 8. SPARES... 19 2
1. GENERAL Installation of the unit Read carefully this manual before to start installation operations. This unit comply with low voltage directive CEE/73/23 and electromagnetic compatibility CEE/89/336. Installation is to be done by qualified and trained technicians installers. Check all local safety regulations. Control earth electrical connection. Check that available voltage and electrical frequency are complying with stamped indications of the unit nameplate. Check that general electrical alimentation is correctly protected against over-voltage, shortcircuit and electrocution. Once installation is effective, check all functions are correctly running and explain the use and safety details to the user. Receiving and storage of goods When receiving a shipment, check the conditions of the goods and report immediately any damage in transit to the shipping company and to the manufacturer. Check that type and number of units are strictly conforming to the order acknowledgement bill or transport bill. If not, report immediately to the shipping company and to the manufacturer. Store the unit in dry (< 80% hygrometry) and clean area. Assure no vibrations or chocks. If storage period exceed 1 year, check and control the unit before installation. Do not place heavy articles on the unit. Unpack the unit with precautions and prevent any risk. Location Use this unit only for application which has been defined by technical office and/or manufacturer. WARNING : Before any kind of work on the unit or access to internal components, switch off the main electrical power supply. Keep this unit out of frozen area. Keep this unit out of flammable gases area. Keep this unit out of corrosive area (i.e. marine environment). Maximum air supply temperature must not exceed 60 C. Manufacturer recommends maintaining air supply < 37 C. Failure to take proper accounts of the above advice and unauthorized modification of the electrical connections will render the manufacturer warranty of the product null and void. In any case of dysfunction, switch off the unit and contact our after sale services. Packing and pallet should be recycled according to the local regulations. Location to avoid : Areas near excessive heat sources. Wet areas and /or where the unit could be in contact with water. Recommended locations : The easiest place for installer; Take care sufficient clearance around the unit allow dismantling of components (filter, coils, fan). Condensing water pipe can reach a sewer pipeline. WARNING : The water condensing pipe must have a continuous down slope - minimum 2%. Connection to the sewer pipeline must be done with a siphon. Siphon is to be dimensioned according to the condensing water flow. Cold water feed pipe must be fully insulated to prevent any condensing water drop. 3
2. INSTALLATION UNPACKING Check that type and number of units are strictly conforming to the order acknowledgement bill or transport bill. If not, report immediately to the shipping company and to the manufacturer. check the conditions of the goods and report immediately any damage in transit to the shipping company and to the manufacturer. Check indications on the nameplate. Make sure the unit are as close as possible to the final installation site before to unpack. Do not handle the unit with the condensing trolley and/or exchanger collector and/or condensate pump and/or spigots. AREA FOR LOCATION Take care sufficient clearances around the unit allow easy dismantling of components (filter, coils, fan). If necessary proceed to test of components extraction. Electrical and hydraulic connections are located on the same lateral face of the unit (unless otherwise specified on order, the standard delivery is the right face). INSTALLATION AT CEILING The supporting structure must be able to carry the unit weight and prevent deformation, breaks or vibrations during the operation. Use a hydraulic or electrical special lift and a folding ladder to facilitate this task. Remove all debris and construction material from the ducts in order to prevent any damage to the unit at start up. Mark the position of the threaded hangers (not supplied) on the ceiling (you may use a drilling template for more accurate positioning or if there are numerous units to settle). Recommended hangers diameter is 8 mm. The method of fixing the hangers depends on the ceiling type. When moving the unit, do not use water pipe, condensate trolley, valves or condensing pump to lift it. Once the threaded hangers are fixed to the ceiling, tighten the 4 nuts. Leave a space between the the ceiling and the unit in order to adjust finally when the unit has been leveled. With an horizontal bubble level indicators adjust the hangers nuts so that the unit is inclined 5 mm towards the condensate drain pan. In the other direction, the unit must be perfectly horizontal. Condensate water exhaust pipe. The condensate drain pan has a 14 mm outside diameter. A flexible pipe with a 16 mm or 25 mm inside diameter can be used (not supplied). The condensate drain pipe shall have a constant down slope of 2 % (2 cm/m). Install a 50 mm (minimum) siphon to prevent gases and odors from flowing back into ceiling void. If this constant fall of condensate drain pipe cannot be done, i twill be necessary to use a condensate pump (contact our service). We recommend to insulate the condensate drain pipe with 5 to 10 mm neoprene or polyurethane. If several units are connected to a common collector, follow this connection sketch : Before operating the unit, ensure that the water flows into the internal condensate drain pan by pouring 1 or liters of water into it. If there is a condensate pump check start and stop. In case of problems, check the pipe slope and control obstructions. 4
3. AIR DUCT CONNECTION Number of Airclip spigots FUN 40 I/U FUN 50/60 I/U FUN 50/60 V Inlet Min 1 1 1 Diam. 200 Max 3 4 4 Outlet Min 1 1 1 max 3 4 2 Diam. 125 Fresh air 1 1 1 Number of Airclip spigots FUN 80/90 I FUN 80/90 U Inlet Min 2 1 Diam. 200 Max 5 2 Outlet Min 2 2 max 5 4 Diam. 125 Fresh air 1 1 5
Number of Airclip spigots FUN 120 I Inlet Min 3 Diam. 200 Max 6 Outlet Min 3 max 6 Diam. 125 Fresh air 1 The ducted fan coil FUN is monobloc, and therefore includes at suction and discharge the plenums functions. The installer is free to select the duct networks he wishes for each particular cases of installation. The number of spigots and their position must comply with above sketches. The plastic spigots (so called «AIRCLIP») are delivered not fitted on the units. The Airclip spigots are common to all size of FUN and can be fitted at inlet as well as outlet. 5 Before to fit the Airclip spigot, remove the relevant caps of the structure. These caps can be easily removedwith a mallet or by making lever with a turn-screw in order to break the small metallic clips. Check that inside insulation has been properly removed together with the caps. If necessary clear the duct opening with a cutter and remove all insulations debris. If there is no duct tat suction (free inlet air entrance), it is recommended to take off all inlet caps. When caps have been removed, settled the Airclip spigot. The fastener must lock the spigot and press the O-ring. The fastening is quite resistant. Now, if Airclip spigot is to be removed for any reason the only solution is to break it. Airclip spigot can be settled before to put the fan coil at ceiling it is easier. Connect the air ducts. In order to guarantee good air tightness, the duct should overlap the whole Airclip spigot. The pressure losses of these ducts must be compatible with the unit performance. The duct must be as smooth as possible. Avoid sharp bends. Check that there are no leaks or kinks, and that there is no dirt or installation debris inside the ducts. Debris within the ducts might damage the fan wheel and the damper in the air diffusers.. If necessary sound reducer can be added on the air duct networks. 6
INLET FRESH AIR A lateral cap diam 100 mm or 125 mm can be removed for fresh air introduction. Standard Aircalo fresh air Airclip spigots are diam. 125 and delivered not fitted on the unt. Follow same instructions to remove fresh air caps than main ducts cap (see above). Fresh air must be introduced in the unit with convenient air pressure and filtered. Minimum fresh air temperature must not be under 2 C. The fresh air spigot can be equipped with a fresh air controller with constant air volume. (3 different air flow are available) If the unit is fitted with a return air temperature sensor, the constant fresh air flow rate must not exceed 50% of the supply air flow delivered by the unit at minimum speed. To operate correctly, the constant fresh air flow controller requires a differential pressure in the range of 50 Pa to 200 Pa (standard is 70 Pa). Controller Diam 125 Airclip Seal flange 7
4. WATER CONNECTIONS Diameter Size FUN 40 FUN 50 / 60 FUN 80 / 90 FUN 120 Main coil (3 or 4 rows) 1/2" Gas female 1/2" Gas female 1/2" Gas female 3/4" Gas female Auxiliary coil (1 row) 1/2" Gas female 1/2" Gas female 1/2" Gas female 1/2" Gas female Limit of use : Maximum water pressure : 10 bar Minimum ambiant air temperature : 5 C, maximum : 32 C Minimum water temperature : 2 C, maximum : 100 C Maximum outlet air temperature 60 C. Warning Electrical coil must not be activated when warm water fill the main water coil. Unless otherwise firmly indicated onto the unit, the water inlet must be connected to the lower coil pipe (when unit is settled at ceiling) and the water outlet must be connected to the upper coil pipe. This apply also when the unit is delivered with modulations valves fitted on it. Torque to be use to tighten the hydraulic fastener is 25 Nm. We recommend using torque wrenches. We recommend use of stop valves on each pipe of coils. Ensure that a gasket is installed between the screw connector and the stop valve. In case of leaks, we decline any responsibility due to low quality or improper quality of gaskets supplied by installer. We recommend the use of flexible water pipes for easier operation. Take care that there is no mechanical strength on the unit, especially on the drain pan. Important : If so, the condensate pump would not work! If the flexible pipes are in contact with the drain pipe, then use cables in order to hang them. OK The upper coil pipe has an air relief screw. When all units are installed, open the stop valves on the manifold bleed and then pressurize the circuits. To bleed the coils, slightly loosen the bleed screws. The installation can then be started. Take care to insulate all water pipes, especially those for chilled water, in order to avoid the condensing water drop on the false ceiling. 8
Modulating valves Modulating valves can be delivered assembled on the unit in factory. Otherwise, carefully observe the direction indicated by the arrow on the valves, based on the connection side and the valve type. Standard is 230 V - 5 VA. Valves can be 2 ways or 3 ways with by-pass. Modulating valves must close the water inlet when there is no electrical alimentation (by-pass open). In case of demand of the thermostat, the valve opens gradually. When temperature reach the thermostat set, (or if electrical alimentation is switch off), the modulating valve close gradually and open the by-pass Follow the wiring diagram to connect accordingly the valve actuator. We recommend a control system which make impossible opening of valve if fan is not running. 5. ELECTRICAL CONNECTION Electrical installation must conform to local and international regulations and be done by qualified and authorized technicians, according to the wiring diagram shown at the end of this manual or supplied separately. Electrical supply is to be 230 V monophasic +earth, 50 Hz. (Limit : mini 198 V, maxi : 264 V) Achieve the earth connection before all other electrical connections. Installation must have an isolating device upstream (for example a doublepole circuit breaker). If necessary, an easily operated emergency stop device (such as a punch-button switch) must cut off the power to all equipment. These safety devices shall be sized and installed in accordance with IEC Recommendation 364. These devices are not supplied. Connections must be done at the electrical connector supplied. Access to this connector can be done by removing the safety cover. Motor power supply Type FUN 40 FUN 50 FUN 85 FUN 120 Motor AC EC AC EC AC EC AC EC Alimentation (V) 230 mono Frequency (Hz) 50 / 60 Motor maxi power (W) 60 106 186 106 372 212 558 318 Motor maxi current (A) 0.27 0.8 0.84 0.8 1.68 1.6 2.52 2.4 AC motors have 5 speeds available and consequently the unit has 5 air flow available (see hereunder connection sketch, the speeds identification according to the color of the wire). Choice is given among these 5 speeds to connect Low / Medium / High speed according to the engineering of the installation (you can refer to the performance data sheets given previously and/or to our technical documentation www.aircalo.fr). If required performance data-sheets may be supplied. For EC motors, the voltage setting must be done according to the airflow defined at engineering step. If required performance data-sheets may be supplied. The control system is to be adapted to EC motors with voltage regulation. 9
Option : Electrical heater - Alimentation & Nominal current Electrical heater power FUN 40 FUN 50 FUN 85 FUN 120 375 W 1.65 (A) 1.65 (A) - - 500 W 2.20 (A) 2.20 (A) - - 750 W 3.25 (A) 3.25 (A) 3.25 (A) - 1000 W 4.35 (A) 4.35 (A) 4.35 (A) - 1125 W - - - 4.9 (A) 1500 W - - 6.55 (A) 6.55 (A) 2000 W - - 8.70 (A) - 2250 W - - - 9.80 (A) 3000 W - - - 13.05 (A) Note : A safety thermostat with automatic set up is integrated in the unit. The set up is automatically done by switching off the unit. (Wait about 1 minute to let the set up be effective). No dismantling is required for this operation. In case of dysfunction of this thermostat a thermal fuse will operate. It will be then necessary to change the full electrical coil kit. Warning : Electrical coil cooling is necessary when temperature is reached : Post-ventilation It consists in the use of a timer to let refresh the coil : - For electrical heater of 750 W, 1500W and 2250 W refreshing time required is 30 seconds. - For electrical heater of 1000 W, 2000W and 3000 W refreshing time required is 60 seconds. Eventually, lack of electrical heater cooling may bring damage of the heater and/or the fan-coil. We recommend to avoid the use of the smallest speed available for AC motors, for the unit with optional electrical heater. 10
ELECTRICAL CONNECTOR FOR AC MOTOR 11
ELECTRICAL CONNECTOR FOR EC MOTOR 12
6. DIMENTION AND WEIGHT Weight 40 50 60 80 90 120 40 50 60 80 90 120 kg FUN I FUN I MCP Version 2 pipes 21 30 31 44 45 58 22 32 33 45 47 60 Version 4 pipes 22 32 33 45 47 61 23 34 34 47 49 62 kg 33FUN U FUN U MCP Version 2 pipes 21 30 31 53 54-22 32 33 54 55 - Version 4 pipes 22 32 33 55 56-23 34 34 56 57 - kg FUN V FUN V MCP Version 2 pipes - 31 31 45 46 - - 32 33 46 47 - Version 4 pipes - - - 33 34 47 49 - Water coil volume (l) 40 50 60 80 90 120 Main coil 1.2 1.4 1.8 2.2 2.5 3.3 Auxiliary coil 0.5 0.6 0.6 0.8 0.8 0.9 13
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Drawings can be modified at any time. Formal sketch of nits delivered can be supplied on request. 17
7. MAINTENANCE Before any maintenance operation, switch off the unit for safety reason. Maintenance can be done by qualified and authorized technicians. Filters cleaning Frequency of filters cleanings depends on the conditions of use of the unit. We recommend 2 months. Filters must be changed regularly at least every 12 months. Access to the filter is from the below. Unlock. Loosen the 4 screws and remove the below panel (suction side). Remove the filter and replace with new one. Disinfecting the condensate drain pan (FUN version I and U) The condensate drain pane is an area of permanent dampness (when running with chilled water) which encourage developpement of bacteries and legionellosis. The fan-coil FUN has been designed for hotel and medical applications with special features to let remove the drain pan easily and quickly : Removal of drain pan Access to the drain pan is from below. 1. Unscrew the 5 screws and remove the below panel (discharge side). 2. Remove the high-density foam strip supporting the drain pan (take care to support the pan by hand) 3. Slide down the drain pan by 20 mm approx. Remove the drain pan by the below (or by the side) 4. Dry the pan, eliminate moisture, use special disinfectant spray. NOTE : Removal of drain pan do not need previous removal of water coil. The water coil stay connected. 18
Long period stopping (> 4 months) Before to switch on the unit and at least once a year : - Clean or change the filter. If clogged filters are not changed they can increase the air pressure drop and the general performance f the unit may be degraded. - Check the coil and if necessary clean it. You may use a vacuum cleaner and/or compressed air. - Check the condensate drain pan and disinfect if necessary (moisture). - Check electrical connections. Additional maintenance To remove the water coil, just unscrew the 4 screws on each side of the unit and slide the coil (together with the drain pan). To remove the electrical fan motor : - Remove the panel below (at suction side). - Disconnect the fan assembly power supply cables (identified and note the wired fan speed). - The fan-motor is held in place by 2 M7 screws. Remove these 2 screws with an allen wrench. - Remove the fan-motor together the metal support plate. User guide Once the unit is installed and test have been achieved, explain to the user the main points of this manual (specially for maintenance) and explain the running of the unit together with the control system. How to start and stop. How to change or modify the running. How to set the temperature required. Transfer to the user this manual and all technical data sheets supplied by the manufacturer in order to be able to proceed to maintenance in the future and modify the installation in the future. The user must store these documents carefully. 8. SPARE PARTS Part FUN 40 FUN 50 FUN 60 FUN 80 FUN 90 FUN 120 2 Pipes coil BAT 913 BAT 923 BAT 924 BAT 933 BAT 934 BAT 944 4 Pipes coil BAT 915 BAT 925 BAT 926 BAT 935 BAT 936 BAT 946 AC Fan motor VEN 074 VEN 078 VEN 078 2 x VEN 078 2 x VEN 078 3 x VEN 078 EC Fan motor VEN 079 VEN 079 VEN 079 2 x VEN 079 2 x VEN 079 3 x VEN 079 EU3 Filter FTR 940 FTR 940 FTR 940 FTR 941 (I/V) FTR 941 (I/V) FTR 943 EU4 Filter FTR 944 FTR 944 FTR 944 FTR 945 (I/V) FTR 942 (U) FTR 945 (I/V) FTR942 (U) FTR 947 Drain pan support foam strip Airclip spigot DN 125 Airclip spigot DN 200 MOU020 MOU021 MOU021 M0U022 MOU022 MOU023 VIR125 VIR200 19
M 20-10-15 UK Tel : +33 5 56 70 14 00 - Fax +33 5 56 70 14 09 www.aircalo.fr 14 Rue Cassiopée 33160 Saint Médard en Jalles FRANCE 20