TABLE OF CONTENTS
1. GENERAL MAINTENANCE INSTRUCTIONS .......................................................................... 5
1.1 Construction characteristics ................................................................................................
1.2 TAC technology fans .............................................................................................................
1.3 About the counterflow AIR/AIR heat exchanger ..................................................................
1.4 Filters ...................................................................................................................................
1.5 Installation control datasheet (see appendix) ......................................................................
1.6 Warranty ..............................................................................................................................
1.7 Conformity ...........................................................................................................................
5
5
5
6
6
6
6
2. INSTALLATION INSTRUCTIONS .......................................................................................... 7
2.1 Installing the unit ................................................................................................................. 7
2.2 Connecting the drain pan .................................................................................................... 7
3. WIRING INSTRUCTIONS .................................................................................................... 8
3.1 General information ............................................................................................................ 8
3.1.1 General schematic of the HRup units .................................................................................... 8
3.1.2 Schematic of the T° sensors positioning in the HRup units ................................................... 9
3.2 Power supply to the fans and the control devices .............................................................. 9
3.3 Power supply for the electrical antifreeze protection coil KWin (option) ........................... 9
3.4 Power supply and connections for the electrical post heating coil KWout (option) ........... 9
3.5 Connecting the post heating water coil (option) ............................................................... 10
3.5.1 Power supply ........................................................................................................................ 10
3.5.2 Water connection (to be made by the installer) ................................................................. 10
4. TAC 4 CONTROL SYSTEM ................................................................................................. 11
5. MAINTENANCE ............................................................................................................... 12
5.1 Every 3 months .................................................................................................................. 12
5.2 Every 12 months ................................................................................................................ 12
APPENDIX : Installation control datasheet .......................................................................... 14
1. GENERAL MAINTENANCE INSTRUCTIONS
1.1 Construction characteristics
The structure is made out of omega shaped anodized aluminum profiles connected by reinforced polypropylene
auto-extinguishable (M1) corner pieces. The panels are 30mm double skin steel plates insulated. The outside
panels are 0,8mm thick pre-painted (5µm primer + 20µm polyester)-gray RAL 9002 color, covered with a plastic
protection (to be removed after installation). The inside panel is 0,8mm galvanized steel. This combination allows
the exposure of the panels to outdoors conditions, and forms a rigid structure. Thermal insulation is carried out by
EPS panels (density 30 g/l), self-extinguishing (M1 class), in conformity with the European environment standards,
inserted between layers. The HRup is mounted on a steel frame and is mono-structured. All the access doors to
the ventilators and filters are equipped with handles.
Air tightness:
Internal: Class 1 as per EN 13141-7.
External: Class 2 as per EN 13141-7.
1.2 TAC technology fans
The HRup series is equipped with TAC technology centrifugal ventilators. The TAC4 DG control is specifically
developed to take advantage of this technology. Verify that the supplied voltage corresponds to the specification of
the ventilators and that the connection is made according to the supplied wiring instructions. See
www.lemmens.com for more information on the advantages of the TAC technology.
Warning! : The starting up / stopping of the unit must be activated by using the softstop function on
K1/K2/K3 or via the RC/GRC/MODBUS, and not by shutting off the power supply.
Always check the following electrical specifications:
Power supply voltage: 230VAC (210V<V<250V).
Power supply frequency: 50/60 Hz.
Grounding the unit is compulsory
The motor is self-protected against overloading. It is thus NOT necessary to install an electrical overload protection
device. See section 3.2 for detailed wiring instructions.
Insulation class
Fans/HRup: IP44.
Nominal temperatures: -10°C/+55°C.
Conformy: CE (motors are also UL approved).
Before starting the unit
- If the fan wheel is rotating properly, without resistance?
- Verify if the installation and the connections are made according to the applicable European standards.
- Are the precautionary measures to avoid an accident taken? (Wiring, rotating parts, security measures,)
Operating conditions
The temperature over the fan motor cannot be lower than -10°C, or superior to 55°C. The unit is not de signed to
operate in an aggressive or an explosive environment. It is strongly not advised to stop and start the unit more
often than every 5 minutes.
1.3 About the counterflow AIR/AIR heat exchanger
Protect the heat exchanger by regularly cleaning or replacing the filters.
To protect from frosting, the TAC4 DG control is as standard delivered with an inbuilt heat exchanger antifreeze
system (by unbalancing the in and out airflows). There is also the KWin pre-heater option available (except for the
HRup 450) to accomplish this if deemed necessary.
The HRup units are specified not to exceed a frontal air speed on the heat exchanger of 2,2m/s.
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HRup installation and maintenance manual
1.4 Filters
HRup units are delivered with G4 filters for the air ‘out’ flow and F7 filters for the air ‘in’ flow. Filters are the
protectors of the heat exchanger, but also of the quality of the air you breathe. Check regularly (once a month) the
state of the filters. Vacuum the filters if necessary, and replace them when they are too dirty. Clogged filters can
create the following failures:
- Insufficient ventilation
- Excessive increase of the rotation speed of the fan creating excessive noise and power consumption
- A damaged filter allows 'dirty' air to enter the heat exchanger which will eventually clog the heat exchanger
Filter identification for replacement:
Unit type
Filter(s) air “out”
Filter(s) air “in”
HRup 450
HRup 800
HRup 1200
HRup 2000
1 x G4 (415x200x50) – cid 125061
1 x G4 (470x287x50) – cid 125054
1 x G4 (830x287x50) – cid 125055
2 x G4 (503x370x50) – cid 125063
1 x F7 (415x200x50) – cid 125068
1 x F7 (470x287x50) – cid 125056
1 x F7 (830x287x50) – cid 125057
2 x F7 (503x370x50) – cid 125062
1.5 Installation control datasheet (see appendix)
When the installation is completed and running, we strongly advise that the installer fills in the installation
datatsheet recapitulating all the data useful for maintenance of the installation. Please keep a copy of this
datasheet closeby as it may come handy for many reasons:
•
make a clear communication in case of discussion with the manufacturer
•
information if you need to change parameters when necessary,
•
this document can become an important factor in case of guarantee issues.
1.6 Warranty
The warranty of the manufacturer begins at the date of invoicing of PLC to the installer. The warranty is of 2 years,
except on the mobile parts where it is of 1 year.
The warranty is limited to the replacement of the defective parts, and does not include labor and traveling
expenses. The warranty becomes void if:
•
The installation is not accomplished according to the prescriptions described in this above.
•
Repairs were carried out by unqualified staff.
•
The startup control datasheet (see appendix) is not filled in properly and not made available when claiming
1.7 Conformity
CE, under formal condition that the final product integration is made in conformity with the applicable standards.
6
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HRup installation and maintenance manual
3. WIRING INSTRUCTIONS
3.1 General information
3.1.1 General schematic of the HRup units
2
12
7
4
5
11
6
10
1
3
8
9
1. Main switch for power supply fans and control
2. Main switch for power supply to pre (Kwin) and/or post (Kwout) heating coils (options)
3. Centralized wiring box of the CB4 TAC4 DG circuit (factory pre-wired)
4. Supply fan(s)
5. Exhaust fan(s)
6. Post-heating water or electrical coil (NV ou KWout option)
7. F7 class filter at fresh air inlet
8. Pre-heating electrical antifreeze coil (KWin option)
9. Drain pan and drain
10. By-pass 100%
11. Air/Air heat exchanger
12. G4 filter on exhaust air
Only electrical connections made by the installer are in 1/2/3.
8
3.1.2 Schematic of the T° sensors positioning in th e HRup unit
To allow easier identification of the temperature sensors 4 different wire colors are used:
-
T1 : black wire
T2 : white wire
T3 : blue wire
T4 & T5 : green wire
3.2 Power supply to the fans and the control devices
All the internal cables (fans, controls, sensors,…) to the main switch are factory pre-wired. All the power supply
wiring that remains is the main power supply to the main switch.
Wiring specifications:
Unit type
HRup 450
HRup 800
HRup 1200
HRup 2000
Supply Voltage
(1)
1 x 230V
1 x 230V
1 x 230V
1 x 230V
Maximum amps
Protection type (2)
3,1 A
5,5 A
7,0 A
14,3 A
D – 10.000A – AC3
D – 10.000A – AC3
D – 10.000A – AC3
D – 10.000A – AC3
Protection caliber
8A
8A
8A
16A
(1) Grounding is compulsory
(2) D type “slow” reaction curves - shutoff power 10.000A - AC3.
3.3 Power supply for the electrical antifreeze protection coil KWin (option)
All the internal cables of the KWin coil to the main switch are factory wired. All that needs to be wired is the main
power supply to the main switch.
Wiring specifications:
Unit type
HRup 450
HRup 800
HRup 1200
HRup 2000
Supply voltage
3 x 400V + N
3 x 400V + N
3 x 400V + N
KWin heating
capacity
Maximum amps
Not available
3 kW
4,5 kW
6 kW
4,3 A
6,5 A
8,7 A
3.4 Power supply and connections for the electrical post heating coil KWout (option)
All the internal cables of the KWout coil to the main switch are factory wired. All that needs to be wired is the main
power supply to the main switch.
Wiring specifications:
Unit type
HRup 450
HRup 800
HRup 1200
HRup 2000
Supply voltage
3 x 400V + N
3 x 400V + N
3 x 400V + N
KWoutn heating
capacity
Maximum amps
Non disponible
3 kW
4,5 kW
6 kW
4,3 A
6,5 A
8,7 A
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HRup installation and maintenance manual
3.5 Connecting the post heating water coil (option)
The post-heating water coil is delivered with a motorized 3-way valve (non-mounted).
3.5.1 Power supply:
Refer to installation and setup of post heating control manual (delivered with NV option).
3.5.2 Water connection (to be made by the installer):
•
Connection schematic:
•
These are the specifications for the water coil connection:
Unit type
HRup 800
HRup 1200
HRup 2000
Diameter
on the coil
Diameter on
the valve
1/2’’
1/2’’
1/2’’
G 1B
G 1B
G 1B
Coil Capacity
(*)
4,5 kW
7,7 kW
12,5 kW
Water flow (*)
199 l/h
339 l/h
553 l/h
Pressure loss (*)
1,4 kPa
11,3 kPa
13,5 kPa
(*) Nominal values for following selection conditions: air in T°: 18°C, water in/out T: 90/70°C. For o ther conditions
refer to the HRup selection software or provided data sheet for the project.
10
4. TAC4 CONTROL SYSTEM
The TAC4 control device manages the following features :
-
Fan airflow management (accurate knowledge of fan’s working point)
Management of time slots
Automatic bypass control (freecooling)
Heat exchanger anti-freeze protection control
Automatic motorized inlet and exhaust damper control (option)
Electrical pre-heater control (option)
Water or electrical Post-heater (option)
Control of external post-coil (option)
RTU or TCP/IP MODBUS Communication (option)
The TAC4 control circuit is factory pre-wired.
There are 4 ways to ‘communicate’ with the TAC4 control :
•
•
•
•
RC TAC4 (LCD remote control)
GRC TAC4 (graphic touchscreen display, can control up 247 units)
MODBUS RTU network (usually to connect to a BMS)
MODBUS TCP/IP network for a webserver type application, also allows GPRS communication
The following options can be combined with TAC4 control :
-
RC TAC4 Option : remote control to setup, control and visualize the parameters.
Please refer to TAC4 DG – RC TAC4 installation and user’s manual for detailed information
-
GRC TAC4 Option : graphic remote touchscreen to setup, control and visualize the parameters.
Please refer to TAC4 DG – GRC TAC4 installation and user’s manual for detailed information
-
SAT TAC4 BA/KW Option:
regulation of 2 external heat exchangers (electrical/water,hot and/or cold)
please refer to SAT TAC4 BA/KW installation and user’s manual for detailed information
-
The SAT3 Option is a Circuit with 2 relays (2 SAT3 can be plugged)
•
When plugged in position OR1/OR2: status of “Fan On” warning and of “Pressure alarm” warning
and/or
•
When plugged in position OR3/OR4 : status of NV option circulator and of «bypass»
please refer to SAT3 installation and user’s manual for detailed information
-
SAT TAC4 MODBUS Option : MODBUS RTU communication
please refer to SAT TAC4 MODBUS installation and user’s manual for detailed information
-
TCP/IP TAC4 MODULE Option:
MODBUS TCP/IP communication.
please refer to TAC4 DG - TCP/IP installation and user’s manual for detailed information
-
GPRS TAC4 MODULE Option:
GPRS Communication. Please refer to TAC4 DG - GPRS installation and user’s manual for detailed
information
Each one of these communication configuration is fully described in a separate installation manual
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HRup installation and maintenance manual
5. MAINTENANCE
Attention: before handling and/or opening the access panels it is compulsory to shut down the power supply
using the general switch located on the front panel. Iif options KWin and\or KWout are installed, then shut down
the corresponding general switches.
Regular maintenance of the HRup unit is essential to guarantee a good operation of the device and a long life
expectancy. The maintenance frequency will depend on the application and on the actual environment conditions
but in a general way the following controls are advised :
5.1 Every 3 months
1.
Check for any alarm indicated on the control device. In case of alarm refer to control manual.
2.
Check the state of filter clogging. The control device allows to set a pre-defined ‘filter clogging’ threshold (refer
to installation manual). If need be replace filters. Filters that are too clogged can generate the following
problems :
•
•
•
•
Insufficient ventilation
Excessive increase of fan rotation speed, creating excessive sound level
Excessive power consumption (power consumption will increase exponentially to an increase in pressure
drop, for a constant airflow)
A damaged filter allows unfiltered air to enter heat exchanger (risk of clogging) and into ventilated room.
List of replacement filters :
3.
Unit type
Filter(s) air “out”
Filter(s) air “in”
HRup 450
HRup 800
HRup 1200
HRup 2000
1 x G4 (415x200x50) – cid 125061
1 x G4 (470x287x50) – cid 125054
1 x G4 (830x287x50) – cid 125055
2 x G4 (503x370x50) – cid 125063
1 x F7 (415x200x50) – cid 125068
1 x F7 (470x287x50) – cid 125056
1 x F7 (830x287x50) – cid 125057
2 x F7 (503x370x50) – cid 125062
Inspection and cleaning of the inside of the unit:
- Vacuum clean any accumulation of dust in the unit.
- Inspect and gently vacuum clean if need be the heat exchanger. Use brush accessory to protect fins.
- Clean the possible condensation marks and possible accumulations in the drainpan.
5.2 Every 12 months
1.
Check for any alarm indicated on the control device. In case of alarm refer to installation manual.
2.
Check the state of filter clogging. The control device allows to set a pre-defined ‘filter clogging’ threshold (refer
to installation manual). If need be replace filters. Filters that are too clogged can generate the following
problems :
•
•
•
•
Insufficient ventilation
Excessive increase of fan rotation speed, creating excessive sound level
Excessive power consumption (power consumption will increase exponentially to an increase in pressure
drop, for a constant airflow)
A damaged filter allows unfiltered air to enter heat exchanger (risk of clogging) and into ventilated room.
See above for list of replacement filters
12
3. Inspection and cleaning of the inside of the unit:
- Vacuum clean any accumulation of dust in the unit.
- Inspect and gently vacuum clean if need be the heat exchanger. Use brush accessory to protect fins.
- Clean the possible condensation marks and possible accumulations in the drainpan.
- Clean drainpan
- Clean the inside of the bypass. To access interior of bypass it is necessary to force-open it, proceed as
follows: jump terminals IN4 and +12V on the CB4 TAC4 DG circuit board. The bypass is now open,
independently of temperature conditions.
- Remember to remove jump between terminals IN4 and +12V once cleaning of bypass is done
4. Fan maintenance:
Check again if power supply is shut down and fans are not running.
Check cleanness of fan. Clean if necessary, be careful not to alter balancing of the fan wheel (do not remove
balancing clips). Dismount fans if necessary.
5. Check airtightness of unit:
Particularly check that side access panels are well closed and that airtightness seals are in a good state.
Replace if necessary.
_____________________________________________________________________________________
Although we put a lot of care in the making of our documentation, we cannot be held responsible for any error and/or
omissions that could have slipped in.
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HRup installation and maintenance manual
Appendix: Installation control datasheet (to be filled in after starting the installation)
Installed by:
Installer’s name: ___________________________________________
Company name:_________________________________________
Address:__________________________________________
Telephone: ________________________________________
Installation date: ___/___/___
CONFIGURATION PARAMETERS :
1
2
3
HRup model
Working mode
If CA mode:
4
If LS mode:
5
If CPs mode:
6
7
% EXT/PUL
Pressure alarm (modes CA / LS only)
8
9
10
If KWin option :
If KWout option
If NV option :
CA LS CPs Other
m³h K1 =
m³h K2 =
m³h K3 =
Vmin =
Vmax =
m³h≡Vmin =
m³h≡Vmax =
% on K3 =
Assignment Pa=
V (or
% on K3 =
%
Activated ? yes / no
If yes:
Automatic / Manual setup
Initialisation:
Supply:
m³h
Pa
Exhaust:
m³h
Pa
T° KWin =
°C
T° KWout =
°C
T° NV
=
°C
Pa)
Indicate here all changes made in the advanced setup, if any:
VALUES READ OFF DISPLAY WHEN HRup in OPERATION:
1
2
3
4
Supply Aiflow
Supply pressure
Exhaust airflow
Exhaust pressure
m³/h
Pa
m³/h
Pa
14
P. LEMMENS COMPANY S.A.
Parc Industriel de Sauvenière, 102, Chaussée de Tirlemont, B-5030 GEMBLOUX
TEL. : +32 (0) 81 62 52 52, FAX : +32 (0) 81 62 52 53
www.lemmens.com
© PLC 09/2011 - Cid 050046