HEALTH AND SAFETY
Information for the Installer and Service Engineer
The company takes every reasonable care to ensure these products are designed and constructed to meet general safety
requirements, when properly used and installed to manufacturers instructions.
Steel Parts
Every reasonable care has been taken to remove sharp edges on steel components but it is recommended to use protective gloves
when handling the units.
Working Conditions and Pre-installation Check
When working on the appliance it is the installer/engineers responsibility to ensure that any necessary personal protective clothing
or equipment required complies with current health and safety requirements.
This section ‘Working Conditions’ deals with the hazards that could be encountered when any work is carried out on the equipment
for which this manual is written.
Therefore the following points should be observed to avoid any safety or health hazards
The unit shall be checked to ensure that:-
1. It is suitable for the electrical supply available.
2. It is suitable for the atmosphere or the environment in which it is to be used.
3. It is suitable for the working media, temperature and pressure for which it is to be used.
4. It is manually isolated from the electrical mains supply
5. Electrical equipment is earthed to comply with IEE regulations and local by-laws.
6. All electrical work must be carried out by a Qualified Electrical Engineer.
7. The unit is wired in accordance with IEE regulations.
8. The procedure for removing and replacing the filter media is carried out as laid down in this manual.
Cautionary Notes
9. No part of the unit shall be dismantled until a careful study has been made of this manual.
10. This manual deals in detail with installation, commissioning and servicing and shall be strictly adhered to.
11. All persons performing any maintenance or repair work on these units must be fully trained and competent to carry out the
necessary tasks.
12. On completion the interior shall be left clean and free of debris and all access panels shall be correctly re-fastened.
Water Treatment
13. Check for any treatment that is required to the water supply for prevention of corrosion of the equipment.
14. The materials of construction in contact with the water are copper tubes, brass fittings and valve bodies, and stainless
steel valve stem.
15. In addition, allowance should be made for materials in the external pipe system.
Information regarding the necessary action to be taken can be obtained from the relevant Water Authority, particulars of
which can be found in the Water Engineers Handbook Yearly Edition.
2 48008002-06
CONTENTS:
INTRODUCTION Introduction to the product. 4
PRODUCT IDENTIFICATION Product Identification 4
DELIVERY AND INSTALLATION Receipt of Equipment. 5
INSTALLATION Dimensional details 6Pre Unit Installation 7
Fitting unit 7
Fitting float switch 7-9
Connection of ductwork 9
COMMISIONING Airside Measuring and Balancing 10
Electric Air Heaters 10
SERVICE AND MAINTENANCE Warranty 10
Fans 11
Electric Heating Element 11
Controls 12
Condensate Tray 12
Coils 12
Filters 13
Insulation 13
Routine Maintenance Schedule 13
WIRING Controls General 14
GENERAL INFORMATION Component Specification. 14
3 48008002-06
INTRODUCTION
Quartz range of fan coil units are a purpose built range of cooling and heating units that are factory wired and tested and suitable
for ceiling or void mounted.
All casings are manufactured from heavy gauge self finished galvanised steel.
The casing has multiple removable access panels to provide easy access to all serviceable components.
All units are thermally and acoustically insulated with a class 0 insulation
The heat exchange coils are suitable for both heating and cooling using low pressure hot water and chilled water.
All units are fitted with drain trays mounted below the coil to collect and drain any condensation produced during normal operation.
Option of factory fit condensation pump.
Option of factory fit Electric Air Heater Elements
EC/DC Fan Motor are fitted as standard.
AC Fan Motors are available as an option.
AC Units are fitted as standard with High performance, low energy, and external rotor motor fans with thermal contactors built into
windings.
AC Speed control of the fan motors is achieved by means of a multitapped auto transformer which is wired to a three speed and
fine adjustment switches.
Supplied with continuous filament media filters with an extended surface that vastly increases the periods between maintenance
and will last up to 6 times as long as a normal filter.
EU2 grade filters are standard with EU3 grade filters are available as an option, with the option of a metal mesh.
Service access to the fan is from the underside via a full width removable access panel.
Note: Where it is necessary to connect additional electrical or hydraulic controls equipment to the unit to provide a
functional product or where controls have been free issued for factory fitting the responsibility for their correct function
and any associated warranties remain the contractors responsibility.
PRODUCT IDENTIFICATION
The identification serial number label can be found on the controls box
and identifies the unit type, part number and the serial number of the unit.
This information should be recorded and quoted in any correspondence between end user and manufacturer.
The identification serial number label can
be found on the controls box
Fig1
4 48008002-06
DELIVERY AND INSTALLATION
Receipt of Equipment.
The purchaser is responsible for off loading the units.
No responsibility can be accepted for damage sustained during unloading from the delivery vehicle
Upon receipt of equipment a visual inspection should be made of the fan coil units and any damage noted on the delivery form.
The driver delivering the equipment should endorse particulars of any damage or short delivery.
All claims for damage or short delivery should be advised to TEV LTD. In line with the terms and conditions for the supply of goods
or services which can be viewed at www.tevlimited.com/terms.html
Off Loading Units.
The units are supplied on pallets and shrink- wrapped unless otherwise specified and should be off-loaded from the delivery vehicle
using a forklift truck or similar equipment.
The fan coils must not suffer any impact or be dropped under any circumstances and should never be handled in such a way as to
cause any damage to coil pipe work, control box or drip tray etc.
Any packaging should not be removed until the fan coil is ready for installation.
Packaging should only be removed if damage is suspected at the time of delivery.
Do not use the drain tray or pipe connections to lift the unit as this could damage the parts and cause problems when
fitting the unit
EXTENDED STORAGE
Should it be necessary to store units on site for any period of time prior to installation it is important that they are stored in a clean,
dry, secure area where there is no possibility of the units being damaged.
Maintenance
It is essential that the following instructions as laid down in this section are carried out and maintained during the period of storage
before commissioning.
Internal Surfaces
If ducting is not connected it is essential that all inlets, discharge openings and pipe openings are completely sealed.
Whenever any access panels are removed for inspection purposes they are to be replaced and made secure, care to be taken not
to damage the seal.
External Surfaces
The exterior shall be kept free from any falling building materials, dampness extreme cold or heat. The unit exterior surfaces must
be inspected on a monthly basis and any signs of corrosion or scratches are to be treated immediately.
Static Indentation
Machines fitted with ball bearings may be damaged if left stationary for long periods. The balls and races may suffer damage by
fretting corrosion (false brinelling, stationary vibration marking). Consequently, no motor should be permitted to stand on a vibrating
floor while in storage if it can be avoided. If this is unavoidable, then the machine should be placed on thick blocks of rubber, cork
or felt.
Filters
All filters must be suitable wrapped and sealed to prevent damp and ingress of dust or foreign bodies, and must be held in a dry
store.
The foregoing instructions are intended to preserve the life of all static and moving parts of the equipment during the period of
storage. It is advisable that regular attention to the equipment is maintained.
When the equipment is to be put into commission the Maintenance Manual is to be strictly adhered to.
The procedures detailed above are particularly brought to your attention and do not exclude other necessary procedures
commensurate with good engineering practice.
5 48008002-06
Unit Model
Dim 'A'
Dim 'B'
Spigot Options
Weight
(approx Kg)
AMB 1
630 595 1-2-3-4
37 AMB 2
880 845 1-2-3-4
45
AMB 3
1230
1195 1-2-3-4-5
55
AMB 4
1230
1195 1-2-3-4-5
60 AMB 5
1430
1395 1-2-3-4-5
70
AMB 6
1430
1395 1-2-3-4-5
75
AMB 7
1780
1745 1-2-3-4-5-6
85 AMB 8
1780
1745 1-2-3-4-5-6
90
AMB 9
1780
1745
1-2-3-4-5-6
95
INSTALLATION
UNIT DIMENSIONS STANDARD UNIT AND LOCO2
Fig 2.
6 48008002-06
Float Switch & Cable Tie Packed
Pre Unit Installation:
1. Ensure when positioning the units that suitable access is available for removing air filter and other routine maintenance
including the removal of coils and fans.
2. Identify the correct units
3. Before removing any packaging check the identity of the fan coil against identity labels on the unit.
Fitting Units
1. Prepare drop rods ready to accept the fan coil units M6,M8 or M10
2. Fit washers and nuts onto drop rods before lifting the unit
3. Use the lock nuts to level the unit and then lock in position
[Note: Studding, nuts and washers not supplied with units]
Fig 3.
4. Packaging should be left in place to protect the unit until ready for fitting.
5. DO NOT USE THE DRAIN TRAY OR PIPES/ VALVES TO LIFT THE UNIT INTO POSITION
6. Suspended the fan coil on the drop rods, level the unit up using a spirit level checking to ensure the unit sits level in both
directions.[the drip tray is designed with a built in fall to ensure condensation runs to the drain connection]
7. Use nuts and washers to secure unit in position.
Units supplied with condensation pumps fitted. [Factory fit option]
8. The float switch is packed in a plastic bag and stored in the drain tray to avoid it being damaged during transit. The float
switch will require fitting to the drain tray drain stub and securing in position using the nylon cable tie supplied.
9. Once the fan coil is fitted it is important to ensure that the float valve sits level and the vent pipe terminates higher than
the condensation tray see fig 5
Fitting the Float Switch on site on units with factory fitted. condensation pump
10. The float switch / mounting bracket assembly must be assembled to the drain pipe on site during installation.
The Float switch is supplied pre piped and packed in the drain tray. See Fig. 4
Fig. 4
7 48008002-06
Float Switch Bracket
Float Switch
Vent Pipe
11. Once the unit is fitted in position remove the float valve assembly from the drain tray unscrew the self tapping screw in the
drain tray and use it to secure the float switch bracket in position on the end of the drain tray. To ease fitting the float
switch can be slid out of the plastic fixing bracket fit as shown in Fig. 5
Fig. 5
12. It is important that the float switch sits level when the fan coil unit is fully installed and that the open end of the vent pipe is
higher than the water level in the drip tray.
13. The drain pipe from the condensate pump must be run to a common drain.
It is important that any condensate pump installed must be in accordance with the manufacturer’s requirements.
Fig. 6
14. It is recommended to use flexible duct connections when connecting to sheet metal ductwork.
15. All connecting ductwork must be independently supported before connecting to the fan coil spigots.
16. Ensure all actuator heads are correctly fitted to the valves.
Typical valve assembly with actuators fitted.
These can be four way or two way valves
depending on specification of unit.
Fig. 7
8 48008002-06
T Bar Grid False Ceiling
with 10 mm Thick Fibre Board
Roof
Return Air Grille or Diffuser
Must not be positioned directly
below the unit intakes
Fresh Air Supply Duct
Ceiling Void
Fan Coil Unit
Internal Room
Accoustically Lined Diffuser
Plenum
Minimum 1 Metre Length Of
Acoustic Flexible Ducting
17. All electrical wiring must comply with BS7671 and local by-laws, all components where applicable should be provided with
all the necessary safety protection and isolating devices.
18. Connect pipe work to the unit refer to fig. 9 for connection detail.
19. Once the units are fitted in position prior to commissioning they must still be protected from damage.
CONNECTION OF DUCTWORK TO QUARTZ DUCTED FANCOILS
Note: The provided ducts are there as a means of connecting the ductwork to the fan coil. Following the below steps will ensure
trouble free installation. All ductwork must be in line with the spigots on the unit before securing in position. The ducts
must slide over the spigot connections without having to use excessive force.
Note: Having to force the duct work to line up with the spigots may cause damage to the spigots and dislodge them from there
fixings.
Typical installation
showing ductwork
connected to unit
The ducts should be pushed fully over the spigot up to the outer casing of the unit and secured to the spigot with screws,
once fitted they should be then sealed around the end of the duct and the outer casing of the fan coil.
IMPORTANT.
The spigots on the unit are there for the sole purpose of providing a connection for the ductwork to the unit. They are not
designed to support the weight of the ductwork and all duct work should be installed square to the spigots this will
eliminate the need for excessive force to make the connection. Duct work should be installed in accordance with CIBSE
HVCA DW144 : Specification for sheet metal duct work.
Fig. 8
All units must be installed in accordance with good engineering standards.
9 48008002-06
Flow connection heating
Return connection heating
Flow connection cooling
Return connection cooling
COMMISSIONING
Once units are fully installed they must be commissioned to ensure they have been correctly fitted in accordance with
manufacturer’s instructions.
Isolate mains supply before
1. Check that the unit is fitted correctly and all supporting drop rods are secure and lock nuts have been tightened.
2. Ensure that all the unit sections are thoroughly clean and free from any installation debris.
3. Check the coil faces are clean and free from dust; check all the water connections to the coil for leaks.
4. Ensure all air is vented from both coils and the system independently
5. Check the filters to make sure they are clean and free from dust and correctly fitted.
6. Ensure all access panels and blanking plates are securely fixed in position.
7. Check that all actuators are securely fitted to the correct valves.
8. Check electrical work to ensure it complies with BS7671 and that the necessary safety and isolating devises have been
fitted.[refer to wiring diagram supplied with the unit ]
9. Use manual air vents to vent any air trapped in the coil.
Manual Air Vents
Fig. 9
R/H pipe work connections shown
10. Check the condensation drain tray for debris and remove any if found.
11. Pour some water into the drain tray to verify the free flow of water.
12. Units with condensation pumps fitted check the operation of the condensation pump by pouring a small amount of water
into the drain tray and ensure the pump clears any water, and operates any alarms etc.
13. Start the fan and blow-through the system thoroughly.
14. Before operating Electric Air Heaters[if fitted] the air flow through the unit should be established.
15. Check the air volume and external pressure is as specified. Adjust air volume as necessary using speed selector and fine
adjustment switches.
16. Check the motor full load current. Nameplate denotes full load current at speed 6 [NR40]. Nameplate value to be unit max
current value.
17. Check the on/off temperature across the coil and adjust water flow accordingly.
18. Check the function of the controls and [water flow temperatures.]
19. After initial start up and continuous running of the unit it is recommended that the following checks are carried out,
a] Motor full load current.
b] Condition of filter. c] Condensate and drains for free flow and leaks. d] Operation of controls.
20. AC motor units, there is a fan speed switch to give three main speeds and a fine adjustment switch for adjusting fan motor
speed.
21. On EC / DC motor units the speed control must not exceed 10.0Vdc and be capable of supporting a 2mAmp Load
AIRSIDE MEASURING AND BALANCING
The most accurate air side measurement for air volume and balancing are obtained by taking readings with an anemometer
traverse across the inlet to the fan coil unit.
10 48008002-06
Pressure readings are most accurately obtained if taken in the discharge ducting of the fan coil unit
Where dampers are fitted in the ductwork they should be used for balancing purposes only and not to regulate the air volume.
Where possible this unit should be adjusted at the fan coil unit.
Electric Air Heaters [if fitted]
Wiring should be in accordance with I.E.E regulations and local by-laws and wired to the appropriate wiring details issued with the
unit. Ensure that all cables and connectors used are suitable for the load being carried.
Important: the fans unit’s must be running before switching on the electric heater elements.
The fan control must be interlocked with the heater control.
Electric heater elements are fitted with a thermal auto reset high temperature cut outs switches on each element, and a manual
reset safety thermostat located on the fan deck.
Before switching on the electric heaters ensure the correct airflow through the unit, a reduced or no air flow will case the thermal cut
out protection switches to operate.
IMPORTANT
If the manual re-set thermostat cuts out isolate all power to the electric heater units before resetting, the cause of the cut
out most be determined and rectified before re setting the manual cut out thermostat.
SERVICE AND MAINENANCE
GENERAL
This section of the manual deals with the requirements for service and maintenance of Quartz fan coil units and must be read
before any maintenance is attempted.
WARNING: It is essential that before any work is carried out the unit is isolated externally from the electrical supply.
For full warranty details see TEV Limited Terms and Conditions for the supply of goods and/or services at
A regular check on the fan/motor assembly is advisable to ascertain if the motor is overheating and that the fan impeller is free
running and has not sustained any damage. If any overheating is occurring, check that the full load current of the motor is within the
nameplate rated value, the impeller is running free and that there is no obstruction upstream of the fan causing a high resistance
with consequent lack of airflow. Also check that the external resistance of the unit is not low, thus causing an increase in power
input.
Check security of fan fixing bolts.
FAN IMPELLOR
Check the condition of the impellor blades any debris deposited on the blades should be removed using a soft brush; take care not
to damage the blades.
TO REMOVE FAN ASSEMBLY THE FOLLOWING PROCEDURE MUST BE ADOPTED.
1. Isolate electrical supply.
2. Loosen the screws securing the fan access panel to the bottom of the unit this will allow the panel slide in the keyhole
slots and can be removed. Move panel to a safe place to avoid damaging.
3. Disconnect wiring loom from terminal block on side of fan scroll.
4. Remove two off M6 screws connecting fan scroll to bulkhead.
11 48008002-06
If fitted Electric
Heating Element
M6 Bolts
Wiring Loom
Fig. 10
View from underside of unit larger units fitted with multiple fans.
5. Remove fans from unit through access opening, taking care not to damage impellers.
6. Before replacing the access panel check that all the insulation is still firmly fixed in position and all seals are intact replace
or re fix if damaged or loose.
7. To re-install, follow reserve procedure.
8. Ensure that the fans are securely fitted back in position and access panel screws are tight.
Electric Air Heater Elements. Fig. 10
NOTE: Elements may be 1.5 kW or 2 kW output and must be replaced with the same size output element only [the output
is stamped onto the top flange of the element]
1. Isolate electrical supply.
2. Loosen the screws securing the fan access panel to the bottom of the unit this will allow the panel slide in the keyhole
slots and can be removed. Move panel to a safe place to avoid damaging.
3. The electric air heater elements are fitted over the fan outlet openings in the air out let plenum chamber and each element
are held in place with two fixing screws.
To Remove Element:
4. Loosen retaining screws and slide element upwards letting the screw head pass through the key hole slots.
5. Remove wires from element, take note of terminal connections used.
6. Remove elements from the unit. [must be replaced with same output size]
7. Replace in the reverse order making sure that all retaining screws are fitted and secure and all the wire connections are
the same configuration.
CONTROLS
All controls are housed inside a purpose designed ventilated control housing mounted to the side of the unit.
Note: The type of controls fitted will vary depending on what controls were specified refer to wiring diagram.
Fig. 11
CONDENSATE TRAY
The condensate tray may be removed for cleaning independently of the coil.
Should any debris be found, the condensate tray should be cleaned thoroughly. Ensure drain connection is free from obstructions.
To remove condensate tray the following procedure must be adopted:-
1. Isolate the electrical supply.
2. Disconnect drainpipe from condensate tray after ensuring all water has been drained off.
3. Remove four M6 tray retaining screw at underside of unit.
4. Lower drain tray down from the bottom of the unit.
5. Clean the tray thoroughly and insect all seals and replace if damaged
6. To replace, reverse the above procedure ensuring all fixing screws are replaced and tight.
12 48008002-06
COILS
The coil shall be inspected every three months to ascertain if any solids or foreign matter have accumulated between the fins and
that the coil connections are free from leaks. Should any matter be found, the coils shall be cleaned by using a soft brush and a
mild solution of detergent. Great care to be taken not to damage the fins. Should the fins become contaminated too frequently it is
advisable to check the air filter to ensure it is correctly fitted and functioning correctly. Coils are fitted with manual air vents to be
used for venting air from the coils.
To remove the coil and condense tray assembly from the unit the following procedure must be adopted:-
1. Isolate the electrical supply
2. Isolate flow and return pipe work to both heating and cooling connections
3. Drain down both heating and cooling coils. Then remove flow and return pipe work to valves and disconnect the condense
pipe from the drain tray..
4. Disconnect valve actuator control leads.
5. Support weight of condensate tray and remove four-off M6 screws holding tray to unit.
6. Support coil and remove 8- M5 bolts. Slide the coil down out of the unit.
CAUTION – The fins on coils are easily damaged and can have sharp edges so protective gloves should be warn,
care should be taken when removing.
7. To re-install follow reverse procedure remembering to vent coil when re-filling with water.
8. Ensure all seals are intact and fixing screws are secure.
9. Check all water connections for leaks.
FILTERS
Filters must be properly maintained in order to ensure proper air cleaning efficiency. Dirty filters will reduce the air volume handled
by the unit, thus adversely affecting its performance. The length of time between cleaning of filters is dependant upon the
environment. A six to twelve month cycle is normal, more frequent servicing may be required in some cases.
Filters on Sapphire series-units are held in place by an inbuilt channel top and bottom.
To remove the filter:
Place fingers in material loops and gently pull out.
Filters on units with out return air plenums shall be removable from the open inlet, and via a bottom access panel on units with
return air plenums. [see fig. 12]
Material Loops used to remove Filters
Fig. 12
Optional pad in frame washable air filter pads.
These can be cleaned by gently tapping and removing loose dust with a compressed air-line or vacuum cleaner. Having removed
the pad from the frame, fully immerse in warm water to which a mild detergent has been added. Agitate the water until all
contaminants have been removed. Rinse in clear water, and then allow to drain and dry before replacing pad into the filter frame.
INSULATION
The insulation must be checked annually for condition and to make sure it is still firmly fixed in position, if a piece of insulation
becomes loose it could restrict the air flow through the unit.
If insulation shows signs of deterioration it must be replaced, if peeling off then it must be
made secure.
To replace the insulation the following procedure must be adopted:-
1. Isolate the electrical supply.
2. Peel off affected insulation pad from casing and discard.
3. Remove old securing tape and residue foam.
4. Clean the area thoroughly before securing insulation in place with new adhesive tape.
5. Press new insulation pad into position on tape.
NOTE: REPLACEMENT INSULATION MUST HAVE CLASS ‘O’ FIRE RESISTANCE
13 48008002-06
EXTERNAL SURFACES
Item
Variable
6
Monthly
Yearly
Page
Motors ● 11
Fan Impeller
●
11
Condensate Tray
●
12
Coils ● 12
Filters ● 13
External Surfaces
●
13
Insulation and seals
●
13
Item
Master Unit(s)
Slave Unit(s)
Transformer 240/24VAC
1 off
N/R*
Controller
1 off
N/R*
Heating. 4 port valve (if specified) Or,
Contactor for Electric Heating
1 off
1 off
Single Stage
1 off
1 off
Cooling 4 port valve (if specified)
Temperature Detector
1 off
1 off
Return air or room mounted
1 off
As required N/R
The unit casings and access panels should be checked for any signs of corrosion. Any rust found should be cleaned and the area
treated to prevent any further rusting.
ROUTINE MAINTENANCE SCHEDULE
WHEN MAKING ENQUIRES FOR SPARES YOU WILL NEED TO HAVE THE FOLLOWING INFORMATION AVAILABLE,
UNIT MODEL, SERIAL NUMBER, QUK NUMBER (QUK NO. IS THE FIRST 4 DIGITS OF THE WIRING DIAGRAM)
THIS INFORMATION IS REQUIRED TO IDENTIFY THE CORRECT SPARES.
WIRING DETAIL, CONTROLS, and ANCILLARY EQUIPMENT
GENERAL
For wiring information refer to the wiring diagram fitted to the unit.
Controls fitted may be one of the following arrangements:-
a) Heating only.
b) Heating using electric elements.
c) Cooling only.
d) Heating and cooling in sequence with a dead band between modes.
Normally the Cooling medium will be chilled water. Heating medium will normally be L.P.H.W but alternative coils are available to
suit secondary water temperatures.
Alternatively Electric Heating elements are available, and can be supplied wired for single phase or three phase supply as
appropriate or as specified.
Multiple units fitted on the same system may be controlled through one controller wired through a master unit, or controlled through
individual controllers.
Refer to Layout Drawings or the Design Specification for individual unit control requirements, check the serial plate for specification
details.
For Fault finding and commissioning of the controls, refer to controls manufacture’s technical data.
CONTROLS-MAJOR COMPONENTS
*Note: The number of slave units is limited by the controller output and varies from manufacturer to manufacturer. If in
doubt please contact TEV LTD.
Slave units are fitted with a transformer to provide multi-speed selection.
We reserve the right to alter designs and specifications at any time without notification
To view our Terms and Conditions visit www.tevlimited.com/terms.html
14 48008002-06
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