Aira HCV User guide

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Installation, Startup, Operation,
Service & Maintenance Manual
HCV & HCVR
Evaporative Cooler / Heater

CONTENTS
HCV & HCVR Evaporative Cooling & Gas Heating
Page 2of 26
Contents
GENERAL INFORMATION ............................................................................................................4
Unit Configurations / Components ................................................................................................ 7
OPERATING INSTRUCTIONS....................................................................................................... 8
Wall Control Options ................................................................................................................... 8
General Operation ...................................................................................................................... 9
HCVR Return Air Models .............................................................................................................. 9
INSTALLATION INSTRUCTIONS................................................................................................10
Installation Guidelines............................................................................................................... 10
Installation .............................................................................................................................. 10
On receipt of equipment......................................................................................................... 10
Unit Location ........................................................................................................................ 10
Flue..................................................................................................................................... 11
Gas Supply........................................................................................................................... 11
Electrical Supply ................................................................................................................... 11
Water Supply........................................................................................................................ 12
Water Setup ......................................................................................................................... 12
Water Supply........................................................................................................................ 12
Dump Valve (Optional) .......................................................................................................... 13
Drain ................................................................................................................................... 13
Roof Stands............................................................................................................................. 14
COMMISSIONING .....................................................................................................................15
Cooling Section ........................................................................................................................ 15
Heating Section........................................................................................................................ 16
Temperature Control................................................................................................................. 17
UNIT SERVICE ..........................................................................................................................18
Blower and Drive Components ................................................................................................... 18
Cooling Section ........................................................................................................................ 18
Heating Section........................................................................................................................ 19
Clean and Service ................................................................................................................. 19
Remove Pilot Assembly and Burner Bars .................................................................................. 19
Remove Main Burner Bars ...................................................................................................... 19
Cleaning burners................................................................................................................... 19
Gas Controls......................................................................................................................... 20
Fault Finding............................................................................................................................ 20
Cooling Section ..................................................................................................................... 20
Inadequate cooling................................................................................................... 20
Pilot flame goes out.................................................................................................. 21
Pilot flame does not light .......................................................................................... 21
Burners do not come on when pilot flame is alight and room thermostat is ‘Made’............ 21
Unit overheats and locks out limit switch .................................................................... 22

CONTENTS
HCV & HCVR Evaporative Cooling & Gas Heating
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System fan motor fails to operate .............................................................................. 22
Burner flames are yellow or tend to ‘float’ ................................................................... 22
Primary aeration incorrect......................................................................................... 22
Fan does not start.................................................................................................... 20
Overheating Motor ................................................................................................... 20
Belt slip or excessive belt wear .................................................................................. 20
Pump fails too operate.............................................................................................. 20
Pump runs but water not circulated or pads dry ........................................................... 20
Heating Section .................................................................................................................... 21
Unit locks out .......................................................................................................... 21
Pilot flame lights but will not hold in ........................................................................... 21
Heating not delivering proper amount of heat.............................................................. 21
Flame flash back and burning at orifices. .................................................................... 21
Delayed or rough ignition.......................................................................................... 21
COMMISSIONING REPORT........................................................................................................ 23
WARRANTY TERMS AND INFORMATION ...................................................................................24

Safety Information
HCV & HCVR Evaporative Cooling & Gas Heating
Page 4of 26
GENERAL INFO THIS HEATER IS TO BE INSTALLED BY AN AUTHORISED
PERSON ONLY
DO NOT Operate this appliance before reading the manual.
DO NOT Place articles on or against this appliance.
DO NOT Use or store flammable materials near this appliance.
DO NOT Operate this appliance with panels, covers or guards removed.
DO NOT Spray aerosols in the vicinity of this appliance while it is in operation.
This AIRA unit must be installed in accordance with these instructions, local gas fitting regulations,
municipal building codes, electrical wiring regulations, Australian Standard AS/NZS 5601 Gas Installations
and any other relevant statutory requirements.
Employers and Employees Responsibility
The installation and maintenance of gas ducted
heating units, particularly at height, has the
potential to create Occupational Health and Safety
issues for those involved. Installers are advised to
ensure they are familiar with relevant State and
Federal legislation, such as Acts, Regulations,
approved Codes of Practice and Australian
Standards, which offer practical guidance on these
health and safety issues. Compliance with these
regulations will require appropriate work practices,
equipment, training and qualification of workers.
Seeley International provides the following
information as a guide to contractors and
employees to assist in minimising risk.
Risk Assessment
A risk assessment of all hazardous tasks is required
under legislation. A risk assessment is an essential
element that should be conducted before the
commencement of work, to identify and eliminate
the risk of falls and other risks, or to minimise these
risks by implementing control measures. This does
not need to be a complicated process - it is a matter
of assessing the job to be done and considering
what actions are necessary so the person doing the
job does not injure themselves.
This should be considered in terms of:
What are the chances of an incident occurring?
What could the possible consequences be?
What can be done to reduce, or better still,
eliminate the risk?
HANDLING THE HEATER
The heater has lifting lugs for crane hook-up. Hooks, jacks, or chains must not be applied around casing or
control box.
POSITIONING THE HEATER
Heater should be installed so that it is level. Allow 1200mm clearance at the front and control side of the
heater and 500mm on the bottom, top, and other side. Air intake to the unit should not be restricted in
any manner.
Wiring Electrical connections must be in accordance with all relevant Australian standards.
Avoid quiet areas:
Directly above, below or outside bedrooms, living room, lounge room, dining room etc. Some points to
consider
Preferred installation locations:
Above, below or outside laundry, bathroom, kitchen, garage etc’
PIPING
Gas piping should be sized adequately, in accordance with the Australian Gas Association’s installation code
AG501.

Safety Information
HCV & HCVR Evaporative Cooling & Gas Heating
Page 5of 26
SOME POINTS TO CONSIDER
Some points to consider when working on or in a roof
What is the best and safest access to the roof and working areas?
What condition is the roof in? Should the roof structure and surface be checked?
Does the worker have appropriate footwear?
Are all power cables/extension leads safe and appropriately rated?
Are all ladders, tools and equipment suitable and in good condition?
Where ladders are to be used, is there a firm, stable base for them to stand on? Can they be tied or
secured in some way at the top?
Is there a roof anchor to attach a harness and lanyard to? If so, instruction should be issued for the
use of an approved harness or only suitably trained people used.
Are all tools and materials being used, prevented from slipping and falling onto a person at ground
level? Is the area below the work area suitably protected to prevent people entering this area?
Does the work schedule take into account weather conditions, allowing for work to be suspended in
high winds, thunder storms/lightning or other types of weather giving wet, slippery surfaces?
Is there an on-going safety check system of harnesses, ropes, ladders and access/lifting equipment,
and any anchor points on roofs before the commencement of work?
Is there a system which prevents employees from working on or in roofs if they are unwell or under
the influence of drugs or alcohol?
Are there any special conditions to consider i.e. excessive roof pitch, limited ground area, fragile roof,
electrical power line

GENERAL INFORMATION
HCV & HCVR Evaporative Cooling & Gas Heating
Page 6of 26
AIRA HCV/R series heater/cooler units are an indirect fired gas warm air heater with an evaporative cooler
section attached. This unit can be used in closed in areas such as offices, shops, restaurants, schools,
Take-away food stores, glasshouses etc. HCV/R units can be wired up to suit site condition requirements
and options. These options include: Single or two speed motors, duct louvers, electronic modulating gas
trains, return air, etc.
The heating section usually consists of a stainless steel indirect fired heat exchanger, RAM - 5EM7-01 flame
controller, electronic ignition, high limit switches and pre and post heat switches. A room thermostat is
connected to read heat requirement in the application. As the temperature in the room and the thermostat
set position get closer the gas valve modulates. There are many different options available to ensure
suitability of the equipment to suit a particular site.
Evaporative cooling is via Celpad water saturated pads. This type of pad has more stability, longer life and
airflow as compared to older aspen style pads and less maintenance is required. A Variety of covers can
be provided including marine grade louvre protection, fire screens, insect screens and filters.
Ventilation is achieved by simply turning the fan on without the water pump running. This mode of
operation is used when ambient temperature can be utilised to cool down or heat up the work area. I.e. if
the work area is has machinery that is generating heat above 22°c and the ambient temperature is 18°C
with high humidity the ventilation mode can be selected.
With a Return air function installed, gas consumption is reduced. Supply air is heated and then returned
through the heat exchanger to be reheated. If the heater is fitted with a modulating gas train, the burner
will modulate down to low fire and then turn off when the room thermostat reaches the pre selected
temperature. When the unit is operating in return air mode, fresh air is still fed into the heated area at a
lower rate to ensure air remains fresh.
As the AIRA/HCV/R is indirectly fired the flue gasses must be flued to the atmosphere. The flues must be
clear of any air intakes, eaves etc. as per Australian gas regulations. The efficiency of a heat exchanger
unit is approximately 80%.
Commissioning is to be done by an experienced 'A' Type approved service person and does not normally
require an inspection by the Office of Gas Safety (OGS).
Control of the Unit can be via a number of methods. The standard controller is a 5 gang wall mount switch
allowing the unit to operate in high cool/low cool/ventilation/heat modes. Some people find a rotary dial
easier to operate. The unit can also be controlled via push button control or via Building management
system (BMS) or Variable speed drive (VSD). Controls are not designed to switch quickly between heating
cooling and ventilating but graduate temperature toward desired outcome. Please contact Factory for
clarification re control wiring.
VSD
Push Button
Rotary Dial
5 Switch

GENERAL INFORMATION
HCV & HCVR Evaporative Cooling & Gas Heating
Page 7of 26
UNIT CONFIGURATIONS /COMPONENTS
HCV Outside view (marine grade aluminum)
Flue Cowl
Adjustable
Stand
Heater
Cooler
HCV internal view
Motor &
Pulley
Blower Assembly
& Pulley
Heater
Gas Train
Return air HCV (Rear return)
Fresh Air Louvre
Inlet
Thermostat
Control Box
Outlet
Thermostat
Supply Air
Damper Motor
Gas Valve
Inlet
Modulating
Gas Valve

OPERATING INSTRUCTIONS
HCV & HCVR Evaporative Cooling & Gas Heating
Page 8of 26
OPERATING IN STRUCT ION S
WALL CONTROL OPTIONS
The HCV can be controlled a variety of ways.
Standard supplied control is a 5 switch wall mount gang switch.
1.1 Remote selector switch panel functions.
The switch panel consists of five individually marker rocker switches and a warning lamp. The
switch panel is specially designed for use with HCV units, and gives a selection range of ‘OFF, LOW
VENT, HIGH VENT, LOW COOL, HIGH COOL and HEAT.’ The switch marked ‘PRESS’ is used to reset
the appliance when the red warning light is alight. Switch settings for unit control are as follows:-
OFF
FAN SWITCH OFF, OTHER SWITCHES ANY POSITION.
LOW VENT
FAN SWITCH ON, COOL SWITCH OFF, HEAT SWITCH OFF, HIGH-LOW
SWITCH IN LOW POSITION
HIGH VENT
FAN SWITCH ON, COOL SWITCH OFF, HEAT SWITCHOFF, HIGH-LOW SWITCH
IN HIGH POSITION.
LOW COOL
FAN SWITCH ON, COOL SWITCH ON, HEAT SWITCHOFF, HIGH-LOW SWITCH
IN LOW POSITION.
HIGH COOL
FAN SWITCH ON, COOL SWITCH ON, HEAT SWITCH OFF, HIGH-LOW SWITCH
IN HIGH POSITION.
HEAT
FAN SWITCHON, COOL SWITCH OFF, HEAT SWITCH ON, HIGH-LOW SWITCH
IN LOW POSITION. Note that heating will not operate with high-low switch in
high position.
1.2 Optional Rotary remote selector switch functions.
Hi-Cool
Evaporative cooling, dampers open, maximum air delivery
Lo-Cool
Evaporative cooling, dampers closed to preset position, corresponding
decrease in air volume.
Hi-Vent
Fresh air ventilation, dampers open, maximum air delivery.
Lo-Vent
Fresh air ventilation, air quantity reduced as for ‘Lo-Cool’.
Heat
Fresh air ventilation together with heating to maintain comfort heating to an
area whilst providing required air changes of fresh air per hour.
These switches are specially designed and manufactured for Aira HCV units for special applications.
They give an operating range of Hi-Vent, Lo-Vent, Hi-Cool and Heat.
Note: Other Controls can be designed and or supplied on request for specialist applications. VSD
drive can be supplied loose (Programing by others) or shielded cable installed. Usually a VSD drive
is fitted to a single speed motor.

OPERATING INSTRUCTIONS
HCV & HCVR Evaporative Cooling & Gas Heating
Page 9of 26
GENERAL OPERATION
1. Ensure that all fuses on switchboard are in position.
2. Ensure isolating switch for unit situated inside the heater section is in “ON” position.
3. Set room thermostat to 21°C. This may be varied later if desired.
4. The limit air thermostat will have been set during commissioning to give the desired comfort air off
temperature.
5. Heat –unit operates and discharge dampers close to predetermined position to give design
temperature rises across unit or design L/sec air flow. Provided entering air temperature is below
duct thermostat setting, a gas control valve will vary the gas flame to maintain a controlled air off
temperature.
6. Should the burner fail to operate and the red lockout light comes on, wait five minutes after
observing red light to ensure unit is venting and then press and release reset button. Unit should
relight and operate.
7. When selector is turned “OFF” the fan may continue to run for up to five minutes to allow for cooling
down of the heat exchanger.
8. Vent / Set selector switch to “High”. Fan motor only will operate. Heating section is de-energised.
9. Set selector switch to “Low”. Dampers will close to same position as for heating and fan will operate
at reduced air volume. Heating section is de-energised.
10. Cool –Unit operates on “High” or “Low” air output (damper opening as in high and low vent). Water
pump and fan operate. Heating section is de-energised.
11. To shut down gas burners completely, close main stop cock at unit and turnoff isolating switch in the
heater section of the unit.
HCVR RETURN AIR MODELS
The HCVR Return Air Models are designed to allow full fresh air on cooling as per standard HCV, but then
allow economical return air heating during the heating mode. This is achieved by motorized dampers
automatically closing off the cooling fresh air section and opening a motorised return air heat damper at
the heating section of unit. Dampers can also be set proportionally to allow some fresh air during heating.
Standard control on Return Air Models is on/off gas control operated to a standard on/off room thermostat.
Optional electric Modulation is available to modulate burner operation in conjunction with a compatible 0-
10 volt Modulating room thermostat. Leaving air tempering is not required on Return Air models due to the
recirculated room air temperature.
IMPORTANT: If heater will not operate after carrying out instructions as detained above,
contact the installer or Aira for further advice.
During normal operation in cooling mode it is important that the water bleed-off is operating and is not
shut off or blocked. This bleed-off will prevent an accumulation of salts and solids in the unit. Bleed off also
ensures a constant supply of fresh water into the cooler. A Dump valve is also recommended to ensure no
water remains within cooler when unit not in use. Aira coolers have a very small water sump ensuring little
water is wasted in a dumping cycle.

INSTALLATION INSTRUCTIONS
HCV & HCVR Evaporative Cooling & Gas Heating
Page 10 of 26
INSTALLATION IN STRUC T IONS
INSTALLATION GUIDELINES
LPG Appliances subject to gas supply authority inspection.
The building structure should be able to carry the operating weight of unit, all relevant stands and
ductwork, as well as service and installation personnel.
Keep unit clear of any heating flues, kitchen exhaust, toilet exhaust, sewerage vent pipes etc. Keep ample
clearance on all air inlet sides of unit. A basic rule is not less than 1 meter. Do not site the unit over or
near a skylight. Installation or service personnel could fall through causing damage and injury. Roof stand
kits are available for all models. Ensure that stand is fitted such that the unit remains level.
When slinging any unit for a crane lift, ensure that an adequate sized rope sling is used. The sling should
be wrapped round the bottom of the unit. DO NOT tie slings around and under the roof (top) panel or
through the fan housing. It is advisable when slinging unit to use a bar or wooden spreader laid across the
top of the unit protruding past edges sufficient to stop damage to paint or roof panel.
NOTE: Base panel lifting frames with hooks or eye holes are standard on all sizes of HCV unit.
Consult local building codes for any special requirements. For example: water supply, gas supply, electrical
supply and building structural computations.
Electricity Supply: All electrical connections and wiring must conform to AS3000 and be in
accordance with local requirements.
Flue: Material and installation shall comply with A.G.A Code 5601 (Installation code for Gas
Burning Appliances and Equipment).
Gas Supply: A gas supply line of adequate size shall be connected to the heater. Refer AS 5601
pipe sizing chart.
Water Supply: All water connections and piping must conform to standard codes and local
requirements.
Do not locate unit in an enclosed plant room unless sufficient openings are available to ensure air pressure
in the plant room cannot become negative with all items in the plant room operating. For installations
similar to this, consult fuel supply authority prior to installing. Temperature rise on ”HEAT” must be within
the range of 11°C to 33°C on full flame. Overheating due to incorrect damper setting or restrictive
ductwork may cause problems with heating operation, causing high limit safety control to activate. Gas
burner pressure must be set as per data plate. Firing rate cannot be increase beyond data plate rating. As
part of installation procedure, units must be set up and tested by authorised installer.
INSTALLATION
The following recommendations are not intended to supplant or take precedence over relevant official
regulations.
On receipt of equipment
a) Inspect the unit for any damage caused in transit. Any such damage must be immediately reported
to the shipper of the goods.
b) The unit has been factory tested to check for correct operation of all components. If any part is
obviously missing or damaged, notify the supplier immediately.
c) Check the appliance to ensure that the H.C.V has been supplied for the correct supply, ie Natural,
Towns or LPG gas.
Unit Location
a) The H.C.V is designed essentially as a roof top or external ground mount unit, however, under
certain conditions it can be located in a plant room if positive pressure is maintained by mechanical
ventilation or the heater section is isolated from the cooler section within the plantroom. This
equipment is not designed for long and complex air distribution ductwork and as such the H.C.V
should be located as close as practicable to the points of air distribution. Depending on large