Fresh-r In-The-Wall User manual

In-The-Wall
Installation manual
IMPORTANT: Read this manual carefully before installing the fresh-r
Keep this manual for future use.

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Installation manual
Foreword
Installation manual for the contractor/owner installer
Dear contractor,
Thank you for purchasing the fresh-r In-The-Wall. This manual is intended for
professionals and contains all the necessary installation information.
To install the fresh-r correctly and safely, it is essential that you read this information
carefully and familiarize yourself with the fresh-r before you start. The fresh-r requires a
fused 220V mains electricity supply with earth and must be connected by a qualified
electrician.
The information in this manual is important for the correct and safe installation of the
fresh-r. With the table of contents, you’ll be able to find the right information in the
manual quickly.
This is the installation manual. Besides this manual there is also a user manual available which
covers operation and maintenance.
These manual covers installation of the Fresh-r In-The-Wall ONLY. It does not include
the Everywhere version
Some illustrations might differ from the actual model and options that you have
purchased.
NOTICE

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Contents
Contents............................................................................................................................................................................................ 3
1. Intended use ........................................................................................................................................................................... 5
2. Target group............................................................................................................................................................................ 5
3. Symbols used in thismanual................................................................................................................................................... 5
4. General safetyinstructions..................................................................................................................................................... 6
5. Main components................................................................................................................................................................... 6
6. Installation Frame................................................................................................................................................................... 7
7. Installation Frame Assembly.................................................................................................................................................. 8
8. Tools needed for the installation......................................................................................................................................... 10
9. How to install the fresh-r...................................................................................................................................................... 11
10. Prepare the fresh-r unit........................................................................................................................................................ 14
11. Install the fresh-r .................................................................................................................................................................. 17
13. To install the grilles do the following: ................................................................................................................................. 22
14. Connect the fresh-r electrically and test its functionality................................................................................................... 23
15. Connect the fresh-r to the internet...................................................................................................................................... 23
16. Installation checklist............................................................................................................................................................. 25
17. Specifications ........................................................................................................................................................................ 25
18. Declaration ofconformity .................................................................................................................................................... 26
Figure 1 Main components ..................................................................................................................................... 6
Figure 2 Installation frame contents ........................................................................................................................ 7
Figure 3 Bending U shap top and bottom metal edge ............................................................................................... 8
Figure 4 Timber frame screwed together................................................................................................................. 8
Figure 5 Fasten the bottom U shape with the screws provided.................................................................................. 8
Figure 6 Place the 2 U shaped metal edges ............................................................................................................. 8
Figure 8 Fit the two middle strips so that all edges do not overlap............................................................................. 9
Figure 7 Install the screws and secure the middle strips so that they are fitting properly against the U shape that has
been fastened with screws ..................................................................................................................................... 9
Figure 9 Break U shape into 3 pieces ....................................................................................................................... 9
Figure 10 Top U shape metal edge........................................................................................................................... 9
Figure 11 Installation Frame configured for the ITW Everywhere .............................................................................10
Figure 12 Drilling dimension diagram......................................................................................................................12

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Figure 13 Minimum distance from leading metal edge (surface finish) to the outer wall inside the cavity is 21cm.......13
Figure 14 Cutting lower duct to length....................................................................................................................14
Figure 15 Cutting upper duct to length ...................................................................................................................14
Figure 16 Measuring the wall thickness ..................................................................................................................14
Figure 17 Deburr and chamfer the duct pipes making insertion into the white ring possible ......................................15
Figure 18 Bottom outlet of Fresh-r USE Hard PVC glue to ensure water tight seal......................................................15
Figure 19 DO NOT USE PCV GLUE Top of Fresh-r unit...............................................................................................15
Figure 20 Use plenty –move fast as it sets quickly like contact glue .........................................................................15
Figure 21 Hard plastic PVC glue –critical function ...................................................................................................15
Figure 22 Slide the insulating cover over the duct pipe –use Polymax to make an air tight connection.......................16
Figure 23 Insert the duct into the white ring ...........................................................................................................16
Figure 24 Internal wall sealing................................................................................................................................16
Figure 25 Mounting bracket as shipped ..................................................................................................................16
Figure 26 Lower end of fresh-r properly secured.....................................................................................................16
Figure 27 Mounting bracket formed and fixed with screw in dedicated hole.............................................................16
Figure 28 Fresh-r everywhere mounted inside installation frame .............................................................................17
Figure 29 Fresh-r everywhere with duct connection and closed top .........................................................................17
Figure 30 Fresh-r mounted inside installation frame................................................................................................17
Figure 31 Low loss bend fitted directly onto adapter ...............................................................................................18
Figure 32 Fresh-r standard duct adapter 204 x 60mm..............................................................................................18
Figure 35 Square to round (125mm) fitted..............................................................................................................18
Figure 33 Square to round adapter with .................................................................................................................18
Figure 34 Square to round adapter with .................................................................................................................18
Figure 38 Chicane bend using 2 x45........................................................................................................................18
Figure 36 Adapt and Radial 3 X 75 connection piece direct to adapter flange ............................................................18
Figure 37 90 degree bend using 2 X 45....................................................................................................................18
Figure 39 Adapt and Radial socket RDA 3 x 75.........................................................................................................19
Figure 40 Adapt and Radial socket RDA 3 x 75.........................................................................................................19
Figure 42 Insulate between fresh-r and installation frame .......................................................................................20
Figure 41 Depth of PUR injection............................................................................................................................20
Figure 44 Fit door and frame into installation frame................................................................................................20
Figure 43 Secure door frame at each side with screws provided...............................................................................20
Figure 45 diagram of lower pipe –2 degree fall and 20mm protrusion.....................................................................21
Figure 46 seal the Outerwall ..................................................................................................................................21
Figure 47 Outer grill alignment...............................................................................................................................22
Figure 48 Outer grille.............................................................................................................................................22
Figure 49 Microchip config page.............................................................................................................................24

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1. Intended use
The fresh-r In-The-Wall is a decentral ventilation unit with heat recovery. The
fresh-r takes heat from the stale air it expels and uses it to warm up the fresh air
it brings in from outside.
It improves air quality for a healthy indoor air quality and at the same time
reduces your energy bill. No ducting is needed for this unit, which makes
installation easier than a conventional HRV system. The fresh-r is equipped with
CO², RH and temperature sensors and has an intelligent control system.
The fresh-r has been set-up and tested prior to delivery. Other than
checking/ensuring correct installation there is no requirement for commissioning.
The fresh-r On-The-Wall may only be installed on an external wall.
2. Target group
The manual describes how to install the fresh-r. The installation must be done by
contractors who are familiar with local building regulations.
Connecting the fresh-r to the mains electricity supply must be done by a qualified
electrician.
3. Symbols used in this manual
3.1 Safety symbols
DANGER
Indicates an immediate risk of irreversible injury or death
when not observed.
CAUTION
Indicates that the product may be damaged if the
procedures are not followed carefully.
NOTICE
Alerts the user to additional information and possible problems.
3.2 Other symbols
CE marking: This is the CE logo indicating that the fresh-r meets
the legal requirements.

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4. General safety instructions
• Connecting the fresh-r to the mains electricity supply must be done by a qualified
electrician.
• Risk for electric shocks or electrocution. Turn off the mains electricity supply in the
distribution box before connecting the fresh-r electrically.
• The person responsible for installing the fresh-r should be familiar with the local
building regulations.
5. Main components
Figure 1 Main components
A.
ON/OFF switch
B. Power connection wire 3 meter
C. Unibody
D. Front door
E. Grille x 2 pieces including screws and wall
plugs
F. Duct pipe EPP covers
G. Duct pipes
DANGER
A
B
C
E
F
G
D

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6. Installation Frame
Figure 2 Installation frame contents
A. 2No. Metal edge for top and bottom
B. 4No. Distance screws + 4 No. wall plugs, 24No. wood screws for mounting metal edges, 6No. wood
screws for securing door frame into timber frame, 8no. wood screws for assembly of timber frame.
C. 2 No. Left and Right middle pieces –metal edge
D. 1No.Top piece of timber frame
E. 1No.Bottom piece of timber frame
F. 2No. side pieces timber frame
A
B
C
D
F
E
NOTE: Recess

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Figure 5 Fasten the bottom U shape with the screws
provided
7. Installation Frame Assembly
Figure 4 Timber frame screwed together
7.1 Assemble the timber frame
i) Put the 4 pieces of the timber frame together with the recess all facing inwards and all on the top
edge.
ii) Use the 8 screws to fix the pieces together. The top and bottom pieces each have 4 pilot holes
where the screws should be used.
iii) Don’t fully tighten the 4 screws on the part with the cutout yet.
iv) Bend the two long metal strips so that they form a U shape
Figure 3 Bending U shap top and bottom metal edge
Figure 6 Place the 2 U shaped metal edges

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Figure 7 Install the screws and secure the middle
strips so that they are fitting properly against the U
shape that has been fastened with screws
Figure 9 Break U shape into 3 pieces
Figure 8 Fit the two middle strips so that all edges do not overlap
v) Place the top and bottom U-shaped metal edge
vi) Secure the metal edge on the end without a cutout using the screws supplied
vii) Fit the middle pieces between the U shapes and ensure that the edges are flush with no over lap
viii) Secure the middle pieces tightly against the previously secured U shape
ix) Tight the 4 wood screws to draw the top inwards until the U shape fits properly against the middle
strip.
x) Secure the U shape with the screws provided.
7.2 Installation Frame for Everywhere version
Figure 10 Top U shape metal edge

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i) Break the uninstalled U shape into 3 pieces
ii) Insert the two side pieces and secure with screws
iii) The top edge can be fitted and secured after installing the Fresh-r unit and extract duct connection
Figure 11 Installation Frame configured for the ITW Everywhere
8. Tools needed for the installation
• Equipment to drill 2 round holes (Ø 160 mm) in the wall (typically water-cooled
diamond core drill)
• Equipment to cut the rectangular hole (1190mm X 340mm) in the inner wall –
typically a disc cutting machine
• Torx 25 screwdriver
• Posidrive No. 2 screwdriver (Philips)
• 6mm Allen Key
• 8 mm masonry drill, 8mm wood drill
• PVC cement (this is standard glue for hard PVC)
• Spirit level (or another tool to check for a prefect vertical position)
• Deburring or grinding tool, such as a file
• EPP Glue (Bison Polymax) and expanding foam

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9. How to install the fresh-r
The person responsible for installing the fresh-r should be familiar with the
local building regulations.
9.1 Prepare the wall
You will need a rectangular hole cutting in the inner wall 1190mm X
340mm and two round holes (Ø 160 mm) in the outer wall of the building,
for the air pipes; the lowest hole needs to have a slope of 2 degrees .
For efficient ventilation place the unit centrally in the room, ideally at
approximately 80cmfrom the floor level, but not too high. You should be able to
see the user controls easily, which are mounted at the top left corner of the
unit.
1. The duct pipes are 16mm off center to the right when looking from inside of
the house.
2. The duct pipe core holes must be drilled from inside to outside any slight
misalignment can be concealed when installing the grilles on the outside.
9.2 Cutting the rectangular cavity
• Mark the rectangle on the wall avoiding interference with electrical cables or water
pipes. See figure 12 below for dimentions
• Check that you are content with where the duct pipe holes will be drilled with
reference to the outer visual appearance of the grilles, adjust if necessary.
• Use a disc cutter fitted with an appropriate masonry disc and cut the top horizontal,
followed by the two vertical sides. Only cut through the inner wall to the air gap. The
air gap is probably filled with insulation. Knock the block work out as you go and
finally cut the bottom horizontal. You may need to clean the corners out using a
hammer and chisel.
• After cutting the cavity, remove the insulation if present and mark out the duct hole
centers in accordance with the diagram in fig 13 above.
DANGER
CAUTION

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Figure 12 Drilling dimension diagram
9.3 Drilling the 160mm duct holes
To drill the lower big hole (160 mm) , do the following:
1. Drill from inside through both the inner wall across the cavity (if
present) and through outer wall at a downward angle of 2
degrees. This is to allow the condensate to drain towards outside.
To drill the upper big hole (160 mm), do the following:
2 Drill from inside through both the inner wall across the
cavity (if present) and through outer wall
3 Remove dust and other materials from the holes.
4 Get a duct pipe (this is the grey PVC pipe) with EPP cover
(this is a foam tube) and try if it fits the holes.

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Figure 13 Minimum distance from leading metal edge (surface finish) to the outer wall inside the cavity is 21cm
9.4 Mount the installation frame
To mount the installation frame, do the following:
• Insert the built-up installation frame into the cavity –chapter 7. The metal edge
should be set so that it is flat with the wall all the way around, level and plumb.
• Measure the distance between the front metal edge and the outer wall –there needs
to be 21 cm as a minimum. Adjust the setting of the frame if needed.
• If the installation frame needs to be set with the metal edge protruding past the
desired finish level of the wall you can make a rectangular frame to make up the
difference (something like a picture frame idea)
• After setting the frame at the correct minimum depth use an 8mm drill and drill
through the side of the installation frame and into the wall deep enough to sink the
wall plugs of the distance screws into. Drill 4 holes 2 on the left and two on the right
–1 towards the top and the other towards the bottom of the frame on each side.
• Screw the distance screw into the wall plug (2 or 3 turns of the screw) and then push
the wall plug/screw through the timber frame into and into the wall.
• Tighten the distance screw using an Allen key until the head of the screw is flush
with the surface of the wooden frame.
NOTE –if the cavity is not deep enough then the door for the fresh-r will not
properly fit and ventilation will be impeded.

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D1
D1 - 173mm
D1 137mm
Figure 14 Cutting lower duct to
length
Figure 15 Cutting upper duct to length
10. Prepare the fresh-r unit
10.1 Cut the duct pipes to length
To. cut the duct pipes, do the following:
1. Remove the EPP covers.
2. Cut the upper duct pipe (input fresh air) to the total width of the wall (D1) + 25mm
3. Cut the lower duct pipe (output stale air) to the total width of the wall(s) (D1) + 65mm
Tip: Use a wide tape or two paper sheets taped together to mark the duct pipes and get a
perpendicular cut.
NOTE D1 must be measure from the front of
the metal edge of the installation frame after
final fixing and through to the outer surface of
the wall where the grilles will be placed
Figure 16 Measuring the wall thickness

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4. Deburr and chafer the end of the duct pipes that will be inserted into the Fresh-r. Use
a deburring tool, such as a file .
10.2 Install the duct pipes into the fresh-r
1. Use PVC glue to seal the lower pipe into the white ring. The lower duct pipe is the condensate
drain and needs to be water tight. Apply PVC glue to the last 3 cm of the duct and to the white
ring.
Figure 17 Deburr and chamfer the duct pipes making insertion
into the white ring possible
Figure 19 DO NOT USE PCV GLUE Top of
Fresh-r unit
Figure 18 Bottom outlet of Fresh-r USE Hard PVC glue
to ensure water tight seal
Figure 21 Hard plastic PVC glue –critical function
Figure 20 Use plenty –move fast as it sets quickly like
contact glue
X

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Figure 23 Insert the duct into the white ring
Figure 22 Slide the insulating cover over the duct pipe –use Polymax to make an air
tight connection
Figure 26 Lower end of fresh-r properly secured
2. After applying PVC glue, insert the chamfered end into the white ring and firmly push until it
completely bottoms out against the black EPP material. You need to move fast because the PCV
glue sets quickly. You will not be able to move the pipe at all withing approx. 30 seconds –so do
not pause during this operation.
3. Install the upper duct pipe in the same way. Do not glue the grey pipe into position but do glue the
insulating cover in the same way as the lower duct pipe.
4. Apply polymax around the outside of the insulator so that it will form an air tight seal.
5. Bend the 4 mounting brackets so that they fall flat across the front edge of the installation frame.
Figure 24 Internal wall sealing
Figure 25 Mounting bracket as shipped
Figure 27 Mounting bracket formed and fixed with
screw in dedicated hole

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Figure 28 Fresh-r everywhere mounted inside installation
frame
Figure 29 Fresh-r everywhere with duct connection and closed
top
11. Install the fresh-r
11.1 Mount the unit onto the wall
1. Lift the fresh-r complete with fitted duct pipe and insulators to the prepared wall.
2. Correct orientation is with the electrical control panel upper left.
3. Guide the duct pipes into the 160mm holes in the wall
4. Guide the electrical cable taking care not to trap it.
5. Make the electrical connection - this can be to a junction box within the wall or a surface mounted
junction box depending upon you electrical design
6. Press the fresh-r into the installation frame and secure each mounting bracket with a screw in the
dedicated holes that are provided in the metal edge.
11.2 Extract duct connection
There are many configurations for the extract duct connection and this will depend entirely on the routing that
is specific to your ventilation design in conjunction with the building design with reference to joists, open
spaces and ceilings etc. See collage of examples below. The unit needs to be installed first and then to run
the ducting from the unit to the extract points. All joints must be glued air tight. All ducting running through a
cold zone needs to be insulated to avoid heat loss and condensation.
Figure 30 Fresh-r mounted inside installation frame

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Figure 34 Square to round adapter with
125mm round connected
Figure 37 90 degree bend using 2 X 45
Figure 36 Adapt and Radial 3 X 75 connection
piece direct to adapter flange
11.3 Examples of extract duct connections
Figure 32 Fresh-r standard duct adapter 204 x 60mm
Figure 35 Square to round (125mm) fitted
directly to adapter
Figure 38 Chicane bend using 2 x45
Figure 31 Low loss bend fitted directly onto adapter
Figure 33 Square to round adapter with
125mm round connected –side view

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Figure 40 Adapt and Radial socket RDA 3 x 75
Figure 39 Adapt and Radial socket RDA 3 x 75

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Figure 41 Insulate between fresh-r and installation frame
Fill this gap all of the way
around the fresh-r with
PUR foam.
Figure 42 Depth of PUR injection
11.4 Insulate between the gap between the fresh-r and the installation
frame
Now that you have installed the fresh-r unit as well as the extract ducts (everywhere version only) the gap
between the fresh-r unit and the installation frame needs to be closed with PUR foam. See figure 42
To do this you need to insert the PUR foam nozzle into the gap and all the way to the bottom (8cm) see
figure 41. The red arrow indicates where the PUR injection nozzels needs to reach and the black arrow
points to a depiction of how much fill is required.
The objective is to provide sufficient PUR fill to close the gap and also to insulate the front metal part
of the unibody from the cold. Failure to prevent the insulate properly will result in the entire metal
work of the fresh-r becoming very cold in the winter and a lot of heat loss will take place.
11.5 Install the door on to the mounted fresh-r
The door has been configured in the factory to open in the direction chosen at the time of purchase. This
orientation can be changed on site by swapping the hinges around.
To mount the door, follow the steps below:
1. Lift the door frame assembly on to /in to the metal edge frame
2. Open the door and line up the holes along each side. Fix with the screws provided
Figure 43 Fit door and frame into installation frame
Figure 44 Secure door frame at each side with screws provided