iCEBOX PFU-45-067 User manual

FAN COIL
UNITS
Installation,
Operation and
Maintenance Manual

FAN COIL
UNITS
IceBox double skin fan coil units
(FCUs) are designed and built
for Australian and New Zealand
conditions. Incorporating all Australian
standards applicable to FCUs whilst
providing a robust, low noise and
flexible solution that can achieve
the strictest design criteria of any
individual project.
IceBox FCUs are a low profile, double skin construction unit with high static
EC ebm-papst plug fans. With AHRI certified coils for cooling and heating
applications, the units are suitable for a wide range of commercial and
industrial applications.
The double skin, compact design provides efficiencies using electronically
commutated fans. This is the ideal solution for balancing airflow and
acoustically sensitive projects.
Hospital and health facilities, shopping centres, tenancy fit-outs, hotels and
apartments, office buildings, schools and universities are all benefiting from
working with IceBox.
IceBox is committed to providing comfort and assurance with a certified and
quality solution for your next project or design.
2 | ICEBOX FAN COIL UNITS IOM

CONTENTS
GENERAL SAFETY GUIDELINES, INTENDED USE AND WARRANTY 04
LIFTING AND RIGGING 05
MIXING PLENUM 06
FILTERS AND FRAMES 07
COIL SECTION 08
FAN SECTION 09
CONDENSATE DRAIN 10
ACCESS DOORS AND PANELS 11
STANDARD FEATURES / OPTIONAL ACCESSORIES 12
UNIT IDENTIFICATION 13
4 ROW TECHNICAL PERFORMANCE 14
6 ROW TECHNICAL PERFORMANCE 15
ELECTRICAL CONNECTION DRAWING 16
DIMENSIONAL DRAWINGS 17
MAINTENANCE SCHEDULE 24
WARRANTY REGISTRATION FORM 25
ICEBOX FAN COIL UNITS IOM | 3

GENERAL SAFETY
GUIDELINES INTENDED USE
WARRANTY OF THE
PRODUCT
IceBox fan coil units are a custom designed and built product to suit
particular project requirements and are supplied in accordance with the
approved construction drawings.
This operation manual is intended for use by rigging sub-contractors,
installing contractor and service personnel working on the IceBox units.
Failure to comply with any of these requirements could result in serious
damage to the equipment, the property in which it is installed, as well as
severe personal injury or death to themselves and people at the site. It
is expected that the personnel installing or servicing the IceBox units are
qualified accordingly to enable the individual to perform the assigned
tasks properly and safely. It is essential that, prior to performing any
task on this equipment, this individual shall have read and understood
the on-product labels, this document and any referenced materials. The
individual shall also be familiar with and comply with all applicable
industry and governmental standards and any regulations pertaining to
the task in question.
During rigging, installation, operation, maintenance and service of the
IceBox units, an individual may be exposed to certain components or
conditions including, but not limited to: heavy objects, materials under
pressure, rotating components and electrical voltage. Each of these items
has the potential, if misused or handled improperly, to cause serious
damage to property, equipment or personnel. It is the obligation and
responsibility of the installer and operating service personnel to identify
and recognize these inherent hazards, protect themselves, and proceed
safely in completing their tasks.
IceBox units are manufactured to create a desired indoor air quality, air
temperature, humidity or to filter normal or contaminated air.
IceBox units are suitable for both indoor or outdoor operation, in a
temperature range from -20.0°C to +60.0°C and for the supplied air
conditions from -20.0°C to +45.0°C. Any operation outside of these
conditions must be agreed in writing by Oceania Solutions Group.
Any additional changes to the supplied equipment of third party
components will be the responsibility of the individual or company whom
installed them, not Oceania Solutions Group.
IceBox units are supplied with a 12 month warranty on parts. A labour
and parts warranty can be obtained at the time of purchasing the units.
Please contact your local IceBox agent for details.
The warranty can be null and void if any modifications are carried out
without prior written approval from Oceania Solutions Group for the
IceBox units.
For the parts warranty to be upheld, the following conditions must be
satisfied:
1. All of the scheduled maintenance and operations detailed in this
manual must be performed at the specified times by suitably trained
and qualified service personnel.
2. Only genuine and approved spare parts by Oceania Solutions
Group must be used. Please contact Oceania Solutions Group or
your local IceBox agent for details.
3. Failure to satisfy any of these conditions will automatically void the
warranty.
A full copy of our terms and conditions of warranty is available on our
website.
4 | ICEBOX FAN COIL UNITS IOM

MODEL WEIGHT (KG)
PFU-45-067 76
PFU-45-079 85
PFU-45-102 99
PFU-45-135 131
PFU-50-163 157
PFU-50-191 176
LIFTING AND RIGGING
LIFTING WITH A FORKLIFT
Unit weights and dimensional information is
found on the packing details. Please exercise
extreme caution when lifting or moving the
IceBox unit with a forklift. Do not exceed the
weight or height limit of the forklift.
Never allow the forklift forks to make contact
directly with the side or the bottom panel of the
IceBox unit.
Make careful consideration of the unit’s centre
of gravity and distribute the weight equally
on both forks. Test load to see if the weight is
equally distributed before continuing the lift.
Do this by lifting the unit a few centimetres off
the ground level and checking stability before
lifting or transporting the unit.
RIGGING WITH A CRANE
Unit weights and dimensional information is
found on the packing details. Please contact
Oceania Solutions Group if you have any
doubt or questions.
PERSONAL SAFETY
When lifting, installing or working on
equipment, always adhere to safety codes
and guidelines. PPE is required, ensure
safety goggles, work gloves, work boots and
protective clothing is worn.
MOUNTING BRACKETS
All IceBox units are manufactured with
mounting brackets, they are positioned at a
variety of points around the FCU base. Please
note the IceBox units should be lifted into
position using soft slings and NOT chains. The
use of chains may cause damage to the exterior
panels, pipe work or accessories installed
on the unit and will not be covered under
warranty.
Where units have to be raised into a position
overhead, installers must check unit weight
is within the safe tolerance of the working
capacity of the lifting device.
LIFTING THE UNIT
There is a requirement for spreader bars, as
you would do when lifting any air conditioning
equipment to ensure no crushing effect on the
IceBox unit.
When lifting equipment never stand under
the load or lift equipment on to roof areas
in windy conditions. Only lift when weather
conditions are favourable for the scope of
works undertaken.
ICEBOX FAN COIL UNITS IOM | 5

1. IceBox FCUs are not always supplied with
a mixing box. This is depending on the
order, please check the approved drawings
or contract our office if in doubt.
2. The mixing box section can be supplied
with multiple sets of dampers. Dampers
supplied are constructed from high quality
material and components.
3. Dampers can be supplied with handles
to manually operate the dampers. A
locknut is available on the handle to fix
the position of the damper opening should
it be manually operated. A lock-nut is
available on the handle to fix the position
of the damper opening should it be
manually operated.
4. Should the damper require to be actuator
operated, the handle can be removed and
be fixed with the damper actuators.
5. Dampers do not require any heavy
maintenance. Cleaning of foreign material
is highly recommended to ensure correct
and smooth operation.
MIXING PLENUM
6. Internal moving parts of the damper may
require monitoring to ensure the correct
function throughout the life of the AHU.
7. Periodic cleaning of the mixing box, as
conditions require, will ensure correct
operation and prolong lifespan.
8. Dampers with rubber seals on the blades
will be required to be checked and cleaned
quarterly.
6 | ICEBOX FAN COIL UNITS IOM

1. IceBox FCUs are not always supplied with
filters or frames. This is depending on the
order, please check the approved drawings
or contract our office if in doubt.
2. The filter frames are generally supplied as
galvanized steel frames unless otherwise
requested. It is internally lined with a
gasket. When the filter is compressed on
the gasket, it provides a seal for the filters
to minimize air from bypassing the filters.
Four metal clips are used on each side of
the filter frame to hold and compress the
filters on to the filter frame. Each clip shall
be properly engaged onto the filter frame
after each service of the filters.
3. There are the possibility of two standard
off the shelf filter frame sizes. One being
full size and the other in half size. These
standard sizes are widely used in the
general filter industry. The full size filter
actual dimension is 595x595mm while
the half size filter actual dimension is
290x595mm.
4. The synthetic fibre filter casing thickness is
47mm while the bag filter casing thickness
is 21mm with an extended surface bag
length of either 380mm or 530mm.
5. The synthetic fibre filter is disposable
type and needed to be serviced based
on operational requirement. The synthetic
fibre filter may deform over time requiring
replacement
6. A lack of maintenance might cause
clogging on the filter and will subsequently
reduce the AHU air flow rate.
7. The bag filter should be replaced in
accordance with the site requirements.
8. The bag filter is used to filter fine dust
that might not be visible through normal
vision. If not serviced regularly, it could
cause reduction in AHU air flow rate. If
not serviced for a period of time, the risk
of damage to the integrity of the panel
structure of the AHU due to high negative
section pressure created by the fan due to
clogged filters.
9. Filters should be monitored by an
appropriate device to determine when
replacement or cleaning is required.
10. The recommended final pressure drop limit
shall be 200Pa for synthetic fibre filter and
a limit of 300Pa limit for bag filter.
FILTERS AND FRAMES
PANEL AND BAG FILTERS BAG FILTERS
ICEBOX FAN COIL UNITS IOM | 7

1. The coil section will consist of finned tubes
heat exchanger (cooling and or heating
coils) with a drain pan.
2. The finned tubes heat exchanger is made
of aluminum fins mechanically bonded to
a matrix of staggered copper tubes. The
casing of the heat exchanger is made of
thick aluminum sheet. The water distribution
header to the heat exchanger is made from
copper material.
COIL SECTION
3. The finned tubes heat exchanger is
a non-rotating component and does
not require any part replacement.
Should air handled by the AHU be of
a corrosive nature the fins may deteriorate
over time. Fin protection coating is highly
recommended for such operation
conditions.
4. Heat exchangers will require periodic
cleaning to ensure operating efficiency and
longevity. If coils have been treated,
periodical inspections of the corrosion
applied is recommended during the
cleaning process. The corrosion treatment
may need to be re-coated depending on
the recommendations from the product
manufacturer. Details can be found on the
label adjacent to the coil panel.
5. The drain pan is made from SS304
material in accordance with the AS3666.
To ensure the best indoor air quality
possible, cleanliness of the coil and drain
pan is required. Regular maintenance and
cleaning will be required.
6. During the regular service visits check
obstructions in the drain pipe of the AHU.
8 | ICEBOX FAN COIL UNITS IOM

1. IceBox fan(s) supplied in the FCU are as
per the approved drawings provided.
IceBox fan coil unit include but are not
limited to EC plug fans as standard
or an option for AC fans as a special
manufacture.
2. EC plug fans are wired to a junction box
inside the fan section.
3. All wiring connections shall be properly
terminated and all conduits shall be sealed
properly to ensure no air channeling
through the conduit that might cause
moisture ingression.
7. The fan assembly should be checked
regularly for its vibration level.
8. After a long period of operation during
which the grease keeps its lubrication
performance (30,000 h for standard
applications), a bearing change may be
required. For standby FCUs, during periods
of long idling periods, the fan should be
put to operate on regular intervals. This is
to prevent the bearings from mechanical
load and the avoid ingress of moisture.
9. Any canvas connection between the
fan and the air inlet structure should be
periodically checked to ensure integrity. If
damaged, a replacement will be required.
FAN SECTION
4. The power supply cable connection shall be
ensured correct as per the wiring label on
the motor nameplate.
5. For safety and the correct operation the fan
should not exceed the recommend rotation
speed or voltage on the nameplate.
6. Any works to the fan section shall only be
carried out when the unit is not operational
and it is safe to enter the environment.
Electrical isolation and lock out procedures
as per relevant codes of practice.
ICEBOX FAN COIL UNITS IOM | 9

Each condenser drain must be equipped with
a U-trap. The following conditions are essential
for correct operation:
1. At each drain a U-trap must be connected.
2. Several drains may not be connected to
one U-trap.
3. The water from the U-trap must run in a
funnel.
CONDENSATE DRAIN
4. Before starting, fill the U-trap with water.
5. The heights H1, H2 and H3 can be
determined from the maximum negative
pressure (p) and maximum pressure (p) in
the section of the U-trap or be determined
by the information on the technical data
sheet as follows:
• Total pressure pges = 1196 Pa
• Dynamic pressure pdyn = 83 Pa
• Total static pressure pstat = pges – pdyn =
1113 Pa
• 1 mmWS = 9,81 Pa
• H1 > 1113/9,81 = 114 mm + 15 mm
(Safety) = ca. 130 mm
• H2 = 65 mm
• U-trap intake side (in direction of airflow
before the fan), see Figure 54
• H1 [mm] > p [mm WS]
• H2 [mm] > p/2 [mm WS]
10 | ICEBOX FAN COIL UNITS IOM

1. The access doors do not require scheduled
maintenance but checks to ensure the door
closes correctly.
2. Access doors should only be used when the
AHU is not in use. Using the access doors
while AHU is in operation is not permitted
at any time.
ACCESS DOORS AND PANELS
3. Access doors are available in hinged or lift
off panel arrangement.
4. During delivery and rigging of the air
handling sections, the door positions and
or section could move during handling of
the unit. The access doors and/or hinges
should be realigned once in final position
and the air handling unit is level.
5. Please ensure handles are in the open
position when closing the access door
and once the access door is closed turn
90° clockwise to secure.
6. Negative section access doors could
potentially close due to the suction without
notice. Positive section access doors could
open once the handle for the locking lug is
turned to an open position. Both situations
could cause serious injuries to anyone
working on the units and also can damage
the access doors due to high impact.
ICEBOX FAN COIL UNITS IOM | 11

Brackets for under ceiling mounting are
standard. Optional 100mm base for floor
mounted installations.
AHRI certified water coils. Cooling coil 4 row
standard with 6 row optional. Heating 1 row
standard with 2 row optional.
Single or multiple EC ebm papst
plug fans 240V/SOHZ/IPh.
The standard offer will be 25mm thick
polyurethane panel with 0.5mm internal
galvanised and 0.5mm external prepainted
galvanised sheet metal (PPGI).
SS304 inclined drain pan as standard.
AS3666 compliant.
Hard or flexible connections, flanged edge or
spigots can be provided to suit the installation
requirements.
G4 Filters are standard.
Optional 50mm panel filters F5/F7 or 100mm
V Form or bag filters with mixing box available
upon request.
Electrical heaters are optional, wiring to double
safeties (Auto/Manual) junction box rated to
IP56. Airflow switch and SCR/SSR by others.
Access doors and service lights.
MOUNTING BRACKETS
WATER COILS
EC PLUG FANS
DOUBLE SKIN PANEL
DRAIN PAN
DUCT CONNECTIONS
FILTERS AND FRAMES
HEATERS
ADDITIONAL FEATURES
RECENT PROJECT:
163 ABBOTT STREET
QUEENSLAND
12 | ICEBOX FAN COIL UNITS IOM

UNIT IDENTIFICATION
Each IceBox unit is supplied with a self-adhesive identification label. The label displays the
following information:
• Serial number
• Unit model
• Fan supply air volume (l/s)
• Motor kW
The labels are located on the outside of the access door of each fan section. Any communication
with the Oceania Solutions Group service department will require the corresponding serial number
to be provided for identification of the IceBox unit.
MORE FROM THE ICEBOX RANGE
IceBox modular AHUs can be
used for both indoor and outdoor
installations, with the proven ability to
perform in tropical to below freezing
temperatures.
To suit your thermal bridging requirements, non-cold tracking options are
available. All units are manufactured in accordance with EN1886:2007
and built to comply with Australian Standards AS/NZS 3666, with
particular attention to access for cleaning and maintenance.
With features and benefits that can be included as standard, IceBox
modular AHUs are available today and ready for your next project.
ICEBOX
AIR HANDLING
UNITS
RECENT PROJECT:
NUDGEE COLLAGE
ICEBOX FAN COIL UNITS IOM | 13

Air flow rate l/s 300 380 530 750 1100 1300
Ext static pressure Pa 250 250 250 250 250 250
Cooling
Coil rows # 4 4 4 4 4 4
Fin/in # 12 12 12 12 12 12
Face vel m/s 2.2 2.2 2.2 2.2 2.2 2.2
On coil temp (°c) DB 25.0 25.0 25.0 25.0 25.0 25.0
WB 18.0 18.0 18.0 18.0 18.0 18.0
Off coil temp (°c) DB 12.8 13.1 13.0 13.1 12.7 12.4
WB 12.0 12.3 12.2 12.3 11.9 11.6
Capacity (kw) TOTAL 6.0 7.2 10.3 14.3 22.3 27.5
SENSIBLE 4.2 5.1 7.2 10.1 15.3 18.6
Water in °C 6.0 6.0 6.0 6.0 6.0 6.0
Water out °C 12.0 12.0 12.0 12.0 12.0 12.0
Water flow l/s 0.24 0.29 0.41 0.57 0.89 1.09
Water speed m/s 0.94 0.76 0.81 0.75 1 1.24
Water pd kPa 30 29 12 11 25 30
Pipe conn BSP 1/2 1/2 1 1 1 1-1/4
Heating
Coil row # 1 1 1 1 1 1
On coil temp (°c) DB 20.0 20.0 20.0 20.0 20.0 20.0
Off coil temp (°c) DB 33.2 33.6 34.1 34.1 34.4 33.7
Capacity (kw) TOTAL 4.8 6.3 9.2 12.9 19.5 21.9
Water in °C 80 80 80 80 80 80
Water out °C 60 60 60 60 60 60
Water flow l/s 0.06 0.08 0.11 0.16 0.24 0.27
Water pd kPa 2 4 11 11 30 19
Pipe conn BSP 1/2 1/2 1/2 1/2 1/2 1/2
Fan
Fan speed contrl # EC EC EC EC EC EC
Drive type # DD PLUG DD PLUG DD PLUG DD PLUG DD PLUG DD PLUG
Fan+mtr qty # 1 1 1 2 2 2
Fan model # 280 280 280 2x280 2x280 2x280
Motor power W 500 500 500 2x500 2x500 2x500
Power rating V/Ph/Hz 220-1-50 220-1-50 220-1-50 220-1-50 220-1-50 220-1-50
Dimensional
Model 25mm
PU PANEL
CASING
PFU-45-067 PFU-45-079 PFU-45-102 PFU-45-135 PFU-50-163 PFU-50-191
Weight (kg) 75 83 98 129 156 173
Dimension(mm) h-w-l 450-670-800 450-790-800 450-1020-800 450-1350-800 500-1630-800 500-1910-800
Model 50mm
PU PANEL
CASING
PBU-50-073 PBU-50-084 PBU-50-107 PBU-50-140 PBU-55-168 PBU-55-196
Weight (kg) 88 97 114 148 178 198
Dimension(mm) h-w-l 500-730-800 500-840-800 500-1070-800 500-1400-800 550-1680-800 550-1960-800
4 ROW TECHNICAL PERFORMANCE
14 | ICEBOX FAN COIL UNITS IOM

Air flow rate l/s 300 380 530 750 1100 1300
Ext static pressure Pa 250 250 250 250 250 250
Cooling
Coil rows # 6 6 6 6 6 6
Fin/in # 12 12 12 12 12 12
Face vel m/s 2.2 2.2 2.2 2.2 2.2 2.2
On coil temp (°c) DB 25.0 25.0 25.0 25.0 25.0 25.0
WB 18.0 18.0 18.0 18.0 18.0 18.0
Off coil temp (°c) DB 10.9 10.4 10.5 10.4 10.8 10.4
WB 10.6 10.2 10.2 10.1 10.5 10.1
Capacity (kw) TOTAL 7.2 9.6 13.3 19.0 26.9 33.1
SENSIBLE 4.8 6.4 8.8 12.6 17.9 21.8
Water in °C 6.0 6.0 6.0 6.0 6.0 6.0
Water out °C 12.0 12.0 12.0 12.0 12.0 12.0
Water flow l/s 0.29 0.38 0.53 0.76 1.07 1.31
Water speed m/s 0.76 1.01 0.93 1 0.8 1
Water pd kPa 30 29 29 25 16 26
Pipe conn BSP 1/2 1 1 1 1-1/4 1-1/4
Heating
Coil row # 1 1 1 1 1 1
On coil temp (°c) DB 20.0 20.0 20.0 20.0 20.0 20.0
Off coil temp (°c) DB 33.2 33.6 34.1 34.1 34.4 33.7
Capacity (kw) TOTAL 4.8 6.3 9.2 12.9 19.5 21.9
Water in °C 80 80 80 80 80 80
Water out °C 60 60 60 60 60 60
Water flow l/s 0.06 0.08 0.11 0.16 0.24 0.27
Water pd kPa 2 4 11 11 30 19
Pipe conn BSP 1/2 1/2 1/2 1/2 1/2 1/2
Fan
Fan speed contrl # EC EC EC EC EC EC
Drive type # DD PLUG DD PLUG DD PLUG DD PLUG DD PLUG DD PLUG
Fan+mtr qty # 1 1 1 2 2 2
Fan model # 280 280 280 2x280 2x280 2x280
Motor power W 500 500 500 2x500 2x500 2x500
Power rating V/Ph/Hz 220-1-50 220-1-50 220-1-50 220-1-50 220-1-50 220-1-50
Dimensional
Model 25mm
PU PANEL
CASING
PFU-45-067 PFU-45-079 PFU-45-102 PFU-45-135 PFU-50-163 PFU-50-191
Weight (kg) 75 83 98 129 156 173
Dimension(mm) h-w-l 450-670-800 450-790-800 450-1020-800 450-1350-800 500-1630-800 500-1910-800
Model 50mm
PU PANEL
CASING
PBU-50-073 PBU-50-084 PBU-50-107 PBU-50-140 PBU-55-168 PBU-55-196
Weight (kg) 88 97 114 148 178 198
Dimension(mm) h-w-l 500-730-800 500-840-800 500-1070-800 500-1400-800 550-1680-800 550-1960-800
6 ROW TECHNICAL PERFORMANCE
ICEBOX FAN COIL UNITS IOM | 15

1PHASE CONNECTION
RECENT PROJECT:
163 ABBOTT STREET
QUEENSLAND
16 | ICEBOX FAN COIL UNITS IOM

PFU-45-067
SIDE VIEW
TOP VIEW
RECENT PROJECT:
REVESBY WORKERS CLUB
NEW SOUTH WALES
ICEBOX FAN COIL UNITS IOM | 17

SIDE VIEW
TOP VIEW
PFU-45-079
18 | ICEBOX FAN COIL UNITS IOM

SIDE VIEW
TOP VIEW
PFU-45-102
RECENT PROJECT:
DHL BRISBANE AIRPORT
QUEENSLAND
ICEBOX FAN COIL UNITS IOM | 19

SIDE VIEW
TOP VIEW
PFU-45-135
20 | ICEBOX FAN COIL UNITS IOM