Remak X Series User manual

INSTALLATION AND OPERATING INSTRUCTIONS
Modular air-handling units
X
Series
11/2022

2
Contents
General information
Air-handling units REMAK series X are manufactured in accordance with valid Czech and European regulations and technical
standards.
Due to the concept of air-handling units REMAK X series, these including their individual parts, are not intended for
direct sale to end users. Every installation must be performed in accordance with a professional project created by a qualified
ventilation designer who is responsible for the proper selection and dimensioning of components concerning their suitability
for a given application.
Air-handling units REMAK series X (or units) must be installed and used only in accordance with this documentation. The
manufacturer is not liable for any damage caused by devious usage and in case of vialation buyer bears all risks.
The installation and operating instruction must be available for the operating and servicing staff (it is advisable to place this
instruction in the air-handling unit vicinity).
Units containing water heater sections and/or sections with drain pans must be installed in a way which prevents any
accidentally caused damage (e.g. exchanger freezing, condensate drainage not working). It is recommended to install the units
in a machine-room with waterproof floor and/or floor trap.
When handling, installing, wiring, commissioning, repairing or servicing the units, it is necessary to observe valid safety
regulations, standards and generally recognized technical rules. In particular, it is necessary to use personal protection means
(e.g. gloves) due to sharp edges and corners
All connected equipment must comply with the respective safety standards and regulations.
Commissioning as well as every service and maintenance must be noticed in the unit Operations logbook (see Warranty
and complaint conditions Remak a.s.)
Any changes or modifications to individual components of the REMAK X series air- handling units which could affect their
safety and proper functioning are forbidden.
Before installing and using the REMAK X series air handling units, it is necessary to familiarize yourself with and observe
the directions and recommendations included in the following chapters.
Commissioning may only be performed by an authorized company licensed personnel in accordance with generally and
locally valid regulations.
In case of components and materials disposal, it is necessary to adhere to all locally valid environmental and waste disposal
regulations.
In the case of total unit liquidation, all principles of waste separation must be observed.
Up-to-date version of this document is available at website www.remak.eu
Use and operating conditions .........................................................................................................................................................................................3
Air-handling unit construction .........................................................................................................................................................................................3
Information and safety labels ..........................................................................................................................................................................................3
Unit access side ...................................................................................................................................................................................................................3
Packing and transport .......................................................................................................................................................................................................3
Transport and handling of parts......................................................................................................................................................................................3
Storage conditions..............................................................................................................................................................................................................4
Installation..............................................................................................................................................................................................................................5
Rotary heat exchanger/regenerator section (ROV).................................................................................................................................................7
Unit bocks assembly.......................................................................................................................................................................................................... 8
Accessories assembly, roof assembly...........................................................................................................................................................................8
e condensate drainage..................................................................................................................................................................................................8
Air duct connection.............................................................................................................................................................................................................9
Connection of heating and cooling media...................................................................................................................................................................9
Connection of water and glycol exchangers ..............................................................................................................................................................9
Připojení přímých výparníků.............................................................................................................................................................................................9
Připojení elektrických zařízení a prvků MaR............................................................................................................................................................10
Připojení motorů (ventilátory) ......................................................................................................................................................................................11
Electromagnetic compatibility (EMC)........................................................................................................................................................................11
Door panel settings - full-fledged hinges ..................................................................................................................................................................11
Commissioning and putting into operation.............................................................................................................................................................12
General Inspection prior to first unit Start-Up........................................................................................................................................................13
First Start-Up checks.......................................................................................................................................................................................................14
Operating rules..................................................................................................................................................................................................................14
AHU Inspection and maintenance ..............................................................................................................................................................................15
Periodical checks..............................................................................................................................................................................................................14
Cleaning ...............................................................................................................................................................................................................................16
Inspection/checks ............................................................................................................................................................................................................16
Service, Spare Parts........................................................................................................................................................................................................20
Disposal and recycling ....................................................................................................................................................................................................21

Modular air-handling units, Series X
3
Use and operating conditions, Air-handling unit construction, Packing and transport
Use and operating conditions
REMAK series X air-handling units are designed for
comfortable air-handling and air-conditioning in an air flow
range from 1,000 m3/h to 35,000 m3/h at fan air pressure
difference of up to 2,500 Pa.
They are intended for handling of air without solid, fibrous,
sticky, aggressive, respectively explosive impurities. The air
must be free of corrosive chemicals or chemicals aggressive
to zinc and steel, respectively aluminium.
REMAK series X units are supplied with factory-installed
base-frame and are primarily intended for installation on floor
or steel support construction/frame supplanting the floor.
REMAK series X air-handling units can be used without any
additional measures in normal environments (IEC 60364-
5-51, resp. ČSN 33 2000-5-51 ed. 3, ČSN 33 2000-1 ed.2)
and in rooms with extended ambient temperature ranging
from -40 °C to +40 °C. When selecting the air-handling unit,
it is necessary to take into account the temperature and
humidity of the inlet and outlet air in relation with the ambient
temperature and humidity. It is especially necessary to analyze
the relation of the unit‘s casing classification pursuant to EN
1886 and the risk of condensation, respectively frost deposit.
Ingress protection (objects, water) is IP 44. IP 44 protection
level does not refer to accessories and control components
(they must be assessed separately based on their particular
documentation).
The unit equipped with the outdoor roof is water spray proof
(rain up to 60° from vertical) and providing the particular
instructions specified further are followed, the unit can be
used outdoors.
Air-handling unit construction
Unit construction is modular with casing consisting of panels,
bars interconnected by plastic or metal corners and screws.
Panels which are expected to enable occasional service access
to the internal components are provided with grab handles to
make handling easier.
For regular service purposes such as replacement of filter
inserts, cleaning of internal components, etc, selected
sections are provided with latch-hinges or with swivel locks.
All panels are of sandwich construction with anti-corrosion
surface treatment; side panels with a total thickness of 50
mm, bottom and upper panels are 60 mm thick.
The panels are made of steel sheets – galvanized steel sheets
(inner and outer skins) or painted steel sheets (inner, outer or
both skins), or stainless steel sheets (inner skin only).
The steel sheets are primarily 0,8 mm thick, continuous hot-dip
galvanized EN 10 346 Z275 g/m2, corrosion resistance for
C2 environment class as per EN ISO 14713.
Painted panels are made of continuous hot dip galvanized
steel sheets EN 10 346 Z275 g/m2 + 25 µm polyester paint
(corrosion resistance RC3 according to ČSN EN ISO 14713-1),
or polyester powder coated RC4).
The inner panel insulation is made of 50 or 60 mm thick
fireproof mineral wool with 50 or 65 kg/m3 density. Self-
adhesive sealing with temperature resistance from -40 °C
to +80 °C and water absorption below 5%, is applied on the
contact surfaces of panels. Casing parts are sealed with a
silicone-free sealant of temperature resistance from -40 °C
to +80 °C.
The REMAK series X air-handling unit consists of sections.
The section consists of the casing and inner modules/
components. The unit sections can be factory-assembled to
so-called „transport- installation“ blocks.
Door hinges
Door panels are equipped with latch-hinges : which can
function as a latch or as a door hinge.
Each door panel is equipped with one (top) latch- hinge on
each side with an additional safety function (pressure relief)
to prevent it from opening. To open the door, it is always
necessary to unlock (see Fig.1).
Each latch-hinge is equipped with a simple locking function
against accidental opening i.e. with a hex key lock, which
locks the latch-hinge against tilting (see Fig. 2).
ATTENTION: Door latch-hinges enable the entire panel to
be removed. Before doing so , respect the panel weight and
other possible risks with its handling!
ATTENTION: The door panels closing the electrical
equipment are provided with an additional bonding via PE
conductor!
Information and safety labels
Each block is provided with a product label
REMAK series X air-handling units, respectively particular
sections, are provided with information labels indicating
information important for connection, commissioning and
operation.
The „Caution - other Danger“ label situated on
the particular unit service panels indicates the
hazard of getting caught by moving parts
The label „Warning – Electric shock hazard“
on the particular sections and their service panels
alerts the risk of accident caused by electric current
Product label contains technical parameters of the
particular section. The user is obliged to ensure that all unit
labels stay undamaged and readable throughout the entire
unit service life. When damaged, especially in case of safety
labels these must be repaired immediately.
Fig. 2 – lockingFig. 1 – security latch
hex key 4 mm

4
Transport and handling of parts
Fig. 3 – transport leg and its disassembly
Packing
A block without a base-frame is placed on a pallet as
a transportation standard. A block with a base frame and
fixed legs is shipped as standard without a pallet (Fig. 2).
Blocks with the base frame and without the fixed legs can
be equipped with removable factory installed single-use
sheet metal legs, intended for handling during dispatch and
transport (Fig. 3) or these can be put on a pallet.
ATTENTION: demountable sheet metal legs for dispatch
and transport, have to be dismantled before placing the
section on the installation site - 4 x M8 screw (Fig. below).
REMAK X series transport blocks are packed in PE foil,
and if appropriate, provided with cardboard and polystyrene
protection.
ATTENTION: Fixing of the REMAK X series units by means
of car straps and bands is possible transversely only or it is
necessary to use a sufficiently strong spacer which prevents
the casing deformation – see Fig below.
Transport and handling of parts
Units REMAK X series are delivered to the installation site
in the form of transport blocks which can be also stacked
(see chapter Stacking) .
The loading and unloading can be performed by a fork-lift
truck (pallet or transport orifice in the base-frame) or a crane
(suspension orifice in base-frame corners)
If lifted by a crane, spacer bars must be inserted between
the lifting ropes to prevent unit damage.
When handling a unit section without a base frame fork-lift
truck, forks of a sufficient length must be used to ensure that
the lifted section sits on the forks completely.
When handling the unit section with a base frame then
forks must be inserted beneath both frame beams.
If the unit section width is over 1000 mm then the
base-frame is provided with the third or even fourth inner
longitudinal beam.
These additional beams are also load-bearing and when
handled by means of a fork-lift truck (from both the front or
rear side), it is sufficient that the forks reach the outer and
inner beam i.e. 900 mm.
In a similar way beams are added the to the base-frames
of sections where the service side is protruded (e.g. water
heater section with covered inlet pipes).
Unit access side
Units' construction enables the energy/media connections
and service access of the particular sections to be combined/
placed at different unit sides. The connection side is always
understood in the airflow direction (Fig. 1).
Packing and transport
Stacking
Transport blocks of REMAK series X units up to the cross
section of 1100 x 1100 mm are allowed to be stacked
providing the following rules are followed:
Max. two blocks may be stacked upon each other
ATTENTION: separation layer (e.g. robust cardboard) must
be placed between the blocks to prevent collateral damage
The block placed in the upper position can be equipped
with the base-frame, the legs of any type cannot be mounted
at least one edge of the upper section base-frame (front or
rear) must be aligned with the corresponding edge of the
lower section to ensure the weight distribution; separation
layer (e.g. robust cardboard) is also a must.
The section placed on the upper position must not overlap
in any direction over the lower one.
The fan and gas heater sections must be always situated
down.
Plate and rotary heat exchanger sections cannot be
stacked.
Fig. 2 – transport of sections
Fig. 4 – fixing by means of straps
fixing by car straps - lengthwise
ATTENTION:
lengthwise fixing is allowed
with crossbars only
fixing by car straps - crosswise
Fig. 1 – unit access side options
top view
air stream
direction
LEFT configuration RIGHT configuration

Modular air-handling units, Series X
5
Storage conditions, Installation
Fig. 6 – minimal service access space
When handling the units in the above-described way, it is
always necessary to check the centre of gravity by lifting the
unit slightly (the centre must always be above the forks) and
to be highly cautious during entire handling.
ATTENTION: When transporting, respectively handling, it
is always necessary to pay increased attention to the parts
(pipes, electric wiring elements) protruding from the sides
of transport block.
ATTENTION: All transport blocks may be transported and
handled only in their normal operating position!
ATTENTION: Increased attention must be paid to the
safety of persons as well as the product when handling
the rotary heat exchanger which is very unstable due to its
dimensions (tall and narrow), weight, and high positioned
center of gravity. The manufacturer always recommends
fixing the position of the rotary heat exchanger by
suitable roping, if it is not assembled to the other unit
blocks!
The rotary heat exchanger can be stored, transported or
handled ONLY in the vertical position. Any tilting results in
rotor misalignment and damage. If the dimensions of the
rotary exchanger section exceed the height of the lorry, it is
necessary to cover it with an additional tarpaulin.
All single piece rotary exchangers are equipped with
registered tilt indicators, and starting from a certain rotor
diameter also by the impact indicators. The intactness of
these indicators is a condition of the warranty validity.
Storage conditions
As standard, the air-handling units are packed in PE foil.
These must be stored indoors complying with the following
conditions:
Maximum relative air humidity must not exceed 85 %.
Ambient temperature must range from -20 °C to +40 °C.
ATTENTION: moisture must not condense on the surface
and inside the unit, e.g. during a rapid change in temperature
and humidity of the surrounding air which would subsequently
reach the dew point (intensive, unsightly surface oxidation of
the galvanized layer may subsequently occur)
The air-handling unit must be protected against dust,
gases and caustic vapours, or other chemical substances
which could cause corrosion of the unit’s structural parts
and components.
The air-handling unit must not be exposed to the effects
of weather and direct solar radiation
Sections of air-handling units REMAK X series may only
be stored in their operational position.
Installation
Installation site / plane
Unit blocks must be assembled - horizontal/leveled, so
in case of a unit installed on the base-frame with or without
fixed base legs, the installation site must be strictly leveled
and flat. Maximum misalignment of the floor or supporting
structure intended for the air-handling unit installation must
not exceed 1 mm per 1 meter. When using the adjustable
legs intended to floor unevenness compensation, the max
floor unevenness cannot exceed -20 up to +5 mm. Due to
the loading limit the leg tilt must not exceed 10°.
Observance of these conditions is essential for installation
as well as for the air-handling unit operation.
The air-handling unit equipped with an integrated base-frame
does not need any special anchoring.
It is advisable to ground the air-handling unit with grooved
rubber stripes (not part of delivery)
ATTENTION: while installing the rotary exchanger section
(ROV) it is necessary to adhere to the horizontal position of
the frame which affects the rotation of the rotor and the
tightness of the section (prevention of rotor misalignment).
Space for service access
When planning the air-handling unit location, it is
necessary to ensure the sufficient space for maintenance and
service (including potential extension of internal components
to the service side) . The needed space depends on the
particular unit section configuration (internal modules) - see
Fig. 6
Minimal distance to the walls is following:
750 mm: filter
0,8 x width (W): fan section
1,15 x width (W): heater, cooler, drop eliminator, plate heat
exchanger, rotary heat exchanger
For common service, maintenance, and guarantee repairs,
it is necessary to ensure access to the rotor of the rotary
heat exchanger from both front sides (access from the
adjacent sections). Should this not be possible due to the
unit configuration, it is also necessary to ensure a possible
extension of the whole section out of the unit assembly.
Installation setup
Prior to installation following actions must be performed:
check of the rotary parts free rotation (fans, dampers,
rotary heat exchanger) disassembly of the block transport
legs (see chapter “Transport”
Fig. 5 – handling options

6
Rotary heat exchanger/regenerator section
(ROV)
ATTENTION: In order to avoid dynamic load on the rotor
during transport, the rotor of the despatched exchanger is
fastened by means of removable parts. The rotor fasteners
must be removed before the final exchanger assembly into
the AHU .
ATTENTION: While installing, it is a must to adhere
to the horizontal position of the base frame and the rotor
vertical position (ROV). Failure to do so shall cause the rotor
misalignment and affects the tightness and lifetime of the
entire section..
It is recommended to connect the exchanger to the
other sections first from one side (see chapter Connecting
the unit sections) and to check its vertical position. The gap
between the rotor and its sealing on the circumference must
be even and the rotor has to spin freely (no signs of friction
at any position).
The rotor misalignment can occur due to improper
handling, transport, or improper installation.
ATTENTION: If the misalignment prevents the free
rotor spinning , the rotor must be re-centered - contact the
Remak service.
Gas heating section
Installation, commissioning and inspection of the section
with indirect gas-fired heating as well as of burner are
described in detail in a separate designated Operating and
assembly instruction , which is a part of the accompanying
unit technical documentation.
For correct, trouble-free and safe operation, it is necessary
to connect the safety and control elements that are supplied
with the section.
The gas heating section must be connected to the
ventilation duct with flexible connector temperature resistant
up to 200 °C.
Connection to the smoke flue must comply with all norms
and standards of the given state and must be performed by
a professionally certified company. The flue is not included
in the delivery.
Incaseofbeingaburneroperatedoutdoorsinthetemperature
range -20 °C to -40 °C, a special heated burner cover and a
burner with a flange for external air supply must be installed.
Fig. 10 – Rotary heat exchanger with(out) head panels
(a)
Fig. 9 – mounting of legs to the base frame
front
panels (b)
no panels
check of the power supply and other media (according to
the project and technical specification of the delivered unit)
ATTENTION: Any faults must be removed before starting
the installation.
Blocks identification
Each block sheet contains information to which unit the
particular block belongs, the block designation and its
graphically marked position in the unit layout.
Base legs installation
By virtue of safety and transport, the fixed or adjustable
legs may not be mounted
and it is necessary to install
them on the site (it has to
be done before final set-up
and connection to the other
blocks).
To mount the fixed or
adjustable legs to the base
frame, lift and place the
section or block on spacer
(eg. wooden timber, bricks,
etc. of sufficient height
according the height of leg
and space needed for mounting)
Attention: Spacer must be stable to prevent the section
from tipping over.
Screw the fixed or adjustable legs with 4 M8 × 25 screws,
via a fan/tooth and a wide washer to the pre-installed M8
self- clinching nuts in the section base frame – the fixed legs
mounting screws are included loose (fig 9).
Unit blocks assembly
Fig. 7 – sheet with unit sections and parts identification
Fig. 8 – fixed leg

Modular air-handling units, Series X
7
Unit blocks assembly
Fig. 11 – inner/outer position of self- aligning connectors
outer position of
self-aligning connector inner position
of self-aligning connector
Fig. 12 – sections connection (connectors + M8 screw)
nut and screw M8
(connection set )
Burner being operated outdoors in the temperature
range 0 °C up to -20 °C must be equipped with cover and a
thermostatically controlled heating cable has to be installed.
This set is standardly part of the delivery.
A combustion chamber condensate drainage (½“ pipe) is
installed In the rear part of the section. In the case of outdoor
installation, the drainage freezing has to be prevented. A flue
drainage also has to be ensured.
Installation of a closed heated burner cover
The external air supply for the burner is to be made by means
of flexible duct. To pass the flexible duct through the cover,
a hole is to be made at the appropriate place, in which the
hose has to be sealed. The air intake must be out of the
heated space.
The TBW 500 burner cover heater has to be attached to
the heater panel under the burner valve block using a mount
(enclosed with 4 screws). The electrical connection is to the
7-pin burner connector. The heating power supply is taken
directly from the burner and therefore it is necessary that
the terminal "L" in the burner is always under voltage . The
thermostat in the burner cover is set to a temperature 5 °C.
When the temperature in the cover falls below the set value,
the heating is switched on.
Unit blocks assembly
General information
Assembly of the individual unit sections is performed using
the self-aligning connection set, screws and M8 nuts. On the
sections outer front and rear sides there are factory installed
self- aligning connectors (in case of units with air currents
side-by-side arrangement the rear self-aligning connections
are installed inside the section). When the blocks are put
together the connectors fit into each other. Sealing 50 x 8
mm is factory installed on the block's contact surface.
Based on the current site layout the block connectors can
be relocated to the casing inner side where the M6 rivet nuts
are factory installed.
ATTENTION: When changing position of the self-aligning
connectors (inner–outer), always screw the original M6
screws back into the loose holes.
Blocks assembly procedure
Mating sides (with sealing) of the individual blocks
constituting the air-handling unit have to be pressed together
ATTENTION: Check the state and intactness of the
factory installed seal before pressing the section together
ATTENTION: it is absolutely necessary to align the
sections vertically (spirit level) and horizontally before you
press and screw them together (alignment of the sections
has a fundamental impact on the connection quality and
tightness as well as on the subsequent flawless unit function
as a whole).
Aligned and pressed together sections are screwed using
the preinstalled self-aligning connectors and tightened
by means of M8 screw and nut (M8 x 35 allen head) - M8
screws and nuts are put in the factory installed self-aligning
connectors - see fig. 12.
Rotary exchanger/regenerator
external connection - procedure
ATTENTION: it concerns only sections that protrude
the unit width
After pressing together and aligning, tighten the
connection by means of the preinstalled rectangular
sheet metal couplings and M8 screws with washers into
the prepared holes in the front panels of the rotary heat
exchanger.
Rectangular sheet metal couplings are factory pre-
installed on the rotary heat exchanger section.
Unscrew the self-aligning connectors mounted on the
adjacent blocks and sheet metal couplings are connected
to their holes. Disassembled couplings can be used for
possible internal connections.
Component Place of installation
Pt100 – flue-gas
temperature sensor
to the flue-gas exhaust
(flue-gas duct)
it must be installed
during device as-
sembly
ESD3J – triple ther-
mostat
gas heater section
(behind the heat ex-
changer, following the
airflow direction)
installed by the
manufacturer
TH 167 – emergency
thermostat
just preceding the gas
heater section
it must be installed
during device as-
sembly
Table 1 – included M&C components

8
Fig. 16 – outdoor roof parts connection
part 1
lower flange
part 2seal EPDM 15x3
higher flange
Procedure for connecting the roof parts
– AHU branches arranged side-by side
Sections of the outdoor units with the branches (air currents)
side-by-side arrangement are standardly equipped with
factory installed roof.
Roof parts of sections positioned in series,need to be
standartly connected according to the corresponding
procedure (see procedure - sections connected in series).
At mechanically connected sections/branches positioned
side-by side/in parallel a small gap occurs between their
roof parts.
This gap has to be sealed using enclosed PU sealant (PU
sealant, it is part of the supplied assembly kit).
e condensate drainage
Sections (cooling, plate heat exchanger, steam
humidification, etc.) with installed sloped stainless steel drain
pans to drain condensate, must be fitted with a condensate
water trap/siphon kit.
Drain pans are connected through the casing by DN40
outlet which enables the drainage kit fitting. The condensate
draining kits are available only as optional accessories.
A separate condensate draining kit must be used for each
individual drainage. The condensate draining piping must be
lead into a free atmosphere, i.e. it must not be lead directly
into the closed sewerage system.
Accessories assembly
Accessories (if a part of delivery) i.e. rain louvers, outer
dampers are factory installed on the appropriate blocks as a
standard. Flexible connectors are delivered in bulk.
Accessories can be dismantled, for example, due to the
space for handling and transport - fastening with screws and
guide rails (louvers, exhaust extension).
Fig. 13 – connection by means M8 screws
and rectangular couplings
screw M8 for sections connection
oval aperture for M6 screws – sections connection
Fig. 15 – fastening with screws and guide railsрельсы)
Fig. 14 – accessories
flexible connector (DV)rain louver/exhaust extension
Unit blocks assembly, Roof assembly
Roof assembly
In case of the outdoor unit selection, sections are equipped
with factory installed outdoor roof as standard. Each section,
which after assembly is not covered by another unit upper
deck section (airstream branches above each other), is
provided with a separate roof part. After sections assembly,
the installed roof parts of the individual sections form an
intact unit roof.
Procedure for connecting the roof parts
- sections in series
EPDM 15x3 seal has to be fixed on one of the roof flanges
contact surfaces
After connecting and tightening the sections, the flange
with the seal is pressed to the flange of the counterpart
(section) and provides a tight connection
ATTENTION: before putting and tightening the sections
together the overlapping flange must be put over the counter
part flange - the subsequent correct vertical alignment of the
sections is necessary to avoid flange damage.

Modular air-handling units, Series X
9
ATTENTION: If there is a risk of freezing (eg. outdoor
installation), it is necessary to insulate the siphon and
condensate draining piping, respectively keep the ambient
temperature above freezing point, e.g. with an electric
heating cable!
Dimensioning, water trap/siphon height calculation see
fig. 17 below.
Siphon DN40 type HL 136.2 for drain pans with the option
of water refilling. To be used for over- and underpressure.
Available as an optional accessory (fig 18)
Before first startup and after prolonged shutdown of the
unit, it is necessary to fill the siphon in overpressure with
water through the plastic plug.
The height of the unit above the bottom (sum of base
frame below ůlpw height + legs + structural framework ,
etc.) must be adjusted to the required height of the siphon.
Siphon in overpressure
Location of the outlet in the air duct behind the fan (air
is forced).
Siphon in underpressure
Location of the outlet in the air duct before the fan (air
is sucked)
e condensate drainage
Air duct connection
Flexible connector (DV)
Flexible connector (DV) is always factory installed on the
respective AHU inlets/outlets.
Ventilation duct must be connected by means of a flexible
connector (DV), which prevents the transmission of vibrations
and eliminates the potential non-alignment of the duct with
the AHU outlet opening.
ATTENTION: Connected ductwork must not load /
deform the flexible connector (DV) and the unit casing.
ATTENTION: After ductwork connection and during AHU
operation, flexible connectors must not be fully stretched or
compressed (there is a risk of its damage). After connection
to the ductwork the optimal length of the flexible connector
(DV) is about 150 mm (fully stretched DV is 160 mm).
Connection of heating and cooling
media
The exchanger/coil can be connected on the unit outside
(directly to the coil header connection), or inside the unit
(prepared to the connection of the exchanger or mixing set
inside the unit casing)
Header connections are always equipped with external
thread (threaded flanges are not part of shipment)
ATTENTION: weight and dilatation forces of cooling
and heating media fittings must not impact the unit casing
ATTENTION: When connecting the feeding fittings to the
heat exchangers, use two wrenches to tighten the screws to
avoid the exchanger headers rupture by torsion.
Fig. 18 – siphon (optional accessory)
Fig. 17 – Siphon height calculation
siphon in underpressure
Hmin (mm) = P (Pa) / 10
H
2H
H: 1.000 Pa = 100 mm
siphon in overpressure
P – total fan pressure
H
2H
Fig. 19 – threaded header input/ouput for cooling
and heating media connection
Fig. 20 – connection of fittings to exchangers
When tightening the
nuts, secure the pipe with
an anti-twist wrench.

10
Air duct connection, Connection of heating and cooling media, Exchangers
Fig. 21 – exchanger´s connection
Fig. 22 – connection of glycol circuit
glycol cooler glycol heater
1) pump
2) vent valve
3) feed/drain valve
4) safety valve
5) expansion tank
6) pressure gauge
3 1 3
2 4 5 6 2
air stream
direction
(left handed
design)
air stream
direction
(right handed
design)
inlet outlet
outlet inlet
Water and Glycol Heat exchanger connection
To achieve maximal output the counter-flow connection of
the heat exchangers is required. (Fig 21)
The corresponding connection points are marked with labels
on the unit side panel (heating water inlet, heating water
outlet, coolant inlet, coolant outlet).
The water coils are equipped as standard with a manual air
vent valve G 3/8 “, mounted in the upper part of the collector
(for direct external connection it is located outside the unit).
ATTENTION: After connecting the exchanger coil (heater
and cooler, mixing set including) to the piping, it is necessary to
pressurize (fill with water) and vent the entire circuit, including
the heat exchanger. Consequently, perform a leakage check of
all pipe connections as well as the exchanger itself (including
the heater/cooler section interior check).
The manufacturer is not liable for damage caused by leaky
connections or damaged exchangers.
Direct evaporators
Direct evaporators must be connected by a professional
contractor authorized to refrigerating equipment installment.
The direct evaporators are pressure-tested and factory
filled with nitrogen.
They can be filled with the following refrigerants - R134a,
R152a, R404a, R407c, R410a, R507 (ASHRAE Number).
Local refrigerant legislation has to be always respected.
Fig. 23 – evaporator´s connection
dual circuit
inlet
outlet
single circuit
1
2
1
2
1
2
1
2
inlet
outlet
air stream direction
(left handed design)
air stream direction
(right handed design)
air stream direction
(right handed design) air stream direction
(left handed design)
Wiring and control system installation
The wiring and control system installation must be
performed by qualified professionals authorized to perform
wiring of the given type.
The wiring must be performed in accordance with locally
valid directives and standards, and in compliance with
the Installation and Operating Instructions of particular
components (frequency inverters, pressure and temperature
sensors, etc).
ATTENTION: Before switching on, it is necessary to check
the conformity of voltage, frequency and protection with
the data stated on the particular component label and the
cross-sections of the connecting cables as stated in project
documentation.
ATTENTION: an initial inspection of the electrical
equipment must be carried out before start-up (see chapter
Unit commissioning)!
Motor wiring (fans)
To ensure the proper unit function, the motors must
be connected so that they rotate in the correct direction.
The EC and PMblue motors are equipped with electronics
that ensure the correct fan rotation direction according to
the manufacturer's motor parameter settings to the given
impeller and also monitors for fault conditions; fault is
signalled by a fault contact.
AC motors are equipped with thermistors as
standard, which provide information about the faults
(overheating) of the motor to protect the motor from
overload damage (to be evaluated by the control
system). AC fans rotation direction must be ensured
by the correct motor phase connection to the mains.
These protections must be connected in accordance with
the specified wiring diagram. Fan section can be equipped
with the service switch. The service switch placement and
connection must be performed in accordance with locally

Modular air-handling units, Series X
11
Wiring and control system installation
valid directives and standards as well as in compliance with
the Installation and Operating Instructions.
The service switch (shipped as an optional accessory)
is intended to disconnect the fan and the thermo contacts
from the power.
This prevents the unintentional start and presence of voltage
on the thermocontacts during maintenance.
ATTENTION: Service switch is neither main nor
emergency switch. After switching the service switch on
again, it is necessary to check the state of the STE and STD
relays, respectively of the parent control system, and reset the
failure of the TK thermo-contacts caused by disconnecting
the service switch.
Fan sections with AC motors (single speed)
They are alternatively usable/supplied in two possible
mains supplies - therefore they must always be connected,
or when connecting the wiring, it is necessary to check
and possibly reconnect the motor (correct connection
of the winding to the star or to the delta (Y/D) in the
motor terminal block), in accordance with the project
design and the design of the motor winding with regard
to the actual operating value of the supply voltage (and
frequency) from the mains, or from the frequency inverter.
As standard, the motors are designed for nominal voltage
230 VD or 400 VY (up to 3 kW) or for 400 VD / 690 VY (above
3 kW) at a mains frequency of 50 Hz.
„star“ connection (Y)
„delta“ connection (D)
Rotary heat exchangers with AC motors
Similarly as the fan AC motors, exchanger AC motors
are always three-phase powered-up either single-phase
230 V or three phase in two possible variants (wye - delta
Y/D in the motor terminal box) – therefore they always
have to be connected (or run the check the proper
connection) in accordance with the project design and
motor winding type with regards to the particular supply
voltage (and frequency) from the mains, or from the
frequency inverter.
As standard, the motors are designed for nominal
voltage 230 VD or 400 VY at a mains frequency of 50 Hz.
See figure above for wye (Y) and delta (D) wiring.
Electric heater connection
A heater wiring diagram is enclosed in each electric heater.
The control system must provide the heater blocking so that
it cannot be switched on without running the fan. After heater
switch off, the fan has to be running for at least five minutes.
The air flow through the heater must match its designed
output to prevent overheating of the heating rods.
Gas heater connection
A burner and gas-fired heater/burner wiring diagram is
enclosed in each gas heater. The control system has to ensure
that the heater cannot be switched on without running the
fan. After heater switch off, the fan has to be running for at
least five minutes.
The air flow through the heater must match its designed
capacity to prevent overheating.
IBET electric preheaters
The heater is designed to preheat a part of the internal
AHU space and may be operated as a stand-alone heating
component without forced airflow. A wiring diagram is
included in each electric air heater.
Electromagnetic compatibility (EMC)
Electrical installations involving frequency inverters always
require special attention and professional conduct to ensure
trouble-free operation (taking into account the project and
specific conditions).
Frequency inverters are by their nature a significant
source of interference to the mains and also the generated
voltage for the powered electric motor is not a pure (single-
frequency) sine wave.
Basic interference suppression is usually implemented
by frequency inverter manufacturers, nevertheless electrical
installations with frequency inverters require special
attention and professional installation to ensure trouble-free
operation – meeting the requirements of technical directives
and standards for electrical equipment compatibility (EMC
interference) as well as to avoid fans electric motors faults,
even faults of the frequency inverters itself
Motor damage during operation with the frequency
inverter can be caused by increased winding insulation
voltage stress and by the occurrence of harmful bearing
currents.
It is always necessary to solve this issue with regard to the
project and specific conditions, certain standard measures –
general principles have to be always observed.
Frequency inverter output side
Shielded power cables must always be used on the output
side of the frequency inverter (between the motor and the
frequency inverter), and the shielding must be grounded at
both ends of the cable (with large area 360° contact) both in
the metal clamp on the inverter side and by proper installation
of the shielded cable into the metal EMC grommet in the
motor terminal box. Also, any devices installed between
the inverter and motor (e.g., emergency switches, terminal
boxes) must be shielded and grounded. The motor thermal
protection (thermistors) should be always connected to the
inverter using shielded cables.

12
Electromagnetic compatibility (EMC)
ATTENTION: installation of anything that is connected to
the AHU and any other structures must not damage the unit
(eg tightness, casing due to excessive load, etc.), obstruct
the opening of the door panels, operation and maintenance.
Grounding and protective bonding
Protection against electrical injury
After on site installation and before putting into operation
(in terms of wiring) the installation company has to assure
proper grounding and protective bonding complying with
the locally valid standards and corresponding to the risks of
environment at the installation site (eg. humidity) as well as
the influence of the other equipment and electric lines which
are not related to the AHU.
Door panel settings – full-fledged hinges
Once the unit sections have been properly placed and
connected (or when servicing) there is possible to set / adjust
the door panels correct position (within the hinge setting
range) and align them to the adjacent columns and bars - the
ideal gap size between panels is about 3 mm (diminishing
possible scratching when handling the door panel).
The door panel position (gap) is adjusted using the screws
hidden under the covers accessible after opening the shutters
and oval holes in the hinge (Fig. below).
ATTENTION: if there is a problem with scratching or
the gap size even after adjusting the door panel (within the
hinge range), it is necessary to check the section/ base frame
planeness (floor).
Door panel (hinges) compression setting
The used hinges enable (within their range) the setting of
the required door panel compression (tightness).
Adjusting the compression is done by tightening or loosening
the screw accessible when removing the cover of the hinge.
The individual unshielded wires in the motor terminal block
and in the controller must be as short as possible whereas
the distances between the leads, power and signal wires,
must be as large as possible.
Since high voltage slope steepness and voltage
peaks increase the stress of the motor winding insulation
when operating with a frequency inverter it is advisable
/ recommended to limit their influence by output filter
elements – a motor choke with the same clock as the
switching frequency of the frequency inverter (chokes are
intended for specific frequency) or using appropriate output
filters (dU/dt filter).
These help to reshape the rectangular signal at the inverter
output to signal closer to the sine wave.
By filtering the output current, it also has a very
beneficial effect on reducing the radiation from the motor
cable (eg. interference to acoustics). At the same time,
they compensate – reduce the capacitive currents that
additionally load the power part of the inverter when using
long cables (unless the inverter is directly on the AHU casing).
To eliminate (max. reduce) negative effects of the winding
voltage stress as well as the bearing currents on the motor
bearings, we recommend using sinusoidal filters on all poles.
These filters reduce voltage slopes steepness and capacitive
currents and replace the output (motor) chokes with even
greater efficiency.
The sinusoidal filter is the most efficient output
interference suppression device. It almost completely
eliminates the disturbance by pulse width modulation, ie.
at the output of the sinusoidal filter the voltage and output
current have almost sinusoidal waveform.
When using sinusoidal filters on all poles (between all
phases and to the neutral wire), it is not necessary to use
shielded cables on the motor supply (and EMC bushing)
and the electromagnetic motor noise from higher harmonic
currents is also reduced.
Wires from the inverter to the filter should be as short as
possible (centimeters).
Frequency inverter input side
The control cables (MODBUS line or 0–10V signal)
between the frequency inverter and the control unit should
always be shielded (see also VCS control units wiring
schemes).
External EMC filters or commutating chokes are to
be usually used on the input side of the inverter to meet
increased EMC requirements (sensitive industrial plants,
residential, commercial and light industry premises).
Mains-side chokes reduce harmonic noise injected back
into the line and extend the service life of the inverter´s
rectifier and mainly its capacitors - that is why the chokes
are also highly recommended when connecting frequency
inverters close to large transformers to limit charging
currents (reduces the current inrush when the inverter is
plugged in).
Connection and assembly - other accessories
Any other accessories have to be installed according to
the AHU specification and the installation instructions of the
accessories manufacturer.
Fig. 24 – door panel setting

Modular air-handling units, Series X
13
Commissioning and putting into operation, General Inspection prior to rst unit Start-Up
Commissioning and putting into operation
Preparation to commissioning
Once the unit installation is finished and all related
equipment connected (ductwork , media connections, wiring,
condensate drainage, control elements, etc.), it is possible to
start with the preparation and commissioning conducting.
ATTENTION: the unit may be put into operation only by
an authorized personnel having the required professional
qualifications.
ATTENTION: before first putting into operation, the initial
electrical inspection (protocol) of all ventilation installation
componentes has to be performed by a professional
technician.
Safety measures
Sections, where injury hazards occur (electric shock,
rotating parts, etc.) or with connection points (heating water
inlets/outlets, air flow direction, etc.) are always labelled with
warning or information label.
It is forbidden to start or run the air-handling unit fans if
the panels are open or removed. The hazard of trapping by
movable parts is indicated by a label situated on the service
door of the air-handling unit. Service doors must always be
closed during air-handling unit operation.
Before starting any work in sections containing electric
equipment (fan, electric heater, etc.), it is essential to turn off
the main switch and take measures to prevent unintentional
circuit switch on during service operation.
When draining a heat exchanger, the water temperature
must be below +60 °C.
Under voltage, it is forbidden to disassemble the electri
service panelof the heater (except for performing the specific
checks described later in this document) and any change of
the safety thermostat setting made by the manufacturer.
It is forbidden to operate the electric heater without the
outlet air temperature control and ensuring the transported
air constant flow rate.
Once the gas heating section has been professionally
commissioned, the set parameters of the equipment cannot
be changed to ensure safety and trouble-free operation.
Checks and procedures prior to first unit
Start-Up
Outside of the air conditioning unit
The service panels are provided with hinges and external
closures. The closure simultaneously serves as a handle. A
special tool – a wrench – is needed to open/close the closure,
all closures must be fully working.
proper air-handling unit alignment
proper connection of all air-handling unit parts to the
respective air ducts
proper connection of all cooling and heating circuits and
availability of heating/cooling media
proper connection of all electrical appliances
all condensate drain kits are installed and flushed
proper installation and wiring of all control components
proper conductive bonding and proper earthing is
performed
all parts of the unit are free of foreign objects
proper insulation of the heat exchanger connection ducts
ensuring the surface temperature lower than +60 °C
Electric Wiring
all electrical appliances are connected
all control elements are installed and connected
proper wiring of all individual electrical components of
the air-handling unit according to the corresponding wiring
diagrams
conductive bonding and proper grounding is performed
grounding and bonding check as a part of the entire
building plan
Filter Sections
state of filters
mounting of filters
setting of differential pressure sensor
Fan section
intactness and impeller free rotation
tightening of the module screw connections
cleanliness of the fan impeller, inlet and outlet
free of foreign objects
Water and Glycol Heater Sections
heat transfer surface state
inlet and outlet duct state
mixing set state
state, connection and installation of antifreeze protection
components
Sections of water/Glycol coolers, Direct evaporators
heat transfer surface state
correctness and tightness of the cooling circuit connection
proper siphon assembly corresponding to the pressure
conditions in the chamber
watering the siphon
Plate Heat Exchanger Section
exchanger fins state
functionality of the bypass damper or mixing damper
proper siphon assembly corresponding to the pressure
conditions in the chamber
watering the siphon
connection of temperature protection sensors
Rotary Heat Exchanger Section
exchanger rotor and frame alignment
checking of the rotor for free rotation
Belt tension check
rotor sealing – tight fit check
correct motor wiring
motor rotation direction (for the correct rotation see
arrow on the motor)
motor input current (see the product label)
Electric heater section
mechanical state of the heater and heating elements,
cleanliness of the heating coils surface and the heater interior,
free of foreign objects
inspection of all heater connections (power, control and
protective wiring)

14
First Start-Up checks
Fig. 25 – fan sampling probes
Fig. 26 – pressure difference measurement
fan type ER fan type GR
Gas heater section
condensate drain connection
connection of sensors and thermostats and their
functionality
connection of the gas burner
connection to the flue gas ducting
bypass damper functionality
IBET Electric preheating
functionality and blocking check
safety/operating thermostat check
ATTENTION: Until the complete ventilation system is set
up, the air-handling unit can be put into operation provided
the unit inlet damper is closed. Operating the air-handling
unit while the ventilation system is not set up completely
can cause motor overloading and permanent damage. If
the air-handling unit includes a second filtration stage, it is
advisable to run the pilot operation with the second filter
stage inserts removed.
First Start-Up checks
Check the proper direction of the impeller rotation – see
the arrow on the impeller or spiral casing
Check the rotary heat exchanger proper (see the arrow on
the rotor) and free rotation (no signs of scrape)
Check the input current of connected equipment (it must
not exceed the maximum permissible value stated on the
product label)
After 5 minutes of operation check the fan bearings
temperature. ATTENTION: This check may only be
performed if the fan is switched off!
Check the water level in the condensate draining siphon. If
the water had been drawn off, it is be necessary to increase
the siphon height
Check the state and mounting of the filters
During the pilot operation, it is necessary to check the
air-handling unit for unusual noise and excessive vibrations.
The pilot operation should last at least 30 minutes. After its
completion the air-handling unit must be inspected again. Pay
special attention to filters (check them for damage), the fan
section and the correct function of condensate drainage. In
case of excessive vibrations it is necessary to check again the
fan module and perform vibration intensity measurement, if
necessary. If the vibration intensity of the free impeller fan
module exceeds 2.8 mm/s (measured at the motor bearing
shield on the impeller side), the fan must be checked and
balanced by a professional technician. Before putting the air-
handling unit into permanent operation, it is recommended
to replace or regenerate the filter inserts.
Set up of the entire ventilation system (protocol) must
be performed during the pilot operation.
Electric heater
ATTENTION , electric heater may be put into operation
only after the fan has reached operating speed.
When commissioning for the first time, the heaters
must be burned by switching on for 15 minutes at the
fan maximum operating speed ; the unit has to be under
surveillance.
Gas heater
This is a dedicated gas fired appliance/equipment
requiring special commissioning procedure.
After the installation of a gas-fired AHU , it is necessary
to order a separate burner commissioning at the burner
manufacturer or its service agent.
The connection of the triple thermostat and the gas
burner must be carried out in accordance to the relating
documentation.
In addition to the burner adjustment, connection of the
safety thermostats and control elements to the burner
control circuits and the air handling unit (fans) shall be
checked.
Burner commissioning protocol has to be drawn specifying
the gas heater temperatures settings, emergency and safety
elements checks.
The section is supplied with separate documentation
delivered by the combustion chamber manufacturer, which
is a part of the technical documentation for the REMAK X
series unit.
WARNING, never start the gas heating block when the
AHU (fans) is stopped, otherwise, there is a risk of local
overheating and damage of some components (e.g. filters,
drop eliminator, etc.).
Check of the fan air flow set up
After unit instalment and commissioning air flow can be
checked and set up using a simple method of measurement
at the diffuser. This method eliminates to some extent faulty
results determined by duct air speed measurement which are
caused mainly by turbulence and non-linear air flow.
For this method of the air flow measuring, sampling probes
are installed as standard on the casing of the fan section
(provided the section is not equipped with a measuring
device).

Modular air-handling units, Series X
15
First Start-Up checks
Air flow calculation at different temperature than 20 °C
qv – air flow rate
k – fan factor (provided by the fan manufacturer)
Δpw – static pressure difference (measured value)
– air density at operating temperature
AHU Inspection and maintenance
AHU inspection and maintenance can be performed only
by adult skilled persons, familiar with the operating and
installation instructions for Remak X-Series units.
When performing inspection and maintenance, it is necessary
to follow these instructions and regulations; neither
manufacturer nor supplier bear responsibility for damage
caused by infringement of these instructions and regulations.
Safety measures
A warning or information label is always placed on sections
with shock hazards (electric current, rotating parts, etc.) or
with connection points (heating water inlet-outlet, airflow
direction, etc.).
It is forbidden to start or operate the unit fans with open
or dismantled panels. The risk of entrapment by moving parts
is indicated by a label on the unit service door. The service
door must always be closed during operation and locked (if
available) to prevent unwanted access.
Before starting work on the fan section (part), it is
essential to switch off the main switch and take measures
to prevent the unintentional fan start during the service
operation.
When draining the heat exchanger, the water temperature
must be lower than +60 °C.
Continuous Operation Checks
Continuous unit operation checks are performed by visual
inspection and listening test at least once a week, without
intervention in the unit operation.
Operator control checks (during operation):
fans and motors operation (noise and vibration) check
by listening, ie the unit must not show excessive vibrations
as well as inappropriate sounds (strong droning , knocking,
whistling, or any other acoustic signs of bearing malfunction).
check the filters for blockages via the pressure differential
sensor and replace them if necessary - see filter replacement
procedure (page 16)
checking the functionality of the heat recovery system,
if visually possible
functionality of the air temperature control
the condition and functionality of the control system
connected to the unit, the correct functioning of which is
necessary for the operation of the unit and the air handling
unit as a whole.
the presence of water in the siphon with refilling if
necessary
K-factor ( data needed to calculate the air flow) of the
particular fan type is indicated on the fan section product
label.
The formulas for air flow calculation and the scheme for
determining the measurement of the difference between
the static pressure in front of the fan inlet diffuser and the
static pressure in the fan diffuser are shown in the figure
below (Fig. 26).
Air flow Rate Determination – Fan
Air flow calculation (standard air temperature 20 °C, density
1,2 kg/m3):
AHU Inspection and maintenance, Periodical checks
Operating Rules
Before putting the air-handling unit into permanent operation,
the plant operator must issue Operating rules in accordance
with locally valid regulations.
Following content is recommended:
configuration, intended use and a function description in
all operating modes
description of all safety and protective unit elements
and functions
health protection principles, safety and operating rules
requirements for operating staff qualification and training,
a list of personnel authorized to operate the air-handling unit
detailed emergency and fault instructions to be followed
by the operating staff
specific operating situations during different climate
conditions (e.g. summer or winter operation)
inspection, checking and maintenance schedule, including
a list of checking acts, and the way of their recording
records of operating staff training, operation inspections
and cleaning of the rotary heat exchanger (subject to Remak
a.s. guarantee validity)
the obligation to log and keep an unit Operations Logbook,
with records (and protocols) of regular maintenance,
cleaning and performed service actions (required for possible
complaints - see Warranty and complaint conditions of
Remak a.s.)

16
Periodical checks
The user shall determine the air handling unit periodical
inspection intervals based on to the operating conditions
(eg enhanced dust nuisance atc) , however, at least:
a) a) Once every three months (protocol)
Check for contamination and possible damage to the basic
functional groups of the air-handling unit:
filters (hygiene condition, clogging rate, unacceptable
damage or perforation)
heat recovery, heat-exchangers (functionality, fouling,
leakage or damage)
humidification system (hygiene condition, functionality,
circuit tightness, nozzle or honeycomb clogging)
condensate drainage (no residual water in the pan or
elsewhere, condensate drainage permeability)
b) Once every six months (protocol)
Check all the functional groups of the air-handling unit
for functionality, failure-free state, potential corrosion,
cleanliness and hygiene, including necessary maintenance,
cleaning and repair and/or replacement of damaged parts
It is usually carried out in the spring and autumn, i.e., before
the winter and summer season during a short unit shut-down
c) Once a year (protocol)
General service inspection of the air-handling unit
focused on functionality, flawlessness, corrosion, cleanliness
and hygiene, including casing and roofs, combined with
general maintenance, cleaning, disinfection, repair and/or
replacement of damaged parts
It is carried out mainly in the summer months during a
longer unit shut- down
Basic service check topics
cleaning of the external casing and all covering parts/
roofs (see the chapter Cleaning)
cleaning of inlet and outlet chambers
replacement of filter inserts and cleaning of the chamber
inspection and cleaning of fans
inspection and cleaning of the plate or rotary heat
exchanger
inspection and cleaning of heat exchangers, circuit
leakage check
cooling system inspection, including potential refrigerant
refilling performed by a cooling technician
inspection and cleaning of the humidification system
(disinfection, nozzle cleaning, inspection of steam generator
containers)
inspection and cleaning of the drain pan and condensate
drainage system
inspection and cleaning of closing dampers (including
set up)
electric heater state and connection check
gas fired heating section check (adjustment of the burner
by an expert technician)
check of the steam generator and steam distribution
system states
checking the weight (saturation state) of the activated
carbon cartridges
inspection of elastic connections tightness
cleaning of air ducts and all accessory elements, insulation
check
cleaning of other areas of the air-handling unit (service
and air mixing sections, etc.)
inspection of fire dampers (by an authorised technician)
treatment of damaged surfaces or already corrosion-
affected parts by a suitable method (painting)
general cleaning of the machine-room
The cleaning procedure is described in the respective
chapters.
Cleaning
Inspection of unit cleanliness and removal of coarse dirt
must be performed at least twice a year
It is advisable to perform general cleaning as part of the
service inspection at least once a year while the air-handling
unit shut-down
When cleaning the air-handling unit, remove all dirt from
external and internal parts of the unit, including the roof (if
installed)
All components intended to be opened, released, or
easily disassembled must be put into a position that enables
thorough unit interior cleaning
Deposited and not removed dirt can be a source of
bacterial contamination and cause corrosion (In case of
corrosion, the corroded surface must be immediately treated
with suitable anti-corrosion agent
ATTENTION: cleaning is allowed only if the unit is
switched off and ensured against accidental start.
ATTENTION to foreign voltages (such as electric
heating and preheat elements power supply, etc.)
Dry cleaning
Dry cleaning can be performed by wiping with a dry cloth,
hand brushing, or vacuuming with a mild suction
Compressed air cleaning (blowing) – can be performed
only on the unit parts dismantled from the unit casing, so
that dirt is not to be blown to other unit parts
ATTENTION: dry cleaning must be carried out only in a
way that prevents damage, especially to sealed joints and
painted surfaces, without the use of abrasives. In the event
of damage, affected surface and sealings must be repaired
immediately.
Wet cleaning
Wet cleaning is performed by wiping with a wet mop ,wet
brush brushing and/or drops vacuuming under mild suction
It is possible to use a common detergent, free of chlorine,
solvents and abrasives
Water jet cleaning can be performed using conventional
jet cleaners and exclusively to sections equipped with a
condensate drain pan - max water jet pressure must not
exceed 0,25 MPa.
Chemical cleanup (disinfection) can be performed by
applying of disinfecting agents (liquid, gaseous) (not dry
agents) using hand wiping (mop, jet cleaner or gas generator
ATTENTION: wet cleaning and water jet cleaning cannot
be applied to absorbent surfaces (eg splitters of the sound
attenuators).
Cleaning, Inspections/checks

Modular air-handling units, Series X
17
Inspections/checks
ATTENTION: during wet cleaning, it is necessary to
ensure safe disconnection of electrical components from
the supply voltage.
ATTENTION: chemical cleaners used for wet cleaning and
disinfection must not affect materials used.
ATTENTION: all cleaning must be conducted with closed
inlet and outlet dampers, it is recommended to have an inlet
filter fitted/placed.
ATTENTION: for cleaning, do not use any brushes or
similar harsh, surface-damaging tool.
The basic methods of cleaning the individual specific
installations of REMAK X ahus are described further in
the relevant chapters of this manual.
Inspections/checks
Unit casing check
State and cleanliness check of the casing external and
internal surface - clean the surface (see chapter Cleaning)
Anti-corrosion protection check (galvanized, painted
surface…)
Service and door panels seals check – state, intactness,
tightness
Hinges, handles state and function check including
pressure adjustment
Roof state and tightness check (outdoor design)
Unit bonding and grounding check (central ground
contact)
Check of the ductwork connection, flexible connectors
tightness and state check
Fan module check
Inspection of the equipment when disconnected from the
power supply:
ATTENTION: Mind the extraneous voltage (such as
electric heating and preheating external power supply.
ATTENTION, while checking, the fan must be first
switched off (use the service switch) and wait for the fan to
come to a complete stop (wait at least 2 minutes) before
opening the door! Failure to do so may result in the door
being blown off due to overpressure in the unit and the risk
of being trapped by the rotating part of the fan impeller!
ATTENTION, Before starting inspection and maintenance,
it is necessary to prevent the unprompted/spontaneous fan
start up and to ensure that it cannot be started by another
person!
Impeller and the entire fan module cleanliness check -
vacuum rough dirt and dust, wipe off fine dirt with a damp
mop
Check the fan impeller intactness and free rotation
Check the fan module screw tightening
Check silent block state and module mounting
Check the flexible connection (DV) state and tightness
Check the motor wiring, clamp tightening in the terminal
box and bonding (grounding)
Fan Inspection after a short test run:
Check the vibrations (imbalance), bearing noise and
excessive motor warming
At the perceived higher level of fan module/components
vibrations , a control measurement should be performed
and, if necessary, the fan module should be rebalanced to
complying parameters.
Check the motor wiring, clamps tightening and bonding
(grounding)
Check/measure the motor current, voltage and symetry
of phases
Motor bearings
Bearings do not require (and do not allow) lubrication
maintenance during their lifetime. The expected life time of
a motor ball bearing, calculated by the standard calculation
method, is determined by the F10h grease lifetime and
range approximately 30,000–40,000 operating hours
for standard use. When the lifetime of the F10h grease is
reached, the bearing must be replaced. This expected bearing
lifetime can be significantly reduced if operated under other
conditions such as higher vibration, higher shock, higher or
lower temperatures, moisture, impurities in the ball bearing,
or improper regulation. To achieve trouble-free operation,
replacement of motor bearings is recommended after
approximately 20,000 hours, but no later than 3 to 4 years or
as specified by the motor manufacturer. Shutdown or inactivity
of the equipment does not extend this period.
Important:
The standard lifetime data refers to normal, expected
operating conditions. Effective bearing lifetime is
fundamentally affected by real operating conditions.
Therefore, continuous and regular inspections and prescribed
service intervals are essential.
Attention must be also paid to undesirable long-term still
standing (long-term unilateral loading of the bearing without
lubrication and lubricant mixing leads to bearing damage
and lubricant degradation), this also refers to long-term
storage (6 months or more). In this case, compulsory motor
start must be executed (according to the motor and/or fan
manufacturer instruction). It is recommended to replace
bearings after 2 years of storage.
The motor or fan may be only disassembled in justified
cases such as bearings replacement. Disassembly and
servicing may be only carried out by a qualified person. It is
recommended to carry out repairs by a qualified workshop
or service center of the motor/fan manufacturer.
Whenever the fan/motor section is disassembled and
reassembled, the fan module must be rebalanced.
Damper check
Damper cleanliness check – vacuum the dirt and dust,
wipe off fine dirt with a damp mop
Free damper blades rotation check
Proper damper closure check
Proper actuator connection and function check
Filter module check
ATTENTION: dust captured on the filter inserts can cause
breathing problems and skin, mucous membranes or eyes
allergic reactions. Therefore it is always necessary to use
suitable protective equipment and to avoid direct contact
with trapped dust while maintaining and replacing filters.
Check the filters insert state and clogging degree
Filter module fastening check (seals state check or
replacement)

18
Inspections/checks
Replacement of filter inserts
ATTENTION: when replacing filters, it is necessary to
avoid contamination of the unit and new filters by dust
trapped in the old ones
ATTENTION, wear protective gloves when changing
the filters.
ATTENTION: metal filters and grease traps can be
washed with hot water and a suitable degreasing detergent.
ATTENTION: Disposal of used filter inserts must be
ensured in an environmentally friendly manner
Replacement filter inserts need to be always ordered from
the manufacturer as a complete set. To order, it is necessary
to indicate filter type (pocket, frame, etc.), as well as type and
size of the AHU unit and the relevant filtration class. It is not
necessary to specify the dimensions of the individual inserts
of which the filter module/wall consists.
Fig. 27 – seal sticking on the filter frame and filter insert
replacement
Course filtration:
ISO coarse
 Dp0 + 50 Pa
 3x Dp0 Dp0 ... initial
pressure drop of
the clean filter
 smaller value
applies
Fine filtration:
ISO ePM1
ISO ePM2.5
ISO ePM10
 Dp0 + 100 Pa
 3x Dp0
Filter section and filter module cleanliness check - vacuum
the dirt and dust, wipe fine dirt with a damp mop (it is
recommended to put the profiled seal out of the horizontal
rails)
Check the function and settings of the differential pressure
sensors
Maximal filter inserts (pocket and frame filters)
replacement interval can be given by a local legislation
(e.g EN 16798-3 or VDI 6022 + DIN 1946-4), regardless of
clogging and current pressure loss: 12 months - 2000 hours
for the first stage filtration, for further filtration stages and
filters in the air outlet a maximum of 24 months - 4000 hours
is recommended)
If the filter inserts are at the end of their service life
(according to the operating instructions or the valid
standards), damaged or clogged (see the value of the static
pressure drop), it is always necessary to replace them.
Maximal static pressure difference for particular filter
classes (according to EN13053:2020):
Filter replacement procedure
The filters are replaced by pulling out the individual inserts
fromtherailtowardstheserviceside,withouttheneedforatool.
In the case of a lever system, it is necessary to first release
their grip by pulling back the lever (Figure 28). The reverse
procedure applies for assembly.
Metal filters and trays for catching grease can be washed
with hot water and a suitable detergent, which promotes
degreasing.
Fig. 28 – filter locking lever mechanism
unlocked locked
Frame seal installation
Does not apply to filter inserts held by a lever mechanism,
Figure 28.
When replacing and before inserting each new filter insert,
it is necessary to stick a seal to its frame in the following way:
The seal (soft foam self-adhesive PE tape) is always glued to
the rear vertical edge of the plastic frame of each inserted
insert on the side closer to the horizontal seal that is on the
frame of the structure (see Fig. 27).
ATTENTION: The filter inserts of the pocket or frame filter
module have to be inserted in the vertical position, with the
pockets in the flow direction.

Modular air-handling units, Series X
19
Inspections/checks
Description
Symbol
Values Effects in vent
of deviation
Hydrogen ion
concentration pH 7,5 - 9 < 7 > 9
Corrosion
Fouling
Calcium and
magnesium content
Hardness
(Ca/Mg) 4 – 8,5 °D > 8,5 Fouling
Chloride ions Cl- < 50 ppm Corrosion
Carbon dioxide Fe3+ < 0,5 ppm Corrosion
Iron ions Mg2+ < 0,05 ppm Corrosion
Carbon dioxide CO2< 10 ppm Corrosion
Hydrogen sulphate H2S < 50 ppb Corrosion
Oxygen O2< 0,1 ppm Corrosion
Chlorine Cl2< 0,5 ppm Corrosion
Ammonia NH3< 0,5 ppm Corrosion
Ratio of carbons/
sulphates
HCO3
2- /
SO4
2- >1 <1 Corrosion
Direct evaporator module check
ATTENTION: check the function and state of the entire
refrigeration circuit system (state and amount of refrigerant,
tightness, expansion valve, condensing unit…), it may be
performed by an authorized refrigeration technician only
Evaporator check (fins damage, clogging…)
Removal of dirt from the exchanger surfaces - cleaning by
vacuuming or steam cleaning - cleaning must be performed
with the utmost care to avoid mechanical damage to the
evaporator fins
Regular check of the whole condensate drainage system
cleanliness, function and patency (drain pan , siphon and its
respective other connections / outlets…) is necessary
Functionality and tightness of the entire cooling circuit
Cleanliness of the drop eliminator (if the eliminator is
installed in a section)
Plate heat exchanger - (DEV)
Plate heat exchanger state check (fins damage, clogging)
Removal of dirt from the heat exchanger plates - cleaning
by vacuuming, compressed air or steam cleaner - cleaning
must be performed with the utmost care to avoid mechanical
damage to the heat exchanger plates
By-pass damper cleanliness and blades rotation check
Mixing damper cleanliness and blades rotation check (if the
mixing damper is installed in the section)
Cleanliness of the drop eliminator (if the eliminator is
installed in a section)
Regular check of the entire condensate drainage system
cleanliness, function and patency (drain pan siphon and its
respective other connections / outlets ...)
Rotary heat exchanger (ROV)
ATTENTION: before starting the check and/or
maintenance, it is necessary to wait for the complete stop
of the rotor and prevent unintentional start-up or start-up
of the rotor by another person
Exchanger rotor check (rotor foil damage, clogging,
torsion bars damage…)
Removal of impurities from the exchanger rotor
- cleaning by vacuuming (bristle dust attachment),
compressed air, steam - cleaning must be performed with
the utmost care to avoid mechanical damage to the rotor
foil
Activated carbon cartridge check
The pressure drop of the activated carbon filter wall does
not change during clogging.
The most effective way of saturation checking is the
periodic filter cartridge weighing. When the maximum
adsorption capacity is reached, i.e. an increase of the coal net
weight between 20 to 50% is reached (depending on the type
of coal and the gas to be captured, data available on request
from the manufacturer), the coal must be reactivated. When
this limit is exceeded, the filtration efficiency decreases. The
total weight of a standard cartridge 450 mm long in the clean
state is 2,500 g, the weight of the cartridge 2,000 g (max.
recommended increment 400 to 1,000 g).
The charcoal reactivation is carried out including the
cartridge. It is therefore advisable to have a spare set.
Further replacement intervals can be determined on the
basis of the aforementioned control measurements.
Water exchangers (heaters, coolers) check
ATTENTION: Operational surface temperature of the
heater and its connections may exceed a safe contact/
touch temperature of 60° C; before servicing, maintenance
and inspection, it is necessary to wait for sufficient cooling
ATTENTION: when treating, using and applying heating
and cooling media (additives, mixtures) of heaters/coolers,
observe the manufacturers safety recommendations and
regulations
Check water exchanger state check (fins damage,
clogging …)
Removal of dirt from the heat exchanger surfaces -
cleaning by vacuuming or steam cleaning - cleaning must be
carried out with the utmost care to avoid mechanical damage
to the water exchanger fins .
It is important to check the heat exchanger venting
Regular check of the entire condensate drainage system
cleanliness, function and patency is necessary (drain pan,
siphon and its respective other connections / outlets…)
Tightness of the fittings and entire system
Frost protection function
Mixing set function and state check
Cleanliness of the drop eliminator (if the eliminator is
installed in a section)
ATTENTION: when operating the exchanger with a water
circuit, or even when shutting it down in winter, the exchanger
must be filled with a safe antifreeze solution of water and
glycol or water must be completely drained and removed,
for example by blowing the exchanger with compressed air.
Warning: Residual water in the heat exchanger can
freeze and cause the copper pipes rupture.
Recommended water quality for heat exchangers that
operate using low pressure hot water and chilled water:
A good water quality – e.g. salt and lime free drinking water
– increases the lifetime and efficiency of the heat exchanger
Check the limiting values (shown in the table above)
annually to prevent damage to the hydraulic system and
its components
If necessary inhibitors must be added.
ATTENTION: stated limiting water quality values are
orientation only and are not a warranty subject!

20
Spare Parts and Service, Disposal and recycling
Fig. 29 – removing of splitters from the section
Rotor seal state and tightness check, circumferential
and radial
The rotor free rotation and wobble check
Rotor drive (cables connection and tightening in the
terminal box) and the belt tension check
Filter clogging check on the air supply and exhaust side
ATTENTION: In case of any rotor damage, wobble,
or drive failure, always contact the service department
Remak a.s.
Checking and tightening electrical connections and
checking the condition of the insulation of the conductors.
The condition of the heating coils is checked by measuring
the phase resistance at the supply terminals.
Steam humidifier check
All required checks are specified in the Instruction delivered
with the humidifier. Follow these instructions.
Yearly or no later than 2500 operation hours:
replacementofcylinders,stateandformofpipes,distribution
pipescheckandtightening,electricconnectiontighteningcheck
IMPORTANT: Electric parts! Steam cylinders can be hot
and contain boiling water. In case of water leakage there
is a risk of scorch or electric burn! Check frequency and
component lifetime are subject of change based on water
quality and operating conditions
Adiabatic evaporative humidifier check
All required checks are specified in the Instruction delivered
with the humidifier. Follow these instructions.
evaporative module and drop eliminator check
water pan/tank cleanliness check
Check of the water installation incl. evaporative module
water supply lines
Float function check (in case of circulation systems)
In case of apparent pollution or clogging, thorough
cleaning of the whole system is necessary. Clogged
evaporative module has to be replaced.
Electric heater
ATTENTION, electric appliance! Access allowed only if
switched off from the power supply and safely cooled down!
ATTENTION, fins of the heating coil are sharp and there
is a risk of injury!
Heating coils cleanliness check. Dirt and dust can be
vacuumed.
Check and tightening of electrical connections and check
of the conductors insulation state. State of the heating coils
is has to be made by measuring the phase resistance at the
supply terminals.
IBET electric preheating
the mechanical condition of the heater and heating
elements, the cleanliness of the surface of the heating coils
the outer surface and the interior of the heater
checking the functionality of the equipment
checking the function of safety/operating thermostat
tightening of the wires in the terminal and screwed
connections
Sound attenuation - splitters
Splitters state check, especially laminated fabric damage
check
Removal of dirt and dust from the splitters surface -
cleaning is performed by vacuuming - it is necessary to
prevent damage, tearing of the laminated fabric
Attenuation module splitters fixation check (screws)
If necessary, the splitters can be removed from the
section by removing service panels and unscrewing of the
fastening screws.
Flexible connector (DV)
Flexible connector state and tightness check
Removal of dirt - clean by vacuuming and wiping by a
damp mop
DV galvanic coupling check
Accessories – rain louvers, intake and exhaust extension
State and attachment to the unit check
Cleaning and removal of trapped dirt from ofthe protective
grid