System air HHFlex C User manual

1177fil HHFlex C/R/P/S
AHU Control
Operating Instructions
V8.00

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Contents
1 SAFETY CONSIDERATIONS 5
1.1 General 5
1.2 Avoid Electrocution 5
1.3 Abbreviations used 5
2 CONTROLLER DESCRIPTION 6
2.1 Overview 6
2.2 Power Supply 6
2.3 Battery 6
2.4 Indications 6
2.5 Mapping of Inputs/Outputs 7
2.6 Technical data 8
2.6.1 Common Data Controller 8
2.6.2 Communication 8
2.6.3 Casing 8
2.6.4 Inputs 8
2.6.5 Outputs 8
2.6.6 External display 8
2.6.7 TCP/IP port 8
3 HUMAN MACHINE INTERFACE 9
3.1 E-DSP External display unit 9
3.2 Overview 9
3.3 Log in 9
3.4 Menu tree external display 10
3.5 Access levels external display 11
3.6 Web panel 11
3.7 Connection to the unit 11
3.8 Login Screen 12
3.9 Overview Screen 13
3.10 Dashboard screen 13
3.11 Actual/Setpoint screen 14
3.12 Alarm Status screen 14
3.13 Inputs/Output screen 14
3.14 Analog Inputs screen 15
3.15 Analog Outputs screen 15
3.16 Digital Inputs screen 16
3.17 Digital Outputs screen 16
3.18 Time Program screen 17
3.19 Settings screen 18
3.20 Factory Screen 18
4 HHFlex – BASIC CONTROL FUNCTIONS 19
4.1 Temperature Control 19
4.1.1 Temperature control in occupied mode 19
4.1.2 Supply air temperature (TT02)control 19
4.2 Economy mode based on OAT (TT06) 19
4.2.1 Room air temperature (TT05) control 20
4.2.2 Extract air temperature (TT03) control 21
4.2.3 Temperature control in non-occupied mode 21

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4.3 Fan speed control 22
4.3.1 Fixed Fan Speed Control 22
4.3.2 High / low speed operation 22
4.3.3 Air Flow Control 22
4.3.4 High / low air flow operation 22
4.3.5 Supply Duct Pressure Control 22
4.3.1 Supply and exhaust Duct Pressure Control 23
4.3.2 Indoor Air Quality Control 23
4.4 Heat Recovery Monitoring 23
4.4.1 Low Supply Air Temperature Monitoring 23
4.4.2 High Supply Air Temperature Monitoring 23
4.4.3 Frost Protection without Pre-Heating 23
4.5 Filter Monitoring equipped with a pressure sensor 24
4.1 Dry outdoor filter control equipped with a pre-heater 24
4.2 Occupancy Management 24
4.3 Stand alone mode 24
4.3.1 Internal Clock 24
4.3.2 Operation Time Extension 24
4.4 Remote mode 24
4.5 Building Fire Management 25
5 HHFlex – OPTIONAL CONTROL FUNCTIONS 25
5.1 Air Dampers 25
5.2 Hot-water reheating Coil 25
5.3 Water Coil Frost Protection (TA01) 26
5.4 Warm Up at Unit Start Up 26
5.5 Unit Frost Protection 26
5.6 Chilled-water Cooling Coil 26
5.6.1 Temperature Control 26
5.8 Change-over water Coil for Heating and Cooling 27
5.8.1 Heat/Cool Thermostat (TS01) 27
5.8.2 Temperature Control 27
5.8.3 Water Coil Frost Protection (TA05) 27
5.8.5 Warm Up at Unit Start Up 28
5.8.6 Unit Frost Protection 28
5.8.7 Defrost of heat-pump 28
5.8.8 Backup electric heater 28
5.9 Electrical reheating Coil 29
5.9.1 Temperature Control 29
5.9.2 Overheating protection (TA04) 29
5.9.3 Cool down at unit stop 29
5.10 Electrical pre-heating Coil 30
5.10.1 Heat Recovery Frost Protection 30
5.10.2 Overheating protection (TA03) 30
5.10.3 Cool down at unit stop 30
5.11 Hot water pre-heating Coil 31
5.11.1 Heat Recovery Frost Protection 31
5.11.2 Water Coil Frost Protection (TA01) 31
5.11.3 Warm Up at Unit Start Up 31
5.11.4 Unit Frost Protection 31
5.12 Direct-expansion coil 32
5.12.1 Condensing unit/reversible unit with staged capacity 32
5.12.2 Condensing unit/reversible unit with variable capacity 32
5.13 Water pump anti-blocking system 32

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5.14 Recirculation air damper (CD06) 32
5.15 Mixing Box management 33
5.15.1 ON/OFF recirculation 33
5.15.2 Modulated recirculation as heating/cooling capacity 33
5.15.3 Minimum fresh air threshold 33
5.15.5 Modulated recirculation using CO2 sensor 34
5.15.6 Modulated recirculation as heating/cooling capacity with fresh air calculation 34
5.17 Fast building temperature warm-up/cool-down before an occupied period 35
5.18 Operation of chilled beams during unoccupied periods 35
5.19 Heat pump defrost 35
5.20 Minimum/maximum room temperature in an unoccupied period 35
5.21 Humidification control 36
5.21.1 Description control algorithm 36
5.21.2 Default settings for relative humidity control 37
5.23 Dehumidification control 38
5.23.1 Description control algorithm 38
5.23.2 Default settings for relative humidity control 38
6 DIAGNOSTICS & TROUBLESHOOTING 39
6.1 General 39
6.2 Displaying Alarms 39
6.2.1 E-DSP External display unit 39
6.2.2 Web Panel 39
6.3 Alarm report 39
6.4 Resetting Alarms 39
6.5 Alarms List 40
7 BUS COMMUNICATION 42
7.1 General 42
7.2 Modbus 42
7.2.1 Communication Settings 42
7.2.2 Modbus type 42
7.2.3 Modbus functions 42
7.2.4 Max. 47 registers 42
7.2.5 Communication limits 42
7.2.6 Scale factor 42
7.3 BACnet IP 43
7.4 ANNEX 1 - BACNET PROTOCOL IMPLEMENTATION AND CONFORMITY 44
The manufacturer reserves the right to change the specifications without prior notice.
Graphics and photos are for illustration purposes only and not contractually binding.

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1 SAFETY CONSIDERATIONS
1.1 General
Installation, start-up and servicing of equipment can be hazardous if certain factors particular to the installation are not
considered: operating pressures, presence of electrical components and voltages and the installation site (elevated plinths
and built-up up structures). Only properly qualified installation engineers and highly qualified installers and technicians,
fully trained for the product, are authorized to install and start-up the equipment safely. During all servicing operations
all instructions and recommendations which appear in the installation and service instructions for the product, as well as
on tags and labels fixed to the equipment and components and accompanying parts supplied separately, must be read,
understood and followed.
•Apply all standard safety codes and practices.
•Wear safety glasses and gloves.
•Use the proper tools to move heavy objects. Move units carefully and set them down gently.
1.2 Avoid Electrocution
Only personnel qualified in accordance with IEC (International electro technical Commission) recommendations may be
permitted access to electrical components. It is particularly recommended that all sources of electricity to the unit be shut
off before any work is begun. Shut off the main power supply at the main circuit breaker or isolator.
1.3 Abbreviations used
AHU Air Handling Unit
AI Analog Input
AO Analog Output
CHO Change Over Coil
CWC Cold Water Coil
DI Digital Input
DO Digital Output
EAT Extract Air Temperature
HWC Hot Water Coil
IAT Inlet Air Temperature (Sensor placed just before heat recovery exchanger)
OAT Outdoor Air Temperature
RAM Random Access Memory (volatile memory)

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2 CONTROLLER DESCRIPTION
HHFlex controller is an electronic control system to regulate Air Handling Units.
The control system consists of two controllers which are described hereafter.
2.1 Overview
Controller Overview
Port 2 and TCP/IP are only available on the main controller
2.2 Power Supply
Each controller operates at 24 VDC and has a power consumption of 4 VA (without load, without display).
In the event of a power supply interrupt, the unit restarts automatically without the need for an external command. However, any
faults active when the supply is interrupted are saved and may in certain cases prevent unit from restarting.
2.3 Battery
The resources and the program are stored in RAM. To ensure that they are not lost and that the hardware clock
continues to run when there is a power failure, the controller is equipped with a buffer battery.
The buffer time is at least 5 years.
The buffer battery is a 3V lithium battery (CR2032).
The battery voltage is monitored. When battery is low the P/B Indication LED lights red.
2.4 Indications
The upper left corner of each controller contains four LEDs which give the status indication of the controller.
Designation Colour Description
P1 RxTx Yellow/
Green
Port 1: Receiving/transmitting
P2 RxTX Yellow/
Green
Port 2: Receiving/transmitting
TCP/IP Green/
Yellow
Fixed green: Link
Flashing green: Traffic
Flashing yellow: Identification
P/B Green/
Red
Power supply / Low battery
level

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2.5 Mapping of Inputs/Outputs

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2.6 Technical data
2.6.1 Common Data Controller
Supply voltage 24 VAC ±15%, 50….60 Hz or 20…36 VDC
Power consumption 4 VA (without load, without display)
BTL approval EXOreal 3.1-1-02 or later
+C output +24 V DC, 0,15 A, short-circuit proof
Operating system EXOreal C
Battery backup Memory and real-time clock, at least 5 years
Ambient temperature 0…50⁰C
Storage temperature -20…+70⁰C
Relative humidity (non-condensing) Max. 95%
Dimensions (WxHxD) 149 x 121 x 60 mm
Din controller width 8 ½
EMC emissions and immunity standard: This product conforms to the requirements of the EMC Directive
2004/108/EC through product standards EN 61000-6-1 and EN 61000-6-3.
RoHs: This product conforms to the Directive 2011/65/EU of the European Parliament and of the Council.
2.6.2 Communication
Serial RS485 (EXOline or Modbus with automatic detection/change over)
TCP EXOline-TCP, BACnet/IP, Modbus/IP (requires EXOreal 3.1.1-01 or later)
Modbus 8 bits, 1 or 2 stop bits. Odd, even (Fs) or no parity.
Speed (Port 1 and Port 2) adjustable 1200-38400 bps
2.6.3 Casing
Protection class IP20
Mounting DIN-rail mounting or mounting in cabinet
Plastic Polycarbonate, PC
2.6.4 Inputs
Analogue inputs, AI 0(4)…20 mA, 0…10 V, 0…200 mV, PT-1000, DIN Ni1000, LGNi1000,
12 bits A/D
Digital inputs, DI Potential-free contact, 24 V DC, configurable for pulse input
Universal inputs. UI AI or DI (see above)
2.6.5 Outputs
Analogue outputs, AO 0…10 V DC, 5 mA, 12 bit D/A, short circuit-protected
Digital outputs, DO Mosfet 24 V AC/DC, 2 A. Max 8 A in total.
24 V DC output 0.15 A, short circuit-protected
2.6.6 External display
Models E3-DSP, ED9200 or ED-RU
Connection 4P4C modular connector.
Max. cable length 100 m
2.6.7 TCP/IP port
Connection RJ45, 10Base-T/100Base-TX auto-negotiation
Cable length Max. 100 m (min Cat 5)
Power consumption + 1 VA in addition to basic consumption.

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3 HUMAN MACHINE INTERFACE
3.1 E-DSP External display unit
3.2 Overview
The display menu system is accessed using seven buttons:
The LEDs have the following functions:
Designation Function Colour
There are one or more
unacknowledged
alarm(s)
Flashing red
There are one or
more remaining,
acknowledged alarm(s)
Fixed red
You are in a dialogue
box where it is possible
to switch to change mode
Flashing
yellow
Change mode Fixed yellow
3.3 Log in
The standard passwords are 3333 for basic level with the lowest access (guest) and 2222 for level giving more access (operator).
Menu tree external display

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3.4 Menu tree external display
ACTUAL /
SETPOINTS
ACTIVATE OUT
OF HOUR
OUT OF HOURS
OVERRIDE TIME
TEMPERATURE
HUMIDITY
DE-HUMIDITY
AIR VOLUME /
FANSPEED
DUCT PRESSURE
INDOOR AIR
QUALITY
FILTER SENSOR
HEAT RECOVERY
UNIT
CONFIGURATION
OUTDOOR
TEMPERATURE
SUPPLY
TEMPERATURE
ROOM
TEMPERATURE
EXTRACT
TEMPERATURE
INLET HUMIDITY
SUPPLY HUMIDITY
ROOM HUMIDITY
EXTRACT HUMIDITY
INLET HUMIDITY
SUPPLY HUMIDITY
ROOM HUMIDITY
EXTRACT HUMIDITY
SUPPLY FAN
EXHAUST FANSUPPLY DUCT
EXHAUST DUCT
SUPPLY
EXHAUST
ENDRUNMODE
TEMPERATURE
CONTROL
HUMIDITY
CONTROL
FANCONTROL
OUTDOOR
COMPENSATION
NIGHTCOOLING
MAIN CONTROLLER
SLAVE 1
CONTROLLER
SLAVE 2
CONTROLLER
TIME SCHEDULE RUN SCHEDULE
LOW SPEED
NIGHTCOOLING
RECIRCULATION
PUMPTEST
HOLIDAYS
SETTINGS
PRESSURE FAILURE
SUPPLY
TEMPERATURE
FILTER SENSOR SUPPLY
EXHAUST
END
LOW
HIGH
SUPPLY FAN
EXTRACT FAN
FACTORY
INPUTS/ OUTPUTS
RUNTIME
ADJUST
TIME/ DATE
COMMUNICATION
DEFAULT SCREEN SOFTWARE
VERSION
TYPE AND SERIAL
NR.
MODBUS CONFIG
BACNET IP CONFIG
MANUAL-AUTO
ACCES RIGHTS
MAIN CONTROLLER
SLAVE 1
CONTROLLER
SLAVE 2
CONTROLLER
GATEWAY
EXOLINE ADDRES
CURRENT IP
ADDRESS
SUBNETMASK
ELECTRIC FROST
HEATER
ELECTRIC BOOSTER
HEATER
AHU ON
HEAT DEMAND
COLD DEMAND
RELEASE DX
PUMP PREHEATER
PUMP BOOSTER
HEATER
PUMP COOLER/
CHANGE-OVER
PUMP RUN-A-
ROUND COIL
HUMIDIFIER
MAIN CONTROLLER
SLAVE 1
CONTROLLER
SLAVE 2
CONTROLLER
LOG ON
LOG OFF
CHANGE
PASSWORD
FIRE ALARM
SETTINGS
ALARM LOG
GATEWAY
DNS
ALARM SETTINGS

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3.5 Access levels external display
VISIBLE FOR EVERYONE NO CHANGES CAN BE MADE
VISIBLE FOR EVERYONE USERS LOGGED IN AS GUEST 3333) OR HIGHER CAN MAKE CHANGES
VISIBLE FOR EVERYONE USERS LOGGED IN AS OPERATOR 2222) OR HIGHER CAN MAKE CHANGES
ONLY VISIBLE FOR USERS LOGGED IN AS FACTORY
3.6 Web panel
Access to the data of HHFlex can be done thanks to a PC with Google Chrome.
3.7 Connection to the unit
To access the HHFlex controller, enter the IP address of the unit in the address bar of the web browser.
The controller has two IP addresses, one service IP address and one user IP address.
The controller is working in service IP address mode when Digital Input DI7 of the main controller is closed (connect
+24VDC to DI7) and is working in user IP address mode when DI7 is open.
The default service IP and user IP address of the unit is 169.254.24.1.
The user IP address can be changed in the “Settings” menu when operating in service IP address mode or with the E-DSP
under Service => Communication
The service IP address can’t be changed.
The IP address of the PC, directly connected to the unit should be in the same group as the IP address of the unit
(169.254.*.*).
Minimum web browser configuration:
•Google Chrome
Many users can be connected at the same time. There is no priority between users; last modification is taken into account.
Language of the web browser must be set in English, France or Dutch.

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3.8 Login Screen
Klick on the login button
There are three login levels:
• Basic level with the lowest access;
Login : Guest
Password : 1111
• Level giving more access;
Login : Operator
Password : 2222
• Level with full access, for manufactory purpose only

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3.9 Overview Screen
Displays the process diagram and status of the unit.
This is a read only folder. No settings can be made.
3.10 Dashboard screen
Displays relevant modes and actual values.
All values written in blue can be changed. As soon as a value has been changed and you have pressed enter, the value is
downloaded to the HHFlex controller.
Users logged in as Operator can make changes on this pages.

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3.11 Actual/Setpoint screen
Displays relevant setpoints and actual values.
All values written in blue can be changed. As soon as a value has been changed and you have pressed enter, the value is
downloaded to the HHFlex controller.
Users logged in as Guest can make changes on this pages.
3.12 Alarm Status screen
Shows actual Alarms and Status of the unit.
Alarms can acknowledged, blocked or unblocked
Users logged in as Guest or Operator can make changes
BE CAREFUL: Blocking Alarm can lead to unsafe situations.
3.13 Inputs/Output screen
Shows actual values for all inputs and outputs.
This is a read only folder. No settings can be made.

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3.14 Analog Inputs screen
Shows actual values for all analog inputs .
For testing purpose only all functions can manually set here to a certain value.
Only users logged in as Operator can make changes.
BE CAREFUL: All settings which are made here will be executed.
Protections like frost protection, max temperature electric heater and minimum airflow electric heater will be ignored.
3.15 Analog Outputs screen
Shows actual values for all analog outputs .
For testing purpose only all functions can manually set here to a certain value.
Only users logged in as Operator can make changes
BE CAREFUL: All settings which are made here will be executed.
Protections like frost protection, max temperature electric heater and minimum airflow electric heater will be ignored.

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3.16 Digital Inputs screen
Shows actual values for all digital inputs .
For testing purpose only all functions can manually set here to a certain value.
Only users logged in as Operator can make changes.
BE CAREFUL: All settings which are made here will be executed.
Protections like frost protection, max temperature electric heater and minimum airflow electric heater will be ignored.
3.17 Digital Outputs screen
Shows actual values for all digital outputs .
For testing purpose only all functions can manually set here to a certain value.
Only users logged in as Operator can make changes
BE CAREFUL: All settings which are made here will be executed.
Protections like frost protection, max temperature electric heater and minimum airflow electric heater will be ignored.

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3.18 Time Program screen
Here you can set the time programs:
• Run schedule.
• Low Speed schedule. (Run schedule must be active)
• Night cooling schedule.
• Recirculation schedule.
• Pump test schedule.
• Holiday program
All values written in blue can be changed by users logged in as Guest or Operator.
As soon as a value has been changed and you have pressed enter, the value is downloaded to the HHFlex controller.
The day begins at 00.00 hours and ends at 24.00 hours

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3.19 Settings screen
All values written in blue can be changed by users logged in as Operator. As soon as a value has been changed and you
have pressed enter, the value is downloaded to the HHFlex controller.
Only users logged in as Operator can make changes
BE CAREFUL: Bad PID parameters can lead to unstable control.
3.20 Factory Screen
For manufactory purpose only, data can be read but changed only by manufactory

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4 HHFlex – BASIC CONTROL FUNCTIONS
4.1 Temperature Control
4.1.1 Temperature control in occupied mode
The HHFlex AHU controller can control either:
the supply air temperature (TT02)
or the extract air temperature (TT03) (cascade control of the supply air temperature)
or the room air temperature (TT05) (cascade control of the supply air temperature)
The selection of the temperature controlled is made in the menu Configuration (menu Actual/Setpoint) .
To save energy, HHFlex controller offers the possibility to correct the setpoint based on the actual outdoor temperature.
All setpoints are configurable in the menu Actual/Setpoint.
4.1.2 Supply air temperature (TT02)control
To activate this function select supply air temp. in the configuration menu.
If OAT correction is selected there is compensation on the supply air temperature according the graph:
4.2 Economy mode based on OAT (TT06)
If the option “Eco mode on Outdoor Temp” is selected in the configuration menu (Actual/Setpoint) then mechanical
heating/cooling can be disabled between 2 OAT values. Heat recovery device can also be stopped during this “economy
mode” thanks to a configuration parameter.
Max. Cooling
HR + Gradual Cooling
Free Cooling
Off
Free Cooling
Heat Recovery (HR)
HR + Gradual Heating
Max. Heating
Room Temperature
Hysteresis set by user
Hysteresis set by user
Threshold set
by Advanced User
function of
extract air temp
and
OAT °C (TT06)
Y1 30°C
Y2 22°C
X2
Y3 14°C
X3
X1
-30 -20 -10 0 10 20 30 40 50°C
SAT (TT02) setpoint
Occupied ModeUnoccupied Mode

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4.2.1 Room air temperature (TT05) control
To activate this function select room temp. in the configuration menu
If OAT (TT06)correction is selected there is outdoor compensation on setpoint according the graph:
RAT (TT05) setpoint
correction
-30 -20 -10 0 10
20
30 40
50°C
OAT
°C (TT06)
X1 X3
Y3 +2 K
Y1 -2 K
Y2 0 K
X2