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Euroclima ZHK Series Instruction Manual

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INSTRUCTION MANUAL

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Summary of Contents for Euroclima ZHK Series

  • Page 1 INSTRUCTION MANUAL...
  • Page 2 Instruction Manual ZHK In addition to the instructions in this guide, subject-specific standards, as well as local, national and international regulations must be observed. After completion of the work, please give this instruction man- ual to the operating staff. Please keep the complete instruc- tion and operating manual filed with your other documents.

  • Page 3: Table Of Contents

    Instruction Manual ZHK Table of contents Introduction ..........................6 Model code ........................6 Intended use / foreseeable misuse .................. 7 1.2.1 Intended use ........................7 1.2.2 Foreseeable misuse ......................8 Modular design ........................ 8 Documentation ........................ 8 Safety instructions / Guidelines to conformity to laws and directives ......10 CE-conformity / installation instructions for safe operation ..........
  • Page 4 Electric heaters ......................83 7.6.1 AHUs equipped from EUROCLIMA with control ..............84 7.6.2 AHUs which are not equipped from EUROCLIMA with control ......... 86 Differential pressure restriction for plate heat exchangers ..........86 7.7.1 General indications ......................86 7.7.2 Prevention measures ......................
  • Page 5 Instruction Manual ZHK 8.2.2 Manually starting the compressor via EUROCLIMA control system ......... 97 8.2.3 Refrigerant ......................... 97 8.2.4 Compressor lubricant ......................97 Test run ......................... 98 8.3.1 Adjusting variable pullies ....................98 8.3.2 Resonance at fans ......................99 Maintenance ........................100 Electrical connection, control cabinet ................
  • Page 6 Instruction Manual ZHK 12 Disassembly and disposal ....................123 12.1 Disassembly ........................ 123 12.2 Disposal ........................124 Figure index ..........................125 Table index ..........................129 Original Instructions - V07-19.0 5/129...

  • Page 7: Introduction

    Instruction Manual ZHK Introduction This is the instruction and operation manual for an air handling unit, hereinafter designated as ‘AHU’. Model code 15/6 – 15/6 ZHK INOVA AHU type (standard) AHU execution AHU size supply air AHU size exhaust air Legend used for AHU type ZHK INOVA casing type with thermal separation profile...

  • Page 8: Intended Use / Foreseeable Misuse

    In this case, corrosion of the AHU or inappropriate filtration of the air could be a result of a planning error, for which EUROCLIMA de- clines the responsibility, because the AHU is built according to the confirmed specifications.

  • Page 9: Foreseeable Misuse

    Instruction Manual ZHK Components provided by the customer If it is planned and agreed, that EUROCLIMA installs components in the AHU, which are provided by the customer, EUROCLIMA only accepts liability, if there are significant mistakes in construc- tion. The warranty for proper functionality of the provided components as well as the component con- cerned safety requirements is excluded.
  • Page 10 At differences between this manual and the instruction manual of the component manufac- turer, the instruction manual of the component manufacturer has to be applied. In case of doubt, please contact your EUROCLIMA office. V07-19.0 9/129...

  • Page 11: Safety Instructions / Guidelines To Conformity To Laws And Directives

    CE-conformity / incorporation declaration according to Machinery Directive 2006/42/EC An AHU (or any part thereof) supplied by EUROCLIMA is by definition of Machinery Directive 2006/42/EC an incomplete machine, because it is limited in function and is only a part of the build- ing system.
  • Page 12 See chapter 7.2 (AC motors). Frequency controller for Plug fans Also, if not supplied by EUROCLIMA, a frequency converter must be installed to reach the calcu- lated operating point. For details see chapter 7.5 (Variable, frequency-controlled drives (VFD, frequency converters)).

  • Page 13: Indications For Minimizing Specific Hazards

    Instruction Manual ZHK Indications for minimizing specific hazards 2.2.1 General indications An improperly performed maintenance can pose a security risk! Risk of thin sheets, when working on AHU During work on AHU (or on parts), there is a substantial risk of cutting with thin sheets as e.g.
  • Page 14 Instruction Manual ZHK during the work. The housing of the AHU interior lighting (can have separate supply) is not cur- rent-carrying. all moving parts, especially the fan wheel, motor and heat wheel have come to a standstill; wait at least 5 minutes after switching off before opening the doors. for maintenance of frequency controlled motors, a waiting time of 15 minutes is recommended –...

  • Page 15: Refrigeration Circuit

    Instruction Manual ZHK Prevention of hazards caused by suddenly falling out door panels while opening of remova- ble panels Removable door panels can fall out after detaching the connections and lead to in- juries. Particular care should be taken when removing pressure sided doors be- cause they can be firmly in place then suddenly detach.

  • Page 16: Conformity To Laws And Directives

    Instruction Manual ZHK Safety indications for operation The following instructions must be observed urgently for the safe operation of ATEX AHUs: Operating conditions in accordance to the intended use. In the immediate environment of the AHU there should be no substances ac- cording to EN 1127-1:2011, which are prone to spontaneous combustion, such as pyrophoric substances.

  • Page 17: Staff Selection And Qualification

    They will be triggered if the pressure drop at the filter exceeds the maximum permissible value. See chapter 9.3 (air filters). If above mentioned equipment is not included in delivery by EUROCLIMA, it has to be provided on site.
  • Page 18 Instruction Manual ZHK Depending on the material used and the environmental conditions, a superficial corrosion may occur on components like e.g. motor shafts, fan shafts, pulleys, clamping bushes, sheet cutting edges, and so forth. The resulting corrosion layer protects the underlying material from further corroding and does not represent a defect of the component or the device (see also chapter The packaged delivered goods may include multiple parts of the device.

  • Page 19: Lifting By Forklift / Lift Truck

    Lifting by forklift / lift truck In accordance with the EUROCLIMA drawing the AHU will be delivered as monobloc or more deliv- ery section(s). The AHU parts or the monobloc are delivered on pallets and can be unloaded and moved by forklift or lift truck.

  • Page 20: Overlifting Of Ahu Sections With Crane Lugs

    Parts of the AHU may only be lifted with lugs individually - never bolt parts to- gether before lifting. Lateral load on lifting lugs is not allowed. The lifting of monoblocs by crane lugs is permitted only in exceptional circum- stances and requires the written approval by EUROCLIMA. V07-19.0 19/129...

  • Page 21: Control Of Weight Limits Of Delivery Sections

    Instruction Manual ZHK 3.3.1 Control of weight limits of delivery sections Depending on the base frame height (see Figure 7), delivery sections may be lifted with lifting lugs up to the following weight, refer to Table 1. Base frame height H (mm) Max.

  • Page 22: Necessary Actions Before Lifting Delivery Sections With Crane Lugs

    Instruction Manual ZHK 3.3.2 Necessary actions before lifting delivery sections with crane lugs Opening accessories such as dampers, flexible connections, hoods, etc. must be removed before lifting, see the following examples. This equipment must be lifted separately on a pallet and then be reinstalled.
  • Page 23 Instruction Manual ZHK Figure 11: Delivery section with mounted crane lugs Example 2: Figure 12: Delivery section with mounted flexible connection Figure 13: Delivery section with dismounted flexible connection 22/129 V07-19.0...

  • Page 24: Mounting Of Crane Lugs

    Instruction Manual ZHK Figure 14: Delivery section with mounted crane lugs 3.3.3 Mounting of crane lugs Crane lugs are supplied in two versions and will be attached on the front side of the respective de- livery section in accordance with the necessary preparations, described in chapter 3.3.2 (Neces- sary actions before lifting delivery sections with crane lugs).

  • Page 25: Lifting By Crane Lugs

    Bolts and nuts are delivered with the lifting lugs and must be tightened with the torque according to Table 2. If the lifting lugs are already mounted by EUROCLIMA, the screws must be checked be- fore lifting of the AHU.

  • Page 26: Overlifting Of Monoblocs

    Instruction Manual ZHK Figure 17: Load carrying equipment guided Figure 18: Uniform force effect over front side Overlifting of monoblocs If several sections or the entire AHU is combined into one delivery unit, then this is called a mon- obloc. Chapter 3.4 (Overlifting of monoblocs) is only valid for the delivery form “Monobloc”.
  • Page 27 The bolts are mounted already by EUROCLIMA, if this option is agreed. (Figure 22). The crane lugs are included in the scope of delivery of EUROCLIMA, if the lifting of the mon- obloc by monobloc crane lugs is agreed.

  • Page 28: Further Necessary Actions For The Overlifting Of Both, Delivery Sections On Crane Lugs As Well As Monoblocs

    The lifting of monoblocs is just permitted for the case described above, with the particular crane lugs delivered by EUROCLIMA. Further necessary actions for the overlifting of both, delivery sections on crane lugs as well as monoblocs The AHU sections or monoblocs must be lifted with appropriate equipment e.g.

  • Page 29: Storage

    Instruction Manual ZHK The load carrying equipment is not permitted to exceed an angle of maximum 15 ° to the vertical and must be spread apart to avoid damage to the casing, refer to Figure 26. max. 15° max. 15° Figure 26: Permitted angle for load carrying equipment guidance Storage The delivery sections generally are packed in nylon.

  • Page 30: Foundation / Erection

    Instruction Manual ZHK you want to please to yourself, the planner, the owner and other observers of the AHU, then we strongly recommend covering and protect the AHU against dirt and damage during the installa- tion and commissioning process, see Figure 27. Figure 27: Protection against dirt Foundation / erection Space requirements:...

  • Page 31: Erection

    Instruction Manual ZHK Figure 28: Solid foundation and strip foundation The installation of underlayment with impact sound insulation properties and high specifications is highly recommended. It is recommended, depending on the location of the erection, to underlay the AHU with cork, Mafund plates or Sylomer strips. The used absorbent material must be adjusted to the load to achieve optimum noise insulation.

  • Page 32: Actions To Prevent Potential Risks

    In this context, it is recommended to conclude an insurance against damage caused by water and other liquids. EUROCLIMA is not liable for damages that may arise due to leakage of the AHU, of fittings, of pipes or hoses or due to condensation.

  • Page 33: Special Guidelines For Flat Ahus - Ceiling Ahus

    Instruction Manual ZHK Figure 29: Suspension of ceiling AHUs AHU which are not designed to stack, may not be stacked (one on top of the other). Spray humidi- fier will need either one-both sides higher foundations or on one-both sides feet, which are sup- plied if ordered, refer to Figure 30.
  • Page 34 Instruction Manual ZHK The suspension can consist only of transverse profiles (transversely to the air flow), as shown in Figure 31, or of transverse profiles with additional longitudinal profiles (longitudinal to the air flow), see Figure 32. In order to prevent deflection of the bottom panel, the maximum distance of the supporting pro- files should not exceed 1 m to each other.

  • Page 35: Assembly

    Instruction Manual ZHK Assembly If climbing on the AHU is unavoidable during assembly, for example, for connect- ing the roof plates, it must be ensured by appropriate measures. For example, us- ing boards, that the weight is distributed evenly, in order to avoid bending of the roof panels.
  • Page 36 Instruction Manual ZHK Figure 36: Applying the sealing agent Figure 35: Sealing agent (Sikaflex) Pulling together AHU sections The AHU sections must be aligned precisely and the front sides shall be exactly parallel to the other. If necessary, some minor corrections can be made by placing steel plates under the section. The AHU sections can be pulled together with belts which attach on the base frame, as shown on Figure 37 and Figure 38.
  • Page 37 Instruction Manual ZHK Procedure: ZHK 2000 – Housing type: Snap in construction – To remove the external panel - start at the corners - use a screwdriver – refer to Figure 40. After removing the external panel, remove the insulation. Figure 40: Removal of the external panel ZHK INOVA –...

  • Page 38: Standard Connections And Connection Components

    Instruction Manual ZHK 5.1.2 Standard connections and connection components The connection via base frame must be always made at all AHUs, see Figure 44 and Figure 45. Figure 44: Hexagon bolt with locknut M8x20 / M10x30 / M12x40 Figure 45: Bolt connection of base frames Additionally, to the base frame, there are other possibilities for connecting AHU parts.
  • Page 39 Instruction Manual ZHK Figure 48: Easy Connection at two-sto- Figure 49: mounted Easy Connection at two-storey AHUs rey AHUs Figure 50: Hexagon bolt with locknut Figure 51: Connection angle Figure 52: Connection via connection an- M8x20 Figure 53: Hexagon bolt with nut M6x6 Figure 54: Connection frame n x 152,5 Figure 55: Hexagon bolt with nut M6x16...

  • Page 40: Detailed Solutions And Connection Components

    Instruction Manual ZHK 5.1.3 Detailed solutions and connection components Connection between door frame / door frame and door frame / internal panel Screw spacing: 152 mm Figure 57: Tapping screw ø8 x 11 Figure 58: Tapping screw Ejot ø8 x 16 Figure 60: Connection between door frame / internal Figure 59: Joint on the AHU drawing panel...
  • Page 41 Instruction Manual ZHK Connection of internal panels with the front side of the casing Figure 63: Self-tapping screw TORX Figure 64: Joint on the AHU 25 ø4,8 x 16 drawing Figure 65: Joint at the AHU Connection of internal and external panel (ZHK INOVA) Figure 67: Screw connection of internal and exter- Figure 66: Self-tapping pan head screw TORX 25 ø4 x 25 nal panel...

  • Page 42: Establishing The Screw Connection Of Ahu Parts

    Instruction Manual ZHK Connection of connection frame and partition walls Screw spacing: according holes in the connection frame partition wall connection frame with holes Figure 70: Self-tapping screw ø6,3 x Figure 71: Connection frame and partition Figure 72: Screwing of the wall (not screwed yet) parts 5.1.4...
  • Page 43 Instruction Manual ZHK Figure 73: Bolting delivery sections together Reinsert the insulation and remount the external panel At AHUs of the series ZHK 2000 in outdoor execution or with outer aluminum panels, the white protective film must be removed from the sealing tape before mounting (Figure 74). Figure 74: Removing the protective film 42/129 V07-19.0...

  • Page 44: Special Features For Roof Ahus And Device Separations At Wet Areas

    Instruction Manual ZHK ZHK 2000 – Casing type: Snap-In-Construction Start at the bottom to mount the external panels (Figure 75). Figure 75: Pushing in the external panel ZHK INOVA – Casing type: Screwing-Construction The outer panel lay on the inner panel and fixing with TORX-screws (see Figure 76, Figure 77, Figure 78).
  • Page 45 Instruction Manual ZHK Note: To prevent leaks, these actions shall also be performed when extreme operating conditions are expected or wet cleaning is planned! Figure 79: Sealing surfaces at wet areas Figure 80: Sealing the frontal joints Joints Joint Access (door) Figure 82: Sealing the section con- Figure 81: AHU separation acces- nection (joint) with the sealing agent...
  • Page 46 Instruction Manual ZHK 1. at the base frame cover / base frame valance above 2. at the base frame frontside 3. sealing of the base frame and to the roof profile (at two-storey AHUs) 4. sealing of open base frame holes (if present) 5.
  • Page 47 Instruction Manual ZHK Roof flange AHU flange Figure 86: Applying the sealing agent on the frontal joints Combination AHU in weather-resistant execution side by side If parts of outdoor AHUs are set up side by side, then the metal sheet roof, which overlaps both parts of the AHU, has to be mounted on site.

  • Page 48: Cable Gland

    Figure 91: Closing of the joints with sealant 5.1.6 Cable gland For the connection of engines, pumps, electric heaters, sensors, etc., EUROCLIMA loosely sup- plies material for cable glands (Figure 95), which must be installed properly. The following proce- dure is recommended: 1.

  • Page 49: Transport Lock

    Instruction Manual ZHK Size External drilling diameter Internal drilling diameter (of the cable gland) (for screwing) (for sleeve) M 16 M 20 M 25 M 32 M 40 M 50 M 63 Table 3: Drilling diameters for cable glands Figure 92: Step drill 3.

  • Page 50: Securing The Position Of Ahus

    Instruction Manual ZHK Figure 96: Transport lock 5.1.8 Securing the position of AHUs Floor AHUs must be fixed on the foundation to secure the position. A direct coupling, see Figure 97 left, should be avoided because of structure-borne sound transmission. If you use structure- borne sound insulated underlayment, the fixing by lugs is particularly suitable to avoid the displace- ment of the AHU in all directions (Figure 97 right).
  • Page 51 Instruction Manual ZHK not locked Figure 99: Door ‚closed’, not ,locked’ Figure 98: Door ‚open’ Doors which allow access to the fan section are equipped with a door lock. Figure 100 shows the lock in the position 'locked', locking slit is in vertical position.
  • Page 52 Instruction Manual ZHK Hinged doors in INOVA-execution differ just in the casing and hinge execution from the 2000-exe- cution (see figure beneath). Figure 105: Hinge for INOVA-exe- Figure 106: opened hinged door Figure 104: Hinged door (ZIS) cution (ZIS) Readjustment of the door panel position Because of the handling of AHU sections, the position of the door panel can move (see Figure 107 or Figure 110).
  • Page 53 Instruction Manual ZHK If the above described readjustment of the door panel is not sufficient, then misalignment in the erection is the cause and must be appropriately corrected. Removable door panel with locking mechanism TRA (ZHK 2000) Beside the hinged doors, it is also possible to execute doors as a removable door panel. Clamping means, which are on four, six or more places on the door panel, enable the fixation of the panel in order to provide a closed air duct in the inside of the AHU.
  • Page 54 Instruction Manual ZHK Figure 116: fixed door panel (TRA- Figure 117: Undoing the door panel Figure 118: door frame without door (TRA-E) from the door frame panel (TRA-E) Removable door panel ZIB (ZHK) Beside the hinged doors, the access to the inside of AHUs with INOVA-casing is also possible by removable panels.

  • Page 55: Dampers

    Instruction Manual ZHK Therefore, particularly when opening pressure-sided doors, it must be done very carefully. Open the door panel carefully and detach it slowly from the sealing. At the sudden detaching of the panel, the user must be able to carry the weight of the door.

  • Page 56: Panel Filter And / Or Bag Filter Laterally Removable

    A seal is stuck to the filter. This seal is necessary, to avoid filter-bypass-leakages. If it is not in- cluded in the scope of supply of EUROCLIMA, it must be provided by the customer. The seal must be attached on the front side,...

  • Page 57: Laterally Removable Bag Filters With Clamping Mechanism

    Instruction Manual ZHK Bag filters are installed similarly. Bags shells hang vertically. 5.4.3 Laterally removable bag filters with clamping mechanism When inserting and fixing the laterally removable bag filters with a clamping mechanism, proceed cautiously, so as not to damage them. The installation of laterally removable bag filters must be carried out as follows: 1.

  • Page 58: Hepa Filters

    If a sealing is not included in the manufacturer delivery, a suitable sealing is delivered (loose) by EUROCLIMA. This sealing is then to fix on the filter cell, or alternatively on the filter frame. The assembly of the filter is done through the filter fixer supplied loose, as shown in Figure 139 up to Figure 142.

  • Page 59: 5.4.5 Activated Carbon Filter

    Instruction Manual ZHK Figure 139: Attaching the brackets Figure 140: Inserting the filter cell Figure 141: Inserting the clamps Figure 142: Clamping the filter cell There are two assembling possibilities for HEPA filters: Standard HEPA filter frame The filter frames are mounting in the AHU casing. They fulfill the prefilter function for terminal HEPA filters.

  • Page 60: Dampers With External Gear Wheels

    (if not chosen as an option and sup- plied by EUROCLIMA). External gear wheels have to be covered on site...

  • Page 61: Installation

    (STRAUB coupling) is recommended (Figure 149). This coupling could be included optionally in the scope of delivery from EUROCLIMA, if not, then it must be provided on site. In order to avoid a damage of the copper pipe of the heat exchanger due to mechanical force, a ring is used to rein- force the copper pipe (Figure 147 and Figure 148).
  • Page 62 Instruction Manual ZHK Figure 148: copper pipe with inserted reinforc- Figure 147: copper pipe with reinforcing ring ing ring Figure 149: STRAUB coupling Figure 150: mounted STRAUB coupling Other types of connections, for example welding or soldering are not recommended by EURO- CLIMA, because of risk of fire to neighboring materials.

  • Page 63: Steam Heat Exchanger

    Instruction Manual ZHK Hydraulic connection schemes of heating or cooling coil should be carried out as shown in the scheme Figure 152 with a three way valve as a mixing valve. Compared with a flow control using a straight-through valve this connection avoids unequal temperature profiles, in that way air heating or cooling is quite uniform along the coil surface.

  • Page 64: Plate Heat Exchangers For Refrigeration Circuits

    Instruction Manual ZHK 6.1.3 Plate heat exchangers for refrigeration circuits Refrigeration circuits of ETA-POOL-AHUs may contain a condenser for warming the pool water as an option. The connection of the condenser to the pool water or to the water pipes for general use must be done according to the blue arrows shown in Figure 155: Bottom inlet Top outlet...

  • Page 65: Humidifier, Indirect Adiabatic Cooling

    The water treatment system is not supplied by EUROCLIMA and must be provided by the customer on site. In order to reach a sufficient oper- ation safety, the circulation water quality should be in following range:...

  • Page 66: 6.2.3 Special Indications For Different Humidification Systems

    Instruction Manual ZHK purposed to protect the drinking water against pollution. For instance, installation of safety equip- ment to prevent against drinking water against contamination due to backflow. Before commissioning, such appropriate measures must be executed by the operator on site to en- sure the conformity to EN 1717.
  • Page 67 Instruction Manual ZHK flexible tube is not long enough, see Figure 158. in case that costumer applied lubricant at the flexible tube during installation. In this situation, the relating tube connection may loosen and cause a water leakage and subsequent damages! To ensure a proper operation and to minimize the risk of water leakage, EURO- CLIMA highly recommends installing and checking the clamp connections accord- ing to the instructions below.
  • Page 68 Instruction Manual ZHK Ensure, that the free distance between the two ends of the rigid (grey) tubes is not less than 20 mm and not more than 60 mm according the drawing. Ensure that the (black) flexible tube covers the (grey) rigid tube ends at each side for a length of 60 mm according to the drawing.
  • Page 69 UV water treatment, the rod may be bent to pass the UV circuit tubes). Tighten the lower nut and the counter nut in order to tie down slightly the tube assembly. In case of problems or needing support with your product, do not hesitate to contact EUROCLIMA for any further clarification.

  • Page 70: Evaporative Humidifier

    Fresh water operation A solenoid valve must be provided by the customer on site for the fresh water supply line. If the AHU is equipped with an EUROCLIMA control, the necessary power supply is indicated on the wir- ing diagram.

  • Page 71: Drain For Condensate And Excess Water

    CLIMA. 6.3.1 Standard siphons A space-saving design of the necessary siphon height can be completed by EUROCLIMA on re- quest. Contact your sales representative for detailed information. The following conditions are essential for correct operation: At each drain a siphon must be connected.

  • Page 72: Ball Siphons

    6.3.2 Ball siphons If ball siphons with the below shown design are supplied by EUROCLIMA, then the following in- structions should be observed during installation: Depending on the suction side or pressure side mounting position, the siphon body has to be in- stalled so that the direction of the arrow (see Figure 165) corresponds to the flow direction.
  • Page 73 Instruction Manual ZHK Siphon on suction side (in direction of airflow before the fan) Figure 166: Suction side execution Siphon on pressure side (in direction of airflow after the fan) The black plug must be removed for the pressure side installation (see Figure 168). Figure 167: Pressure side execution 72/129 V07-19.0...

  • Page 74: Duct Connection - Airside Connection To Ahu

    Figure 168: Pressure side installation: remove the black closing plug Duct connection – airside connection to AHU Depending on the customer's requirements, EUROCLIMA devices are equipped with various ac- cessories and options for attaching air duct elements like dampers, flexible connections, frames, panel flanges, etc.
  • Page 75 Instruction Manual ZHK Mounting components of the duct system directly on the external panel of the AHU Figure 169: Airside duct connection directly on the external panel of the AHU The procedure is as follows: The dimensions (internal dimensions) of the device opening can be taken from the device drawing or measured directly at the AHU.
  • Page 76 Instruction Manual ZHK Figure 170: Mounting of duct components on the external panel of the AHU Number of screws The duct components are screwed as follows, each at a distance of 120 mm from the corner additional number of screws see Table 6 and Figure 171. Additional number of Length or width screws...

  • Page 77: Insulation Of Fresh Air Damper

    Instruction Manual ZHK Figure 171: Information on the screw distance 6.4.1 Insulation of fresh air damper Before connecting the duct section, the flange of the fresh air damper must be insulated in the course of the fresh air duct insulation on site. This action is urgently required to prevent the for- mation of condensation by heat transfer.

  • Page 78: Electrical Connection

    Instruction Manual ZHK At heating coils: Control-technological frost protection: Installation of a thermostat on the air outlet side for alarm triggering (Setting trigger temperature 5 °C). In the event of an alarm, the mixture valve opens (100%), the heating circuit pump gets a signal and the fan is switched off automatically. At run around systems: Usage of water/glycol fluid mixtures with adequate glycol concentration.
  • Page 79 Single-speed motors Single-speed motors are suitable for direct and star-delta starting. If the wiring to the AHU outside was done by EUROCLIMA, standard wiring is for direct start. Wiring for star-delta start is possible on request. All single-speed motors are suitable for frequency converters. The frequency range of the motor is shown in Figure 172.
  • Page 80 Instruction Manual ZHK 2) Motor with frequency converter: circuit breaker is sufficient If the motor is operated at the frequency converter, a short circuit protection by a circuit breaker is adequate. Attention: Danger due to leakage current! Leakage current exceeds 3.5 mA. It is the task of the operator or the certificated electrician to provide an suitable earth (see 7.1 Connecting to an external pro- tective conductor system) of the AHU.
  • Page 81 Instruction Manual ZHK Voltages must not exceed 5 V at the temperature sensor. This leads to its de- struction! Alternative to PTC: Motors with integrated bimetal sensor (thermal contact, Clixon) - op- tional Bimetal detectors are used for thermal monitoring of motor windings and consist of two successive rolled metals, with unequal thermal expansion coefficients.
  • Page 82 Before connecting the motor check the rotating field of mains connection with a suitable device. Af- terwards, connect the phases accordingly to motor terminal or main switch (if supplied and wired by EUROCLIMA). Figure 177: Rotation marking of Figure 178: Rotation marking of...

  • Page 83: Ec Motors

    – must be activated. Figure 180: Main switch ZHK-AHU with EUROCLIMA-control Control box is equipped with main switch in execution RED-YELLOW as specified above It is the responsibility of the client to ensure that the above specified requirements, according to...

  • Page 84: Variable, Frequency-Controlled Drives (Vfd, Frequency Converters)

    ZHK-AHU without EUROCLIMA-control The specified main switch must be provided by of the client Is to carry out independent from EUROCLIMA supply of main switch for fan motor. Fan motor main switch cuts just the motor off. Furthermore, on responsibility of the client must be ensured that all items 1 to 10 of the above...

  • Page 85: Ahus Equipped From Euroclima With Control

    2 independent safety thermostats. 7.6.1 AHUs equipped from EUROCLIMA with control Units, which are supplied from EUROCLIMA with control, are limiting the supply air temperature to a default value of 35 °C. The execution and function, as specified below, is supplied by EUROCLIMA.
  • Page 86 Instruction Manual ZHK Secondly: By software via controlling. In case of failure contactors immediately cut off the electric heater from power supply. The 2 safety thermostats are connected in serial connection. The 2 safety thermostats are equipped with manual reset. After triggering, the reason for stopping must be detected and eliminated before the reset of the thermostat! Thermostat 1 (Figure 181 and Figure 182)

  • Page 87: Ahus Which Are Not Equipped From Euroclima With Control

    In case of dehumidification wheel downstream of electric heater, it is ensured that control rotates the wheel while electric heater is on (additional enabling contact). 7.6.2 AHUs which are not equipped from EUROCLIMA with control Supply of EUROCLIMA contains: 2 independent safety thermostats...

  • Page 88: Prevention Measures

    Unless otherwise stated, the assumed pressure situation in the ducts (suction and pressure side) for the technical design is based on the specification of EN13053. The real pressure situation in the ducts must be checked before commissioning. If there are any deviations, EUROCLIMA must be contacted.
  • Page 89 Instruction Manual ZHK One possibility for pressure monitoring is a differential pressure switch. The usage is described as follows: Depending on the fan arrangement, one or two differential pressure switches must be provided, see Figure 187 to Figure 190. The differential pressure switches monitor the differential pressures, which the plate heat ex- changer is exposed to.

  • Page 90: Frost Protection For Plate Heat Exchanger

    At low temperatures and high air speeds, the condensate in the plate heat exchanger can freeze and cause its icing. For devices supplied by EUROCLIMA with control, this is prevented by pressure monitoring of the plate heat exchanger and the temporary adjustment of the supply air volume flow. For devices sup- plied by EUROCLIMA without control, appropriate measures are required to protect the plate heat exchanger on site.

  • Page 91: 7.10 Uv Section

    The number of lamps to be installed will be determined in consultation with your EUROCLIMA office. EUROCLIMA is not able to determine, the amount of germs killed through the use of UV-C- lamps.

  • Page 92: Variable Frequency Controlled Drives (Frequency Converter) - Parameters

    8.1.1 Variable frequency controlled drives (frequency converter) - parameters The frequency converter must be configured, if not done by EUROCLIMA (please refer to technical data sheet): parameterization using the following Table 9 respectively the provided manufacturer's operating instructions and data from EUROCLIMA technical data sheet.
  • Page 93 Instruction Manual ZHK Parameters for Danfoss frequency converter FC102 Description Value Note 0-... Display 0-01 Language [1] German [0] English, [5] Italian 0-02 Switching between Hz/rpm [1] Hz Display in Hz or rpm 0-20 Display line 1.1 [1601] Setpoint [unit] 0-21 Display line 1.2 [1610] Power [kW]...

  • Page 94: Airflow Measurement By Differential Pressure Measurement At The Fan

    Instruction Manual ZHK 8.1.2 Airflow measurement by differential pressure measurement at the fan If the fan is provided with pressure test points for airflow measurement and black test points are provided on the outside of the fan unit (accessories are indicated on the technical data sheet), then a differential pressure signal can be taken.

  • Page 95: Heat Exchanger

    Airflow rate indicator type PREMASREG 7161 This airflow indicator is used by EUROCLIMA and is supplied with the AHU, if included in the scope of delivery. The setting of the parameters must be made by the customer before commis- sioning.

  • Page 96: Electric Heater

    Instruction Manual ZHK Steam heat exchanger filling Open vent and drain valve on the condensate drain. Open the steam valve only slightly at the beginning, until steam is coming out of the drain and vent valve (on the condensate drain outlet). Close drain and vent valve and open steam valve fully.

  • Page 97: Spray Humidifier

    If the limit is reached, the blowdown valve must be opened. High pressure spray humidifier If no commissioning of the high pressure spray humidifier is agreed with EUROCLIMA, the manu- facturer of the component must be contacted directly.

  • Page 98: Refrigeration Circuit

    8.2.2 Manually starting the compressor via EUROCLIMA control system The compressor can be started via the display of the EUROCLIMA control system as follows: 1. Start page → All Settings → Password handling → Enter the password Note: Manually starting the compressor can only be performed at service level (Password level 4;...

  • Page 99: Test Run

    Instruction Manual ZHK Air entering in the system is to avoid strictly! For R407C and R134a scroll compressors use Emkarate RL 32 3MAF oil. Test run After having done the preparatory work the AHU can be started for the test run. For testing the device and measuring the motor data and the volumetric flow rate, the device must be fully connected to the operational duct system.

  • Page 100: Resonance At Fans

    Most commercially available frequency converters have a feature to address these problems. If the airflow is incorrect and if you require support on this matter, please contact EUROCLIMA. 8.3.2 Resonance at fans The operation of fans at the resonant frequency (and multiples of it) must be avoided, in order to prevent high vibration loads.

  • Page 101: Maintenance

    At AHUs with EUROCLIMA control, the resonant range can be suppressed. For that purpose, the appropriate setting in the software must be done at the commissioning process.

  • Page 102: Electrical Connection, Control Cabinet

    To order spare parts please contact your EUROCLIMA sales partner. EUROCLIMA recommends, depending on the specified AHU execution, performing checks, maintenance and repair work in compliance to the specifications according to VDI 6022 sheet 1, requirements regarding operation and maintenance.
  • Page 103 Instruction Manual ZHK The fan bearings are lubricated for life. Except the pillow block bearings of larger fans, with de- manding operating conditions, should be lubricated annually in accordance with Table 13 be- low and this should be done with lithium soap grease (see Table 14) for recommended grease types.

  • Page 104: Motor

    Instruction Manual ZHK 9.2.2 Motor Check the motor for cleanliness and clean if necessary. Measure current consumption, which must not exceed the rated current indicated on the name- plate. Motor bearings In case of irregular or unusual sounds, the corresponding bearing must be replaced. Small and medium sized motors are equipped with closed bearing, running for several years without the need of lubrication.

  • Page 105: Re-Tensioning Of Belts

    Instruction Manual ZHK Slippage / pulley too small / overloading / damaged disc / eccentricity, wobble – Figure 201 Figure 201: Unfavorable operating conditions (2) Disc worn / grooved not uniform / dust, dirt / moisture, humidity – Figure 202 Figure 202: Unfavorable operating conditions (3) Alignment / offset wheels / non-parallel plates / discs rotated to each other –...
  • Page 106 Instruction Manual ZHK Figure 204: Adjustment of pullies Pulley diameter d in mm Max. distance x in mm < 112 < 224 < 450 < 630 Table 16: Maximum deviation at adjustment of pulleys For quick results during the pulley alignment for factory mounted pullies, we recommend setting the same protruding thread size of the threaded rods on the left and right side shown in Figure 205.

  • Page 107: Replacing Of Belts

    Instruction Manual ZHK Figure 206: Belt transmission and tensioning data sheet Following two methods to determine the tensioning are described: Force-way measurement The information Test force FE Indentation depth TE Statistical belt tension (belt tension), FS The belts are to be tensioned so that the deflection TE is when the belt is loaded with the test load in point FE (such as with a spring balance).

  • Page 108: Air Filters

    All filters should be checked for tightness, because otherwise they could be sucked in and could lead to damage. If AHUs are equipped with EUROCLIMA control, then a corresponding warning message is dis- played on the HMI (see Figure 209) when the differential pressure limitation is reached.

  • Page 109: Panel Filters

    Instruction Manual ZHK 9.3.1 Panel filters Dry panel air filters (cleanable). The contamination level of the filter can be controlled by the differ- ential pressure drop (check every 14 days to 1 month). When reaching the pressure difference in- dicated in the technical data sheet, cleaning or replacement is required. 9.3.2 Bag filters Contamination level of the filter can be controlled by the differential pressure drop (check every 14...

  • Page 110: Refrigerant

    Instruction Manual ZHK Corrosion spots must be cleaned and protected with zinc dust paint. Antifreeze protection Check antifreeze activity before each winter season. Also check the frost protection thermostat for the correct setting. Drain pan Drain pan and drain should be checked for debris and cleaned, if necessary – Figure 210. clean here Figure 210: Cleaning of air coolers Droplet eliminator...

  • Page 111: Spray Humidifier

    Instruction Manual ZHK The maintenance of pumps and motors must be done according to the manufacturer's instruc- tions. Regular cleaning of all components largely determines the hygiene of the entire system. When unused for long periods, the water must be released for hygiene reasons and the drain must be cleaned properly.

  • Page 112: Steam Humidifiers

    Avoid direct contact with the lamps. Dampers EUROCLIMA dampers of type J are nearly maintenance free. Check for dirt, damage and corro- sion, clean if necessary with compressed air or steam jet. Check the function and correct rotation.

  • Page 113: Heat Wheels

    Instruction Manual ZHK Check for proper operation of the differential pressure switch – for function refer to chapter 7.7 (Differential pressure restriction for plate heat exchangers). If there is a bypass damper, please refer to chapter 9.7 (Dampers). Attention! Heat exchanger must not be damaged mechanically or chemically through clean- ing.

  • Page 114: 9.11 Refrigeration Circuit

    Have to be performed according to EU-regulations indicated in Records for refrigeration circuit application in air-conditioning units supplied by EUROCLIMA. The checks must be executed by a certified refrigeration technician. The intervals for the checks depend on the refrigerant filling quantity.

  • Page 115: Maintenance

    (Manually starting the compressor via EUROCLIMA control system). Follow the maintenance and inspection requirements of the compressor manufacturer. These instructions are supplied by EUROCLIMA or can be ordered from EUROCLIMA. Filter drier: Each refrigeration circuit is equipped with a filter drier. If the refrigeration circuit has to be repaired, the filter drier must be replaced.

  • Page 116: Inspection

    If an electronic expansion valve is used, necessary values must be entered into the correspond- ing controller (according to the instructions of the valve manufacturer). Instructions from the valve manufacturer are supplied by EUROCLIMA. High pressure safety switch: The high pressure switch stops the compressor when the allowed equipment pressure is exceeded.

  • Page 117: 9.12 Hygienic Ahus

    Clean or rinse out condensate outlet from time to time. 9.12 Hygienic AHUs The maintenance plan for EUROCLIMA AHUs you will find in chapter 9.13 of the instruction man- ual. EUROCLIMA recommends maintenance in dependence on: VDMA 24186 part 1 and VDI 6022 part 1.
  • Page 118 Instruction Manual ZHK Component Action Section month ¼ year ½ year year Reference chapter Housing Ch / Cl Housing inside and outside Fan / motor Corrosion check 9.2.1 Fan Flexible connection Vibration isolators Protection grid Water drain Ch / Cl / M Fan bearings according to Table 13 (Lubrication intervals for Ch / Cl / M...

  • Page 119: 10 Information On Airborne Noise Emitted By The Ahus - On Request

    Instruction Manual ZHK 10 Information on airborne noise emitted by the AHUs - on request Sound data can be printed on request on the technical data sheet, sample see Figure 213. The sound power is specified as A-weighted sound power level: Line 1: Sound power over the casing Line 2: Sound power inlet Line 3: Sound power outlet...
  • Page 120 Instruction Manual ZHK Selection for type of ex- Avoidance sources Degree of Use in Unit category plosive atmosphere of ignition security zone Gas / gas-mixture or Even in rare mal- very high steam / gas-mixture or fog functions Gas / gas-mixture or Even with the high steam / gas-mixture or fog...

  • Page 121: 11.2 Information Regarding The Unit, Protective Systems And Components

    Instruction Manual ZHK 11.2 Information regarding the unit, protective systems and components Example of designation T3 (inside/outside) Group Category (2 inside / 3 outside) G for gas, D for dust Ignition protection type (abbr.) Temperature class Evidence of compliance with EC - Directive 2014/34/EC The manufacturer declares conformity to ATEX, in addition to equipment in category 2, the technical documentation in accordance with EC Directive 94/9/EC of TÜV South Germany deposited.

  • Page 122: 11.3 Information For Erection, Assembly, Commissioning, Maintenance And Repair

    Instruction Manual ZHK An atmosphere with pressures from 0.8 bar to 1.1 bar shall be present in the environment of the AHU. Commissioning, operation: Before the commissioning of the AHU, it has to be ensured that all doors are closed and properly sealed so that there are no leaks and the device cannot be opened unintentionally.

  • Page 123: Air Filters

    11.3.6 Field devices On site assembled field devices must comply the ATEX class specified by EUROCLIMA. The electrical components (switches, lights, sensors, motors, etc.) must be approved for opera- tion in explosive atmospheres and must be equipped with an appropriate marking.

  • Page 124: Disassembly And Disposal

    Instruction Manual ZHK 12 Disassembly and disposal 12.1 Disassembly At disassembly, the safety instructions of chapter 2 (Safety instructions) must be considered. It also apply the instructions in chapter 3 (Reception control / unloading / transportation to in- stallation site). The housing can be disassembled relatively easy: Disassembly of the housing: Disassembly of the external panels and removal of the insulation.

  • Page 125: Disposal

    Instruction Manual ZHK 12.2 Disposal The operator is responsible for the disposal of the shipment (packing material), operation (filters, tools, spare parts etc.), and for the disposal of the AHU itself. The disposal of the material must be done by qualified technicians according to the international, national and local regulations.

  • Page 126: Figure Index

    Instruction Manual ZHK Figure index Figure 1: Do not climb on the AHU! ........................17 Figure 2: Delivery in parts ..........................17 Figure 3: Delivery as monobloc ........................18 Figure 4: Transport correct ..........................19 Figure 5: Transport incorrect ..........................19 Figure 6: Center of gravity centrally between the forks ..................
  • Page 127 Instruction Manual ZHK Figure 60: Connection between door frame / internal panel ................39 Figure 61: Self-tapping screw ø6,3 x 22 ......................39 Figure 62: Application of self-tapping screws ....................39 Figure 63: Self-tapping screw TORX 25 ø4,8 x 16 ................... 40 Figure 64: Joint on the AHU drawing ........................
  • Page 128 Instruction Manual ZHK Figure 120: fixing mechanism at door frame (ZIB) ................... 53 Figure 121: fixed door panel (ZIB) ........................53 Figure 122: Safety device – catching lever....................... 54 Figure 123: Assembly of safety device on door panel ..................54 Figure 124: Closed position ..........................
  • Page 129 Instruction Manual ZHK Figure 180: Main switch ............................ 82 Figure 181: Thermostat with cover cap on the reset button ................85 Figure 182: Thermostat with uncovered reset button ..................85 Figure 183: Thermostat 2 ..........................85 Figure 184: Connection scheme for electric heater ..................86 Figure 185: Plate exchanger section in technical data –...

  • Page 130: Table Index

    Instruction Manual ZHK Table index Table 1: Maximum AHU part weights for lifting by crane lugs ................20 Table 2: Tightening torque for screws ......................24 Table 3: Drilling diameters for cable glands ..................... 48 Table 4: water quality of supply of humidifier following VDI 3803 ..............64 Table 5: Specifications - size and number of clamps for flexible connecting tubes .........
  • Page 131 Fax +39 0464 437 298 Tel. +91 22 4015 8934 info@biniclima.eu info@euroclima.in www.biniclima.eu www.euroclima.com Euroclima V07-19.0 Due to it’s commitment of continuous product development and improvement, Euroclima reserves the right to change specifications without notice. © Copyright by euroclima.com / fotolia.com...

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