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Euroclima ZHK Manual

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ZHK
INSTRUCTION MANUAL

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  • 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 Supplementary instructions to this instruction manual ............. 6 Limitation of liability ......................6 Type key .......................... 6 Intended use / foreseeable misuse .................. 7 1.4.1 Intended use ........................7 1.4.2 Foreseeable and considered misuse ................... 8 Modular design ........................
  • Page 4 Electric heaters ......................91 7.6.1 AHUs equipped by EUROCLIMA with control ..............91 7.6.2 AHUs which are not equipped from EUROCLIMA with control ......... 93 Differential pressure restriction for plate heat exchangers ..........94 7.7.1 General indications ......................94 7.7.2 Prevention measures ......................
  • Page 5 High-pressure spray humidifier ..................104 Steam Humidifier ......................104 Refrigeration circuit...................... 105 8.2.1 General notes ........................105 8.2.2 Manually starting the compressor via EUROCLIMA control system ....... 105 8.2.3 Refrigerant ........................105 8.2.4 Compressor lubricant ....................... 106 Test run ........................106 8.3.1...
  • Page 6 Instruction Manual ZHK 11.2 The ATEX type key...................... 128 11.3 Supplementary notes on AHU design ................129 11.4 Ignition temperature and temperature classes ............. 129 11.5 Additional instructions for foundation and erection, assembly, connection and commissioning, maintenance and repair ..............131 11.5.1 Foundation and erection ....................

  • Page 7: Introduction

    AHU to enable the safe and correct use of an AHU con- structed by EUROCLIMA. The target group of this instruction manual are all persons who are di- rectly involved with transport, assembly, commissioning and installation, operation, maintenance, troubleshooting and disassembling (see also chapter 2.5 (Staff selection and qualification)).

  • Page 8: Intended Use / Foreseeable Misuse

    Generally, a HVAC specialist, knowing the exact application of the AHU, generates a specification, in which customer requirements for the AHU are defined. The properties of the AHU, specified by EUROCLIMA, are agreed with the customer and are stated on the technical data sheets and draw- ing of the AHU.

  • Page 9: Foreseeable And Considered 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 and does not accept any responsibility, because the AHU is built according to the confirmed specifications.

  • Page 10: Modular Design

    1.6 Documentation The AHU will be delivered with the following documentation: Instruction manual ZHK (This document is an There is a marked cardboard box, which con- extract of the complete instruction and operating tains loosely delivered parts inside of the manual and includes chapters 1 to 4.)

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

    At differences between this manual and the instruction manual of the component manufacturer, the instruction manual of the component manufacturer has to be applied. In case of doubt, please contact your EUROCLIMA office. Safety instructions / Guidelines to conformity to laws and directives 2.1 Symbols in this manual...

  • Page 12: Personal Protective Equipment

    Instruction Manual ZHK Safety instructions with the signal word „NOTICE” indicates a non-immediate or potential hazard situation that, if not avoided, could result in damage of property and equipment. NOTICE! In order to draw attention to special, situation-related dangers, the following warning symbols,...

  • Page 13: Indications For Minimizing Specific Hazards

    Instruction Manual ZHK Symbol Description of personal protective equipment Protective clothing and ensembles: Protective work clothing is used to protect against being caught by moving or rotating parts, stitches, cuts, dust, etc. Do not wear chains, rings or other jewelry.
  • Page 14 Instruction Manual ZHK Danger due thin sheets and sharp edges, when working on AHU During work on AHU (or on parts), there is a substantial risk of injury because of thin sheets and sharp edges. For example, roof sheets, fins of heat exchangers, corners and edges - Use personal protective equipment: wear protective helmet, gloves, safety shoes and long protective clothing.
  • Page 15 Instruction Manual ZHK for maintenance of frequency controlled motors, a waiting time of 15 minutes is recommended – it gives time to break down the residual capacitive charge of the frequency converter. Remove the keys from the doors with a door lock before entering the interior of the AHU. Keep the key out of reach of all unauthorized persons.

  • Page 16: Refrigeration Circuit

    Instruction Manual ZHK Avoid body contact with descaling agents, as it can cause chemical burns and se- rious eye damage. When handling descaling agents, wear appropriate protective clothing (e.g. gloves, goggles etc.) and ventilate the room well. WARNING! Prevention of hazards caused by the sudden detachment of door panels while handling re-...

  • Page 17: Atex Ahus

    Appropriate measures must be taken against all types of ignition sources that are not specific to the AHU and are not included in the Euroclima scope of delivery. Safety indications for maintenance and repair work In addition to the safety instructions in chapter 2.3 (Indications for minimizing specific hazards)

  • Page 18: Conformity With Directives, Regulations And Laws / Assembly Instructions For Safe And Compliant Operation

    2.4.1 2006/42/EC For an AHU (or any part thereof) supplied by EUROCLIMA, an EC declaration of conformity in ac- cordance with the EC Machinery Directive 2006/42/EC will be issued. When the AHU is a part of the building system. For the device’s safe, practical and intended opera- tion, it is the responsibility of the customer to make sure that all on site works are carried out before the device can commence operations.

  • Page 19: Installation Instructions For A Safe And Compliant Installation In The Building System

    Instruction Manual ZHK Depending on the chosen purpose of the AHU, in addition to the EC Machinery Directive 2006/42/EC the following European directives can be applied: Electromagnetic compatibility directive 2014/30/EU Commission regulation Ventilation Units (EU) No. 1253/2014 *) Pressure equipment directive ‘PED' 2014/68/EU ATEX directive 2014/34/EU *) ErP conformity according to commission regulation (EU) Nr.
  • Page 20 Motor connection See chapter 7.2 (AC motors). Frequency controller for Plug fans Furthermore, if not supplied by EUROCLIMA, a frequency converter must be installed to reach the calculated operating point. For details see chapter 7.5 (Variable, frequency-controlled drives (VFD, frequency converters)).

  • Page 21: Erp Conformity According To Commission Regulation (Eu) Nr. 1253/2014

    They will be triggered if the pres- sure 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 must to be provided on site.

  • Page 22: Reception Control / Unloading / Transportation To Installation Site

    Loose supplied parts and assembly materials are in a nylon bag or a specific box in the AHU. If damage is found, immediately complete a damage report and send it to EUROCLIMA. Only then can the transport company make a claim with the insurer (It is important to note the dam- age on the shipping documents with date and signature in the presence of the carrier).
  • Page 23 Instruction Manual ZHK The delivery form is agreed with the customer in the order clarification and can be: 1) Supplied in parts Figure 3: Delivery in parts Delivery in parts allow the supply of major equipment in small sections and provides better ac- cessibility and maneuverability.

  • Page 24: Lifting By Forklift / Lift Truck

    3.2 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 25: Further Necessary Actions For The Overlifting Of Both, Delivery Sections On Crane Lugs As Well As Monoblocs

    Instruction Manual ZHK 3.3 Further necessary actions for the overlifting of both, delivery sections on crane lugs as well as monoblocs Make sure that nobody is under the raised load. Before lifting, check that there are no objects on the load.

  • Page 26: Over Lifting Of Ahu Sections With Crane Lugs

    Instruction Manual ZHK max. 15° max. 15° Figure 8: Permitted angle for load carrying equipment guidance 3.4 Over lifting of AHU sections with crane lugs Chapter 3.4 is only valid for the delivery form “Delivery in parts (delivery sections)”. For overlifting of AHUs delivered as “Monobloc”, see chapter 3.5 (Overlifting of monoblocs).

  • Page 27: Necessary Actions Before Lifting Delivery Sections With Crane Lugs

    Instruction Manual ZHK Base frame height Figure 9: Base frame height The weight of single delivery sections is shown in the attached drawing (on each delivery section). The delivery sections are marked with L1, L2, L3, etc. on the drawing and with the same number corresponding on the section itself.
  • Page 28 Instruction Manual ZHK Example 1: Figure 11: Delivery section with mounted damper Figure 12: Delivery section with dismounted damper Figure 13: Delivery section with mounted crane lugs V07-21.0 27/140...
  • Page 29 Instruction Manual ZHK Example 2: Figure 14: Delivery section with mounted flexible connection Figure 15: Delivery section with dismounted flexible connection Figure 16: Delivery section with mounted crane lugs 28/140 V07-21.0...

  • Page 30: Mounting Of Base Frame Crane Lugs

    Instruction Manual ZHK 3.4.3 Mounting of base frame crane lugs For mounting crane lugs on AHU casing sections when plate heat exchanger and heat wheel parts are delivered disassembled see chapter 3.6 (Lifting when heat wheel or plate heat exchanger casing is delivered in parts).

  • Page 31: Lifting By Crane Lugs

    Bolts and nuts are delivered with the lifting lugs and must be tightened with the torque according to Table 4. If the lifting lugs are already mounted by EUROCLIMA, the screws must be checked be- fore lifting of the AHU.

  • Page 32: Weight Details For Monoblocs

    Instruction Manual ZHK 3.5.1 Weight details for monoblocs The weight of the monobloc is specified on the AHU drawing. This weight must be considered at choosing appropriate transportation means. 3.5.2 Lifting of monoblocs Monoblocs are generally delivered with a perforated counter-frame – hole diameter 50 mm –...

  • Page 33: Lifting When Heat Wheel Or Plate Heat Exchanger Casing Is Delivered In Parts

    The bolts will be mounted already by EUROCLIMA, if this option is agreed. (Figure 24). The crane lugs are included in the scope of delivery of EUROCLIMA, if the lifting of the mon- obloc by crane lugs is agreed.

  • Page 34: Lifting Of Heat Wheel Or Plate Heat Exchanger

    Instruction Manual ZHK 2. Lifting of heat wheel or plate heat exchanger: for assembling the crane lugs supplied by the component manufacturer and for lifting the heat wheel or plate heat exchanger, the lifting instructions and specifications of the respective component manufacturer must be followed.

  • Page 35: Assembly Of Flat Crane Lugs

    Figure 31: Assembly of flat crane lugs Bolts and nuts are delivered with the lifting lugs and must be tightened with the torque according to Table 5. If the lifting lugs are already mounted by EUROCLIMA, the bolts must be checked before lifting of the AHU.

  • Page 36: Storage

    Instruction Manual ZHK ATTENTION on correct assembly of the flat crane lugs: The flat crane lugs must only be used to lift the top parts of the casing when the heat wheel or plate heat exchanger casing is delivered in parts, as shown in Figure 31. The use of the flat...

  • Page 37: Foundation / Erection

    Instruction Manual ZHK Figure 33: Protection against dirt Foundation / erection Space requirements: At the location, for proper maintenance and installation of components there should be adequate space for the devices. Therefore, a free working space of AHU width + 300 mm needs to be availa- ble.
  • Page 38 It is important to distinguish whether the AHU is resting on the base frame, or whether it is equipped with device feet supplied by EUROCLIMA. The maximum permissible load limits per unit foot must not be exceeded and are as follows: per unit foot with height adjustment max.

  • Page 39: Erection

    Distance of the contact surfaces in longitudinal direction of the AHU (air flow direction) when resting on device feet: If the AHU is equipped with device feet supplied by EUROCLIMA, the positions of the device feet are shown in the device drawing by EUROCLIMA. In this example, each device foot forms a con- tact surface on the foundation.

  • Page 40: Actions To Prevent Potential Risks

    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 41: Special Guidelines For Flat Ahus - Ceiling Ahus

    Instruction Manual ZHK Figure 37: Suspension of ceiling AHUs AHU which are not designed to stack, should not be stacked (one on top of the other). Spray hu- midifier will need feet depending on the foundations, either on one side or both sides, which are supplied if ordered or requestred (refer to Figure 38).
  • Page 42 Instruction Manual ZHK The suspension can consist only of transverse profiles (transversely to the air flow), as shown in Figure 39, or of transverse profiles with additional longitudinal profiles (longitudinal to the air flow), see Figure 40. 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 43: Assembly

    Instruction Manual ZHK Assembly If climbing on the AHU is absolutely necessary during assembly, for example, for connecting the roof plates, appropriate measures must be put in place. For exam- ple, using boards, that the weight is distributed evenly, in order to avoid bending or denting of the roof panels.
  • Page 44 Instruction Manual ZHK Section connection points, screw connections between inside and outside, connection openings and bushings, and all other openings, which penetrate or protrude from the casing must addition- ally be sealed with SIKAFLEX (For example, heat exchanger connections, mounting screws, duct connections, measuring openings, etc.), as shown on Figure 44 and Figure 45.
  • Page 45 Figure 48: Removable external panels Procedure: ZHK 2000 – Housing type: “snap-in” construction – To remove the external panel - start at the corners - use a screwdriver – refer to Figure 49. After removing the external panel, remove the insulation. Undertake caution to prevent any damage either to the panel or to...

  • Page 46: Standard Connections And Connection Components

    AHU series/type and are listed below, ranked by the execution sequence and configuration. ZHK INOVA and ZHK VISION: Easy Connection, see Figure 55 up to Figure 58 Connection angle, connection frame, see Figure 59 up to Figure 63...
  • Page 47 Instruction Manual ZHK Figure 56: Connection via Easy Connection Figure 55: Easy Connection Figure 57: Easy Connection at two-sto- Figure 58: Mounted Easy Connection at two-storey AHUs rey AHUs Figure 59: Hexagon bolt with locknut Figure 60: Connection angle Figure 61: Connection via connection...

  • Page 48: Detailed Solutions And Connection Components

    Instruction Manual ZHK n x 152,5 Figure 64: Hole spacing of the internal panel 5.1.3 Detailed solutions and connection components Connection between door frame / door frame and door frame / internal panel Screw spacing: 152 mm Figure 65: Tapping screw ø8 x 11 Figure 66: Tapping screw Ejot SHEETtracs®...
  • Page 49 25 ø4,8 x 16 drawing Figure 73: Joint at the AHU Connection of internal and external panel (ZHK INOVA and ZHK VISION) Figure 74: Self-tapping pan head screw TORX 25 ø4 x 25 Figure 75: Screw connection of internal and exter-...

  • Page 50: Establishing The Screw Connection Of Ahu Parts

    Instruction Manual ZHK Figure 78: Self-tapping screw ø6,3 x 22 Figure 79: Connection of two units on top of each other Connection of connection frame and partition walls Screw spacing: according holes in the connection frame partition wall connection frame with holes Figure 80: Self-tapping screw ø6,3 x...
  • Page 51 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, this provides extra protec- tion and adherence.

  • Page 52: Special Features For Roof Ahus And Device Separations At Wet Areas

    Instruction Manual ZHK Figure 85: Pushing in the external panel ZHK INOVA and ZHK VISION – Casing type: Screwing-Construction The outer panel lay on the inner panel and fixing with TORX-screws (see Figure 86, Figure 87, Figure 88). Figure 86: Insertion of the outer...
  • Page 53 Instruction Manual ZHK Figure 89: Sealing surfaces at wet areas Figure 90: Sealing the frontal joints Joints Joint Access (door) Figure 92: Sealing the section con- Figure 91: AHU separation acces- nection (joint) with the sealing agent sible via door For roof AHUs, also the roof flange is to seal, refer to Figure 93.
  • Page 54 Instruction Manual ZHK After assembling the entire sealing implementation has to be checked for durability and robust- ness. Figure 94: Sealing of the base frame cover At AHUs in outdoor execution, an additional separation bar (included in the scope of delivery) must be mounted at the separation positions at the roof flange, see Figure 95.
  • Page 55 Instruction Manual ZHK 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. The scope of supply includes as follows: All parts of the AHU with roof inside panel inclusive insulation.

  • Page 56: Cable Gland

    Figure 101: 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 105), which must be installed efficiently and properly. The following procedure is recommended: 1.

  • Page 57: Transport Lock

    Instruction Manual ZHK Figure 103: Sleeve Figure 104: Screwing Figure 105: Cable gland A drill with the diameter for the corresponding gland diameter (see Table 7, column 2) is sufficient for the insertion of cables into a cabinet or a single walled housing. In this case the screw is locked with the supplied locknut from the inside.

  • Page 58: Doors

    If AHUs will be erected on roofs, a structural engineer must design the attachment of the AHU, based on the local situation and weather conditions. 5.2 Doors Hinged doors EU.T (ZHK 2000) and ZIS (ZHK INOVA and ZHK VISION) The EU-hinged doors in ZHK execution have the following design features: Space-saving design Operated by a handle lever.
  • Page 59 Instruction Manual ZHK locked Figure 111: Delivery of the keys Figure 110: Door ‚closed’ and ‚locked’ Abovementioned doors with locks are an effective safety device according to EN ISO 12499: there is no situation whereby entering during fan operation is required, refer also to chapter 2.3 (Indica- tions for minimizing specific hazards).
  • Page 60 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 handle the doors as a removable door panel. A Clamping system which consists of 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 61 (TRA) (TRA) Removable door panel with screw connection TRA-E (ZHK 2000) Beside the hinged doors, it is also possible to execute doors as a removable door panel. The door panel is held in place by screws. The screws are put through the prepared holes at the edge of the door panel and screwed to the door frame.
  • Page 62 Instruction Manual ZHK Figure 129: Fixing screw with Figure 130: Fixing mechanism at Figure 131: Fixed door panel clamping piece (ZIB) door frame (ZIB) (ZIB) Pay attention at removable door panels, because after undoing the connection they could suddenly detach and lead to injuries. Therefore, always use both...

  • Page 63: Dampers

    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 64: Panel Filter And / Or Bag Filters In Filter Frame

    Instruction Manual ZHK Figure 136: Pulling out the filters Figure 137: Pull-out mechanism 5.4.2 Panel filter and / or bag filters in filter frame Filters are supplied loose and have to be fixed by clips as follows: 1. Take the filter clips, which are included in the supply and are attached to brackets on the filter frame (Figure 138).
  • Page 65 Instruction Manual ZHK Figure 141: Loosen the clamps Figure 142: Slide in the filters Figure 143: Clamping the filters Attention: For soft bags, the lower parts of the bags of the filter cells need to be lifted up in order to prevent damage by the clamping system. Again proceed...

  • Page 66: Hepa Filters

    If a sealant is not included in the filter 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 following two installation frames are available for HEPA filters: Standard HEPA filter frame The filter mounting frame is mounted in the AHU housing.

  • Page 67: Activated Carbon Filter

    Instruction Manual ZHK Figure 152: Inserting the clamps Figure 153: Clamping the filter cell 2. Filter types with metal frames shall be fixed with tensioning corners and additional pressure plates as shown in Figure 154. Figure 154: Filter tensioner with pressure plate HEPA frame “Filter Safe”:...

  • Page 68: Dampers With External Gear Wheels

    Instruction Manual ZHK Figure 155: Activated carbon filter cartridge Figure 156: Base plate for activated carbon filters Dampers with external gear wheels At these dampers, the slats are moved via an external gear wheel connection. The installation of a suitable cover, which protects against injury and prevents...

  • Page 69: Installation

    (STRAUB coupling) is recommended (Figure 161). 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 damage of the copper pipe of the heat exchanger due to mechanical force, a ring needs to be in- serted to reinforce the copper pipe (Figure 159 and Figure 160).
  • Page 70 Instruction Manual ZHK Figure 160: Copper pipe with inserted rein- Figure 159: Copper pipe with reinforcing ring forcing ring Figure 161: STRAUB coupling Figure 162: 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 71: Steam Heat Exchanger

    Instruction Manual ZHK Hydraulic connection schemes of a heating or a cooling coil should be carried out as shown in the scheme Figure 164 with a three way valve used 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 72: 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...

  • Page 73: 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 sufficient opera- tional safety limits, the circulation water quality should be within following range:...

  • Page 74: Protection Of The Drinking Water Against Pollution

    Instruction Manual ZHK 6.2.2 Protection of the drinking water against pollution During installation, it must be ensured by appropriate measures that the installer complies with EN1717. This European Standard contains general requirements to safety installations, which are purposed to protect the drinking water against pollution. For instance, installation of safety equip- ment to prevent against drinking water and against contamination due to malfunction or a backfill.
  • Page 75 Instruction Manual ZHK delivered number of clamps are not fixed during installation installation of different clamps (not the original ones) corresponding clamps fixed with too high or too low torque flexible tube is not long enough, see Figure 170. in the event that the costumer applied lubricant at the flexible tube during installation.
  • Page 76 Instruction Manual ZHK 1. Flexible tube length: The flexible tube length L is delivered in standard with L = 180 mm. For some installations shorter tubes may be installed. In this case cut the flexible tube to match the drawing in Figure 170.
  • Page 77 Instruction Manual ZHK Fixing of the clamps Tighten the clamps using a torque wrench. Fix the screw with a torque of 5/ 6,5 Nm. Figure 171: Mounted clamps Installation of threaded strut The threaded strut is mounted on the pressured side and holds the pressure side tube in position, in order to relieve the pressure side flexible tube connection from axial forces.

  • Page 78: Evaporative Humidifier

    Required components listed in Figure 173 (except position 6 “Blowdown by tacosetter” which is always included in the scope of supply from EUROCLIMA) can be selected or must be pro- vided on site, which is therefore the responsibility of the customer. All electrical components must be integrated into the customers control system.

  • Page 79: Standard Siphons

    Instruction Manual ZHK 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 further detailed information. The following conditions are essential for correct operation: At each drain, a siphon must be connected.

  • Page 80: Ball Siphons

    Instruction Manual ZHK 6.3.2 Ball Siphons If Ball Siphons with the design shown below are supplied by EUROCLIMA, then the following in- structions should be followed 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 176) corresponds to the flow direction.

  • Page 81: Duct Connection - Airside Connection To Ahu

    Figure 179: Pressure side installation: remove the black closing plug 6.4 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 82 Instruction Manual ZHK A suitable seal (not included in the scope of supply) has to be installed between the device housing and the component of the duct system. The aero-technical connections must be executed free of tension and torsion. For example no forces / loads are allowed to be transmitted to the device housing by means of attached acces- sories such as ducts etc.
  • Page 83 Instruction Manual ZHK Figure 181: 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 10 and Figure 182.

  • Page 84: Insulation Of Fresh Air Damper

    Instruction Manual ZHK Figure 182: Information on the screw distance 6.4.2 Insulation of fresh air damper Before connecting the duct section, the flange of the fresh air damper must be fully insulated. This action is imperative to prevent the formation of condensation by heat transfer.

  • Page 85: Electrical Connection

    Instruction Manual ZHK At heating coils: Control-technological frost protection: Installation of a thermostat on the air outlet side to trigger alarm or temperature variation alert. (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.
  • Page 86 Single-speed motors Single-speed motors are suitable for direct and star-delta starting. If the wiring to the AHU outside was completed and installed 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.
  • Page 87 Instruction Manual ZHK 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 a suitable earth (see 7.1 Connecting to an external pro- tective conductor system) of the AHU. An incompetently fitted earth of the fre- DANGER! quency converter could lead to death or to serious injuries.
  • Page 88 Instruction Manual ZHK 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. When they are heated, they expand un- evenly and can switch a contact.
  • Page 89 Instruction Manual ZHK Correct direction of motor rotation is a result of direction of fan impeller rotation which is marked by an arrow: for EC fan refer to Figure 189, for plug fan refer to Figure 187, for fan with housing refer to Figure 188.

  • Page 90: Ec Motors

    In order to prevent high vibration loads and damage, critical speeds or operat- NOTICE! ing frequencies must be avoided, see chapter 8.3.2 (Vibration verification). EUROCLIMA, therefore, recommends that operating conditions are continually monitored and as- sessed. When using residual current circuit breakers (RCDs), the supply line must be protected by means of an all-current sensitive (type B or B+) residual current circuit breaker.

  • Page 91: Variable, Frequency-Controlled Drives (Vfd, Frequency Converters)

    The specified main switch must be provided by the client If EUROCLIMA is not asked to provide components/ mechanisms, the supply and installation of a main switch for the fan motor must be undertaken by the client and/ or contractor. Fan motor main switch only cuts the motor off.

  • Page 92: Electric Heaters

    7.6.1 AHUs equipped by EUROCLIMA with control Units, which are supplied by EUROCLIMA with control, are limiting the supply air temperature to a default value of 35 °C. This execution and function, as specified below, is supplied by EUROCLIMA.
  • Page 93 Instruction Manual ZHK By using an enabling contact (see Figure 194) the control engineering also ensures that the elec- tric heater can only start its operation when the fan is running. If in case of main power failure (for example lightning strike) this automatic run- ning cannot be ensured.

  • Page 94: Ahus Which Are Not Equipped From Euroclima With Control

    In the event of dehumidification at the wheel downstream of electric heater, it is ensured that con- trol rotates the wheel while electric heater is on (additional enabling contact). 7.6.2 AHUs which are not equipped from EUROCLIMA with control Supply by EUROCLIMA contains:...

  • Page 95: Differential Pressure Restriction For Plate Heat Exchangers

    It is the full responsibility of the client to undertake this task. WARNING! The minimum safety requirements described in chapter 7.6.1 (AHUs equipped by EUROCLIMA with control) have to be ensured and is the full responsibility of the customer to do so. 7.7 Differential pressure restriction for plate heat exchangers 7.7.1 General indications...

  • Page 96: Pressure Monitoring With Differential Pressure Switch

    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 97: Frost Protection For Plate Heat Exchanger

    At low temperatures and high air speeds, the condensate in the plate heat exchanger can freeze and ice over. 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 98: Lighting

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

  • Page 99: Commissioning

    + -5% is permitted. 8.1.1 Variable frequency controlled drives (frequency converter) - parameters The frequency converter must be configured, if this is not undertaken by EUROCLIMA. Therefore, the relevant persons must refer to technical data sheet: parameterization using the following Table 98/140 V07-21.0...
  • Page 100 Instruction Manual ZHK 13 and respectively the provided operating instructions of the frequency converter manufacturer and data from EUROCLIMA technical data sheet. Observe and follow safety instructions of chapter 2.3 (Indications for mini- mizing specific hazards) and safety instructions of the frequency converter manufacturer (supplied by EUROCLIMA).
  • Page 101 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...

  • Page 102: 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 103: 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 104: Electric Heater

    Instruction Manual ZHK 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 105: 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 high-pressure spray must be contacted directly.

  • Page 106: 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 107: Compressor Lubricant

    Instruction Manual ZHK 8.2.4 Compressor lubricant Compressor oil, a synthetic ester oil, is highly hygroscopic, so that the bound moisture in the oil cannot be completely removed by the evacuation of refrigeration circuit. Air entering into the system must be completely avoided.

  • Page 108: Vibration Verification

    Most commercially available frequency convert- ers have a feature to address these problems. If the airflow is incorrect and support is required on this matter, please contact EUROCLIMA. 8.3.2 Vibration verification Check on the quiet running of the fan.

  • Page 109: Maintenance

    If a frequency converter is used for running the fan, then the resonant range can be suppressed directly there. At AHUs with EUROCLIMA control, the resonant range can be suppressed. For that purpose, the appropriate setting of the software must be done at the commissioning process.

  • Page 110: Electrical Connection, Control Cabinet

    DANGER! Please note that EUROCLIMA is not responsible for damage caused by improper handling of sol- vents and cleaning agents, and our company would not be liable for resulting mechanical damage. Solvents and cleaning agents should not contain alcohol for use on coated surfaces.

  • Page 111: Fan

    Instruction Manual ZHK During operation of the AHU, an excessive vibration level can occur due to an unfavorable air flow, accumulation of dirt and dust, lack of and / or incorrect cleaning and maintenance. Furthermore, vibrations can be transmitted from and to external system components.

  • Page 112: Motor

    Instruction Manual ZHK Figure 209: Fan bearing with grease nipple (example Comefri NTHZ) Supplier Type Basis Temp. range FINA Marson HTL 3 Lithium 30 °C / +120 °C SHELL Alvania Fett 3 Lithium -20 °C / + 130 °C ESSO...

  • Page 113: V-Belt Drive

    Instruction Manual ZHK For different, unfavorable operating conditions, the intervals are to be reduced according to the motor manufacturer's instructions. Recommended grease types for the re-lubrication of motor bearings can be taken from Table 18 chapter 9.2.2 (Fan). 9.2.4 V-belt drive...

  • Page 114: Re-Tensioning Of Belts

    Instruction Manual ZHK Alignment / offset wheels / non-parallel plates / discs rotated to each other – Figure 213. Figure 213: Unfavorable operating conditions (4) 9.2.5 Re-tensioning of belts Moving the motor away from the fan adjusts the tensioning of the belt.
  • Page 115 Instruction Manual ZHK Figure 215: Adjustment of pulleys via threaded rods In case of various pulley widths, the gap must be equal on both sides. The belt drive is to be re-tensioned, after the first 10 operating hours. Belt tension The correct tension of the belt is obtained through adjustment in compliance with the tensioning data, which is calculated separately for each drive.

  • Page 116: Replacing Of Belts

    Repeat these steps until alignment and belt tension are correct. 9.3 Air filters EUROCLIMA recommends, in accordance with the REHVA (Federation of European Heating, Ven- tilation and Air Conditioning Associations), to wear safety gloves and FFP3 respirator when chang- ing air filters, and to dispose of the dirty filters in a sealed bag To ensure the performance and the energy-efficient operation of the AHU, the air filters must be replaced regularly.

  • Page 117: Panel Filters

    All filters should be checked for tightness and fit, because otherwise they could be sucked in and could lead to damage and/ or poor functioning and quality. If AHUs are equipped with EUROCLIMA control, then a corresponding warning message is dis- played on the HMI (see Figure 219) when the differential pressure limitation is reached.

  • Page 118: Activated Carbon Filters

    Instruction Manual ZHK 9.3.4 Activated carbon filters If saturation is reached (expiration of the designated operation hours), the activated carbon car- tridges must be changed. Proceed as followed: 1. Release cartridge from base plate (bayonet fastening). 2. Insert and fix a new filter cartridge.

  • Page 119: Refrigerant

    Instruction Manual ZHK Droplet eliminator Check the droplet eliminator about once per year for contamination. Remove fins and clean it if necessary. Please make sure that the fins are installed properly and are not bent or have popped out of the frame.

  • Page 120: Spray Humidifier

    Instruction Manual ZHK Check solenoid valves for functionality and clean if necessary. Check control and safety devices for functionality. 9.5.2 Spray humidifier The instructions of chapter 9.5.1 are to be applied analogously. Check water supply for proper function and check the water level, if necessary, adjust the float valve so that the valve closes at a water level of 10 –...

  • Page 121: Uv Section

    Avoid direct contact with the lamps. 9.7 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 122: Heat Wheels

    Instruction Manual ZHK 9.10.2 Heat wheels Check the drive unit according to the heat wheels manufacturer's instructions. In general: The construction of the storage mass is nearly completely self-cleaning. The rotor can be cleaned with compressed air, water, steam and grease-dissolving household cleaning products.

  • Page 123: 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 124: Maintenance

    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 125: Inspection

    Instruction Manual ZHK Low pressure safety switch: The low pressure switch stops the compressor when the equipment pressure falls below the allowed low pressure limit. A functional check must be carried out during commissioning and must be per- formed at each time maintenance work is undertaken.

  • Page 126: Hygienic Ahus

    Instruction Manual ZHK 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 depending on the following: VDMA 24186 part 1 and VDI 6022 part 1. In chapter 7 of VDI 6022 part 1, you can find detailed requests on operation and maintenance.
  • Page 127 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 9.2.2 Fan Flexible connection Vibration isolators Protection grid Water drain Ch / Cl / M...

  • Page 128: Information On Airborne Noise Emitted By The Ahus - On Request

    "c". Declaration of conformity in accordance to the EU - Directive 2014/34/EU EUROCLIMA declares conformity to ATEX. The technical documentation in accordance with EU – Directive 2014/34/EU is deposited at TÜV South Germany. The declaration of conformity to ATEX applies only to the original delivery AHU and with proper repair and maintenance. When changes on the AHU are made, which are not agreed in writing, the declaration of conformity loses its validity.

  • Page 129: The Atex Type Key

    Instruction Manual ZHK 11.2 The ATEX type key Example of designation: inside / ouside CE - European conformity mark Ex - Explosion protection mark (ATEX di- rective) Equipment group II (above ground) Equipment category (2 inside / 3 outside) Type of environment (G Gas / D Dust)

  • Page 130: Supplementary Notes On Ahu Design

    Instruction Manual ZHK The device-specific explosion protection measures of this category (outside) must provide the nec- essary security at disturbances and error states, which usually must be considered. 11.3 Supplementary notes on AHU design Designed for kind Unit cate- Usage in...
  • Page 131 Instruction Manual ZHK Temperature classes at gases: Temperature class Max. surface tempera- ture [°C] gas Acetone Cyclohexa- Petrol none Diesel Ammonia Acetic acid-an- Fuels hydride Aviation Benzene n-Butane fuels Acetic acid n-butyl alcohol Fuel oils Ethane n-Hexane Ethyl acetate Explosion group:...

  • Page 132: Additional Instructions For Foundation And Erection, Assembly, Connection And Commissioning, Maintenance And Repair

    Instruction Manual ZHK The maximum allowable surface temperature must always be lower than the ignition temperature of the explosive atmosphere. Safety factors are considered. DANGER! 11.5 Additional instructions for foundation and erection, assembly, connection and commissioning, maintenance and repair In addition to these specific specifications, the general instructions in this manual (in case of differ- ing specifications, the ATEX-specific specifications must be observed in priority) and the instruc- tions in the manuals of the component manufacturers (e.g.

  • Page 133: Motor

    DANGER OF EXPLOSION! Field devices On site assembled field devices must comply the ATEX classification specified by EUROCLIMA. The electrical components (switches, lights, sensors, motors, etc.) must be approved for opera- tion when there is a risk of explosion and must be equipped with an appropriate marking.

  • Page 134: 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 applies to the instructions in chapter 3 (Reception control / unloading / transportation to installation site). The housing can be disassembled relatively easy: Disassembly of the housing: Disassembly of the external panels and removal of the insulation.
  • Page 135 Instruction Manual ZHK Components (exam- Material CER / EWC ples) European Waste Code Casing panels, built-in VZ and VZB sheet metal 170405 components, base Stainless steel 170405 frames, heat exchangers Aluminum 170402 Copper tube 170401 Copper cable Copper cable 170411...
  • Page 136 Instruction Manual ZHK Figure index Figure 1: Example AHU type key ....................6 Figure 2: Do not climb on the AHU! ....................21 Figure 3: Delivery in parts ......................22 Figure 4: Delivery as monobloc ....................22 Figure 5: Transport correct ......................23 Figure 6: Transport incorrect ......................
  • Page 137 Instruction Manual ZHK Figure 54: Bolt connection of base frames ................... 45 Figure 55: Easy Connection ......................46 Figure 56: Connection via Easy Connection ................. 46 Figure 57: Easy Connection at two-storey AHUs................46 Figure 58: Mounted Easy Connection at two-storey AHUs ............46 Figure 59: Hexagon bolt with locknut M8x20 ................
  • Page 138 Instruction Manual ZHK Figure 109: Door ‚closed’, not ,locked’ ..................57 Figure 110: Door ‚closed’ and ‚locked’ ..................58 Figure 111: Delivery of the keys ....................58 Figure 112: ‚Closed’ ........................58 Figure 113: ‚Open’ ........................58 Figure 114: Hinged door (ZIS) ...................... 58 Figure 115: Hinge for INOVA and VISION-execution ..............
  • Page 139 Instruction Manual ZHK Figure 164: Hydraulic connection scheme..................70 Figure 165: Drain valve ........................ 70 Figure 166: Vent valve ......................... 70 Figure 167: Condenser for warming pool water ................71 Figure 168: Notes concerning plate heat exchangers ..............71 Figure 169: Parts of spray humidifier pump circuit ................ 73 Figure 170: Correct positioning of the flexible connecting tube (black);...
  • Page 140 Instruction Manual ZHK Figure 214: Adjustment of pulleys ....................113 Figure 215: Adjustment of pulleys via threaded rods ..............114 Figure 216: Belt transmission and tensioning data sheet ............114 Figure 217: Multi-groove pulleys – attaching the belts ..............115 Figure 218: Extract (filter section) of technical data ..............
  • Page 141 Instruction Manual ZHK Table index Table 1: Warning symbols of situation-related dangers ..............11 Table 2: Symbols of personal protective equipment ..............12 Table 3: Maximum AHU part weights for lifting by crane lugs ............25 Table 4: Tightening torque for screws ................... 30 Table 5: Tightening torque for bolts ....................
  • Page 142 Tel. +91 22 4015 8934 info@biniclima.eu euroclimarus@euroclima.com info@euroclima.in www.biniclima.eu www.euroclima.com www.euroclima.com (work in progress) Euroclima V07-21.0 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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