Exhausto VEX4000 Assembly And Installation Manual
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Exhausto VEX4000 Assembly And Installation Manual

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3005541-2022-10-03
VEX4000
Assembly and installation
Product information............................................................... Chapter 1 + 6
Mechanical assembly............................................................ Chapter 2 + 3
Electrical installation.............................................................. Chapter 4
Commissioning and operation............................................... Chapter 5
EXHAUSTO A/S
Odensevej 76
5550 Langeskov, Denmark
Tel.: +45 65 66 12 34
Fax: +45 65 66 11 10
exhausto@exhausto.dk
www.exhausto.dk
VEX4000
Original instructions

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  • Page 1 VEX4000 3005541-2022-10-03 VEX4000 Assembly and installation Product information............... Chapter 1 + 6 Mechanical assembly............Chapter 2 + 3 Electrical installation.............. Chapter 4 Commissioning and operation..........Chapter 5 Original instructions EXHAUSTO A/S Tel.: +45 65 66 12 34 Odensevej 76 Fax: +45 65 66 11 10 5550 Langeskov, Denmark exhausto@exhausto.dk...

  • Page 2: Table Of Contents

    3005541-2022-10-03 1. Introduction 1.1. Application.............................. 8 1.2. Unit configurations..........................8 1.3. Terms used in the instructions - simplified diagrams.................9 1.3.1. Diagram 1 - Air handling unit with rotor, mixer section (MR) and dual-coil (HW-CW).....9 1.3.2. Diagram 2 - Air handling unit with rotor and integrated cooling (ICC) and water heating coil (HW)...................................
  • Page 3 3005541-2022-10-03 3.13.1. Connecting the cooling coil......................47 3.13.2. Ventilation requirements....................... 48 3.13.3. Simplified diagram coolant ......................49 3.14. DX Cooling............................49 3.14.1. General warnings for a unit with DX cooling................. 49 3.14.2. Connection ...........................49 3.14.3. Technical data ..........................49 3.15. Integrated cooling IC/ICC........................50 3.15.1.
  • Page 4 Scope This instruction manual is for use with EXHAUSTO VEX-type air handling units. Please refer to the product instructions regarding accessories and extra equipment. The instructions must be fully observed to ensure personal safety and to protect the equipment and ensure its correct operation.
  • Page 5 3005541-2022-10-03 Lock the air han- dling unit during operation Use an NV8 Allen key to lock the doors. All door locks on the air handling unit must be locked during operation. 5/64...
  • Page 6 - PS HT (limit for disconnection because of high pressure) - PS HT (limit for disconnection because of low pressure) Always have the production number ready when contacting EXHAUSTO A/S about the product. Choose the correct documentation for the task.
  • Page 7 3005541-2022-10-03 VEX4000 Assembly and Operation and EXcon hand- EXcon Print out from Electrical docu- installations maintenance held terminal instructions mentation for instructions instructions Menu and the order (elec- calculation pro- alarm list trical diagrams) gram Mechanical assembly » Electrical installa- tion »...

  • Page 8: Introduction

    1. Introduction 1.1 Application VEX4000 covers a wide capacity range, from 800 to 40,000 m³/h, with 10 different unit sizes (VEX4010 - VEX4100), which means it is ideal for comfort ventilation in many types of buildings - from schools, institu- tions and offices, to hotels, hospitals and industrial premises.

  • Page 9: Terms Used In The Instructions - Simplified Diagrams

    Introduction 3005541-2022-10-03 1.3 Terms used in the instructions - simplified diagrams 1.3.1 Diagram 1 - Air handling unit with rotor, mixer section (MR) and dual-coil (HW-CW). 9/64...

  • Page 10: Diagram 2 - Air Handling Unit With Rotor And Integrated Cooling (Icc) And Water Heating Coil (Hw)

    Introduction 3005541-2022-10-03 1.3.2 Diagram 2 - Air handling unit with rotor and integrated cooling (ICC) and water heating coil (HW). 10/64...

  • Page 11: Diagram 3 - Air Handling Unit With Rotor And Integrated Cooling Without Cold Recovery (Ic)

    Introduction 3005541-2022-10-03 1.3.3 Diagram 3 - Air handling unit with rotor and integrated cooling without cold recovery (IC). 11/64...

  • Page 12: Diagram 4 - Various Coils

    Introduction 3005541-2022-10-03 1.3.4 Diagram 4 - Various coils 12/64...

  • Page 13: Location Requirements

    Introduction 3005541-2022-10-03 Designation Function Extract air Exhaust air Outdoor air Supply air Coil box Control box coil Circulation pump Cooling coil (water cooled) Cooling coil (coolant) ECEF EC control for extract air motor ECSF EC control for supply air motor Rotor section EXcon EXcon control system panel...

  • Page 14: Requirements For Underlying Surface

    ● Sound emission ● Thermal loss Condensation Condensation in the ducts may occur when the exhaust/outdoor air has high humidity. EXHAUSTO recommends a condensation outlet is also fitted at the lowest point in the ducts. No duct connection If one or more of the spigots is not connected to a duct: Fit a protective net to the spigots with a maximum mesh width of 20 mm.

  • Page 15: Handling And Transport

    EXselectPRO. 2.1.5 Handling the air handling unit VEX4000 is supplied either as an assembled or sectional unit. In both cases, the remaining transport is executed using a forklift truck or crane, depending on the conditions at the assembly site.
  • Page 16 Handling and transport 3005541-2022-10-03 Specially for cool- If the air handling unit is supplied with a section with a cooling machine: Always ing machine, inte- transport this section on a max. incline of 30°, to avoid oil running from the com- grated cooling pressor.
  • Page 17 Handling and transport 3005541-2022-10-03 Lifting the sections Lifting ● Check the weight on the information plate on the specific sec- tion. ● Use a minimum of two straps. 17/64...
  • Page 18 Handling and transport 3005541-2022-10-03 Lifting the assembled air handling unit on base (indoors) Lifting Check the weight of the whole air handling unit against the type plate on the heat exchanger section. When lifting with a lifting beam: ● Check the weight of the whole air handling unit against the type plate on the heat exchanger section.

  • Page 19: Storage And Unpacking

    In general, the product should be protected from dust before it is started – this is due to dust and hygiene considerations. 2.2.2 Storage and unpacking Indoor/outdoor VEX4000 air handling units are supplied either assembled or in sections, packaged in plastic. storage Indoor storage Outdoor storage ●...

  • Page 20: Mechanical Installation

    Mechanical installation 3005541-2022-10-03 3. Mechanical installation 3.1 Installing the air handling unit - procedure 3.1.1 Procedure for assembly The following chapter describes the mechanical assembly of the VEX unit. The main points for assembly are: 1. Set the air handling unit on feet or on a base - level out. 2.

  • Page 21: Units With Cross-Flow Heat Exchanger

    Mechanical installation 3005541-2022-10-03 3.2.2 Units with cross-flow heat exchanger Description Photo ● Mount the fan section guide panels with the ac- companying screws. Guide panels must be mounted be- fore the sections are assembled. Applies only to VEX sizes 4080, 4090 and 4100. 3.3 Installing a sectional VEX 3.3.1 Assembly of manual-assembly base The base must be completely level, otherwise the sections will twist and the doors will...
  • Page 22 Mechanical installation 3005541-2022-10-03 Step Action Picture: (1-6) In addition, the parts to the base are: - Side guide for base (D) - Bolts and nuts for assembly of base - Adjustment screws for base (F) ● Assemble the cross members (A) using the brackets (C) and fit the crossbars (B).

  • Page 23: Positioning Of Sections

    Mechanical installation 3005541-2022-10-03 Step Action Picture: (1-6) ● Fit the side brackets (D) once the air handling units is placed on the base. 3.3.2 Positioning of sections The individual sections' section number + the total number of sections which the VEX consists of (e.g. 3/5) is stated on the information plate.

  • Page 24: Fitting

    3005541-2022-10-03 3.4 Fitting 3.4.1 Section assembly fitting The VEX4000 sections can be tightened together in several different ways, depending on what is appro- priate for the assembly site, and the order of the sections. There are three types of fitting:...

  • Page 25: Interior Fitting

    Mechanical installation 3005541-2022-10-03 3.4.2 Interior fitting Assembly 25/64...

  • Page 26: Simple Exterior Assembly Fitting (Ebs4000) - Rear Or Top

    Mechanical installation 3005541-2022-10-03 3.4.3 Simple exterior assembly fitting (EBS4000) - rear or top In those cases where it is difficult to get to the rear interior fittings and tighten the sections together, the exterior assembly fitting can be used both on the rear and on the top. Description Picture: Supplied fitting...

  • Page 27: Fitting For Feet

    Mechanical installation 3005541-2022-10-03 Description Picture: On the top of sections Examples: Fitting fitted on the top of sections 3.4.4 Fitting for feet Fitting used for assembly of the air handling unit, when the available space makes it difficult to use the interior assembly fitting.
  • Page 28 Mechanical installation 3005541-2022-10-03 Mark up the threaded bar once the sections have been correctly set up. Shorten the threaded bar to the measured length. NB: use the hole closet to the corner in the foot. The square nut will "lock" against the foot, so the nut can be tightened in the other end of the threaded bar.

  • Page 29: Base Fitting

    Mechanical installation 3005541-2022-10-03 3.4.6 Base fitting Description Photo ● Fitting for base behind VEX The base fitting must always be used when the base has been supplied loose. 3.5 Special assembly factors 3.5.1 Inspection hatch(es) in different sections Fan section Description Photo If the access conditions are restricting, access...
  • Page 30 Mechanical installation 3005541-2022-10-03 ● Loosen the screws, push the hatch up and put it to the side. REMEMBER to re-fit the hatch be- fore staring up the VEX. Access to assembly fitting via the mem- Description Photo brane sleeve ● Remove the rubber membrane to access the section assembly fitting (fan section).

  • Page 31: Removing Cooling/Heating Coil (Cw, Hw, Hwr)

    Mechanical installation 3005541-2022-10-03 Rotor section Description Photo Use the inspection hatches in the rotor section, if the access condi- tions for assembly or servicing on the adjacent sections is restric- ted. 3.5.2 Removing cooling/heating coil (CW, HW, HWR) If the access conditions in the VEX make it difficult to tighten the interior rear fitting, it may be helpful to take the coil out of the section.
  • Page 32 Mechanical installation 3005541-2022-10-03 Step Action Picture: Remove the exterior flange and two in- terior flanges on the spigots. ● Remove the exterior black rubber flange. ● Unscrew the screws that hold the interior flanges. ● Remove the interior flanges. ● Remove all of the plugs on the pan- 32/64...
  • Page 33 Mechanical installation 3005541-2022-10-03 Step Action Picture: 7a+b ● Unscrew all of the screws that hold the panel. 8a+b ● The panel can now be removed. 9a+b ● The coil is positioned loosely on a rail above the condensation tray. 10a+b ●...

  • Page 34: Removal Of Electric Heating Coil (He)

    Mechanical installation 3005541-2022-10-03 3.5.3 Removal of electric heating coil (HE) If the access conditions in the VEX make it difficult to tighten the interior rear fitting, it may be helpful to take the coil out of the section. Step Action Picture: Lift off the door hinge at the top so the section door can be fully opened.

  • Page 35: Connection Of Plugs And Sockets

    Half sections that shall be fitted on the top of the air stream must always be supported – including dur- (single height) ing assembly. The fixture for this is not part of the EXHAUSTO delivery. 3.6 Connection of plugs and sockets 3.6.1 Connection of plugs and sockets...

  • Page 36: Setting Up An Assembled Outdoor Vex

    3.7 Setting up an assembled outdoor VEX 3.7.1 Assembled Outdoor VEX on base EXHAUSTO recommends that the VEX unit is secured to the building to prevent it from becoming dislodged during a storm. The mounting tabs that are fitted in the end sections can be used for this purpose, see drawing in table below.

  • Page 37: Avoid Condensation Forming

    In case of doubt, contact EXHAUSTO for advice. 37/64...

  • Page 38: Exhaust Air Caps (Accessories) Outdoor

    Mechanical installation 3005541-2022-10-03 3.8 Exhaust air caps (accessories) Outdoor 3.8.1 Fitting of exhaust air/inlet cap Step Action 1. Exhaust air cap 2. Inlet cap 1. Exhaust air cap: ● Fit the exhaust air cap on the spigot using screws all the way around. 38/64...
  • Page 39 Mechanical installation 3005541-2022-10-03 Step Action 2. Inlet cap: ● The set consists of inlet cap, cover rails and sealing strip (not shown in photo). ● Set the sealing strip on the spigot, exercise care to ensure the strip is fitted correctly. ●...

  • Page 40: Condensation Outlet

    Mechanical installation 3005541-2022-10-03 3.9 Condensation outlet 3.9.1 Establishment of condensation outlet The connection must be made by an authorised plumber. The execution of the condensation outlet must take into consideration that the doors must be able to be opened, and that inspection, servicing and operation of the air han- dling unit should be unhindered.

  • Page 41: Requirements For Water Trap

    Mechanical installation 3005541-2022-10-03 3.9.3 Requirements for water trap If a siphon water trap is not used, the water trap must be executed in accordance with the following di- mensions: Min 75mm Min 50mm If the air handling unit has been in operation with closes damper, the water trap must be checked and if required topped up with water.

  • Page 42: Door Locks

    Mechanical installation 3005541-2022-10-03 3.10 Door locks Adjustment of door lock The door locks on the air handling unit can be adjusted in a horizontal or vertical direction. Step Action Open the door on which the lock need to be adjusted Vertical adjustment: Loosen the two screws and adjust the part of the door lock which lies on the unit frame.

  • Page 43: Commissioning The U Pipe Manometer

    Mechanical installation 3005541-2022-10-03 3.11.2 Commissioning the U pipe manometer Step Action Fill the supplied manometer liquid, as stated on the included note. Fit the hoses from each side of the hose spigot and down to the manometer's spigots. Note the tempera- The supplied liquid (with a density of 1.00) can tolerate temperatures in the range ture range.

  • Page 44: Connection Of Water Heating Coil

    Mechanical installation 3005541-2022-10-03 Before the hoses are fitted: ● If required, adjust the indicator so that it is on 0 via the screw in the bottom of the gauge. ● Fit the hoses from each side of the hose spigot and down to the pressure gauge spigots. The filter pressure drop curves can be seen in the section "Technical data".
  • Page 45 Mechanical installation 3005541-2022-10-03 The supply and return flow on the heating coil can be seen via the label on the door. Supply flow on the top spigot and return flow on the bottom spigot: Return flow on the top spigot and supply flow on the bottom spigot: The pipe layout must be carried out by an authorised plumber.

  • Page 46: Ventilation Requirements

    Mechanical installation 3005541-2022-10-03 3.12.2 Ventilation requirements Bleeding #It is the responsibility of the contractor/customer to ensure that the bleeding option is correctly instal- led and that the building owner is informed of the risk of insufficient bleeding, regardless of whether the coil(s) in question are built into a ventilation system or mounted separately in the duct system.

  • Page 47: Connecting The Cooling Coil

    Mechanical installation 3005541-2022-10-03 Type Water heating circuit principle Simplified diagram Mixing Variable flow in the primary circuit loop 1 (supply) and constant flow in sec- ondary circuit (VEX unit) Mixing Variable flow in the primary circuit loop 2 (supply) and in the secondary cir- cuit (VEX unit) 3.13 Connecting the cooling coil 3.13.1 Connecting the cooling coil...

  • Page 48: Ventilation Requirements

    Mechanical installation 3005541-2022-10-03 Supply air temperature sensor The pipe layout must be carried out by an authorised plumber. Hold extra counter force on the manifolds when connecting the cooling coil to the pipe system. 3.13.2 Ventilation requirements Bleeding #It is the responsibility of the contractor/customer to ensure that the bleeding option is correctly instal- led and that the building owner is informed of the risk of insufficient bleeding, regardless of whether the coil(s) in question are built into a ventilation system or mounted separately in the duct system.

  • Page 49: Simplified Diagram Coolant

    Mechanical installation 3005541-2022-10-03 3.13.3 Simplified diagram coolant Type Coolant circuit principle Simplified diagram Mixing Variable flow in the primary circuit loop 1 (supply) and constant flow in sec- ondary circuit (VEX unit) Mixing Variable flow in the primary circuit loop 2 (supply) and constant flow in sec- ondary circuit (VEX unit) a) The valve must be adjusted on...

  • Page 50: Integrated Cooling Ic/Icc

    Mechanical installation 3005541-2022-10-03 3.15 Integrated cooling IC/ICC 3.15.1 General warnings for a unit with integrated cooling Note that the coolant from the condenser and evaporator must be collected and dis- posed of in accordance with national regulations concerning the disposal of coolants. Note that if the door is opened in the cooling section, there is a risk of frostbite from touching cold components.

  • Page 51: Motor Valve

    3.17.2 Flexible duct system connections (optional), only for METU connections. The VEX4000 series of air handling units can be ordered with flexible duct system connections. Flexible duct system connections are used to attenuate any vibrations out in the duct system.

  • Page 52: Readjustment

    Mechanical installation 3005541-2022-10-03 3.18.2 Readjustment After transport and installation of the sections, it may be necessary to readjust the rotor. Adjustments may be made on both sides of the rotor. ● Remove the plugs from the deck housing on both sides of the rotor over the rotor suspension to gain access to the bolts.

  • Page 53: Purging Zone (Optional)

    3.19.1 In general The fan units are fitted in each section. All sizes in the VEX4000 series are supplied with plenum fans, however VEX4080 - 4100 can be ordered with an alternative axial fan, type ZerAx®. Whether it is plenum fans or ZerAx®.

  • Page 54: Establishment Of Smoke Evacuation Damper

    Mechanical installation 3005541-2022-10-03 3.20 Establishment of smoke evacuation damper For VEX4000 or- NB: The VEX can tolerate operation at max. 70°C for 60 minutes. dered with smoke evacuation damper Smoke evacuation In case of fire, the external smoke evacuation damper opens, allowing smoke to bypass the filter and principle move directly to the exhaust air fan.

  • Page 55: Electrical Installation

    Should you want to be able to make the entire air handling unit completely de- energised , EXHAUSTO recommends that a repair switch is installed, designed like the isolation switch, immediately in front of the connection terminal for the air handling units in the fixed installation.

  • Page 56: Short-Circuit Current

    Electrical installation 3005541-2022-10-03 Power supply cable When dimensioning the supply cable, the conditions at the installation location, including temperature and cable duct layout, must be taken into consideration. Fault current switch ● The unit must be protected against indirect contact. If fault current switches are fitted in the installation, they must be of a type that meets the fol- lowing requirements: VEX4010-4100...

  • Page 57: Startup

    3005541-2022-10-03 5. Startup The VEX4000 air handling unit must be started up in accordance with a fixed procedure. When starting up, it is important to first ensure there is air circulation to prevent damage to the heating coil or cooling coil.

  • Page 58: Fans Start-Up

    Startup 3005541-2022-10-03 5.2 Fans start-up 5.2.1 Start-up table Step Action Check that all of the sections are cleaned free of any foreign bodies (metal shavings, paper or similar). Connect the supply voltage. Check again that the damper shuts out the air. Switch on the fans.

  • Page 59: Measurement Of Airflow And Pressure Drop Across The Filters

    Startup 3005541-2022-10-03 VEX size Total number fans Fan size k-factor, k [l/s] k-factor, k [m³/h] 4010 26.6 4020 33.6 4030 54.7 4040 70.0 4050 70.0 4060 85.6 4070 105.8 4080 2 x 500 2 x 70 2 x 252 4090 2 x 560 2 x 85.6 2 x 308...

  • Page 60: Technical Data

    Technical data 3005541-2022-10-03 6. Technical data 6.1 MVM valves, data 6.1.1 MVM motor valve Valve 2-way – K 0.4 – 40 3-way – K 0.4 – 58 Test pressure 1600 kPa Max. differential pressure 350 kPa Permissible media temperature -10°C to 120°C The valve will remain permanently open if the differential pressure is above 1400 kPa Motor...
  • Page 61 Technical data 3005541-2022-10-03 Product parts Material Sheet parts Aluzinc Recycle after disassembly Bypass dampers, heat ex- Aluminium Recycle changers, condensation trays, and profiles Insulation Mineral wool Recycle after disassembly Door gasket CFC and HCFC-free For landfill waste or incineration cellular rubber Fan motors, bypass mo- Aluminium, steel, cop- Recycle after disassembly...
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