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Euroclima Oceania T-TWO ZHK 2000 Instruction Manual

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ZHK 2000 / INOVA
Te c hni c al IOM Man u al

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Summary of Contents for Euroclima Oceania T-TWO ZHK 2000

  • Page 1 ZHK 2000 / INOVA Te c hni c al IOM Man u al...
  • Page 2 instruction manual ZHK 2000 / T-TWO / INOVA / ETA In addition to the instructions in this guide, subject-specific standards, as well as local, national and international regulations must be observed. 2/113 V01-16...
  • Page 3 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Index Introduction ........................... 6 Model code ........................6 Intended use / foreseeable misuse ................... 7 1.2.1 Intended use ......................7 1.2.2 Foreseeable misuse ....................7 Modular design ......................... 8 Documentation........................8 Safety instructions ........................

  • Page 4: Table Of Contents

    AHUs equipped from EUROCLIMA with control ETAMATIC ........67 7.5.2 AHUs which are not equipped from EUROCLIMA with control (which have to be equipped with controls on responsibility of the client) ............67 Differential pressure restriction for plate heat exchangers ..........70 Lighting ...........................
  • Page 5 instruction manual ZHK 2000 / T-TWO / INOVA / ETA 9.3.4 Auto roll filters ......................93 Heat exchangers ......................93 9.4.1 Medium water / steam....................93 9.4.2 Refrigerant ....................... 94 9.4.3 Electric Heater ......................94 Humidifier, Air washers ....................94 9.5.1 Pump ........................
  • Page 6 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Introduction 1.1 Model code ZHK 2000 S 15/6 – 15/6 AHU type (standard) AHU execution Unit size supply air Unit size exhaust air Legend used for AHU type ZHK 2000 / ZHK T-TWO / Housing types ZHK INOVA ETA XXX...

  • Page 7: Intended Use / Foreseeable Misuse

    Operation at other conditions must be agreed in writing. If products and components of other manufacturers are used, these must be recommended or ap- proved by EUROCLIMA. On-site changes are in full safety responsibility of the operator. 1.2.2 Foreseeable misuse...
  • Page 8 instruction manual ZHK 2000 / T-TWO / INOVA / ETA 1.3 Modular design Because of the modular AHU design, the manual covers all the possible sections and components which can be delivered. The ordered range is smaller and can be seen on the technical data sheet - see chapter 1.4 (Documentation).

  • Page 9: Safety Instructions

    2.1.1 CE-conformity 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 10 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 7.4 (Variable, frequency-controlled drives (VFD, frequency converters)).
  • Page 11 instruction manual ZHK 2000 / T-TWO / INOVA / ETA 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. roof sheets, fins of heat exchangers, corners and edges - Use per- sonal protective equipment: wear protective helmet, gloves, safety shoes and long protective clothing.
  • Page 12 instruction manual ZHK 2000 / T-TWO / INOVA / ETA for maintenance of frequency controlled motors, a waiting time of 15 minutes is recommended – time to break down the residual capacitive charge of the frequency converter. Remove the key from doors with door lock before entering in the casing of the AHU. Keep the key out of reach of unauthorized persons.
  • Page 13 instruction manual ZHK 2000 / T-TWO / INOVA / ETA 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, …) and ventilate the room well. Please note the instructions on the unit and subsequent instructions exactly.
  • Page 14 instruction manual ZHK 2000 / T-TWO / INOVA / ETA 2.2.3 ATEX units General safety indications ATEX units may not be used near: High frequency sources (e.g. transmitter systems) Strong light sources (e.g. laser beam systems) Ionizing radiation sources (e.g. X-ray machine) Ultrasound sources (e.g.
  • Page 15 Loose supplied parts and assembly materials are in a nylon bag or a box in the unit. If damages are found, immediately a damage report must be created and sent to EUROCLIMA. Only then the transport company can make the claim against the insured (Note damage on the shipping documents with date and signature in the presence of the carrier).
  • Page 16 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 1: Do not climb on the unit Differentiation of delivery For unloading, transporting and lifting an AHU to its final installation location, two fundamentally different forms of delivery are to be differentiated. The delivery form is agreed with the customer in the order clarification and can be: 1) Supplied in parts (delivery sections) Figure 2: Delivery in parts (delivery sections)
  • Page 17 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Sections have a base frame, on which on each corner a (supplied) crane lug can be attached. Size and weight of the sections are indicated on the AHU drawing, see Figure 7. 2) Supplied as monobloc Figure 3: Delivery as monobloc If the space conditions allow the delivery of a monobloc, then the assembly at the installation...

  • Page 18: Unloading / Transportation To Installation Location

    3.2 Unloading / transportation to installation location Forklift, lift truck transport In accordance with the EUROCLIMA drawing the AHU will be delivered as one or more delivery section(s). The AHU parts are delivered on a pallet and can be unloaded and moved by forklift or lift truck.
  • Page 19 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. 3.3.1 Control of weight limits of delivery sections Depending on the base frame height (see Figure 15), delivery sections may be lifted with lifting lugs up to the following weight, refer to Table 1.
  • Page 20 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 7: AHU section drawing with weight details 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.
  • Page 21 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 9: Delivery section with dismounted damper Figure 10: Delivery section with mounted crane lugs Example 2: Figure 11: Delivery section with mounted flexible connection 21/113 V01-16...

  • Page 22: Mounting Of Crane Lugs

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 12: Delivery section with dismounted flexible connection Figure 13: 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.
  • Page 23 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 14: Mounting of crane lugs Bolts and nuts are delivered with the lifting lugs and must be tightened with the torque according to Table 2. Base frame height Figure 15: Base frame height 23/113 V01-16...
  • Page 24 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Base frame height H [mm] Bolt type M8x20 M8x20 M12x30 M12x30 Table 2: Tightening torque for bolts 3.3.4 Lifting of delivery sections with crane lugs The load carrying equipment must not run over the operating side of the AHU, but it must run over the opening or the front side of the AHU (Figure 16).
  • Page 25 instruction manual ZHK 2000 / T-TWO / INOVA / ETA For overlifting of units delivered as “Delivery in parts (delivery sections)”, see chapter 3.3 (Over- lifting of AHU sections with crane lugs). 3.4.1 Weight details for monoblocs The weight of the unit is specified on the AHU drawing (attached on monobloc). Calculation exam- ple referring to monobloc from Figure 18.
  • Page 26 3.5 (Further necessary actions for the overlifting of both, delivery sections on crane lugs as well as monoblocs) have to be performed. The Lifting of monoblocs by crane lugs is permitted only in exceptional circum- stances and requires the written approval by EUROCLIMA. 26/113 V01-16...
  • Page 27 instruction manual ZHK 2000 / T-TWO / INOVA / ETA 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. belt with hook. The recommended minimum load capacity per load carrying equipment is 50% of the total weight of the delivery section or monobloc.

  • Page 28: Foundation / Erection

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 3.6 Storage The delivery sections generally are packed in nylon. This package is suitable to protect the AHU during loading and unloading from bad weather, but not for outdoor storage. The insertion into a dry area after unloading is therefore essential for the preservation of the unit.
  • Page 29 instruction manual ZHK 2000 / T-TWO / INOVA / ETA According to EN 13053 and VDI 3803 it is not permitted, that the bottom of the AHU replaces the building roof. Furthermore it is not permitted that the AHU takes over any function of the building, neither in terms of tightness nor insulation.

  • Page 30: Actions To Prevent Potential Risks

    In this context, it is recom- mended 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 31: General Indications For The Erection

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 4.2.3 General indications for the erection The AHU sections must be precisely aligned 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. After the prepositioning the AHU-sections can be pulled together with belts which act on the base frame, as shown on Figure 25 and Figure 26.
  • Page 32 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 28: Suspension of ceiling units AHU which are not designed to stack, may not be stacked (one on the other).Air washer will need either one-both sides higher foundations or on one-both sides feet, which are supplied if ordered, refer to Figure 29.
  • Page 33 instruction manual ZHK 2000 / T-TWO / INOVA / ETA 4.2.4 Special guidelines for flat units – ceiling units Usage For the suspension under a ceiling. Assembly of the individual components of the flat units The individual components are screwed together by use of comfort compound – see Figure 30. The assembly should still be done on the ground, since the comfort compounds on the top side of the flat unit may no longer be accessible after positioning on the ceiling.
  • Page 34 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 31: Suspension with transverse profiles Figure 32: Suspension with longitudinal and transverse profiles 34/113 V01-16...
  • Page 35 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Assembly 5.1 Assembly of casing 5.1.1 Actions before the assembly of casing If several AHU sections have to be connected, then the procedure after the pre-positioning of the sections is as follows: Remove crane lugs If lifting lugs are mounted, remove them.
  • Page 36 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 34: Removal of the external panel Applying the sealing strip The supplied self-adhesive sealing strip (Figure 35) has to applied on the inner edge of the section flange, refer to Figure 36. Figure 35: Sealing strip Figure 36: Applying the sealing strip For roof units as well as at device separations directly before or after a wet area (e.g.

  • Page 37: Standard Connections And Connection Components

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 5.1.2 Standard connections and connection components Base frame connection Figure 39: Hexagon bolt with locknut M8x20 / Figure 40: Screw connection of base frames M10x30 / M12x40 Connection via panels, connection angles and connection frame Depending on the cross section of the AHU, cases A, B and C (as described below) can be differ- entiated.
  • Page 38 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 43: Hexagon bolt with locknut M8x20 Figure 44: Connection via connection angle Case C: unit width >= 2.440 mm Connection frame, screw spacing minimum 305 mm Figure 45: Hexagon bolt with nut M6x6 Figure 46: Connection frame Additionally the following rule applies: 1) Internal mounted connection angles and frames are accessible and the sections are properly...
  • Page 39 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 47: Tapping screw ø8 x 11 Figure 48: Joint on the AHU drawing Figure 49: Connection between door frame / internal panel Connection of 3 mm thick casing components without holes Figure 50: Self-tapping screw ø6,3 x 22 Figure 51: Application of self-tapping screws Connection of internal panels with the front side of the casing...
  • Page 40 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 55: Hexagon bolt with nut Figure 56: Connection of roof Figure 57: Mounting of the sliding (stainless steel) M6x16 plates 5.1.4 Assembly of delivery sections Bring the delivery sections in the exact mounting position and push them together as near as pos- sible.
  • Page 41 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 59: Tightening the screws Reinsert the insulation and remount the external panel From the external panels of roof units, or units with external aluminum panels the white protective film from the sealing tape must be removed before mounting (Figure 60). Figure 60: Removing the protective film Start at the bottom to mount the external panels (Figure 61).

  • Page 42: Special Features For Roof Units And Device Separations At Wet Areas

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 61: Pushing in the external panel For roof units also the supplied slide bar must be mounted on the roof flange. 5.1.5 Special features for roof units and device separations at wet areas For roof units as well as at device separations directly before or after a wet area (e.g.
  • Page 43 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 64: Sealing the roof flange Roof flange Unit flange Figure 65: Applying the sealing agent on the frontal joints 43/113 V01-16...

  • Page 44: Cable Gland

    5.1.6 Cable gland For the connection of engines, pumps, electric heaters, sensors, etc., EUROCLIMA loosely sup- plies material for cable glands (Figure 71), which must be installed properly. The following proce- dure is recommended: 1. Drilling through unit casing (at right angles to the surface).
  • Page 45 instruction manual ZHK 2000 / T-TWO / INOVA / ETA 3. Insert sleeve (inside – see Figure 69) and screwing (outside – see Figure 70) into the drillings and screw them together (see Figure 71). Figure 69: Sleeve Figure 70: Screwing Figure 71: Cable gland A drilling with the diameter for the corresponding screwing (see Table 3, column 2) is sufficient for the insertion of cables into a cabinet or a single walled housing.
  • Page 46 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 73: Door ‚open’ Figure 74: Door ‚closed’, not ‚locked’ Doors which allow access to the fan section are equipped with a door lock. Figure 75 shows the lock in the position 'locked' offer a physical barrier as a protection against the danger zone stay securely in position and can be opened only by using a key during the operation do not permit access to the fan section...
  • Page 47 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Readjustment of the door panel position Because of the handling of AHU sections, the position of the door panel can move (see Figure 79). Due to the inclination of the door panel of the EU hinged doors, problems can arise when closing and sealing of the door panel.

  • Page 48: Laterally Removable Prefilters

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA During the installation it must be noted, that the filter bags will not be clamped or damaged. Each filter bag must freely adjust itself in the airstream. Incorrectly mounted filters can be sucked in by the fan and lead to its destruction. 5.4.1 Laterally removable prefilters The filters are supplied mounted and are equipped with a pull-out tool for more than one filter per guiding.

  • Page 49: Laterally Removable Bag Filters With Clamping Mechanism

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 5.4.2 Prefilters 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 in brackets on the filter frame (Figure 85).

  • Page 50: 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 92 up to Figure 95.

  • Page 51: Dampers With External Gear Wheels

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

  • Page 52: Hygienic Ahu's

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 5.6 Hygienic AHU’s After assembly all grooves and joints at the connection positions must be sealed with the sup- plied sealing agent. In case of exchange of components sealing must be restored. Access of components is ensured by door positions upstream and downstream of the compo- nent, therefore components are accessible or side removable for cleaning and maintenance.
  • Page 53 instruction manual ZHK 2000 / T-TWO / INOVA / ETA The piping of the heat exchanger should hinder a for maintenance required expansion of the heat exchanger as less as possible. Recommended sealing material for threaded sleeves: Steam heat exchanger, use special sealant Water / glycol heat exchangers, use Teflon tape.

  • Page 54: Steam Heat Exchanger

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA To vent and drain the heat exchanger connection, valves are mounted (on request). To ensure cor- rect operation must be ensured, however, that the vent is on the highest point of the whole water cycle and the drain at the lowest.
  • Page 55 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 102: Plate heat exchangers for refrigeration circuits Application of plastic water tubes is not allowed because refrigerant - and there- fore also plate heat exchanger - may reach temperatures of 110° C or higher! Never install the chloration in front of the water inlet of the plate heat exchanger.

  • Page 56: Connection Of Indirect Adiabatic Cooling

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 6.2 Connection of indirect adiabatic cooling ETA-PAC-AHU’s are equipped with an indirect adiabatic cooling device. Carry out connection to piping system as shown in Figure 104. Figure 104: Indirect adiabatic cooling 6.3 Condensate drain Each drain must be equipped with a siphon.

  • Page 57: Ball Siphons

    Figure 106: Siphon on pressure side 6.3.2 Ball siphons If ball siphons with the below shown design are included in the delivery from EUROCLIMA, then the following items 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 107) corresponds to the flow direction.
  • Page 58 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 107: Observe the mounting position - flow direction according to the arrow Siphon on suction side (in direction of airflow before the fan) Figure 108: 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 110).

  • Page 59: Duct Connection

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 109: Pressure side execution Figure 110: Pressure side installation: remove the black closing plug 6.4 Duct connection The air conditioning work must be executed tension and torsion free. To prevent structure-borne sound transmission is an intermediary flexible connector recom- mended with at least 140 mm width.

  • Page 60: Insulation Of Fresh Air Damper

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 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 61 Single-speed motors Single-speed motors are suitable for direct and star-delta starting. If the wiring to the unit 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 111.
  • Page 62 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Not start Overload Decrease of mains voltage Failure of a conductor in the three phase power supply 2) Motor with frequency converter: circuit braker is sufficient If the motor is operated at the frequency converter, a short circuit protection by a circuit breaker is adequately.
  • Page 63 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Not apply voltages above 5V at the temperature sensor. This leads to its destruc- tion! Alternative to PTC: Motors with integrated bimetal sensor (thermal contact, Clixon) - optional Bimetal detectors are used for thermal monitoring of motor windings and consist of two successive rolled metals, with unequal thermal expansion coefficients.
  • Page 64 Figure 115, for fan with housing refer to Figure 116. 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 repair switch (if supplied and wired by EUROCLIMA). 64/113 V01-16...

  • Page 65: Repair Switch (Emergency Stop Switch)

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 115: Rotation marking of Figure 116: Rotation marking of plug fans housing fans Fastening torque for electrical connections on the control panel refer to Table 4: Thread M4 M5 M6 Ø...

  • Page 66: Variable, Frequency-Controlled Drives (Vfd, Frequency Converters)

    ZHK-AHU without EUROCLIMA-control Specified repair switch must be provided on responsibility of the client Is to carry out independent from EUROCLIMA supply of repair switch for fan motor. Fan motor repair 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 67: Electric Heaters

    EUROCLIMA delivery. Units, which are supplied from EUROCLIMA with control, are limiting the supply air temperature to a default value of 35° C. 7.5.2 AHUs which are not equipped from EUROCLIMA with control (which have to...
  • Page 68 The safety related correct implementation of control has to be carried out on side in full responsibility of the client. EUROCLIMA proposes a safety concept as specified below as minimum requirement: Control-side limitation of the air temperature after the electric heater The control of the electric heater has always to take place so, that the air temperature after the electric heater never exceeds the permitted air temperature in the unit (40°...
  • Page 69 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Cover cap on reset button Reset button Figure 118: Thermostat with Figure 119: Thermostat with cover cap on the reset button uncovered reset button Thermostat 2 (Figure 120) Position of thermostat casing: fastened on outside panel of AHU casing Triggering temperature: set to 70°...

  • Page 70: Differential Pressure Restriction For Plate Heat Exchangers

    Only one fan is working (supply- or exhaust air), which can increase the pressure in some cases. EUROCLIMA provides as optional differential pressure switches, which shall be used as described below: For each fan, which can produce an unacceptably high pressure, a differential pressure switch will be provided.

  • Page 71: Lighting

    ZHK 2000 / T-TWO / INOVA / ETA If no differential pressure switches are included in the delivery of EUROCLIMA (shown in the tech- nical data sheet), then another appropriate on site measure device must protect the plate heat ex-...

  • Page 72: Commissioning

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA lighting with an at least protection of IP65 were used. Switches or junction boxes mounted on the outside of rooftop units must also have at least protection class IP65. For units with integrated control and lighting, an additional power supply for the lighting must be provided and separated from the power supply for the control cabinet.

  • Page 73: Variable Frequency Controlled Drives - Parameters

    + -5% is permitted. 8.1.1 Variable frequency controlled drives - parameters The frequency converter must be configured, if not done by EUROCLIMA (please refer to technical data sheet): parameterization using the following Table 6 respectively the provided manufacturer's operating instructions and data from EUROCLIMA technical data sheet.
  • Page 74 instruction manual ZHK 2000 / T-TWO / INOVA / ETA 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] Setpoing [unit]...

  • Page 75: Airflow Measurement By Differential Pressure Measurement At The Fan Nozzle

    The air density at the measuring point is to set up manually, depending on altitude, temperature and humidity. In most cases, 1.2 kg/m³ is a suitable value. Note: If in the EUROCLIMA delivery the device for airflow measurement is included, this must be configured on site in responsibility of the client before commissioning.
  • Page 76 instruction manual ZHK 2000 / T-TWO / INOVA / ETA 76/113 V01-16...
  • Page 77 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Processing the pressure signal in other devices Devices from other manufacturers may require a conversion of the K-value. Therefore always ask for the formula, which the device is using. 77/113 V01-16...

  • Page 78: Heat Exchanger

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 8.1.3 Heat exchanger The heat exchangers, fittings and valves shall be tested for tightness. Attention! Refrigerant If direct expansion heat exchangers or air cooled heat exchangers are installed, the system must be filled with refrigerant after the complete assembly.

  • Page 79: Humidifier / Air Washer

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA In addition, the output of a warning message when the final pressure loss is reached must be ensured during the commissioning. The resulting maintenance actions are described in chap- ter 9.3 (Air filters). 8.1.6 Humidifier / Air washer Drain pan must be cleaned thoroughly.

  • Page 80: Refrigeration Circuit

    The water, which is absorbed by the oil cannot be removed sufficiently. 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: 1. Start page Enter the password...

  • Page 81: Refrigerant

    ZHK 2000 / T-TWO / INOVA / ETA 8.2.3 Refrigerant Refrigerants used by EUROCLIMA are halogenated hydrocarbons, preferably R407C and R134a. These are also known as safety refrigerants (safety group A1 according to EN378 part 1) in con- trast to flammable refrigerants such as Propane or toxic refrigerants such as Ammonia.
  • Page 82 instruction manual ZHK 2000 / T-TWO / INOVA / ETA In addition, the actual power consumption of all phases’ shall be measured and compared with the nameplate. If the actual power consumption is too high, there is maybe a faulty connection. The system must be shut down immediately.
  • Page 83 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Belt type Pulley type Min. working di- H max. Max. working di- ameter [mm] [mm] ameter [mm] RST 84 RST 95 RST 100 RST 108 RST 108 RST 120 RST 129 RST 139 RST 146 RST 156...

  • Page 84: Maintenance

    Most commercially available frequency converters have a feature to address these problems. If the air flow is incorrect, then please contact in doubt the competent EUROCLIMA office. Maintenance EUROCLIMA units are built mostly maintenance free and easy to maintain. The maintenance inter- vals are indicative for normal operating conditions.
  • Page 85 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Flexible connections are to be checked for damage / visual inspection. Check vibration isolators for proper mounting / damage (visual inspection). Check the protection grid (Fan in and/or outlet) if available for correct installation / damaged (visual inspection).

  • Page 86: Motor

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA Plug fan The fan is directly flanged to the motor due to the absence of the belt drive it is a service friendly component. To reach the operating point, a frequency converter is required. Deposits on the wheel can cause damage (risk of fatigue fracture) - impeller can burst - Danger! Visually inspect: Check the wheel for any particular weld cracking.
  • Page 87 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Reasons for increased belt wear or defect Belt contact the groove bottom / unequal set of belt / tension is too high or too low – Figure Figure 130: Unfavourable operating conditions (1) Slippage / pulley too small / overloading / damaged disc / eccentricity, wobble –...

  • Page 88: Re-Tensioning Of Belts

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 9.2.4 Re-tensioning of belts Moving the motor away from the fan does the tensioning of the belt. Depending on the size of the motor is this: On a rocker swivel On rails slidably mounted.
  • Page 89 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 135: 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 re-tension the first time after about 10 hours. Belt tension The correct tension of the belt is obtained if you have the same data as calculated (separately for each drive).

  • Page 90: Replacing Of Belts

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA Following two methods for determining 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 91: Panel Filters

    ZHK 2000 / T-TWO / INOVA / ETA If units are equipped with EUROCLIMA control, then a corresponding warning message is dis- played on the HMI (see Figure 138) when the differential pressure limitation is reached. Figure 138: Warning message filter If such a warning message is displayed, then appropriate actions have to be taken immediately (e.g.

  • Page 92: Bag Filters

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 9.3.2 Bag filters Contamination level of the filter can be controlled by the differential pressure drop (check every 14 days to 1 month). Reaching the pressure difference indicated in the technical data sheet cleaning or replacement is required.

  • Page 93: Auto Roll Filters

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 9.3.4 Auto roll filters Detailed maintenance instructions are in the auto roll filter section! These filters work automatically and can be monitored by the controlling device. A warning indi- cates the filter strip is finished. The filter roll must be replaced. Every six months the oil level is to check.

  • Page 94: Refrigerant

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA Droplet eliminator Check droplet eliminator about once a year for contamination. Remove fins and clean if necessary. Contamination can cause damage by water drops and reduce the performance of the device. Please make sure that the fins are installed properly and are not bent.

  • Page 95: Air Washers

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 9.5.2 Air washers In general: Check water supply for properly function and check the water level, adjust if necessary. Fill tank and siphon with clean water and adjust the float valve so that the valve closes at a wa- ter level of 2-3 cm below the overflow.

  • Page 96: Spray Tube Humidifiers

    Clean drain pan and drain. 9.6 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. Spray the wheels with silicone spray if necessary.

  • Page 97: Heat Wheels

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA o Removed fibers and dust at the exchanger inlet with a brush. o Clean oils and fats with hot water, household cleaners or degreasing steam. Check for proper operation of differential pressure switch – for function refer to chapter 7.6 (Differential pressure restriction for plate heat exchangers).

  • Page 98: Refrigeration Circuit

    9.10.1 Leakage checks have to be performed according to EU-regulations indicated in Records for refrigeration circuit application in air-conditioning units supplied by EUROCLIMA. Execution by certified refrigera- tion technician at intervals that depend on the refrigerant filling quantity. have to be documented in Records for refrigeration circuit application in air-conditioning units.

  • Page 99: Maintenance

    EUROCLIMA control system). Follow maintenance and inspection requirements of compressor manufacturer. These instruc- tions are supplied from EUROCLIMA or can be ordered from EUROCLIMA. Filter drier: Each refrigeration circuit is equipped with a filter drier. If refrigeration circuit has to be repaired filter drier must be replaced.

  • Page 100: Inspection

    ZHK 2000 / T-TWO / INOVA / ETA With an electronic expansion valve the corresponding values must be followed by control unit. Instructions from 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 101: Hygienic Units

    Clean or rinse out condensate outlet from time to time. 9.11 Hygienic units The maintenance plan for EUROCLIMA AHU’s you will find in the general part of instruction man- ual. EUROCLIMA recommends maintenance in dependence on: VDMA 24186 part 1 and VDI6022 part 1.
  • Page 102 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Ch = Check, C = Clean, M = Maintenance Component Action Section monthl ¼ year ½ year year Reference chapter Fan / motor Corrosion check 9.2.1 Fan Flexible connection Vibration isolators Protection grid Water drain Ch / Cl / M...

  • Page 103: Information On Airborne Noise Emitted By The Air Conditioning Units - On Request

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 10 Information on airborne noise emitted by the air conditioning units - on request Sound data can be printed on request on the technical data sheet, sample see Figure 143. The sound power is specified as A-weighted sound power level: Line 1: Sound power over the casing Line 2: Sound power inlet...
  • Page 104 instruction manual ZHK 2000 / T-TWO / INOVA / ETA 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...

  • Page 105: Information Regarding The Unit, Protective Systems And Components

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 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...

  • Page 106: Information For Commissioning, Maintenance And Repair

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA Air leakage rate: The air leakage rate of the air conditioner is determined at a vacuum of 400 Pa. The device corre- sponds to the tightness class L1 to EN 1886. Tightness Class L1 corresponds to a maximum air leakage rate of 0.15 l/(s*m2).

  • Page 107: 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 108: Declaration Of Conformity

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 11.3.7 Declaration of conformity 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 109: Disposal

    instruction manual ZHK 2000 / T-TWO / INOVA / ETA 12.1.2 Disposal The operator is responsible for disposal of the shipment (packing material), operation (filters, tools, spare parts etc.), and for the disposal of the air handling unit itself. The disposal of the material must be done by qualified technicians according to the international, national and local regulations.
  • Page 110 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure index Figure 1: Do not climb on the unit ....................16 Figure 2: Delivery in parts (delivery sections) ................16 Figure 3: Delivery as monobloc ..................... 17 Figure 4: Transport correct ......................18 Figure 5: Transport incorrect ......................
  • Page 111 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 53: Joint on the AHU drawing..................... 39 Figure 54: Joint at the AHU ......................39 Figure 55: Hexagon bolt with nut (stainless steel) M6x16 .............. 40 Figure 56: Connection of roof plates ..................... 40 Figure 57: Mounting of the sliding bar ...................
  • Page 112 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Figure 106: Siphon on pressure side..................... 57 Figure 107: Observe the mounting position - flow direction according to the arrow ....... 58 Figure 108: Suction side execution ....................58 Figure 109: Pressure side execution ..................... 59 Figure 110: Pressure side installation: remove the black closing plug ...........
  • Page 113 instruction manual ZHK 2000 / T-TWO / INOVA / ETA Table 10: Recommended grease types ..................85 Table 11: Lubrication intervals for motor bearings (in month) ............86 Table 12: Maximum deviation at adjustment of pulleys ..............88 Table 13: Maintenance plan ......................102 Table 14: AHU categories ......................
  • Page 114 For more information on our latest projects, visit www.oceania-group.com PO Box 429 Cannon Hill QLD 4170 Click to follow our socials info@oceaniahvac.com www.oceania-group.com...

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