Climaster ZerAx. Eco-designkrav. Climaster ZerAx type ZCN-M guide GB

Climaster ZerAx Climaster ZerAx type ZCN-M guide 924784-0 GB Eco-designkrav

Important This document is made available as it is. Novenco reserves the right to make changes without prior notice due to further development of the product. Copyright (c) 1998-2012, Novenco A/S. All rights reserved. Trademarks Novenco is a trademark of Novenco A/S. The ZerAx -trademark and the ZerAx-design are registered by Novenco A/ S. Patents are pending on the ZerAx-manufacturing processes and technologies. Patent no. PA200901117, PA200901118, PA200901119. Other trademarks mentioned in this document are the property of their respective owners. Marking Climaster ZerAx type ZCN-M is CE marked in agreement with the EU s machine directive. See appendix D. Declaration of conformity on page 63. Help Questions regarding installation, operation and maintenance of the Climaster ZerAx type ZCN-M can be directed to Novenco s hotline. Tel.: +45 5578 1400 New versions of this guide are available at www.novencogroup.com. Guide generated 5 July 2012. 2 Climaster ZerAx type ZCN-M guide / Important

Contents 1 Introduction............. 5 1.1 About this guide............ 5 1.2 Application................ 5 1.3 Unit types................. 5 2 Handling................ 7 2.1 Receipt.................... 7 2.2 Handling.................. 7 2.3 Weights................... 8 2.4 Storage.................... 8 2.5 Scope of delivery........... 9 3 Mechanical installation... 11 3.1 Setting up and assembly.... 11 3.1.1 Requirements for installation site........... 11 3.1.2 Setting up........... 12 3.1.3 Placement and assembly of sections........... 12 3.1.4 Mounting of roof..... 15 3.1.5 Baffle plate.......... 17 3.2 Water connections......... 17 3.2.1 Piping.............. 17 3.2.2 Water traps.......... 17 3.3 Fan units................. 18 3.3.1 Air quantity meter for ZerAx(R) fan........... 19 3.3.2 Air quantity meter for plug fan............ 21 3.4 Handles on doors.......... 23 3.5 Filter guard............... 23 3.6 Duct connections.......... 24 3.6.1 Dampers............ 25 3.6.2 Water heating coil.... 26 3.6.3 Cooling coil......... 28 3.7 Rotary exchanger.......... 30 3.7.1 Control and truing... 30 3.8 Mixing and recirculation damper........................ 31 4 Electrical installation..... 33 4.1 Running of cables through panels....................... 33 4.2 Fan motors................ 34 4.3 Rotary control............. 34 5 Startup................ 35 5.1 Startup procedure.......... 35 5.1.1 Fans................ 35 5.2 Unit with rotary exchanger.. 36 5.2.1 Purging sector....... 36 6 Maintenance............ 39 6.1 General inspection......... 39 6.2 Cleaning.................. 39 6.2.1 Unit casing.......... 39 6.2.2 Silencers............. 40 6.2.3 Dampers............ 40 6.2.4 Rotary exchanger..... 40 6.2.5 Cross-flow heat exchanger................... 41 6.2.6 Heating coils......... 41 6.2.7 Cooling coils......... 42 6.2.8 Fans................ 42 6.2.9 Other components.... 42 6.3 Control................... 42 6.3.1 Heating and cooling coils 43 6.3.2 Airtightness......... 43 6.3.3 Rotary exchanger..... 43 6.4 Lubrication of dampers..... 43 6.4.1 Connecting rod....... 44 6.5 Replacing parts............ 44 6.5.1 Filters............... 44 6.5.2 Belt drive (rotor)...... 45 6.5.3 Heating and cooling coils 45 7 Servicing the unit........ 47 7.1 Panels.................... 47 7.2 Doors..................... 47 7.3 Dampers.................. 48 7.3.1 Connecting rod....... 48 7.4 Rotary exchanger........... 48 7.4.1 Brush seal........... 48 7.4.2 Bearings............. 49 7.4.3 Belt drive............ 49 Climaster ZerAx type ZCN-M guide / Contents 3 MU 14528 0412

7.5 Cross-flow exchanger...... 49 7.5.1 Demounting heat exchanger............. 50 7.5.2 Heat exchanger and damper............. 50 7.5.3 Drip tray............ 51 7.6 Heating and cooling coils... 51 7.6.1 Demounting......... 52 7.6.2 Frost protection...... 52 7.7 Fans..................... 52 7.7.1 ZerAx(R) fan........ 53 7.7.2 Plug fan............ 54 A Technical specifications.. 57 B Electrotechnical connections 59 B.1 Rotor controls............. 59 C Spare parts............. 61 D Declaration of conformity. 63 E Service and warranty.... 65 E.1 Conditions................ 65 E.2 Warranty................. 65 E.3 Contact information........ 65 Index...................... 67 4 Climaster ZerAx type ZCN-M guide / Contents

1. Introduction 1.1 About this guide 1.2 Application 1.3 Unit types The Novenco Climaster ZerAx type ZCN-M unit ensures a stable and healthy indoor climate. The high efficiency and robust design mean that the unit will be a delight and a benefit for many years to come. This guide describes installation and maintenance of the unit casing and all components. It is recommended to familiarise yourself with the contents in the guide and to read relevant sections as needed. The Climaster ZerAx type ZCN-M unit is intended for comfort ventilation in institutions, schools, kindergartens, after-school centres, offices, shops, etc. It is also suitable for use in industrial facilities with specific demands for air quality and volumes. The units are made in eight sizes consisting of air handling components which are built together. All are equipped with heat recovery in the form of either a cross-flow or rotary heat exchanger. The units are prepared for connection of controls as well as of external cooling units. Cooling coils are offered as option. Climaster ZerAx type ZCN-M units are made as single- or two-string versions in the following variants. Heating and ventilation Heat recovery Air conditioning and cooling Climaster ZerAx type ZCN-M guide / 1. Introduction 5

6 Climaster ZerAx type ZCN-M guide / 1. Introduction

2. Handling 2.1 Receipt Climaster ZerAx type ZCN-M units are designed and produced in a way that make them simple and easy to handle, dismantle and put back together. This chapter describes how this is done. Upon receipt at the installation site, inspect the unit for transport damages and also check that the delivery is complete. Important: Notify the carrier immediately of damages and missing items. 2.2 Handling Climaster ZerAx type ZCN-M units are delivered assembled or in separate sections for on-site assembly. The further transport is in both cases done by truck or by crane, depending on the conditions ruling on the installation location. Important: Transporting by truck require the forks to reach all the way underneath and to lift on the base frame on both sides of the section. It is prohibited for people to be on top of the unit housing. Using the surfaces for storage is also prohibited. Assembled units can be lifted by crane in the hoisting fittings on the base frame. Figure 2.1 Lifting of assembled unit Climaster ZerAx type ZCN-M guide / 2. Handling 7

Single sections have transport feet and hoisting lugs in the top corners. Lifting by crane must, due to safety issues, be done with straps and shackles. Figure 2.2 Hoisting lug (left) and shackle mounted in hoisting lug (right) 2.3 Weights Total weights and dimensions for single sections and for the units are found in the printout from the Climaster Designer calculation program. 2.4 Storage Climaster ZerAx type ZCN-M units are delivered packaged in plastic. If they are stored outdoors they must be covered so that there is ventilation under the covering in order to avoid condensation from forming. Outdoor storage must be of a shorter duration. When storing for a longer time the plastic packaging must be removed out of regard to the formation of condensation and the units must be stored indoors in dry areas. For periods longer than 3 months the fan wheels must be turned regularly by hand. Assembled units with roofs intended for outdoor installation can be stored outside, but should be covered to avoid soiling at the installation site and at the same time allow for ventilation under the cover. 8 Climaster ZerAx type ZCN-M guide / 2. Handling

2.5 Scope of delivery A Climaster ZerAx type ZCN-M delivery also includes a number of loose parts. All parts are packaged and listed separately on the packing list. 1. Base frame 7. Screws and nuts for assembly of sections 2. Screws and plugs for handles 8. Plastic coverings for corners 3. Fittings with hooks 9. Plugs for plastic coverings 4. Fittings 10. Square key 5. Set screw with foot 11. Handles 6. Sealing strips Figure 2.3 Loose parts included in unassembled units For assembled and unassembled units Base frame (option for unassembled units) The base frame (1) with transverse base angles is supplied unassembled including bolts and fittings (3+4) for attachment of the unit to the frame. A number of set screws (5) for alignment is also included in the packing with loose parts. The base frame is packed on a pallet. Plastic coverings Each unit is supplied with plastic coverings (8) with plugs (9) for covering of the corners when the hoisting lugs are removed. Handles and square key One square key (10) is supplied. Handles (11) are supplied in the ordered number. The parts are included in the packing with loose parts together with screws and plugs (2). For unassembled units Sections and nameplate Climaster ZerAx type ZCN-M guide / 2. Handling 9

Each section is numbered 1 to x. The number is the casing number and appears from the nameplate on the casing. Figure 2.4 Nameplate showing casing number Sealing material Self-adhesive sealing strips (6) 12 x 6.4 mm for sealing of joints are enclosed in the packing with loose parts. Internal section joints The sections are provided with four internal corner plates with free hole for assembly by means of an 8x25 mm hexagon-headed screw and an 8 mm square nut (7). Sides longer than 1500 mm are also provided with a fitting mid-side. Options supplied as loose parts Water traps Wet sections such as cross-flow exchangers and cooling coils are delivered with water traps for connection to external drains. Flexible connections External connections for duct connection of in- and outlet openings are delivered with assembly rails. Roof This is a plate of AluZink. Damper for in- and outlets Assembly rails for duct connections Silencers Baffle plates for outlet Air flow meter 10 Climaster ZerAx type ZCN-M guide / 2. Handling

3. Mechanical installation The Climaster ZerAx type ZCN-M unit must be set up on a stable and solid surface. Overview of installation 1 Set up the unit. 2 Release the safety catches on the fan units. 3 Connect the drip tray to the drain (units with cross-flow exchangers). 4 Mount any handles on doors 5 Connect the ducts 3.1 Setting up and assembly Mount the closing damper (option) Connect the cooling unit to the cooling coil (option) 6 Prepare heat exchanger (rotary or cross-flow) The loose parts described in section 2.5 Scope of delivery on page 9 are used when setting up and assembling the unit. 3.1.1 Requirements for installation site In front of the unit there must be a free area along the entire length to ensure easy access in connection with inspection and service. It must be possible to open the doors in their entire width, which for inspection purposes means at least 750 mm. For service purposes it is recommended that the area is as wide as the unit so that all components can be easily pulled out. Units placed on roofs may not be used as part of the roof or construction. The roof must be complete underneath the units. All vertical and horizontal joints between the individual sections on units installed outdoors must be carefully sealed with a weather resisting joint filler, e.g. a suitable silicone. Degrease the surfaces carefully before jointing. Climaster ZerAx type ZCN-M guide / 3. Mechanical installation 11

3.1.2 Setting up When the installation site is prepared, the base frame is placed. Disassembled frames are assembled using fish joints. Joints must be supported by set screws. Figure 3.1 Assembly of base frame and fist joint with set screw The base frame is aligned by mounting and adjusting the remaining set screws in the holes in the frame. The distance between set screws or other kind of support must be less than 1300 mm. Please use the pre-drilled holes in the frame to make sure of this. Important: The base frame must be completely horizontal, as the sections otherwise will get distorted when placed. A clear sign of distorted sections are doors which cannot keep tight. 3.1.3 Placement and assembly of sections Numbers in parentheses in the following refer to figure 2.3 Loose parts included in unassembled units on page 9. Sections are assembled on the base frame in numerical order. The section numbers (casing number) are written on the nameplates on the sections. See figure 2.4 on page 10 Remove the transport feet before placing a section on the base frame, then mount and fasten the plastic coverings to the frame by means of the enclosed fittings (4) and bolts. Figure 3.2 Fastening to the frame in corners and on the sides Fasten the unit to the side of the base frame using fittings with hooks in the ends (3) and with 6.3 x 13 mm tapping screws. 12 Climaster ZerAx type ZCN-M guide / 3. Mechanical installation

Remove the hoisting lugs and fit the plastic coverings on sections mounted on the base frame or on underlying sections. Plug the holes in the plastic coverings. Figure 3.3 Removing hoisting lug and fitting plastic covering Before placement of an adjoining section, sealing strips must be fitted on the contact surfaces along the border on one of the sections. Important: Degrease the surface before fitting the sealing strip. Use an alkaline degreasing agent such as HP2000 diluted with water in the ratio 1:10. Sealing strip Figure 3.4 Fitting of sealing strip Place the next section on the base frame and push it against the previous. Sections must be placed precisely, pushed closely together and aligned with the base frame or any subsections. Mount internal corner fittings with screws and bolts. If the base frame or the sections are twisted, it must be fixed before mounting of the fittings. Figure 3.5 Mounting of corner fittings and optional mid-fitting Climaster ZerAx type ZCN-M guide / 3. Mechanical installation 13

Important: Avoid enlarging the holes in the corner fittings, but straighten the base frame or sections instead. It is vital to the unit performance that the joints are correct. Sides longer than 1500 mm have an internal joints on the middle as well. Access to internal unit parts is achieved through the inspection doors or by removing a side panel. See section 7.1 Panels on page 47. Functions that are in the way can be pulled out. Screws are mounted in fittings and tightened crosswise with a 6 mm hexagonal spanner until there is a 1 mm gap between the sections. Figure 3.6 Gap between sections Mount the remaining fittings evenly along the sides with 6.3 x 13 mm selftapping screws. See figure 3.2 Fastening to the frame in corners and on the sides on page 12. Top sections in units with two air flows are mounted the same way as the bottom sections. It is important that both top and bottom sections are aligned with each other. Holes are drilled in the doorways with a 5.5 mm bit through the frame profiles. The sections are screwed together with 6.3 x 13 mm selftapping screws. Two screws are mounted in the profiles of the doorway to the fan. Figure 3.7 Drilling of holes in door openings 14 Climaster ZerAx type ZCN-M guide / 3. Mechanical installation

3.1.4 Mounting of roof Mounting of roof 1 Attach sealing strip to unit. 2 Insert pop rivets in the cover profiles and place these over the ends on the unit. Position the cover profiles by lowering the pop rivets down between the frame and the panels, and push each profile towards the end. Use the holes closest to the end, if the number of sections is uneven. Use the holes furthest away from the end, if the number of sections is even. 3 Drill holes through the cover profiles in the unit. Fasten the cover profiles with screws. Climaster ZerAx type ZCN-M guide / 3. Mechanical installation 15

4 Put a u-profile lengthwise of the unit and mount the roofing sheets at the cover profiles. Place the upward bent edges on the roofing sheets under the cover profiles and lay the sheets down on the unit. The u-profile give an incline on the roofing sheets. 5 Attach sealing strips to the remaining roofing sheets and place them on the unit. 6 Rivet the roofing sheets together and fasten them to the cover profiles in one end of the unit. 7 Drill holes through the roofing sheets in the unit. Fasten the roofing sheets with screws and nylon washers. 16 Climaster ZerAx type ZCN-M guide / 3. Mechanical installation

8 Fasten the cover profiles and roofing sheets finally in the opposite end of the unit. 9 Mount u-cleats on the roof joints and insert plastic plugs in the ends. 3.1.5 Baffle plate 3.2 Water connections 3.2.1 Piping 3.2.2 Water traps Mount baffle plate on outlet flange for fans with free outlet, i.e. which are not connected to ducts. Use U-cleats for mounting of baffle plate. Mount corner coverings on the U-cleats. U-cleats and corner coverings are included. Connection to external pipe systems is done by an authorised plumber. The pipe layout must leave the operation of the unit unobstructed. It must be possible to open doors and perform inspections. Lead-in of pipes through panels must be provided with seals on the inside panels. The seals are, however, mounted in the panels from the outside. Drains from wet sections, i.e. cooling coils, cross-flow exchangers and certain filters, must be fitted with water traps. Plastic water traps are available as accessories. The traps are intended for negative pressure and equipped with balls to keep them tight without being water filled. The traps are f.x. connected to drains from the drip trays in Climaster ZerAx type ZCN-M guide / 3. Mechanical installation 17

cross-flow sections. All drains from drip trays are without thread and Ø32 mm on the outside. 9 8 7 6 5 4 3 88 Max. 157 2 1 30-70 mm 1. Set screw with foot 6. Pipe Ø32 mm 2. Base frame 7. Water trap 3. Drip tray 8. Ball 4. Drain connection, Ø32 mm without thread 9. Drain connection, Ø32 mm 5. Angle Figure 3.8 Water trap fitted on drain To work, the height of the water in the water trap (H-measurement) must be higher than the pressure height in the unit ( p inside/ outside in the unit at the water trap). The pressure equals the sum of the pressure loss in the extract duct and the filter pressure loss. If p = 550 Pa, then the H-measurement must be at least 55 mm plus the increased pressure loss for fouling of the filters including 10 mm for safety. The minimum is 300 Pa equalling 30 mm. The gives an H-measurement of 85 mm. Example Calculation of H-measurement To achieve sufficient height the unit must be put on set screws. It is recommended to make the H-measurement as large as possible. Pipe (6) can f.x. be shortened, if the water trap is too high. The drain pipe (9) from the water trap is lead to the drain with a gradient of min. 3. The drain pipe must end open over the drain. A water trap must be mounted for each drip tray. More drip trays can be fitted over the same drain (9). The gradient of all drain pipes must be 3. The max. negative pressure for a water trap at a unit with adjustable feet is 1200 Pa. 3.3 Fan units The fan units are each fitted with locking rods marked with yellow flex. These must be removed when the air handling unit is in place. The locking 18 Climaster ZerAx type ZCN-M guide / 3. Mechanical installation

rods ensure that the flexible rubber suspension remain undamaged during transport. Figure 3.9 Plug fan with transport protection 3.3.1 Air quantity meter for ZerAx(R) fan The air quantity meter is optional, and consists of a measuring probe mounted in the fan inlet and a manometer mounted outside on the fan section door together with two measuring outlets. One outlet is connected to the probe, the other to the inner fan section. Calibration of manometer 1 Make sure all manometric liquid in the U-shaped short-circuit hose (3) has run down into the measuring vessel (2). 2 Cut the tube as shown below. Figure 3.10 Air quantity meter for ZerAx fan Figure 3.11 Climaster ZerAx type ZCN-M guide / 3. Mechanical installation 19

3 Loosen the screws (5 and 6) and calibrate the meter carefully by turning the measuring vessel (2) in the base plate (1) until the indicator (4) points at 0 on the fixed pressure scale (A). Figure 3.12 4 Tighten the screws (5 and 6). Calibration of the 0-position should be done approx. at the temperature at which the meter is to be used. To avoid manometric liquid is blown out of the measuring vessel (2) the length of the middle wick (7) is dimensioned to allow air to pass through if the pressure exceeds the pressure range of the meter. 5 Fit the included blue reduction nipples (10) in the tubes. This prevents a too fast air flow. Figure 3.13 6 Fit the tubes on the measuring taps. The tube from the measuring probe is fitted on (+) and the tube from the fan section on (-) on the manometer. Setting of the air quantity scale The measuring probe is calibrated and the air quantity is calculated with the formula. q = 1 k -- p t 20 Climaster ZerAx type ZCN-M guide / 3. Mechanical installation

Calibration values Fan type AZN Constant, k p t [Pa] q [m 3 /s] 500 / 350 5.21 400 3.84 560 / 350 3.94 400 5.07 630 / 350 3.01 400 6.65 710 / 350 2.31 400 8.66 800 / 350 1.78 400 11.21 900 / 350 1.39 400 14.41 1000 / 350 1.11 400 18.0 Table 3.1 Calibration values 3.3.2 Air quantity meter for plug fan The calibration values p t and q are found in the table and the manometer is set as described below. 1 Turn the air quantity scale (A) with a sharp object figure 3.13 through the slot in the top right-hand corner of the manometer until the air quantity q on the blue scale is opposite the pressure p t on the fixed scale. 2 Read the air quantity in m 3 /s on the blue scale. Given: Climaster ZCN 18/8 with fan type AZN 560/350, where p t = 400 Pa, q = 5.07 m 3 /s Turn the blue scale (A) until q = 5.07 m 3 /s is opposite pt = 400 Pa. The setting of the manometer is now done. Turn the green marking indicating ±15% air quantity until 5.07 m 3 /s is in the middle of the area. Example Setting of air quantity scale Important: The air quantity meter is unsuited for fitting on outdoor air handling units. The meter is optional, and consists of a measuring probe mounted in the fan inlet and a manometer mounted outside on the unit together with two measuring outlets. One outlet is connected to the probe, the other to the inner fan Climaster ZerAx type ZCN-M guide / 3. Mechanical installation 21

section (suction chamber). Two pressure tubes connect the measuring outlets to the manometer. 1 - + - + 4 5 2 3 Fitting of air quantity meter 1 Cut the pressure tube at the top of the manometer. 2 Push the end pieces onto the (-) and (+) nipples (1), respectively. Calibration of manometer 1 Turn off the air handling unit. 2 Displace the measuring pipe (2) until the 0-point on the printed scale (3) is aligned with the lower part of the ball in the pipe. Setting of the air quantity scale Figure 3.14 Air quantity meter for plug fan 1 Turn on the air handling unit and set it to run at a pressure that can be read clearly on the printed pressure scale, f.x. 1000 Pa. 2 Loosen the centre screw (5) and turn the scale (4) until air quantity and differential pressure match each other. The air quantity is calculated with the following formula. q = 1 -- p k t Unit Fan size CCL Constant, k q [m 3 /s] 9/6 280 315 48.08 37.88 0.66 0.83 13/8 400 500 23.38 14.29 1.35 2.21 18/8 500 560 14.29 11.68 2.21 2.71 18/10 560 710 11.68 7.35 2.71 4.30 21/10 630 710 9.45 7.35 3.35 4.30 Table 3.2 Calibration values for air quantity at 1000 Pa 22 Climaster ZerAx type ZCN-M guide / 3. Mechanical installation

Unit Fan size CCL Constant, k q [m 3 /s] 21/12 710 800 7.35 5.81 4.30 5.44 21/15 800 900 5.81 4.56 5.44 6.93 21/18 900 1000 4.56 2.92 6.93 10.83 Table 3.2 Calibration values for air quantity at 1000 Pa (Continued) 3.4 Handles on doors 3 Turn the transparent plastic disk until the middle of the green field corresponds with the set pressure and air quantity ratio. 4 Tighten the centre screw carefully. The handles can be included as loose parts to avoid transport damages and are enclosed in the packing with loose parts. A set of handles consists of 1 handle with lock and key and 1 handle without lock. The lockable handle is mounted at a convenient height. Mind handles when opening unit doors. Figure 3.15 Handle with and without lock Important: If the fan is unprotected, it must only be possible to open the doors with the square key. Handles must not be mounted on potentially unsafe sections. Such sections are opened with the square key. 3.5 Filter guard The filter guard is optional and is a manometer of the u-pipe type. If included, it is mounted on the door to the filter section. Inside the unit, tubes are lead from two measuring points, one on each side of the filter, to the connec- Climaster ZerAx type ZCN-M guide / 3. Mechanical installation 23

tions on the door. Fill the manometer with the included fluid and connect the tubes, before starting up. 3.6 Duct connections Figure 3.16 U-pipe manometer The connection dimensions for ducts and dampers are shown below. Dimension [mm] Unit Rectangular 1 9/6 300(200)x600 13/8 500(300)x1000 18/8 500(300)x1500 18/10 700(400)x1500 21/10 700(400)x1800 21/12 900(500)x1800 21/15 1200(700)x1800 21/18 1500(900)x1800 Round Ø500 Ø560 Ø500 Ø560 Ø500 Ø560 Ø630 Ø710 Ø560 Ø630 Ø710 Ø560 Ø630 Ø710 Ø710 Ø800 Ø710 Ø800 Ø900 Ø1000 Table 3.3 Connection dimensions for ducts and dampers 1. Numbers in parentheses are for slim inlets used with the SB-mixing functions. Round ducts are fastened to the duct connections with clips. 24 Climaster ZerAx type ZCN-M guide / 3. Mechanical installation

Connect rectangular ducts to the in- and outlet openings on the air handling unit with LS-cleats. 35 150 Unit Flexible connection Figure 3.17 Connection with LS-cleat Usually flexible connections are unnecessary for duct connections, as vibration dampers and flexible connections are built-in between the fan and unit casing. External flexible connections are, however, available as options. Duct 3.6.1 Dampers Dampers have aluminium blades mounted with synthetic bearings in frames. The damper movement occurs by means of a coupling plate with slots for regulation rods. Rust proof pins are fitted on each damper shaft. Retaining ring Shaft Guide bearing Coupling plate Figure 3.18 Assembly of coupling plate on damper Internal and external dampers are mounted on the unit with LS-cleats. Climaster ZerAx type ZCN-M guide / 3. Mechanical installation 25

Dampers on the unit are intended for mounting of damper motors. One damper shaft on each damper is provided with a shaft extension Ø15 x 80 mm for direct mounting of a damper motor. Pointed screw Shaft extension Figure 3.19 Extending the damper shaft Guide pin After electric connection of the damper motor, adjust the movement of the damper motor and damper blades to each other as shown in the installation instructions for the damper motor. Important: Important: Outdoors installation require protection of the damper motors from water and freezing temperatures. If no duct is fitted on the pressure side of the fan, a protective guard net must be installed. 3.6.2 Water heating coil The built-in heating coil is an integrated part of the air handling unit. Water is connected to the connection pieces from the coil leading out through the side of the unit. Deliveries of units fitted with controls include a modulating 3-way 0-10 V motor valve for controlling the water flow. The centre valve is blinded on units using district heating water. The valve is mounted on or just after the output connection piece from the heating coil. Important: Outdoor installation require protection of the motor valve from water and freezing temperatures. The heating coil is comprised of copper pipes with aluminium fins mounted in a steel plate frame. Flow and return flow occur through collecting pipes with connectors lead out through the side panel. 26 Climaster ZerAx type ZCN-M guide / 3. Mechanical installation

The collector pipe is fitted with a branch for air cock and a branch for drainage. Return flow Flow Figure 3.20 Connectors from heating coil Connection to the pipe system must be done by an authorised plumber. Remember to hold counter on the collector pipe when the heating coil is connected to the pipe system. Screw threads must be packed after the customary plumbing and heating rules. Figure 3.21 Counter hold of collector pipe The flow pipe should always be connected to the lowermost branch piece on the heating coil. Unit Heating coil 9/6-2 pipes / 4 pipes 3/4 / 1 13/8-2 pipes / 4 pipes 1 / 2 18/8-2 pipes / 4 pipes 1 1/4 / 2 18/10-2 pipes / 4 pipes 1 1/4 / 2 21/10-2 pipes / 4 pipes 1 ½ / 2 21/12-2 pipes / 4 pipes 2 / 3 21/15-2 pipes / 4 pipes 2½ / 4 21/18-2 pipes / 4 pipes 2½ / 4 Table 3.4 Pipe connection dimensions The layout of the water circuit depends on whether boiler water or district heating water is used as heating medium. See the principle diagrams below. Climaster ZerAx type ZCN-M guide / 3. Mechanical installation 27

Please note that systems using district heating water are constructed without shunt arrangements. VM Max. 5 m VM Max. 5 m Return AB A Return AB A B V T T V T T Min. 60 kpa diff. pressure Extra pump activated by low diff. pressure VO Min. 60 kpa diff. pressure Extra pump activated by low diff. pressure Mount closed coupling V F V T V F V T Supply Supply Boiler feed water District heating water Figure 3.22 Water circuits for heating coils 3.6.3 Cooling coil F = Filter (not included) VO = Stop valve V = Shut-off valve T = Thermometer VM = Motorised valve The heating coil must be protected against frost burst via the built-in controls, which at the risk of frost opens the valve for water flow, stops the ventilation and closes the damper for outdoor air. A frost sensor must be mounted on the return flow pipe from the heating coil. The cooling coil is built-in the air handling unit and constructed the same way as a heating coil. Cooling fluid is connected to the connection pieces from the coil lead out through the side of the air handling unit. Important: Outdoors installation require protection of the motor valve from water and freezing temperatures. Return flow Flow Figure 3.23 Cooling coil 28 Climaster ZerAx type ZCN-M guide / 3. Mechanical installation

The circuit for circulation of the cooling fluid is constructed as shown below. VM Max. 5 m Return AB A V T T B Min. 60 kpa diff. pressure Extra pump activated by low diff. pressure VO V F V FS T Supply F = Filter (cooling unit) VM = Motorised valve FS = Flow switch VO = Stop valve V = Shut-off valve T = Thermometer Figure 3.24 Circuit for circulation of cooling fluid Unit Cooling coil 9/6-4 pipes / 6 pipes / 8 pipes 2 x 1 / 2 x 2 / 2 x 1½ 13/8-4 pipes / 6 pipes / 8 pipes 2 x 1½ / 2 x 2 / 2 x 2½ 18/8-4 pipes / 6 pipes / 8 pipes 2 x 1 1/4 / 2 x 2½ / 2 x 2½ 18/10-4 pipes / 6 pipes / 8 pipes 2 x 2 / 2 x 2½ / 2 x 3 21/10-4 pipes / 6 pipes / 8 pipes 2 x 2½ / 2 x 3 / 2 x 3 21/12-4 pipes / 6 pipes / 8 pipes 2 x 2½ / 2 x 2½ / 2 x 3 21/15-4 pipes / 6 pipes / 8 pipes 2 x 3 / 2 x 4 / 2 x 4 21/18-4 pipes / 6 pipes / 8 pipes 2 x 3 / 2 x 4 / 2 x 4 Table 3.5 Pipe connection dimensions The piping must be done by an authorised plumber. Hold counter on the collector pipes when connecting the cooling coil to the pipe system. The cooling coil must be protected against frost burst via the built-in controls which opens the water flow valve at the risk of frost, stops the ventilation and closes the outdoor air damper. A sensor must be mounted on the return water pipe from the cooling coil. Climaster ZerAx type ZCN-M guide / 3. Mechanical installation 29

3.7 Rotary exchanger 3.7.1 Control and truing Figure 3.25 Rotary heat exchanger Transport, handling and setup of the unit can mean that the rotor needs truing in the rotor section, before the first startup. Check that the gap between the rotor and housing is approx. 18 mm and of equal width along the entire rotor circumference. The brush seal forms the seal between the airflows. The rotor is fastened in the housing with screws through an adjustment disc (eccentric), a slot in the frame and a disc in the shaft end. This provides means for adjusting the rotor position in the housing. The units ZCN 9/6 and 13/8 have eccentric in the side without separation, i.e. at the purging sector. The units ZCN 18/8 and 21/12 have eccentric in both sides. The gap is adjusted by removing the cover over the adjustment screw and loosening the centre screw in the shaft end. Adjust the rotor with the adjustment disc until the gap between rotor and housing is the same along the rotor circumference. Figure 3.26 Removing cover and adjusting gap For ZCN 9/6-18/10 the wrench opening is 32 mm for the adjusting disc. 30 Climaster ZerAx type ZCN-M guide / 3. Mechanical installation

For ZCN 21/10 and 21/12 the wrench opening is 41 mm for the adjusting disc. For ZCN 21/15 and 21/18, please see the enclosed documentation. After adjustment, tighten the centre screw and mount the cover over the adjusting disc. 3.8 Mixing and recirculation damper The mixing damper can be fitted with a damper motor, which for a unit in separate parts is best done before assembly. Figure 3.27 Mixing damper in BA function in separate unit Climaster ZerAx type ZCN-M guide / 3. Mechanical installation 31

32 Climaster ZerAx type ZCN-M guide / 3. Mechanical installation

4. Electrical installation This chapter describes the electrical installation of the Climaster ZerAx type ZCN-M. Important: The electrical installation must be carried out by an authorised electrician to ensure protection against electrical shock. CE documentation must be drawn up by the responsible electrician according to EN 60204-1. Connection order 1 Run up cables to the unit. This means cables for control of heat exchanger, motors, signal cables for sensors and other equipment installed afterwards in the unit. See appendix B.1 Rotor controls on page 59. 2 Cut holes for running through of cables in the unit housing. 3 Run the cables in the unit housing and connect them. Fan motors Rotary control (units with rotary exchanger) 4 Close the unit. Connection of single components are described in the following. Please note that connection of the supply voltage is done during startup of the unit. See chapter 5. Startup on page 35. 4.1 Running of cables through panels The openings, which cables are run through in the panels of the unit housing, must be airtight and without sharp edges. Cables must not be run through the inspection doors. Cut holes for cables with a locksaw and fit the cable inlets. Inside Outside Holes in panels [mm] External cable diameter [mm] 19 7-10 23 10-14 29 14-20 38 20-26 48 26-35 Figure 4.1 Cable inlet and hole sizes in panels The airtight cable inlet is on the inside of the panel. A gasket is fitted in the outside panel to protect the cable from the sharp plate edge. Climaster ZerAx type ZCN-M guide / 4. Electrical installation 33

4.2 Fan motors 4.3 Rotary control Connect the motors in accordance with current regulations in the terminal boxes on the motors. Connection diagrams are found in the box lids. Important: Install a lockable service switch on the outside of the air handling unit. Use rubber cables of approved type and in accordance with current regulations to connect the motors. Important: Do not run cables through inspection doors. The length of the cable must allow for the fan unit to be pulled out completely for service. A length of 1.5 x width of air handling unit is recommended. Secure the cable after installation to prevent it from touching the fans. Additional information on connection and service of the fan motors is available in the installation and maintenance guides included with the motors. In a unit with rotary changer the connection in the control box is done with reference to the connection diagram in appendix B.1 Rotor controls on page 59. 34 Climaster ZerAx type ZCN-M guide / 4. Electrical installation

5. Startup 5.1 Startup procedure 5.1.1 Fans The Climaster ZerAx type ZCN-M unit must be started up according to the set procedure to ensure this is done properly. At startup it is important that the fans are started first, i.e. before the heating coil and any cooling system. There must be air circulation to prevent damages to the heating coil or cooling system. If the unit fitted with a rotary exchanger, the purging sector must be adjusted at the first startup after the installation. In the following is described how the fans are started up and how the purging sector is adjusted in a unit with rotary exchanger. Note that the supply voltage is connected and turned on last. Startup of unit 1 Check that the unit is set up correctly. 2 Mount and connect the external connections, including the heating coil, cooling system and air duct system. Important: The air duct system must be mounted and connected to the unit, before starting the fans. Connection of supply voltage and startup of any heating coils follows afterwards. 3 Check that external components and sensors are mounted and connected correctly. 4 Start up the fans as described below. Startup of fans 1 Remove the transport protection. These are marked with yellow flex. Figure 5.1 Transport protection of plug fan 2 Check that the fan wheels turn freely without touching the housing. Climaster ZerAx type ZCN-M guide / 5. Startup 35

3 Check that all foreign bodies (paper, tools and similar) are removed from the air passages. 4 Check that the motors are fastened. 5 Check that air ducts are mounted on the pressure sides of the fans. A fan with direct access, i.e. without connection of an air duct, must be fitted with a wire guard. 6 Check that a earthing connection for the electrostatic potential in the motor is mounted. 7 Connect the supply voltage. 5.2 Unit with rotary exchanger 5.2.1 Purging sector 8 Start the fans briefly and long enough to verify the direction of rotation is as indicated by the arrows on the fan casings. 9 Turn off the fans and reconnect the supply voltage dependent on the direction of rotation from the brief start. 10 Check that no dampers close for the air. 11 Turn on the fans. Note: Units with controls can take several minutes to start up. 12 Check that the fan vibration level is normal. The level should not exceed 7 mm/s, measured in 2 points with 90 offset outside on the fan casing (ZerAx fans) or inlet cone (plug fans) and the free end of the motor. If the vibration level exceeds 11 mm/s, the fan must be balanced. Important: Be extraordinary cautious when checking vibrations, as this is only possible with the fan section door open and thereby direct access to rotating parts. 13 Check the vibration level again after 30 minutes of operation. 14 Close the air handling unit. Important: Always keep the doors to the unit closed for safety reasons. The unit is then in operation. After a power failure, the unit is started as normal. After the unit is started for the first time, the purging sector must be adjusted. Leakages between the outdoor and exhaust airflows cannot be completely removed. But by making sure that p11 < p22 and p12 < p21, transfer of polluted exhaust air to the outdoor air through leakages is minimised. A certain volume of polluted exhaust air is transferred through the rotation of the heat exchanger where the exchanger passes from the exhaust airflow 36 Climaster ZerAx type ZCN-M guide / 5. Startup

to the outdoor airflow. To counter this a purging sector is fitted on the exchanger. Measuring tap - p12 Measuring tap - p22 q12 - p12 q21 - p21 Exhaust air q11 - p11 Outdoor air q22 - p22 Pos. 6 Pos. 5 Pos. 4 Pos. 3 Pos. 2 Pos. 1 Pos. 0 Figure 5.2 Purging sector The purging sector is adjustable in 7 positions, denoted pos. 0 to 6. At delivery the sector is set in pos. 0. In heat exchangers where the outdoor airflow is located at the bottom, the rotor must rotate downwards, when viewed from the access side. Adjust the sector upwards, until pos. 6 is the upper hole. The opposite is the case for heat exchangers, where the outdoor airflow is located at the top. Here the rotor must rotate upwards, when viewed from the access side. Adjust the sector downwards until pos. 6 is the bottom hole. Sizes 9/6 13/8 have nine holes of which the two holes on the other side of pos. 0 are not used. The purging sector must be adjusted according to the pressure conditions p22-p12 in accordance with the below table. Sector setting Differential pressure [Pa] Position 6 0 < p 22 - p 12 < 185 1 Position 5 185 < p 22 - p 12 < 240 Position 4 240 < p 22 - p 12 < 335 Position 3 335 < p 22 - p 12 < 535 Position 2 535 < p 22 - p 12 < 1300 Position 1 1300 < p 22 - p 12 Position 0 p 22 - p 12 < 0 2 Table 5.1 Pressure conditions in purging sector 1. Incomplete purging at p 22 - p 12 < 150 Pa 2. No purging at p 22 - p 12 < 0 Pa Climaster ZerAx type ZCN-M guide / 5. Startup 37

38 Climaster ZerAx type ZCN-M guide / 5. Startup

6. Maintenance 6.1 General inspection In order for the Climaster ZerAx type ZCN-M unit to function as intended and to deliver the requested performance it is important that it is regularly serviced. Described in this chapter is how and when the recommended maintenance should be carried out, which components should be checked, how parts are replaced, etc. Turn off the voltage for the unit by setting the maintenance switch in position 0. Lock the switch and wait for the unit to stop. Important: The unit must be stopped completely, before any doors are opened. The fans take a minimum of 2 minutes to run down. Depending on the chosen configuration, the doors are opened using a square key or with the keys for the door handles. Twice a year fans, anti-vibration mountings and sealing tightness must be checked. Also check for abnormal sounds and vibrations. Vibrations can be caused by dust accumulations on the fan wheels and should disappear after cleaning. Otherwise the bearings and wheel balance must be checked. The air inlet must be kept free from foreign bodies such as paper, leafs, etc. See also description in connection with each component. Activities General inspection Light internal cleaning Filter control Check of other functions Thorough check and cleaning of the entire unit Intervals Once every 6 months First time after 1 month, then every 3rd month First time after 1 month, then every 3rd month Every 3rd month Once a year Table 6.1 Recommended intervals for cleaning 6.2 Cleaning Regular maintenance ensures that the unit works and performs according to specifications. Maintenance of the individual components is described below. 6.2.1 Unit casing The unit casing consists of a frame fitted with panels. The frame is assembled by means of insertion joints and has soft rounded edges. Climaster ZerAx type ZCN-M guide / 6. Maintenance 39

The internal surfaces are smooth and must be kept clean from dust and dirt, especially in front of the filters. Cleaning is done by vacuuming and in a way which prevents dust from being blown into the serviced areas. 6.2.2 Silencers The silencer baffles are housed in the unit casing and mounted in rails at the top and bottom. The baffles consist of 200 mm mineral wool coated with black glass splinter on both sides and mounted in a sheet casing. Cleaning is done by vacuuming. If it is impossible to reach between the baffle slots, remove the side panels and take the baffles out for cleaning. See section 7.1 Panels on page 47. The baffles are placed on angle profiles in the bottom of the section. They are not fastened and can be pulled out once the side panel is removed. Important: Avoid damaging the surface of the baffles during service. Especially when cleaning. The distance between the baffles is ensured by the distance fittings mounted in each corner. In the ZCN 13/8 the rearmost baffle is 100 mm thick and without distance fittings. This baffle must, due to sound technical causes, be placed at the back, i.e. opposite the inspection side, when assembling the silencer. 6.2.3 Dampers 6.2.4 Rotary exchanger The dampers are maintenance-free, but should be inspected and kept clean of accumulations of dirt and dust. This applies both to air passages, as well as the regulating mechanisms. Trouble free regulation is secured by keeping the regulator lubricated, for example with graphite grease, where metal parts slide against each other. For air streams with degreasing effect this is particular important. The rotary heat exchanger is placed in the middle of the unit and consist of a rotor, step motor and drive belt. Control of the rotor depends on the installed solution. Access must only occur after the unit is fully stopped. Open the unit in the operation side to access. Important: The unit must be stopped completely, before the doors are opened. 40 Climaster ZerAx type ZCN-M guide / 6. Maintenance

The controls and step motor can sit together with the rotor. The step motor is maintenance-free. Figure 6.1 Position of controls (left) and step motor 6.2.5 Cross-flow heat exchanger 6.2.6 Heating coils Even though the unit is fitted with filters, dust still settles on the rotor. Clean the rotor at regular intervals to keep system performance. Access the rotor by opening the inspection doors in the filter sections and pulling the filters out, or, if the unit is fitted with inspection room type DA, by opening the doors in these. Clean the rotor by vacuuming it using a mouth piece with a soft brush, or by using pressurised air. If air is used, the blowing must be done from the clean towards the dirty side. Vacuum and wipe off the unit casing when done. Even though the unit is fitted with filters, dust still settles on the dampers and heat exchanger block. The dirt is concentrated on the first 50 mm of the block. For normal ventilation it is sufficient to brush the inlets and outlets once a year. Complete cleaning can be done with pressurised air or by washing down with water. Air handling units installed in more demanding environments, such as industrial units, should be cleaned more often. Washdown with water can be done using high-pressure flushing or soapy water. It is recommended to use a 90 nozzle tube with flat flushing nozzle and a max. flushing pressure of 100 bar. The exchanger block must be pulled out for cleaning with water. The block can weigh considerably and require suitable support. Important: Avoid flushing the plate directly with high-pressure water. Check and clean the water trap and drain when cleaning the exchanger block. Keep the heating coils free from dust and foreign bodies to ensure hygienic conditions and performance. Dry dust can normally be removed with pressurised air (toward the air direction) or with a suitable industrial vacuum cleaner. Dust on the fins on the Climaster ZerAx type ZCN-M guide / 6. Maintenance 41

6.2.7 Cooling coils 6.2.8 Fans 6.2.9 Other components 6.3 Control supply air side can be removed with a soft brush or a duster. Sweep the fins lengthwise and not across. Important: Cleaning the fins must be done with caution as these are vulnerable to impacts. Damp or greasy dirt must be removed with hot water or a steam jet (against the airflow direction). Hold the jet at an angle not exceeding 15 from vertical position. Otherwise the fin edges may bent. Other components in the pipe system and the system in general should be maintained and cleaned according to directions. Cleaning intervals depend on the degree of dust in the air. Cooling coils are mounted with drip trays with drain for condensate extended out through the access side. Clean the coils by flushing with water. The drip tray as well as the drain must be kept clean to avoid formation of algae. In units with high air speeds an eliminator mat for catching droplets is mounted after the cooling coil. The eliminator mat can be pulled out for cleaning. Remove all dust and water in the bottom of the unit casing immediately after cleaning, preferably with a dust-water vacuum cleaner. Turn off the power supply for the unit by setting the maintenance switch in position 0. Lock the switch and wait for the unit to stop. Important: The unit must be stopped completely, before opening any doors. The fans take a minimum of two minutes to stop. Check the operation of the fan twice a year, for example if there are abnormal sounds or vibrations. Vibrations during operation, may be caused by dirt and dust on the impeller, bearings or fan wheel. Cleaning is best done with a cloth and soapy water. If vibrations remain after cleaning, expert assistance should be called for immediately. Operation with vibrations present shortens the life of fans and motors. Components in the pipe system for regulation and ventilation as well as other components with importance for the operation of heating and cooling coils, must be maintained according to the service instructions. The function must be checked at regular intervals. To ensure the performance is in accordance with the system specifications, it is recommended to test this at least twice a year. Check it more often, if the system is installed in an environment affecting the operation to a larger degree. 42 Climaster ZerAx type ZCN-M guide / 6. Maintenance

6.3.1 Heating and cooling coils 6.3.2 Airtightness Both the function of the system as a whole and of the individual components must be checked. Depending upon the operation pattern, inspect the coils now and then for dirt and dust. The inspection is best done by shining with a flashlight between the fins. Also check if impurities have resulted in a smaller air volume and performance compared to control measurements made when the unit was new. To ensure airtightness of the unit, the doors are fitted with rubber sealing strips (1), which are fixed in grooves on the circumference of the doors. The sealing strips must be intact and checked upon service and when cleaning. 1 2 Figure 6.2 Rubber sealing strips on door 6.3.3 Rotary exchanger 6.4 Lubrication of dampers The locking units in the doors are fitted with roller tongues (2). Important: Close and lock the doors after service to maintain performance and safety. If panels or doors are fitted with for example temperature sensors, washers must be mounted on the inner panel plates. Holes in outer plates on the panels have no effect on the tightness of the unit, but should be sealed on units installed outside. When de- and re-mounting panels, the sealing must be airtight. Usually it is necessary to replace the adhesive sealing strip (9 x 4.5 mm). Besides lists and doors, the tightness of pipe and cable inlets as well as duct connections, including flexible connections, must be regularly checked. At fitting intervals during operation, check that the brush seal fit tightly against the rotor surface. See section 3.7.1 Control and truing on page 30. Problem-free regulation is ensured by keeping the regulating mechanisms lubricated, for example with graphite grease, where metal parts slide against each other. Climaster ZerAx type ZCN-M guide / 6. Maintenance 43

6.4.1 Connecting rod 6.5 Replacing parts 6.5.1 Filters In units with cross-flow exchangers the above also applies to the damper on the exchanger block. Metal connecting rods (ball joints) between two dampers or for damper motor must be kept clean and well greased. Replace parts in the unit as needed, i.e. when the prescribed tolerances are exceeded or when the performance drops to an unacceptable level. The unit is fitted with one or more filters. The filters are type marked, sit in holders and are fixed with locking rails. The rails press the filter frame against the rubber seal. Release the rails by pulling out the knob. Figure 6.3 Replacement of pocket filter Filters are single-use filters that must be replaced when the recommended end pressure loss p is reached. The service life of the filters depends on the operation load and the dust concentration in the air. Check the pressure loss at regular intervals and avoid exceeding the recommended end pressure losses, as it reduces the air volume and lowers the system efficiency. Please note that large dust concentrations in the filters may create unhygienic conditions. Description Type Pressure [Pa] F5 Pocket filter 200 F7 Pocket / compact filter 200 F8 / F9 Pocket / compact filter 300 Table 6.2 Recommended end pressure losses for filters The recommended end pressure loss can, however, be lower than specified as the air volume may not vary more than ±10%. The filter frames are marked with information plates telling the filter type and order number. See appendix C. Spare parts on page 61. 44 Climaster ZerAx type ZCN-M guide / 6. Maintenance

6.5.2 Belt drive (rotor) 6.5.3 Heating and cooling coils The rotor is fitted with one spare belt. If the belt driving the rotor breaks, use the spare. Mount it by loosening and tipping the step motor out, after which the belt can be mounted. The rotor should, at the first given opportunity, be fitted with a new spare belt. This should be carried out by a service professional, as the belt is welded together. The elasticity of the belt constitutes the belt tightening. Frost burst of the coils can occur if these are not in operation or insufficiently frost protected, e.g. with a glycol mixture. When there is a risk of ice up, the coils must be emptied completely. This is done by blowing pressurised air through the pipes. In case of repairs, it is important to avoid welding or soldering on the coils as long as there is pressure in the system and the pipes are filled with fluid. Disconnect the coils from the system and drain them for fluid before working on them. Climaster ZerAx type ZCN-M guide / 6. Maintenance 45

46 Climaster ZerAx type ZCN-M guide / 6. Maintenance

7. Servicing the unit 7.1 Panels Apart from regular maintenance, as described on page 39, during service it may be necessary to make repairs. This chapter describes how the components in the Climaster ZerAx type ZCN-M are handled in this connection. The panels are 50 mm thick, double-layered and with mineral wool between. The side panels are screwed onto the frame structure with self-tapping 6.3 x 13 mm screws and a socket spanner width of 10 mm. The outside diameter of the spanner may be max. Ø14 mm to be able to go through the holes in the outer panel sheets. The holes are covered by black plastic plugs. Figure 7.1 Demounting of panel The end, top and bottom panels are fastened to the frame from the inside with self-tapping screws. The panels are fitted with adhesive sealing strips (9 x 4.5 mm). 7.2 Doors The access side is fitted with tight-fitting doors constructed as the panels. The doors have mechanically attached rubber sealing strips. The hinges are adjustable. Loosening the screws with inside hexagon heads in the rear edge of the door, allows for adjustment of the doors both horizontally and vertically. Remember to tighten the screws when done. Figure 7.2 Adjusting door position Climaster ZerAx type ZCN-M guide / 7. Servicing the unit 47

The doors are fitted with tongue locks and opened with handles or with the included 8 mm square key. The doors can be opened 180 to ensure easy access for inspection and service. The doors are demounted by removing the staples from the hinges. Figure 7.3 Demounting of staples from hinges 7.3 Dampers 7.3.1 Connecting rod 7.4 Rotary exchanger When performing service requiring demounting of the connecting rod, the damper movement must be reset carefully. Too early damper impact, when this closes, can overload the damper motor and damage the damper. The rotary exchanger consists of a rotor and a drive system. The ball bearings are internal and fastened to the casing with a screw through an adjusting disc (eccentric), a slot in the frame and a disc in the end of the shaft end. Figure 7.4 Screw and disc for fastening of rotor 7.4.1 Brush seal In ZCN 9/6 and 13/8 brush seals are mounted on the rotor side opposite the purging sector. The seals are fitted along the rotor circumference and on the frame. The top and bottom air flows are thereby separated length- and crosswise. In ZCN 18/8 to 21/12 all brush seals are mounted on the frame. However, there is no brush seal at the discharge side of the fresh air. 48 Climaster ZerAx type ZCN-M guide / 7. Servicing the unit

The purging sector and the drive system are positioned as shown below and depends on the position of the rotary exchanger. Return air Fresh air Return air Fresh air Fresh air Return air Fresh air Return air 94138LA 94138LB 94138RA 94138RB Figure 7.5 Position of purging sector and drive system Please refer to the enclosed documentation in connection with ZCN 21/15 and 21/18. 7.4.2 Bearings Rotor bearings are ball bearings, which do not need to be lubricated. When the service life of the bearings has expired, they must be replaced. Replacement should be performed by a service professional. 7.4.3 Belt drive 7.5 Cross-flow exchanger The belt drive has a maintenance free elastic belt. The elasticity of the belt is the belt tightening. See 6.5.2 Belt drive (rotor) on page 45 for details regarding replacement of the belt. In units with cross-flow exchangers, that is sizes 13/8, 18/10 and 21/12, the cross-flow section is built around the plate heat exchanger. In the exchanger the hot and cold air flows pass each other separated by thin metal plates. Both side of the exchanger block has by-pass to allow for wholly or partly leading of the fresh air round the block. Figure 7.6 Side-view of cross-flow section Climaster ZerAx type ZCN-M guide / 7. Servicing the unit 49

The exchanger block is made as a single block with the by-pass duct located in the back of the section and opposite the access side of the unit. The shut-off and by-pass dampers can be operated with two damper motors or be coupled for operation of both dampers with the same motor. Pos. RB Extract Outdoor air Pos. LA Outdoor air Outdoor air Extract Extract Extract Outdoor air Figure 7.7 Examples of cross-flow sections The shut-off damper arrangement is mounted inclined and directly on the heat exchanger. The by-pass damper is also mounted inclined next to the heat exchanger to have the damper shafts end to end. Unit Torque [Nm] 1 13/8 5 18/10 10 21/12 10 Table 7.1 Torque for dampers 1. Multiply the values by two for coupled dampers. 7.5.1 Demounting heat exchanger The damper motor is mounted directly on the shaft. The torque must be equal to or greater than the torques in the above table. Important: The unit must be stopped before opening the doors. Remove doors, panel, posts and also the longitudinal profile. The damper arrangement is inserted in two rails and can be pulled out after demounting the electrical connection to the damper motors. The heat exchanger is mounted in four rails. One at the top, one in the bottom and two in the deck between the upper and lower parts of the unit. After demounting, the heat exchanger block can be pulled out. Note: Check that the washers and sealing strips are intact before re-mounting. Replace them if they are defective. 7.5.2 Heat exchanger and damper The cross-flow exchanger section is fitted with a by-pass duct for leading the fresh air round the heat exchanger. For regulation of the fresh air, the section is fitted with an inclined damper arrangement consisting of three dampers. 50 Climaster ZerAx type ZCN-M guide / 7. Servicing the unit

The dampers are mounted directly on the heat exchanger and the by-pass ducts. Figure 7.8 Damper on exchanger block The regulation of the damper arrangement is modulated with one or more damper motors. The arrangement is prepared for mounting of damper motors on an 8 mm square shaft. The following variants are made. Damper arrangements Two damper motors for individual regulation of the two air flows Coupled for mounting of a single damper motor for shutting off of the by-pass duct when the heat exchanger is active and vice versa. Figure 7.9 Regulation mechanisms with one and two damper motors The modulating operation of the damper motor means that it must be considered a wear part to be replaced, when it stops working. 7.5.3 Drip tray 7.6 Heating and cooling coils The cross-flow exchanger section is fitted with a drip tray, for collection of condensate in the exhaust air. The drip tray is fitted with a drain, which is smooth on the outside and Ø32 mm. The drain is lead out through the unit casing, and fitted with a water trap. See section 3.2.2 Water traps on page 17. If needed, the cross-flow heat exchanger can be fitted with an eliminator mat in the exhaust air side. The heating and cooling coils must be demounted in order to be serviced. Climaster ZerAx type ZCN-M guide / 7. Servicing the unit 51

7.6.1 Demounting 7.6.2 Frost protection 7.7 Fans Demounting the heating or cooling coils, for example for repairs, requires holding counter on the collector pipe when disassembling and assembling the pipe connections. This is to prevent deformation of the copper tubes, which otherwise may leak. See figure 3.21 on page 27. When remounting a cooling coil it is important to seal carefully around the coil. Little air leakages with high air velocities can cause entrainment of condensate over the edges of the drip tray for the coil. Heating and cooling coils must be protected against frost burst. A constant water flow and modulated regulation of the water temperature, is the best way to counter this. See sections 3.6.2 Water heating coil on page 26 and 3.6.3 Cooling coil on page 28, respectively. The system should be fitted with automatic controls, which in danger of frost open the valve for water flow, stop the fan and close the fresh air damper. Cooling coils for direct expansion are serviced after the same principle as for water cooling coils. Refer to the cooling company s instructions for maintenance on the piping system and the components. The fan units are each mounted in a section. The motors on both ZerAx and plug fans are fitted with integrated frequency converters. Anti-vibration mountings are fitted on each fan unit. The fan units are placed in the unit casing on two cross-rails. Figure 7.10 ZerAx fan Important: Doors in sections with fans without protection are opened using the square key. The ZerAx fans are type AZN with the outlet opening connected to the discharge panel by means of a flexible connection secured with suspension rails. The fan unit is mounted in the bottom of the section, and attached to the transverse rails in the access side with screws. Inspection and service is car- 52 Climaster ZerAx type ZCN-M guide / 7. Servicing the unit

ried out through the inspection door on the access side. The discharge panel has an outside spigot for connection of round ducts. Figure 7.11 Round duct spigots on ZerAx fans The plug fans are direct driven, single-inlet centrifugal fans with backwardcurved blades mounted without fan housing. The unit consist of a fan wheel mounted directly on the drive shaft of a single-speed motor. The motor is a standard base motor with connection in terminal box. Figure 7.12 Plug fan The inlet funnel on the suction side is mounted against the suction chamber. A flexible rubber seal isolates the fan from the rest of the unit, thus preventing spreading of vibrations. Important: The fan is as standard unprotected. Hence, the door to the section is opened with the square key. 7.7.1 ZerAx(R) fan Demount the fan unit and pull it out to service it or the motor. Demounting fan unit 1 Turn off the air handling unit, put the safety switch in position 0 and lock it. 2 Wait a minimum of two minutes before opening the doors. Important: The fans take a minimum of two minutes to come to a complete halt. 3 Open the door to the fan section. Climaster ZerAx type ZCN-M guide / 7. Servicing the unit 53

4 Loosen the flexible connection between panel and fan. 5 Remove the rails holding the rubber cloth forming the connection. Push the cloth together. 6 Remove the screws in the bottom supporting the fan unit. 7 Pull the fan out and support it appropriately. 8 The flexible connection must be completely free of the spigot on the outlet panel. Motor sizes Weights [kg] -90 24.3-100 39.4-112 46.9-132 100.9-160 139.2-180 200.5 Table 7.2 Maximum motor weights 9 Demount the motor cable in the terminal box. The motor and fan unit can now be serviced. ZerAx fans are serviced as described in Novenco s installation and maintenance instructions, document no. 922950-0. The instructions are available on www.novenco-building.com and are sent on request. Important: Avoid exposing individual parts to shocks when handling the fan. Shocks can damage motor bearings and fan parts. Mounting of fan unit 1 Connect the motor cable in the terminal box. 2 Push the fan unit back in position. 3 Fasten the fan unit with screws in the bearings. 4 Mount the rails holding the rubber cloth. 5 Fasten the flexible connection between panel and fan. 6 Close the door to the fan section. Lock the door using the square key. The mounting of the fan unit is now complete. Startup the fan as described in section Startup of fans on page 35. 7.7.2 Plug fan Demount the motor to service the fan unit or motor. Demounting fan unit 1 Turn off the air handling unit, put the safety switch in position 0 and lock it. 2 Wait a minimum of two minutes before opening the doors. 54 Climaster ZerAx type ZCN-M guide / 7. Servicing the unit

Important: The fans take a minimum of two minutes to come to a complete halt. 3 Open the door to the fan section. The door is opened using the square key. 4 Remove the screws in the access side. The screws fasten the outer frame on the fan unit to the rails. There are two screws in front of and two behind the motor. 5 Release the fan unit from the discharge panel. Connection between fan unit and panel Rubber seal Flexible connection Description Insert a steel mounting plate between the seal and the panel to protect the rubber seal when pulling the fan past the opening. Remove the two screws on the access side, which fasten the flexible connection to the panel. Keep the connection clear of the panel opening when pulling the fan unit past it. 6 Pull the fan out and support it appropriately. Fan size Weights 1 [kg] 280 22 315 32 400 45 500 70 560 101 630 146 710 186 800 270 900 392 1000 495 Table 7.3 Maximum motor weights 1. The weight is composed of the motor, fan mounting and rotor. Depending on the length of the motor cable, pull the cable clear of the fan casing to handle the motor. 7 Demount the motor cable in the terminal box. The motor and fan unit can now be serviced. Mounting fan unit 1 Place the fan unit on the rails in the bottom of the section. 2 Push and centre the fan unit in front of the discharge panel. Connection between fan unit and panel Rubber seal Description Insert a steel mounting plate between the seal and the panel to protect the rubber seal when pulling the fan past the opening. Remove the mounting plate when the fan is in place. Climaster ZerAx type ZCN-M guide / 7. Servicing the unit 55

Connection between fan unit and panel Flexible connection Description Keep the connection clear of the panel opening when pushing the fan unit past it. Attach the connection to the panel with the two screws. 3 Fasten the fan unit to the discharge panel. Remember to remove the mounting plate for units with rubber seals. Units with flexible connections are fastened to the panel with two screws. 4 Mount the four screws holding the fan unit to the rails in the bottom of the section. 5 Close the door to the fan section. Lock the door using the square key. The mounting of the fan unit is now complete. 56 Climaster ZerAx type ZCN-M guide / 7. Servicing the unit

A. Technical specifications 9/6 13/8 18/8 18/10 21/10 21/12 21/15 21/18 Unit data Max. air volumes m 3 /s 1.1 3.0 4.5 5.8 7.0 9.0 11.0 13.0 Dampers Airtightness class DS/EN 1751, class 3 Filters Disposable pocket filters of glass fibre, type F5, F7 or F8/F9 Cross-flow exchanger with bypass (alt.) Cross-flow exchanger, torque for by-pass damper 1 Nm 5 10 10 Cross-flow exchanger, torque for heat exchanger damper Nm 5 10 10 Rotary exchanger with elec. controls (alt.) Rotary exchanger, rotor diameter mm 570 1250 1525 1780 2020 2420 2900 3200 Plate type and insulation 0.7 mm AluZink 50 mm mineral wool 70 kg/m 3 Duct connections 2 mm 300x600 500x1000 Ø500 Ø560 500x1500 Ø500 Ø560 700x1500 Ø500 Ø560 Ø630 Ø710 700x1800 Ø560 Ø630 Ø710 900x1800 Ø560 Ø630 Ø710 1200x1800 Ø710 Ø800 Service area min. from front mm Minimum 750 or enough to open doors completely Electrical motor data Power supply V, Hz Calculates with Climaster Designer Rotary exchanger control, supply V, Hz 1x230 V, 50 Hz Power input kw Depends on configuration and is calculated with Climaster Designer Full load current A Calculates with Climaster Designer Fan data Types Plug or ZerAx -fan Specific performance data etc. Calculates with Climaster Designer 1500x1800 Ø710 Ø800 Ø900 Ø1000 Hot-water heating coil (option) Pipe connection 2 pipes / 4 pipes ¾ / 1 1 / 2 1¼ / 2 1¼ / 2 1½ / 2 2 / 3 2½ / 4 2½ / 4 Specific data for dimensioning, performance etc. Calculates with Climaster Designer Cooling coil (option) Pipe connection 4 pipes / 6 pipes / 8 pipes Specific data for dimensioning, performance etc. Other options Length of overhang for exhaust box 2 x 1 / 2 x 2 / 2 x 1½ 2 x 1½ / 2 x 2 / 2 x 2½ 2 x 1 1/4 / 2 x 2½ / 2 x 2½ 2 x 2 / 2 x 2½ / 2 x 3 2 x 2½ / 2 x 3 / 2 x 3 2 x 2½ / 2 x 2½ / 2 x 3 Calculates with Climaster Designer 2 x 3 / 2 x 4 / 2 x 4 2 x 3 / 2 x 4 / 2 x 4 mm 405 540 600 730 1. Units with double by-pass have twice the torque specified here. 2. Rectangular connections are also made with more narrow inlets for use in SB-mixing functions. See the overview in table 3.3 Connection dimensions for ducts and dampers on page 24. Climaster ZerAx type ZCN-M guide / A. Technical specifications 57

58 Climaster ZerAx type ZCN-M guide / A. Technical specifications

{ { U { { { { B. Electrotechnical connections B.1 Rotor controls DIP Function Rotation guard Max speed Direction Motor type NL On Off 200 RPM 150 RPM CCW CW RHX2-12M RHX2-14M RHX2-16M * Depends on the direction of the supply air. ** Depends on the unit size. RHX2-12M is for ZCN 9/6 to 18/10. RHX2-14M is for ZCN 18/12 to 21/10. COM NC NO On Off 0-10 VIn DIP +10 VOut In Max. speed Direction Status light Yellow Green Red On Stop On Alarm Green Yellow Flash A- A+ B- B+ Purging Rotation guard pulse Rotation guard alarm White Brown MODBus Mainline 230 VAC Alarm relay 4 and 6 close on alarm or no 230 V supply Reset Digital In Rotation guard Figure B.1 Climaster ZerAx type ZCN-M 9/6 21/10 Stepmotor Supply voltage of 24 V- on the contacts 5, 7 and 9. 0-20 ma 4-20 ma 0-10 V { { L1 N S1 S2 S3 PEPEPE V W 1 2 3 4 5 6 7 8 9 10 11 12 13 + - - + Mains (230 V) 50-60 Hz Error condition S1 and S2 closed during operation S2 and S3 closed by defects or net failure Three-phase AC motor (3x230 V) in delta connection with standard motors 230/400 V +10 V reference Control signal 0-10 V, 0-20 ma 4-20 ma Blue Running check brown Black (Potential-free contact) Control unit release Thermostat relay motor PTC resistor motor Operating condition 11 and 13 closed during operation 12 and 13 closed when not in operation or by faults or net failure Figure B.2 Climaster ZerAx type ZCN-M 21/12 21/18 Climaster ZerAx type ZCN-M guide / B. Electrotechnical connections 59

60 Climaster ZerAx type ZCN-M guide / B. Electrotechnical connections

C. Spare parts Note that each order number for filters contains one filter cassette. Components Type Order no. Variant Comments 599547-0 9/6 Without bottom pan 599551-0 13/8 Without bottom pan 910442-0 18/8 592x592x305 mm and 6 pockets Filter F5 Filter F7 Filter F8 / F9 Glass filter Glass filter Glass filter 910442-0 911535-0 18/10 636034-0 21/10 636035-0 636036-0 21/12 636037-0 636038-0 21/15 636039-0 636040-0 21/18 911545-0 911546-0 9/6 592x592x305 mm and 6 pockets 592x287x305 mm and 6 pockets Without bottom pan With bottom pan Without bottom pan With bottom pan Without bottom pan With bottom pan 592x490x635 mm and 10 pockets 908264-0 13/8 592x592x635 mm and 10 pockets 908264-0 18/8 592x592x635 mm and 10 pockets 908264-0 911543-0 18/10 592x592x635 mm and 10 pockets 592x287x635 mm and 10 pockets 636048-0 21/10 Without bottom pan 636049-0 636050-0 636051-0 636052-0 636053-0 636054-0 21/12 21/15 21/18 Without bottom pan With bottom pan Without bottom pan With bottom pan Without bottom pan With bottom pan 599609-0 9/6 Without bottom pan 599613-0 13/8 Without bottom pan 599615-0 18/8 Without bottom pan 599617-0 18/10 Without bottom pan 636055-0 21/10 Without bottom pan 636056-0 636057-0 636058-0 636059-0 636060-0 636061-0 21/12 21/15 21/18 Without bottom pan With bottom pan Without bottom pan With bottom pan Without bottom pan With bottom pan Table C.1 Spare parts Climaster ZerAx type ZCN-M guide / C. Spare parts 61

Components Type Order no. Variant Comments 40001759 9/6 40001761 13/8 40001762 18/8 Spare belts for rotors 40001763 18/10 40005578 21/10 40001765 21/12 Contact Novenco 21/15 Contact Novenco 21/18 Table C.1 Spare parts (Continued) 62 Climaster ZerAx type ZCN-M guide / C. Spare parts

D. Declaration of conformity In accordance with the EC Machinery directive 2006/42/EC, appendix II, A Manufacturer: Novenco A/S Industrivej 22 DK-4700 Næstved hereby declares that the air handling units Climaster ZerAx type ZCN-M size 9/6-13/8-18/8-18/10-21/10-21/12-21/15 and 21/18 conform to the demands from the directives below, provided that the products are installed in accordance with the installation instructions. Changes made to the products nullifies this declaration. Directives EC Machinery Directive 2006/42/EC EMC Directive 2004/108/EC LVD 2006/95/EC is produced in accordance with the following harmonised standards: EN ISO 12100, EN ISO 13857 EN 60204-1 Næstved, 02.04.2012 Steen Hansen R&D manager Novenco A/S Climaster ZerAx type ZCN-M guide / D. Declaration of conformity 63

64 Climaster ZerAx type ZCN-M guide / D. Declaration of conformity

E. Service and warranty E.1 Conditions E.2 Warranty E.3 Contact information Novenco provides technical advice in connection with installation, function test and training of operation staff. Novenco provides 12 months base warranty from the time of delivery. The warranty covers material and manufacturing faults on the air handling unit and controls. Wear parts are not covered by the warranty. Address: Novenco A/S Industrivej 22 DK-4700 Næstved Climaster hotline: +45 5578 1400 Service department: service@novencogroup.com Climaster ZerAx type ZCN-M guide / E. Service and warranty 65

66 Climaster ZerAx type ZCN-M guide / E. Service and warranty

Index A About this guide..................... 5 Application......................... 5 C Cleaning........................... 39 See Maintenance Connection Cooling coil..................... 28 Water-heating coil............... 26 Diagrams See Electrotechnical connections Contact information................. 65 Cooling Connection of coil............... 28 Frost burst of coil................ 29 Cross-flow exchanger Damper motor.................. 50 Drip tray....................... 17 Heat exchanger.................. 50 Maintenance.................... 41 Safety.......................... 50 Service......................... 49 D Declaration of conformity............ 63 Demounting doors See Handling and Service Drip tray for cross-flow exchanger.... 17 Duct connections................... 24 See Installation E Electrical installation See Installation Electrotechnical connections......... 59 Terminal diagrams............... 59 See also Terminal diagrams F Fan units.......................... 18 Demounting plug fans............ 54 Demounting ZerAx fans......... 53 Fan motors...................... 54 Motors.......................... 53 Transport protection.............. 18 Filters............................. 44 Replacement..................... 44 Service life...................... 44 Spare part numbers............... 61 G General inspection See Maintenance H Handling Demounting doors............... 47 Handling......................... 7 Scope of delivery.................. 9 Storage.......................... 8 Weights.......................... 8 Help Questions........................ 2 Hotline............................ 65 I Important........................... 2 Inspection See Maintenance Installation Assembly of unit................. 11 Automatic voltage cut-off See CE documentation Calibration of plug fans........... 21 Calibration of ZerAx fans........ 19 CE documentation............... 33 Damper motors.................. 25 Dampers..................... 25, 26 Drip tray (cross-flow exchanger)... 17 Duct connections................. 24 Electrical........................ 33 Fan motors...................... 34 Fan units........................ 18 Filter guard..................... 23 Climaster ZerAx type ZCN-M guide / Index 67

Handles on doors................ 23 Mechanical..................... 11 Requirements for installation site.. 11 Rotary exchanger................ 30 Setting up................... 11, 12 Supply voltage See CE documentation Unit on roof..................... 11 Water traps..................... 17 Introduction........................ 5 L Lubrication........................ 43 M Maintenance....................... 39 Air inlet........................ 39 Airtightness..................... 43 Belt drive....................... 45 Cleaning........................ 39 Control......................... 42 Cooling coils.............. 42, 43, 45 Cross-flow exchanger............ 41 Dampers....................... 40 Filters.......................... 44 General inspection............... 39 Inspection...................... 39 Lubrication of dampers........... 43 Other components............... 42 Plug fans....................... 42 Recommended cleaning intervals.. 39 Replacing parts.................. 44 Rotary exchanger............. 40, 43 Service......................... 39 Silencers........................ 40 Unit casing..................... 39 Water-heating coils........ 41, 43, 45 ZerAx fans..................... 42 Marking See Declaration of conformity Mechanical installation See Installation Mixing damper..................... 31 Motors See Fan units P Pin connections See Electrotechnical connections Plug fans........................... 53 Calibration...................... 21 Demounting..................... 54 Maintenance..................... 42 Pocket filters See Filters R Receipt See Handling Recirculation damper................ 31 Repair See Replacing parts and Maintenance Replacing parts Belt drive in rotary exchanger...... 45 Damper motor in cross-flow exchanger.......................... 50 Filters.......................... 44 Rotary exchanger................... 30 See also Installation Bearings........................ 49 Belt drive....................... 49 Brush seal....................... 48 Control................... 30, 34, 40 Drive belt....................... 40 Maintenance..................... 43 Purging sector................... 36 Safety........................ 40, 42 Spare belt.................... 45, 49 Step motor...................... 40 Truing.......................... 30 S Scope of delivery..................... 9 Service.......................... 47, 65 See also Maintenance Connecting rod for damper........ 48 Cooling coils.................... 51 Cross-flow exchanger............. 49 Dampers........................ 48 Demounting doors............... 47 Fans............................ 52 Rotary exchanger................ 48 Service area..................... 57 Water-heating coils............... 51 Setting up unit See Installation Spare parts......................... 61 Startup............................ 35 Procedure....................... 35 68 Climaster ZerAx type ZCN-M guide / Index

Storage............................. 8 T Technical specifications.............. 57 Terminal diagrams.................. 59 Rotor controls................... 59 Trademarks......................... 2 Transport protection................ 18 U Unit types.......................... 5 W Warranty.......................... 65 Conditions...................... 65 Water-heating coils Connection...................... 26 Demounting..................... 52 Frost protection.................. 28 Maintenance............... 41, 43, 45 Service.......................... 51 Weights............................. 8 Z ZCN hotline........................ 65 ZerAx fans........................ 52 Calibration...................... 19 Demounting..................... 53 Maintenance..................... 42 Climaster ZerAx type ZCN-M guide / Index 69

70 Climaster ZerAx type ZCN-M guide /.

MU 14528 0412 Novenco develops and manufactures ventilation and fire-fighting systems that are marketed and distributed worldwide through subsidiaries and agents. The company was founded in Denmark 1947 and has become one of the world-leading suppliers. Novenco symbolises quality and environmentally responsible operation and is certified according to ISO 9001 and ISO 14001. The company headquarters are located in Naestved, Denmark. Novenco, Hi-Pres, XFlow, and ZerAx are registered trademarks of Novenco. Read more about Novenco on the internet. Novenco A/S Industrivej 22 4700 Naestved Denmark Phone: +45 70 12 42 22 Fax +45 55 75 65 50 www.novenco-group.com