Novenco Air Handling Units

Novenco Air Handling Units Climaster ZCF Guide 919432-0 GB

Important This document is provided As is and is subject to change without notice. Novenco reserves this right due to continuous product development. Copyright (c) 2002 2007, Novenco. All rights reserved. Trademarks Novenco is a trademark of Novenco. Other trademarks appearing in this document are the property of their respective owners. New editions of this guide can be found on www.novenco.biz. 2 ZCF

Contents 1. About this guide..................4 2. Application.......................4 3. Reception on site..................4 4. Handling.........................4 4.1 Dismantling of units to facilitate transport 4 4.2 Weights 5 5. Storage..........................5 6. Scope of delivery..................5 6.1 Setscrews 5 6.2 Handles 5 6.3 Shut-off dampers 5 6.4 Packaging of loose parts 5 6.5 Cooling unit and cooling coil (optional) 5 7. Unit installation...................6 7.1 Levelling the base frame 6 7.2 Reassembling the unit after transport 6 7.3 Duct connections 6 7.4 Piping 6 8. Description of unit casing...........6 8.1 Panels 6 8.2 Doors 6 8.3 Cleaning 8 8.4 Tightness 8 8.5 Unit maintenance 8 9. Dampers.........................8 9.1 Shut-off dampers 8 9.2 Maintenance 8 9.3 Damper motors 9 10.Filters...........................9 10.1 Filter monitor 9 10.2 Filter replacement/cleaning 9 10.3 Service life 10 10.4 Recommended final pressure drops 10 10.5 Replacement filters 10 11.Rotary heat exchanger............10 11.1 Geared motor and controller 10 11.2 Brush seals 10 11.3 Rotor bearings 10 11.4 Belt drive 10 11.5 Centring the rotor 11 11.6 Pressure balance adjustment 11 11.7 Cleaning 12 12.Cross-flow heat exchanger (ZCF 5, 8, 11, 15)............................... 12 12.1 Heat exchanger/damper 12 12.2 Drip pan/water trap 12 12.3 Cleaning 13 13.Hot-water heating coil............ 13 13.1 Pipe connections 13 13.2 Cleaning 14 13.3 Removing heating coils 14 14.Electric heating coil............... 15 15.Fan............................ 15 15.1 Electric connection of motors 15 15.2 Before start-up 16 15.3 Start-up procedure 16 15.4 General inspection and maintenance 16 15.5 Dismantling and reassembling fan unit 16 16.Cooling unit..................... 17 16.1 Installation 17 16.2 Start-up procedure 17 16.3 Cleaning and maintenance 17 16.4 Dismantling and disposal 17 17.Electric heating coil and power module............................... 18 18.Electric connection of the rotor control............................... 19 19.Spare parts list................... 20 20.Declaration of conformity......... 21 ZCF 3

1. About this guide The guide describes installation and maintenance procedures for the unit casing and all components contained in the unit. The installation and maintenance are described in section 7. Unit installation on page 6 and ends with section 16. Cooling unit on page 17. 2. Application Climaster ZCF is designed for use in comfort ventilation systems in schools, kindergartens, youth centres, offices, shops, etc. Climaster ZCF is available in eight sizes, with either cross-flow or rotary heat exchanger for heat recovery. These bolts must be removed, which is best done using a 19 mm socket wrench with ratchet, fig. 4.2. Fig. 4.2 3. Reception on site Receiving the unit on site involves checking that it is undamaged and that the delivery is complete and correct. Any damage or missing parts must be reported immediately to the forwarding agent. 4. Handling ZCF units are supplied on base frames and can be transported by fork-lift truck or hoisted by crane using the lifting lugs located on the corners of the unit. When hoisting by crane, use belts fitted with shackles, fig. 4.1. Fig. 4.3 Sections are joined together with six 8 mm internal hexagon screws in each section, figs. 4.2 and 4.3. The hinges of the middle doors are fitted to the posts between sections. After removing the screws and hinges, the sections can be separated and transported individually. Fig. 4.1 4.1 Dismantling of units to facilitate transport With the exception of ZCF 5 and ZCF 8, it is possible to dismantle the ZCF units into three major section to facilitate transport in situations where this is desired. The sections must be unbolted from the base frame. The unit is attached to the base frame by four 12 mm hexagonal bolts screwed into the casing in each of the four corners. 4 ZCF

4.2 Weights All values are in kg unless otherwise stated. Cooling coils, which are optional, are identified on the dimensions of the connection. These dimensions are in mm. Unit ZCF 5 ZCF 8 ZCF 11 ZCF 15 ZCF 20 ZCF 25 ZCF 30 ZCF 37 Total weight with cross-flow heat exchanger 277 358 482 612 Total weight with rotary heat exchanger 279 362 477 594 862 890 1170 1280 Fan unit with motor 20 25 33 48 66 80 90 145 Heating coil 7 9 11 14 27 27 36 36 Rotary heat exchanger 22 34 45 59 115 115 160 160 Cross-flow heat exchanger with damper 22 25 33 68 Weights of individual sections ZCF 11 ZCF 15 ZCF 20 ZCF 25 ZCF 30 ZCF 37 Section with fan/heating coil/filter 159 194 278 292 376 431 Section with fan/filter 150 184 251 265 340 395 Section with cross-flow heat exchanger 145 204 Section with rotary heat exchanger 144 180 275 275 376 376 Base frame for cross-flow heat exchanger 28 31 Base frame for rotary heat exchanger 24 27 56 56 76 76 Cooling unit (optional) YCSA 8 TP YCSA 12 TP YCSA 18 TP YCSA 26 TP YCSA 36 TP YCSA 50 TP YCSA 60 TP Weight 130 185 220 390 400 624 706 Cooling coil (optional) 450x450 580x550 680x650 1000x600 1250x800 1450x1000 Weight 23 31 39 48 79 120 5. Storage On delivery, ZCF units are packaged in plastic. If units are to be stored outdoors, they must be covered to allow air to circulate beneath the cover to prevent condensation. Units must only be stored outdoors for short periods. If units are to be stored for longer periods, they must be stored indoors in a dry location and the plastic packaging be removed to prevent condensation. 6. Scope of delivery The following are supplied with the ZCF unit. 6.1 Setscrews The unit is supplied with six setscrews for levelling the base frame. The setscrews are included in the loose parts package. 6.3 Shut-off dampers A fresh-air shut-off damper, with damper motor and spring return, is supplied as standard. A shut-off damper with damper motor for the exhaust duct is available on order. 6.4 Packaging of loose parts All the above-mentioned loose parts are packed in one or two cardboard boxes (depending on their number) and listed separately on the packing list. 6.5 Cooling unit and cooling coil (optional) These parts are delivered including duct adapter pieces for installation between the cooling coil and the air duct. Please note that pipes for carrying of cooling fluid from the cooling unit to the cooling coil are not part of the delivery. 6.2 Handles One set of handles is supplied with ZCF 5 and ZCF 8 and three sets of handles are supplied with ZCF 11, ZCF 15, ZCF 20, ZCF 25, ZCF 30 and ZCF 37. Each set consists of one handle with lock and key and one handle without lock. A handle with lock must be fitted to each door. The handles are included in the loose parts package. ZCF 5

7. Unit installation 7.1 Levelling the base frame The unit is levelled using the six setscrews, screwed into the underside of the base frame, fig. 7.1. Fig. 7.1 There must be ample free space in front and along the entire length of the unit for inspection and service. For inspection: It must be possible to fully open the doors. For service: It is strongly recommended that the service area be as wide as the unit itself so that unit components can be pulled out without difficulty. Width, largest door [mm] With cross-flow heat exchanger With rotary heat exchanger ZCF 5 ZCF 8 ZCF 11 ZCF 15 ZCF 20-25 ZCF 30-37 1010 1040 710 800 936 1010 710 800 900 900 Unit width 770 940 1080 1220 1677 1937 7.2 Reassembling the unit after transport After the base frame and sections have been transported to the installation site, they must be reassembled. Carefully level the base frame before reassembling the sections, fig. 7.1. If the base frame is not completely level, the sections get twisted during assembly and the doors cannot close tightly. Also check that the sealing strips between sections are intact. If the strips have been damaged, they must be replaced. Replacement strips are available from Novenco. Circular duct connections have lip seals. Rectangular ducts are connected by means of LS rails. If ZCF unit is to be equipped with cooling functionality, the included duct adapter is installed between the ZCF unit and the cooling coil. The coil can alternatively be placed after a bent in the air duct. This is typically used in connection with vertical air delivery, as the cooling coil must be installed in a vertical position because of the condensation run-off. 7.4 Piping Pipe entries through the panels are fitted with a seal on the inner panel plate. The seal is fitted in the panel from the outside. 8. Description of unit casing The unit casing is made up of panels. The inner surface is smooth to facilitate easy cleaning. 8.1 Panels The panels are 50 mm thick and consist of two aluzinccoated steel plates with mineral wool core. 8.2 Doors The access side of the unit is equipped with tight fitting doors, which are constructed similar to the panels. ZCF 5 and ZCF 8 have two doors, which are relatively wide and mounted on external hinges. ZCF 11, ZCF 15, ZCF 20-25 and ZCF 30-37 with rotary heat exchanger have three doors. ZCF 11 and ZCF 15 with cross-flow heat exchanger have four doors. Outermost doors are mounted on external hinges while middle doors have hidden hinges with hinge pins, fig. 8.2. If there is insufficient room for doors to be fully opened, they can be taken off by removing the hinge pins. 7.3 Duct connections Unit ZCF 5 Ø315 ZCF 8 Ø400 ZCF 11 Ø500 ZCF 15 800 400 ZCF 20-25 1150x700 ZCF 20-25 vertical 1150x700 ZCF 30-37 1250x900 ZCF 30-37 vertical 1500x700 Duct connection [mm] Fig. 8.1 6 ZCF

Middle doors are taken off by removing the hinge pins, fig. 8.1. Doors are equipped with sealing strips that form seals against the various components within the unit. Fig. 8.2 Doors are fitted with a rubber sealing strip, which is held in place in a groove around the circumference of the door, fig. 8.3. Fig. 8.4 The doors open in the full height of the unit and are equipped with roller tongue lock, fig. 8.3. The upper locks on doors to sections with positive pressures have an extra tongue for safety reasons. Handles are delivered as loose parts to prevent damages from transport. Handles must be mounted on doors with the lockable handle at the top, fig. 8.4. One set of handles is supplied with ZCF 5 and ZCF 8, and three sets are supplied with ZCF 11, ZCF 15, ZCF 20-25 and ZCF 30-37. Each set consists of one handle with lock and key and one handle without lock. A handle with lock and a handle without lock must be fitted to each door. The handles are included in the loose parts package. The doors open through 180, thus facilitating access for inspection and service. Be careful not to damage the handles when opening the middle doors on ZCF 11, ZCF 15, ZCF 20-25 and ZCF 30-37, fig. 8.5. Fig. 8.3 Fig. 8.5 ZCF 7

8.3 Cleaning The inner surfaces of the Climaster casing must be kept free from dust and other foreign matter, especially in front of the filters. Dirt is best removed using a vacuum cleaner to prevent it from being blown into the served areas. The maintenance of individual components is described in the respective sections. 8.4 Tightness The sealing strips on the doors must be intact. Pipe entries and cable glands must be airtight. Check regularly that duct connections are airtight. 8.5 Unit maintenance The air inlet must be kept free of foreign matter (paper, leaves, etc.). Recommended intervals (see also under individual components) General inspection: Once a month 9. Dampers 9.1 Shut-off dampers Unit Damper ZCF 5 Round ZCF 8 Round ZCF 11 Round ZCF 15 Rectangular SJD ZCF 20-25 Rectangular SJD ZCF 20-25 vertical Rectangular SJD ZCF 30-37 Rectangular SJD ZCF 30-37 vertical Rectangular SJD Damper motors are available as accessories. The connection dimensions for the dampers are given by the duct connections. See section 7.3 Duct connections on page 6. Light internal cleaning: After the first month of operation and every third month thereafter Filter inspection: After the first month of operation and every third month thereafter Inspection of other functions: Every third month Major overhaul and cleaning of entire unit: Once a year Fig. 9.1 9.2 Maintenance Dampers are practically maintenance free, but should be kept clean and free of coatings of dirt and dust. This applies to both the air path and the regulating mechanism outside the air path. In addition, trouble-free operation is ensured if all wearing parts in the regulating mechanism are kept well lubricated at all times, e.g. using graphite grease. 8 ZCF

10. Filters The unit is equipped with an F7 pocket filter in the fresh-airway and an F5 filter in the extraction line. The filters, which are marked with their type designation, are inserted into holders and held in place by locking rails that press the filter frame against the rubber seal. The rails are released by pulling the black knob outwards. Fig. 9.2 Fig. 10.1 Fig. 9.3 9.3 Damper motors Damper motors are accessories and must, if they are mounted, be serviced in accordance with instructions from the supplier. 10.1 Filter monitor A filter monitor can be delivered as an accessory. Fig. 10.2 10.2 Filter replacement/cleaning The filters are disposable and must be replaced when the recommended final pressure drop, Δp, is reached. ZCF 9

10.3 Service life Filter service life depends on operating conditions and the dust concentration in the air. It is inadvisable to prolong the service life of filters beyond the recommended final pressure drop as this will reduce the air quantity and impair system performance. Dust accumulation in the filters can also create unhygienic conditions in the system. 10.4 Recommended final pressure drops The maximum recommended final pressure drop across the filters is 200 Pa. The recommended final pressure drop may be lower than this as the air quantity must not vary more than ±10%. 11. Rotary heat exchanger The rotary heat exchanger consists of rotor, geared motor, drive belt and controller. 11.1 Geared motor and controller The geared motor, controller and belt drive are accessed by opening the doors leading to the rotor on the access side of the unit after the unit has been stopped. The controller and geared motor are mounted on the same bracket, and the controller must be removed to access the motor, fig. 11.1. The gear motor is maintenance free. 10.5 Replacement filters Replacement filters are ordered with reference to the tables below. Filter class F5 Unit No. of filters W * H * L No. of pockets ZCF 5 1 592 * 389 * 300 6 ZCF 8 1 795 * 439 * 300 8 ZCF 11 1 592 * 592 * 300 6 1 287 * 592 * 300 3 ZCF 15 1 592 * 592 * 300 6 1 490 * 592 * 300 5 ZCF 20-25 2 592 * 490 * 305 6 2 592 * 287 * 305 6 ZCF 30-37 3 592 * 287 * 305 6 3 592 * 592 * 305 6 Fig. 11.1 Filter class F7 No. of Unit filters W * H * L No. of pockets ZCF 5 1 592 * 389 * 300 12 ZCF 8 1 795 * 439 * 380 16 ZCF 11 1 592 * 592 * 470 10 1 287 * 592 * 470 5 ZCF 15 1 592 * 592 * 470 10 1 490 * 592 * 470 8 ZCF 20-25 2 592 * 490 * 635 10 2 592 * 287 * 635 10 ZCF 30-37 3 592 * 287 * 635 10 3 592 * 592 * 635 10 11.2 Brush seals The brush seals surrounding the rotor are attached to the rotor by screws on the inside of the rotor and are held in place by a clamp bracket. The brush slides on the smooth plate, fig. 11.1. The brush seal across the rotor forms a seal between the two airways. The seals require no adjustment, figs. 11.2. 11.3 Rotor bearings The rotor bearings are lubrication-free ball bearings. They must be replaced when their service life has expired. Replacement should be performed by a service technician. 11.4 Belt drive The belt drive is fitted with a maintenance-free elastic belt. Belt elasticity is belt tightening, fig. 11.1. 10 ZCF

The rotor is equipped with a spare belt. Should the belt break, the spare belt is used and the rotor must be fitted with a new spare belt as soon as possible. This should be performed by a service technician as the belt must be welded together. Re-tighten the centring screw when a gap of equal width has been achieved around the entire circumference of the rotor. 11.5 Centring the rotor Before start-up, check that the gap between the rotor and casing is of equal width all the way round. Fig. 11.3 Fig. 11.2 If it is not, the rotor must be centred. To do so, turn the 10 mm internal hexagon centring screw about half a turn, figs. 11.2 and 11.3. The rotor can then be adjusted along the horizontal axis by moving the screw up or down until the gap is of equal width at the top and bottom, figs. 11.2 and 11.3. The rotor is adjusted along the vertical axis by pushing the centring screw backwards or forwards using a heavy-duty screwdriver or similar instrument. 11.6 Pressure balance adjustment To prevent contaminated exhaust air from being mixed with the fresh-air supply, the correct pressure balance between the two airways must be established. In other words, there must be a greater negative pressure ahead of the rotor in the extraction airway than behind the rotor in the supply airway. In practice, this means that the accumulated pressure drop in the extraction duct, inlet and filter must be numerically greater than the accumulated pressure drop in the fresh-air duct, inlet, filter and rotor exchanger. ZCF 11

12. Cross-flow heat exchanger (ZCF 5, 8, 11, 15) The heat exchanger section consists of a cross-flow plate heat exchanger with a large number of narrow channels through which the warm and cold airflows pass each other, separated by thin metal sheets. 12.1 Heat exchanger/damper The cross-flow heat exchanger section is equipped with a bypass duct, thus allowing fresh air to be led past the heat exchanger. For fresh-air regulation, the section is equipped with an inclined damper arrangement mounted directly on the heat exchanger and bypass duct. Fig. 11.4 To achieve this, the unit is equipped with adjustment plates ahead of the filter in the extraction line, fig. 11.4. Fig. 11.5 Two gauge connectors marked + and are located on the outside of the unit, fig. 11.5. Negative pressure in the supply airway is marked. Negative pressure in the extraction airway is marked +. 11.7 Cleaning Although the unit is equipped with air filters, dust may accumulate on the rotor surface over time. To maintain unit efficiency, the rotor must be cleaned regularly. The rotor is accessed for cleaning by opening the doors after the unit has stopped. The rotor is cleaned using a vacuum cleaner with soft brush attachment or using a jet of compressed air. If compressed air is used, cleaning must be performed from the clean side towards the dust-coated side and the unit casing must subsequently be vacuumed and wiped clean. Fig. 12.1 Regulation of the damper arrangement can be modulated using a damper motor. A damper motor type Belimo LM24 is available as an accessory. The modulating operation means that the damper motor must be replaced when necessary, fig. 12.1. 12.2 Drip pan/water trap The cross-flow heat exchanger is equipped with a drip pan for collecting and draining condensation. The drip pan is fitted with a smooth Ø32 mm drain. The drain extends through the bottom of the unit casing and must be fitted with a water trap. The water trap is intended for negative pressure and has a ball to ensure that it is tight, even when drained of water. To function correctly, the water level in the water trap must be greater than the pressure head in the unit at the drain under the cross-flow exchanger. This pressure equals the sum of the pressure drop in the extraction duct and in the filter. 12 ZCF

13. Hot-water heating coil The heating coil consists of copper tubes with aluminium fins mounted in a sheet steel frame. Supply and return water is through headers with connections extended through the end panel. On ZCF 20, 25, 30 and 37 the heating coil is mounted externally on the end panel. Pipe entries are fitted with a seal on the inner panel plate. The seal is fitted in the panel from the outside. Headers are fitted with connections for air and drain cocks, fig. 13.2. Fig. 12.2 To achieve sufficient height, the unit must be mounted on the accompanying setscrews and the water trap must be fitted as shown in the photograph. A pipe must lead from the water trap to a drain. The pipe must have an incline of at least 3 and be openended above the drain. 12.3 Cleaning Although the unit is equipped with filters, dirt may accumulate on the heat exchanger block over time. Coatings of dirt typically accumulate on the first 50 mm of the block, thus making cleaning easier. During normal operation, brushing the inlet and extract once a year will suffice. If the heat exchanger block is very dirty it can easily be pulled out of the unit and washed with detergent solution, fig. 12.3. Also check that the water trap and drain are not clogged. 13.1 Pipe connections Pipe connections must be installed by an authorised plumber. Counter hold the header while connecting the heating coil to the piping. The supply line must always be connected to the lower connection on the heating coil. Unit ZCF 5 G ½ ZCF 8 G ½ ZCF 11 G ½ ZCF 15 G ¾ ZCF 20-25 1 ZCF 30-37 1½ ZCF 20-25 vertical 1 ZCF 30-37 vertical 1 Pipe dimension For systems using a boiler to provide hot water for the heating coil, the water flow is controlled by means of a shunt arrangement. Systems using district heating water as heat medium are without shunt arrangements, fig. 13.1. Fig. 12.3 ZCF 13

VM Max. 5 m Return AB A B V T T Min. 60 kpa diff. pressure Extra pump activated by low diff. pressure VO V T Supply Boiler water Return Min. 60 kpa diff. pressure Supply VM V T T Extra pump activated by low diff. pressure V T AB A Mount closed coupling Max. 5 m Fig. 13.3 External heating coil (ZCF 20, 25, 30, 37) 13.2 Cleaning In the interests of hygiene and heating efficiency, heating coils must be kept free of dust and foreign matter. They are cleaned from the air inlet side using a vacuum cleaner. Care must be taken during cleaning as the aluminium fins are highly susceptible to impact damage. Cleaning intervals depend on the amount of dust in the air. District heating water V = Shut-off valve VM = Solenoid valve VO = Overflow valve T = Thermometer Fig. 13.1 Water circuits Other components: Pipe system components, including those for regulation and venting, and all other components of importance for heating coil operation must be maintained in accordance with instructions and their proper functioning must be checked at regular intervals. 13.3 Removing heating coils If, during repair of heating coils, it is necessary to dismantle and subsequently reassemble pipe connections, headers must be counter held to prevent the copper tubing from being damaged and springing leaks. If it is necessary to remove the heating coil from the unit, the fan unit must first be removed, fig. 13.4. This applies to ZCF 5, 8, 11 and 15. Fig. 13.2 Pipe connections to heating coil (ZCF 5, 8, 11, 15) 14 ZCF

ZCF 20, 25, 30 and 37 have externally mounted heating coils, which can be removed, fig. 13.3. 15. Fan The fan unit is a plug fan with motor mounted on vibration dampers. The unit is secured with two transport protectors marked with yellow flex. The unit is mounted on two cross rails attached to the casing, fig. 13.4. Note: The fan is unguarded and the doors are therefore fitted with lockable handles, fig. 8.3. Fig. 13.4 14. Electric heating coil 1. Built-in electric heating coil with low-temperature tube type heating elements and built-in controller (ZCF 5, 8, 11 and 15). Note: The minimum air flow rate across the built-in heating elements is 1 m/s, which prevents overheating of the elements. 2. Duct heating coil for installation in the delivery air duct behind the unit. 3. Externally mounted heating coil (ZCF 20, 25, 30 and 37). The electric heating coil is connected as described in section 17. Electric heating coil and power module on page 18. Most fans are run at RPMs that are different from that of the motor. It is therefore necessary to couple the motor to a frequency converter. The RPMs and frequency are calculated for each unit using the Climaster Designer program. The results are found in the technical specifications printed with the program. Frequency converters can be delivered as accessories. 15.1 Electric connection of motors The fan motors are installed in the factory, but are not electrically connected as standard. The electrical connection is to be made by authorised personnel, and according to existing regulations, in the motor terminal box. See the diagram on the inside of the box lid. It is recommended to fit a lockable maintenance switch on the outside of the unit. The motor must be connected by means of a rubber cable approved according to existing regulations. Connection of a frequency converter should be done using a shielded cable. The converter must be fitted with a required noise filter in accordance with the EMC directive. The cable must not be lead through the inspection doors. The length of the cable should be at least 1.5 m x the width of the unit to allow for pulling the fan unit completely free during service. After fitting of the cable, it must be secured to avoid contact with the impeller. More information on connection and maintenance are found in the installation and maintenance instructions which are attached to the motors or packed together with the loose parts. ZCF 15

15.2 Before start-up Before starting the fan, check that the transport protectors have been removed. the fan impeller rotates freely without touching the intake funnel. all foreign matter (paper, tools, etc.) are removed from the airways. casing. This, however, requires an appropriate supporting stand for the fan unit. 15.3 Start-up procedure For safety reasons, the fan must not be started before the duct system has been installed and connected to the unit, and the doors are closed. If there is no duct on the pressure side of the fan, a protective grille has to be installed. 15.4 General inspection and maintenance Before opening the door to the fan section, the power supply to the unit must be disconnected and the safety cut-out switch must be set to 0 and locked. The door must not be opened before the fan has stopped rotating. This takes at least two minutes. The fan, sealing tightness and vibration dampers must be checked twice a year, including checking for occurrence of abnormal sounds and vibrations. Vibrations can be caused by dust accumulating on the fan impeller and will usually cease after cleaning. The motor must be serviced in accordance with the accompanying instructions. Fig. 15.2 When refitting the fan unit, the mounting plate must be inserted between the rubber seal and the casing to protect the seal as it is pushed past the opening in the casing. An end stop on the cross rail indicates the correct position of the fan unit. When the fan unit is correctly positioned, remove the mounting plate and re-tighten all four screws. 15.5 Dismantling and reassembling fan unit It may be necessary to dismantle the fan unit to service the motor. The power supply to the unit must be disconnected before opening the door to the fan section. The safety cutout switch must be set to 0 and locked. The door must not be opened before the fan has stopped rotating. This takes at least two minutes. To remove the fan unit, loosen the screws securing it to the cross rails. There are two screws in front of the motor and two behind it. Insert the included mounting plate between the rubber seal and the casing in order to pull the fan unit out safely. The cable is long enough to allow the fan unit to be pulled completely free of the 16 ZCF

16. Cooling unit Systems with the optional cooling functionality include the following parts. Cooling unit Cooling coil Duct adapter for cooling coil The cooling units are designed for cooling of water or glycol and are unsuited for other purposes. Unit ZCF 20-25 1½ ZCF 30-37 2 Pipe dimension (standard) 16.2 Start-up procedure Refer to the user guide for the cooling unit for information on how to start-up the unit. Starting and stopping of the cooling unit is carried out independently of the ZCF unit. 16.3 Cleaning and maintenance The cooling unit is serviced according to the directions in the user guide for the unit. Fig. 16.1 16.1 Installation The cooling unit is installed and connected to the cooling coil according to the enclosed installation guide. The circuit for circulation of the cooling fluid is constructed as shown below. The cooling coil must be kept free of dust and foreign objects in the interest of hygiene and cooling efficiency. Cleaning is done by vacuuming the coil from the air inlet side. It must be done with caution, as the aluminium fins are susceptible to impact damage. How often cleaning is required depends on the dust concentration in the air. Other components in the cooling pipe system, which influence on the operation of the cooling coil must be serviced accordingly. The function of the components must be checked regularly. VM Max. 5 m Return Return AB A B V T T Supply Min. 60 kpa diff. pressure Supply V = Shut-off valve VM = Motor valve VO = Overflow valve T = Thermometer Extra pump activated by low diff. pressure V The piping must be done by an authorised plumper. Counter hold the header while connecting the cooling coil to the piping. T VO Fig. 16.2 Condensate drain pipe 16.4 Dismantling and disposal This must be done as described in the user guide for the cooling unit. If, in case of repairs or changing of the cooling coil, it is necessary to disconnect and connect pipe connections to and from the cooling coil, the header must be counter held in order to avoid deformation of and leaking from the copper pipes. Unit Pipe dimension (standard) ZCF 5 + 8 ¾ ZCF 11 1 ZCF 15 5/4 ZCF 17

17. Electric heating coil and power module Important All connections must be done by an authorised technician. The electric heating coil is connected to a Novenco power module. The module is prepared for the Novenco ZCF control ES850, but can also be connected to an external binary step controller. Alternatively, the power module can be removed, and the heating coils connected to another external power controller. Refer to the documentation for this and for the electric heating coils if this is the case. Please note that the heating coils have built-in controls on ZCF 5-15. For ZCF 20-37 the placement of the controls are system specific. The controls for the heating coils are connected as shown below. 400V 230V Maximum load is 35A per live connection. Do NOT connect N in the neutral point. Heating coils must be balanced. The power is the same in all live connections. R3 R3 L3 L2 L1 R3 feed 3 x 400V 3 x 25A 3 x 230V 50A Maximum load is 25A per live connection. Do NOT connect N in the neutral point. Heating coils must be balanced. The power is the same in all live connections. Maximum load is 16A per live connection. Do NOT connect N in the neutral point. Heating coils must be balanced. The power is the same in all live connections. R2 R1 R0 R2 R1 L3 L2 L1 L3 L2 L1 R2 feed 3 x 400V 3 x 16A 3 x 230V 20A R0 + R1 feed 3 x 400V 3 x 16A 3 x 230V 20A R0 = Maximum load is 10A per live connection. Do NOT connect N in the neutral point. Heating coils must be balanced. The power is the same in all live connections. R0 Switch for 3 x 400V or 3 x 230 V Factory default is 3 x 400 V. For operation at 3 x 230V the jumper must be moved. Heating element dimensions R0 = Equals 12.5 % of total capacity R1 = Equals 12.5 % of total capacity R2 = Equals 25 % of total capacity R3 = Equals 50 % of total capacity 1 2 3 4 5 6 7 8 To controller Kl 1 } Connect in series with the = Kl 2 fire circuit in the controls Kl 3 = 24 VDC, relay R0, grp1 * Kl 4 = 0 VDC * Connection of a binary step controller requires R0 and R3 to be coupled together on terminals 3 and 8. Excess temp. Fire 8-wire control cable Kl 5 = 24 VDC, cut-off at excess temperature Kl 6 = 24 VDC, relay R1, grp2 Kl 7 = 24 VDC, relay R2, grp3 Kl 8 = 24 VDC, relay R3, grp4 * 18 ZCF

18. Electric connection of the rotor control Important All connections must be done by an authorised technician. The rotor control is of type MicroMax180 and requires 1x230 V with phase, neutral and ground. The output from the alarm relay and the input to the rotor monitor are routed and connected. L N U V W T T 13 14 15 2 3 9 10 w b Input 1 x 230V M 3 ~ Output 3 x 230V Input thermo contact Output alarm relay (Max. 8 A / 250 V AC) + - Input signal 0-10 V Input rotor monitor S The connections in the diagram are the following. Thermocontact (T-T) Alarm relay (13-14-15) Input signal Rotor monitor (9-10) This must be closed if the thermoswitch in the motor fails to close. Closes between 14-15 in case of alarm or power outage. Max. 8A / 250VAC 0-10 V The white cable is connected to pin 9 and the brown to pin 10. The magnet is installed with the south pole towards the transmitter. Max. distance is 15 mm. ZCF 19

19. Spare parts list Components Order no. ZCF sizes Comments Filters F5 Filters F7 Spare belts for rotors 918135-0 5 592x389x300 918136-0 8 795x439x300 918137-0 11 + 15 592x592x300 918138-0 11 287x592x300 918140-0 15 490x592x300 911537-0 20 + 25 592x490x305 911535-0 20-37 592x287x305 910442-0 30 + 37 592x592x305 918141-0 5 592x389x300 918142-0 8 795x439x380 918143-0 11 + 15 592x592x470 918144-0 11 287x592x470 918146-0 15 490x592x470 911545-0 20 + 25 592x490x635 911543-0 20-37 592x287x635 908264-0 30 + 37 592x592x635 40002424 5 40002425 8 40002426 11 40002427 15 40003590 20 + 25 40003591 30 + 37 20 ZCF

20. Declaration of conformity In accordance with the European Machinery Directive 98/37/EC, Annex II A Manufacturer: Novenco A/S Address: Industrivej 22 DK-4700 Naestved We hereby declare that Novenco air handling units Climaster ZCF 5, Climaster ZCF 8, Climaster ZCF 11, Climaster ZCF 15 Climaster ZCF 20, Climaster ZCF 25, Climaster ZCF 30 and Climaster ZCF 37 all without controls a) meet the requirements of the directives mentioned below provided that the products are installed in accordance with the enclosed instructions. If the products are altered in any way, this declaration no longer applies. Directives EC Machinery Directive 98/38/EC EMC Directive 89/336/EC (amended by 92/31/EC and 93/68/EC) Low Voltage Directive 73/23/EC (amended by 93/68/EC) b) are manufactured in accordance with the following harmonised standards. EN 292-1, EN 292-2, EN292-2/A1, EN 294 EN 60204-1 Naestved, 01.07.2007 Bjarne Soerensen Department manager Novenco A/S ZCF 21

MU 13729 0707 Novenco develops and manufactures ventilation and fire fighting systems that are marketed and distributed world-wide 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 friendly products. The company is certified according to ISO 9001 and ISO 14001. The headquarters of Novenco is located in Naestved, Denmark. Novenco, Hi-Pres and XFlow are registered trademarks of Novenco. Read more about Novenco on the Internet. Novenco A/S Industrivej 22 DK-4700 Naestved Denmark Tel. +45 70 12 42 22 Fax +45 55 75 65 50 www.novenco.biz