Euroclima ZHK User manual

ZHK
INSTRUCTION MANUAL

Instruction Manual ZHK
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In addition to the instructions in this guide,
subject-specific standards, as well as local, national and
international regulations must be observed.
!
After completion of the work, please give this instruction man-
ual to the operating staff. Please keep the complete instruc-
tion and operating manual filed with your other documents.
!

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Table of contents
1Introduction ............................................................................................................................ 6
1.1 Supplementary instructions to this instruction manual ..................................................... 6
1.2 Limitation of liability ......................................................................................................... 6
1.3 Type key.......................................................................................................................... 6
1.4 Intended use / foreseeable misuse.................................................................................. 7
1.4.1 Intended use ........................................................................................................................7
1.4.2 Foreseeable and considered misuse...................................................................................8
1.5 Modular design................................................................................................................ 9
1.6 Documentation ................................................................................................................ 9
2Safety instructions / Guidelines to conformity to laws and directives ............................. 10
2.1 Symbols in this manual.................................................................................................. 10
2.2 Personal protective equipment ...................................................................................... 11
2.3 Indications for minimizing specific hazards .................................................................... 12
2.3.1 General indications ............................................................................................................12
2.3.2 Refrigeration circuit............................................................................................................15
2.3.3 ATEX AHUs .......................................................................................................................16
2.4 Conformity with directives, regulations and laws / Assembly instructions for safe and
compliant operation ....................................................................................................... 17
2.4.1 EC declaration of conformity in accordance to EC machinery directive 2006/42/EC........17
2.4.2 Installation instructions for a safe and compliant installation in the building system .........18
On site assembly and installation ................................................................................... 18
ErP conformity according to commission regulation (EU) Nr. 1253/2014 ....................... 20
2.5 Staff selection and qualification ..................................................................................... 20
3Reception control / unloading / transportation to installation site ................................... 21
3.1 Reception control .......................................................................................................... 21
3.2 Lifting by forklift / lift truck .............................................................................................. 23
3.3 Further necessary actions for the overlifting of both, delivery sections on crane lugs as
well as monoblocs ......................................................................................................... 24
3.4 Over lifting of AHU sections with crane lugs .................................................................. 25
3.4.1 Control of weight limits of delivery sections .......................................................................25
3.4.2 Necessary actions before lifting delivery sections with crane lugs....................................26
3.4.3 Mounting of base frame crane lugs ...................................................................................29
3.4.4 Lifting by crane lugs ...........................................................................................................30
3.5 Overlifting of monoblocs ................................................................................................ 30
3.5.1 Weight details for monoblocs.............................................................................................31
3.5.2 Lifting of monoblocs ...........................................................................................................31
3.6 Lifting when heat wheel or plate heat exchanger casing is delivered in parts ................ 32
3.6.1 Assembly order of disassembled delivered casing parts...................................................32
3.6.2 Lifting of heat wheel or plate heat exchanger....................................................................33
3.6.3 Assembly of flat crane lugs................................................................................................34
3.7 Storage.......................................................................................................................... 35
4Foundation / erection ........................................................................................................... 36
4.1 Foundation .................................................................................................................... 36
4.2 Erection......................................................................................................................... 38
4.2.1 Potential risks that could arise at the erection site ............................................................38
4.2.2 Actions to prevent potential risks .......................................................................................39
4.2.3 General indications for the erection ...................................................................................39
4.2.4 Special guidelines for flat AHUs –ceiling AHUs................................................................40
5Assembly .............................................................................................................................. 42
5.1 Assembly of casing........................................................................................................ 42
5.1.1 Actions before the assembly of casing ..............................................................................42
5.1.2 Standard connections and connection components..........................................................45
5.1.3 Detailed solutions and connection components ................................................................47
5.1.4 Establishing the screw connection of AHU parts...............................................................49

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5.1.5 Special features for roof AHUs and device separations at wet areas ...............................51
5.1.6 Cable gland........................................................................................................................55
5.1.7 Transport lock ....................................................................................................................56
5.1.8 Securing the position of AHUs...........................................................................................56
5.2 Doors ............................................................................................................................ 57
5.3 Dampers........................................................................................................................ 62
5.4 Airfilters ......................................................................................................................... 62
5.4.1 Panel filter and / or bag filter laterally removable ..............................................................62
5.4.2 Panel filter and / or bag filters in filter frame ......................................................................63
5.4.3 Laterally removable bag filters with clamping mechanism ................................................63
5.4.4 HEPA filters........................................................................................................................65
5.4.5 Activated carbon filter ........................................................................................................66
5.5 Dampers with external gear wheels............................................................................... 67
5.6 Hygienic AHUs .............................................................................................................. 67
6Installation ............................................................................................................................ 68
6.1 Heat exchanger connection........................................................................................... 68
6.1.1 General notes ....................................................................................................................68
6.1.2 Steam heat exchanger.......................................................................................................70
6.1.3 Plate heat exchangers for refrigeration circuits .................................................................71
6.2 Humidifier, indirect adiabatic cooling ............................................................................. 72
6.2.1 Water quality ......................................................................................................................72
6.2.2 Protection of the drinking water against pollution ..............................................................73
6.2.3 Special indications for different humidification systems ....................................................73
Spray humidifier –Installation of the pump circuit .......................................................... 73
Evaporative humidifier .................................................................................................... 77
High pressure spray humidifier ....................................................................................... 77
Steam humidifier............................................................................................................. 77
6.3 Drain for condensate and excess water......................................................................... 77
6.3.1 Standard siphons ...............................................................................................................78
6.3.2 Ball Siphons .......................................................................................................................79
6.4 Duct connection –airside connection to AHU................................................................ 80
6.4.1 Requirements.....................................................................................................................80
6.4.2 Insulation of fresh air damper ............................................................................................83
6.5 Pumps........................................................................................................................... 83
6.6 Freeze protection measures .......................................................................................... 83
7Electrical connection............................................................................................................ 84
7.1 Connecting to an external protective conductor system................................................. 84
7.2 AC motors ..................................................................................................................... 84
7.3 EC motors ..................................................................................................................... 89
7.4 Main switch (emergency stop switch) ............................................................................ 89
7.5 Variable, frequency-controlled drives (VFD, frequency converters) ............................... 90
7.6 Electric heaters.............................................................................................................. 91
7.6.1 AHUs equipped by EUROCLIMA with control ...................................................................91
7.6.2 AHUs which are not equipped from EUROCLIMA with control .........................................93
7.7 Differential pressure restriction for plate heat exchangers ............................................. 94
7.7.1 General indications ............................................................................................................94
7.7.2 Prevention measures .........................................................................................................94
7.7.3 Pressure monitoring with differential pressure switch .......................................................95
7.8 Frost protection for plate heat exchanger ...................................................................... 96
7.9 Lighting.......................................................................................................................... 97
7.10 UV section..................................................................................................................... 97
8Commissioning..................................................................................................................... 98
8.1 Preliminary steps........................................................................................................... 98
8.1.1 Variable frequency controlled drives (frequency converter) - parameters.........................98
8.1.2 Airflow measurement by differential pressure measurement at the fan ..........................101
8.1.3 Heat exchanger................................................................................................................102
8.1.4 Electric heater ..................................................................................................................103

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8.1.5 Air filters ...........................................................................................................................103
8.1.6 Humidifier / Air washer.....................................................................................................103
General indications....................................................................................................... 103
Spray humidifier............................................................................................................ 104
Evaporative humidifier .................................................................................................. 104
High-pressure spray humidifier..................................................................................... 104
Steam Humidifier .......................................................................................................... 104
8.2 Refrigeration circuit...................................................................................................... 105
8.2.1 General notes ..................................................................................................................105
8.2.2 Manually starting the compressor via EUROCLIMA control system ...............................105
8.2.3 Refrigerant .......................................................................................................................105
8.2.4 Compressor lubricant.......................................................................................................106
8.3 Test run....................................................................................................................... 106
8.3.1 Adjusting variable pulleys ................................................................................................106
8.3.2 Vibration verification.........................................................................................................107
9Maintenance........................................................................................................................ 108
9.1 Electrical connection, control cabinet........................................................................... 109
9.2 Fan / motor group........................................................................................................ 109
9.2.1 Vibrations .........................................................................................................................109
9.2.2 Fan...................................................................................................................................110
9.2.3 Motor................................................................................................................................111
9.2.4 V-belt drive.......................................................................................................................112
9.2.5 Re-tensioning of belts ......................................................................................................113
9.2.6 Replacing of belts ............................................................................................................115
9.3 Air filters ...................................................................................................................... 115
9.3.1 Panel filters ......................................................................................................................116
9.3.2 Bag filters .........................................................................................................................116
9.3.3 HEPA filters......................................................................................................................116
9.3.4 Activated carbon filters.....................................................................................................117
9.4 Heat exchangers ......................................................................................................... 117
9.4.1 Medium water / steam......................................................................................................117
9.4.2 Refrigerant .......................................................................................................................118
9.4.3 Electric Heater .................................................................................................................118
9.5 Humidifiers .................................................................................................................. 118
9.5.1 General indications ..........................................................................................................118
9.5.2 Spray humidifier ...............................................................................................................119
9.5.3 Evaporative humidifiers....................................................................................................119
9.5.4 High-pressure humidifiers................................................................................................119
9.5.5 Steam humidifiers ............................................................................................................119
9.6 UV section................................................................................................................... 120
9.7 Dampers...................................................................................................................... 120
9.8 Sound attenuators ....................................................................................................... 120
9.9 Weather louver............................................................................................................ 120
9.10 Energy recovery systems ............................................................................................ 120
9.10.1 Plate heat exchangers .....................................................................................................120
9.10.2 Heat wheels .....................................................................................................................121
9.10.3 Heat pipes........................................................................................................................121
9.10.4 Accublocks.......................................................................................................................121
9.11 Refrigeration circuit...................................................................................................... 122
9.11.1 Leakage checks ...............................................................................................................122
9.11.2 Maintenance ....................................................................................................................123
9.11.3 Inspection.........................................................................................................................124
9.12 Hygienic AHUs ............................................................................................................ 125
9.13 Maintenance plan ........................................................................................................ 125
10 Information on airborne noise emitted by the AHUs - on request .................................. 127
11 AHUs in ATEX execution ................................................................................................... 127
11.1 Specific instructions for ATEX AHUs ........................................................................... 127

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11.2 The ATEX type key...................................................................................................... 128
11.3 Supplementary notes on AHU design.......................................................................... 129
11.4 Ignition temperature and temperature classes............................................................. 129
11.5 Additional instructions for foundation and erection, assembly, connection and
commissioning, maintenance and repair...................................................................... 131
11.5.1 Foundation and erection ..................................................................................................131
11.5.2 Assembly, connection and commissioning......................................................................131
Ensure the tightness of the AHU .................................................................................. 131
Motor: ........................................................................................................................... 132
Fan section................................................................................................................... 132
Air filters........................................................................................................................ 132
Heat exchangers / steam humidifiers ........................................................................... 132
Field devices................................................................................................................. 132
11.5.3 Maintenance and repair ...................................................................................................132
12 Disassembly and disposal ................................................................................................. 133
12.1 Disassembly................................................................................................................ 133
12.2 Disposal ...................................................................................................................... 133
Figure index .............................................................................................................................. 135
Table index................................................................................................................................ 140
-Original Instructions -

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1 Introduction
1.1 Supplementary instructions to this instruction manual
This is the instruction manual for an air handling unit, hereinafter designated as ‘AHU’. This instruc-
tion manual is provided as part of the AHU to enable the safe and correct use of an AHU con-
structed by EUROCLIMA. The target group of this instruction manual are all persons who are di-
rectly involved with transport, assembly, commissioning and installation, operation, maintenance,
troubleshooting and disassembling (see also chapter 2.5 (Staff selection and qualification)).
This instruction manual must be kept in the immediate vicinity of the AHU and must always be ac-
cessible to personnel. The fundamental requirement for safe and effective operating is that all
safety and handling instructions provided in this instruction manual are observed and implemented.
This includes local occupational health and safety regulations and general safety regulations for
the area of application of the AHU
1.2 Limitation of liability
EUROCLIMA assumes no liability or warranty for damages or consequential damages due to the
following:
-Non- observance/ adherence to the instruction manual and / or other applicable documents
-Non intended use or misuse
-Use of untrained personnel
-Unauthorized structural changes
-Technical changes
-Use of non-approved spare parts
1.3 Type key
ZHK INOVA 15/6 –15/6
AHU type
AHU size supply air
AHU size exhaust air
Figure 1: Example AHU type key
Legend used for AHU type
ZHK VISION
casing type with thermally decoupled version T2-TB1
ZHK INOVA
casing type with thermally decoupled version T2-TB2
ZHK 2000
casing type version T3-TB3
ZHK NANO
compact AHU series / casing type with thermally decou-
pled version T2-TB2
ETA XXX
key ETA: including control
ETA POOL
compact AHU for pool dehumidification with refrigeration
circuit (option)
ETA MATIC
control for AHUs

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Legend for the AHU size
Example 15/6: the first index (15) corresponds to the clear width, the second index (6) to the clear
height. According to the following table, the dimensions in mm are →15/6 = 1525 x 610 mm (clear
width x clear height)
This information applies both to the ratios of the supply air and the exhaust air.
1.4 Intended use / foreseeable misuse
1.4.1 Intended use
The AHU is used, depending on the chosen purpose for
-transportation and conditioning of air in and out of habitable buildings or vessels.
-creation of a desired room air quality in living and work spaces
-creation of an acceptable comfort or desired working conditions
-depending on the AHU type, the air conditioning is done primarily by
oAir change
oControl of air temperature and air humidity
oFiltration of normal polluted air
oFiltration at specific requirements (clean room and so on)
The AHU is suitable for
-operation in the range of the agreed design data
-an ambient air temperature range of –20 °C to + 60 °C at installation site, if electrical/electronic
components are mounted on the outside of the AHU, then + 40 °C maximum
-a minimum temperature of the transported air of -20 °C (if necessary, freeze protection
measures must be installed)
-a maximum temperature of the transported air of +60 °C
-inside the AHU at motors and other electrical/electronic components up to +40 °C maximum
The AHU must be used as intended and in the appropriate environment, if not this is categorized
as misuse of the device. If there is any case of AHU misuse, then the warranty/ guarantee be-
comes null and void, which means immediate expiration of the complete warranty and / or guaran-
tee claims.
The operation within other conditions must be agreed in writing. Unless otherwise agreed, the de-
sign of the AHU is for a nominal density of the air of 1,20 kg/m³.
Design responsibility for AHUs, are built according to customer specifications
AHUs from EUROCLIMA as described in this manual are designed, built and delivered according
to customer requirements and specifications. Therefore, EUROCLIMA can select and offer a num-
ber of materials and components, which are varied in quality levels.
Generally, a HVAC specialist, knowing the exact application of the AHU, generates a specification,
in which customer requirements for the AHU are defined. The properties of the AHU, specified by
EUROCLIMA, are agreed with the customer and are stated on the technical data sheets and draw-
ing of the AHU.
Index
3
4
6
9
12
15
18
21
24
Dimension (mm)
305
457,5
610
915
1220
1525
1830
2135
2440
Index
27
30
33
36
39
42
45
48
Dimension (mm)
2745
3050
3355
3660
3965
4270
4575
4880

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Thus, the assessment of the suitability of the AHU for the specific application (e.g. used materials
or filter classes) is not the responsibility of EUROCLIMA. Therefore, a disclaimer applies for EU-
ROCLIMA, if the suitability of the AHU for the specific application and installation site should not be
fully stipulated.
As an example, the use at highly polluted or corrosive air (e.g. close to the sea, in industry atmos-
phere or at contaminated/corrosive exhaust air) is mentioned. In this case, corrosion of the AHU or
inappropriate filtration of the air could be a result of a planning error, for which EUROCLIMA de-
clines and does not accept any responsibility, because the AHU is built according to the confirmed
specifications.
Other applicable documents
The following documents apply in addition to this manual:
-Technical data sheets of the AHU from EUROCLIMA
-AHU drawings
-Order confirmation
-Operating and instruction manuals and, if applicable, data sheets of the supplier components
or component manufacturers
-Wiring diagram and operation manual of AHUs with control
-If applicable, further drawings
Components provided by the customer
If it is planned and agreed, that EUROCLIMA installs components in the AHU, which are provided
by the customer, EUROCLIMA only accepts liability, if there are significant mistakes in construc-
tion.
The warranty for proper functionality of the provided components, as well as the component con-
cerned safety requirements, is excluded.
It is important to note, the issued EC declaration of conformity applies only for the scope of delivery
from EUROCLIMA, not for components provided by the customer.
Changes of the AHU by the customer
Attention!
If there are any changes to the AHU undertaken by the costumer after delivery, then the warranty
becomes invalid. Subsequent changes of the AHU, which are not authorized by EUROCLIMA, are
the sole responsibility of the executing person, concerning functionality as well as all safety as-
pects.
1.4.2 Foreseeable and considered misuse
Other than the above use, it is considered as damaging and must be excluded totally:
-The commissioning of equipment, prior to performing the steps indicated in the assembly in-
structions and operation with opened, unsecured service doors is a serious risk and hazard.
-Opening the AHU, without securing the main switch in the off position, represents a significant
risk and hazard.
-The operation of an AHU equipped with an electric heater while the fan-motor is cut off, or if the
fan is working at a limited airflow (for example, caused by closed dampers or similar and with
the electric heater in operation) produces an imminent fire risk.
-The operation in combustible conditions is prohibited, as long as the AHU is not executed in
accordance with the ATEX directive 2014/34/EU. Application of AHUs in ATEX execution, see
chapter 2.3.3 (ATEX AHUs) and chapter 11 (AHUs).
-Handling of air with corrosive / aggressive components.
-Pressure-sided doors can detach suddenly while opening. So, there is a significant risk of injury
for the user. See chapter 5.2 Doors.

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-The operation in a location with high relative humidity causes condensation on the unit sur-
faces.
-The operation in a corrosive ambient atmosphere (e.g. salt water, etc.).
1.5 Modular design
Because of the modular AHU design, the instruction manual covers all the possible sections and
components which can be delivered. The ordered range is smaller and can be viewed on the tech-
nical data sheet - see chapter 1.6 (Documentation).
In this manual, stated parts/components that are not part of the delivered AHU, can therefore be
disregarded.
1.6 Documentation
The AHU will be delivered with the following documentation:
Instruction manual ZHK (This document is an
extract of the complete instruction and operating
manual and includes chapters 1 to 4.)
There is a marked cardboard box, which con-
tains loosely delivered parts inside of the
AHU.
QR-Code for the download of the complete man-
ual
On the AHU and in the delivered manual on
page 1
Depending on AHU type and execution, the following documentation is included:
Operation and instruction manuals of compo-
nents or can be downloaded from the homepage
of the component manufacturers.
There is a cardboard box containing loosely
delivered parts inside of the AHU.
Delivery documentation and packing list (scope
of delivery)
will be handed over upon acknowledgement
of receipt
Operation manual control incl. data point list
ETA MATIC / ETA POOL / ETA NANO_COM-
PACT_FLAT
in control cabinet
AHU drawing
applied on each delivery section
Wiring diagram for ETA
in control cabinet
Depending on type of accessories, the following documentation is included:
K-value for airflow measurement
There is a cardboard box containing loosely
delivered parts inside of the AHU.
Belt drive and tension data
There is a cardboard box containing loosely
delivered parts inside of the AHU.
Piping & instrumentation diagram
in control cabinet
Records for refrigeration circuit application
in control cabinet
The above mentioned documentation must always be available when working on the AHU!

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You will also find stickers with danger, warning and caution labels and other instructions on and
inside the AHU. In this manual and on labels used symbols:
Indicate safety instructions –or yellow triangle with the corresponding hazard pic-
togram
Indication to avoid damage
WARNUNG!
Danger due to illegible labels!
Over time, labels can become illegible and degrade, so that dangers are not rec-
ognized, and important operating instructions cannot be followed. It is therefore vi-
tal that all safety, warning and operating instruction labels are always kept in
clearly legible condition and damaged labels must be replaced immediately.
In addition to the contents of this manual, the instruction manuals of the component manufacturers
must be followed. These will be delivered separately or can be downloaded from the homepage of
the appropriate component manufacturer. In case of contradiction between this manual and in-
struction manual of the component manufacturer for safety instructions, the most technically accu-
rate interpretation is valid. At differences between this manual and the instruction manual of the
component manufacturer, the instruction manual of the component manufacturer has to be applied.
In case of doubt, please contact your EUROCLIMA office.
2 Safety instructions / Guidelines to conformity to laws and directives
2.1 Symbols in this manual
The safety instructions in these operating manuals are marked by symbols. They are highlighted
by key words which stipulate the severity and extent of a danger. These safety instructions must be
observed and adhered to under all circumstances in order to avoid accidents, personal injury,
hazards and damage to property.
DANGER!
Safety instructions with the signal word „DANGER”indicates a hazardous situation
which, if not avoided, are certain to result in death or serious injury.
WARNING!
Safety instructions with the signal word „WARNING” indicates a hazardous situa-
tion that, if not avoided, could result in death or serious injury.
CAUTION!
Safety instructions with the signal word „CAUTION” indicates a hazardous situa-
tion that, if not avoided, could result in minor or moderate injury.

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NOTICE!
Safety instructions with the signal word „NOTICE” indicates a non-immediate or
potential hazard situation that, if not avoided, could result in damage of property
and equipment.
In order to draw attention to special, situation-related dangers, the following warning symbols,
among others, are used in the safety instructions:
Warning symbol
Type of hazard
Warning of general danger
Warning of electrical voltage
Warning of pointed objects and sharp edges
Warning of inflammable substances
Warning of rotating parts
Warning of hot surface
Warning of tilting parts
Warning of suspended load
Warning of sudden detachment of unhinged doors
Warning of UV radiation
Table 1: Warning symbols of situation-related dangers
2.2 Personal protective equipment
Personal protective equipment is intended to protect people against a risk to their safety or health
at work. Therefore, during the various operations on and with the AHU, personnel must wear the
following personal protective equipment (pay attention to correct application!):

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Symbol
Description of personal protective equipment
Protective clothing and ensembles:
Protective work clothing is used to protect against being caught by
moving or rotating parts, stitches, cuts, dust, etc.
Do not wear chains, rings or other jewelry.
Head protection:
Industrial helmets protect the head from falling, swinging, falling or fly-
ing objects, as well as from bumping into objects.
Hand protection:
Protective gloves protect hands from injuries caused by cutting, saw-
ing, trapping, etc., as well as from chemical and thermal hazards.
Foot and leg protection:
Foot and leg protection, such as safety shoes, protect against bump-
ing into objects, pinching, kicking or kneeling in pointed or sharp ob-
jects, as well as against falling or rolling objects.
Eye and face protection:
Eye and face protection are used to protect against foreign objects
and solids, as well as against chemical and thermal hazards.
Hearing protection:
Hearing protection is used to protect against noise that is harmful to
hearing.
Falling protection:
Falling protection is used to protect against an increased risk of falling
if certain height differences are exceeded. Falling protection, such as
safety harnesses, may only be used by specially trained people for
this purpose.
Respiratory protection:
Respiratory protection protects against the inhalation of hazardous
substances, as well as in the case of insufficient oxygen content.
Skin protection:
Skin protection serves to protect against skin diseases and skin dam-
age.
Table 2: Symbols of personal protective equipment
2.3 Indications for minimizing specific hazards
2.3.1 General indications
WARNING!
An improperly performed maintenance can pose a danger, hazard and/or risk!

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Danger due thin sheets and sharp edges, when working on AHU
WARNING!
During work on AHU (or on parts), there is a substantial risk of injury because of
thin sheets and sharp edges. For example, roof sheets, fins of heat exchangers,
corners and edges - Use personal protective equipment: wear protective helmet,
gloves, safety shoes and long protective clothing.
Lighting
For work on AHU (maintenance and inspection work) make sure there is adequate lighting.
Firefighting in case of fire
In general, the local fire protection regulations must be observed.
WARNING!
-If the AHU is part of the smoke extraction system, then the specifications
of this system have to be observed.
-Otherwise, the power supply of the AHU must be shut down immediately
at all conductors. In addition, the dampers must be closed to consequently
prevent oxygen supply and fire spread.
Exposure to harmful substances in case of fire
WARNING!
In case of fire, some materials can produce harmful substances. In addition,
harmful vapors can escape from the AHU. Therefore, severe respiratory protec-
tive equipment is required and the danger zone has to be avoided.
Exposure to rotating parts / hot surfaces / electrocution
When working on and/or in the AHU note the following risks:
WARNING!
Indentation of body parts in moving parts (belt drive, fan impeller, external damper
gear wheels …).
WARNING!
Burns and scalds on hot AHU components such as heat registers, heat exchang-
ers, …
DANGER!
Electrocution on current-carrying parts such as electric motors, frequency convert-
ers, electric heaters, control cabinets, interior lighting etc.
Therefore it must be ensured that prior to working on and/or in the AHU that the following tasks are
adhered to:
-all electrical and live parts, such as cable plug connections, fan motors, valves, motors and
electric heaters are disconnected from the power supply by using the main switch (emergency
stop) and that the switch is locked in position 'off' in order to effectively prevent the re-activation
of the device during the work. The housing of the AHU interior lighting (can have separate sup-
ply) is not live/active.
-all moving parts, especially the fan wheel, motor and heat wheel have stopped completely. It is
important to wait at least 5 minutes after shutting down the device before opening the doors.

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-for maintenance of frequency controlled motors, a waiting time of 15 minutes is recommended –
it gives time to break down the residual capacitive charge of the frequency converter.
-Remove the keys from the doors with a door lock before entering the interior of the AHU. Keep
the key out of reach of all unauthorized persons.
-Check that the hot substance supply, such as steam, is interrupted and all the heat registers,
heat exchangers, etc. are cooled to ambient temperature.
WARNING!
In case of standstill of the plant (e.g. power failure), make sure that the main
switch is always checked. Only when it is in the off position and secured against
unintentional restart, appliance doors can be opened, cable plug connections can
be disconnected and work on the device can be carried out.
Start of the AHU
Ensure after thze completion of work and before starting the device that:
-nobody is in the AHU.
-all protective devices are working, (optional safety devices such as the door guard and belt
guard mounted again) and doors equipped with door locks are locked and the keys are re-
moved –refer to chapter 5.2 (Doors).
Storage of potential energy in gases and fluids
WARNING!
All heat exchangers can be operating up to a maximum pressure of 15 bar. If the
fluid is under higher pressures, the safety and tightness cannot be guaranteed.
Preventing the risk of explosion and fire spread
WARNING!
To prevent the fire spreading, fire dampers shall be installed into the ducts be-
tween the fire compartments.
Prevention of exposure caused by antifreeze agents
WARNING!
Avoid body contact with antifreeze agents, because they may cause burns. Al-
ways wear appropriate protective clothing (e.g. gloves, goggles etc.).
WARNING!
In case of fire, avoid the danger zone and meet any safeguards and regulations. It
is recommended to wear a mouth guard, because of the risk of poisoning by in-
haling the vapors.
Prevention of hazards caused by steam heaters or humidifiers
WARNING!
Scalding risk from hot steam! Therefore, make sure that no steam pressure is
present and the system is cooled before working on the steam piping.
WARNING!
Avoid any type of ignition source when cleaning the humidifier and the associated
components and circuits by means of a descaling agent. With strong descaling
agents, direct sunlight can already cause a fire.

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WARNING!
Avoid body contact with descaling agents, as it can cause chemical burns and se-
rious eye damage. When handling descaling agents, wear appropriate protective
clothing (e.g. gloves, goggles etc.) and ventilate the room well.
Prevention of hazards caused by the sudden detachment of door panels while handling re-
movable panels
WARNING!
Removable door panels can fall out suddenly after detaching the connections and
can lead to injuries. Particular care should be taken when removing pressure sided
doors because they can be firmly in place and then suddenly detach. The user
must be able to carry the weight of the door. Two persons are needed when han-
dling doors with a surface of > 0.5 m²
Please note the instructions on the AHU and follow subsequent instructions exactly.
2.3.2 Refrigeration circuit
Preventing the risk of exceeding the maximum operating pressures PS
WARNING!
Never exceed the maximum operating pressures PS, which are specified on the
type plate (even not for test purposes). Damage may limit the security, effective-
ness and lifetime of the system. Never operate the refrigeration system with a
closed discharge line valve.
Risk of burns on hot surfaces
WARNING!
On the compressor casing, pipelines and circuit components and on the oil sump
heater surface temperatures of far higher than 100 °C may occur, which may
cause serious injuries. Wear the required personal protective equipment (protec-
tive goggles, gloves, etc.).
Prevention of risks due to contact with refrigerant
WARNING!
Physical contact with refrigerant must be strictly avoided as it can cause severe
frostbite and damage the retina - temperature range, for example R407C at ambi-
ent pressure is approximately –44 °C!
Prevent the risk of suffocation
DANGER!
Safety refrigerants are odorless, tasteless and can contaminate the air and cause
suffocation (MAK - value 1000 ppm).
-In case of refrigerant leaks, immediately leave the affected room. Enter only with breathing pro-
tection and ensure adequate ventilation.
-Refrigerant is heavier than air and will collect at the lowest room point. For small refrigerant
charges, this risk is significantly reduced.
-Refrigerant and compressor oil react as soon as they come into touch with open flame toxic
substances. Do not inhale!
-Do not smoke in the technical room!
-For more information refer to chapter 8.2.3 (Refrigerant).

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2.3.3 ATEX AHUs
If instructions differ, the ATEX-specific instructions must be given priority. In addition to the actions
mentioned here, the instructions according to chapter 11 (AHUs) have to be observed.
General safety indications
Hazardous areas must be rated on the frequency and duration of the occurrence of hazardous ex-
plosive atmospheres (gas / air or steam / air mixtures and / or dust / air mixtures). This is described
in Directive 1999/92/EC. Because of this zoning an adapt AHU must be used. The relationship be-
tween zones and category as per Table 22 (chapter 11.3 (Supplementary notes on AHU de-
sign)) described.
WARNUNG!
ATEX AHUs may not be used near:
-High frequency sources (e.g. transmitter systems)
-Strong light sources (e.g. laser beam systems)
-Ionizing radiation sources (e.g. X-ray machine)
-Ultrasound sources (e.g. ultrasound echo testing equipment)
Safety indications for operation
The following instructions must be observed urgently for the safe operation of ATEX AHUs:
-Operating conditions in accordance to the intended use.
-In the immediate environment of the AHU there should be no substances ac-
cording to EN 1127-1:2019-10, which are prone to spontaneous combustion,
such as pyrophoric substances.
-Permanent and adequate ventilation of the installation room to prevent the
creation of an explosive atmosphere, which is caused by leakage.
-Do not exceed 80 % of the maximum permitted speed of the fan, as it could
otherwise lead to sparking and damage.
-Appropriate measures must be taken against all types of ignition sources that
are not specific to the AHU and are not included in the Euroclima scope of
delivery.
Safety indications for maintenance and repair work
In addition to the safety instructions in chapter 2.3 (Indications for minimizing specific hazards)
and in chapter 2.5 (Staff selection and qualification), the following special safety instructions
must be observed:
-Work may only be performed within a clean atmosphere with no risk of explo-
sion.
-The formation of conditions, which could create a risk of explosion need to be
counteracted by adequate ventilation.
-Also, if necessary, it could be required to flush the system with fresh air, in
order to remove or dilute any vapors or other air impurities, which could cause
an explosion risk.
-When the system is at a standstill, the concentration of the atmosphere can
change and thus increase the risk of explosion. Therefore, all types of ignition
sources must be avoided during maintenance. If necessary, it might be re-
quired to carry out an assessment or air monitoring with a gas detector before
starting work and during work.
-Work may only be carried out in areas where there are no ignition sources. It
is particularly important to ensure that all work equipment is approved for the
corresponding area (see EN 1127-1 appendix A and TRBS 2152).
-Use only suitable tools according to EN 1127-1:2019-10 to prevent sparking.
-Perform work only with conductive footwear (according to BGR 132) in order
to avoid electrostatic charging.

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-To prevent the formation of by stirring up dust deposits, all internal and exter-
nal device surfaces must be continuously cleaned.
-To avoid static charging, cleaning work may only be performed with a wet
cloth.
2.4 Conformity with directives, regulations and laws / Assembly instructions for
safe and compliant operation
2.4.1 EC declaration of conformity in accordance to EC machinery directive
2006/42/EC
For an AHU (or any part thereof) supplied by EUROCLIMA, an EC declaration of conformity in ac-
cordance with the EC Machinery Directive 2006/42/EC will be issued.
When the AHU is a part of the building system. For the device’s safe, practical and intended opera-
tion, it is the responsibility of the customer to make sure that all on site works are carried out before
the device can commence operations. This preparation is necessary and vital for the device and
system to work effectively. These types of works are described in chapter 2.4.2 (Installation in-
structions for a safe and compliant installation in the building system) and in the following
chapters of this instruction manual.
The AHU must be mounted and operated professionally, according to the specifications stipulated
in this instruction manual. The safe operation of the AHU in the overall building system is thus the
responsibility of the customer.
The CE-conformity / EC declaration of conformity applies for the delivery state of the AHU.
In the mounted state, the AHU fulfills the requirements of the specified European directives
and harmonized standards only if the instructions and information in this instruction man-
ual are carefully observed and implemented.
The issued EC declaration of conformity declares that due to its concept and type, as well as in de-
sign placed into the market by EUROCLIMA, the AHU complies with the fundamental health and
safety requirements of the EC Machinery Directive 2006/42/EC.
EUROCLIMA thus follows the Eurovent interpretation of the Machinery Directive:
[Eurovent 6/2-2015 “Recommended code of good practice for the interpretation of Directive
2006/42/EC on machinery concerning air handling units”, vom 19. Oktober 2015.]
Applied European directives and harmonized standards:
Every AHU by EUROCLIMA is a customized produced unit. Therefore, please refer to unit specific
EC declaration of conformity of the delivered AHU for information on the applied European direc-
tives and harmonized standards.
Depending on the particular application and country-specific requirements and laws it is possible,
that the AHU does not meet the valid requirements at the ordered state at delivery.
Therefore, you the customer and installer of the AHU are responsible, before commission-
ing of the AHU, to check the conformity of the entire system to the valid laws and directive.
If there are any doubts about the conformity of the AHU with the local (on site) valid laws and direc-
tives, the AHU is only allowed to be put into operation, if the conformity of the AHU in the system is
unequivocally guaranteed.

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Depending on the chosen purpose of the AHU, in addition to the EC Machinery Directive
2006/42/EC the following European directives can be applied:
-Electromagnetic compatibility directive 2014/30/EU
-Commission regulation Ventilation Units (EU) No. 1253/2014 *)
-Pressure equipment directive ‘PED' 2014/68/EU
-ATEX directive 2014/34/EU
*) ErP conformity according to commission regulation (EU) Nr. 1253/2014
„Out of scope“ – AHUs according to technical data –information therefor on technical device data
sheets - with the following characteristics are excluded from the area of application of the regula-
tion (EU) 1253/2014:
Exemptions:
- Exemption 1: AHU without fan (valid in the absence of supply air fan or exhaust air fan or both)
- Exemption 2: AHU operates only in recirculation mode
- Exemption 3: AHU for cruise ships/ships
- Exemption 4: AHU for delivery outside the European Union
- Exemption 5: AHU operates only in potentially explosive air conditions, according to EU Di-
rective 2014/34/EU (valid for supply air, exhaust air or both).
- Exemption 6: AHU operates only in toxic, abrasive or flammable air
- Exemption 7: AHU operates only with air temperatures greater than 100 °C
- Exemption 8: AHU contains a heat exchanger and a heat pump for heat recovery in accord-
ance with regulation (EU) 1253/2014. Article 1.1 (g)
- Exemption 9: AHU with ERS and integrated refrigerating machine for heating purposes
The mentioned exemptions refer only to regulation (EU) 1253/2014. Basically, the instructions in
this instruction manual apply. For the special requirements of the specific AHU resulting from the
applicable exemption, the special agreements defined in the order clarification apply.
2.4.2 Installation instructions for a safe and compliant installation in the building
system
On site assembly and installation
For the proper installation of AHU equipment and the safe operation of the system, depending on
the configuration of the AHU, before the first start at least, the following points must be imple-
mented or upgraded and is the responsibility of the client:
Assembly of delivery sections
The delivery sections of the AHU must be assembled and linked together, according to the sup-
plied drawing. See the chapter 4 (Foundation / erection).
Secure inlet and outlet openings
All the inlet and outlet openings must be connected to ducts or respectively equipped with grilles,
to prevent the risk of persons accessing moving parts (such as fan wheels) during operation.
Main switch
See chapter 7.3 (EC motors).
Installation of ceiling AHUS –flat AHUs
See chapter 4.2.4 (Special guidelines for flat AHUs –ceiling AHUs).
Installation of filters
See chapter 5.4 (Airfilters).

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Temperature limitation
Ensure that a control system is fitted and that the AHU is only operated with a supply air tempera-
ture below the allowable maximum (see chapter 1.4.1 Intended use, when not stated otherwise in
the technical data). For this purpose, the continuous monitoring of the supply air must be ensured
on site.
Measures regarding noise attenuation
On request, available sound data can be used, as a basis for the measurement and calculation of
sound (such as for sound attenuators). For information regarding the emitted sound power level
over the openings see the technical data sheet, which is available on request –refer to chapter 10
(Information on airborne noise emitted by the AHUs - on request).
Measures to minimize the risk of water damage or damage caused by similar media
See chapter 4.2.2 (Actions to prevent potential risks).
Motor connection
See chapter 7.2 (AC motors).
Frequency controller for Plug fans
Furthermore, if not supplied by EUROCLIMA, a frequency converter must be installed to reach the
calculated operating point. For details see chapter 7.5 (Variable, frequency-controlled drives
(VFD, frequency converters)).
Connection to an external protective conductor system
See chapter 7.1 (Connecting to an external protective conductor system).
Electric heater
Installation (if not supplied by EUROCLIMA) and connection of thermostats for safety shutdown,
see chapter 7.6 (Electric heaters).
Plate heat exchanger
Installation (if not supplied by EUROCLIMA) and connection of differential pressure switches to
protect the plate heat exchanger from damage in chapter 7.7 (Differential pressure restriction
for plate heat exchangers).
Siphons
Connecting according to chapter 6.3 (Drain for condensate and excess water).
Dampers with external gear wheels
According to chapter 5.5 (Dampers with external gear wheels).
Flexible connection
Installations (if not supplied by EUROCLIMA) refer to chapter 6.4 (Duct connection –airside
connection to AHU).
Heat exchanger
For all heat exchangers which are connected on-site, irrespective of the medium used (water, wa-
ter-glycol mixture, aqueous vapor, refrigerant etc), it must be ensured, by the customer, that the
resulting assembly meets the pressure equipment directive ‘PED' 2014/68/EU.
Field equipment for roof AHUs
Onsite mounted field devices for roof AHUs, for example, damper position motors or pressure
switches must be weather-protected in case of insufficient IP class. Furthermore, depending on the
installation situation, possible protection against icing.