Euroclima ZHK Series User manual

ZHK
INSTRUCTION MANUAL

Instruction Manual ZHK
V07-19.0 1/129
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.
!
Betriebsanleitung!
Instruction manual!
Manuale d’istruzione!
ET 174-0

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Table of contents
1Introduction ............................................................................................................................ 6
1.1 Model code...................................................................................................................... 6
1.2 Intended use / foreseeable misuse.................................................................................. 7
1.2.1 Intended use ........................................................................................................................7
1.2.2 Foreseeable misuse.............................................................................................................8
1.3 Modular design................................................................................................................ 8
1.4 Documentation ................................................................................................................ 8
2Safety instructions / Guidelines to conformity to laws and directives ............................. 10
2.1 CE-conformity / installation instructions for safe operation............................................. 10
2.1.1 CE-conformity / incorporation declaration according to Machinery Directive 2006/42/EC 10
2.1.2 Installation instructions for the proper installation in the building system..........................10
2.2 Indications for minimizing specific hazards .................................................................... 12
2.2.1 General indications ............................................................................................................12
2.2.2 Refrigeration circuit ............................................................................................................14
2.2.3 ATEX AHUs .......................................................................................................................14
2.3 Conformity to laws and directives .................................................................................. 15
2.3.1 General ..............................................................................................................................15
2.4 ErP conformity according to directive (EU) 1253/2014................................................... 15
2.5 Staff selection and qualification ..................................................................................... 16
3Reception control / unloading / transportation to installation site ................................... 16
3.1 Reception control .......................................................................................................... 16
3.2 Lifting by forklift / lift truck .............................................................................................. 18
3.3 Overlifting of AHU sections with crane lugs ................................................................... 19
3.3.1 Control of weight limits of delivery sections .......................................................................20
3.3.2 Necessary actions before lifting delivery sections with crane lugs....................................21
3.3.3 Mounting of crane lugs.......................................................................................................23
3.3.4 Lifting by crane lugs ...........................................................................................................24
3.4 Overlifting of monoblocs ................................................................................................ 25
3.4.1 Weight details for monoblocs.............................................................................................25
3.4.2 Lifting of monoblocs ...........................................................................................................25
3.5 Further necessary actions for the overlifting of both, delivery sections on crane lugs as
well as monoblocs ......................................................................................................... 27
3.6 Storage.......................................................................................................................... 28
4Foundation / erection ........................................................................................................... 29
4.1 Foundation .................................................................................................................... 29
4.2 Erection......................................................................................................................... 30
4.2.1 Potential risks that may arise at the erection site ..............................................................30
4.2.2 Actions to prevent potential risks .......................................................................................31
4.2.3 General indications for the erection ...................................................................................31
4.2.4 Special guidelines for flat AHUs –ceiling AHUs................................................................32
5Assembly .............................................................................................................................. 34
5.1 Assembly of casing........................................................................................................ 34
5.1.1 Actions before the assembly of casing ..............................................................................34
5.1.2 Standard connections and connection components..........................................................37
5.1.3 Detailed solutions and connection components ................................................................39
5.1.4 Establishing the screw connection of AHU parts...............................................................41
5.1.5 Special features for roof AHUs and device separations at wet areas ...............................43
5.1.6 Cable gland........................................................................................................................47
5.1.7 Transport lock ....................................................................................................................48
5.1.8 Securing the position of AHUs...........................................................................................49
5.2 Doors ............................................................................................................................ 49
5.3 Dampers........................................................................................................................ 54
5.4 Airfilters ......................................................................................................................... 54
5.4.1 Panel filter and / or bag filter laterally removable ..............................................................55

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5.4.2 Panel filter and / or bag filters in filter frame ......................................................................55
5.4.3 Laterally removable bag filters with clamping mechanism ................................................56
5.4.4 HEPA filters........................................................................................................................57
5.4.5 Activated carbon filter ........................................................................................................58
5.5 Dampers with external gear wheels............................................................................... 59
5.6 Hygienic AHUs .............................................................................................................. 59
6Installation ............................................................................................................................ 60
6.1 Heat exchanger connection........................................................................................... 60
6.1.1 General notes ....................................................................................................................60
6.1.2 Steam heat exchanger.......................................................................................................62
6.1.3 Plate heat exchangers for refrigeration circuits .................................................................63
6.2 Humidifier, indirect adiabatic cooling ............................................................................. 64
6.2.1 Water quality ......................................................................................................................64
6.2.2 Protection of the drinking water against pollution ..............................................................64
6.2.3 Special indications for different humidification systems ....................................................65
Spray humidifier –Installation of the pump circuit .......................................................... 65
Evaporative humidifier .................................................................................................... 69
High pressure spray humidifier ....................................................................................... 69
Steam humidifier............................................................................................................. 69
6.2.4 Connection of indirect adiabatic cooling ............................................................................69
6.3 Drain for condensate and excess water......................................................................... 70
6.3.1 Standard siphons ...............................................................................................................70
6.3.2 Ball siphons........................................................................................................................71
6.4 Duct connection –airside connection to AHU................................................................ 73
6.4.1 Insulation of fresh air damper ............................................................................................76
6.5 Pumps........................................................................................................................... 76
6.6 Freeze protection measures .......................................................................................... 76
7Electrical connection............................................................................................................ 77
7.1 Connecting to an external protective conductor system................................................. 77
7.2 AC motors ..................................................................................................................... 77
7.3 EC motors ..................................................................................................................... 82
7.4 Main switch (emergency stop switch) ............................................................................ 82
7.5 Variable, frequency-controlled drives (VFD, frequency converters) ............................... 83
7.6 Electric heaters.............................................................................................................. 83
7.6.1 AHUs equipped from EUROCLIMA with control................................................................84
7.6.2 AHUs which are not equipped from EUROCLIMA with control .........................................86
7.7 Differential pressure restriction for plate heat exchangers ............................................. 86
7.7.1 General indications ............................................................................................................86
7.7.2 Prevention measures .........................................................................................................87
7.7.3 Pressure monitoring with differential pressure switch .......................................................87
7.8 Frost protection for plate heat exchanger ...................................................................... 89
7.9 Lighting.......................................................................................................................... 89
7.10 UV section..................................................................................................................... 90
8Commissioning..................................................................................................................... 90
8.1 Preliminary steps........................................................................................................... 90
8.1.1 Variable frequency controlled drives (frequency converter) - parameters.........................91
8.1.2 Airflow measurement by differential pressure measurement at the fan ............................93
8.1.3 Heat exchanger..................................................................................................................94
8.1.4 Electric heater ....................................................................................................................95
8.1.5 Air filters .............................................................................................................................95
8.1.6 Humidifier / Air washer.......................................................................................................95
General indications......................................................................................................... 95
Spray humidifier.............................................................................................................. 96
Evaporative humidifier .................................................................................................... 96
High pressure spray humidifier ....................................................................................... 96
Steam Humidifier ............................................................................................................ 96
8.2 Refrigeration circuit........................................................................................................ 97
8.2.1 General notes ....................................................................................................................97

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8.2.2 Manually starting the compressor via EUROCLIMA control system .................................97
8.2.3 Refrigerant .........................................................................................................................97
8.2.4 Compressor lubricant.........................................................................................................97
8.3 Test run......................................................................................................................... 98
8.3.1 Adjusting variable pullies ...................................................................................................98
8.3.2 Resonance at fans .............................................................................................................99
9Maintenance........................................................................................................................ 100
9.1 Electrical connection, control cabinet........................................................................... 101
9.2 Fan / motor group........................................................................................................ 101
9.2.1 Fan...................................................................................................................................101
9.2.2 Motor................................................................................................................................103
9.2.3 V-belt drive.......................................................................................................................103
9.2.4 Re-tensioning of belts ......................................................................................................104
9.2.5 Replacing of belts ............................................................................................................106
9.3 Air filters ...................................................................................................................... 107
9.3.1 Panel filters ......................................................................................................................108
9.3.2 Bag filters .........................................................................................................................108
9.3.3 HEPA filters......................................................................................................................108
9.3.4 Activated carbon filters.....................................................................................................108
9.4 Heat exchangers ......................................................................................................... 108
9.4.1 Medium water / steam......................................................................................................108
9.4.2 Refrigerant .......................................................................................................................109
9.4.3 Electric Heater .................................................................................................................109
9.5 Humidifiers .................................................................................................................. 109
9.5.1 General indications ..........................................................................................................109
9.5.2 Spray humidifier ...............................................................................................................110
9.5.3 Evaporative humidifiers....................................................................................................110
9.5.4 High pressure humidifiers ................................................................................................110
9.5.5 Steam humidifiers ............................................................................................................111
9.6 UV section................................................................................................................... 111
9.7 Dampers...................................................................................................................... 111
9.8 Sound attenuators ....................................................................................................... 111
9.9 Weather louver............................................................................................................ 111
9.10 Energy recovery systems ............................................................................................ 111
9.10.1 Plate heat exchangers .....................................................................................................111
9.10.2 Heat wheels .....................................................................................................................112
9.10.3 Heat pipes........................................................................................................................112
9.10.4 Accublocs.........................................................................................................................112
9.11 Refrigeration circuit...................................................................................................... 113
9.11.1 Leakage checks...............................................................................................................113
9.11.2 Maintenance ....................................................................................................................114
9.11.3 Inspection.........................................................................................................................115
9.12 Hygienic AHUs ............................................................................................................ 116
9.13 Maintenance plan ........................................................................................................ 116
10 Information on airborne noise emitted by the AHUs - on request .................................. 118
11 ATEX AHUs ......................................................................................................................... 118
11.1 General notes.............................................................................................................. 118
11.2 Information regarding the unit, protective systems and components............................ 120
11.3 Information for erection, assembly, commissioning, maintenance and repair............... 121
11.3.1 Foundation and erection ..................................................................................................121
11.3.2 Assembly, connection ......................................................................................................121
11.3.3 Fan section ......................................................................................................................121
11.3.4 Air filters ...........................................................................................................................122
11.3.5 Heat exchangers / steam humidifiers ..............................................................................122
11.3.6 Field devices ....................................................................................................................122
11.3.7 Declaration of conformity .................................................................................................122

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12 Disassembly and disposal................................................................................................. 123
12.1 Disassembly................................................................................................................ 123
12.2 Disposal ...................................................................................................................... 124
Figure index .............................................................................................................................. 125
Table index................................................................................................................................ 129
-Original Instructions -

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1 Introduction
This is the instruction and operation manual for an air handling unit, hereinafter designated as
‘AHU’.
1.1 Model code
ZHK INOVA S 15/6 –15/6
AHU type (standard)
AHU execution
AHU size supply air
AHU size exhaust air
Legend used for AHU type
ZHK INOVA
casing type with thermal separation profile
ZHK 2000
casing type without thermal separation profile
ZHK NANO
compact AHU series
ETA XXX
key ETA: including control
ETA XXX COOL
including refrigeration circuit
ETA MATIC
standard
ETA POOL SPA
compact AHU for pool dehumidification with refrigeration
circuit (option)
ETA POOL OLYMPIC
for pool dehumidification including plate heat exchanger
and refrigeration circuit
ETA PT
heat recovery by plate heat exchanger
ETA ACCU
heat recovery by accumulator
ETA ROT
heat recovery by heat wheel
ETA WP
refrigeration circuit, heat pump function
ETA PAC
indirect adiabatic cooling
CLEANLINE
for hygienic use, including control
Design key AHU execution
S
AHU for indoor installation
DG
AHU for outdoor installation
I
AHU Industrial –heavy version of the panels
HG
AHU hygienic execution
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)
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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This information applies both to the ratios of the supply air and the exhaust air.
1.2 Intended use / foreseeable misuse
1.2.1 Intended use
The AHU is used, depending on the chosen purpose for
-transportation and conditioning of air in and out of buildings, in which humans stay
-creation of a desired room air quality in the occupied area of humans
-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 operation at other conditions must be agreed in writing. Unless otherwise agreed, the design
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 of the series ZHK 2000 and ZHK INOVA, as described in this manual are designed, built and
delivered according to customer requirements. Therefore, EUROCLIMA can select and offer a
number 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.
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 the responsibility, because the AHU is built according to the confirmed specifications.

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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.
For AHUs with components provided by the customer no CE-conformity is generated due to this
reason.
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 safety aspects.
1.2.2 Foreseeable misuse
Other than above use, is considered as improper and must be excluded totally:
-The commissioning of equipment, prior to performing the steps indicated in the assembly in-
structions and operating with the fan section door open, is a serious security risk.
-Opening the AHU, without securing the main switch in the off position, represents a massive
security risk.
-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 an explosive atmosphere is prohibited, as long as the AHU is not executed in
accordance with the ATEX directive. Application of AHUs in ATEX execution, see chapter 11
(ATEX AHUs).
-Handling of air with corrosive / aggressive components.
-Pressure-sided doors can detach suddenly while opening. So, there is a risk of injury for the
user. See chapter 5.2 Doors.
1.3 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 seen on the tech-
nical data sheet - see chapter 1.4 (Documentation).
In this manual, treated parts/components that are not part of the delivered AHU, can therefore be
disregarded.
1.4 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 cardboard box for loosely deliv-
ered 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

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Depending on AHU type and execution, the following documentation is included:
Components operation manual
There is a cardboard box for loosely deliv-
ered parts inside of the AHU.
AHU drawing
applied on each delivery section
Wiring diagram for ETA
in control cabinet
Operation manual control ETA MATIC /
ETA POOL
in control cabinet
Depending on type of accessories, the following documentation is included:
K-value for airflow measurement
glued on the inside of the fan section door
Belt drive and tension data
There is a cardboard box for loosely deliv-
ered parts inside of the AHU.
Data point list
in control cabinet
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!
You will also find stickers with warning 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
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 component manufacturer. In case of contradiction between this manual and instruction manu-
als of the component manufacturer for safety instructions, the most restrictive interpretation is
valid. At differences between this manual and the instruction manual of the component manufac-
turer, the instruction manual of the component manufacturer has to be applied. In case of doubt,
please contact your EUROCLIMA office.