Exhausto VEX4000 Instruction Manual

VEX4000
Assembly and installation
Product information............................................................... Chapter 1 + 6
Mechanical assembly............................................................ Chapter 2 + 3
Electrical installation.............................................................. Chapter 4
Commissioning and operation............................................... Chapter 5
Original instructions
3005541-2022-10-03 VEX4000
EXHAUSTO A/S
Odensevej 76
5550 Langeskov, Denmark
Tel.: [phone]
Fax: [phone]
[email protected]
www.exhausto.dk

1. Introduction
1.1. Application.............................................................................................................................................. 8
1.2. Unit configurations.................................................................................................................................8
1.3. Terms used in the instructions - simplified diagrams.........................................................................9
1.3.1. Diagram 1 - Air handling unit with rotor, mixer section (MR) and dual-coil (HW-CW).....................9
1.3.2. Diagram 2 - Air handling unit with rotor and integrated cooling (ICC) and water heating coil (HW).
.................................................................................................................................................................. 10
1.3.3. Diagram 3 - Air handling unit with rotor and integrated cooling without cold recovery (IC)...........11
1.3.4. Diagram 4 - Various coils.............................................................................................................. 12
1.4. Location requirements......................................................................................................................... 13
1.4.1. Installation site requirements........................................................................................................ 13
1.4.2. Requirements for underlying surface........................................................................................... 14
1.4.3. Requirements for duct system...................................................................................................... 14
2. Handling and transport
2.1. Transport and delivery......................................................................................................................... 15
2.1.1. Once the VEX has arrived at the assembly site ...........................................................................15
2.1.2. Delivery ........................................................................................................................................ 15
2.1.3. VEX delivered assembled or in sections ......................................................................................15
2.1.4. Weight ..........................................................................................................................................15
2.1.5. Handling the air handling unit....................................................................................................... 15
2.2. Storage and unpacking........................................................................................................................ 19
2.2.1. Before unpacking.......................................................................................................................... 19
2.2.2. Storage and unpacking ................................................................................................................ 19
3. Mechanical installation
3.1. Installing the air handling unit - procedure........................................................................................20
3.1.1. Procedure for assembly................................................................................................................ 20
3.2. Preparation for installation.................................................................................................................. 20
3.2.1. Fitting of adjustment screws ........................................................................................................ 20
3.2.2. Units with cross-flow heat exchanger .......................................................................................... 21
3.3. Installing a sectional VEX.................................................................................................................... 21
3.3.1. Assembly of manual-assembly base ........................................................................................... 21
3.3.2. Positioning of sections ................................................................................................................. 23
3.4. Fitting.....................................................................................................................................................24
3.4.1. Section assembly fitting ............................................................................................................... 24
3.4.2. Interior fitting ................................................................................................................................ 25
3.4.3. Simple exterior assembly fitting (EBS4000) - rear or top..............................................................26
3.4.4. Fitting for feet................................................................................................................................ 27
3.4.5. Threaded bar fitting, assembly via feet on rear of the VEX.......................................................... 27
3.4.6. Base fitting ................................................................................................................................... 29
3.5. Special assembly factors.....................................................................................................................29
3.5.1. Inspection hatch(es) in different sections .....................................................................................29
3.5.2. Removing cooling/heating coil (CW, HW, HWR)...........................................................................31
3.5.3. Removal of electric heating coil (HE)............................................................................................34
3.6. Connection of plugs and sockets....................................................................................................... 35
3.6.1. Connection of plugs and sockets ................................................................................................. 35
3.7. Setting up an assembled outdoor VEX...............................................................................................36
3.7.1. Assembled Outdoor VEX on base ............................................................................................... 36
Avoid condensation forming..........................................................................................................37
3.8. Exhaust air caps (accessories) Outdoor............................................................................................ 38
3.8.1. Fitting of exhaust air/inlet cap....................................................................................................... 38
3.9. Condensation outlet............................................................................................................................. 40
3.9.1. Establishment of condensation outlet........................................................................................... 40
3.9.2. SIPHONE electrical heat tracing ..................................................................................................40
3.9.3. Requirements for water trap ........................................................................................................ 41
3.10. Door locks............................................................................................................................................. 42
3.11. Filter monitor.........................................................................................................................................42
3.11.1. Measuring pressure drop across filters (VDI6022)....................................................................... 42
3.11.2. Commissioning the U pipe manometer.........................................................................................43
3.11.3. Commissioning the Magnehelic® pressure gauge ...................................................................... 43
3.12. Connection of water heating coil........................................................................................................ 44
3.12.1. Connection of water heating coil ..................................................................................................44
3.12.2. Ventilation requirements............................................................................................................... 46
3.12.3. Principle diagram ......................................................................................................................... 46
3.13. Connecting the cooling coil.................................................................................................................47
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3.13.1. Connecting the cooling coil........................................................................................................... 47
3.13.2. Ventilation requirements............................................................................................................... 48
3.13.3. Simplified diagram coolant ...........................................................................................................49
3.14. DX Cooling............................................................................................................................................ 49
3.14.1. General warnings for a unit with DX cooling................................................................................. 49
3.14.2. Connection ...................................................................................................................................49
3.14.3. Technical data .............................................................................................................................. 49
3.15. Integrated cooling IC/ICC.....................................................................................................................50
3.15.1. General warnings for a unit with integrated cooling ..................................................................... 50
3.15.2. Connection ...................................................................................................................................50
3.16. Motor valve............................................................................................................................................51
3.16.1. Motor valve, MV2W/MV3W...........................................................................................................51
3.17. Duct connections..................................................................................................................................51
3.17.1. Duct connection............................................................................................................................ 51
3.17.2. Flexible duct system connections (optional), only for METU connections. .................................. 51
3.18. Air handling units with rotary heat exchangers................................................................................ 51
3.18.1. Rotor section.................................................................................................................................51
3.18.2. Readjustment ...............................................................................................................................52
3.18.3. Purging zone (optional).................................................................................................................53
3.19. Fans....................................................................................................................................................... 53
3.19.1. In general ..................................................................................................................................... 53
3.19.2. Plenum fans ................................................................................................................................. 53
3.20. Establishment of smoke evacuation damper.....................................................................................54
4. Electrical installation
4.1. Scope of installation.............................................................................................................................55
4.2. Dimensioning and electrical installation............................................................................................ 55
4.2.1. Electrical connection/data............................................................................................................. 55
4.2.2. Installation requirements and recommendations......................................................................... 55
4.2.3. Short-circuit current ......................................................................................................................56
5. Startup
5.1. Start-up procedure............................................................................................................................... 57
5.2. Fans start-up......................................................................................................................................... 58
5.2.1. Start-up table ............................................................................................................................... 58
5.3. Determination of airflow, pressure drop across the filter................................................................. 58
5.3.1. Determination of airflow (plenum fan)........................................................................................... 58
5.3.2. Measurement of airflow and pressure drop across the filters ...................................................... 59
6. Technical data
6.1. MVM valves, data.................................................................................................................................. 60
6.1.1. MVM motor valve ......................................................................................................................... 60
6.2. Pressure drop curves...........................................................................................................................60
6.3. Environmental declaration...................................................................................................................60
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Symbols, terms and warnings
Prohibition symbol Failure to observe instructions marked with a prohibition symbol may result in
serious or fatal injury.
Danger symbol Failure to observe instructions marked with a danger symbol may result in per-
sonal injury and/or damage to the unit.
Scope This instruction manual is for use with EXHAUSTO VEX-type air handling units. Please refer to the
product instructions regarding accessories and extra equipment.
The instructions must be fully observed to ensure personal safety and to protect the equipment and
ensure its correct operation. EXHAUSTO A/S accepts no liability for accidents caused by equipment
not used in accordance with the manual’s instructions and recommendations.
Supply air/extract
air
These instructions use the following terms as given in DS447-2013:
● Supply air
● Extract air
● Outdoor air
● Exhaust air
Opening the air
handling unit
Do not open the service doors until power has been disconnected at the isolation
switch and the fans have stopped. The isolation switch is located on the door of
the heat exchanger section. When the isolation switch is in the OFF position, the
light inside the VEX unit can still be switched on and the service socket in the
panel can be used. Everything else on the VEX is de-energised.
There is an extra and separate built-in isolation switch on the door to the electric
heating coil. Units with electric heating coils thus have two isolation switches,
both of which must be in the OFF position to ensure the unit is de-energised.
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Lock the air han-
dling unit during
operation
Use an NV8 Allen key to lock the doors.
NB: All door locks on the air handling unit must be locked during operation.
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Information plate
The sections' information plate shows:
1 ● VEX size and designation for the section.
● Production number and production year.
● Maximum and minimum short-circuit current.
2 ● Supply voltage and the maximum current consumption.
3 ● The section numbers and the total number of sections for the air han-
dling unit (the sections are installed in numerical order from left to
right).
● The section type, if required see the table explaining the type under
the sections "Terms in the instructions - simplified diagrams".
● Weight of the section.
● Weight of the assembled air handling unit.
4 ● Information in connection with ECO design (only on information plate
for fan sections)
● For sections with cooling machine:
- Coolant
- Amount
- PS HT (limit for disconnection because of high pressure)
- PS HT (limit for disconnection because of low pressure)
NB: Always have the production number ready when contacting EXHAUSTO A/S about the product.
Choose the correct documentation for the task.
Find your information.
VEX4000 Assembly and
installations
instructions
Operation and
maintenance
instructions
EXcon hand-
held terminal
Menu and
alarm list
EXcon
instructions
Print out from
calculation pro-
gram
Electrical docu-
mentation for
the order (elec-
trical diagrams)
Supplied docu-
mentation »
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VEX4000 Assembly and
installations
instructions
Operation and
maintenance
instructions
EXcon hand-
held terminal
Menu and
alarm list
EXcon
instructions
Print out from
calculation pro-
gram
Electrical docu-
mentation for
the order (elec-
trical diagrams)
Mechanical
assembly »
Electrical installa-
tion »
Start-up -
operation »
Maintenance -
Service »
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1. Introduction
1.1 Application
VEX4000 covers a wide capacity range, from 800 to 40,000 m³/h, with 10 different unit sizes (VEX4010 -
VEX4100), which means it is ideal for comfort ventilation in many types of buildings - from schools, institu-
tions and offices, to hotels, hospitals and industrial premises. All of the variants have heat recovery either
via a crossflow heat exchanger or rotary heat exchanger, and they can be fitted with a fully integrated con-
trol system.
1.2 Unit configurations
All of the VEX4000 air handling units are configured in the calculation program EXselect Pro. A print
out from the program containing all of the specific data and dimensions for the air handling unit is at-
tached with the other documentation; instructions and electrical documentation (specific electrical dia-
grams, etc.)
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1.3 Terms used in the instructions - simplified diagrams
1.3.1 Diagram 1 - Air handling unit with rotor, mixer section (MR) and dual-coil (HW-CW).
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1.3.2 Diagram 2 - Air handling unit with rotor and integrated cooling (ICC) and water heating coil
(HW).
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1.3.3 Diagram 3 - Air handling unit with rotor and integrated cooling without cold recovery (IC).
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1.3.4 Diagram 4 - Various coils
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Designation Function
1.1 Extract air
1.2 Exhaust air
2.1 Outdoor air
2.2 Supply air
Coil box Control box coil
CP Circulation pump
CW Cooling coil (water cooled)
DX Cooling coil (coolant)
ECEF EC control for extract air motor
ECSF EC control for supply air motor
ER Rotor section
EXcon EXcon control system panel
FANIO 1, P1 Airflow measurement, supply air
FANIO 2, P1 Airflow measurement, exhaust air
FANE/FANS FAN sections (FANE = EXHAUST), (FANS = SUPPLY)
HP High pressure transducer
HW Water heating coil
HW-CW Water heating coil - cooling coil
HWR Heat recovery coil (store solution)
IC Integrated cooling machine
ICC Rotary heat exchanger with integrated cooling machine
Light Light in the section
LP Low pressure transducer
MVM Motor valve
MR Mixer section
DRHX Control unit for the rotary heat exchanger
SP Empty section
TE11 Temperature sensor, extract air
TE12 Temperature sensor, exhaust air
TE21 Temperature sensor, outdoor air
TE22 Temperature sensor, supply air
TE-RWT Return water temperature sensor
TS-RWT-X External return water temperature sensor
TE-SWT Supply temperature sensor
1.4 Location requirements
1.4.1 Installation site requirements
Space requirements There must be free space in front of the air handling unit along the whole length to ensure easy access
for inspection and servicing. The doors must be able to be opened to their entire width, i.e. for inspec-
tion this is at least 950 mm.
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In connection with servicing, it is recommended that the service area is as wide
as the air handling unit, since all of the components can thus be easily taken out.
Outdoor
Air handling units installed on a roof may not be incorporated as part
of the roof cover of the building. There must be a complete roof under
the air handling units.
1.4.2 Requirements for underlying surface
When installing the sections, the surface must be:
● flat
● level (+/- 3 mm per metre)
● hard
● resistant to vibration
1.4.3 Requirements for duct system
Silencers The duct system must be fitted with silencers specified by the Project Manager, in accordance with the
requirements of the operating area.
Bends (only for ple-
num fans)
A duct bend may be fitted immediately after the unit, because the airflow in the spigot has a uniformly
moderate speed profile, which results in negligible system pressure loss.
Bends (only for ax-
ial fan, ZerAx®)
It is recommended that a straight length of pipe is fitted after the axial fan with a length that is 3 x the
fan's diameter, before any bend is added.
Insulation The duct system must be insulated against:
● Condensation
● Sound emission
● Thermal loss
Condensation Condensation in the ducts may occur when the exhaust/outdoor air has high humidity. EXHAUSTO
recommends a condensation outlet is also fitted at the lowest point in the ducts.
No duct connection If one or more of the spigots is not connected to a duct: Fit a protective net to the
spigots with a maximum mesh width of 20 mm.
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2. Handling and transport
2.1 Transport and delivery
2.1.1 Once the VEX has arrived at the assembly site
● Check the air handling unit and any supplied accessories for any transport damage immediately on
arrival at the assembly site.
● Check that the delivery is complete.
If there is any damage or something missing, point it out immediately to the haulier.
2.1.2 Delivery
Overall the delivery consists of:
● VEX unit, assembled or in sections and designed for indoor or outdoor assembly, see the subse-
quent table.
● Supplied loose parts and accessories.
2.1.3 VEX delivered assembled or in sections
Assembly
site
Delivery VEX size Set-up method NB:
Indoor Sectional VEX 4010-4100 Feet If required, fit adjustment screws on the
feet.
4010-4070 100 mm base for manual assembly. If required, fit adjustment screws on the
base.
4080-4100 Fit on site on 200 mm trestle/UPE base If required, fit adjustment screws on the
base.
Outdoor Sectional VEX 4010-4100 Fit on site on 200 mm trestle base
0-4000 mm.
If required, fit adjustment screws on the
base.
Fit on site on 200 mm UPE base
4000-8000 mm.
If required, fit adjustment screws on the
base.
Assembled VEX 4010-4100 Fitted on 200 mm trestle base 0-4000
mm.
If required, fit adjustment screws on the
base.
Fitted on 200 mm UPE base 4000-8000
mm.
If required, fit adjustment screws on the
base.
Supplied loose for
assembled or sec-
tional VEX
● Base - Base is supplied separately incl. bolts and fitting for securing the air handling unit to the
base.
● Any screws (accessories) for alignment are also enclosed in the packaging with loose parts.
Supplied loose only
for sectional VEX
● 4 x simple exterior assembly fittings (EBS4000).
2.1.4 Weight
The air handling unit's assembled weight and dimensions, and the weight and dimensions of the indi-
vidual sections are stated on the supplied print out from the calculation program EXselectPRO.
2.1.5 Handling the air handling unit
VEX4000 is supplied either as an assembled or sectional unit. In both cases, the remaining transport is
executed using a forklift truck or crane, depending on the conditions at the assembly site.
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Specially for cool-
ing machine, inte-
grated cooling
IC/ICC
If the air handling unit is supplied with a section with a cooling machine: Always
transport this section on a max. incline of 30°, to avoid oil running from the com-
pressor. If the incline exceeds 30°, the suction spigot on the compressor must
face upwards.
>30°
>30°
Lifting with forklift
truck
Transport with forklift truck: The truck forks must extend all the way under the
section and lift on the frame on both sides of the section. Nothing should be
moved/stored on the top of the sections.
Lifting by crane For safety reasons, a shackle must be used when lifting by crane.
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Lifting the sections Lifting
● Check the weight on the information plate on the specific sec-
tion.
● Use a minimum of two straps.
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Lifting the assembled air handling unit on base (indoors) Lifting
Check the weight of the whole air handling unit against the type plate on the heat exchanger section.
When lifting with a lifting beam:
● Check the weight of the whole air handling unit against the
type plate on the heat exchanger section.
● Use the rigging fixtures which are fitted on the base.
● The lifting beam must have a width that is +200 mm wider than
the assembled air handling unit.
Rigging fixture
When lifting with straps:
● Check the weight of the whole air handling unit against the
type plate on the heat exchanger section.
● Use the rigging fixtures which are fitted on the base.
Rigging fixture
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Lifting the assembled air handling unit on base (outdoors) Lifting
Check the weight of the whole unit against the type plate on the heat exchanger section.
When lifting with a lifting beam:
● Use the rigging fixtures which are fitted on the base.
● The lifting beam must have a width that is +200 mm wider than
the assembled air handling unit incl. gutters.
RD13763-01
Rigging fixture
2.2 Storage and unpacking
2.2.1 Before unpacking
Unpacking
In general, the product should be protected from dust before it is started – this is due
to dust and hygiene considerations.
2.2.2 Storage and unpacking
Indoor/outdoor
storage
VEX4000 air handling units are supplied either assembled or in sections, packaged in plastic.
Indoor storage Outdoor storage
● In the case of long-term storage, the plastic packaging
may be required be opened at the bottom, so that there
is ventilation under the cover, while still preventing soil-
ing.
● VEX air handling units or sections must be stored in-
doors in areas where the air is dry.
● When storing for more than three months, the fan impel-
lers should be regularly turned by hand.
● Sections must be covered in a way that ensures there is ventila-
tion under the cover to avoid condensation.
● Assembled VEX air handling units with roofs which are designed
for outdoor installation may be stored outside but they should be
covered over to prevent soiling on the construction site. If re-
quired, open at the bottom, so that there is ventilation under the
cover, while still preventing soiling.
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3. Mechanical installation
3.1 Installing the air handling unit - procedure
3.1.1 Procedure for assembly
The following chapter describes the mechanical assembly of the VEX unit. The main points for assembly
are:
1. Set the air handling unit on feet or on a base - level out.
2. Tighten the air handling unit together with the supplied fittings.
3. Connect plugs and sockets
4. Connect the condensation tray(s) to the condensation outlet.
5. Fit any handles onto the doors.
6. Connect the ducts.
7. Connect cooling coil to cooling machine (optional)
8. Ready the heat exchanger (rotary or crossflow heat exchanger).
3.2 Preparation for installation
3.2.1 Fitting of adjustment screws
● Slightly raise the section so that the feet are
free.
● Fit the adjustment screws below the feet.
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