Exhausto VEX5000 Series User manual

EXHAUSTO A/S
Odensevej 76
5550 Langeskov,
Denmark
Tel.: [phone]
Fax: [phone]
[e-mail]
www.exhausto.dk
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VEX5000
Assembly, installation and maintenance
instructions
Original instructions
VEX5000
M O D U L E S
R A N G E

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1. Introduction
1.1 Use ........................................................................................................................6
1.2 Unit configurations.............................................................................................. 6
2. Handling and transport
2.1 Transport and delivery ........................................................................................ 7
2.1.1 Once the VEX has arrived at the assembly site ........................................... 7
2.1.2 Extent of the delivery .................................................................................... 7
2.1.3 Weight .......................................................................................................... 8
2.1.4 Handling the air handling unit ....................................................................... 8
2.2 Storage.................................................................................................................. 9
3. Mechanical assembly
3.1 Setting up and assembling ............................................................................... 10
3.1.1 Installation site requirements ...................................................................... 10
3.1.2 Setting up the base .................................................................................... 11
3.1.3 Positioning and assembly of sections ........................................................ 11
3.2 Fitting roof (outdoor air handling units) .......................................................... 14
3.2.1 Preparation ................................................................................................. 14
3.2.2 Fitting of roof .............................................................................................. 15
3.2.3 Baffel plate .................................................................................................. 17
3.2.4 Air diffuser ................................................................................................... 17
3.3 Fans..................................................................................................................... 18
3.3.1 Transport safety fitting ................................................................................ 18
3.4 Handles on doors............................................................................................... 20
3.5 Duct connections............................................................................................... 20
3.5.1 Flexible connections.................................................................................... 20
3.5.2 ZerAx® fans ................................................................................................ 20
3.6 Filter monitor (optional) .................................................................................... 21
3.6.1 Filling with liquid ......................................................................................... 21
3.7 Damper................................................................................................................ 21
3.8 Rotary heat exchanger ...................................................................................... 22
3.8.1 Check ......................................................................................................... 22
3.9 LonWorks®......................................................................................................... 22
4. Pipe system
4.0.1 Circuit for heating coil ................................................................................. 24
4.0.2 Circuit for cooling coil ................................................................................. 24
4.0.3 Circuit for liquid coupled heat exchanger ................................................... 24
4.1 Condensation outlet .......................................................................................... 25
4.1.1 Establishment of condensation outlet ......................................................... 25
4.1.2 Water trap.................................................................................................... 25
5. Electrical installation
5.1 Dimensioning and electrical installation ......................................................... 26
5.2 Supply voltage ................................................................................................... 26
5.3 Running of cable through panels..................................................................... 27
5.4 Motor connection............................................................................................... 27
5.5 Connections in the control system box (EXcon control system) ................. 27

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6. Startup
6.1 Start-up procedure............................................................................................. 29
6.1.1 Fans start-up ............................................................................................... 29
7. After commissioning
7.1 After 2–3 weeks of operation ............................................................................ 31
8. Maintenance
8.1 Replacement of filters ....................................................................................... 32
8.2 Filter design........................................................................................................ 33
8.3 Cleaning.............................................................................................................. 33
9. Technical specifications
10. Technical electrical connections (EXcon control system)
10.1 Control system component names ................................................................ 35
10.2 Connection diagrams ...................................................................................... 37
10.2.1 Terminal block .......................................................................................... 37
10.2.2 Rotary heat exchangers ............................................................................ 38
10.2.3 Crossflow heat exchangers....................................................................... 44
10.2.4 Liquid coupled single string....................................................................... 50
10.2.5 Electric heating coil ................................................................................... 56
10.2.6 Serial Modbus cable ................................................................................. 57
10.2.7 Rotor control ............................................................................................. 57
10.3 External connections....................................................................................... 57
10.3.1 Digital inputs ............................................................................................. 58
10.3.2 Analogue inputs ........................................................................................ 58
10.3.3 Analogue outputs ...................................................................................... 59
10.3.4 Digital outputs............................................................................................ 59
11. Flow diagrams
12. Spare parts

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Prohibition symbol
Failure to observe instructions marked with a prohibition symbol may result
in fatal injury.
Danger symbol
Failure to observe instructions marked with a danger symbol may result in
personal injury and/or damage to the unit.
Instruction manual
application
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 the safety of
others, and to protect the equipment and ensure its correct operation. EXHAUSTO A/S
accepts no liability for accidents caused by the product not being used in accordance
with the manual’s instructions and specifications.
It is recommended that the preliminary chapters about the installation, startup, operation
and maintenance are read.
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 run-on time for the fans
is at least two minutes.
Symbols, terms and warnings

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Information plate The sections’ information plate can be read.
• VEX size and designation for the section.
• Production number and production year.
• Maximum and minimum short-circuit current.
• Supply voltage and the maximum current consumption.
• Section number and the total number of sections for the air handling unit
• Section type, see if required, the table below for an explanation of type.
• Weight of the section and assembled air handling unit.
• K factor [m3/h]
• Filter type
• Information in connection with ECO design (only on information plate for fan
sections)
Code on the information plate The section contains
IL Inflow
OL Outflow
SP Empty section, if required distribution board
FX Filter Coarse (Type M5)
FX Filter Fine (Type F7 and F9)
FX Panel air filter (Type G2 and G4)
ER Rotary heat exchanger
EX Crossflow heat exchanger
TC Liquid coupled heat exchanger
NR Sound baffles
HG Gas burner
HW Water heating coil
HW Water heating coil, wide
HEC Electric heating coil
XE Humidifier
MR/MS/MD Mix function
CW Cooling coil
CW Cooling coil, wide
FAN AX ZerAx® fan
FAN PF Plenum fan
DC Droplet separator

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1.Introduction
1.1 Use
VEX5000 covers a wide capacity range, from 4,500 to 50,000 m³/h, with nine different
unit sizes (VEX5020 - VEX5200), which means it is ideal for comfort ventilation in many
types of buildings - from schools, institutions and offices, to hotels, hospitals and
industrial premises. All variants can be fitted with a fully integrated control system.
1.2 Unit configurations
VEX5000 air handling units are designed as single or two-string air handling units and
are divided into the following main groups:
• Heating and ventilation
• Heat recovery
• Air conditioning and cooling
If the air handling unit is supplied with an EXcon control system, it can be operated via
the Web and with a handheld terminal.
All of the VEX5000 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 included with the rest of the documentation.

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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 damage or something is missing, point this out immediately to
the haulier.
2.1.2 Extent of the delivery
In addition to the air handling unit, a VEX5000 delivery may include several loose parts.
All of the loose parts are enclosed in packaging and included in the packing list.
For unassembled
air handling units
• Base (optional for unassembled):
The base with cross member (1) is supplied separately and includes bolts and
fitting (3+4) for securing the air handling unit to the base. A number of adjustable
screws (5) and fitting for alignment. The base is enclosed in packaging on a
small pallet.
• Plastic covers:
Corner covers (8) and plugs (9) for covering the corners, once the hoist eyes are
removed.
• Handle and square key:
One square key (10). Handles (11) are supplied as per the number ordered,
together with screws and plugs (2).
• Sealing material:
Self-adhesive sealing strip (6) 12 x 6.4 mm for sealing joints.
• Interior sectional joints:
The sections are equipped with four interior corner fittings with clearance holes.
The fitting are assembled using 8 x 25 mm screws, and an 8 nut (7). Sides that are
longer than 1500 mm must also be equipped with fittings in the middle of the side.
1. Base 7. Screws and nuts
for assembling sections
2. Screws and plugs for handles 8. Plastic covers for corners
3. Fittings with hooks 9. Plugs for plastic covers
4. Fittings 10. Square key
5. Levelling screw with foot 11. Handles for doors
6. Sealing strip

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Optional – can be
supplied as loose
parts
• Water trap
The crossflow heat exchanger and cooling coils are supplied with a water trap for
connection to an external drain.
• Flexible connections
External connections for connection to duct system of the inlet and outlet
openings are supplied with assembly rails.
• Roof - in the form of Aluzinc® plate.
• Assembly rails for connections to the duct system
• Silencers
• Baffel plates for drain
• Isolation switch
• Sensors for temperature, CO2 and pressure
• Fire thermostat
• Handheld terminal to control the control system
• CD for LonWorks
2.1.3 Weight
The air handling unit’s total weight and dimensions, and weight and dimensions of the
individual
sections are stated on the supplied print out from the calculation program
EXselectPRO.
2.1.4 Handling the air handling unit
VEX5000 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.
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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Single section Single sections are equipped with transport feet and lifting eyes in the top corners.
The lifting eyes may only be used on sections weighing less than 1500
kg.
Assembled air
handling unit
When lifting the assembled unit on a base, use 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.
2.2 Storage
VEX5000 air handling units are supplied either assembled or in sections, packaged in
plastic.
If they are stored outdoor, they must be covered over, so that there is ventilation under
the top cover to avoid the condensation formation. Outdoor storage must only take place
for short periods.
When storing for longer periods, the plastic packaging must be removed because of
condensation formation and the air handling units must be stored indoors in dry areas.
When storing for more than three months, the fan impellers should be regularly turned
by hand.
Assembled air handling units with roofs which are designed for outdoor installation may
be stored outside but they should be stored in a covered location to prevent soiling on
the construction site, and also ensure that there is ventilation under the location’s cover.
RD13763-01

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3.Mechanical assembly
The VEX5000 air handling unit must be installed on a stable surface with a strong
foundation.
Setting up of the air handling unit
1. Set up the air handling unit.
2. Remove the fan unit’s transport safety fitting, if this is fitted.
3. Fit any handles onto the doors.
4. Connect the ducts
5. Connect the base tray and droplet separator to the drain (drain plug)
6. Connect the cooling coil, heating coils and liquid heat exchanger.
7. Establish electrical connections.
Accessories which can be subsequently fitted
•LonWorks
® module (if the air handling unit is supplied with an EXcon control
system)
3.1 Setting up and assembling
The assembly and set-up contains loose parts, which are described in the
section“Extent of delivery”. The loose parts have been placed in the first fan section.
Outdoor air
handling units
It is important that the roof is fitted on the air handling unit at the same time it is set up.
This is to prevent water entering the air handling unit.
3.1.1 Installation site requirements
There must be free space in front of the air handling unit along the whole length to
ensure easy access for inspection, cleaning and servicing.
The doors must be able to be opened to their entire width, for inspection and cleaning,
in some cases this is 1200 mm. 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
Air handling units installed on roofs may not be incorporated as part of the roof cover of
the building. The air handling units must have a complete roof deck under them.
All vertical and horizontal joints between the individual sections must be
carefully sealed with a suitable sealant that is weather-resistant, e.g.
construction silicone. Carefully degrease all of the surfaces before applying
the sealant.
Important: When installing outside, the damper motor and motor valves must be
protected against penetrating water and frost.

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3.1.2 Setting up the base
Place the base on a suitable installation site that has a foundation and which has been
prepared. If the base is separated, assemble the cross members using mounting tabs.
3.1.3 Positioning and assembly of sections
Numbers written in parenthesis is the following section, refer to loose parts that are
named in the section“Extent of delivery”.
Assemble the sections on the base in numerical order, starting with no. 1, from left to
right. If the system is a 2-string system, align the top sections in after the bottom
sections.
The section numbers are stated on the information plates on the sections.
1. Fit a levelling screw under each tab joint.
2. Fit and adjust the remaining levelling screws in the holes in the member so
that the foundation is levelled.
The distance between the levelling screws may not exceed 1300 mm, this
is ensured by using the pre-bored holes in the side members.
Important: The base must be completely level, otherwise the sections
will twist when they are subsequently fitted
and the doors will not seal properly when closed.
1. Remove the transport feet before the sections are placed on the base.
2. Fit the plastic covers where the feet were and secure the section to the
base using the fittings (4) and bolts.
3. Secure the air handling unit on the side of the base using the fittings that
have hooks in the ends (3). Use 6.3 x 1.3 mm sheet metal screws.

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4. Remove the lifting eyes once the section is positioned on the base or on an
underlying section.
5. Fit the plastic covers and plug the holes.
6. Stick the sealing strip onto the contact surface along the inner edge on the
section before positioning the adjacent section.
7. Move the next section onto the base and push it up against the preceding
section.
Important: The sections must be positioned precisely next to each
other and levelled in accordance with the base or underlying section.
Sealing strip

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To access the inside of the air handling unit, do so through the inspection doors or by
removing a side panel. If necessary, pull out functional parts that are in the way. Fit
screws in the fitting and tighten in a cross pattern, using a 6 mm hex key until there is a
gap of approx. 1 mm between the sections.
Once the bottom layer of the air handling unit with two airflows is assembled, fit the
sections in the top layer in the same way, since the sections are aligned in accordance
with the underlying sections.
8. Fit the interior corner fittings using screws and bolts.
Important: The holes in the corner fittings may not be enlarged.
Instead, fully align the base or the sections. The joins must be correct
for the sake of the air handling unit’s output.
9. Fit the interior fittings in the middle of the sides that are longer than 1500
mm.
10.Tighten in a cross pattern, using a 6 mm hex key until there is a gap of
approx. 1 mm between the sections.
11.Fit the remaining fittings, evenly distributed along the sides.
Use 6.3 x 13 mm sheet metal screws.
12.Finally, drill a 5.5 mm hole through the frame profiles in each door opening.
13.Screw the profiles together using a 6.3 x 13 mm sheet metal screw.
Fit two screws to the profiles in the door opening.

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3.2 Fitting roof (outdoor air handling units)
3.2.1 Preparation
The roof is built up of a number of pre-fabricated roofing panels, of various lengths
between 280-560 mm.
The roofing panels come in different sizes - but calculated to match the roof-size.
It is recommended that the roofing panels are laid loosely before they are secured, to
ensure that all of the panels are positioned correctly.
Supplied with roof
• Sealant for sealing between sections (9)
• Sealing strip for attaching to the air handling unit (9)
• U profile to form a drain on roof (1)
• End piece for overhang (5)
• If required, end piece corners for exchanger (2)
• Roofing panels in varying widths of up to 560 mm (4)
• Roofing panels facing ends, up to top section (3)
• Roof finishing facing ends (7)
• 2-part roofing panels for rotary exchanger, with mounting tab
• Assembly rails for roofing panels and plastic ends (6/10)
• Self-tapping screws with washer/pop rivets(8)
1
2
3
4
5
5'
6
7
8
9
10

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3.2.2 Fitting of roof
1. Seal between the sections.
2. Stick the sealing strips on the top of the air handling unit on all of the outsides (A).
3. Lay the U profile along (in the middle) the air handling unit as a roof ridge, to
achieve a fall toward the sides. Trim the U profile so that it ends a couple of
centimetres inside the air handling unit (B).
4. Lay the first roofing panel in against the top section.
5. Lay the next roofing panels, except the last. Pop rivet the roofing panels together
(F).
6. Fit the end piece profile 560 mm from the outside of the second last roofing panel
(C).
7. Turn the last roofing panel into the end piece profile and place it in position. Secure
using pop rivets (D/E).
8. Push the assembly rails in over the plate joints. Close using plastic end (G/H).
9. Secure roof facing top section using the plate “Roof finish facing end”.
Seal the joint.
10.Screw self tapping screws using nylon washers in all of the prepared holes.
Air handling unit
with rotor 1. Fit the end piece in one end with approx. 2 cm of overhang.
2. Lay the U profile lengthwise, so that it ends a couple of centimetres inside the air
handling unit.
3. Lay the next roofing panel, except the last. Pop rivet the roofing panels together (F).
4. Fit the end piece profile 560 mm from the outside of the second last roofing panel
(C).
5. Turn the last roofing panel into the end piece profile and place it in position. Secure
using pop rivets (D/E).
6. Push the assembly rails in over the plate joints. Close using plastic end (G/H).
7. Screw self tapping screws using nylon washers in all of the prepared holes.
Air handling unit
with wide rotor
ABCD
EFGH

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1. Start with the 2-part roofing panel
2. Assemble the 2-part roofing panel using the mounting tab.
3. Fit the assembled plates on the rotor.
4. Seal the plate joint.
5. Fit the four end piece corners.
6. Lay the rest of the roof next to the rotor and finish as the bottom part.

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3.2.3 Baffel plate
For fans with free outflow without duct connection, fit baffel plate on the outflow ends.
Keep the baffel plate at the correct distance using 6 or 8 braces.
1. Bend the braces in the square holes so that they align with the holes in the baffel
plate.
2. Remove the loose fitted flange.
3. Fit the braces on the flange using the supplied countersunk bolts.
4. Fit the baffel plate on the braces.
5. Fit the flange with the baffel plate on the air handling unit again.
3.2.4 Air diffuser
The air diffuser must be fitted after the fan.
1. Remove the loose fitted end panel on the air handling unit.
2. Fit the air diffuser to the panel using the supplied countersunk bolts.
3. Re-fit the panel with the air diffuser to the air handling unit.
The air diffuser must be supported or suspended.

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3.3 Fans
Important: If there is not a duct on the pressure side of the fan, a protective
net must be fitted.
3.3.1 Transport safety fitting
The transport safety fitting is marked with a yellow label.
The fan unit can be equipped with a transport safety fitting, which locks the vibration
damping for the unit. Remove the transport safety fitting when the air handling unit is
installed in its final location.
ZerAx® fans All ZerAx® fans are equipped with two points, which lock all four rubber feet during
transport. Pull the two points out from the service side.
Plenum fans Larger plenum fans fitted on springs as vibration dampers, are secured using four
fittings, which must be removed.
NB Smaller plenum fans which are vibration damped using rubber feet do not have a
transport safety fitting.
ZerAx® fan transport safety fitting
Plenum fan transport safety fitting

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3.3.2 Airflow determination
The airflow can be determined on the basis of the pressure difference across the fan
(∆P) and the fan’s calculation constant (K).
Pressure difference is calculated in Pascal(Pa) and using the equation shown below, the
airflow (q) is determined in m3/h.
Example: The airflow is calculated for a fan of the type ER/RH63C.
The analogue pressure difference is read as 700 Pa and in the table shown
below, an ER/RH63C fan has a K value of 381
If the unit for airflow is desired to be in l/s, divide by 3.6.
3
5'
Example: Plenum fan
¨P x K = q
700 Pa x 381 = 10.080 m
3
/h
Plenum fan ZerAx® fan
Fan type K value [m3/h] Fan type K value [m3/h]
RH/ER22C 47 AZN 500/350 692
RH/ER25C 60 AZN 560/350 913
RH/ER28C 75 AZN 630/350 1197
RH/ER31C 95 AZN 710/350 1558
RH/ER35C 121 AZN 800/350 2017
RH/ER40C 154 AZN 900/350 2593
RH/ER45C 197 AZN 1000/350 3240
RH/ER50C 252
RH/ER56C 308
RH/ER63C 381
RH/ER71C 490
RH/ER80C 620
RH/ER90C 789
RH/ER10C 999
RH/ER11C 1233

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3.4 Handles on doors
The handles can be supplied loose to avoid damage during transport and are supplied
as loose parts in packaging. A set of handles consists of 1 handle with lock and key, and
one handle without a lock. The lockable handle must be fitted at a suitable height.
Exercise caution with the handle when opening the door.
Important: If the fan is unprotected, the doors must be able to be opened using
the square key or be equipped with at least one handle that is lockable.
3.5 Duct connections
Round ducts can be secured to the duct spigots using a clamp.
Rectangular ducts are connected to inlet and outlet openings on the air handling unit
using LS rails or METU fittings.
3.5.1 Flexible connections
The unit has built-in vibration dampers between the fan and frame.
If further vibration damping is desired, flexible connections at the duct connection can
be supplied as accessories.
3.5.2 ZerAx® fans
Optimal
installation
It is recommended that the distance to
the nearest duct bend from a ZerAx®
fan is at least 3 x the fan’s
diameter [3 x D].
Minimum
installation
It is recommended that the minimum
distance to the nearest duct bend from
a ZerAx® fan is the fan’s diameter [D].
3 x D> 3 x D>
½Dr>
D>D>
½Dr>