System air Rotovex 2400 EL Operating manual

Air Handling Unit
ROTOVEX
Operating and Maintenance
Instruction
Drift- och skötselanvisning
SE
GB

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Contents
Page
Declaration of Conformity
4 Electrical connection
5 Check after connection
6 Automatic system/control
7 External connections
8 Description of functions/electrical heating
9 Description of functions/water heating
10 Starting up ROTOVEX
11 Inspection and care of fans
12 Inspection and care of electrical heater
1 Inspection and care of water heater
14 Inspection and care of filter and rotor
15 Measurements and specifications
16 Alarms, damper
17 Configuration of Corrigo
NB. Systemair AB reserve the rights at any time, without prior notice, make changes
and improvements to the contents of this manual.

GB
Manufacturer
Our products are manufactured in compliance with
applicable international standards and regulations.
Systemair AB
Industrivägen
SE-7 9 0
Skinnskatteberg
SWEDEN
Office: [phone]
Fax: [phone]
The manufacturer hereby confirms that the following
products:
Air handling units
Rotovex 2400H Rotovex 2400 EL, Rotovex
3800 H , 3800 EL, Rotovex 4800 H , Rotovex
4800 EL.
Comply with the following EC-directives:
EC Declaration of Conformity
as defined by the EC Machinery Directive
98/ 7/EEC, Annex II A. Fans for ventilation in air
handling systems with air from non-explosion
hazardous premises. This machinery must not be
put into operation until prior to reading mounting
instructions and safety information.
The following harmonized standards are in use:
EN 60 0 4-1 Rotating electric machinery; ratings
and performances.
EN 60 204-1
Safety of machinery; electrical equipment of
machines; general requirements.
EN 292-1
Safety of machinery; basic concepts, general
principles for design.
EN 294
Safety of machinery; safety distances to prevent
danger zones reached by the upper limbs.
Remark: EN 294 only complies when fitted contact
safety device is part of the extent of delivery.
EC Declaration of Conformity
as defined by the EC Low Voltage Directive
7 /2 /EEC and 9 /68/EEC
The following harmonized standards are in use:
EN 60 5-1
Electric domestic products and similar – safety-
general requirements.
EN 60 5-2-40
Safety of household and similar electrical
appliances - Part 2-40: Particular requirements for
electrical heat pumps, air-conditioners and
dehumidifiers.
EN 50 106 Electric domestic products and similar-
Safety-Instructions for control of manufacture.
Remark: EN 50 106 complies for internally wired
products only.
EC Declaration of Conformity
as defined by EC’s EMC-directive 89/ 6/EEC,
92/ 1/EEC and 9 /68/EEC
The following harmonized standards are in use:
EN 61000-6-4: Electromagnetic compatibility (EMC)
- Part 6-4: Generic standards - Emission standard
for industrial environments
EN 61000-6-2 Electromagnetic compatibility (EMC)
– Part 6-2: General requirements – Immunity for
appliances in industrial environments.
The complete technical documentation is available.
Skinnskatteberg, 06 Feb 200
Mats Sándor
Technical Manager

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Electrical connection
The unit must not be put into
operation until all the electrical and
mechanical safety precautions have
been taken.
The ROTOVEX unit should be perman-
ently connected to the mains electric
supply through the lockable safety
switch on the gable, as shown in the
figure.
The unit’s nominal electrical values
and manufacturing number are shown
on the plate just under the safety
switch.
If the unit is equipped with a heater
that has separate power supply
(see table below). The unit shall bee
provided with a working switch,
see figure.
Switch for disconnection from the
supply, shall have at least 3 mm
contact separation in all poles.
Electrical data for the unit:
Rotovex Mains Unit (A) Heater
[k ]
Heater with separate
power supply [A]
2400HW 2 0V1~ 5,5 *10,0 -
2400EL 400V N~ 10,0 ,0 -
2400EL 400V N~ 5,5 **12,0 **17,5
2400EL 2 0V ~ 5,5 **12,0 ** 0
800HW 400V N~ 6,0 *15,0 -
800EL 400V N~ 12,5 4,5 -
800EL 400V N~ 6,0 **15,0 **22
800EL 2 0V ~ 6,0 **15,0 ** 8
4800HW 400V N~ 8,5 *20,0 -
4800EL 400V N~ 17,0 6,0 -
4800EL 400V N~ 8,5 **12,0 **17,5
4800EL 400V N~ 8,5 **24,0 ** 5
4800EL 2 0V ~ 8,5 **12,0 ** 0
4800EL 2 0V ~ 8,5 **24,0 **60
*For incoming/outgoing hot water 55/40°C
**Electric heater (above 6 KW) has separate incoming power supply. For 2 0V ~ you need a
transformer (2 0V ~ to 400V ~) for the unit supply.

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To check after connection
• Fans
Make sure the fan wheels
rotates in correct direction.
• Damper
Make sure the damper motors opens
and shuts correctly.
• Stop/control valve for hot water
Make sure the valve opens and shuts
correctly.
• Pressure/Temperatures
Make sure the pre-set values for
airflow and temperature is correct.
• Closing pressure difference for the
filter
Make sure the pressure sensors at the
filter are set to the correct closing
pressure = alarm mode.
Recommended closing pressure
approx. 240 Pa.

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Automatic system/control
All ROTOVEX functions are controlled
from the Corrigo panel. For further
information refer to the supplied
Corrigo user manual.
Sp: 18.0 Act: 17.8
System: Normal run
05:05:30 15:45
Regulator vent. sys
A - Control box: Corrigo E28
B - Control box: rotor
C - Control box: supply air fan
D - Control box: exhaust air fan
E - Control box: electric heating
F – Control panel. Connects to a fast coupling inside
the connection box on the gable of the unit.

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External connections
* These inputs may only be wired to voltage free contacts.
All external connections are done in the connection boxes found on each end plate of
the unit. There is a sign on the inside illustrating the various functions and how they
are to be connected.
Terminal block Description Remark
1 G Valve actuator, supply voltage, Heating/cooling 24V AC
14 G0 Valve actuator, supply voltage, Heating/cooling Neutral
4 AO1 Control signal water heating 0-10V DC
57 AO Control signal water cooling 0-10V DC
PE Water pump, supply voltage. HW Heating Ground
45 N Water pump, supply voltage. HW Heating Neutral
46 L1 Water pump, supply voltage. HW Heating 2 0V AC
9 DO6 Water pump, control voltage (contactor). Cooling 24V AC, 0,5A
G DO ref Water pump, control voltage (contactor). Cooling
DO2 Damper, exhaust air 24V AC, 0,5A
4 G0 Damper, exhaust air Neutral
5 G Damper, exhaust air 24V AC
6 DO1 Damper, fresh air 24V AC, 0,5A
7 G0 Damper, fresh air Neutral
8 G Damper, fresh air 24V AC
56 AI Extract air temperature sensor PT 1000
Agnd AI ref Extract air temperature sensor
27 UAI1 Fresh air temperature sensor PT 1000
Agnd UI ref Fresh air temperature sensor
1 AI4 Supply air temperature sensor PT 1000
2 AI ref Supply air temperature sensor
55 DO4 DX cooling, step1 24V AC, 0,5A
54 DO5 DX cooling, step2 24V AC, 0,5A
5 DO ref DX cooling, step1 and 2
*64 DI Run-indication/alarm circulation pump Cooling or
*Ref DI DI ref Run-indication/alarm circulation pump Cooling
*47 DI5 Fire alarm or
*Ref DI DI ref Fire alarm
*48 DI6 External stop
*Ref DI DI ref External stop
*49 DI7 Extended operation, Normal
*50 DI ref Extended operation, Normal
*59 DI8 External alarm
*Ref DI DI ref External alarm
40 DO7 Sum alarm, A- and B-alarm
G DO ref Sum alarm, A- and B-alarm
51 Net + LON
52 Net - LON
60 G Pressure transmitter, supply voltage 24V AC
61 AI1 Pressure transmitter, control signal. Supply air 0-10V DC
62 AI ref Pressure transmitter
6 AI2 Pressure transmitter, control signal. Extract air 0-10V DC
28 UAI2 Free to use
Agnd UI ref Free to use
58 UAI Free to use
Agnd UI ref Free to use
*Ref DI DI ref Is used together with UDI
By spring-loaded
damper, connect
33/35
By spring-loaded
damper, connect
3 /38

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Description of functions
Electrical heating, extract air temperature
control with cascade function.
Function
Start and stop times are set in the
Control panel. To maintain constant
room temperature the RC receives a
signal from GT and regulates the VVX
and the electrical heater in sequence.
The GT1 sensor is used to limit the
max and min supply air temperature.
Maximum temperature in the electrical
re-heater is controlled by GTM. GTO
disconnects the heater, gives an alarm
signal and stops the appliance in case
of overheating.
ST1 closes the fresh air damper when
the appliance is stopped. In case of an
unintended stop on the rotor, the RCR
gives an alarm, which is displayed on
the Control panel as an alarm.
Also displayed in the Control panel are
date and time, operating status,
desired and actual room temperature.
GP1 and GP2 give alarm signals when
the actual value exceeds the pre-set
desired value for pressure drop over
the filter.
Designation Name
FF Exhaust air fan
TF Supply air fan
GT1 Sensor, supply air
GT2 Sensor, fresh air
GT Sensor, extract air
GTM Sensor, max temperature
in the electrical re-heater.
GTO Sensor overheating in
heater
GP1 Pressure guard, extract
air filter
GP2 Pressure guard, supply
air filter
RC Regulator Corrigo E28
RCF Control box: exhaust air
RCT Control box: supply air
RCR Control box for rotor
DR Motor, rotor
VVX Heat exchanger rotor
ST1 Damper, fresh air
ST2 Damper, exhaust air

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Description of functions
Water heating, extract air temperature
control with cascade function.
Function
Start and stop times are set in the
Control panel. To maintain constant
room temperature the RC receives a
signal from GT and regulates the VVX
and SV in sequence. The GT1 sensor
is used to limit the max and min supply
air temperature.
If there is a risk of frost in the water
heater SV opens completely.
If the temperature drops further, an
alarm is set off and the appliance
stops. GTF maintains constant water
temperature even when the fans have
stopped.
ST1 closes the fresh air damper when
the appliance stops. In case of an
unintended stop on the rotor, the RCR
gives an alarm, which is displayed on
the Control panel as an alarm.
Also displayed in the Control panel are
date and time, operating status,
desired and actual room temperature.
GP1 and GP2 give alarm signals when
the actual value exceeds the pre-set
desired value for pressure drop over
the filter.
Designation Name
FF Exhaust air fan
TF Supply air fan
GT1 Sensor, supply air
GT2 Sensor, fresh air
GT Sensor, extract air
GTF Sensor for frost protection
GP1 Pressure guard, extract
air filter
GP2 Pressure guard, supply
air filter
RCF Control box: exhaust air
RCT Control box: supply air
RC Regulator Corrigo E28
RCR Control box for rotor
DR Motor, rotor
VVX Heat exchanger rotor
SV Valve regulator, water
valve
ST1 Damper, fresh air
ST2 Damper, exhaust air

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Starting up ROTOVEX
Instructions
In order to start up and run all the
functions the sensors and other
external attachments must be fitted.
Start the Rotovex by using the control
panel. Follow the instructions in the
Corrigo E – User Manual. Start with
chapter 6. Display, LEDs and buttons.
Set the menu language
Press the OK button while switching on
the mains supply.
Press the OK button. Choose language
with the UP / DOWN buttons. Confirm
the choice with the OK button.
Configuration/Settings
Refer to the Corrigo E – User Manual.
The unit is pre-set to constant airflow
and Extract air temperature control
with cascade function. Week schedule
is pre-set to Normal fan speed
between 07:00–16:00 Monday to
Sunday and stopped the rest of the
time.
For more detailed information see the
Commissioning record in the Operating
and Maintenance Instruction.
Important!
Do not forget to set the current time
and date.

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Inspection and care of the fans
For inspection and care of the fans
open the front covers of the unit.
Important!
Disconnect the power supply before
opening the covers.
Fans
When cleaning or carrying out other
maintenance work where the fans
need to be removed, proceed as
follows:
1. Loosen all cable connectors and
pressure hoses
2. Loosen the lock nut at the foot
. Pull out the fan cartridge
Proceed in the reverse order when
replacing the fan.
Push the fan cartridge in and make
sure that the lock nut is in place (fig 2).
Important!
DO NOT use water when cleaning the
inside of the unit.

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Inspection and care of the
electrical heater
The heater is positioned in the same
section of the appliance as the rotor. It
is easy to remove for servicing or
cleaning. The connecting cables are
provided with quick connectors for
easy disconnection.
Regulating the heater
The power requirement for the heater
is adjusted according to the extract air
temperature, as set on the control
panel. The temperature is indicated
using a sensor in the extract air.
A Pulser regulates the power
requirements for the heaters.
ROTOVEX 2400 000W 12000W
ROTOVEX 800 4500W 15000W
ROTOVEX 4800 6000W 12000W
24000W
If the manual overheating protection for
the heater trips, it can be reset as
follows after the appliance has cooled
down:
1. Loosen the cable connectors
2. Pull out the heater until the
reset button is visible
. Press the reset button
4. Push in the heater
5. Reconnect the cables
Position of the heater

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Inspection and care of the water
heater
The heater is positioned in the same
section of the appliance as the rotor. It
is easy to access for installation of hot
water pipes.
When starting, the battery should be
bled using the air nipple on the collec-
tor to prevent air bubbles disturbing the
water flow. See figure below (A).
Regulating the heater
The power requirements for the heater
are adjusted according to the extract
air temperature, as set on the control
panel. The temperature is indicated
using a sensor in the extract air.
Service and maintenance
The heater does not normally require
any service or maintenance. Check the
supply air side a couple of times a year
and clean if necessary.
Brush or vacuum the radiator. Take
great care when in contact with the
surface of the radiator, which must not
be deformed.
Heater power
ROTOVEX 2400 10000W
ROTOVEX 800 15000W
ROTOVEX 4800 20000W
A – Venting device
B – Frost protection sensor
Position of the heater

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Inspection and care of filter
ROTOVEX is supplied with a class F7
supply air filter and class F5 exhaust
air filter. The filter is divided into 2
cassettes for ease of handling. The
filters are stretched with extensible-
rails against sealing strips to minimise
leakage.
The filters are disposable and should
be replaced when the pressure drop
exceeds the given limit.
The filter can be ordered from
ROTOVEX suppliers or from
Systemair.
Inspection and care of rotating
heat exchanger
ROTOVEX is fitted with a rotating heat
exchanger. The rotor is made of
aluminium.
Service and maintenance
Clean the surface of the exchanger
using a vacuum cleaner with a brush
fitting. Take great care not to damage
the surface. Inspect and clean the heat
exchanger surface when changing the
filter, at least twice a year.
Clean using the exhaust air filter
space, turning the rotor by hand to
access the whole surface. If
necessary, compressed air may be
used to remove dirt.
If the transmission belt is worn or slack
it should be replaced. Contact
Systemair Service for help.

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Measurements and specifications
Illustrations below are of a right-mounted version. The left-mounted version has the
inspection hatch on the opposite side. Duct connectors are rectangular, with
connection frame for joining guides.
For connection directed upward on exhaust air, see view below.
Systemair
Exhaust air connection upwards (Option)
N - Electrical connection through safety switch
O - Pipe connection for water heating, internal dimension 15 R (1/2”)
P - Appliance separates here
Q - Minimum space to enable rotor replacement = A-150
R - Minimum space for door 670 mm
Dimensions, heater connection
K L M
ROTOVEX 2400 7 210 145
ROTOVEX 800 4 4 190 145
ROTOVEX 4800 487 190 145
Table of measurements
A B C D E F G
Weights
[kg]
ROTOVEX 2400 1000 600 00 125 150 200 795 00
ROTOVEX 800 1120 600 400 108 104 260 915 40
ROTOVEX 4800 12 0 800 400 1 5 165 215 1025 75

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Damper (accessories)
Table of measurements
A B
ROTOVEX 2400 600 00
ROTOVEX 800 600 400
ROTOVEX 4800 800 400
Damper option:
1. Two position actuator
2. Spring return actuator
The damper is intended for closing
the fresh air/exhaust air connections.
Standard air tightness class
Alarms
Alarm button (pos.1) opens the alarm
queue.
Press this button and active and non-
acknowledged alarms will be displayed
in the menu window. The LED for
alarms (pos.2 ) is blinking if there are
non-acknowledged alarms and steady
if the alarms are still active but have
been acknowledged.
If there are multiple alarms use UP /
DOWN buttons to move between them.
An alarm can be acknowledged or
blocked by using OK and UP / DOWN
buttons. To abort and go back to start
menu select Cancel and press LEFT
button. For alarm settings see the
Commissioning protocol.
Extra stop function
For some alarm types such as electric
heating high temperature limit and
water heating frost protection it would
be dangerous to not stop the unit on
alarm. Therefore, for such alarm types,
the program will always reset the stop
function to Active even if the operator
should choose Inactive.
It is unfortunately not possible to
remove the display text concerning the
stop function for these alarm types.
This since the available program space
demands that all alarms are treated in
the same way in the display.

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Commissioning record
Company
Responsible
Customer Date Installation
Object / Unit Item no. Installation address
Model / size Series no.
Present time and date set. Week schedule set.
External connections such as sensors, dampers, external alarms etc. done.
Function Preset value Set value
Temperature (°C).
Control function Temp.
Set point
Outdoor compensating
(supply air controlling)
Outdoor / supply temp.
Point 1,2 and
Point 4,5 and 6
Point 7 and 8
Min. supply set point
Max. supply set point
Switching point, between
supply and cascade
regulating
Supply Exhaust Room
18,0 °C
- 0,0 / 22,0 -20,0 / 21,0 -11,0 / 20,5
-4,0 / 20,0 5,0 / 19,5 12,5 / 19,0
21,0 / 18,5 0,0 / 18,0
12,0 °C
0,0 °C
1 ,0 °C
Supply Exhaust Room
°C
/ / /
/ / /
/ /
°C
°C
°C
Air flow
Fan regulation Airflow (m /h)
Pressure (Pa)
CO2 (ppm)
Airflow (m /h)
Pressure (Pa)
CO2 (ppm)
Set point Normal Supply fan
* . Extract fan ** . Supply fan Extract fan
Set point Reduced Supply fan
***.
Extract fan
****.
Supply fan Extract fan
Outdoor compensation
Lower point -20.°C 0 .m /h, Pa
Upper point 10.°C 0 .m /h, Pa
Lower point °C m /h, Pa
Upper point °C m /h, Pa
Only reduced fan speed
when outdoor is below.
-20 °C °C
Rotovex 2400 * 2 00 m /h or 250Pa ** 2 00 m /h or 250Pa *** 1500 m /h or 100Pa **** 1500 m /h or 100Pa
Rotovex 800 * 500 m /h or 250Pa ** 500 m /h or 250Pa *** 2000 m /h or 100Pa **** 2000 m /h or 100Pa
Rotovex 4800 * 4500 m /h or 250Pa ** 4500 m /h or 250Pa *** 2500 m /h or 100Pa **** 2500 m /h or 100Pa

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Function Preset value Set value
Cooling
Control function cooling
On/off function
Not active 0-10V On/off
1step 2step step binary step
Not active 0-10V On/off
1step 2step step binary step
Number of binary steps 1 2 1 2
Lowering of min. control
temp. supply air, DX cooling
5,0 . °C °C
Humidity
Control function
humidification.
Disable
Humidification
De-humidification
Humidification / De-humidification
Disable
Humidification
De-humidification
Humidification / De-humidification
Sensors
(0-10V DC for 0-100% RH)
Room sensor
Room and Duct sensor (max limiting)
Room sensor
Room and Duct sensor (max limiting)
Set point 50. % RH % RH
Max. limit (duct sensor) 80. % RH % RH
eek scheduler settings
Preset week schedule is:
Period 1. 07:00-16:00 Monday-Sunday, normal fan-speed.
Period 2. 00:00-00:00 Monday-Sunday. 00:00-00:00 inactivates the period.
eekday Period Normal Reduced
Mon. 1
: - : : - :
2
: - : : - :
Thu. 1
: - : : - :
2
: - : : - :
Wed. 1
: - : : - :
2
: - : : - :
Thurs. 1
: - : : - :
2
: - : : - :
Fri. 1
: - : : - :
2
: - : : - :
Sat. 1
: - : : - :
2
: - : : - :
Sun. 1
: - : : - :
2
: - : : - :
Holidays (month.day) Holidays (month.day) Holidays (month.day) Holidays (month.day)
1. . - . 7. . - . 1 . . - . 19. . - .
2. . - . 8. . - . 14. . - . 20. . - .
. . - . 9. . - . 15. . - . 21. . - .
4. . - . 10. . - . 16. . - . 22. . - .
5. . - . 11. . - . 17. . - . 2 . . - .
6. . - . 12. . - . 18. . - . 24. . - .

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Function Preset value Set value
Frost Protection
Mode (EL unit Off): On On Off
Frost limit temperature: See Alarm settings/
Low frost guard temp
See Alarm settings/
Low frost guard temp
Set point when stopped:
(return water)
10. °C °C
P-band when running:
5.
Pressure Input
Supply/Exhaust Air Fan
Supply Air Fan Pressure at 0V
Supply Air Fan Pressure at 10V
Exhaust Air Fan Pressure at 0V
Exhaust Air Fan Pressure at 10V
0. (Pa)
CAV 1600 Pa VAV 500 Pa
0. (Pa)
CAV 1600 Pa VAV 500 Pa
(Pa)
(Pa)
(Pa)
(Pa)
Night cooling
Mode: Off On Off
Run when day outdoor temp is
higher than: 22. °C °C
Stop when night outdoor temp is
higher than: 15. °C °C
Stop when night outdoor temp is
lower than: 5. °C °C
Stop when room temp is lower
than:
18. °C °C
Cool Recycling
Mode: Off On Off
Start Limit: 2. °C °C
Control On Demand
Min time for control on demand: 60. min min
Support control: Off On Off
Run Exhaust Air Fan when support
control active On On Off
CO2 control Off
On when active time channel
On when in-active time channel
On
Off
On when active time channel
On when in-active time channel
On
CO2 control Type Damper
Fan
Damper
Fan

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Function Preset value Set value
Fire Function
Fire damper function: Off
Damper normally closed
Damper normally opened
Off
Damper normally closed
Damper normally opened
Extraction when fire alarm: Off On Off
Fire input: Normally opened
Normally closed
Normally opened
Normally closed
Fire damper exercise: No exercise
Exercise with
ventilation running
Exercise with
ventilation stopped
No exercise
Exercise with
ventilation running
Exercise with
ventilation stopped
Fire damper run time: 90. s s
Fire damper interval: 1. days days
Fire damper exercise hour 0. h h
Mixing damper Min Limitation
Mode: Off On Off
Limit: 5. % %
External Set point Knob
External set point knob: Off On Off
Min set point of knob: 12. °C °C
Max set point of knob: 0. °C °C
Heat Pump (H unit)
Pump stop mode (EL unit Off): On On Off
Pump stop delay: 5. min min
Stop pump at temp: 10. °C °C
Pump stop hysteretic: 1. °C °C
Pump exercise hour: 15.
Cool Pump
Pump stop delay 5. min min
General
Heat Pump Indication Motor Protection
Run Indication
Motor Protection
Run Indication
Cool Pump Indication Motor Protection
Run Indication
Motor Protection
Run Indication
Outdoor Temperature Related
Settings
Full heat when outdoor temp is
below
. °C °C