System air ZRS Series Manual

Installation, Operation and Maintenance instruction EN
ZRS Smoke gas fan

Table of contents
1 Introduction .......................................................... 1
1.1 Product description ......................................1
1.2 Intended use ..............................................1
1.3 Document description...................................1
1.4 Product overview.........................................1
1.5 Name plate ................................................1
1.5.1 Type designation ............................. 2
1.6 Product liability............................................ 2
2 Safety .................................................................2
2.1 Safety definitions......................................... 2
2.2 Safety instructions ....................................... 2
2.3 Personal protective equipment ....................... 3
3 Transportation and storage ...................................... 3
4 Installation............................................................ 4
4.1 To do before the installation of the
product......................................................4
4.2 To Install the product .................................... 4
5 Electrical connection............................................... 5
5.1 To do before the electrical connection .............. 5
5.2 To connect the product to the power
supply.......................................................5
5.3 Speed controller for AC motors....................... 5
5.4 To install motor protection for AC
motors ......................................................5
6 Commissioning ..................................................... 6
6.1 To do before the commissioning......................6
6.2 To do the commissioning............................... 6
7 Operation.............................................................6
7.1 To start a product with an AC motor ................. 6
7.2 To stop the product ......................................6
7.2.1 To stop the product in an
emergency..................................... 6
8 Maintenance......................................................... 7
8.1 Maintenance schedule.................................. 7
8.2 To clean the product..................................... 7
8.3 Spare parts ................................................ 7
9 Troubleshooting..................................................... 8
10 Disposal.............................................................9
10.1 To disassemble and discard the parts of the
product......................................................9
11 Warranty ............................................................ 9
12 Technical data ................................................... 10
12.1 Technical data overview .............................. 10
12.2 Product dimensions ................................... 10
12.3 Wiring diagrams ........................................ 11
12.3.1 Wiring diagrams for ZRS
fans ............................................ 11
12.3.2 Wiring diagrams for speed
controller for AC motors .................. 11
13 EU Declaration of Conformity................................ 14
14 UK Declaration of Conformity................................ 15

1 Introduction
1.1 Product description
The product is a smoke gas fan with an AC motor.
The product is not supplied with an external speed control or
power switch.
1.2 Intended use
The product is intended to prevent insufficient draft from
stoves, ovens and fire places. The maximum temperature of
transported air is 200 °C.
The product is not applicable for transportation of air that
contains explosive, flammable or aggressive media. The
product is not applicable for locations where there is a risk of
explosion.
1.3 Document description
This document contains instructions for installation, operation
and maintenance of the product. The procedures must be
done by approved personnel only.
Speak to Systemair for more information on how to install the
product in different installation locations.
1.4 Product overview
1
5
4
6
2
7
3
1. Casing
2. Protection grille
3. Insulation carpet
4. Name plate with airflow direction arrow
5. Connection box
6. Steel wire
7. Steering rods
1.5 Name plate
32 65
789
41
11
13
12
10
1. Type designation: Product name, dimension and motor
type. Refer to 1.5.1 Type designation.
2. Input power, W
3. Frequency, Hz
4. Certifications
5. Scannable code1
6. Find more information about the product on the System-
air documentation portal1
7. Country of production
8. Airflow direction arrow
9. Weight, kg
10. Serial number: part number/production number/produc-
tion date
11. IP class, enclosure class
12. Current, A
13. Voltage, V
1
1. Use a mobile device to scan the scannable code and go to the Systemair documentation portal for more documentation and document
translations.

Note:
The data on the name plate applies to “standard air” that is
specified in the standard ISO5801.
1.5.1 Type designation
Product name ZRS
Dimension 170
180
Motor type AC, 1–phase, 230 V
1.6 Product liability
Systemair is not liable for damages that the product causes
in these conditions:
• The product is incorrectly installed, operated or
maintained.
• The product is repaired with parts that are not original
spare parts from Systemair.
• The product is used together with accessories that are not
original accessories from Systemair.
• The product is used without motor protection.
2 Safety
2.1 Safety definitions
Warnings, cautions and notes are used to point out specially
important parts of the manual.
Warning
If you do not obey these instructions,
there is a risk of death or injury.
Caution
If you do not obey these instructions,
there is a risk of damage to the product,
other materials or the adjacent area.
Note:
Information that is necessary in a given situation.
2.2 Safety instructions
Warning
Read the warning instructions that follow
before you do work on the product.
• Read this manual and make sure that you understand the
instructions before you do work on the product.
• Obey local conditions and laws.
• The ventilation contractor and the operator are responsi-
ble for correct installation and intended use.
• Keep this manual at the location of the product.
• Do not install or operate the product if it is defective.
• Do not remove or disconnect safety devices.
• Make sure that you can read all warning signs and labels
on the product when it is installed. Replace labels that
have damage.
• Only permit approved personnel to work on the product
and to be in the adjacent area during all work on the
product.
• Make sure that you know how to stop the product quickly
in an emergency.
• Use applicable safety devices and personal protective
equipment during all work on the product.
• Before you do work on the product, stop the product and
wait until the fan impeller stops. Make sure that there is no
voltage on the motor terminals.
• If the maintenance is not correctly and regularly done,
there is risk of injury and damage to the product.
• Only do the maintenance as given in this manual. Speak
to Systemair technical support if other servicing is
necessary.
• Always use spare parts from Systemair.
• Sound levels exceeding 70 dB(A) may occur depending
on model and size. Visit www.systemair.com for more de-
tailed information about your product.
• The product is not to be used by persons, including chil-
dren, with reduced physical, sensory or mental
2

capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction.
• Do not allow children to play with the device.
2.3 Personal protective
equipment
Use personal protective equipment during all work on the
product.
• Approved eye protection
• Approved protective helmet
• Approved hearing protection
• Approved protective gloves
• Approved protective shoes
• Approved work clothing
3 Transportation and
storage
Warning
Make sure that the product does not
become damaged or wet during
transportation. A damaged or wet
product can cause fire or electric shock.
• Before you move the product to the installation location,
examine the packaging for damages.
• Do not move the product by the cables, terminal box, fan
impeller, protection grille, inlet cone or silencer.
• If lifting equipment is used, make sure that the lifting
equipment can hold the weight of the product. Refer to the
name plate for information. Do not lift the product by the
packaging.
Warning
Do not walk below a lifted product.
• Keep the correct side of the packaging up during
transportation. Refer to the arrows on the packaging.
• Load and unload the product carefully.
• Keep the product in a dry and clean location during
storage. Make sure that the ambient temperature during
storage is between –10 and +30 °C. A stable ambient
temperature prevents damage from condensation.
• Keep the product in storage for maximum 1 year.
3

4 Installation
4.1 To do before the installation
of the product
• Use installation material with fire resistance rating for the
installation location.
• Examine the packaging for transportation damage and re-
move the packaging from the product carefully.
• Examine the product and all components for damage.
• Make sure that the motor effect and the fan performance
agrees with the expectations at the installation location.
• Make sure that the information on the name plate and the
motor name plate agrees with the operation conditions.
• Install the product in a location where there is space for
commissioning, troubleshooting and maintenance.
• Make sure that the installation location is clean and dry,
for full safety during electrical work.
• Make sure that the installation surface has sufficient ca-
pacity to hold the weight of the product.
• Refer to the airflow direction arrows on the name plate or
on the product to install the product in the correct position.
• Make sure that all cable glands are tight against the ca-
bles to prevent leaks.
4.2 To Install the product
Note:
Make sure that the installation location has space for
maintenance.
Note:
Install the product so that unwanted vibrations are not
transmitted to duct systems or roof beams.
Note:
The product must be installed horizontally.
Note:
Obey local laws and regulations for installation of the
smoke gas fan.
1Put the supplied insulation carpet on top of the chimney
or duct system.
2Cut a hole in the insulation carpet. Make sure that the
hole has the same dimension as the inlet cone of the fan.
3Install the 4 adjustable steering rods in the holes in the
bottom plate of the fan. Use the supplied screws and
nuts.
4x
4

4Push the fan and steering rods into the chimney. It is not
necessary to attach the fan with screws in the chimney,
the steering rods keeps the fan in position.
5Attach the supplied steel wire. The steel wire keeps the
product on the roof when it is temporarily lifted away from
the chimney during chimney sweeping. The product is
not supplied with screws and plug to attach the steel wire.
6Connect the mains supply to the connection box of the
product. Refer to 12.3 Wiring diagrams.
Note:
The cable has a steel housing that can discolour over time
as it weathers in. The coloring of the steel housing will not
decrease the protection of the cable.
5 Electrical connection
5.1 To do before the electrical
connection
• Make sure that the electrical connection agrees with the
product specification on the motor name plate.
• Make sure that the environment for electrical connection
is clean and dry.
• Make sure that the wiring diagram that is included with the
supply of the product agrees with the terminals in the con-
nection box.
5.2 To connect the product to the
power supply
• Complete the electrical connection for the motor. Refer to
the motor wiring diagram that is included with the product.
• Make sure that the cross section of the protective earthing
is equal to or larger than the cross section of the phase
conductor.
• Install a circuit breaker in the permanent electrical installa-
tion, with a contact opening of a minimum 3 mm at each
pole.
• If a residual current device (RCD) is installed, make sure
that it is an all-current sensitive RCD. Consider if the prod-
uct has a frequency converter or uninterruptible power
supply (UPS).
5.3 Speed controller for AC
motors
Note:
The speed controller alternatives are different for different
motor types. Make sure that your motor is compatible with
the speed controller type before you use it.
The speed can be controlled by voltage reduction using a
transformer. It is also possible to control the fan speed with
frequency converter if the installed frequency converter has
built in all-pole sine filter and shielded cables are not needed.
5.4 To install motor protection for
AC motors
• If the product has an built in motor protection, reset by dis-
connecting the product from power for 60 seconds.
• If the motor has temperature monitors such as thermal
contacts (TK) or thermistors lead out into the terminal box,
these must always be connected in the control circuit us-
ing appropriate motor protection.
• Make sure that an overheated motor cannot start again
automatically when it becomes cool.
• Install the motor cables and the temperature monitor apart.
• If the motor does not have temperature monitors, install a
motor protection switch.
5

6 Commissioning
Caution
• If strong vibrations occur during
commissioning, immediately increase
or decrease the fan speed until the
vibrations are decreased. Continuous
strong vibrations can cause damage
to components.
• Do not increase the fan speed to a
higher rpm value than the maximum
value that is given on the name plate.
The commissioning report is found at www.systemair.com.
6.1 To do before the
commissioning
• Make sure that the installation and electrical connection
are correctly done.
• Visually examine the product and accessories for damage.
• Make sure that the safety devices are correctly installed.
• Make sure that there are no blockages in the air inlet and
the air outlet.
• Make sure that installation material and unwanted objects
are removed from the product and the ducts.
6.2 To do the commissioning
1Set the installed safety switch in the OFF position.
2If it is possible to get access to the fan impeller, do the
steps that follows:
a. If it is necessary, remove parts of the installation.
b. Turn the fan impeller by hand and make sure that it
turn easily.
c. Record the result in the commissioning report.
3Make sure to turn the product in a direction that agrees
with the related arrow on the product.
a. Record the result in the commissioning report.
4If you removed parts of the installation to get access to
the fan impeller, install the removed parts again.
5Set the installed safety switch in the ON position.
6Start the product.
7Set the minimum operation speed.
8Increase the operation speed gradually to the maximum
operation speed.
a. Examine the vibrations in the casing and the bearing
areas at all speed levels.
b. Make sure that the vibrations agree with the specifi-
cations in ISO 14694.
c. Make sure that none of the speed levels cause un-
wanted noise in the product.
d. Record the result in the commissioning report.
9Record the necessary data in the commissioning report.
7 Operation
7.1 To start a product with an AC
motor
1Set the installed safety switch in the ON position.
2Install the external speed controller. Refer to the instruc-
tion manual for the installed speed controller.
7.2 To stop the product
1Set the installed speed controller in the OFF position.
Refer to the instruction manual for the installed speed
controller.
2Set the installed safety switch in the OFF position.
7.2.1 To stop the product in an
emergency
• Set the installed safety switch in the OFF position.
6

8 Maintenance
Warning
Set the installed safety switch in the OFF position before you do the maintenance unless the instructions tell
you differently. Make sure that the safety switch is not accidentally set in the ON position.
8.1 Maintenance schedule
The intervals are calculated from continuous operation of the
product.
Maintenance task Usual operation
conditions
Unusual operation conditions. 1
Each 6
months
Each
year
Each 3
months
Each 6
months
Each
year
Visually examine the product and its components for damage,
corrosion and dirt.
X X
Examine the fan impeller for damage and imbalance. X X
Clean the product and the ventilation system. X X
Do a check of all fasteners and make sure that they are fully
tightened.
X X
Make sure that the product and its components are correctly
operated.
X X
Measure the power consumption and compare the result with
the information on the name plate.
X X
If vibration dampers are installed, make sure that they operate
correctly and examine them for damage and corrosion.
X X
Make sure that the electrical protective equipment and the me-
chanical protective equipment operates correctly.
X X
Make sure that you can read the name plates of the product. X X
Examine all cable connections for damage. Make sure that
the cable glands are tight against the cables.
X X
If flexible connections are installed, examine them for damage. X X
1. The unusual operation conditions are classified as follows: If a stable ambient temperature is higher than 30 °C or lower than -10° C, if the
temperature changes are large or if very contaminated air is transported.
8.2 To clean the product
Caution
• Do not clean the product with a high-
pressure washer.
• Do not clean the product with steel
brushes or sharp objects.
• Do not bend the fan impeller blades.
• Be careful not to move the balance
weights on the fan impeller.
• Remove dirt from the fan and the duct.
• If access to the fan impeller is possible, clean the fan im-
peller with a moist cloth or soft brush.
8.3 Spare parts
• When you send an order for spare parts, include the serial
number of the product. The serial number is found on the
name plate.
• For more information about spare parts, contact technical
support.
• Always use spare parts from Systemair.
• To find spare parts, refer to the scannable code on the
name plate.
7

9 Troubleshooting
Note:
If you cannot find a solution to your problem in this section, speak to Systemair technical support.
Problem Cause Solution
The product does not operate smoothly.
The fan impeller is not correctly
balanced.
Speak to Systemair technical support.
There is dirt on the fan impeller. Clean the fan impeller carefully. Refer
to 8.2 To clean the product.
The fan impeller has damages or
deformations because the transported
air contains aggressive media.
Speak to Systemair technical support.
The fan impeller does not turn in the
correct direction.
Make sure that the electrical connection
is correctly done.
The fan impeller has deformations
because of too high temperatures. • Replace the fan impeller.
• Make sure that the temperature of
the transported air is not higher than
the value on the name plate.
There are unusually strong vibrations in
the product or the duct system.
Make sure that the product is correctly
installed. Do a check of the duct system.
The product is operated in a resonant
frequency range.
Increase or decrease the fan speed
until the product operates smoothly.
Refer to 6 Commissioning.
The air output is not sufficient.
The fan impeller does not turn in the
correct direction.
Make sure that the electrical connection
is correctly done.
The electrical connection is not
correctly done.
Make sure that the electrical connection
agrees with the wiring diagrams.
The air pressure is too low because of
incorrect installation.
Do the necessary changes in the duct
system and installed components to
increase the air pressure. Refer to 6
Commissioning.
The airflow shutters are closed or not
fully open.
Adjust the airflow shutters.
There is blockage in the air inlet or the
duct system.
Remove the blockage.
The product is not applicable for the
installation location.
Make sure that the product is applicable
for the installation location.
There is unusual noise when the
product starts or operates.
There is strain in the connections of the
duct system.
Loosen the connections, align the parts
of the duct system correctly and tighten
the connections.
Thermal contacts, PTC or resistors are
released.
The fan impeller does not turn in the
correct direction.
Make sure that the electrical connection
is correctly done.
The motor is overheated. • Do a check of the motor cooling
impeller.
• If it is possible, measure the
resistance to do a check of the motor
winding.
The capacitor is not connected or not
correctly connected.
Connect the capacitor correctly. Refer
to the included motor wiring diagram.
There is blockage in the motor. Speak to Systemair technical support.
8