AEREX 0040.0420 Operation And Maintenance Instructions Download Page 55

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Reco-Boxx ZXR / ZXA / Flat – Operation and maintenance instructions

[03/

2021]

Notes

Summary of Contents for 0040.0420

Page 1: ...www aerex de AEREX March 2021 Operation and maintenance instructions Operation and maintenance instructions Reco Boxx ZXR ZXA Flat ...

Page 2: ... counterflow ZXR ZXA and Flat 12 5 2 Circuit board SAT3 14 5 3 Circuit board SAT BA KW 13 6 0 Functions 14 6 1 Operating mode 14 6 2 Temperature control 15 6 3 Free cooling 15 6 4 Change over function 16 6 5 Frost protection 17 6 6 Time schedule 18 7 0 Commissioning 19 7 1 Commissioning with Touchscreen TP Touch 20 7 1 1 Home screen 21 7 1 2 Main menu 22 7 1 3 Basic Setup 24 7 1 4 Advanced setup 2...

Page 3: ...000 1600 1800 2300 2700 2900 3200 4200 4700 6200 7000 Yes electrical Yes electrical or water Left Right Backward BW Reco Boxx ZXA Counterflow 900 1500 1900 2500 2800 3700 Yes electrical Yes electrical or water Left Right Backward BW Reco Boxx Flat H Counterflow 550 650 1000 1400 1700 2100 2500 2700 3300 3700 Yes electrical Yes electrical or water Left Right Backward BW Reco Boxx Flat Counterflow 4...

Page 4: ...ing and experience Repair work may only be undertaken by an authorised AEREX specialist After successful installation and commissioning instruct users in the ventilation unit and associat ed control unit 2 3 Non intended use The ventilation unit must not be used in the fol lowing situations under any circumstances Read all the safety instructions Risk of combustion fire from flammable ma terials l...

Page 5: ...vent of a fire or chemicals accident etc Switch the entire ventilation sys tem off immediately until the outside air is safe again Risk during transport from heavy or falling loads Observe applicable safety and accident pre vention requirements Note permissible maximum loading capacity of lifting gear Do not stand under a suspended load Exercise caution when lifting Note transport weight ventilati...

Page 6: ...during removal Sometimes these can be hard to pull out slide in Ensure that you are standing securely and cannot lose your balance and that there is no one under the unit When removing and installing the components support them from below with a hand Risk of injury and health risk when using accessory elements which have not been approved The ventilation unit is tested with original ac cessories a...

Page 7: ...from the air ven tilated fireplaces is monitored by a special safety device In the case of air ventilated fire places for liquid or gaseous fuels the fireplace or the ventilation system must be switched off if the safety device is triggered In the case of air ventilated fireplaces for solid fuels the ventilation system must be switched off if the safety device is triggered In order to permit the i...

Page 8: ... connected by a qualified Electrician Warning Hazardous voltage OUTDOOR AIR Air from outdoor to the AHU SUPPLY AIR Air from the AHU to the building EXTRACT AIR Air from the building to the AHU EXHAUST AIR Air from the AHU to outdoor COOLING COIL BA NV KW HEATING COIL WATER ELECTRICAL SILENCER GD CTm MOTORISED DAMPER PRESSURE SENSOR P Tx TEMPERATURE SENSOR No x 1 2 3 SLIP CLAMP SC MS FLEXIBLE CONNE...

Page 9: ...t Reco Boxx ZXR R Reco Boxx ZXR L Reco Boxx Flat H R BOTTOM view Reco Boxx Flat H L BOTTOM view Außenluft Abluft Zuluft Fortluft Rechtsversion Linksversion Außenluft Abluft Zuluft Fortluft Rechtsversion Linksversion Reco Boxx ZXA R 900 1500 1900 Reco Boxx ZXA L 900 1500 1900 Außenluft Abluft Zuluft Fortluft Rechtsversion Linksversion Außenluft Abluft Zuluft Fortluft Rechtsversion Linksversion Reco...

Page 10: ... for power supply AHU 2 Main switch for power supply electrical coils both internal pre hating and post heating 3 Electrical cabinet 4 Supply fan 5 Extract fan 6 DDM Set for CA airflow measurement option 7 Outdoor air filter bag or pleated 8 Extract air filter bag or pleated 9 Heat exchanger 10 Modulating 100 bypass 11 Drain pan and drain pipe 12 Preheating coil accessory for Counterflow equipment...

Page 11: ...g YES YES Reco Boxx 1000 Flat H 200 1000 800 460 2100 x 435 x 1050 DN 315 0 100 modulating YES YES Reco Boxx 1400 Flat H 400 1400 760 320 2100 x 435 x 1300 DN 315 0 100 modulating YES YES Reco Boxx 1700 Flat H 400 1800 610 220 2100 x 435 x 1600 Connection on the suction side AU AB 800 x 300 Connection on the pressure side ZU FO 400 x 300 0 100 modulating YES YES Reco Boxx 2100 Flat H 400 2200 610 ...

Page 12: ...he AHU TAC5 DT CID 026001 S 2 8 2 und höher TAC5 DG CID 026000 S 2 7 0 und höher F3 F4 F1 F2 MOTOR CONTROL CABLES OUT IN N I T U O Alarm ON AF GND OUT4 OUT5 NV VO A KW 5V PR3 GND PR1 12V RESET Blue Bleu Blauw Blau B A Black Noir Zwart Schwarz GND Red Rouge Rood Rot 12V If DDM Set present Si présence du DDM Set Wenn das DDM Setvohanden ist White Blanc Witte Weiß B A GND 12V DDM Set Green Red Black ...

Page 13: ...damage both circuits permanently 5 3 Circuit board SAT BA KW SAT TAC5 BA KW is a satellite circuit designed to be fitted on the main control board It permits control of external coils Installation The SAT BA KW must be plugged onto the control board circuit see fig 3 Attention The SAT TAC5 BA KW must be plugged in before the circuit is powered SAT must be plugged in correctly wrong positioning can...

Page 14: ...m h K3 2 Torque control 3 torque setpoints to be configured by the user TQ K1 TQ K2 TQ K3 The setpoint is configured in of the maximal torque The torque control allows to vary the fan speed automatically to provide a variable airflow for demand controlled systems DCV This allows for demand controlled fan operation or fan optimisation by a BMS system mostly used in multi zone systems This operation...

Page 15: ...ide Inside 6 3 Free cooling The free cooling function uses the lower temperature of the outside air to cool the building Free cooling is realized by means of the integrated 100 modulating bypass of the heat exchanger PX or the stepless motor control of the rotary heat exchanger RX The optional output O R 4 on the SAT3 relay indicates the position of the bypass The contact will open if the bypass i...

Page 16: ...emperature supply air or extract air to be configured and the setpoint will determine if heating or cooling is automatically acti vated When the unit is equipped with reversible coil or with both a cooling and a heating coil only one setpoint has to be configured Comfort temperature The neutral band prevents the cooling and heating systems from counteracting each other The neutral band is added to...

Page 17: ...setpoint AFn If the exhaust air temperature T3 is 1 C the supply air fans will stop until the exhaust air temperature T3 is 2 C for 5 minutes 2 Modulating bypass The modulating bypass is controlled by the exhaust temperature sensor T3 If Exhaust temperature T3 1 C bypass closed or controlled by free cooling function Exhaust temperature T3 1 C bypass will modulate for the exhaust temperature T3 to ...

Page 18: ...l default or with 2 signals to control the supply airflow the link LS percentage of the nominal link cfr m h Vmin and m h Vmax in setup OR cfr TQ Vmin and TQ Vmax in setup and the rate of the exhaust airflow by the supply airflow with one 0 10 V signal for supply and one 0 10 V signal for exhaust via advanced setup one link LS percentage of the nominal link for supply and one for exhaust In pressu...

Page 19: ... possible HMIs are Touchpanel TP Touch This 4 3 touchscreen display is used when there is a need for a graphical HMI The Touchscreen touch screen is a complete graphic monitoring system where the screens are designed to be intuitive and complete ensuring a userfriendly experience Position switch PCOM4 The most basic interface to control a GLOBAL air handling unit is the 4 position swich This swith...

Page 20: ...rature 0 50 C Maximum length of the cable 100 metres Protection class IP20 Dimensions mm 96 8x148 8x14 5 Power consumption 120mA Image management Start up image At the first start up the basic setup menu will be activated automatically See section 7 1 3 Home Screen See Section 7 1 1 By default the home screen will be shown if no other menu is opened by the user or if selected in the main menu N B ...

Page 21: ...s This fields shows the number of current alarms By clicking on this field more detailed information about the different alarms is available Menu Accessing the main menu see section 7 1 2 Flow Chart The flow chart is not editable by the user the con figuration of the activated options and functions is done throught the product setup menu A code and a special training are desired for access to this...

Page 22: ...er enables you to control the AHU s operating mode time Certain other oversteering functions such as external timer communication etc affect the preset operating modes The controller allows 6 time slots channels to be configured Time and date The current date and time can be set and adjusted if needed The timer automatically takes leap years into consideration The system is preset for auto matic c...

Page 23: ...etail section 7 1 3 Readings The operating status and the Settings can be read Used for performance checks and for generally checking Settings settings power consumption etc No Settings can be altered in this menu group Maintenance Configuration of service related settings A maintenance warning interval can be configured as wel as the filter clogging alarm Advanced setup A code and a special train...

Page 24: ... can be set here The language set ting can be changed at any time in the basic setup menu Setting Settings range Factory setting Language Languages as displayed English Units The desired unit can be set here The unit setting can be changed at any time in the basic setup menu Setting Settings range Factory setting Unit m h l s m h Betriebsmodus Luftvolumenstrom The desired control mode can be set h...

Page 25: ... response to 0 10 V input signals from an external sensor such as a carbon dioxide or a humidity sensor The function can be configured with a positive or a negative logic A ratio between exhaust and supply pressure can be configured in order to create over under or balanced pressure The desired setpoint is preset in l s m h The sleep factor is a lower operating rate for the unit due to e g low occ...

Page 26: ...andling unit in case of emergency The fire alarm function is activated by means of digital input IN3 Setting Settings range Factory setting Input Normally open Normally closed Normally closed Supply airflow 0 max Extract airflow 0 max Periodic maintenance Built in timer for maintenance warning if the maintenance interval is exceeded a maintenance reminder will be dis played Setting Settings range ...

Page 27: ...ory setting Stop if Vlow No Yes Yes Vlow 0 10 V 0 8 V Stop if Vhigh No Yes Yes Vhigh 0 10 V 10 0 V Second 0 10V control signal Function only availalbe if demand control function has been selected in basic setup With this function a sep arate 0 10 V control signal for the extract air can be activated The control signal is connected to the analogue input K3 Setting Settings range Factory setting 0 1...

Page 28: ...enu advanced temperature control parameters can be modified Supply air involves keeping a constant supply air temper ature without consideration to the load in the premises Extract air involves keeping a constant temperature in the extract air duct premises by modulating the supply air temperature The reaction speed of capacity control signal can be mod ified A higher Setting will result in a smoo...

Page 29: ...al connected to input K3 The boost setpoint is preset in l s m h Setting Settings range Factory setting Supply Extract airflow 0 max Boost activation on Contact RH Contact RH on off 0 100 60 40 Vmin max RH on K3 0 10 V 2 0 V 9 5 V RH Vmin max 0 100 2 95 Post ventilation The post ventilation function is used to keep the fans running during a specified laps of time This function is activated automat...

Page 30: ...and main switch Setting Settings range Factory setting Setpoint 9 9 99 9 C 1 0 C PID Pro portional Band 0 100 5 PID Integral 0 100 30 PID Derivate 0 100 11 Electrical postheating coil The electrical postheating coil is installed and config ured in factory The electrical postheating coil will al ways have its separate power supply and main switch The capacity of the coil will be controlled proporti...

Page 31: ...ed seperately from the air handling unit and will not be pre config ured in factory Both the coil and the 3 way valve will have to be installed and wired on site The capacity of the coil will be controlled proportionally in order to keep a temperature as defined by the selected operat ing mode Setting Settings range Factory setting Control mode Exhaust Supply Supply Setpoint 0 99 C 17 0 C Reaction...

Page 32: ... of the water coil When the an ti frost protection temperature of the hydraulic coil de tects a tempeature lower than 4 C default the pump contact is closed and the 3 way valve is opened 100 during 15 minutes If the unit is running the alarm is activated immediately For a water preheating coil the frost alarm is delayed by 2 minutes If frost protection conditions occur when the air handling unit i...

Page 33: ...50043 which is used as communication interface The communication protocol used is MODBUS RTU RS485 Setting Settings range Factory setting Adress 1 247 1 Baudrate 1200 4800 9600 19200 9600 Parity No Yes No LAN configuration The MODBUS TCP IP communication requires an ad ditional satellite circuit CID 025072 which is used as communication interface The communication proto col used is Modbus TCP IP o...

Page 34: ...very 3 months Check for any alarms indicated on the control device In case of an alarm refer to troubleshooting section Check the state of filter clogging The control device allows a pre defined filter alarm threshold to be set Replace filters if necessary Filters that are too clogged can generate the following problems Insufficient ventilation Excessive increase of fan rotation speed Excessive so...

Page 35: ...le or through wet cleaning with water and or solvent Before you begin cleaning cover adjacent functional sections to protect them If cleaning solvent is used do not use solvent that will corrode aluminium or copper 2 Fan maintenance Check again whether the power supply is shut down and fans are not running Inspect and clean the fan impellers to remove any dirt deposits be careful not to alter the ...

Page 36: ...he optional module SAT 3 is installed on the control board Alarm Pa and AF activated LED s on control board Alarm on user interface Alarm communication with networking modules provided that an optional communication module Modbus RTU MODBUS TCP IP and KNX is installed on the TAC5 control board 9 1 Type 1 Alarm indicating a fan failure Conditions Causes Failure of fan Fx This problem is usually cau...

Page 37: ...onnected on IN2 input Causes Pressure alarm setup in airflow control or demand control mode External pressostat connected on IN2 input has triggered Effects unless the status has been changed in advanced setup Displayed on Touchpanel Text displayed LED ALARM LED Pa P 10 Pressure alarm Supply air RED P 20 Pressure alarm Extract air S 40 Pressure alarm from Pressure Switch TAC5 control board AL1 rel...

Page 38: ...essure alarm 2 Corrective action is taken change the working point to one located in the working zone of the fan by reducing the pressure system modifying the nominal airflow and restart the setup operation If this occurs during initializing of the assignment pressure in pressure control mode Corrective action must be taken change the working point to one located in the working zone of the fan by ...

Page 39: ...nd control fan 2 Air flow too low Reduce the pressure on this fan S 23 Demand control fan 2 Air flow too high Minimum limit of the motor reached S 24 Demand control fan 3 Air flow too low Reduce the pressure on this fan S 25 Demand control fan 2 Air flow too high Minimum limit of the motor reached S 34 Constant Air Flow fan 3 Air flow too low Reduce the pressure on this fan S 35 Constant Air Flow ...

Page 40: ... NO open contact by default or as NC if configured so in the advanced setup Effects Displayed on Touchpanel Text displayed LED ALARM LED Pa F 10 FIRE ALARM RED F 11 End of the fire alarm TAC5 control board AL1 relay O R 1 LED ALARM LED AF Fans Alarm status ON Auto reset no The fans are stopped by default in the event of a fire alarm but via the advanced setup it is possible to configure a fixed ai...

Page 41: ...RED M 11 Maintenance 6 months M 21 Operating hours M 22 Operating hours AHU off TAC5 control boards AL1 relay O R 1 LED ALARM LED AF Fans Alarm status ON Stopped if SERVICE STOP FAN Reset via fan run time TACtouch or alarm menu App unless the status has been changed in advanced setup 9 8 Type 8 Alarm indicating a communication breakdown between the TAC5 circuit and the hmi Conditions User interfac...

Page 42: ...short circuit TAC5 control board AL1 relay O R 1 LED ALARM LED AF Fans Alarm status ON Stopped Manual reset mandatory 9 10 Type 10 Alarm indicating failure on T sensor T4 Conditions Only with internal water heating coil WN NV option Causes T sensor T4 located on the coil and connected to the TAC5 circuit is defective open or short circuit or not connected This is used to prevent frosting of the in...

Page 43: ...tomatically reset when the water level in the drain pan is lower than the setpoint and the fans restart automatically 9 12 Type 11 Alarm indicating failure on T sensor T5 Conditions Only with post heating post cooling or free cooling with heat wheel or modulating bypass option Causes T sensor T5 located in the supply duct and connected to the TAC5 circuit is open or short circuited This sensor is ...

Page 44: ...with post heating option Causes The comfort T setpoint cannot be reached actual T lower than setpoint during 15 minutes or 30 minutes if comfort on T2 instead of T5 while post heating is at maximum Effects Displayed on Touchpanel Text displayed LED ALARM LED Pa S 50 Post heating T of the supply air too low RED TAC5 control board AL1 relay O R 1 LED ALARM LED AF Fans ON Auto reset yes ...

Page 45: ...ons as meas ured on the exhaust airflow after heat recovery indicating that the internal electrical EV KWin coil or external hydraulic coil BAin has reached its limit the TAC5 control can take over to guarantee the anti frost function If T assignment T 1 5 C for more than 5 minutes supply and exhaust airflow reduction of 33 if airflow control or demand control and of 25 if pressure control mode fo...

Page 46: ... the advanced setup this alarm indicates that the extracted air temperature at the exchanger output T3 sensor has not exceeded 1 C during 15 minutes after that the bypass has been opened at 100 Effects Displayed on Touchpanel Text displayed LED ALARM LED Pa A 11 Anti freeze Fans stopped RED TAC5 control board AL1 relay O R 1 LED ALARM LED AF Fans Alarm status ON Blinking Stopped Manual reset manda...

Page 47: ...l IBA or external heating coil EBA Causes Indicates that the anti frost protection temperature of the hydraulic coil is lower than 4 C config urable through advanced setup it is important to reduce this Setting for BAin coil if an antifreeze is in the fluid The 3 way valve is automatically opened at 100 for 15 minutes and the heat ing demand contact is closed output SAT3 O R 3 If the AHU is runnin...

Page 48: ...ment of the board or a mechanical blocking verified by a visual inspection of the bypass Effects Displayed on Touchpanel Text displayed LED ALARM LED Pa B 20 Position of the modulating bypass incorrect RED TAC5 control board AL1 relay O R 1 LED ALARM LED AF Fans Alarm Status ON Stopped Manual reset mandatory 9 20 Type 19 Alarm indicating that the hours limit for the maintenance of the filters has ...

Page 49: ...quires a Modbus pressure sensor placed on the heat ex changer and that the modulation of the fans speed is based on the airflow and not on torque When the previous detection is not available the supply T is checked and if it falls below 11 C it is considered that is due to the ice that reduces the heat exchanger efficiency Effects Displayed on Touchpanel Text displayed LED ALARM LED Pa B 20 Incorr...

Page 50: ...ontrol board the REC type needs to be configured in the product setup menu The product setup menu is used to enable specific features or to modify factory settings This must be done by an accredited technician A code and special training is mandatory to access this menu group The table below is valid for con trollers generation TAC5 Please ask Aerex for the REC CODE table info aerex de ...

Page 51: ...ant pressure 3 Constant Airflow CA K1 O m h O l s K2 O m h O l s K3 O m h O l s 4 Constant Torque TQ K1 Torque K2 Torque K3 Torque 5 Demand control 0 10 V LS Vmin V Vmax V m h TQ Vmin O m h O l s m h TQ Vmax O m h O l s on K3 6 Constant pressure CP Assignment Pa O V O Pa on K3 7 Ratio exhaust supply 8 Pressure alarm not for pressure control mode Activated O Yes O No O Automatic O Manual Setup Init...

Page 52: ...aintenance instructions 03 2021 Parameter Name Setting before change Setting of change 1 Date of change 1 Setting of change 2 Date of change 2 10 2 Track changes Enter details when the Setting of a parameter has been changed use only one row per parameter ...

Page 53: ...53 www aerex de Reco Boxx ZXR ZXA Flat Operation and maintenance instructions 03 2021 Notes ...

Page 54: ...54 www aerex de Reco Boxx ZXR ZXA Flat Operation and maintenance instructions 03 2021 Notes ...

Page 55: ...55 www aerex de Reco Boxx ZXR ZXA Flat Operation and maintenance instructions 03 2021 Notes ...

Page 56: ...intenance instructions 03 2021 AEREX HaustechnikSysteme GmbH Steinkirchring 27 78056 Villingen Schwenningen Tel 49 77 20 694 880 Fax 49 77 20 694 881 Service hotline 49 77 20 694 122 info aerex de www aerex de 0185 5115 0200 Version 2021 03 ...

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