AEREX 0040.2001 Operation & Maintenance Instructions Manual Download

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Oper

ation and maint

enance instructions

Operation and maintenance instructions

Reco-Boxx ZXR / ZXA / Flat

Summary of Contents for 0040.2001

Page 1: ...www aerex de AEREX March 2022 Operation and maintenance instructions Operation and maintenance instructions Reco Boxx ZXR ZXA Flat ...

Page 2: ...ircuit board SAT IO Art No 0041 0161 14 5 4 ernal coils control 15 6 0 Functions 16 6 1 Operating mode 16 6 2 Temperature control 17 6 3 Free cooling 17 6 4 Change over function 18 6 5 Frost protection 19 6 6 Time schedule 20 7 0 Commissioning 21 7 1 Commissioning with Touchscreen TP Touch 22 7 1 1 Home screen 23 7 1 2 Main menu 24 7 1 3 Basic Setup 26 7 1 4 Advanced setup 29 8 0 Preventive mainte...

Page 3: ...e heating Integrated post heating Handing Fan Reco Boxx ZXR Counterflow 1000 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 Flat OUT Counterflow 550 650 1000 1400 1700 2100 2500 2700 3300 3700 Yes elec...

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: ...rge by touching the unit handle boards at corners only and use antistatic gloves 6 Bedienungs und Wartungsanleitung 2 0 Symbole und Abkürzungen BW RÜCKWÄRTS GEKRÜMMTER VENTILATOR BF TASCHENFILTER PF FALTENFILTER RX ROTIERENDER WÄRMETAUSCHER PX PLATTENWÄRME TAUSCHER WARNUNG Elektronische Platinen enthalten ESD empfindliche Bauteile Tragen Sie beim Arbeiten an der Steuerung ein an tistatisches Handg...

Page 9: ...chtsversion 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 Boxx ZXA R 2500 2800 3700 Reco Boxx ZXA L 2500 2800 3700 ATTENTION The difference between left and right Flat units is the factory placement of the controls box on opposite sides Outdoor air...

Page 10: ...wer 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 NOTE Illustrations show right hand version R Left versions L are mirror images 12 Preheating coi...

Page 11: ... 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 Flat OUT 400 1400 760 320 2100 x 435 x 1300 DN 315 0 100 modulating YES YES Reco Boxx 1700 Flat H Flat OUT 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 ...

Page 12: ...LAIS OR1 linearer Aktuator für LP linearer Bypass Aktuator auf GRÜNE LED AN EINGESCHALTET SAT RELAIS OR2 linearer Aktuator für LP linearer Bypass Aktuator zu ROTE LED AN ALARM 24 24 V DC min 22 V DC max 26 V DC 0 8 A max 12 12 V DC min 11 49 V DC max 12 81 V DC 0 3 A max HAUPTPLATINE TAC CID026006 5 0 Wiring overview Main control board TAC6 DG XLEM026006 AO1 outpout 0 10V for external hydraulic po...

Page 13: ...piel mit DO7 Ausgang für Heizungsumwälzpumpe Abbildung 2 für DO9 Ausgang für Alarmanzeige Abbildung 3 für DO10 Druckalarm Anzeige Gleiches Prinzip für DO8 und DO11 Abb 3 Abb 2 Abb 1 4 2 DRUCKSCHALTER Bei Anwendungen in denen Druckschalter verwendet werden befolgen Sie bitte die Verdrahtung in Abb 4 mit Druckschalter für den Außenluftfilter an X4 und für den Abluftfilter an X2 HINWEIS Die Anschlüss...

Page 14: ...ie SAT IO muss auf die Hauptplatine aufgesteckt werden siehe Abb 5 Achtung Die SAT IO muss vor dem Einschalten der Stromversorgung auf die Hauptplatine aufgesteckt werden SAT IO muss korrekt aufgesteckt werden eine falsche Positionierung kann beide Platinen dauerhaft zerstören Verdrahtung Die Klemmen der SAT IO sind in Abb 6 dargestellt OR3 OR3 BYPASS STATUS Ausgangsrelais 30 VDC 42 VAC max 2 A DC...

Page 15: ... TO INSULATE KIT KWEXT KWEXT WHITE V GREEN 0 BROWN TO INSULATE KIT KWEXT KWEXT BROWN GREEN WHITE TO INSULATE 4 4 REGELUNG EXTERNER REGISTER Wenn ein externes Register hinzugefügt wurde ist das Set EBA oder das Set KWext erforderlich um entweder das EBA externes hydraulisches verdampfendes kondensierendes Register oder das KWext externes elektrisches Register an die Hauptplatine TAC anzuschließen B...

Page 16: ...higher speed This results in higher power consumption and may also cause discomfort in the form of noise There are three airflow setpoints to be configured by the user mhK1 mhK2 mhK3 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 3 Demand control 0 10 V The airflow is controlled by a 0 10 V signal The control s...

Page 17: ...ilding 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 OR3 OR3 on the SA TIO relay indicates the position of the bypass The contact will open if the bypass is fully closed or close if the bypass is fully or partially open The bypass PX or the rotary heat exchanger RX...

Page 18: ...rature 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 the...

Page 19: ... 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 exceed 1 C The corresponding supply air tem...

Page 20: ...nfigured For each day of the week the operation mode can be either AUTO operate according to time slots or manual selection of speed For each time slot select start time Operating mode Speed selection I II III for CA TQ normal reduced for LS CP and for all modes boost level Heating setpoint if postheater is present Cooling setpoint if postcooler is present ...

Page 21: ...ouch 26 Bedienungs und Wartungsanleitung 6 0 Inbetriebnahme Es stehen mehrere unterschiedliche Bedienschnittstellen Human Machine Interface HMI zur Verfügung Das HMI gibt Zugriff auf die Steuerparameter in der integrierten Steuerung Das HMI an sich enthält keine Programmierung und ist deshalb für den Betrieb der Anlage nicht zwingend erforderlich Die möglichen HMIs sind TACtouch Touchscreen CID372...

Page 22: ...t the home screen will be shown if no other menu is opened by the user or if selected in the main menu N B The appearance of the image varies depending on the type of air handling unit and functions selected Main menu See Section 7 1 2 The main menu is presented as a rotary menu After pressing the menu button at the bottom left corner of the Home Screen the rotary menu will be shown At the first s...

Page 23: ...asiertes Heiz register Kühlregister Anzahl aktiver Alarme Statusanzeigen Hauptmenütaste Elektrisches Heizregister Changeover Register Motorisierte Klappe offen geschlossen öff nend Flussdiagramme Plattenwärmetauscher Rotationswärmetauscher 7 1 1 Home screen The home screen displays the current key data for the air handling unit and is shown is normally displayed if no other menu has been selected ...

Page 24: ...ed Time schedule The built in timer 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 must be set and adjusted after the commissioning and later on if needed The timer automatically ta...

Page 25: ...ettings Advanced setup A code and a special training are desired for access to this menu 32 Operation and maintenance instructions Readings The operating status and the Settings can be read Used for performance checks and for generally checking Set tings settings power consumption etc No Settings can be altered in this menu group Maintenance Configuration of service related settings A maintenance ...

Page 26: ...Torque Airflow 33 Operation and maintenance instructions BASIC SETUP 6 1 3 BASIC SETUP When the air handling unit is started up for the first time the commissioning menu is automatically displayed At the very end of the commissioning menu the commissioning of the unit has to be confirmed by the service technician Once the commis sioning has been confirmed the commissioning menu will not be display...

Page 27: ...bon 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 occupancy that will be activated by speed III Setting Range Factory settin...

Page 28: ...if the maintenance interval is exceeded a maintenance reminder will be displayed Setting Settings range Factory setting 3 monthly warning Yes No No 12 monthly warning Yes No No Commissioning completed When the commissioning has been successful and this is confirmed in this menu the commissioning menu will not be activated automatically anymore Setting Settings range Factory setting Confirmation of...

Page 29: ...gnal is connected to the ana logue input K3 Setting Settings range Factory setting 0 10V on K3 No Yes No Control Exhaust Supply Exhaust Pressure control Function only availalbe if pressure control function has been selected in basic setup The reaction speed of the fans for the balancing of the constant pressure system can be modified A higher Setting will result in a faster reaction speed a lower ...

Page 30: ...Yes No Stop fan when pressure alarm Possibility to stop the fans automatically in case of a pressure alarm Setting Settings range Factory setting Stop fans No Yes No Start torque Possibility to change the fans s starting torque Setting Settings range Factory setting Start Torque 0 100 2 Deactivate softstop With this function the OFF function is deactivated Setting Settings range Factory setting So...

Page 31: ...RH Contact RH on off 0 100 60 40 Vmin max RH on K3 0 10V 2 0V 9 5V 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 auto matically when an electrical heating coil is activated Setting Settings range Factory setting Activation No Yes No Time 0 9999sec 90sec DEACTIVATE SOFTSTOP TEMPERATUR...

Page 32: ...ontrol mode Exhaust Supply Supply Setpoint 9 9 99 9 C 21 0 C Reaction Speed 1 10 5 39 Operation and maintenance instructions Internal coils Water preheating coil By preheating the outdoor air it is possible to prevent mois ture precipitation in the AHU s outdoor air filter to reduce the risk of frosting in the heat exchanger and to eliminate the risk that pressure sensors and motor control systems...

Page 33: ...ctivate change over No Yes No Neutral band High 0 50 C 4K Neutral band Low 0 50 C 2K 40 Operation and maintenance instructions External coils Configuration of the coils This menu will allow for the configuration of any combi nation of external heating and or cooling coil s Setting Settings range Factory setting Type None Hot water Cold water Hot Cold water Reversible water Electric PWM Electric PW...

Page 34: ... 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 35: ...trol variables and parameters are saved on the micro SD card and appended in a CSV format file named TAClog 42 Operation and maintenance i RESTORE FACTORY SETTINGS ALARMS LOG RESET PRODUCT SETTINGS ACCESS CODE CONTACTS K1 K2 K3 MASTER ADVANCED SETUP Restore Factory settings Allows to restore the factory settings Alarms log reset Reset of the alarm log history Product Settings Enables the product s...

Page 36: ... 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 sound levels Excessive power ...

Page 37: ...e 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 i...

Page 38: ...r Text Stufe B 11 Ventilator 1 Fehler 3 B 12 Ventilator 2 Fehler 3 B 13 Ventilator 3 Fehler 3 B 14 Ventilator 4 Fehler 3 43 Bedienungs und Wartungsanleitung 8 0 Störungsbehebung Bedingungen Ursachen Störung von Ventilator Fx Dieses Problem wird normalerweise durch den Ventilatormotor verursacht Andernfalls kann die Störung durch ein internes Steuer oder Strom Kabel oder durch die TAC Schaltung ver...

Page 39: ... ADI2 OR ADI3 input Causes Pressure alarm setup in airflow control or demand control mode External pressostat connected on ADI2 OR ADI3 input has triggered Effects Displayed on Touchpanel Code Text displayed Level P 10 Pressure alarm Supply air 2 P 15 Pressure alarm Extract air 2 S 40 Pressure alarm from Pressure Switch 2 TAC control board ALARM OUTPUT AL dPa OUTPUT LED ALARM Fans Alarm Status ON ...

Page 40: ...larm 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 reducing...

Page 41: ...or reached 2 S 22 Demand control fan 2 Air flow too low Reduce the pressure on this fan 2 S 23 Demand control fan 2 Air flow too high Minimum limit of the motor reached 2 S 24 Demand control fan 3 Air flow too low Reduce the pressure on this fan 2 S 25 Demand control fan 2 Air flow too high Minimum limit of the motor reached 2 S 34 Constant Air Flow fan 3 Air flow too low Reduce the pressure on th...

Page 42: ... the event of a fire alarm but via the advanced setup it is possible to configure a fixed airflow for supply contact IN7 needs to be closed and for exhaust contact IN8 needs to be closed 9 7 Type 7 Maintenance alarm Conditions The running hours feature must be enabled in advanced setup Causes SERVICE ALARM the fan operating time in hours has exceeded the configurable threshold STOP FAN the fan ope...

Page 43: ... circuit 3 T 40 Sensor T4 disconnected 3 T 41 Sensor T4 short circuit 3 TAC control board ALARM OUTPUT AL dPa OUTPUT LED ALARM Fans Alarm Status ON Stopped Manual reset mandatory 9 9 Type 9 Alarm indicating failure on T sensor T7 Conditions Only with water heating coil IBA or EBA option Causes T sensor T7 located on the coil and connected to the TAC circuit is defective open or short cir cuit or n...

Page 44: ...er level in the drain pan is lower than the setpoint and the fans restart automatically 9 11 Type 11 Alarm indicating failure on To 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 TAC circuit is open or short circuit ed This sensor is used to regulate the post hea...

Page 45: ... protection alert Conditions Only with post heating option Causes Frost protection is only selected with electrical pre heating coil KWin or water preheating coil BAin or modulating bypass With KWin or BAin option In certain air T conditions as meas ured on the exhaust airflow after heat recovery indicating that the internal electrical KWin coil or external hydraulic coil BAin has reached its limi...

Page 46: ... FREECOOL in 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 Code Text displayed Level A 11 Anti freeze Fans stopped 3 TAC control board ALARM OUTPUT AL dPa OUTPUT LED ALARM Fans Alarm Status ON stopped Manual reset mandato...

Page 47: ...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 running ...

Page 48: ...l Code Text displayed Level B 20 Position of the modulating bypass incorrect 3 TAC control board ALARM OUTPUT AL dPa OUTPUT LED ALARM Fans Alarm Status ON stopped Manual reset mandatory Diagnostic Stop the unit do an alarm reset check and eventually correct actuator wiring to the control board and then check that the bypass can move physically connect IN3 to 12V to force the bypass to open If the ...

Page 49: ... control board ALARM OUTPUT AL dPa OUTPUT LED ALARM Fans ON Auto reset via dedicated reset 9 20 ype 20 Alarm indicating that the defrost process is active Conditions GUnit with counter flow heat exchanger Causes The ice forming inside of the plate heat exchanger is genrating a pressure drop that is too high for the current airflow This detection requires a Modbus pressure sensor Art No 0043 1119 R...

Page 50: ...ard that it is not present If the sensor is well present check that the address of the wheel is correct Finally check it s status led green led on communication orange blinking If status led are different then it may be due to the cable or to sensor itself that is damaged Wiring is in chain from connec tor RJ3 or RJ4 for sensors 1 DDM Set kit CA supply 2 DDM Set kit CA exhaust and C defrost Art No...

Page 51: ...or the major maintenance has been reached The instructions in this manual for the 12 months maintenance should be followed Reset the hours for major maintenance after this operation this will reset automatically the alarm and give it again after the same period Reset also minor maintenance hours Effects Displayed on Touchpanel Code Text displayed Level M 11 MAJOR MAINTENANCE ALARM 1 TAC control bo...

Page 52: ...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 53: ...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 54: ...aintenance instructions 03 2022 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 55: ...55 www aerex de Reco Boxx ZXR ZXA Flat Operation and maintenance instructions 03 2022 Notes ...

Page 56: ...intenance instructions 03 2022 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 0001 Version 2022 03 ...

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