nilan CTS 602 Installation Instructions Manual

CTS602 LIGHT BY NILAN Version 4.00 - 01.05.2020 M24_Comfort-252-302-Top_GB

General information Safety ............................................................................................................................................................................................................ 4 Power supply ......................................................................................................................................................................................... 4 Introduction .................................................................................................................................................................................................. 4 Documentation ..................................................................................................................................................................................... 4 Unit type ....................................................................................................................................................................................................... 5 Product description .............................................................................................................................................................................. 5 Dimensional drawing ............................................................................................................................................................................ 6 Functional block diagram .................................................................................................................................................................... 7 Accessories .................................................................................................................................................................................................. 8 Electrical pre-heating element for frost protection of the unit ................................................................................................... 8 Electrical pre-heating element for integration ............................................................................................................................... 8 Electrical after-heating element for duct installation ................................................................................................................... 8 Water after-heating element incl. control system for duct installation .................................................................................... 8 EM-box .................................................................................................................................................................................................... 8 DTBU damper ........................................................................................................................................................................................ 9 CO2-sensor ............................................................................................................................................................................................ 9 Expansion PCB ....................................................................................................................................................................................... 9 Fire automation system box ............................................................................................................................................................... 9 Water trap with ball ............................................................................................................................................................................. 9 Vibration absorbers ...........................................................................................................................................................................10 Flexible sound damper .......................................................................................................................................................................10 Pollen filter ...........................................................................................................................................................................................10 Cooker hood filter box .......................................................................................................................................................................10 Wall mount brackets ..........................................................................................................................................................................10 Extension cable HMI control panel ..................................................................................................................................................11 Functional cable ..................................................................................................................................................................................11 Installation Placement ...................................................................................................................................................................................................12 Positioning of the ventilation unit ...................................................................................................................................................12 Top unit .................................................................................................................................................................................................12 Mounting the ventilation unit ...........................................................................................................................................................13 Wall brackets for mounting unit ......................................................................................................................................................13 Electrical installation Electrical connections ..............................................................................................................................................................................14 Safety ...................................................................................................................................................................................................14 Connection overview .........................................................................................................................................................................14 User panel ...................................................................................................................................................................................................15 HMI User panel ....................................................................................................................................................................................15 Wall bracket .........................................................................................................................................................................................15 Electrical connection unit ........................................................................................................................................................................16 Power supply .......................................................................................................................................................................................16 Ventilation unit ...................................................................................................................................................................................16 Electrical connections accessories ........................................................................................................................................................17 Functional cable ..................................................................................................................................................................................17 User selections 1 and 2 (cooker hood) ............................................................................................................................................18 Modbus .................................................................................................................................................................................................19 Fire thermostat / external fire automation system ....................................................................................................................20 EM-box (damper solution) .................................................................................................................................................................21 DTBU damper solution .......................................................................................................................................................................22 External connections .........................................................................................................................................................................23 External pre-heating element ..........................................................................................................................................................24 Installation of electrical pre-heating element for integration ...................................................................................................25 Installation of expansion PCB on CTS602 Light circuit board ....................................................................................................27 Electrical after heating element ......................................................................................................................................................28 Water after heating element ............................................................................................................................................................29 CO2 sensor ...........................................................................................................................................................................................30 Joint alarm ............................................................................................................................................................................................31 Plumbing installation Condensate drain ......................................................................................................................................................................................32 Important information .......................................................................................................................................................................32 Connection of water trap ..................................................................................................................................................................32 Installation water trap with ball .......................................................................................................................................................33 Water after-heating element - duct installation ..........................................................................................................................34

Safety ................................................................................................................................................................................................... 35 Usage .................................................................................................................................................................................................... 35 Electrical connection fire automation system .................................................................................................................................... 35 Connection of fire damper ............................................................................................................................................................... 35 Alarm code .......................................................................................................................................................................................... 36 Start-up and annual testing ............................................................................................................................................................. 36 Schedule for functional testing ....................................................................................................................................................... 38 Ventilation installation Duct system ............................................................................................................................................................................................... 39 Legislation ........................................................................................................................................................................................... 39 Ducts .................................................................................................................................................................................................... 39 Ventilation unit ................................................................................................................................................................................... 39 Supply air ............................................................................................................................................................................................. 40 Roof terminals .................................................................................................................................................................................... 40 Installation example .......................................................................................................................................................................... 40 Balancing .................................................................................................................................................................................................... 41 Important information ...................................................................................................................................................................... 41 Balancing holes ................................................................................................................................................................................... 41 Pressure loss diagram ....................................................................................................................................................................... 42

• Quick guide • Wiring diagram In the Quick guide you will find important information regarding installation and start-up of the unit. If you require further information regarding, for instance, installation of accessories or additional settings in the software, or if you need an extended user manual, the following documents can be downloaded from the Nilan website: • Installation instructions • Software instructions • User Manual • Wiring diagram The instructions can be downloaded from https://www.nilan.dk/en-gb/frontpage/download. If you have questions regarding installation and operation of the unit after having read the instructions, please contact your nearest Nilan dealer. A list of Nilan dealers is available on www.nilan.dk/forhandlere. From factory, the unit has been tested and is ready for operation. CAUTION Always disconnect the power supply to the unit if an error occurs that cannot be rectified via the control panel. CAUTION If an error occurs on electrically conductive parts of the unit, alway contact an authorised electrician to rectify the error. CAUTION Always disconnect the power to supply to the unit before opening the unit doors, for instance for installation, inspection, cleaning and filter change. ATTENTION The unit must be started up immediately after installation and connection to the duct system. When the ventilation unit is not in operation, humidity from the rooms will enter the duct system and create condensate water that can run out of the valves and cause damage to floors and furniture. Condensation may also form in the ven- tilation unit, which can damage its electronics and fans.

duct pressure of 100 Pa. The unit is used primarily in residential buildings. Due to its low sound level it is particularly suitable for ventilation in apartments. The unit ventilates the dwelling by drawing out damp and vitiated air through valves placed in, for instance, bathroom, lavatory, kitchen and utility room. It then blows fresh outdoor air in through valves placed in living areas such as sitting room, family room and bedrooms. The cold outdoor air is heated up by the warm extract air in the high efficiency counterflow heat exchanger. This ensures limited heat loss through ventilation. As standard, the unit is supplied with ISO Coarse > 90% (G4) plate filters that serve to protect the unit from dirt. If you require increased filtration of the outdoor air, you can order an ePM1 50% (F7) pollen filter as an accessory. Right-facing model shown 1. Duct connections 2. Electrical connections 3. Extract air filter 4. Outdoor air filter (Install pollen filter here) 5. 100% Bypass damper 6. Counterflow heat exchanger 7. Condensate drain 8. Supply air fan 9. Extract air fan 10. Automation system

Right model: Left model: Connections: 11. Outdoor air 12. Supply air 13. Extract air 14. Discharge air 15. Condensate drain

Electrical pre-heating element for integration Electrical after-heating element for duct installation Water after-heating element incl. control system for duct installation EM-box If your ventilation unit is not a Polar version with an integral pre-heating element, we recommend that you purchase an external pre-heating element as frost protection of the ventilation unit. During prolonged periods of frost, the high efficiency counterflow heat exchanger will ice up. To prevent ice formation, we recommend that you install an electrical pre-heating element. The pre-heating element consumes limited energy and it ensures efficient heat recovery without periods of defrosting the counterflow heat exchanger. You thereby achieve an overall reduction in energy consumption. Comfort 252/302 Top is ready for installation of an integral pre-heating element. The pre-heating element is easy to install behind the counterflow heat exchanger without using screws or fittings. The 230V power supply is then fed out into the unit for easy and fast connection. The pre-heating element does not regulate itself according to the outdoor temperature, as is most common, but according to the discharge air temperature in the heat exchanger. This results in a much more precise regulation in line with requirements, and it therefore saves energy. Installing an after-heating element allows you to control the supply air temperature in the following cases: • You want to use the ventilation air to heat the dwelling • You want to control the supply air temperature to avoid potential cold draughts and coldness from the ventilation The electrical after-heating element is for installation in the supply air duct. It would be an advantage to place it within the climate screen. It comes with the necessary sensors and connectors. Installing an after-heating element will allow you to control the supply air temperature in the following cases: • You want to use the ventilation air to heat the dwelling • You want to control the supply air temperature to avoid potential cold draughts and coldness from the ventilation The water after-heating element is for installation in the supply air duct. It would be an advantage to place it within the climate screen. It comes with the necessary sensors and connectors as well as a two-way regulation valve for the hot water. If you want to run the cooker hood via the ventilation unit, in some cases there may be insufficient air for cooker hood extraction. If you install an EM-box, you can regulate the extracted air when the cooker hood is in operation, so that less air is drawn from, for instance, the bathroom and the utility room. This will allow enough air for the cooker hood to extract sufficiently. The EM-box is fitted with a metal filter that cleans the air in the cooker hood of grease particles efficiently. It thereby protects the ventilation unit.

Water trap with ball If there is insufficient space for mounting an EM-box in the installation, you can achieve the same effect by controlling the extract air with a DTBU damper. You then have to adjust the duct system yourself with a connection to the cooker hood. If you want to adjust the fan speed level according to use of the dwelling/building (amount of people), you can retrofit a CO2-sensor. You select the CO2-level you want via the control panel. If this level is exceeded, ventilation will increase. With an expansion PCB, it is possible to expand the functions within the control system. • Connecting an after-heating element (supplied with the heating element) • Connecting a CO2-sensor • Connecting a joint alarm The Comfort ventilation unit has a function in its control system that can control 1-2 fire dampers. If you want to activate this function, Nilan can supply you with a connection box, a "Fire automation system box”, with the following connection options: • Connection of 1-2 fire dampers • Connection of external fire thermostat • Connection of user selection 1 (cooker hood) • Connection of Modbus communication to, for instance, CTS unit You connect the box up with the supplied 1 m cable with RJ45 connector. A water trap must be installed to ensure that the condensate water can drain freely from the ventilation unit. Condensation does not form during the summer months and a regular water trap may therefore dry out. If that happens, the water trap will lose its function. When winter returns and condensate water forms again, the water will not be able to drain from the condensate tray. Condensate water may then leak from the unit and cause serious water damage. Every autumn it is therefore important to check that there is water in the water trap. However, if you install a Nilan water trap with ball, the ball will ensure permanent function of the water trap. This saves you refilling the water trap manually every autumn to ensure that it works.

Pollen filter Cooker hood filter box Wall mount brackets It is important to ensure that the ventilation unit does not transfer vibrations to the building. The ventilation unit should therefore be placed on a vibration absorbing material. Nilan can supply effective vibration absorbers to place under the ventilation unit. They are sold in packs of 4. To make it esay to service the unit in the future, we recommend that you fit a flexible connection between the unit and the duct system. Nilan flexible sound damper absorbs sounds effectively from both the duct system and from roof stacks. The ventilation unit comes, as standard, with a plate filter to protect the unit. If the dwelling is used by anybody with, for instance, pollen allergies, you may benefit from purchasing a pollen filter. This should be placed in the outdoor air intake, which will reduce the pollen count in the dwelling. If the extract air needs extra filtration, Nilan can supply a Cooker hood filter box. This can provide extra protection of the ventilation unit if you connect a cooker hood that has not got good filters. It can also help air extraction from, for instance, dormitory rooms where cooker hoods are rarely installed. Nilan can supply wall mount brackets with vibration absorbers which will ease the process of mounting ven- tilation units with top connections. You assemble the wall bracket, mount it on the wall and simply place the ventilation unit into the bracket. There must be room below it for the condensate drain.

Functional cable The control panel for the ventilation unit is connected up with a short wire so it can be installed close to the unit. If you place the unit so the control panel is out of sight, for instance in a cupboard or in the loft, you can order a 15 m extension cable with plug. This allows you to place the control panel where it is visible to the user. It is important that the control panel is visible so the user can see alarms when, for example, filters need replacing. The following external functions can be connected to the ventilation unit via an RJ45 connector: • User selection 1 and 2 (cooker hood) • Modbus communication • Fire thermostat or external fire automation system You can adapt an RJ45 connector yourself in line with the instructions. To facilitate installation, Nilan can supply a 10 m LAN cable with the correct RJ45 connector for the three functions.

The unit makes little noise and it produces only weak vibrations, but you should still take into account potential vibrations that can spread from the unit to individual building components. In order to separate the unit from its underlying surface, it is therefore recommended that you fit vibration absorbers under the unit. There should be approx. 10 mm distance to other building components and to permanent fixtures. Top unit ATTENTON When positioning the unit, you should always consider future service and maintenance. It must be easy to replace filters, and it must be possible to remove, for instance, the exchanger, and to replace fans or other components. ATTENTON A free space is recommended in front of the ventilation unit of at least 60 cm. ATTENTON The unit must be level to enable proper drainage from the condensate tray. ATTENTION If you fit flashings above the unit, there must be enough space to remove these easily.

The unit is equipped with mounting brackets with holes for wall mounting at the top back of the unit. Wall brackets for mounting unit You can purchase wall brackets to use for mounting Top ventilation units. Included are 4 sylomers (vibration absorbers) that will ensure effective absorption of potential vibrations from the ventilation unit to the underlying surface/wall. Contents: 2 side pieces and 3 brackets. Bag with 4 vibration absorbers and 12 rivets for Ø5 mm holes. Rivet the wall mount with a rivet gun as described in the instructions that are supplied with the wall mount. The wall mount bracket has 6 holes for installation on the wall. Finally, place the vibration absorbers one in each corner and place the ventilation unit on the wall mount.

Connection overview All connections are placed at the top of the ventilation unit. 1. Grommet for external connections 2. Connection 230V (remember electrical grounding) 3. Connection RJ45 (fitted plug with lids for fire thermostat) 4. Connection user panel 5. Connection PC Connections shown on the right model. On the left model the connections are mirrored in the left side. ATTENTION All work must be carried out by qualified persons and in compliance with existing legislation and regulations. ATTENTION It is important that the power is off, if you do work to the electrical components of the unit.

The user panel comes with 1.5 meter cable. Wall bracket Mount the HMI panel on the wall using the integrated wall bracket.. The panel should be placed in a visible spot so it is possible to change settings and to monitor warnings or alarms regarding operation of the unit. ATTENTION If you want a longer cable, use a standard LAN cable, max 50 meters. Nilan offers a 15 meter cable with plugs on both ends. The wall bracket is located at the back of the panel. You can detach it by loosening the bracket at the bottom of the panel. You can remove it. Mount the wall bracket on the wall using 2 screws. Click the RJ12 plug into place at the bottom of the HMI panel. The wire can run down along the wall, into the wall or through the groove at the back of the panel.

Power supply The unit is supplied with an EU plug for a 230V power supply. This means that, in principle, you have no protection of electrical grounding. You can secure electrical grounding by connecting the plug to a socket with a ground pin. You can also connect an adapter for a plug with a ground pin. You can fit this plug adapter on the unit, so that the unit is secured electrical grounding to the earthing system. Ventilation unit CAUTION The power supply is plugged into a 230V socket with a safety switch. It is important that the unit has ground connection. Safety switch Power supply 230V ~ 50 HZ max. 13A

Functional cable Many of the external connections are made via an RJ45 port that is installed on the ventilation unit. See the connections overview to locate the RJ45 port. From factory, a shunt plug for fire thermostat connection has been plugged into the RJ45 port. This must be re- moved before the LAN cable is plugged in. The LAN cable enables the following functions: • User selection 1 • User selection 2 • Modbus • Fire thermostat / external fire automation system Connections in relation to the function cable that has an RJ45 connector in one end and loose wires in the other: The length of the LAN cable is 10 m. 1. Green/white 2. Green 3. Orange/white 4. Blue 5. Blue/white 6. Orange 7. Brown/white 8. Brown GND User selection 1 User selection 2 Modbus A1 (+) Modbus B1 (-) Not used Fire thermostat / external fire automation system User selection output (Cookerhood function) ATTENTION If you adapt an RJ45 cable yourself, be aware that wire 8 (Brown) can become live with 12V and must not be short circuited. In Nilan’s LAN cable the wires that are not used are not connected up to the RJ45 connector. With Nilan’s LAN cable there is therefore no risk of short circuits.

If the fire automation system has not been activated in the software, you will have access to both User selection 1 and User selection 2. If the fire automation system has been activated, you will only have access to User selection 1. The user selection functions are used to override standard operation. The input signal must come from a potential-free contact. When connection is established, the function with the settings that have been selected on the control panel under Service/User Selection is activated. The following are examples of situations when user selection functions are used. Connection via Nilan Functional cable Connection of User selection 1 A potential-free signal is connected to User selection 1 via the following: 1. Green/white 2. Green NB: If fire thermostat/external fire automation system is not connected up, make a shunt between: 1. Green/white 7. Brown/white Connection of User selection 2 (overriding the operation) A potential-free signal is connected to User selection 1 via the following: 1. Green/white 2. Orange/white NB: If fire thermostat/external fire automation system is not connected up, make a shunt between: 1. Green/white 7. Brown/white Cooker hood If you choose to run the cooker hood via the ventilation unit, the cooker hood will send a potential-free sig- nal to the ventilation unit when you switch it on. When this happens, the ventilation unit increases the air volume to the set level, so that enough air is drawn through the cooker hood. Fireplace/wood- burning stove Normally, ventilation is balanced with slightly negative pressure in the dwelling so that dampness is not pressed into the building components. This, however, is a disadvantage if you light a fire in your fireplace/ wood-burning stove as the smoke will then enter the dwelling instead of being drawn out through the chimney. When lighting a fire in the fireplace/wood-burning stove, you can activate the user function with a potential-free contact that ensures positive pressure in the dwelling. Smoke is then drawn out of the chimney as intended. Prolonged operation If the ventilation unit is used in an office or a school where ventilation is reduced outside opening hours, it may be necessary to increase ventilation temporarily if the building is used in the evening for, for instance, meetings. In that case you can have a potential-free contact that is activated, causing ventilation to increase, for example for an hour, before operation ceases again. 1. Green/white 2. Green 3. Orange/white 4. Blue 5. Blue/white 6. Orange 7. Brown/white 8. Brown GND User selection 1 User selection 2 Fire thermostat / external fire automation system User selection output (Cookerhood function) ATTENTION If you are not using the Cooker hood setting in User selection, you will be able to use any RJ45 cable. In that case, wire 8 Brown will not carry 12V.

the ventilation unit via external control systems. Please consult the software instructions and the Modbus protocol for further information on settings and registers. Connection via Nilan Functional cable Connection of Modbus communication Establish the Modbus connection via the following: 1. Green/white 4. Blue (+) 5. Blue/white (-) NB: If fire thermostat/external fire automation system is not connected up, make a shunt between: 1. Green/white 7. Brown/white 1. Green/white 2. Green 3. Orange/white 4. Blue 5. Blue/white 6. Orange 7. Brown/white 8. Brown GND Modbus A1 (+) Modbus B1 (-) Fire thermostat / external fire automation system ATTENTION If you are not using the Cooker hood setting in User selection, you will be able to use any RJ45 cable. In that case, wire 8 Brown will not carry 12V.

The ventilation unit can be connected up to an external fire thermostat that will stop the ventilation unit in the event of fire. The same port can be used for connection of an external fire automation system. The control system identifies a broken input signal as fire, and stops. It will only restart once connection to the fire thermostat has been established or the external fire automation system starts signaling again. This must be done manually via the control panel. When you connect up an external fire automation system, it will be necessary for the ventilation unit to restart automatically. You can set for this to happen on the control panel. Please consult the software instructions for further information. Connection via Nilan Functional cable Connection of fire thermostat or external fire automation system Establish the connection via the following:: 1. Green/white 7, Brown/white 1. Green/white 2. Green 3. Orange/white 4. Blue 5. Blue/white 6. Orange 7. Brown/white 8. Brown GND Fire thermostat / external fire automation system ATTENTION If you are not using the Cooker hood setting in User selection, you will be able to use any RJ45 cable. In that case, wire 8 Brown will not carry 12V.

If you want to run the cooker hood via the ventilation unit, in some cases there may be insufficient air for cooker hood extraction. If you install an EM-box, you can regulate the extracted air when the cooker hood is in operation, so that less air is drawn from, for in- stance, the bathroom and the utility room. This will allow enough air for the cooker hood to extract sufficiently. The EM-box is fitted with a metal filter that cleans the air in the cooker hood of grease particles efficiently. It thereby protects the ven- tilation unit. The system works as follows: When you switch on the cooker hood, User selection 1 will be activated. The ventilation unit increases ventilation and sends an output signal to the EM-box that it is to close the damper for extraction from other rooms. However, the damper does not close completely and a reduced level of air extraction from other rooms will still take place. When balancing the damper, the small stop blocks on the damper must be positioned so that the basic ventilation rate is maintained from the other rooms. The solution of connecting an EM-box is carried out easily by using a Nilan Fire box. Connect User selection 1 directly to the Nilan Fire box. Also connect up Modbus and the fire thermostat/external fire automation system through the Nilan Fire box. You can connect up User selection 2 via S1 and S2 under fire damper connection in the Nilan Fire box. NB! Wiring for 230V supply to EM-box damper not included. ATTENTION The EM-box solution cannot be used if the fire automation system has been activated in the software..

If you want to run the cooker hood via the ventilation unit, in some cases there may be insufficient air for cooker hood extraction. An EM-box solution can solve this. However, if there is insufficient space in the installation for an EM-box, the alternative may by to connect up a DTBU damper in the duct system. It has the same function except from having no integral particle filter. You can, howev- er, purchase a filter box with a steel filter that you can install in the duct system. The DTBU damper regulates extraction so that less air is drawn from, for instance, the bathroom or the utility room. This will allow enough air for the cooker hood to extract sufficiently. The system works as follows: When you switch on the cooker hood, User selection 1 will be activated. The ventilation unit increases ventilation and sends an output signal to the DTBU damper that it is to close for extraction from other rooms. However, the damper does not close completely and a reduced level of air extraction from other rooms will still take place. The solution of connecting a DTBU damper is carried out easily by using a Nilan Fire box. Connect User selection 1 directly to the Nilan Fire box. Also connect up Modbus and the fire thermostat/external fire automation system through the Nilan Fire box. You can connect up User selection 2 via S1 and S2 under fire damper connection in the Nilan Fire box. NB! Wiring for 230V supply to DTBU damper not included. ATTENTION The DTBU damper solution cannot be used if the fire automation system has been activated in the software.

cover plate so it is easier to see where the guide tube starts. Run the wire to point 4 (See connections overview). Connection through frommet to external connections.

It is possible to purchase an external electric pre-heating element for frost protection of the ventilation unit. The electric preheating element is mounted in the outdoor air duct before the unit with the necessary temperature sensor. . It is important that the sensor is placed at least 32 cm from the preheating element to achieve correct regulation. The pre-heating element has a three-step safety system that prevents overheating. 9. An operating thermostat regulates the heating and ensures that the supply air temperature does not fall below -1 °C 10. Should the temperature exceed 50 °C, a max. thermostat switches off the pre-heating element. (If installed vertically with downward airflow, the pre-heating element switches off at 70 °C) 11. A safety thermostat switches off the pre-heating element if the temperature exceeds 100 °C. Then, you must reset it manually. Minimum airflow at Ø160: 110m3/h. ATTENSION The heating element must be insulated with a fire retardant insulation material. The cover of the connection box, however, must not be insulated. Dimensional drawing: Positioning options: 7 N L 8 T 1x230V ~ 50 Hz max. 16A Min. 32 cm 276 370 ~50 ~50 71 Ø160

Comfort 252/302 Top is ready for installation of an integral pre-heating element. WARNING The power supply of the ventilation unit must be switched off before you open the doors of the unit. 1. Open the toggle case latch catch on top of the unit (shown in the red circle) and lift out the upper front door. Loosen the 6 screws in the lower front door and lift out the door. 2. Carefully pull out the sensor from the slats in the coun- terflow heat exchanger. 3. Gentle wriggle out the counterflow heat exchanger. It is important not to damage the corner (shown in the red circle). 4. Install the electrical pre-heating element in the open compartment at the rear of the ventilation unit. Gently press the three spikes into the EPS mould and move the heating element into place under the top edge. 5. Connect the power supply, which is located at the bottom of the ventilation unit. Ensure the wire is fed out into the customised groove (shown in the red circle). 6. Gently pull forward the sensor from the electrical pre- heating element. Then, make an incision in the EPS mould so you can push the wire all the way down, below the top edge.

is below the top edge (shown in the red circle). Otherwise the exchanger cannot be pushed back in again. 8. Carefully move the exchanger back into place and push the sensor back into the slat. The sensor from the electrical heating element should also be placed here - but in a sepa- rate slat. Otherwise the slats will expand and the sensors will fall out. Refit the unit doors and connect the power supply.

With an expansion PCB, it is possible to expand the functions within the control system. You can connect a CO2-sensor, a joint alarm and an after-heating element (expansion PCB is included with the heating element) 1. Demount the shown bus cable from the expansion PCB.. 2. Mount the large circuit board supports in the 3 holes on the expansion PCB. 3. Connect the expansion PCB to CN9. Mount the circuit board supports in the holes provided for this on the CTS602 Light circuit board. 4. Mount the expansion PCB on the CTS602 Light circuit board. 5. Connect the wires up in accordance with the wiring diagram. ATTENTION The expansion PCB and the connections must be installed by a certified electrician. The expansion PCB is an accessory for the CTS602 circuit board. Nilan does not supply external components.

An after-heating element is necessary if you want to control the supply air temperature. The electrical after-heating element can be purchased for installation in the supply air duct. The required sensor, PCB board and connectors for the unit are included. Run the wires along the duct and through a grommet on the unit down to the circuit board. Connect the wires in accordance with the wiring diagram. ATTENTION T7 temperature sensor is mounted at the air heater. T2 sensor must be disconnected from the circuit board. The T7 sensor should then be connected to where the T2 sensor was previously connected up. A Connection at the CTS602 PCB board: T7: Temperature sensor (Black) B Connection on the CTS602 Light board: 0-10V (Brown) - GND (Blue) ATTENTION The heating element must be insulated with a fire retardant insulation material. The cover of the connection box, how- ever, must not be insulated. Dimensional drawing: Ø125/Ø160/Ø200 Positioning options: B A Min. 50 cm Min. 2 x Ø T7 T7 CTS602 Light Optionsprint 1x230V ~ 50 Hz max. 16A 9 N L 10 T7 0-10V GND T2 276 370 ~50 ~50 71 Ø

An after-heating element is necessary, if you want to control the supply air temperature. The water after-heating element can be purchased for installation in the supply air duct. The required sensors and connectors for the unit are included. Run the wires along the duct and through a grommet on the unit down to the circuit board. Connect the wires in accordance with the wiring diagram. Dimensional drawing Ø125/Ø160/Ø200: ATTENTION T7 temperature sensor is mounted at the air heater. T2 sensor must detached in the PCB and T7 connect the sensor where T2 sensor was connected. A Connection to the CTS602 PCB board: 0-10V (Orange) - GND (Orange/white) B3: Frost protect. (Green) - GND (Green/white) T9: Temp. sensor (Blue) - GND (Blue/white) B Connection to the CTS602 Light board: T7: Temp. sensor (Brown) - GND (Brown/white) C Connection of the reg. valve: 0-10V (Grey) GND (Black) 24VAC (Red) T7 1x230V ~ 50 Hz max. 16A 24VAC GND 0-10V T9 T9 T7 T7 Min. 50 cm T7 Min. 2 x Ø CTS602 Light Optionsprint T2 T9 B3 C B A GND T7 B3 GND 0-10V GND GND T9 83 310 440 Ø 238 22 32 31 300 3/4" RG 3/4" RG

exchange. The CO2-sensor measures the CO2-level in the extract air. It then regulates the fan speed level accordingly. Installation of CO2-sensor: Connect the power supply 230V to the circuit board. ATTENTION In order to be able to connect up a CO2-sensor, the ventilation unit must have an expansion PCB. This must be purchased separately, but if you have ordered an after-heating element, an expansion PCB is included. 1. Detach the front door of the ventilation unit. Remove the temperature sensor T4 from the counterflow heat exchanger. Then lift the counterflow heat exchanger out of the unit. Install the CO2-sensor on the sloping surface behind the counterflow heat exchanger. 2. Mount the CO2-sensor on the attached bracket with hooks. Then press the CO2-sensor firmly into place in the EPS. 3. Feed the wires from the CO2-sensor through the hole where also the humidity-sensor and the T3 outdoor temperature-sensor run through. Then connect them to the expansion PCB of the control system as shown below.

ed in the same place. An external alarm indicator in the form of an electric bulb or an acoustic signal can be connected to the ventilation unit and announce when an alarm occurs. This could, for example, be when filters need replacing.

When the ventilation unit is in operation, negative pressure of up to 500 Pa can be created. This happens in the part where the condensate drain is situated and corresponds to a 50 mm water column. The water trap should therefore be installed as shown to prevent it from drying out and to stop a potential return flow of condensate water. The connection of the water trap must be airtight. Otherwise air will be drawn into the ventilation unit and it will prevent condensate water from draining away. It could cause water damage if the condensate tray were to overflow and condensate water were to leak from the ventilation unit. After you have installed the water trap, test its function in the following way (the unit must be connected to the duct system): Fill the condensate tray with water, close the unit door and start the ventilation unit at the highest fan speed level. Allow it to run for several minutes. Open the door and check that the water has drained from the condensate tray. The water trap can dry out in the summer. Negative pressure in the chamber will then cause air to be drawn into the ventilation unit and this will prevent condensate water from draining away. You should therefore check the water trap regularly and top up with water when necessary, especially in the autumn. Connection of water trap It is important that the water trap complies with the measurements below. If the water trap is placed outside the climate screen, it should be protected against frost. ATTENTION The condensate drain must be fitted with a water trap to ensure that condensate water can drain away. ATTENTION If you install the ventilation unit outside the climate screen, it is important to protect the condensate drain against frost. This is achieved by using a heating cable and proper insulation of the drain. Frost protection of the unit is the installer's responsibility. USEFUL INFORMATION As an accessory, Nilan can supply a water trap with ball. When the water trap dries out, the ball closes it off and ensures that air cannot be drawn into the ventilation unit. When condensate water is formed again, it will lift the ball, and the water will be able to drain away without problems. Left model Right model Ø20 mm min. 50 mm min. 50 mm Ø20 mm min. 50 mm min. 50 mm

It is important that the water trap complies with the measurements below. If the water trap is placed outside the climate screen, it should be protected against frost. Left model Right model Glue the supplied fittings to the existing spout at the bottom of the ventilation unit. 1. Water trap with Ø32 mm reducing fitting 2. Reducing fitting to Ø20 mm 3. Reducing fitting for 3/4” RG 4. Reducing fitting for 1/2”tube Ø20 mm Ø20 mm Ø20 mm Ø20 mm 100 90-225 Ø76 162 Ø32 Ø32 Ø32 Ø20 123

The water heating element is for duct connection and it cannot be integrated into the ventilation unit. The water heating element is supplied as an accessory consisting of: 1. Water heating element with T9 temperature sensor and frost thermostat B44 2. Actuator and regulation valve Danfoss AME 140/24V 0-10V signal, 2-way valve VZ2 Kv 0.4 (Nilan supply) the Kvs value must be checked against the power supply. Differential pressure: 0.1 - 0.6 bar. With a flow temperature of 60°C and at maximum heat output, the temperature is estimated to fall with 20°C over the heating element. 3. Bleed valve (not supplied by Nilan) 4. Sediment trap (not supplied by Nilan) IMPORTANT regarding Danfoss actuator type AME 140: Reinstallation of the actuator must be done as follows: 1. Disconnect the power supply and remove the cover from the actuator 2. Release the gear by pressing and holding the button at the bottom of the casing, while turning the spindle fully (anticlockwise) 3. Install the actuator and connect up the power supply 4. Move DIP-switch no. 1 to ON, and then to OFF 5. It calibrates automatically for up to 6 minutes. (The diode flashes during calibration. After completion, it stays on) 6. Put the cover on the actuator WARNING The water after-heating element must be installed by a certified plumber. WARNING If you install the water after-heating element outside the climate screen of the building, it must be protected against frost. Supply flow Return flow 1 3 2 4

Usage Nilan's fire automation system is used to monitor, test and check the fire protection components of the ventilation system: • Fire and smoke damper, and fire thermostat Important functions: • Monitors the fire protection system and ensures that dampers and detectors are in fully working order • Tests dampers every 7th day - set for Mondays 10.00 a.m. • If fire is detected, fire and smoke dampers will close and the ventilation unit will stop • If the ventilation unit stops, fire and smoke dampers will close Dampers that are connected up to the system must have a 24V or 230V fire damper motor. The fire automation system is for indoor installation. The automation system can be used within a temperature range of -20 °C to +40 °C. The protection level for fire and smoke dampers must be IP65 Electrical connection fire automation system Connection of fire damper As an optional extra you can purchase Nilan's fire automation system box for connection of fire dampers. The fire automation system is integrated into the CTS 602 control system. ATTENTION All work must be carried out by suitably qualified persons and in compliance with existing legislation and regulations. ATTENTION It is important that the power is off if you do work to the electrical components of the ventilation unit. WARNING Must not be used as a fire alarm system.

Alarm code Set an alarm 96 - "Damper test" if a position (open / closed) has not been fulfilled within the maximum moving time of 120 seconds. The test will fail if: • Current starting position (open) is incorrect • Current position (open and closed) has not altered within the first 12 seconds of moving in each direction • The measured moving time does not range between 15 and 130 seconds Automatic test sequence Start-up and annual testing It is necessary to carry out a complete test of functions after installation of the fire protection automation system. If everything has been installed in accordance with the guidelines and regulations, and the test reveals no errors, the display will show "OK". Connection to the wiring harness 24 /230V AC Connect up neutral (blue) in N Connect up phase (brown) in F Connection of signal cable from fire automation system Connect S1 (white) to screw terminal S1 (GND) Connect S2 (white) to screw terminal S2 (Damper closed, signal) Connect S3 (white) to screw terminal S3 Connect S4 (white) to screw terminal S4 (GND) Connect S5 (white) to screw terminal S5 Connect S6 (white) to screw terminal S6 (Damper open, signal) Connection from external fire thermostat If you want to connect up an external fire/smoke thermostat, remove the shunt from the screw terminal row. In its place connect up the external fire/smoke thermostat. Connection from fire automation system 24 / 230V AC Connect up N (blue) in N1 Connect up L1 (brown) in S Green LED for active damper RJ45 connection to Nilan's ventilation unit

test must be performed again until "OK" is displayed in the menu. For the overall system, all requirements in DS 428 must be met before a delivery can be made. Manual test of fire and smoke dampers You should checked that all dampers change position physically. See the supplier's instructions. Connect the fire damper switches for, respectively, open and closed position to two digital inputs on the circuit board (see wiring diagram). Fire thermostat Temperature sensor is warmed up with fan heater. See the supplier's instructions. Release-signal to ventilation unit During a fire the ventilation unit will shut down and the fire and smoke dampers will close. Following that, the alarm can only be can- celled manually on the control panel. You will then be able to restart the unit. Operating signal from ventilation unit An active signal should cause all dampers to activate (open) if there are no alarms. If there is no signal, the unit will act as in case of fire and all dampers will close.

Spiral ducts Spiral ducts are made from metal and are cut to size using an angle grinder. They are then connected using ducting bends and mani- folds and are fitted in accordance with the blueprint. The ducts are typically placed on the tie beams where they are fixed with perfo- rated band, or they are suspended using suspension band. Avoid unnecessary bending of the ducts. To prevent sound transmission from room to room, you should install a silencer for each room. The ducts must be insulated to prevent heat loss and condensation. In some cases this can be avoided if the ducts are run through the standard insulation or inside the climate screen. NilAIR tubes NilAIR tubes constitute a flexible system that is easy to install. You can easily cut the tubes to size with a Stanley knife and then situate them in accordance with the blueprint without having to use bends and manifolds. You install a manifold box after the unit and run the tubes from the box out to the individual rooms. When using NilAIR tubes, you do not have to install silencers for each room. The sound-damping effect of the tubes ensures that sounds and noise will not be transmitted from room to room. If you install the tubes outside the climate screen, you must insulate them to avoid heat loss and condensation. This is simpler than using spiral ducts as NilAIR tubes are easily led through the standard insulation. NilAIR tubes are more flexible than spiral ducts and you can therefore run the tubes in places that are unsuitable for ordinary spiral ducts. Ventilation unit Nilan recommends installation of flexible connections between the ventilation unit and the duct system. This is to avoid vibrations from the unit being transmitted to the duct system. It will also make it easier to move the unit, which may be necessary during future services of the unit. Nilan can supply Soundflex tubes that you can use as flexible connections between the ventilation unit and the duct system. They will also reduce sounds from the system considerably. The Soundflex tubes are insulated against condensation. It may, however, be necessary with further insulation in order to comply with local requirements with regards to insulation of duct systems. ATTENTION All work must be carried out by qualified persons and in compliance with existing legislation and regulations.

the dwelling/building most efficiently. High-humidity rooms are, for example: • Bathroom • Lavatory • Kitchen • Utility room Supply air Install supply air valves in living areas. Place them strategically so they cause minimum discomfort. It is, for instance, not recommend- ed that you install supply air valves in areas where people are inactive, as the supply air may be experienced as draughty. Living areas may be, for example: • Living room • Family room • Bedroom • Study Roof terminals The position and design of air intake and air discharge should limit pressure oscillations in the ventilation unit caused by wind. Their position should also prevent birds and other animals from getting in. Finally, the position and design should ensure that air intake and the connected duct system are kept free of plants and foreign objects. You must place the air intake so that the risk of a short-circuit from the discharge air is minimised, and with attention to the prevailing wind direction. The air intake should be placed at least 50 cm above the roof surface. On black, flat roofs the distance from the roof to the underside of the intake should be at least 1 m. This will ensure that warm air is not drawn into the building during summer. Air intakes should be placed on the northern or eastern sides of pitched roofs. You should also install a silencer between the unit and the roof stacks to prevent noise disturbance to your surroundings. Installation example

out more air than it blows in. This will prevent dampness from being forced into the constructions of the building. Balancing holes The ventilation unit has been equipped with balancing holes for measuring the volumes of the supply air and the extract air. You can measure the volume through a ball pump valve, which you insert into the 4 holes. Using the curve chart, you can set, approximately, the main air volume at dry operation without condensation. At the side with the extract air, measure the pressure difference dP3-4 [Pa] between the holes marked 3 and 4. Read the air volume qv [m3/h] on the curve chart. At the side with the supply air, measure the pressure difference dP1-2 [Pa] between the holes marked 1 and 2. Read the air volume qv [m3/h] on the curve chart. Once you have carried out the measurements, cover the 4 holes with the round stickers provided. ATTENTION To ensure the ventilation system operates optimally, it is important that it is balanced correctly. We recommend that experts do this. ATTENTION The capacity in the pressure loss diagram is based on a dry exchanger.

dp dp 3 1 2 4 dp dp 3 1 2 4 1 2 3 4 3 2 1 4 4 2 3 1 1 4 2 3 0 20 40 60 80 100 120 140 160 0 50 100 150 200 250 300 350 400 dp [Pa] qv [m3/h] CT250 med Klingenburg GSK 378 mm

inexpediency in the publications or they have other causes. Without prior notice Nilan A/S reserves the right to make changes to the products and instructions. All trademarks belong to Nilan A/S. All rights reserved. Nilan A/S Nilanvej 2 8722 Hedensted Danmark Tlf. +45 76 75 25 00 [email protected] www.nilan.dk United Kingdom: S L Services 25 St Leonards Road, Horsham RH13 6EH West Sussex Tel: +44 (0) 79 19 44 44 52 [email protected] www.nilanuk.com Ireland: Nilan Ireland Ballylahive, Abbeydorney Tel: +353 (0) 87 97 98 361 [email protected] www.nilanireland.ei