Instructions for operation and maintenance

Transcription

1 KOJA oy KOJAmarine KOJAcool oy Air handling unit Future Instructions for operation and maintenance

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3 Index 1. General Commissioning and maintenance...5 Damper section FPTP... 6 Mixing section FPTA... 8 Return air section, tandem FPTB Return air section, superposition FPTC Filter section FSTF Heat recovery section Coil FRTG Rotor FRTR Plate FRTL Heating section FLTV Heating section FLTE Cooling section FJTV Drop separator section FPTE Humidifying section, evaporation FKTK Humidifying section, steam FKTH Inspection section, FTTT Inspection section, FTTR Fan section, centrifugal fan FFTK Fan section, mixed folw fan FFTS Angle section FTTK Sound attenuator section FVTK Wild section FVTV Casing module FMOD Manufacturer s declaration...75 Instructions for the air handling unit Future Instructions for transport, storage and installation Section specific instructions for operation and maintenance (this manual) Brochure, Air handling unit Future Keep this manual in the vicinity of the air handling unit for future reference. Read this manual carefully before taking any further measures. Follow the given instructions, especially those relating to safety. 3

4 1. General Regular checks on the equipment s performance and adherence to the instructions for operation and maintenance are essential preconditions for efficient and economical air conditioning. The instructions for the operation and maintenance of the air conditioning plant contain the operating principles, operating programs, control and wiring diagrams, and position and location drawings for the plant and its subsystems, as well as the set points of the different devices and instructions for their operation and maintenance. 1.1 Operating conditions Air handling units Future of standard construction are designed for indoor use. The ambient temperature must be over 0 o C. The air to be handled must not be corrosive or poisonous, warmer than 70 o C or contain large quantities of water vapour or large particles. 1.2 CEN classification The air handling unit Future is classified according to CEN standard EN 1886 as follows: tightness class of the casing: B heat transfer coefficient class of the casing: T3 1.3 Sound data The sound data of the unit is included in the design calculations that are delivered to the customer enclosed in the acknowledgement of order. 1.4 Safety Before switching on the fan, make sure that the inlet and the outlet of fan section have been connected to the ductwork or that the access to the rotating parts of fan, such as the impeller, through inlet, outlet or access door has been prevented with protective screens or in some other way. The service switch of air handling unit must be installed and serve when the unit is switched on. The damper section of the unit must open before the fan starts CE-marking The air handling unit Future is accompanied with a manufacturer s declaration of the safety of the unit and with other documents relating to the safety of unit sections. The person responsible for assembling the unit so that it meets the definition of machinery given in the Machinery Directive gathers the declarations of conformity for components and the manufacturer declarations, ensures that the essential requirements relating to the safety of machinery are complied with, signs the declaration of conformity for the unit, and attaches a CE mark to the unit. If the unit is installed in a place where it is easily accessible also to other people than service personnel, the handles of access doors must be removed and locked in a safe place Safety equipment Service/safety switch installed in the fan section functions also as an unit emergency switch. (Not included in delivery) Fire In case of fire in the unit, use e.g. a powder extinguisher, do not use water! The materials used in the unit do not produce harmful amounts of any hazardous gases when burning. 1.6 Safety devices 1.61 Anti-freezing thermostat The anti-freezing thermostat is installed in a water space or on a heat transfer surface of the heat exchanger. The thermostat gives an alarm and stops the unit if the water temperature in the heat exchanger drops below the set point (e.g. +8 o C). If the thermostat trips, the cause must be found out. The unit can be restarted by pressing the reset button of the thermostat Filter indicator (differential pressure gauge) The filter indicator is installed in the filter section so that it can measure the pressure difference across the filter. It shows the pressure difference and/or gives an alarm if necessary Fire thermostat The fire thermostat is installed in the inlet or outlet duct. It gives an alarm and stops the unit if the supply air temperature exceeds the set point (e.g. +50 o C). If the thermostat trips, the cause must be found out. Also check if fire dampers (if any) have been actuated. The unit can be restarted by pressing the reset button of the thermostat Flow controller The flow controller is installed in the inlet or outlet duct. It gives an alarm if the sensor does not detect air flow. If an alarm is given, the cause must be found out immediately. Instructions for the operation and maintenance of safety devices are supplied by the device manufacturers.. 4

5 2. Commissioning and maintenance Commissioning Prior to commissioning the air handling unit, make sure that the unit has been installed and cleaned according to the instructions. Also make sure that components and safety devices that are essential for safe operation of the unit have properly been installed. Check the flow rates. The commissioning as well as the training of operating personnel are usually carried out by the supplier of the air conditioning plant. The motor of the fan FFTK-xx-AF may get overloaded if the air volume flow exceeds the designed level. This may happen if, for example, the air handling unit is switched on before all the sections of the unit and of the ductwork are installed, if the fan is switched on with the access door open or if the access door is opened during fan operation. Maintenance Prevent start-up during maintenance! Prior to starting any maintenance and/or repair work, make sure that the work will not cause any unnecessary disturbance to other activities in the building. Stop the unit and turn the service switch to zero position. Remove the fuses for both speeds of 2-speed motors, in the case of a 3-speed motor, remove all fuses. Make sure e.g. by means of a written notice that the unit will not be accidentally started during the work. After completing the maintenance and/or repair work, start the unit and make sure that all shut-off and control devices, instruments and the signal lamp are functioning. The maintenance intervals are only guidelines. The intervals are determined by the utilization rate of the plant and the ambient conditions. The given intervals apply when the plant is used 8 hours a day in city air. In cleaner environments (countryside) the maintenance intervals can be longer, in dirtier environments (industrial park) they must be shorter. It is advisable to have the unit serviced at the beginning (autumn) and at the end (spring) of the heating season. Cleaning, filter, belt and pulley replacements and lubrication of joints and bearings are maintenance activities that can be performed by the plant s own maintenance personnel. Repairs on unit sections, replacement of bearings, and all installation and adjustment operations related to electricity or automation require special expertise. Clean the unit with ordinary detergent. Solvents must not be used in cleaning sections including aluminium parts (heat exchangers). Spare parts mentioned in this manual are available at Koja or the manufacturer in question. Koja Ltd reserves the right to changes without prior notice. 5

6 Damper section FPTP Sizes Flow rate m 3 /s Instructions for design The damper section FPTP is designed to be used for the intake of fresh air and for preventing outdoor air from entering the building when the air conditioning system is out of operation. The damper is operated by an electric actuator. Sizes 3015, 3018, 3021, 3024, 3624, 3627 and 3630 contain two dampers and require two actuators (this does not apply to version 5) situating on the opposite sides. The range of operating temperature is C and the maximum permissible pressure difference across the damper is 1200 Pa. The pressure rise of fan can be higher than the maximum permissible pressure difference of the damper. The multiple leaf dampers of the section shall open just before the fan starts up and close right after the fan has stopped. Construction The version 1 of the damper section FPTP consists of a multiple leaf damper and a connection plate for fixing the damper to the unit casing. The versions 2, 3, 4 and 5 consist each of a thermally insulated casing, and a built-in multiple leaf damper. The multiple leaf damper has opposed, thermally insulated louvres. The louvres and frames are made of hot galvanized steel or stainless steel. The louvres are insulated with mineral wool, the gaskets made of silicon rubber and the bearings of plastic. The damper is equipped with a position indicator. The damper shaft is 100 mm long square tube of size 15 x 15 mm. 6

7 Installation of damper section Required torque and recommended actuator size at different damper areas are less than 0.7 m Nm (10 Nm) m Nm (15 Nm) m Nm (30 Nm) Damper section FPTP can be installed in all positions. The section operates best when the damper louvres are in horizontal position. The air flow direction has no importance to the operation of the multiple leaf damper. Commissioning Make sure that dampers open and close completely and that the actuator works according to control signals. Maintenance Maintenance interval is 6 months. Make sure that damper louvres open and close un-hindered reaching the set limits. Make sure that the lever mechanisms between louvres and those between actuators and shafts are not loose or worn. Lubricate the joints in lever mechanisms with light oil. Tighten screws if necessary and replace worn parts. Make sure that the gaskets of damper louvres and end plates are undamaged. Replace damaged and worn gaskets. Clean the sections if necessary. Order code: Damper section FPTP a b c d e f a) Size b) Handedness R / L c) Version 1, 2, 3, 4, 5E, 5T d) Damper louvre material 1=hot-galvanized, 3=stainless steel e) 0=uninsulated casing, 1=insulated casing f) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Accessories duct connection flange for slip joint (versions 2, 3, 4, 5T, 5E) inspection window (versions 2, 3, 4, 5T, 5E) water drain (versions 2, 3, 4, 5T, 5E only for Future Clean -type) protective screen actuator connection flange of unit size base plate of stainless steel Versions T = damper in the back E = damper in the front 4 5T, 5E 7

8 Mixing section FPTA Sizes Flow rate m 3 /s Instructions for design The mixing section FPTA is designed to be used for the intake of fresh air, for mixing return and outdoor air when separate supply and exhaust units are used and for preventing outdoor air from entering the building when the air conditioning system is out of operation. The damper is operated by an electric actuator. Sizes 3015, 3018, 3021, 3024, 3624, 3627 and 3630 contain two dampers and require two actuators situating on the opposite sides. The range of operating temperature is C and the maximum permissible pressure difference across the damper is 1200 Pa. Construction There are nine different versions of the mixing section FPTA, all of which consist of a thermally insulated casing and built-in multiple leaf dampers. The dampers have against each other turning, thermally insulated louvres. The louvres and the frame are made of hot-galvanized or stainless steel. The louvres are insulated with mineral wool, the gaskets are made of silicon rubber and the bearings of plastic. The dampers are equipped with a position indicator. The damper shaft is a 110 mm long square tube of size 15 x 15 mm. The pressure rise of fan can be higher than the maximum permissible pressure difference of the damper. The multiple leaf dampers of the section shall open just before the fan starts up and close right after the fan has stopped. 8

9 Installation of mixing section Required torgue and recommended actuator size at different damper areas are less than 0.7 m Nm (10 Nm) m Nm (15 Nm) m Nm (30 Nm) Installing position of the mixing section FPTA and the air flow directions are given in ventilation drawings. Order code: mixing section FPTA - a - b - c - d - e a) Size b) Handedness R / L c) Version 1, 2, 3, 4, 5, 6, 7T, 7E, 8T, 8E, 9T, 9E (version 1 and 8 for sizes from 0606, version 2, 3, 4 and 7 for sizes from 0605) d) Damper material 1=hot-galvanized, 3=stainless steel e) Type and material S=zinc coated, A2=stainless steel CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Commissioning Make sure that the dampers open and close completely and that the actuator works according to control signals. Maintenance Maintenance interval is 6 months. Make sure that damper louvres open and close unhindered reaching the set limits. Make sure that the lever mechanisms between louvres and those between actuators and shafts are not loose or worn. Lubricate the joints in lever mechanisms with light oil. Tighten screws if necessary and replace worn parts. Make sure that the gaskets of damper louvres and end plates are undamaged. Replace damaged and worn gaskets. Clean the sections if necessary. Accessories duct connection flange for slip joint access door (versions 1, 2, 3, 4, 5, 6, 7T, 8T, 8E, 9T) inspection window (versions 1, 2, 3, 4, 5, 6, 7T, 8T, 8E, 9T) water drain (only for Future Clean type) hinges for access door lamp actuator set of connecting levers connection flange of unit size base plate of stainless steel Versions T = damper in the back E = damper in the front 7T, 7E 8T, 7E 9T, 9E 9

10 Return air section, tandem FPTB Sizes Flow rate m 3 /s Instructions for design The return air section FPTB is designed to be used for the intake of fresh air, for mixing return and outdoor air when the supply and exhaust parts of the air handling unit are mounted tandem and for preventing outdoor air from entering the building when the air conditioning system is out of operation. The damper is operated by an electric actuator. Sizes 3015, 3018, 3021, 3024, 3624, 3627 and 3630 contain two dampers and require two actuators situating on the opposite sides. The range of operating temperature is C and the maximum permissible pressure difference across the damper is 1200 Pa. Construction There are five different versions of the return air section FPTB all of which consist of a thermally insulated casing and built-in multiple leaf dampers. The dampers have against each other turning, thermally insulated louvres. The louvres and the frame are made of hot-galvanized or stainless steel. The louvres are insulated with mineral wool, the gaskets are made of silicon rubber and the bearings of plastic. The dampers are equipped with a position indicator. The damper shaft is a 110 mm long square tube of size 15 x 15 mm. The pressure rise of fan can be higher than the maximum permissible pressure difference of the damper. The multiple leaf dampers of the section shall open just before the fan starts up and close right after the fan has stopped. 10

11 Installation of return air section Required torgue and recommended actuator size at different damper areas are less than 0.7 m Nm (10 Nm) m Nm (15 Nm) m Nm (30 Nm) Installing position of the return air section and the air flow directions are given in ventilation drawings. Order code: return air section, tandem FPTB a b c d e a) Size b) Handedness R / L c) Version 1, 2, 3, 4, 5E, 5T d) Damper material 1=hot-galvanized, 3=stainless steel e) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Commissioning Make sure that dampers open and close completely and that the actuator works according to control signals. Maintenance Maintenance interval is 6 months. Make sure that damper louvres open and close unhindered reaching the set limits. Make sure that the lever mechanisms between louvres and those between actuators and shafts are not loose or worn. Lubricate the joints in lever mechanisms with light oil. Tighten screws if necessary and replace worn parts. Make sure that the gaskets of damper louvres and end plates are undamaged. Replace damaged and worn gaskets. Clean the sections if necessary. Accessories duct connection flange for slip joint access door (versions 1, 2, 3, 4, 5T) inspection window (versions 1, 2, 3, 4, 5T) hinges for access door actuator lamp water drain set of connecting levers safety latch connection flange of unit size base plate of stainless steel Versions T, 5E T = damper in the back E = damper in the front 11

12 Return air section, superposition FPTC Sizes and 3015, 3018 Flow rate m 3 /s Instructions for design The return air section FPTC is designed to be used for the intake of fresh air, for mixing return and outdoor air when the supply and exhaust parts of the air handling unit are mounted on top of each other and for preventing outdoor air from entering the building when the air conditioning system is out of operation. The damper is operated by an electric actuator. Sizes 3015, 3018, 3021, 3024, 3624, 3627 and 3630 contain two dampers and require two actuators situating on the opposite sides. The range of operating temperature is C and the maximum permissible pressure difference across the damper is 1200 Pa. Construction There are six different versions of the return air section FPTC all of which consist of a thermally insulated casing and built-in multiple leaf dampers. The dampers have opposed, thermally insulated louvres. The louvres and the frame are made of hotgalvanized or stainless steel. The louvres are insulated with mineral wool, the gaskets are of made silicon rubber and the bearings of plastic. The dampers are equipped with a position indicator. The damper shaft is a 110 mm long square tube of 15 x15 mm. The pressure rise of fan can be higher than the max. permissible pressure difference of the damper. The multiple leaf dampers of the section shall open just before the fan starts up, and close right after the fan has stopped. 12

13 Installation of return air section Required torgue and recommended actuator size at different damper areas are less than 0.7 m Nm (10 Nm) m Nm (15 Nm) m Nm (30 Nm) Installing position of the return air section and the air flow directions are given in ventilation drawings. Order code: return air section, superposition FPTC a b c d e a) Size b) Handedness R / L c) Version 1, 2, 3, 4, 5, 6 (versions 1, 2 and 4 for sizes from size 0605) d) Damper material 1=hot-galvanized, 3=stainless steel e) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Commissioning Make sure that dampers open and close completely and that the actuator works according to control signals. Maintenance Maintenance interval is 6 months. Make sure that damper louvres open and close unhindered, reaching the set limits. Make sure that the lever mechanisms between louvres and those between actuators and shafts are not loose or worn. Lubricate the joints in lever mechanisms with light oil. Tighten screws if necessary and replace worn parts. Make sure that the gaskets of damper louvres and end plates are undamaged. Replace damaged and worn gaskets. Clean the sections if necessary. Accessories duct connection flange for slip joint access door inspection window hinges for access door actuator lamp water drain safety latch set of connection levers connection flange of unit size base plate of stainless steel Versions Kiertoilmatoiminto FPTC Inlet air Outlet air 13

14 Filter section FSTF Sizes Flow rate m 3 /s Instructions for design The function of the filter section FSTF is to keep other sections and components (heat exchangers, etc.) clean, to maintain the desired values set for indoor air and to ensure comfort conditions. The casing of the section is available in four lengths. Each casing can be fitted with several types of filters according to the requirements set for the cleanness of indoor air. The fibre filters for trapping particles are made of fibreglass or synthetic plastic. The filter grades are G4, F5, F6, F7 and F8/F9. Gaseous impurities are eliminated from the supply air by means of chemical fibreglass/activatedcarbon filters, or activated carbon filters with cylinder set. The filters are classified according to CEN EN 779. In addition, the filter section can be equipped with a differential pressure gauge and/or filter indicator to detect changes of pressure drop. There must be at least 700 mm of free space on one side of the section for service purposes. Construction The filter section FSTF is available in four lengths. The hygiene type, Future Clean, is available equipped with pull-out filter frame up to unit size The filter section has a thermally insulated casing. The particle filters used are disposable filter cassettes of the module s length. Casettes are pushed into the mounting frame and pressed there against rubber strips made of EPDM. The carboncylinders of activated-carbon filters are fixed to the connection plate. The section has connections for differential pressure gauge and filter indicator. The max. permissible operating temperature is +85 C. Filter applications G3 and G4 (EU3 and EU4, G85 and G95) separates large particles of pollen takes to some extent smoke and staining particles F5 and F6 (EU5 and EU6, F45 and F65) separates all particles of pollen separates greater part of all staining particles F7 (EU7, F85) separates, in addition to the above mentioned, coal and oil smoke separates to some extent cigarette smoke and bacteria F8/F9 (EU8/EU9, F95) purifies the air very effectively of staining particles separates very effectively coil and oil smoke removes effectively cigarette smoke and bacteria F7 (folded) / C (activated carbon) filter separates effectively fine, detrimental particles such as bacteria, blight spores and to minor extent appearing gaseous impurities Activated carbon removes effectively gaseous impurities 14

15 Installation of filter section Filter section FSTF is installed in upright position, shown in the picture, or in horizontal position; then the air flow can be directed upwards or downwards when coarse-grain filters G3 and G4 or folded filters are used. When other filter grades are used, the air flow direction is downwards. Air flow direction is marked on the filter section and on filters. If the marks are missing, the filter section must be installed as shown in the pictures, that is, the air must enter the filter on the filter groove side. Commissioning The filters must be installed before test-running the unit. The filters are placed in the mounting grooves with the folds in upright position and clamped against the gasket. Check that the filters are undamaged and the type is correct. Check that the filters are tightly against the frame gasket and that there are no leakages. Check that the filters are clamped in their places. Check that the pressure-difference gauge is undamaged and reset. Check that the pressure-difference hoses of the filter section are undamaged and in their places. Maintenance The filter section is to be serviced and cleaned twice a year, usually in autumn and in spring. The replacement interval of filters is usually determined by the max. permissible decrease in the air flow due to increased pressure drop across the filter (normally 10% of the design air flow). The pressure drop can be controlled by means of a filter indicator (which shows the pressure difference and/ or gives an alarm if necessary). When the pressure difference across the filter exceeds the set limit, the filter must be replaced. The filter design table shows the max. permissible pressure drop for different filter types Check that the filters are undamaged and the type is correct. Check that the filters are tightly against the frame gasket and that there are no leakages. Check that the filters are clamped in their places. Check that the pressure-difference gauge is undamaged and reset. Check that the pressure-difference hoses of the filter section are undamaged and in their places. Replacement of filters 1. Open the access door and the clamping mechanism. Pull the filter (filters) out of the casing. 2. Clean the casing if necessary. 3. Check the condition of gaskets. Replace worn and damaged ones. NOTE! No gaskets are needed between filters that are mounted parallel to each other. 4. Place new filters in the mounting grooves so that the folds in the filters run vertically. Clamp the filters against the gasket. 5. Close the access door. 6. Restart the fan and check the operation of the filter indicator. Unit size Breadth mm Heightmm Sizes of filter casettes / amount of casettes 287 x x x x Mounting frame is 25 ±1 mm thick. 15

16 Replacement of gasket Dimensions of mounting groove and filter cassette frame Start the mounting of a new gasket from the middle of the frame bottom. Press the gasket against the edge of the plate by hand, you can also use a hammer or another tool, but do not use force. At the corners, bend the gasket into a suitable form by means of, for example, a 20 mm pipe. Cut the gasket, leave it about 5 mm too long. Force the ends together and apply sealant between them. Order code: Filter section FSTF a b c d e f g a) Size b) Handedness R / L c) Filter grade G4S, G4M, G4L, F5M, F5L, F6L, F6XL, F5L, F7XL, F7M, F9XL, F7 & CO, CO d) Length 1=short, 2=medium, 3=long, 4=long (700mm) e) Filter material 1=fibreglass, 2=synthetic, 3=fibreglass/ chemical, 4=chemical f) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel g) Filter frame type 1=standard, 2=pull-out min ±1 Clamp closed 35 ±1,0 Accessories hinges for access door inspection window pressure-difference gauge filter indicator lamp safety latch set of spare filters water drain (only for Future Clean) connection flange of unit size base plate of stainless steel access level Lower frame Clamp closed 35 ±1,0 Middle frame 16

17 Heat recovery section, coil FRTG Sizes Flow rate m 3 /s Outlet pipe of condensation water Ductwork of heat transfer agent Instructions for design The heat recovery section FRTG is designed to be used for recovering thermal energy from the exhaust air and for transferring the recovered energy to the supply air by means of some medium (antifreeze, glycol, etc.). The supply and exhaust parts of the air handling unit can be arranged in any desired way. There must be at least two heat exchangers (coils), even several, one for the supply part and the other for the exhaust part. Standard heat exchangers must always be mounted so that the air flow through the exchanger is horizontal. A free space of at least the section s width must be available or otherwise arrangeable on one side of the heat recovery section for the replacement of the exchanger. The heat transfer surfaces must be accessible for inspection and service through, for example, the adjacent sections or an inspection section FTTT provided with an access door. Below a heat recovery section FRTG there must be at least 200 mm of free space to allow the installation of a water trap (used normally in the exhaust part).the water trap is piped to a floor trap, it must not be connected to other sewerages. The heat exchangers can, if necessary, be equipped with drop separator. Drop separator is used when the air flow through the heat exchanger is very moist or has the velocity of over 2,5 m/s. It is advisable to use a filter in front of the recovery section (both in the supply and in the exhaust part) to make sure that the heat exchanger keeps clean. Construction The heat recovery section FRTG consists of a thermally insulated casing and a built-in heat exchanger. The heat exchanger can be pulled whole out of the casing. The pipes of the heat exchanger are made of copper, the lamellas are aluminium or copper and the frame is aluminium (in the supply part hot-galvanized steel) or stainless steel. The heat exchanger has inlet, outlet, air vent, and water drain. The section has drip tray and condensate drain (exhaust coil). Both the inlet and the outlet are equipped with a connection flange (SFS 2164). The maximum permissible operating pressure is 1.0 MPa. 17

18 Commissioning Make sure that the heat transfer surfaces are clean and undamaged. Open the line control valves and fill the coil with liquid. Bleed the coil. Make sure that the water-connections do not leak. Check the rotation direction of the circulating pump (do not run the pump dry). Check the operation of the anti-freezing thermostat if necessary. Make sure that the control valve is functioning and adjust the line control valves according to the design. The manufacturer of the equipment in question gives the detailed adjustment instructions. Check the drain system of condensation water (outlet coil): drip tray, piping and water trap. Flush the piping and fill in the water trap. The coils of big units have been split in two. The condensation water drain of the outlet coil has to be piped to the sewer also from beyond the unit. Make sure that the water traps and piping have been mounted according to the instructions. Maintenance Make sure that the water-side connections do not leak. Make sure that the heat transfer surfaces are clean and undamaged. The coil can be lightly cleaned with a brush, compressed air or a vacuum cleaner. If there are water connections in the unit, the coil can be cleaned also with water and mild washing agent. Note! No pressure cleaning. At the beginning of every heating season, bleed the coil and check the operation of the anti-freezing thermostat. Inspect and clean the drain system of condensation water: drip tray, piping, water trap (outlet coil). If the heat exchanger gets damaged, it must be repaired in place, sent to the manufacturer to be repaired, or replaced. Order code: Heat exchanger section, coil, inlet FRTG - a - b - c - d - e - f - g - h - i - j a) Size b) Handedness R / L c) Amount of rows 3, 4, 5, 6, 8, 10, 12 d) Pipes and lamellas 1=Cu/Al, 2=Cu/Cu e) Lamella spacing 2; 2,4; 2,8; 3, 5 f) Amount of routes g) Liquid 2=glycol (etylene) 3=glycol (propylene), 4=freezium, 5=thermera h) Concentration % 5, 10, 15, 20, 25, 30, 35, 40, 45, 50 i) Inlet air T j) Type and material (S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Code H is the freezing temperature when Thermera is used. Accessories for inlet side water connection water trap connection flange of the unit size for slip joint base plate of stainless steel Order code: Heat exchanger section, coil, outlet FRTG - a - b - c - d - e - f - g - h - i - j a) Sizes b) Handedness R / L c) Amount of rows 3, 4, 5, 6, 8, 10, 12 d) Pipes and lamellas 1=Cu/Al, 2=Cu/Cu e) Lamella spacing 2; 2,4; 2,8; 3,5 f) Amount of routes g) Liquid 2=glycol (etylene) 3=glycol (propylene), 4=freezium, 5=thermera h) Concentration % 5, 10, 15, 20, 25, 30, 35, 40, 45, 50 i) Outlet P j) Type and material (S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Code H is the freezing temperature when Thermera is used. Accessories for outlet side connection flange of unit size for slip joint separate basin under manifold water trap(s) 18

19 Dimensioning instructions for water trap Coil at inlet side of the fan Δp = P 0 - p 1 (Pa) A min = Δp/ (mm) B min = A/ (mm) p 1 p 0 B A Coil at outlet side of the fan Δp = P 0 - p 1 (Pa) A min = 20 (mm) B min = Δp/ (mm) p 1 p 0 B A The water trap is installed in the position shown in the picture. 19

20 Heat recovery section, rotor FRTR Sizes Flow rate m 3 /s Instructions for design The heat recovery section FRTR is designed to be used for recovering thermal energy and moisture or cooling energy from the exhaust air and for transferring the recovered energy/moisture to the supply air. FRTR can be used when the supply and exhaust parts of the air handling unit are mounted on top of each other and when a slight mixing of supply and exhaust air is allowed. The supply and exhaust air flows that go through the heat exchanger of the section must have opposite directions. Since the two air flows use the same channels, they mix to some extent. The heat transfer surfaces must be accessible for inspection and service through, for example, the adjacent sections or an inspection section FTTT provided with an access door. In front of the heat recovery section, it is advisable to use a filter of at least grade F5 (supply and exhaust parts) to make sure the heat exchanger keeps clean. Construction The heat recovery section FRTR consists of a thermally insulated casing and a built-in rotary heat exchanger. As the rotor turns, supply air and exhaust air flow through it alternately in opposite directions. The heat exchanger can be pulled out of the casing so that the lamellas and the casing can be serviced. The rotor (AL,AH, ALE, AHE) is made of corrugated aluminium sheet. It can be provided with a purging section to prevent the exhaust air from entering the supply air side and to clear the rotor of trash. The max. permissible operating temperature is +70 C. In the table at the end of this chapter the rotors marked with * are delivered as parts. 20

21 Rotor materials and applications Aluminium rotor AL transfers moisture only when water condensates in the rotor. AL has a high thermal efficiency, and it is best suited to air handling systems operating in clean environments. Aluminium rotor AH is hygroscopic which means that it transfers heat and moisture with equal efficiency. AH can be used for recovering thermal energy, moisture and cooling energy from exhaust air in air handling systems operating in clean environments. Note! Elimination of freezing / frosting of rotor! Aluminium rotor ALE has epoxy-coated lamella edges. ALE transfers moisture only when water condensates in the rotor. This rotor has a high thermal efficiency, and withstands high environmental stresses associated with marine weather conditions, industrial environments, etc. Aluminium rotor AHE has epoxy-coated lamella edges. AHE copes with marine weather conditions and industrial environments, and is hygroscopic transferring both heat and moisture. This rotor is highly applicable where a high thermal efficiency is required and where moisture and cooling energy need to be effectively transferred in summertime (hospitals and other health care establishments excl. operating rooms); offices; textile factories, etc. Arrangement of fans in comparison to heat exchanger If it is allowed to use return air in the system, the fans can be arranged in any desired way. If the use of return air is not allowed and if an especially high purging pressure is required, the fans must be arranged according to figure 1 or 2. Room Room Room Fig. 1. Fig. 2. Fig. 3. Purging sector As the rotor turns, some of the exhaust air leaks to the supply air side. If the rotor has a purging sector, the supply air blows the flow channels clear of exhaust air before the rotor reaches the supply air side. According to tests the air leakage is approx ,20% with and % without the purging sector. Room Fig. 4. If the rotor does not have a purging sector, there is no purging air flow to be taken into account. Both the supply and the exhaust air have the same volume flow rate. Required purging pressure (P1-P4) Unit size (P1-P4) = 400 Pa (P1-P4) = 250 Pa Fig. 1. The most common fan arrangement Fig. 2. Recovery of cooling energy is most effective when the fans are so arranged that the heat of the supply air and a part of the heat produced by the fans transfer to the exhaust air. This arrangement is the most suitable solution where the supply air needs to be extremely clean. Fig. 3. Heat recovery is most effective when the fans are so arranged that the heat produced by the outlet fan can be recovered. This arrangement is only applicable where return air is allowed. Fig. 4. If this arrangement is used, special attention must be paid to correct pressure balancing. This arrangement is only applicable where return air is allowed. 21

22 Operation Efficiency The Future dimensioning program calculates the thermal and humidity efficiencies of the selected rotor on the basis of the volume flow and the state of supply and exhaust air. The efficiency can be adjusted by decreasing the rotor speed; the control of supply air temperature downstream from the heat exchanger is based on this principle. All the rotors have the same thermal efficiency at the same air velocity. Air leakage in gaskets A rotary heat exchanger cannot be sealed completely tight. If return air is not allowed in the system, the fans must be so arranged that the supply air pressure is higher than the exhaust air pressure on both sides of the heat exchanger. This way, a certain amount of supply air flows to the exhaust air side and the volume flow of the exhaust air increases. When the pressure difference on one side of the rotor is 400 Pa, the air leakage from one side to the other is approx % at a volume flow of m 3 /s. Elimination of freezing and frosting There are different ways to protect the rotor against freezing, including preheating, by-passing the heat exchanger and decreasing the rotor speed. Either the supply air or the exhaust air can be preheated. Elimination of rotor frosting is used when the outdoor temperature is very low and the exhaust air very moist. If the pressure difference exceeds the set value of the differential pressure switch, the rotation speed of rotor drops to 0.5 1/min when the rotation speed control is used (control automation). If the rotor speed is constant, frosting is eliminated so that the supply air is directed over the rotor by means of damper or the supply air is stopped. The differential pressure switch gives a signal when the damper has to be opened and the supply air fan stopped. Speed control The available control methods are on-off control and continuous control (control automation). In on-off control the rotor efficiency is either 0 or maximum. In continuous control the rotor speed can be freely varied between almost zero and the maximum speed (10 1/ min). When no heat recovery is needed, the rotor is automatically turned by 30 at intervals of 5 minutes to keep it clean. Motor size, power and current Unit size Motor50 Hz Current, A Rotor 1 Rotor 2 Size Power, W 3~230V / , , , , , , , / ,7 180/ ,8 250/ ,6 370/ , / , / ,4 Commissioning The unit must not be used during the construction work. If it is, however, necessary the heat exchanger must be operating. Make sure that the filters have been installed. Make sure that there are no foreign objects in the inlet or outlet duct that could damage the faces of the heat exchanger. Make sure that the rotor is upright. Make sure that the rotor rotates freely. Make sure that the rotor belt has been tightened and that it runs freely and right in place. Adjust, if necessary, the brush seals on the sides of the rotor so that they touch the surface of the heat exchanger. Check also the brush seals on the lower surface of the mid-beam or the rotor and adjust if necessary so that they touch the surface of the heat exchanger. Check that the magnet and sensor of the rotation guard have been right installed. Make sure that the seals of the access door are in place and that they are undamaged. Shut the access door and make sure that the latch is getting tight. Start the unit after inspecting the instructions of the functional sections and after checking that the access doors are shut. Check from the exhaust air side that the rotor rotates in the right direction: from exhaust air side through purging sector to supply air side. In a couple of weeks use, check that the bolts of sectorized rotor periphery plate and the belts are tight, tighten when necessary. If the unit is installed in a place where it is easily accessible also to other people than service personnel, the handles of access doors must be removed and locked in a safe place. 22

23 First actions in case of an alarm when the motor has stopped Cut off the main voltage supply upstream from the control unit, wait 10 seconds and switch the voltage on again. If the motor starts, the motor guard of the control unit had tripped. Make sure that the heat exchanger rotates freely. Check the fuse upstream from the control unit. Check the fuse of the control unit. Check that the rotation guard is in place and it is operating. If the motor still does not work, turn to an expert for further troubleshooting. Maintenance The maintenance interval is 6 months. It is advisable to have the unit serviced at the beginning (autumn) and at the end (spring) of the heating season. Twice a year Check and clean the heat transfer surfaces. Make sure that the brush seals lightly touch the surface of the heat exchanger. Replace the damaged brush seals. Check every six months that the bolts of sectorized rotor periphery plate and the belts are tight, tighten when necessary by shortening the belt. Check the drive belt. The belt stretches during the year, shorten it. If the belt is worn, replace it. In a couple of weeks use, check the tightness of the belt and shorten when necessary. Once a year Check the drive belt. The belt stretches during the year, shorten it. If the belt is worn replace it. In a couple of weeks use, check the tightness of the belt and shorten if needed. Check the drive motor and lubricate the transmission with grease or oil. For more detailed instructions, see the sticker attached to the transmission. Do no mix synthetic and mineral oils or greases. Alter the control signal to see if the speed control is functioning properly and if the control signal is connected correctly. Place the heat exchanger magnet by the sensor of the rotation controller to see if the sensor and the controller magnet are correctly positioned. The distance between them should be mm. Replacement of drive belt Stretch the belt around the heat exchanger and the pulley. Cut the belt so short that, after joining the ends, it barely reaches over the pulley. When the belt is fastened, it expands automatically to the correct tension due to the spring load of the motor mountings. Service place The heat exchange rotor must be accessible for possible replacement and there shall be a free space of the width of the section (max 2000 mm) by the section side. If this is no possible, the space for the replacement of the rotor has to be arranged otherwise. For the inspection and maintenance of the heat exchange surfaces there must be a clear access through, for example, the adjacent sections, or an inspection section FTTT. Installation The heat recovery section FRTR is carried by a forklift or a crane. The section is lifted according to the lifting instructions enclosed in the section delivery. When using the forklift, make sure that the section cannot fall. The section has always to be installed on a straight and firm base in upright position (inlet and outlet unit on one another). The location of the inlet and outlet units as to the heat recovery section is shown in the assembly drawing of the air handling unit. Protect the heat transfer surfaces from water and moisture before the final installation. Do not damage the surfaces of the heat exchanger, the surfaces are sensitive to mechanical stress. Mount the section into the air handling unit. Make sure that the brush seal lightly touches the heat exchanger everywhere. If there is a purging sector in the section, check from the exhaust air side that the rotor rotates in the right direction: from exhaust air side through purging sector to supply air side. Wiring Thread the motor cable through the through-hole to the terminal strip. The manufacturer has connected the internal connections of the heat recovery section at the factory. The detailed wiring diagrams are enclosed in the delivery of the section. 23

24 Order code: Heat recovery section, rotor FRTR a b c d e f g h i j a) Size b) Handedness R / L c) Rotor size 1, 2 d) Version 1, 2 e) Rotor material AL =alum., AH =alum. hygroscop., ALE =alum. epoxy coating., AHE =alum.hygroscop. epoxy coating., AL/S =alum. in parts, AH/S =alum.hygroscop. in parts, ALE/S =alum.epoxycoating, in parts, AHE/S =alum.hygroscop. epoxy coating. in parts f) Purging sector 1=constant speed, 2=control centre g) Control 1=constant speed, 2=control centre h) Manufacturer H, E, KE i) Lamella spacing N=normal, L=dense j) Type and material (S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Accessories hinges for access door R=right, L=left inspection window rotation guard lamp spare belt water drain (only for Future Clean) connection flange of unit size base plate of stainless steel Version 1 Version 2 = supply air = exhaust air Sizes of heat recovery rotors FUTURE unit size Rotor size 1 diameter Rotor size 2 diameter * * * 3500* * 3500* * * 3500* * 3500* * 3500* * 4200* * 4900* * 4900* * rotors are delivered as parts. 24

25 Heat recovery section, plate FRTL Sizes Air flow m 3 /s , 2409, 2412 and 2415 Instructions for design The heat recovery section FRTL is designed to be used for recovering thermal energy from the exhaust air, and for transferring the recovered energy to the supply air by means of a plate heat exchanger operating on the cross-flow principle in case the supply and exhaust parts of the air handling unit can be mounted on top of each other. In a plate heat exchanger, the supply and exhaust air flows use separate channels that cross each other, but do not mix. Every heat recovery section FRTL is equipped with bypass or bypass and section defrosting dampers having tightness class 5 (SFS 5330), T4/T5 (CEN 3/4) which are used for regulating the section temperature and for defrosting the heat exchanger. A free space must be available below the heat recovery section for the installation of the water trap. The exhaust part of the unit can, if necessary, be provided with a drop separator downstream from the heat exchanger. A drop separator is often used when the air flow through the heat exchanger is very moist (>5g/kg), or has a velocity of over 2.5 m/s. It is advisable to use a filter of at least class F5 upstream from the section (both in the supply and in the exhaust part) to keep the heat exchanger clean. A free space of the width of the section (max 2000 mm) must be available on one side of the section or otherwise arrange the possible replacement of the plate heat exchanger. Constructions where the exhaust air flows upwards is not recommended to use if the exhaust air is moist. Construction The heat recovery section FRTL consists of a thermally insulated casing, a built-in plate heat exchanger and dampers used for by-passing or for by-passing and section defrosting. The plate heat exchanger is made of aluminium. Max. permissible operating temperature is +80 C and max. permissible pressure difference between inlet and outlet air is 1000 Pa. The dampers have thermally insulated louvres. Dampers are controlled by the actuator/actuators (accessory/ accessories) and they are installed direct to the shaft/ shafts of bypassing or defrosting dampers. If the dampers are used only for by-passing, the actuator can be on-off controlled. If the dampers are used both for bypassing and defrosting, continuous control is required. There must be a drip tray of stainless steel with water drain both on the inlet and outlet sides of the heat recovery section. The amount of actuators and the torque needed are given in the table below. The length of the actuator movement must be adjusted so that the dampers shut and close but do not exceed the limit. Amount of actuators / Actuator size Nm Unit size Bypassing Bypassing and defrosting (bypass damper) / (1) / 8 + (4) / (1) / 8 + (8) / (1) / 15 + (8) 2409, 2412 and / (1) / 15 + (15) 25

26 Control The heat recovery section FRTL is controlled by means of a by-pass damper and the shut-off damper of the heat exchanger. Methods of control: by-passing by-passing and defrosting. When using by-passing method, the actuator shuts the by-pass damper and opens the shut-off dampers of the heat exchanger when heat recovery is needed. In by-passing operation frost is melted by keeping the pressure difference constant with a pressure switch. In this case part of the supply air is led over the heat exchanger so that the by-pass damper is opened and the shut-off damper of the heat exchanger is shut respectively. When using by-passing and section defrosting methods, the actuators operate as in by-passing operation when heat is recovered. The exhaust side of the heat exchanger may frost if the temperature is below -3 C. When using by-passing and defrosting methods, frost is melted by leading the dampers with a pressure difference switch so that the actuator shuts one of the dampers of the heat exchanger and opens the by-pass damper according to the control. The heat recovery section FRTL is always installed according to the figure beside. Air flow directions are shown in the section and in the air conditioning drawings. Commissioning and maintenance The maintenance interval is 6 months. It is advisable to have the unit serviced at the beginning (autumn) and at the end (spring) of the heating season. Make sure that the heat transfer surfaces are clean and undamaged. Check the operation of the dampers. Check that the actuator and the dampers have the same turning directions. The heat recovery cube is cleaned with a brush, pressure air or vacuum cleaner. If there is a drain system in the section, it can be cleaned with water and mild washing agent. Note! No pressure cleaning! Inspect and, if necessary, clean the drain system for condensed water: drip tray, piping, water trap. Flush the piping and fill the water trap. Make sure that there are no loose pieces, refuse etc, that may get into the fan impeller. Make sure that the cables are undamaged. Check that the seals of the access door and plate heat exchanger are in place and undamaged. Shut the access door and make sure that every latch tightens. If the unit is installed in a place where it is easily accessible also to other people than service personnel, the handles of access doors must be removed and locked in a safe place. If the heat recovery chamber is pressurized, make sure that the fan has stopped before opening the access door. Order code: Heat recovery section, plate FRTL a b c d e f g a) Size , 2409, 2412, 2415 b) Handedness R / L c) Version 1, 2, 3, 5, 6, 7 d) Material of plate 4=aluminium e) Dampers 1=by-pass damper and section defrosting damper, 2=by-pass damper f) Material of damper 1=hot galvanized, 3=stainless steel, 4=aluminium g) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Accessories inspection window water trap lamp safety latch hinge for access door actuator, electric connection flange of unit size for slip joint Versions

27 Dimensioning instructions for water trap Coil at inlet side of the fan Δp = P 0 - p 1 (Pa) A min = Δp/ (mm) B min = A/ (mm) p 1 p 0 B A Coil at outlet side of the fan Δp = P 0 - p 1 (Pa) A min = 20 (mm) B min = Δp/ (mm) p 1 p 0 B A Water trap shall be mounted in the position according to the figure. 27

28 Heating section, fluid FLTV Sizes Flow rate m 3 /s Instructions for design The heating section FLTV is designed to be used for heating the supply air and to be operated by warm fluid. The section must be equipped with an anti-freezing thermostat to avoid damages caused by freezing. A standard heating section FLTV must always be so mounted that the air flow through it is horizontal. A free space of at least the section s width must be available on one side of the section, or otherwise arrangeable, for the replacement of the heat exchanger of the section. The heat transfer surfaces must be accessible for inspection and service through, for example, the adjacent sections, or through an inspection section FTTT provided with an access door. Construction The heating section FLTV consists of a thermally insulated casing and a built-in heat exchanger. The heat exchanger can be pulled out of the casing without dismantling. The pipes of the heat exchanger are copper, the lamellas are aluminium or copper and the frame is hotgalvanized or stainless steel. The heat exchanger has inlet, outlet, air vent, water drain, and connection for antifreezing thermostat sensor. Both the inlet and the outlet are provided with a female pipe thread DN 10...DN 50 or a connection flange according to ISO 357 (bigger sizes). the max. permissible operating temperature is +150 C the max. permissible operating pressure is 1.0 MPa. If water is used as heating medium, the heat exchanger may freeze up and get damaged at temperatures below 0 C. 28

29 Commissioning Make sure that the heat transfer surfaces are clean and undamaged. Open the line control valves and fill the coil with fluid. Bleed the coil. Make sure that the fluid side connections do not leak. Check the rotation direction of the circulating pump (do not run the pump dry). Check the operation of the anti-freezing thermostat. Make sure that the control valve is functioning, and adjust the line control valves according to the plan. Further instructions for adjustment, see the manufacturer s manual. Maintenance Make sure that the fluid side connections of the coil do not leak. Make sure that the heat transfer surfaces are clean and undamaged. Clean the coil gently with a brush, compressed air or a vacuum cleaner. If the unit has a drain, the coil can be cleaned with water and mild detergent. Note! No pressure cleaning. Bleed the coil and check the operation of the antifreezing thermostat always at the beginning of heating season. If the heat exchanger gets damaged, it must be repaired in place, sent to the manufacturer to be repaired or replaced. Connections Right-handed heating section is connected according to the figure 1, left-handed according to the figure 2. Bleed the heat exchanger carefully so that the fluid circulation in pipes is free. The connection principles of both the left-handed and right-handed sections are same. The heat exchanger has inlet, outlet, air vent, water drain and connection for anti-freezing thermostat sensor. the max. permissible operating temperature is +150 C the max. permissible operating pressure is 1.0 MPa Order code: Heating section, fluid FLTV - a - b - c - d - e - f a) Size b) Handedness R / L c) Capacity 1,2, 3, 4, 5 d) Pipes and lamellas 1=Cu/Al, 2=Cu/Cu e) Fluid 1=water, 2=glycol (etylene), 3=glycol (propylene),4=freezium, 5=thermera) f) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Accessories water drain (Future Clean construction) flanged joints anti-freezing thermostat automatic air bleeder connection flange of unit size for slip joint base plate of stainless steel Figure 1. Right-handed connection Figure 2. Left-handed connection Bleeding Water, out Anti-freezing Water, in Drainage Water, in Water, out 29

30 Heating section, electricity FLTE Sizes Flow rate m 3 /s Heating power max. 260 kw Electrical connection diagram is enclosed in the delivery. Instructions for design The heating section FLTE is designed to be used for heating the supply air and to be operated by electricity. The heating section must be so connected to the fan that they always start at the same time. It is also advisable to equip the unit with a flow controller. The heating section must always be so mounted that the air flows through it across the filter and strictly horizontally. A free space of at least the section s width must be available on one side of the section, or otherwise arrangeable for the replacement of the heat exchanger of the section. The heat transfer surfaces must be accessible for inspection and service through, for example, the adjacent sections, or through an inspection section FTTT provided with an access door. The input voltage is usually 3~400 V, 50 Hz, but other ratings are also possible. The heating power and power stages are determined separately for every individual section. The section must be so connected that the fan starts before or at the same time as heating. The fan may stop at the same time as heating or later. Construction The heating section FLTE consists of a thermally insulated casing and a built-in electric heat exchanger. The heat exchanger can be pulled out of the casing without dismantling. The heat exchanger includes a coil with copper pipes and aluminium lamellas. The heating elements are inserted in the pipes. The section may in some cases require more space than is specified in the table of dimensions, depending on the number and division of power stages (the space requirement is checked separately for every individual heating section). All the necessary terminals and cable entry sleeves are ready installed. Heating section FLTE operates by electricity. Electrical connection diagram is enclosed in the section delivery. Operation The heating section equipped with a lamella-type heat exchanger is designed for a min. air velocity of 1.5 m/s at the outlet temperature of 40 C. As the velocity decreases, the temperature rises, and as the velocity increases, the temperature sinks. The heat exchanger features a thermostat and overheating protector. Heating is switched off by the thermostat when the temperature exceeds 75 C and back on when the temperature falls again below 75 C.The overheating protector is a safety device which switches off heating if the temperature rises over the set value of 147 C for some reason e.g. fault. It must be reset manually, but not until the cause of overheating has been found out. The overheating protector is a safety device, and must therefore never be by-passed. If desired, an alarm can be given every time the overheating protector operates. 30

31 Installation The air shall evenly flow on the heat exchanger surface. The section has to be installed at the distance of min mm from the angle section, duct bend (measured from internal angle) or some other section that may cause an uneven flow. The air flow direction must follow the arrow marked on the section and the section has to be so installed that the air flow is horizontal. Note! Be careful when installing the section, the capillary tube of overheating protector is fragile. Note! Keep all flammable materials at a distance of less than 100 mm from the lamella surface. Electrical connections Only an electrical contractor with competent rights is allowed to carry out the electro-technical work. The electrical connection diagram enclosed to the section delivery has to be followed. Note! The fan shall start before or at the same time as the heating starts and stop simultaneously or after the heating power is switched off. Maintenance Make sure that the heat exchanger voltage is switched off before the maintenance work. Make sure that the heat transfer surfaces are clean and undamaged. Clean the heat exchanger gently with a brush, compressed air or a vacuum cleaner. Do not use water! Bent lamellas can be straightened with a lamella comb, available from the manufacturer of the heat exchanger. Make sure that there is no flammable material inside the section at a distance of less than 100 mm from the lamella surface. Make sure that the capillary tube of the overheating protector is undamaged. Check the operation of the heat exchanger during the test run. If the overheating protector trips, there is a fault in the unit. The fault must be found and eliminated before resetting the overheating protector. Make sure that the fan starts before or at the same time as heating and stops at the same time as heating or later. Commissioning Make sure that the heat transfer surfaces are clean and undamaged. Make sure that there is no flammable material inside the section at a distance of less than 100 mm from the lamella surface. Make sure that the capillary tube of the overheating protector is undamaged. Check electrical connections, joints and that the direction of air flow is according to the arrow marked on the section. Give the section a test run. If the overheating protector trips, there is a fault in the unit. The fault must be found and eliminated before resetting the overheating protector. Make sure that the fan starts before or at the same time as heating and stops at the same time as heating or later. Order code: Heating section, electricity FLTE - a - b - c - d - e a) Size b) Handedness R / L c) Capacity 1, 2, 3, 4, 5 d) Power stages 1, 2, 3, 4, 5, 6 e) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Accessories connection flange of unit size for slip joint base plate of stainless steel 31

32 Cooling section, fluid FJTV Sizes Flow rate m 3 /s Instructions for design The cooling section FJTV is designed to be used for cooling the supply air and operated by cold water or frostproof liquid, such as glycol etc. The standard cooling section FJTV must always be so mounted that the air flow is horizontal. A free space of at least the section s width must be available on one side of the section or otherwise arrangeable for the replacement of the heat exchanger (coil) of the section. The heat transfer surfaces must be accessible for inspection and service through, for example, the adjacent sections, or an inspection section FTTT provided with an access door. Below the section, there must be free space for a water trap which has to be led to a floor drain, not to other severage. The section can be equipped with a drop separator if needed. A drop separator is often used when the air flow through the heat exchanger is very moist or has a velocity of over 2.5 m/s, further information in Future dimensioning program. Construction The cooling section FJTV consists of a thermally insulated casing and a built-in heat exchanger. The heat exchanger can be pulled out of the casing without dismantling. The pipes of the heat exchanger are copper, the lamellas are aluminium or copper, and the frame is aluminium or stainless steel. The heat exchanger has inlet, outlet, air vent, and water drain. The section has a drip tray and water drain. If the section is operated by water, the inlet and the outlet are each provided either with an internal pipe thread (DN 10...DN 50) or a connection flange according to ISO 357 (bigger sizes). If the cooling medium is an antifreeze, such as glycol, only connection flanges are used. The max. permissible operating pressure is 1.0 MPa. Due to the construction, the heat exchanger is never completely drained. If water is used as the cooling medium, the heat exchanger may freeze up and get damaged at temperatures below 0 C. 32

33 Commissioning Make sure that the heat transfer surfaces are clean and undamaged. Open the line control valves and fill the coil with fluid. Bleed the coil. Make sure that the fluid side connections do not leak. Check the rotation direction of the circulating pump (do not run the pump dry). Check the operation of the anti-freezing thermostat. Make sure that the control valve is functioning and adjust the line control valves according to the plan. Further instructions for adjustment, see the manufacturer s manual. Check the drain system for condensed water: drip tray, piping, water trap. Flush the piping and fill the water trap. The coils of big units have been split in two. The condensation water drain of the outlet coil has to be piped to the sewer also from beyond the unit. Make sure that the water traps and piping have been mounted according to the instructions. Maintenance Make sure that the fluid side connections do not leak. Make sure that the heat transfer surfaces are clean and undamaged. Clean the heat exchanger gently with a brush, compressed air of vacuum cleaner. Do not use water! If the unit has a drain, the coil can be cleaned with water and mild detergent. Note! No pressure cleaning. Bleed the coil and check the operation of the antifreezing thermostat always in the beginning of heating season. Check the drain system of condensed water: drip tray, piping, water trap. Flush the piping and fill the water trap. Check and clean the condensation water drain system: drip tray, piping and water trap(s). j If the heat exchanger gets damaged, it must be repaired in place, sent to the manufacturer to be repaired or replaced. Order code: Cooling section, fluid FJTV - a - b - c - d - e - f - g - h - i a) Size b) Handedness R / L c) Number of rows 3, 4, 5, 6, 8, 10, 12 d) Pipes and lamellas 1=Cu/Al, 2=Cu/Cu e) Lamella spacing 2; 2,4; 2,8; 3,5 f) Number of lines g) Fluid 1=water, 2=glycol (etylene), 3=glycol (propylene),4=freezium, 5=thermera h) Fluid content % i) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Accessories water trap(s) flanged joints connection flange of unit size for slip joint separate basin under the manifold If the heat exchanger is not used in the heating season, water has to be discharged or it has to be filled with water-glycol fluid to avoid frosting. The heat exchanger does not drain entirely through the drain screw but 20-30% of the total amount of fluid remains. Water can be removed entirely by blowing in compressed air through the bleed screw. 33

34 Dimensioning instructions for water trap Coil at inlet side of the fan Δp = P 0 - p 1 (Pa) A min = Δp/ (mm) B min = A/ (mm) p 1 p 0 B A Coil at outlet side of the fan Δp = P 0 - p 1 (Pa) A min = 20 (mm) B min = Δp/ (mm) p 1 p 0 B A Water trap shall be mounted in the position according to the figure. 34

35 Drop separator FPTE Sizes Flow rate m 3 /s Instructions for design The drop separator FPTE is designed to be used in sections where water drops are condensed into air flow. Dimensioning program Future gives operation suggestions according to the face velocity for the drop separator. Drop separator units can be pulled out for inspection and cleaning, they can also be removed for the winter time, if needed, to minimize the internal pressure loss of the unit. The drop separator has a drip tray with piping. Construction The drop separator unit material is profile polypropylene plastic (VDI 6022 compliance) and the frame stainless steel. The operation temperature of air flow is C. The drop separator units are in thermally insulated casing with a separate access door. Commissioning Make sure that the drop separator units are undamaged and that they have been correctly mounted considering the air flow direction (arrow). Check the discharge system of condensation water: drip tray, piping and water trap. Flush the piping and fill the water trap. Maintenance Make sure that the drop separator units are clean and undamaged. Clean if needed. Clean the heat exchanger gently with a brush, compressed air or vacuum cleaner. Do not use water! If the unit has a drain, the coil can be cleaned with water and mild detergent. Note! No pressure cleaning. Check and clean the discharge system of condensation water: drip tray, piping and water trap. If the drop separator unit gets damaged, it must be repaired in place, sent to the manufacturer to be repaired or replaced.. If the units are not in use during the heating season, we recommend removing the units. If the drop separator section is set downstream of the fan (pressure side), make sure that the fan stops before opening the access door. Order code: Drop separator FPTE - a - b - c - d a) Size b) Handedness R / L c) Cell material 9=plastic d) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Accessories connection flange of unit size for slip joint safety latch 35

36 Humidifying section, evaporation FKTK Sizes Flow rate m 3 /s Instructions for design The humidifying section FKTK is used for humidifying the supply air. The humidifier can be set to maintain the humidity at 65, 85 or 95 % and it can be operated by once-through or circulating water. It is advisable to use a filter having at least grade G3 upstream from the section. If the air contains organic dust, it is recommended to use a filter having at least grade F7. A humidifying section FKTK must always be so mounted that the air flow through it is horizontal. A humidifying section FKTK must always be connected to the motor of the outlet fan so that the fan starts before humidification. The section must be equipped with a drop separator if the air velocity exceeds 3.5 m/s. Construction The humidifying section FKTK consists of a thermally insulated casing and built-in humidifier cassettes of modular lengths. The humidification is carried out by evaporating water from wet surfaces of humidifier cells. The water is led to the humidifier cassettes from above by means of piping and runs down through the criss-cross pattern of humidifier cells. Some water is absorbed into the cells and evaporated to the air flow passing through the cells; the rest drips down on a drip tray. The cells are made of hygroscopic ceramic material that is elastic and poorly burning (class B1 according to DIN 4102, class 1 according to NordTest Fire 004). The frames of the humidifier cassettes, and the humidifier casing are stainless steel. The water distribution system contains brass and plastic parts. The section can be operated by circulating water (pump), or once-through water (constant flow rate valve). The humidifier cassettes and pipes can be removed through an access door for service. The section casing is equipped with a drip tray and water drain made of stainless steel. The max. permissible temperature of air and water downstream from the section is 40 C. The required min./ the max. permissible water pressure at the connecting point is 500/1000 kpa for circulating water, and 150/1000 kpa for once-through water. If the water contains large particles, a filter having at least meshes rating 500 µm must be used in the water supply pipe upstream from the section. If circulating water is used, it is important to make sure that the water change rate of the drip tray is adequate for preventing calcification of the humidifier cells. 36

37 Humidifying The design engineer of the air conditioning system has dimensioned the humidifying section and selected the control system. The design gives the amount of water needed for humidifying, the amount of over-flow water, possible water filter and the operation principle of the humidifying section and the periods of operation. Control Dew point control A dew point sensor measures the absolute humidity downstream from the humidifying section and initiates the preheating heat exchanger so that the humidity value set is achieved. A temperature sensor measures the temperature downstream from the inlet fan and initiates the re-heating heat exchanger so that the temperature set is achieved. The humidifying pump starts when humidification is required and leads water to all the humidifier cassettes. The desired humidity is achieved with an accuracy of ± 1 2%. In order to achieve the desired humidity in the room, the humidity of outdoor air can be decreased by pre-cooling if necessary. On/off control A humidity sensor measures the relative humidity in the room (or in the outlet duct) and switches all the humidifier cassettes on or off depending on which is required to keep the humidity within the set range. A temperature sensor measures the temperature downstream from the inlet fan and initiates the re-heating heat exchanger so that the temperature set is achieved. The humidifying pump starts when humidification is required and leads water to all the humidifier cassettes. As soon as the set max. relative humidity is achieved in the room, all the humidifier cassettes switch off. When the set min. relative humidity is reached, the humidifying pump starts again, and stops again at the max. humidity. The desired humidity is achieved with an accuracy of ±5 10%. Step control A humidity sensor measures the relative humidity in the room (or in the outlet duct), and opens as many solenoid valves as is required in order to keep the humidity within the set range. A temperature sensor measures the temperature downstream from the inlet fan, and initiates the preheating heat exchanger so that the set temperature is achieved. A humidifier cassette is dimensioned to raise the relative humidity in the room from the min. to the max. level. The humidifying pump starts when humidification is required and leads water to the humidifier cassette that has no solenoid valve. When the set min. relative humidity is reached, the humidity sensor opens as many solenoid valves one after the other as is required. In this four-step control, the desired humidity is achieved with an accuracy of ± 3 5 %. Electricity, circulation pump Sizes Humidification ratio 65 % 85 % 95 % Nominal voltage (V) Nominal frequency (Hz) Nominal power (W) Rated current (A) / ,26/0, / ,38/ / ,75/0, / ,10/0,63 Electricity, solenoid valve, step control Nominal voltage (V) Nominal frequency (Hz) Nominal power (W) Rated current(a) 1-phase ,10-0,21 37

38 Commissioning Before commissioning the humidifying section, make sure that the air conditioning plant has been cleaned and that the filters have been mounted. Connect the section to the water supply and let the cells and the tray fill up with water. Make sure that there are no leaks and check the operation of the overflow pipe. If the section is operated by circulating water, start the pump when the tray is full of water. When the air conditioning plant is in operation, monitor the operation of the humidifiers and the control system first daily and then at about one month s intervals: Make sure there are no water leaks. Check if there are water drops on the cells. If there are, consider applying a drop separator. Check the operation of the water distribution system (water must be evenly distributed to the cells). Make sure that the amount of overflow water meets the dimensioned level. Decreased overflow rate may cause calcification in the cells reducing the performance and shortening the lifetime. Check the condensation water discharge system: drip tray, piping and water trap. Flush the piping and fill the water trap. Check that the over-flow water gets freely into the drain. Order code: Humidifying section, evaporation FKTK - a - b - c - d - e - f a) Size b) Handedness R / L c) Humidification ratio1=65 %, 2=85%, 3=95 % d) Water 1=circulation water, 2=once-through water (65 % up to size 3021, 85 % up to size 2418 and 95 % up to size 1818 e) Control 1=dew point control, 2=step control 1 5 steps 3=ON-OFF control f) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Accessories hinges for access door inspection window water trap connection flange of unit size safety latch Maintenance The maintenance interval for the humidifying section is specified in the maintenance plan. It is determined by humidifier type, application, quality and treatment of water, quality of air, etc. The section must be cleaned every time it is put out or into operation. Check the cleanliness also during every service and inspection of the air conditioning plant, or even more often if necessary, and clean if dirty. 38

39 Humidifying section, steam FKTH Sizes Flow rate m 3 /s Instructions for design The humidifying section FKTH is used for humidifying the supply air by means of steam with a temperature of 100 C. The humidification ratio is selected by determining the steam demand (kg/h) according to the prevailing conditions. The section features a space reservation and a supporting plate for the connection of steam pipe(s). There must be, downstream from the section, free space enough for a drip tray and water drain for discharge of possible condensation water from the inner surfaces. A humidifying section FKTH must always be mounted with the steam pipe connections upwards. The air flow through the section must be strictly vertical or horizontal. For service purposes, there must be at least 800 mm of free space on one side of the section. Below the section, there must be at least 200 mm of free space to allow the installation of a water trap. An inspection section FTTT or a drop separator FPTE must be installed downstream from the section. Construction The humidifying section FKTK consists of a thermally insulated casing and a supporting plate for steam pipe(s). The section casing is equipped with a drip tray and water drain made of acid-proof steel. Commissioning Check the condensation water discharge system: drip tray, piping and water trap. Flush the piping and fill the water trap. Maintenance Check the condensation water discharge system: drip tray, piping and water trap. Flush the piping and fill the water trap. Maintenance of the humidifier according to the manufacturer s instructions. Order code: Humidifying section, space for steam pipe FKTH - a - b - c - d a) Size b) Handedness R / L c) Length 450=sizes , 550=sizes d) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Accessories inspection window water trap safety latch connection flange of unit size Commissioning of the humidifier according to the manufacturer s instructions. 39

40 Inspection section, FTTT Sizes Flow rate m 3 /s Instructions for design The inspection section FTTT is used for connecting units, inspection and service works. The inspection section is used for belt-driven fans along with flow equalizer. Construction The inspection section FTTT consists of a casing module equipped with an access door and it can be installed in all positions. Order code: Inspection section FTTT - a - b - c - d a) Size b) Handedness R / L c) Length 250, 300, 400, 650 d) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Inspection section, FTTR Accessories inspection window water drain lamp hinge duct connection flange for slip joint connection flange of unit size for slip joint base plate of stainless steel access level safety latch Sizes Flow rate m 3 /s Instructions for design The inspection section FTTR is used along with heat recovery units Retermia. It is always equipped with a separate unit base. Construction The inspection section FTTR consists of a casing module and an access door (on top). Note! The section does not include a heat exchanger. Order code: Inspection section FTTR - a - b - c - d a) Size b) Handedness R / L c) Length 1050, 1250 d) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Accessories inspection window water drain duct connection flange for slip joint connection flange of unit size for slip joint base plate of stainless steel safety latch 40

41 Fan section, centrifugal fan FFTK Sizes Flow rate m 3 /s Instructions for design The fan section FFTK has a centrifugal fan that is designed to be used in various air conditioning plants. The fan performance testing has been carried out according to standards AMCA and AMCA Future Clean complies with the requirements of the standards VDI 6022 and DIN The fan section must be mounted horizontally. If a section other than FTTT, FTTK, or FVTK version 4 or 5 is installed on the outlet side of a fan section, flow equalization must be ensured by using a flow equalizer FVZT and an inspection section FTTT with a length of at least 300 mm (sizes ) 450 mm (sizes ) 600 mm (sizes ) 800 mm (sizes ) 1000 mm (sizes ) 1200 mm (sizes ) Construction The fan section FFTK consists of a thermally insulated casing and a centrifugal fan with two inlets and an impeller with forward or backward curved blades. The fan and the motor are mounted on the same base frame on vibration dampers made of rubber or springs. The fan outlet is connected to the section casing by means of a flexible joint. The fan is V-belt driven. The motor conforms to the IEC standard and has a protection class IP54. To ensure sufficient cooling of the motor, the air temperature must not exceed +40 C. If the temperature exceeds +40 C, the lifetime of the motor shortens. The fan section is equipped with an access door and external measuring sets. A free space of at least the section s width must be available on one side of the section and at least 400 mm behind the section for service and repair work. The fan section has to be equipped with a service switch to stop the fan before service work. 41

42 Fan Fan AF is a centrifugal fan with forward curved blades. The maximum efficiency is about 70%. The fan curve is flat which means that the effect of the air flow rate on the pressure rise is minimal. The maximum pressure rise is 2000 Pa. Section sizes are Fan AB is a centrifugal fan with backward curved blades. The maximum efficiency is as high as 83 %. The fan curve is sharp which means that the air flow rate keeps almost constant at varying pressures. The maximum pressure rise is 2000 Pa Section sizes are Fan BB is a heavy-duty version of AB. The maximum pressure rise is 3600 Pa. Section sizes are Fan selection The fan BB is selected when the pressure is too high for the fans AB and AF. If both forward and backward curved blades are applicable, the fan is selected on the basis of the desired efficiency, sound level and control method. If the operating point is near the upper limit of the operating range of AB and AF, it is advisable to choose BB. This way it is possible to compensate for any deviations from the pressure drop calculations and to increase later the air flow rate or pressure if necessary. Motor size selection The fan power P A (kw) given by the Future dimensioning program is the shaft input of the fan; P M (kw) is the recommended minimum motor power at direct start, the power loss caused by the belt drive has been taken into account. If a two-speed motor is used, the selection must be based on the power demand of the lower rotation speed taking into account the power loss caused by the belt drive selected according to the higher speed. If two motors are used, the belt power losses caused by both motors and the power loss caused by the rotation of the bigger motor must be taken into account when determining the power demand of the smaller motor. If a frequency converter is used, the motor and the converter must be compatible and they must be dimensioned according to the manufacturers instructions. Flow rate control 1. Motor speed control by means of a frequency converter is a suitable flow rate control method for AF, AB and BB fans of all sizes. 2. Step control with a two-speed motor or two separate motors is a simple and energy-saving flow rate control method suitable for AF, AB and BB fans of all sizes. Frequency converter control, fans AB, BB, The fan (motor) rotation speed is varied by means of a frequency converter. As long as the plant curve keeps constant, the air volume flow changes in proportion to the speed of rotation. The pressure changes in proportion of the rotation speed change to second power and in proportion of power change to third power. If the plant curve changes, the volume flow and the pressure loss must be determined at some operating point. After that they can be changed to desired settings according to the above mentioned proportions. Safety Before switching on the fan, make sure that the inlet and the outlet of the fan section have been connected to the ductwork or that the access to the rotating parts of the fan, such as the impeller, through inlet, outlet or access door has been prevented with protective screens or in some other way. The service switch of the air handling unit must be installed and functioning and the access doors must be shut when the unit is switched on. The damper section of the unit must open before the fan starts. Do not open the access doors when the fan is in operation. If the unit is installed in a place where it is easily accessible also to other people than service personnel, the handles of access doors must be removed and locked in a safe place. Safety equipment Service/safety switch (not included) installed in the fan section serves also as a unit emergency switch. Fire In case of fire in the unit, use e.g. a powder extinguisher, do not use water. The materials used in the unit do not produce harmful amounts of any hazardous gases when burning. 42

43 Commissioning Make sure that there are no loose particles that may get between the belts or into the impeller inside the fan section or fan. Make sure that the flexible joint and the vibration dampers are undamaged and that the fan and motor are laying on the vibration dampers only and that they move freely when moving by hand. Make sure that the electrical cables are undamaged, lead flexibly to the motor and that the cable type is right. Check that the drive and fan operate freely by moving the impeller a couple of turns by hand. Start the fan for a while to see that the rotation direction is according to the arrow marked on the fan. Note! Be extremely careful and make sure that there are no people or loose objects near the fan. All the filters, grilles, valves and other parts of the air conditioning plant have to be installed and preset before a long-term operation. The fan must not be started when inlet and outlet dampers are closed. Clean the fan casing and impeller with a brush, vacuum cleaner or damp cloth. The casing can be gently washed with water if the unit is equipped with drainage for washing water. Check the fastening of bearings. Check the drive (Instruction enclosed). Glance through that the motor is undamaged. Make sure that the seals of access doors are undamaged and in place. Close the access doors and make sure that every latch is tight. If the unit is installed in a place where it is easily accessible also to other people than service personnel, the handles of access doors must be removed and locked in a safe place. V-belt drive The V-belt pulleys have been mounted with a conic sleeve to the shaft in the fan section. V-belts are of types XPZ, XPA and ZPB. Commissioning The V-belt drive has been aligned and tensioned at the factory ready for operation. The belts must be tensioned again during commissioning after 30 minutes operation.according to the chapter V-belt tension, table 1.1. to the highest values. Maintenance Make sure that there are no loose particles that may get between the belts or into the impeller inside the fan section or fan. Make sure that the flexible joint and the vibration dampers are undamaged and that the fan and motor are laying on the vibration dampers only and that they move freely when moving by hand. Make sure that the electrical cables are undamaged, led flexibly to the motor and that the cable type is right. Check that the drive and fan operate freely by moving the impeller a couple of turns by hand. All the filters, dampers, valves and other parts of the air conditioning plant have to be installed and preset before a long-term operation. The fan must not be started when inlet and outlet dampers are closed. Check that the V-belt pulleys and V-belts are not too worn. There are groove gauges to easily and reliably measure the condition of grooves. The gauges are available from the V-belt manufacturers. If the fan has grease fittings, lubricate the bearings according to the instructions enclosed. Replace the worn V-belt pulleys and V-belts. All the belts have to be replaced at the same time if the drive has several grooves. Tighten the fixing screws of the conic sleeve in the V-belt pulley. Check the alignment and tightness of the belts according to the instructions enclosed. Clean the V-belt pulleys and V-belts if needed. Clean the fan casing and impeller with a brush, a vacuum cleaner of a damp cloth. The casing can be gently washed with water if the unit is equipped with drainage for washing water. Check the tightness of the bearing fastenings. Check the drive according to the instructions. Glance through that the motor is undamaged. Start the fan for a while to see that the rotation direction is according to the arrow marked on the fan. Note! Be extremely careful and make sure that there are no people or loose objects near the fan. Make sure that the seals of access doors are in place and undamaged. Replace if needed. Close the access doors and make sure that every latch is tight. If the unit is installed in a place where it is easily accessible also to other people than service personnel, the handles of access doors must be removed and locked in a safe place. The regular maintenance can be scheduled to the beginning and end of the heating season. It is advisable to monitor the operation of the fan and particularly the drive between the regular maintenances. After commissioning, check the tightness and alignment of belts every week. 43

44 Safety equipment Service/safety switch installed in the fan section, serves also as an unit emergency switch. (Compulsory, not included). If the air flow meter does not display right, check the following points: The hoses are in place and undamaged. The hoses are not flattened. There are no blockages in the hoses or pressurized joints. The air flow meter has been reset and the plug of reset screw has been properly closed (see Figure 1). Check that the air flow meter scale is equivalent to the fan size. Check that the hoses have been connected right FFTK fan sizes from the measuring ring of fan to -joint and from the casing to +joint FFTK fan sizes from the measuring pipe (q-dysa) of fan according to the Figure 2 Connection of electric motor and frequency converter The incorrect connection of a frequency converter may damage the bearing of a motor. Only an authorized electrician is allowed to connections. Koja Ltd does not make good the motor damages caused by an incorrect connection if it is made by somebody else than an authorized person by Koja Ltd. A maximum frequency of rotation speed has been determined for the fan and it is given in the fan plate. Make sure that the maximum frequency is not exceeded by the frequency converter. Installation and operation instructions of component manufacturers must be followed. If there are contradictions between the instructions of a manufacturer and this manual, the instructions of a manufacturer must be followed. Position of motor circuit plates must be checked in the connection instructions of motor. Fig 1. The plug of reset screw in the air flow meter Screened cable EMC sleeve If there are no separate concentric braiding earth conductor, the protective sheath is braided and marked with a yellow-green tape or boot and it is connected to the earthing coupling of motor. Electric conductor Protective sheath of cable Cover of electric cable is skimmed 15 mm without hurting protective sheath. Cover of cable 44 Fig 2. The measuring pipe q-dysa in the fan FFTK An electric motor is operated and maintained according to the manufacturer s instructions. Check the motor connection in the link box and/or in the type plate of motor. The electric motor is connected in the electrical network through a shielded connector and it is equipped with a service switch. The motor and frequency converter of the fan are connected with an uniform, screened cable (EMC). The EMC approved inlet sleeve is used for the motor and connecting box. In every inlet, the protective sheath of cable must have a grounding of 360 through EMS sleeve. Make sure that EMC sleeve gets tightly around the cable. The service switch (accessory) between the frequency converter and motor must have EMC Approval and installed according to EMC specifications.

45 Order code: centrifugal fan FFTK - a - b - c - d - e - f - g h - i a) Size b) Handedness R / L c) Fan size 1, 2, 3 d) Fan AF, AB, BB e) Surface treatment 1=hot galvanized, 6=Fe/epoxy f) Drive 31=V-belt g) Outlet position 1=forward up, 2=forward down, 3=upward in front,4=upward in back, 5=downward in front, 6=downward in back, 7=sideward right up, 8=rightward left up h) Vibration damper 1=rubber, 2=spring i) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Accessories drive guard water drain (Future Clean construction) lamp hinge for access door flow equalizer protective guard, outlet protective guard, inlet air flow meter frequency converter service switch spare belt window duct connection flange of outlet for slip joint connection flange of unit size for slip joint base plate of stainless steel Outlet positions

46 Malfunctions and possible causes Damage or fault 1. Broken belt 2. Soft, stretching area in a belt 3. Belt/belts turn in the grooves 4. Drive makes noise or vibrates 5. Belt sides wear fast 6. Belt sides are scratched or slightly torn 7. Belt sides are soft, there is burnt rubber in the grooves 8. Belt sides are torn and cracked 9. Outer surface is scratched and torn 10. All belt surfaces are sticky and lumpy, there is rubber stuck on belt and pulleys 11. Hard belt surface, cracks on the underside Malfunction - Cause/measures Loose belts - Replace and tighten according to instructions Belts at different depths in the grooves, worn pulleys - Replace belts and pulleys Belt forced in the groove - Install new belts according to instructions Hard particles in grooves - Check guards, replace belts Belts unequally tensioned - Follow the instructions Belts of different lengths - Check product codes, replace belts Cracks or flaws in grooves - Replace belts and pulleys Belt touches fixed structures - Check belt condition, replace according to instructions Dust in the drive - Check guards, replace belts and pulleys Drive dimensioned too small - Re-dimension drive Pulley too small - Re-dimension drive - Replace belts and pulleys Short belt, high speed - Check alternative profiles, re-dimension drive Belts tightened during drive standstill - Loosen belts if the drive is out of operation more than 2 months Lubricant or fuel on belts, waxed belts - Clean drive, repair leaks - Replace belts Belts stored in sunshine - Store belts according to instructions Damage, fault

47 Alignment of belts 1. Shafts are not parallel. View from the end 2. Shafts are not parallel even though they seem to be when viewed from above. Align the pulleys by placing a steel ruler against the sides and moving the motor as necessary. Incorrect positions and correct alignment are shown in the figures beside. Storage of V-belts Do not roll up the belts. Keep them dry and away from sunshine. Make sure the belts cannot come into contact with hot surfaces. Tightening of V-belts The belt tension can be adjusted by moving the motor. To move the motor, turn the adjusting screw of the motor mounting plate, or loosen the fixing screws of the motor and turn the adjusting screws of the motor bracket. Make sure that the pulleys keep aligned and the shafts parallel. When the correct belt tension is reached, tighten the fixing screws of the motor. Check the belt tension as follows: 1. Measure the belt span (= unsupported length). 2. Determine the amount of perpendicular bending power that is required for a deflection of 10 mm per span metre. 3. Compare the measured bending power to the values given in the table below. If the measured bending power falls between the set limits, the belt tension is satisfactory. If the measured power is below the lower value, the belt is too slack. The belts of a new drive should always be tightened to the higher value because they stretch during running in. Table 1 Tensioning Power required for a deflection of 10 mm per span metre 3.Shafts are parallel but the pulleys are not aligned Belt profile Diameter of smaller pulley(mm) Newton (N) Kilopond (kp) XPZ XPA XPB/ 5VX Teräsviivain Steel ruler For Gates belts, other belt brands according to the manufacturer s instructions. Belt tension gauge 4. Correct installation: shafts parallel and pulleys aligned. Deflection (mm) Power (kp) 47

48 Belt span Voima Kraft Power Deviation 10 mm per span meter of belt Dismantling Loosen the belts by moving the motor towards the fan. To move the motor, open the fixing screws of the motor and turn the tightening screws, or use the adjusting screw of the motor mounting plate. Lift the belts from the pulleys. Clean the pulleys. Remove the screws, and turn one or two of them, depending on the sleeve type, into the extraction holes, see picture below. The thread is in the conical sleeve. Tighten the screws evenly until the sleeve comes off the hub. Remove the drive from the shaft. Mounting Remove protective grease from the sleeve and the hub. Place the sleeve on the hub, and align the holes. Grease the fixing screws and turn them lightly in place, see picture below. The thread is in the hub. Clean the shaft. Mount the pulley and the sleeve on the shaft. T sleeve locks first, then the pulley can still be moved a little towards the sleeve. Tighten the screws properly with a key. Tap the sleeve lightly with a drift, and tighten the screws again. Repeat this a couple of times to make sure that the sleeve is firmly fixed. Fill the extraction holes for example with grease to protect from dirt. Remove grease from the pulleys, and check the grooves for rust. Adjust the distance between the shafts so that the belts can be installed in the grooves without using force. Make sure that the pulleys are aligned and the shafts parallel. Place the belts in the grooves, and tighten the drive. 48

49 Fan bearings Maintenance In most cases, any flaws in the bearings can be detected by listening. When the bearings are normal, they generate a smooth and uniform sound. Loud and squeaking noises or other abnormal sounds imply that the bearings are worn out. If an electronic stethoscope is used, the abnormal sounds can be detected and even the defective part can be located. A squeaking noise may be caused by insufficient lubrication. Too small a bearing clearance can cause a metallic noise. Dents on the outer race of the bearing can cause vibration which in turn causes a smooth and clear sound. Intermittent sound implies a damage in the rolling element. Noise is generated every time the damaged area comes into contact with the rolling surface. High bearing temperatures are usually a sign of that the bearings are not running normally. Too high temperatures are harmful to the grease and the bearing. Long-term operation at temperatures above 120 C can shorten the lifetime of a bearing. A high bearing temperature may be due to insufficient or excessive lubrication, impurities in the grease, overloading, bearing damage or too small a bearing clearance. Even a slight temperature change can be a sign of impaired operation if the operating conditions have not changed. First lubrication as well as further lubrications normally cause a rise in bearing temperatures lasting one or two days. Check the grease. A change of colour or darkening is usually a sign of impurities in the grease. Larger grains of impurities can be detected by rubbing the grease between your fingers. Check also the gaskets (V-rings, for example) and replace them when needed. Bearing lubrication Sealed lubrication (Y and KH) The bearings with sealed lubrication have been factorylubricated for their entire life ( h). Highquality gaskets in the bearing prevent lubricant from leaking out. The maintenance of this type of bearings consists of cleaning the external surfaces and inspections from time to time. If any abnormal operation or defective gaskets are detected, the bearings must to be replaced. Use proper tools to prevent blows on the balls or rollers of the bearing. Blows cause dents on the rolling surfaces. Even the slightest dents can cause scratchy noises and premature ageing. Re-lubrication, Y bearings (YJ) The bearings have been lubricated at the factory. The ordinary lubrication interval is 6 months. The amount of lubricant to be used is specified in table 2.1. It is not possible to replace the lubricant without breaking the highly efficient gaskets of the bearing. If the bearing gets damaged, it is advisable to replace the entire bearing housing and the bearings. Plummer block bearings (PL) Relubrication The plummer block bearings of a fan running 8 hours a day should be lubricated once a year. If the fan is operating around the clock, the bearings should be lubricated twice a year. Relubrication is carried out while the fan is operating. If the bearings are lubricated during downtime, the fan must be operated in order to distribute the lubricant uniformly in the bearing. The amount of lubricant required for relubrication is as follows: 0,005 x bearing outer diameter x bearing width (mm). Please note that an excessive amount of lubricant can cause a temperature peak in the bearing which may destroy the lubrication properties of the lubricant and lead to bearing damage. Lubrication must be stopped when lubricant starts to seep out of the bearing. Change of lubricant The lubricant should be changed when the bearing has been relubricated a few times, or if the lubricant has caked, darkened or faded (compared to the original color). 1. Clean the outside of the bearing housing. Remove the bearing cover of the bearing housing. 2. Remove all of the old lubricant. Wash the bearing with white spirit or paraffin. Petrol may also be used but bear in mind the inflammability. Check the bearing after cleaning. If even a slightest flaw is discovered, the bearing must be replaced. The bearing should also be oiled because bearings rust easily if the installation is delayed. 3. Spread new lubricant on the rolling elements by hand or with, for example, a plastic smoothing tool. Fill the empty space in the bottom part of the bearing housing halfway with new lubricant. Do not overfill. An excessive amount of lubricant may lead to overheating of bearing. 4. Fit the cover of bearing housing in place. For more detailed instructions, see Mounting the plummer block bearing. 5. Test! Check the bearing, for example, by placing the tip of a screwdriver against the bearing housing and the handle against your ear. The bearing is running properly if you hear a weak humming sound. A whistling sound indicates inadequate lubrication. 49

50 Table 2.1 Amounf of lubricant in re-lubrication (g) Fan size Impeller BB BB BB BB BB BB BB BB BB g Table 2.2 Intervals of relubrication Temperature ( C ) Cleanliness Interval of relubrication 50 clean 8-15 months 70 clean 3-8 months 100 clean 3 weeks - 3 months over 100 clean 1 week - 2 weeks Recommended lubricants Use high-quality bearing greases only, such as: Normal operating conditions ( C): - SKF Alfalub LGMT 2 - Mobilux 2 - Shell Alvania R2 - Esso Beacon 2 Use protective gloves when possible. Regular exposure to paraffin or similar products may cause allergic responses. 50

51 Bearings and replacements Bearing types and designs Impeller Fan size AF Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y YJ YJ AB Y Y Y Y Y Y Y Y Y Y Y YJ YJ YJ BB KH KH KH KH PL PL PL PL PL PL PL PL PL Y = Sealed lubrication: Bearing Y 1. Bearing 2. Eccentric locking ring 3. Clamping screw 4. Rubber damper of bearing YJ = Sealed lubrication: Bearing Y 1. Bearing housing 2. Grease nipple 3. Eccentric locking ring 4. Clamping screw KH = Sealed lubrication, Bearing with conical sleeve 1. Bearing 2. Adapter sleeve 3. Lock washer 4. Locking nut 5. Rubber damper of bearing PL = Relubrication, Plummer block bearing 1. Bearing housing (SNL... ): base and cover 2. Spherical roller bearing 3. Adapter sleeve 4. Lock washer 5. Locking nut 6. Gasket set 7. Guide ring (only one bearing housing with guide) 8. Grease nipple 51

52 Replacement of bearings Dismantling of bearing Y Step 1 Open the clamping screw with an Allen screw. Mounting of bearing Y Step 1 Wipe the inner surface of the bearing to remove the protective agent. Put the bearing into the bearing damper. Step 2 Unscrew the eccentric locking ring by turning it in the direction opposite to the rotation direction. Measure and mark the position of the bearing on the shaft: x = mm Support the shaft with, for example, a rope or a cable tie. Attach one end to the shaft between the bearing bracket and the impeller and the other end with a bolt to the fixing hole of the fan or of the bearing bracket. Remove the support arms from the side plate. X Step 3 Detach the support arms of each other. The bearing is glued to the shaft. Use an extractor tool to remove the bearing from the shaft. Attach the claws of the extractor tool to the inner ring of the bearing. You can also remove the bearing by tapping the inner ring of the bearing with a hammer. Step 4 Replace both the bearing and the bearing damper. Step 2 Mount the support arms on the bearing and the bearing damper. Step 3 Clean the shaft carefully. Apply glue (Loctite 603) on the shaft. Mount the bearing bracket with the bearings on the shaft at the position marked. Fix the support arms to the side plate. Step 4 Mount the eccentric locking ring to the inner ring of the bearing. Turn the ring firmly by hand in the direction of rotation until it locks. Step 5 Tighten the clamping screw of the locking ring with the Allen screw. If you can measure the torque, do not exceed the value specified in table 2.3. Excessive torque can cause cracking of the inner ring of the bearing. Step 6 The bearing is now mounted. Swing the impeller and perform the final inspection. Table 2.3 Tightening torque of the clamping screw Fan size 022/025/028/ /040/045/ /063/071 Impeller AF AB AF AB AF AB M (Nm)

53 Dismantling of bearing with conical sleeve KH Step 1 Release the lock washer tab. Open the nut of the bearing with a spanner wrench. Step 2 Mount the support arms on the rubber damper so that that the larger end of the inner ring of the bearing will face the cone of the adapter sleeve. Step 2 Remove the nut and the lock washer. Measure and mark the position of the bearing on the shaft: x= mm. Support the shaft with, for example, a rope or a cable tie. Attach one end to the shaft between the bearing bracket and the impeller and the other end with a bolt to the fixing hole of the fan or of the bearing bracket. Push the conical sleeve out of the bearing. Step 3 Lubricate the threads of the adapter sleeve and of the bearing nut with molybdenum disulphide compound or similar lubricant. Slide the sleeve onto the shaft. If necessary, use a screwdriver to open the sleeve so that it can slide more smoothly along the shaft. Step 4 Slide the bearing bracket with bearings onto the shaft and push the sleeve into the bearing. If needed, draw the sleeve with a nut into the bearing. Fix the support arms in the side plate. Step 3 Remove the support arms from the casing. Slide the bearing set off along the shaft Slide the sleeve off along the shaft. If necessary, use a screwdriver to open the sleeve so that it can slide more smoothly along the shaft. Detach the support arms. Detach the rubber damper and the bearing from each other. Mounting of bearing with conical sleeve Step 1 Wipe the adapter sleeve and the inner surface of the bearing to remove the protective agent. Apply a thin coating of mineral oil on the casing surface of the sleeve. Put the bearing into the bearing damper. Step 5 Centre the bearings on the shaf acoording to marks. Mount the lock washer and turn the lock nut in place by hand. The skew side of the nut must be against the bearing. Step 6 Turn the nut with a spanner wrench by the torque M [Nm] given in the table 2.4. Lock the nut by turning one of the lock washer tabs into the slot of the nut. Do not, however, loosen the nut to make the tab match the slot. Table 2.4 Tightening torque M of the adapter sleeve Fan size Impeller BB BB BB BB M (Nm)

54 . Dismantling of plummer block bearing (PL) Step 1 Clean carefully the outer surfaces of the bearing housing before starting the work. Mounting of plummer block bearing Step 1 Mount the bearing housing (SNL...)so that the grease nipple faces the fan impeller. The lubricant must move during the bearing, away from the impeller. Clean the dust and dirt off the inside of the bearing housing. Step 2 Open the bolts of the bearing housing cover and lift it off. Measure and mark the position of the bearing on the shaft, x= mm, so that you can mount the bearing at exactly the same place. Step 2 Mounting of gasket set (TSN 5...G) Cut a 90 slit in one of the four gasket halves. Mount the cut gasket in the lower part of the bearing housing, on the opposite side to the grease nipple. This is to make sure that excessive grease can seep out of the bearing housing. Step 3 Release the lock washer tab. Step 4 Loosen the locking nut with a spanner wrench. Step 3 Mount the bearing housing base loosely on the bearing bracket so that it can still move. Mount the gasket halves in the slots of the housing, and fill the slots with grease (SKF Grease LGMT2). Step 5 Lift the shaft out of the bearing housing. Step 6 Remove the locking nut, locking washer and the bearing from the shaft. Step 4 Wipe the adapter sleeve (H3.../VZ425) and the inner hole of the bearing ( CCK/C3W33) to remove the protective agent. Apply a thin coating of mineral oil on the inner surface of the sleeve. Lubricate the threads of the adapter sleeve and bearing nut with molybdenum disulphide compound or similar lubricant. Slide the adapter sleeve onto the shaft. If necessary, use a screwdriver to open the sleeve so that it can slide more smoothly along the shaft. 54

55 Mount the bearing on the adapter sleeve. Push the larger end of the inner ring of the bearing onto the cone of the sleeve. When the bearing locks to the adapter sleeve, push the bearing and the sleeve to the right position on the shaft. Step 7 Lock the nut by turning one of the lock washer tabs into the slot of the nut. Do not, however, loosen the nut to make the tab match the slot. A slight extra tightening is allowed. Step 5 After having lubricated the side of the nut that faces the bearing, put the lock washer and the lock nut in place with the skew side of the nut against the bearing. Fill the bearing with grease (SKF Grease LGMT2). The bearing must be full of grease. Place the shaft with the bearings into the bearing housing. If the bearing is a guide bearing, slide the guide rings (FRB..., 2 pcs) into the bearing housing base. The guide bearing is mounted on the drive side of the fan. If the position of the drive is not known, mount the guide bearing on the right-hand side of the fan. Step 6 Tighten the lock nut to the right torque (table 2.5) with a spanner wrench to apply the right bearing clearance. Step 8 Fill 30% of the bearing housing volume with grease (SKF Grease LGMT2). Table 2.6 Amount of grease in bearing housing Fan size Impeller Bearing housing Amount of grease (g) 056 BB SNL BB SNL BB SNL BB SNL BB SNL BB SNL BB SNL BB SNL BB SNL Fix the bearing cover and bolts. Tightening torque of bolts is given in the table 2.7. Table 2.7 Tightening torque M of bearing cover and bolts Fan size 056/063/ /090/100/ Impeller BB BB BB BB M (Nm) Table 2.5 Tightening torque M of adapter sleeve Fan size 056/063/ /090/ /125/140 Impeller BB BB BB M (Nm)

56 Step 9 When both bearings have been mounted, tighten the bolts that fasten the bearing housing to the bearing brackets. Dismantling of relubricatable bearing Y Step 1 Before starting the work, support the shaft carefully by means of lifting bands, a rope or a lifting tackle. Attach one end to the shaft between the bearing bracket and the impeller. Note! The weight of impeller is kg depending on the size. Table 2.8 Tightening torque M of locking bolts to bearing brackets Fan Size Step 2 Open the clamping screw with an Allen key. 056/063/ / / Impeller BB BB BB BB BB M (Nm) Step 3 Unscrew the eccentric clamping ring by turning it in the opposite direction of the rotation of fan. Measure and mark the position of the bearing on the shaft: x = mm. x Step 4 Remove the fastening bolts of the bearing, and suspend the shaft on a lifting band. Tighten the band, if necessary, so that the impeller does not touch the inlet cone. The bearing is glued to the shaft. Use an extraction tool to remove the bearing from the shaft. Attach the claws of the extraction tool to the inner ring of the bearing. You can also remove the bearing by tapping the inner ring of the bearing with a hammer. Step 5 Replace the bearing housing. 56

57 Mounting of relubricatable bearing Y Step 1 Wipe the inner surface of the bearing to remove the protective agent. Apply glue (Loctite 603) on the area of the shaft where the bearing is to be mounted. The glue makes the joint tight and prevents corrosion. Push the bearing to the position marked on the shaft. Impeller Remove of impeller (sizes ) Step 1 Measure and mark the position of the bearings on the shaft, x = mm, so that you can mount the impeller at exactly the same place. Support the shaft at both sides with, for example, a rope or a cable tie. Attach one end to the shaft between the bearing bracket and the impeller and the other end with a bolt to the fixing hole of the fan or the bearing bracket. Glue Step 2 Fix the fastening bolts of the bearing. Step 3 Mount the eccentric clamping ring in the inner ring of the bearing and turn firmly it by hand in the direction of rotation to lock the ring. Step 2 Remove the bearing brackets with bearings (see the chapter: Replacement of bearings). Step 3 Carefully place the impeller on the bottom of the fan casing. Remove also the clapper from the outlet. Step 4 Tighten the clamping screw of the locking ring with an Allen key. If you can measure the torque do not exceed the value given in table Excessive torque can cause cracking of the inner ring of the bearing. Table 2.9 Tightening torque M of clamping screw Fan size Impeller AF AB AF AB AB M(Nm) Step 4 Measure and mark the position of the impeller on the shaft. Unscrew the clamping screw(s) of hub and pull the shaft off. Step 5 The bearing is now mounted. Swing the impeller and perform the final inspection. 57

58 Step 5 Remove the shaft through the inlet and the impeller through the outlet. Step 4 Centre the impeller in the middle of the casing. Tighten the clamping screw(s) of the hub with an Allen key, see the table below. Mount the clapper. = = Mounting of impeller Step 1 Put the impeller inside the fan casing through the outlet. Table 5.9 Tightening torque M of clamping screw of hub Step 2 Place the key on the shaft. The keyways in the fans AB and BB are eccentric. Place the shorter end of the shaft towards the hub. Fan size 022/025/028/ /040/045/ Impeller B AB BB AB BB M(Nm) Fan size 063/ / Impeller AB BB AF AB BB AB BB M(Nm) Step 3 Mount the inlet cones (of fans AB and BB) so that their rear edges are settled inside the impeller. Push the ready bearing bracket with the bearings onto the shaft. Screw the fastening screws of the support arms into the side plate. Fix the bearings onto the shaft (see the chapter Replacement of bearings). 58

59 Remove of impeller (sizes Step 1 Measure and mark the position of the bearings on the shaft, x = mm, so that you can mount the impeller at exactly the same place. Support the shaft at both sides with, for example, a band or a rope. Attach one end to the shaft between the bearing bracket and the impeller and the other end to an auxiliary support. Step 2 Remove and dismantle first the bearing unit on the service side. On the opposite side you can only remove the bolts of the bearing housing. Step 3 Remove the bearing bracket and the inlet cone screws. Step 4 Place the impeller on the bottom of the fan casing. Step 5 Lift the impeller out of the casing together with the shaft. Mounting of impeller (sizes ) Step 1 Sizes Place the key on the shaft. Push the shaft to the marked position through the hub. Sizes Remove grease from the contact surfaces of the shaft and the hub and from the adapter sleeve. Apply a thin coating of Loctite 603 on the contact surfaces. Push the shaft to the marked position through the hub. Let the glue harden at a temperature of C for about 2 hours before starting the fan. Other temperatures and times may leave the joint loose. Step 2 Lift the impeller into the casing with the inlet cone Step 3 Lift the impeller to the correct height. Fix the support arms in place. Mount the bearing (see the instructions for mounting). Step 4 Mount the inlet cone. Step 6 Measure and mark the position of the impeller on the shaft. Sizes Unscrew the clamping screw(s) of the hub and pull out the shaft. Sizes Warm the hub to a temperature of C to melt the glue in the joints. Pull the shaft out. Step 5 Tighten the clamping screw(s) of the hub (sizes ) with an Allen key. See the tightening torques in the table 2.9 on page 17. Swing the impeller and make sure that the inlet cone has been correctly centred. 59

60 Mountig of impellers LB and HB and inlet cone Centre the impeller and the inlet cone. Dimensions S and T must keep constant all the way. Swing the impeller to make sure that the inlet cone has been correctly centred. Rotation direction of impeller LF Rotation direction of impellers LB and HB Final inspection Finally, make sure that the rotation direction of the impeller is right all the clamping nuts and screws are tight there are not loose objects inside the fan casing. See also chapter 3 of the manual! Trouble shooting Pressure and volume flow are too small Check the direction and speed of rotation Near the outlet, there might be a curve in the duct causing bigger pressure loss than expected -> check the duct system and use a baffle plate Fan vibrates Check the vibration damper Make sure that the impeller is clean Check the bearings Check the alignment of pulleys Check the clamping of bearings, hub and pulleys Bearings make noise See the chapter Monitoring of bearing condition Continual bearing damages Oversize load (too tight belts) Bad or unsufficient lubrication Impurities get into bearings 60

61 Spare parts Centrifugal fan, bearings Fan sizes specified by types AF and AFK Fan size 1 Shaft. d Bearing 2 Shaft d Bearing 3 Shaft d Bearing RS RS YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET YET NP55DECQ30HF RR AR3P5 NP55DECQ30HF RR AR3P NP55DECQ30HF RR AR3P5 NP60DECQ30HF RR AR3P5 NP60DECQ30HF RR AR3P YET YET NP55DECQ30HF RR AR3P5 NP60DECQ30HF RR AR3P5 NP60DECQ30HF RR AR3P NP60DECQ30HF RR AR3P NP55DECQ30HF RR AR3P5 NP60DECQ30HF RR AR3P5 61

62 Centrifugal fan, bearings Fan sizes specified by types Fan size Shaft d Bearing 2 AB, ABS, ABK Shaft d Bearing 3 Shaft d Bearing 0605 O22 20 YET 204 O25 20 YET O22 20 YET 204 O25 20 YET 204 O28 25 YET O28 25 YET 205 O31 25 YET 205 O35 30 YET O31 25 YET 205 O35 30 YET 206 O40 30 YET O31 25 YET 205 O35 30 YET O35 30 YET 206 O40 30 YET 206 O45 35 YET O35 30 YET 206 O40 30 YET 206 O45 35 YET O35 30 YET 206 O40 30 YET 206 O45 35 YET O40 30 YET 206 O45 35 YET 207 O50 35 YET O40 30 YET 206 O45 35 YET 207 O50 35 YET O45 35 YET 207 O50 35 YET 207 O56 40 YET O50 35 YET 207 O56 40 YET 208 O63 45 YET O45 35 YET 207 O50 35 YET O50 35 YET 207 O56 40 YET O50 35 YET 207 O56 40 YET 208 O63 45 YET O56 40 YET 208 O63 45 YET 209 O71 45 YET O63 45 YET 209 O71 45 YET 209 O O56 40 YET 208 O63 45 YET O63 45 YET 209 O71 45 YET 209 NP55DECQ30HF RR AR3P O71 45 YET 209 O80 55 NP55DECQ30HF RR AR3P5 O90 60 NP60DECQ30HF RR AR3P O80 55 NP55DECQ30HF RR AR3P5 O90 60 NP60DECQ30HF RR AR3P NP65DECQ30HF RR AR3P O80 55 NP55DECQ30HF RR AR3P5 O90 60 NP60DECQ30HF RR AR3P NP65DECQ30HF RR AR3P O63 45 YET 209 O71 45 YET O80 55 NP55DECQ30HF RR AR3P5 O90 60 NP60DECQ30HF RR AR3P O90 60 NP60DECQ30HF RR AR3P NP65DECQ30HF RR AR3P O90 60 NP60DECQ30HF RR AR3P NP65DECQ30HF RR AR3P NP65DECQ30HF RR AR3P5 62

63 Centrifugal fan, bearings Fan sizes specified by types Fan size BB, BBS, BBK 1 Shaft d Bearing Housing Gasket 2 pcs Guide ring 1208 O RS1K 1209 O RS1K 1210 O RS1K 1212 O40 30/ RS1K 1509 O40 30/ RS1K 1512 O45 35/ RS1K 1515 O50 35/ RS1K 1809 O45 35/ RS1K 1810 O50 35/ RS1K 1812 O50 35/ RS1K Adapter sleeve 1815 O56 40/ CCK/C3W33 SNL-509N TSN509G FRB3.5/85 H309vz O63 45/ CCK/C3W33 SNL510 TSN510G FRB9/90 H310vz O56 40/ CCK/C3W33 SNL-509N TSN509G FRB3.5/85 H309vz O63 45/ CCK/C3W33 SNL510 TSN510G FRB9/90 H310vz O71 45/ CCK/C3W33 SNL510 TSN510G FRB9/90 H310vz O CCK/C3W33 SNL TSN513G FRB10/120 H O CCK/C3W33 SNL TSN513G FRB10/120 H O63 45/ CCK/C3W33 SNL510 TSN510G FRB9/90 H310vz O CCK/C3W33 SNL TSN513G FRB10/120 H O EK/C3 SNL TSN515G FRB12.5/130 H O EK/C3 SNL TSN515G FRB12.5/130 H EK/C3 SNL TSN516G FRB16/140 H EK/C3 SNL TSN516G FRB12.5/140 H EK/C3 SNL TSN518G FRB12.5/160 H318 63

64 Centrifugal fan, bearings Fan sizes specified by types Fan size BB, BBS, BBK 2 Shaft d Bearing Housing Gasket 2 pcs Guide ring 0909 O RS1K 1206 O RS1K 1208 O40 30/ RS1K 1209 O40 30/ RS1K 1210 O40 30/ RS1K 1212 O45 35/ RS1K 1509 O45 35/ RS1K 1512 O50 35/ RS1K Adapter sleeve 1515 O56 40/ CCK/C3W33 SNL-509N TSN509G FRB3.5/85 H309vz O50 35/ RS1K 1810 O56 40/ CCK/C3W33 SNL-509N TSN509G FRB3.5/85 H309vz O56 40/ CCK/C3W33 SNL-509N TSN509G FRB3.5/85 H309vz O63 45/ CCK/C3W33 SNL510 TSN510G FRB9/90 H310vz O71 45/ CCK/C3W33 SNL510 TSN510G FRB9/90 H310vz O63 45/ CCK/C3W33 SNL510 TSN510G FRB9/90 H310vz O71 45/ CCK/C3W33 SNL510 TSN510G FRB9/90 H310vz O CCK/C3W33 SNL TSN513G FRB10/120 H O EK/C3 SNL TSN515G FRB12.5/130 H O EK/C3 SNL TSN515G FRB12.5/130 H O71 45/ CCK/C3W33 SNL510 TSN510G FRB9/90 H310vz O EK/C3 SNL TSN515G FRB12.5/130 H EK/C3 SNL TSN516G FRB16/140 H EK/C3 SNL TSN516G FRB16/140 H EK/C3 SNL TSN516G FRB12.5/140 H EK/C3 SNL TSN518G FRB12.5/160 H EK/C3 SNL TSN520G FRB12/180 H320 64

65 Centrifugal fan, bearings Fan sizes specified by types BB, BBS and BBK Fan size 3 Shaft d Bearing Housing Gasket 2 pcs Guide ring Adapter sleeve O RS1K 0909 O40 30/ RS1K O45 35/ RS1K 1209 O45 35/ RS1K 1210 O45 35/ RS1K 1212 O50 35/ RS1K 1509 O50 35/ RS1K 1512 O56 40/ CCK/C3W33 SNL-509N TSN509G FRB3.5/85 H309vz O63 45/ CCK/C3W33 SNL510 TSN510G FRB9/90 H310vz O63 45/ CCK/C3W33 SNL510 TSN510G FRB9/90 H310vz O71 45/ CCK/C3W33 SNL510 TSN510G FRB9/90 H310vz O CCK/C3W33 SNL TSN513G FRB10/120 H O EK/C3 SNL TSN515G FRB12.5/130 H EK/C3 SNL TSN516G FRB16/140 H EK/C3 SNL TSN516G FRB16/140 H EK/C3 SNL TSN516G FRB12.5/140 H

66 Fan section, mixed-flow fan FFTS Sizes Flow rate m 3 /s Instructions for design The fan section FFTS has a practically service-free mixed-flow fan. The fan performance testing has been carried out according to the standards ISO 5801 and or DIN Part 2. Future Clean conforms to the requirements of the standards VDI 6022 and DIN This section must always be mounted horizontally. If a section other than FTTT, FTTK, or FVTK version 4 or 5 is installed on the outlet side of a fan section, flow equalization must be ensured by using a flow equalizer FVZT and an inspection section FTTT with a length of at least 300 mm (sizes ) 450 mm (sizes ) 600 mm (sizes ) 800 mm (sizes ) 1000 mm (sizes ) 1200 mm (sizes ) Construction The fan section FFTS consists of a thermally insulated casing, and a mixed-flow fan with one inlet and a fan with backward curved blades. The impeller is mounted directly on the motor shaft. The fan and the motor are mounted on the same base frame on vibration dampers. The fan discharges freely to the section casing. Vibration dampers are selectable either rubber or spring dampers. The inlet of fan is connected to the section casing with a rubber seal or a flexible joint. The motor conforms to the standard IEC and the protection class is IP 54. To ensure sufficient cooling of the motor, the air temperature must not exceed +40 C. If the temperature rises over, the lifetime of motor shortens. The fan section has an access door and it is equipped with a measuring unit outside the casing. Fan section must be equipped with a service switch to stop the operation for maintenance work. 66

67 Fan Fan SB is a centrifugal fan with backward curved blades. The maximum efficiency is high, even 75%. The fan curve is sharp which means that the effect of the air flow rate is quite constant regardless of pressure fluctuations. The maximum pressure rise is 2500Pa. Fan selection If the operating point is near the upper limit of the operating range, it is advisable to choose a bigger fan to compensate for any deviations from the pressure drop calculations and to increase later the air flow rate or pressure if necessary. Motor size selection The fan power P A (kw) given by the Future dimensioning program is the shaft input of the fan. The Future dimensioning program chooses the motor according to shaft input and confidence coefficient of the motor. If a frequency converter is used (recommendation), the motor and the converter must be compatible and they must be dimensioned according to the manufacturers instructions. Flow rate control Motor speed control by means of a frequency converter is a suitable flow rate control method for fans of all sizes. Frequency converter control The fan (motor) rotation speed is varied by means of a frequency converter. As long as the plant curve keeps constant, the air volume flow changes in proportion to the speed of rotation. The pressure changes in proportion of the rotation speed change to second power and in proportion of power change to third power. If the plant curve changes, the volume flow and the pressure loss must be determined at some operating point.if the plant curve changes, the volume flow and the pressure loss must be determined at some operating point. Note! Frequency of the operation point of fan can exceed 50 Hz. Maximum frequency of the fans is given in the fan plate. Safety Before switching on the fan, make sure that the inlet and the outlet of the fan section have been connected to the ductwork or that the access to the rotating parts of the fan, such as the impeller, through inlet, outlet or access door has been prevented with protective screens or in some other way. The service switch of the air handling unit must be installed and functioning and the access doors must be shut when the unit is switched on. The damper section of the unit must open before the fan starts. Do not open the access doors when the fan is in operation. If the unit is installed in a place where it is easily accessible also to other people than service personnel, the handles of access doors must be removed and locked in a safe place. Safety equipment Service/switch (not included) installed in the fan section serves also as an unit emergency switch. Fire In case of fire in the unit, use e.g. a powder extinguisher, do not use water. The materials used in the unit do not produce harmful amounts of any hazardous gases when burning. 67

68 Commissioning Make sure that there are no loose particles that may get into the impeller. Make sure that the flexible joint and the vibration dampers are undamaged and that the fan and motor are laying on the vibration dampers only and that they move freely when moving by hand. Make sure that the electrical cables are undamaged, led flexibly to the motor and that the cable type is right. Check that the drive and fan operate freely by moving the impeller a couple of turns by hand. Start the fan for a while to see that the rotation direction is according to the arrow marked on the fan. Note! Be extremely careful and make sure that there are no people or loose objects near the fan. All the filters, grilles, valves and other parts of the air conditioning plant have to be installed and preset before a long-term operation. The fan must not be started when inlet and outlet dampers are closed. Clean the fan casing and impeller with a brush, vacuum cleaner or damp cloth. The casing can be gently washed with water if the unit is equipped with drainage for washing water. Glance through that the motor is undamaged. Make sure that the seals of access doors are in place and undamaged. Close the access doors and make sure that every latch is tight. If the unit is installed in a place where it is easily accessible also to other people than service personnel, the handles of access doors must be removed and locked in a safe place. Maintenance Make sure that there are no loose particles that may get into the impeller. Make sure that the flexible joint and the vibration dampers are undamaged and that the fan and motor are laying on the vibration dampers only and that they move freely when moving by hand. Make sure that the electrical cables are undamaged, led flexibly to the motor and that the cable type is right. Check that the drive and fan operate freely by moving the impeller a couple of turns by hand. All the filters, grilles, valves and other parts of the air conditioning plant have to be installed and preset before a long-term operation. The fan must not be started when inlet and outlet dampers are closed. Clean the fan casing and impeller with a brush, vacuum cleaner of a damp cloth. The casing can be gently washed with water if the unit is equipped with drainage for washing water. Glance through that the motor is undamaged. Start the fan for a while to see that the rotation direction is according to the arrow marked on the fan. Note! Be extremely careful and make sure that there are no people or loose objects near the fan. Make sure that the seals of access doors are undamaged and in place. Replace if needed. Close the access doors and make sure that every handle is tight. If the unit is installed in a place where it is easily accessible also to other people than service personnel, the handles of access doors must be removed and locked in a safe place.. The fan casing is pressurized, make sure that the fan stops before opening the access door. The regular maintenance can be scheduled to the beginning and end of the heating season. It is advisable to monitor the operation of the fan and particularly the drive between the regular maintenances. 68

69 Safety equipment Service/safety switch installed in the fan section serves also as an unit emergency switch. (Compulsory, not included). If the air flow meter does not display right, check the following points: The hoses are in place and undamaged. The hoses are not flattened. There are no blockages in the hoses or pressurized joints. The air flow meter has been reset and the plug of reset screw has been properly closed (see Figure 1). Check that the air flow meter scale is equivalent to the fan size. Check that the hoses have been connected right - from the inlet cone of impeller FFTS to -joint, from the pressure joint of the suction plate to +joint Connection of electric motor and frequency converter The incorrect connection of a frequency converter may damage the bearings of a motor. Only an authorized electrician is allowed to connections. Koja Ltd does not make good the motor damages caused by an incorrect connection if it is made by somebody else than an authorized person by Koja Ltd. A maximum frequency of rotation speed has been determined for the fan and it is given in the fanplate. Make sure that the maximum frequency is not exceeded by the frequency converter. Installation and operation instructions of component manufacturers must be followed. If there are contradictions between the instructions of a manufacturer and this manual, the instructions of a manufacturer must be followed. Position of motor circuit plates must be checked in the connection instructions of motor. Figure 1. Plug of reset screw in air flow meter If there are no separate concentric braiding earth conductor, the protective sheath is braided and marked with a yellow-green tape or boot and it is connected to the earthing coupling of motor. Screened cable EMC sleeve Electric conductor Protective sheath of cable Cover of electric cable is skimmed 15 mm without hurting protective sheath. Cover of cable An electric motor is operated and maintained according to the manufacturer s instructions. Check the motor connection in the link box and/or in the type plate of motor. The electric motor is connected in the electrical network through a shielded connector and it is equipped with a service switch. The motor and frequency converter of the fan are connected with an uniform, screened cable (EMC). The EMC approved inlet sleeve is used for the motor and connecting box. In every inlet, the protective sheath of cable must have a grounding of 360 through EMS sleeve. Make sure that EMC sleeve gets tightly around the cable. The service switch (accessory) between the frequency converter and motor must have EMC Approval and installed according to EMC specifications. 69

70 Order code: mixed-flow fan FFTS - a - b - c - d - e - f - g h i j - k a) Size b) Handedness R / L c) Fan size 1, 2 d) Fan SB e) Fan coating 1=zinc coated, 6=Fe/epoxy f) Drive 1=direct g) Air flow direction 2=forward, 3=up h) Vibration damper 1=rubber, 2=string i) Manufacturer j) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel k) Length of fan section 1=no safety distance, 2=min. safety distance, 3=incl. service space Air flow direction

71 Angle section, FTTK Sizes Flow rate m 3 /s Instructions for design The angle section FTTK is designed to be used when an air handling unit needs to have an angle because of, for example, the form of the available space. The air flow through the section turns at an angle of 90 and can be directed upwards, downwards or to one side. Construction The angle section FTTK consists of a thermally insulated casing. Order code: Angle section FTTK - a - b - c - d - e a) Size b) Handedness R / L c) Version 1=horizontal, 2=vertical d) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel e) Direction (Version 1: A=down, Y=up, Version 2: O=right, V=left) Accessories access door inspection window water drain lamp hinge connection flange of unit size for slip joint base plate of stainless steel safety latch Version 1 Version 2 71

72 Sound attenuator section, FVTK Sizes Flow rate m 3 /s Instructions for design The sound attenuator section FVTK, versions 1, 2Y and 2A are designed to be used for reducing noise in the inlet and outlet ducts and to be mounted in the AC room in connection with the air handling unit. The versions 2 and 3 of the section are angular attenuators with attenuator elements. The versions 2 and 3 of the section are angular attenuators with attenuator elements Versions 1, 2Y ja 2A must be mounted according to the given instructions so that the lamellas are in vertical position. This is to prevent the attenuator elements from gathering moisture and dirt on the surface. Elements are available in wet-cleanable material. The section can also be equipped with attenuator elements that can be pulled out of the section casing. If this section is installed immediately on the outlet side of the unit, it is necessary to use a flow equalizer FVZT and an inspection section FTTT. Construction The versions 1, 2A and 2Y of the sound attenuator section FVTV consist of thermally insulated casing and built-in attenuator elements. The elements are mm thick and made of mineral wool with fibreglass fabric on the surface. The frame is hot-galvanized or stainless steel. Commissioning The attenuator section FVTK is an absorption damper. The lamellas have to be in vertical position, see the figure. 72 Order code: Sound attenuator section FVTK - a - b - c - d - e - f a) Sizes b) Handedness R / L c) Version 1=direct, 2Y=angle upright up, 2A=angle upright down d) Length of attenuator element (only version 1) 600, 900, 1200, 1500, 1800 e) Cleaning of attenuator element 1=dry, 2=wet f) Type and material S=zinc coated, A2=stainless steel, CS=Future Clean (hygiene type) zinc coated, CA2=Future Clean (hygiene type) stainless steel Versions 1 2A 2Y Accessories access door 1=in front, 2=side, 3=up hinges for access door water drain safety handle connection flange of unit size