Installation instructions
Safety Instructions Operation of Air Handling units and accessories WARNING Installation may only be carried out by qualified personnel. Before taking the air handling unit into operation fit any unused connections with protective mesh. In addition, all electrotechnical and mechanical safety devices must be installed before taking the air handling unit into operation. Before opening the unit check that its power has been disconnected. Take care when opening the isolating valves for the hot water to the air heater. There is a risk of water hammer or steam discharge. When servicing or inspecting the unit, switch off the main circuit breaker before opening the inspection doors. Reset all safety devices before restarting. The clearance in front of electric heaters and electrical cabinets shall conform to applicable electrical safety regulations. Use the control panel to stop the unit. The unit's hatches are fitted with locking handles. Ensure that the unit is always left locked, and that the keys cannot be accessed by unauthorized persons. Do not open inspection hatches when the unit is in operation. Fläkt Woods 8216 GB 2014.05.15 2 Subject to change without notice
Description of the unit Component parts The unit can be supplied in left-hand or right-hand configurations. Refer to the order code in Technical data. Heat recovery unit RDTO-aaa-b-c-d-e Connection (b) 1 = supply air right 2 = supply air left 1. Supply air fan 2. Extract air fan 3. Supply air filter 4. Extract air filter 5. Rotary heat exchanger 6. EC motor 7. Termination blocks for electric power and sensors 8. Control equipment 9. Heat recovery drive motor 10. Post-heating coil 8 7 3 2 6 1 6 9 10 4 Components Left-hand configuration Fan The unit has two direct drive centrifugal fans. These fans are driven by EC motors. Rotary heat recovery unit The speed controlled rotor is fitted with a purge sector and rotation sensor. NOTE! The duct system and components must not weigh down the unit. Duct connection The unit has round duct connections with rubber seals. The distance between fan outlet/damper and air treatment components such as coils and silencers must fulfill the following: - Silencer, min 300mm - Cooling coil, min 600mm (must be mounted for a horizontal airflow) Technical data Electrical cabinet connection Right-hand configuration Size 030 050 Electrical cabinet connection* 3 x 400 V, 50 Hz Motor 0.37 kw 0.80 kw EC motor IP 54 Unit fuse protection 10 A 16 A *Can also be connected to 1x230 V for a unit with a water coil. Connect electric power to the unit through the junction box on the top of the unit. The unit is supplied with 3 x 400 V (or 1 x 230 V with a water coil). The power supply cable shall be provided with an external switch disconnector. Weight Size 030 = 170 kg Size 050 = 175 kg NOTE! The cooling coil must be mounted for a horizontal air flow Fläkt Woods 8216 GB 2014.05.15 3 Subject to change without notice
Transport and installation Transport Transport the unit using a fork lift truck, pallet truck or platform trolley. Erection The unit can be mounted directly onto the surface if this is flat and horizontal. Use adjustable feet to make level the unit, these are available as accessories RDTZ-03-030-1. Adjustable foot 15-85 mm. Space requirement, etc. Size A B C D 030 050 735 735 640 300 A = Unit width B = Filter replacement C = Inspection hatch D = Hatch for the control equipment Space requirements The space around the unit must be planned to take into account routine service work, such as replacing filters and cleaning the fan and casing. There should be a service aisle in front of the electrical cabinet with a width in accordance with applicable laws. The future replacement of the unit's components should also be taken into consideration. The planning of this work is a condition that must be fulfilled to make the CE marking of the installation possible. The unit must be positioned or arranged to facilitate the service of the electrical cabinet. Sound transmission When a unit is positioned next to a wall, low frequency sound can generate vibrations in the wall, even when the sound level from the fan room is acceptable. Generally the unit should be positioned against that wall in the fan room bordering a space that is not noise sensitive. When this is not possible the unit should be positioned 400-500 mm from the wall. Duct lead-throughs must be designed with care so that rigid connections between the duct and wall do not occur. In addition, the seal around the duct must be carefully installed to prevent the transmission of sound to adjacent areas. For sensitive installations it may be a good idea to connect ducts using flexible connections. If the mass and rigidity of the floor are inadequate it can transmit sound in a similar manner. If the floor structure is light it can be improved using a heavy insulating mat under the entire surface area of the unit. The entire underside of the unit should rest on the mat, which can be fitted with a board to cover it. Fläkt Woods 8216 GB 2014.05.15 4 Subject to change without notice
Commissioning Connecting electrical components Read the instructions for the controls before connecting the unit to the electrical grid and taking it into operation. The unit has a fan with forward curved blades and must not be operated without being connected to the duct system. Connect components to terminal blocks in the electrical cabinet. There is a detailed description of this in a separate document: TopMaster - Control equipment. During commissioning the current date and time, along with the required setpoints and operating times, must be set using the Curo Touch control panel, See separate instructions. Mains connection Connect the incoming supply through an external switch disconnector located close to the unit. A size 030 unit is to have a 10 AT external fuse and a size 050 unit a 16 AT fuse. Connect the incoming supply to terminal block group L1, L2, L3, N and earth in the electrical cabinet. Secure the cable to the mounting rail using cable ties before refitting the electrical cabinet cover. Fläkt Woods 8216 GB 2014.05.15 5 Subject to change without notice
Performance testing Starting the unit Starting the unit for inspection After the connection of mains voltage and external control components, the unit is ready to be taken into operation in order to test its connections. 1. Turn the external switch disconnector to 1 (ON). 2. Start the unit. See separate instructions TopMaster Control equipment Dampers Check that the damper opens and closes correctly. Control valve Check that the control valve on the air heater/air cooler is working correctly. The direction of rotation of the rotating heat exchanger Check that the direction of rotation corresponds to the alternatives below. If not see the wiring diagram. Left-hand configuration: The rotor should rotate to the left as viewed from the front. The measuring pressure, Dp m, which is the difference between the pressure in the empty section at the fan inlet and the pressure inside the inlet cone. If exterior airflow display is requested a manometer (RDTZ-06) for flow rate display can be connected. A meauring pressure is obtained on the manometer pressure scale and is used as a reference for the monitoring of the plant. Hoses with 4 mm diameter is mounted between the nipples on the top of the unit andmanometer, see Fig. 1. Positive to positive and negative to negative. If the unit is supplied with flow control the air flow can be read off directly from the control panel. NOTE! Where the unit is supplied with flow control the test socket is used for the pressure sensor Temperature correction The flow scale on the display instrument and flow formula above apply to air at a temperature of +20 C. At other air temperatures the flow must be corrected using the equation: Right-hand configuration: The rotor should rotate to the right as viewed from the front. Air flow measurement The TopMaster has measuring nipples for air flow measurement. Using a measuring pressure Dp (Pa) and a constant (k) the air flow q (l/s) can be calculated using the following equation: q = 1000 x Dp k m The value of constant (k) is shown in the Table below. Size 030 050 k-value extract air fan 56 41 k-value supply air fan 55 49 q = the actual flow through the fan q 20 = the flow reading t = current temperature in C Filter, final pressure drop The final pressure drop for the filter according to the table below, i.e. the pressure drop at which the filter cassette should be replaced, is 100 Pa above the pressure drop for a clean filter. Final pressure drop across the filter Size 030 Air flow m 3 /s 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 Supply air 135 140 170 220 - - - - Extract air 115 120 125 135 - - - - Size 050 Air flow m 3 /s 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 Supply air 130 140 150 160 175 190 200 215 Extract air 115 120 125 135 145 155 170 180 Pressure switch p Fig. 1. Location of measuring nipples on the unit. Where a pressure switch is used it must be set for the final pressure drop specified above. Where there is pressure regulation the pressure switch should be set for a pressure drop of +50Pa. Fläkt Woods 8216 GB 2014.05.15 6 Subject to change without notice
Performance testing Air heater, water Pipe connections The pipes to the heating coil are connected inside the unit in such a way that they do not prevent the disassembly of the fan. See the figures below. Draining Drain the unit through the pipe system. Fins Any deformed fins can be adjusted using fin comb EQAZ-14. Supply TF air fan WARNING! Wear protective gloves when work is being carried out using a fin comb Venting Vent the heat exchanger through the pipe system. WARNING! Warning - hot water! Remedial measures if there is a risk of freezing If the water freezes in a heat exchanger it will burst. This means that water will run out of the system and cause water damage. There is a risk of freezing in ventilation systems at low outdoor temperatures in the following cases: 1. The temperature of the heating medium is too high. There is a particular risk of freezing in the autumn and spring. Adjust the water temperature to the outdoor air temperature. 2. Oversized finned heat exchanger. Lower the water temperature to increase the water flow. 3. The heat supply ceases or decreases. If the supply of heat to the air heater can be expected to cease or decrease significantly, the outdoor air intake must be closed properly and all fans must be stopped. NOTE! Frost protection must not be set to so low a temperature that there is a risk of freezing. If the building is to be left unheated for long periods over the winter, the water must be drained from both the pipework and heat exchanger. Frost protection sensor Contact sensors are fitted to the return line. Apply heat conducting paste between the pipe and sensor to provide good contact between them. Important! When installing an air heater, in which the heating medium is water at a temperature above 100 C, take great care when opening vent cocks and shutoff valves in the system. Serious injuries can be caused by water hammer or steam discharge. Fläkt Woods AB takes no responsibility for the connection of air heaters to the heating system, nor for damage or injury caused by the incorrect planning, installation or maintenance of this system. Pipework and valves etc. are to be designed to take account of pressure drop and function, not the dimensions of the air heater connections. Route the pipes so that their weight does not subject the air heater to load. The air heater must not be subject to the expansion force of the heating system Fläkt Woods 8216 GB 2014.05.15 7 Subject to change without notice
We Bring Air to Life Fläkt Woods is a global leader in air management. We specialize in the design and manufacture of a wide range of air climate and air movement solutions. Our collective experience is unrivalled. We are constantly aiming to provide systems that precisely deliver required function and performance as well as maximum energy efficiency. FWG_TopMaster_Installation_EN_2014.05.15_8216 Copyright 2014 Fläkt Woods Group Condesign_ABS5953 Fläkt Woods Group SA 18, avenue Louis Casaï, CH-1209 Geneva, Switzerland Tel. +41 22 309 3800 email info@flaktwoods.com www.flaktwoods.com See global website for international sales offices www.flaktwoods.com