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FUTURE® S AIR HANDLING UNIT

OPERATION AND MAINTENANCE

INSTRUCTIONS

15 December 2020

Ver 1.7 (We reserve the right to changes without prior notice)

10

Figure 1.1: Future® S code key

The product code of the unit is available in the technical printout included in the unit delivery.

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Summary of Contents for Future S

Page 1: ...Future S air handling unit Operation and maintenance instructions 15 December 2020 version www koja fi ...

Page 2: ......

Page 3: ... 11 2 1 Space reserved for the unit 11 2 2 Unit components in general 12 2 3 Location of duct outlets and handedness of equipment 13 2 4 Commissioning general instructions 14 2 5 Maintenance general instructions 15 3 Fans 16 3 1 Operating conditions 16 3 2 Safety 16 3 3 Commissioning 16 3 4 Maintenance 16 4 Filters 18 4 1 Operating conditions 18 4 2 Safety 18 4 3 Installation and commissioning 18 ...

Page 4: ...aintenance 30 8 3 Fans 32 8 4 Temperature sensors 32 8 5 Pressure transmitters 32 8 6 FxVent controller accessory 33 8 7 HR damper actuators accessory 33 8 8 Safety switch accessory 33 8 9 Heating coil pump group pump pump group accessory 33 8 10 Heating coil pump group control valve pump group accessory 33 9 Other accessories 34 9 1 Safety 34 9 2 Water trap 34 9 3 Fresh and exhaust air dampers ac...

Page 5: ...ce instructions for the equipment 1 1 Operating conditions The standard unit is designed for indoor installation Ambient temperature must be over 0 o C The air to be handled must not be corrosive or poisonous warmer than 40 o C or contain significant amounts of water vapour or large particles CAUTION The permitted operating conditions and any limitations must be checked from the section specific i...

Page 6: ...in service when the unit is switched on The damper section of the unit must open before the fan starts WARNING Do not keep extra objects on top of or inside the unit Do not climb or walk on top of the unit WARNING The earthing continuity of the frame of the ventilation unit must be assured and the frame must be connected to the building s earthing system before operation WARNING The supply cables ...

Page 7: ...ntilation unit CAUTION The unit must be installed in a space accessible only to qualified personnel If the unit is installed in a place where it is accessible to persons other than service personnel the handles of the access doors must be removed and locked in a safe place Ensure during installation commissioning and maintenance that only qualified maintenance personnel have access to the danger a...

Page 8: ...ation of conformity and other documents relating to the safety of the unit sections are supplied with the unit The ventilation system s supplier and person responsible for taking the system into use must ensure that the essential requirements relating to the safety of the unit are complied with and that the equipment manufacturer s instructions are followed Electrical installations and their insta...

Page 9: ...35 EC Commission Regulation 1253 2014 implementing Directive 2009 125 EC with regard to ecodesign requirements for ventilation units The declaration only applies to the ventilation unit within the scope during the time of delivery If any changes are made to the products this declaration will no longer be in effect A risk analysis according to the Machinery Directive requirements has been conducted...

Page 10: ...ors Unwire components and disconnect cables Remove components Disassemble modules into parts if possible Sort and recycle loose parts and components according to the material recycling instructions The device consists of the following materials Modules Hot dip galvanised steel plate mineral wool small amounts of plastic rubber and adhesive mass corner brackets handles hinges and gaskets Shut off d...

Page 11: ... F7L Exhaust air filter ePM10 60 M5L Post heating coil water Water drains and water traps Lifting brackets Adjustable base Electric automation centre with the following field devices installed and wired to terminal blocks o Air temperature sensors 5 pcs o Anti freezing sensor for the heating coil o HR damper actuators counterflow HR or HR control centre rotating HR o HR defrost pressure difference...

Page 12: ... AND MAINTENANCE INSTRUCTIONS 15 December 2020 Ver 1 7 We reserve the right to changes without prior notice 10 Figure 1 1 Future S code key The product code of the unit is available in the technical printout included in the unit delivery ...

Page 13: ...e transport storage and installation instructions 2 1 Space reserved for the unit The space to be reserved for the unit depends on the selected model Check the space required by the unit from its dimensional drawing Figure 2 1 Example of the space to be reserved for the unit NOTE The locations of connections vary according to the unit s handedness and model Check the positions of integrates from t...

Page 14: ...r 2020 Ver 1 7 We reserve the right to changes without prior notice 12 2 2 Unit components in general The figure below describes the unit components on a general level Figure 2 2 Unit components in general The components included in the unit vary according to the selected model ...

Page 15: ...ation of duct outlets and handedness of equipment The following is a general description of the handedness of the device series Figure 2 3 Handedness in general Duct outlet locations are the same for all sizes of Future S series units Only the size and distance between the ducts varies Check the handedness of the unit from the unit s dimensional drawing ...

Page 16: ... commissioning the ventilation unit make sure that the unit has been installed and cleaned according to the instructions that the components and safety devices essential for the safe operation of the unit have been installed properly and that the flow rates have been adjusted The commissioning of the ventilation unit and the training of the operating personnel are usually carried out by the suppli...

Page 17: ...n rate of the air conditioning plant and the ambient conditions The given intervals apply when the plant is used 8 hours a day in city air environment The maintenance intervals are longer in cleaner environments like the countryside and shorter in dirtier environments like industrial areas It is advisable to have the unit serviced at the beginning autumn and at the end spring of the heating season...

Page 18: ...ions against overloading with for example fuses Make sure that the inside of the fan section and the fan are free from any loose parts debris etc that could get into the fan impeller Check that the electrical cables are intact and routed to the motor flexibly and that the type of the cable is correct Check that the drive and fan operate freely by turning the impeller a couple of turns by hand Make...

Page 19: ... inlet and outlet dampers closed If necessary clean the fan casing and impeller with a brush vacuum cleaner or damp cloth Make sure that the fan s direction of rotation is correct Make sure that the access door gaskets are in place and intact Replace if necessary Close the access door and make sure that every latch tightens properly Check that the fan is not making any extra noise If the unit is i...

Page 20: ...Check that the filters are tight against the frame gasket and that there are no leaks Check that the filters are clamped in place Check that the differential pressure gauge is intact and reset Check that the differential pressure hoses of the filter section are intact and in their places At the installation stage the pressure difference limits for the filter indicators must be set according to the...

Page 21: ...vent microbial growth Check that the filters are intact and of the correct type Check that the filters are tight against the frame gasket and that there are no leaks Check that the filters are clamped in place Check that the differential pressure gauge is intact and reset Check that the differential pressure hoses of the filter section are intact and in their places Check that the differential pre...

Page 22: ...ame A new gasket is mounted starting from the middle of the frame bottom Press the gasket against the edge of the plate by hand or carefully with a hammer or some other tool Use for example a 20 mm pipe to bend the corners appropriately Cut the gasket to a length of about 5mm too long Force the ends together and apply sealant between them A With the clamp closed 35 1 0 B Lower frame C With the cla...

Page 23: ... 0 C CAUTION Pipe connections must be carried out by qualified persons only 5 3 Installing CAUTION The coils are always connected so that the fluid flow runs against the direction of the air flow 5 4 Commissioning Make sure that the heat transfer surfaces of the coil are clean and intact Open the line control valves to fill the coil with fluid Bleed the coil Make sure that the water side connectio...

Page 24: ...ner Bleed the coil and check the operation of the anti freezing thermostat at the beginning of each heating season A damaged coil must be repaired in place sent to the manufacturer to be repaired or replaced CAUTION If the coil is not used during the heating season water must be drained from it or it has to be filled with a water glycol mixture to avoid freezing The coil does not drain fully throu...

Page 25: ... serviced at the beginning autumn and at the end spring of the heating season Make sure that the heat transfer surfaces are clean and intact Check the operation of the dampers If necessary lubricate with a silicone based lubricant Check the turning direction of the actuator If necessary change the direction by turning the switch on top of the actuator with a flathead screwdriver of suitable size C...

Page 26: ...peration Make sure that the filters are in place Make sure that the supply or exhaust ducts are free from foreign objects that could damage the faces of the heat exchanger Use a spirit level on the face of the heat exchanger to ensure that the rotor is upright Make sure that the rotor rotates freely Make sure that the rotor belt is suitably tight and running freely in its proper place Make sure th...

Page 27: ...e surface of the exchanger Replace damaged brush seals Check that the belt is suitably tight If the belt slips during start up or stop it must be tightened or possibly replaced according to a separate instruction Check that the speed control operates properly Check the bearing noise and vibration Under normal conditions there is no need to add lubrication as the lubrication in the unit is designed...

Page 28: ...ut prior notice 26 7 4 2 Adjusting rotor position Figure 1 Loosen the hex head screw Figure 2 Carefully tilt the rotor Ensure that the disc lamellas are not damaged Figure 3 Check the inclination by measuring opposite sides Figure 4 When the rotor is positioned at a suitable angle tighten the hex head screw to the correct torque ...

Page 29: ...INSTRUCTIONS 15 December 2020 Ver 1 7 We reserve the right to changes without prior notice 27 Figure 5 Check the horizontal centre of the rotor for measuring points Figure 6 The arrows indicate the measuring points The blue line indicates the inclination ...

Page 30: ...trol unit If the motor still does not work leave further troubleshooting to an expert 7 4 4 Replacement of drive belt The rotor is belt driven The belts loosen during their service life and wear in use For this reason we recommend regular maintenance intervals If the belt is loose shorten it by removing a suitable length of the belt If the belt needs to be replaced we recommend that you contact se...

Page 31: ...ed in such a way that it can be removed from unit casing for example for the duration of maintenance The rotor package is attached depending on the model with screws Removal instructions Remove the rotor mounting screws 3 pcs on the top and 3 pcs on the bottom per side Disconnect the power from the rotor control unit The connections are located on the side of the access door at the bottom Carefull...

Page 32: ...ths Any deficiencies and faults must be fixed immediately CAUTION The protective devices for the electric components must be dimensioned correctly in order to guarantee safe use of the unit 8 2 Commissioning and maintenance Before unit commissioning the power supply and the possible building automation control cable must be connected to the unit The S1800 model is supplied in modules and the elect...

Page 33: ...n the switchboard cover must always be kept closed for personal and component protection When the FxVent controller is included in the unit delivery the controller s operating panel is located outside the switchboard casing The pressure sensors and airflow transmitters are similarly located on a mounting plate above the switchboard for easy operation and readability The switchboard must only be op...

Page 34: ...itor the measurement of the anti freeze sensor and act in such a way that in the event of a freezing hazard coil freezing is prevented by taking the necessary measures 8 5 Pressure transmitters In standard delivery the unit includes pressure difference transmitter for fresh and exhaust air filters and a pressure difference transmitter for heat recovery exhaust air Scalable pressure limits are set ...

Page 35: ...in order to guarantee safe use of the unit Future S units can be equipped with an optional safety switch that switches off the entire unit s 400 V power supply The safety switch can be used to ensure that the equipment is de energised for example for the duration of maintenance work When the safety switch is included in the unit delivery the mains can be connected directly to the safety switch con...

Page 36: ...The S1800 model also has water drains at the back of the unit NOTE When adjusting the height of the unit the vertical space required by the water trap must be taken into account The supplied water trap is installed according to the instructions supplied with the water trap in the position shown in Figure 9 2 1 below Adjust the overall height of the water trap by shortening the pipe and measuring L...

Page 37: ...s smaller in size than DN25 The pump group s glue joints have been tested for pressure at the factory In addition to the glued joints the pump group has level gasket joints components that can be replaced such as the circulator 1 and check valve 4 Figure 9 5 1 Heating coil pump group Table 9 5 1 Component list for the heating coil pump group N o Component name Pcs 1 Grundfos Magna3 25 40 pump 1 2 ...

Page 38: ...e the tightness of the connection Check the joints inlet and outlet connections from the unit s dimensional drawing and join the pipe connections with gaskets Ensure sufficient support of the pump group with appropriate HVAC brackets Connect the pump group to the heating network Flush fill and bleed the network and ensure the pump group s tightness Connect the pump supply and control cable and the...

Page 39: ...pplied with a temperature sensor installed in the duct The preheating coil heats the fresh air entering the ventilation unit to the temperature set on the heater controller e g 15 C according to its own temperature measurement The controller s temperature range is 20 10 C The preheating coil must be equipped with its own supply cable and a correctly dimensioned safety switch The preheating coil is...

Page 40: ...rizontal duct The cooling coil is dimensioned with the Future S dimensioning program and its technical specifications are available in the ventilation unit s technical printout The cooling coil is installed and serviced according to the cooling coil manufacturer s instructions NOTE The cooling coil must be installed in a horizontal duct In connection of installation ensure that condensed water is ...

Page 41: ... no material or moisture inside the cooling coil that does not belong there Ensure that the cooling coil is installed in a duct with horizontal air flow Ensure that condensed water is discharged through the condensation drain without obstruction Condensation drain must be sewered and equipped with a water trap Check the connections inlet and outlet connections and the direction of air flow from th...

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