TCF ZAE Series Manuale utente

INSTALLATION,

OPERATION AND MAINTENANCE

MANUAL

AIR-HANDLING

UNITS

ZAE SERIES

TABLE OF CONTENTS

0. INTRODUCTION

1. DESCRIPTION OF AIR TREATMENT UNIT 4

1.1 COMPOSITION 4

1.2 PERMITI ED USE 4

2. CONTROL, PACKING, TRANSPORTATION 4

2.1 INSPECTION OF SUPPLY AT THE FIRM 4

2.2 PACKING 4

2.3. LOADING, TRANSPORTATION, UNLOADING 4

3. ASSEMBLY ON SITE 5

3.1 . POST-TRANSPORTATION CHECK 5

3.2. PRESERVATION ON SITE 5

3.3. POSITIONING 5

3.3.1. Dim nsions of installation room 5

3.3.2. Bas 6

3.3.3. Vibration damping 6

3.4. ASSEMBLY OF SECTIONS 7

4. CONNECTION TO SYSTEMS AND START-UP 8

4.1. CONNECTION TO DUCTS 8

4.2. CONNECTION OF HEAT EXCHANGERS 8

4.2.1 . Wat r xchang r 8

4.2.2. Dir ct xpansion xchang r 9

4.2.3. St am xchang r 10

4.3. CONNECTION OF HUMIDIFIER SECTIONS 10

4.3.1. F d wat r 10

4.3.2. Hydraulic conn ctions for c ll block or spray

nozzl humidifi rs 11

4.3.3. Humidification with c ll block 11

4.3.4. Humidification with circulating pump 11

4.3.5. Ultrasonic, st am (subm rg d l ctrod s),

compr ss d air humidification 11

4.3.6. St am humidification with subm rg d l m nts 11

4.4. DRAINAGE AND SIPHONING 11

4.5. FILTRATION SECTIONS 12

4.6. FAN MOTOR UNIT 13

4.6.1. El ctric motors 13

4.6.1.1 . Conn ction for dir ct starting 13

4.6.1.2. Conn ction for star—d lta starting 13

4.6.1.3. Dual sp d thr -phas motor 14

4.6.1.4. P rmitt d start tim 14

4.6.1.5. R comm nd d conn ction and prot ction

acc ssori s 14

4.6.2. Fan 15

4.6.3. Driv 15

5. INSPECTION 16

5.1. PRELIMINARY CHECKS 16

5.2. INSPECTION PROCEDURES 16

5.2.1. Pow r board 16

5.2.2. Flowrat ch ck 16

5.2.3. Ch cking h at xchang r ffici ncy 17

5.2.4. Humidification syst m ch ck 18

5.3. CORRECTION OF FLOW RESISTANCE

VALUES IN CIRCUITS AND ADJUSTMENT

OF FAN AlR—MOVlNG PERFORMANCE 18

5.3.1. Insuffici nt l ngth of div rging duct s ction

b tw n Unit d liv ry inl t and obstruction 18

5.3.2. Elbows 19

5.3.3. Control air locks 19

. MAINTENANCE 20

6.1. FOREWORD 20

6.2. FILTRATION SECTIONS 20

6.2.1 . R conditionabl synth tic filt rs 20

6.2.2. M tal filt rs 20

6.2.3. Rotary filt rs 21

6.2.4. R conditionabl bag filt rs 21

6.2.5. Non-r conditionabl m dium/ high

ffici ncy filtration s ctions 21

6.2.5.1. Non-r conditionabl bag filt rs 21

6.2.5.2. Absolut filt rs 21

6.2.5.3. R plac m nt load loss chart 22

6.2.6. Activ carbon filt rs 22

6.3. HEAT EXCHANGERS 22

6.3.1 . Wat r xchang rs 22

6.3.2. Extraction of h at xchang r 22

6.3.3. St am xchang r 23

6.3.4. Dir ct xpansion xchang rs 23

6.4. HUMIDIFICATION SECTIONS 23

6.4.1. Humidification with spray nozzl s 23

6.4.2. Humidification with c ll block 23

6.4.3. Humidification with circulating pump 23

6.4.4. Ultrasonic, st am (subm rg d l ctrod s),

compr ss d air humidifi rs 23

6.4.5. St am humidification with subm rg d

l m nts 23

6.5. FAN SECTION 24

6.5.1. Fan 24

6.5.2. Motor 24

6.5.3. Driv 24

6.5.3.1. D t rmining b lt t nsion 24

6.5.3.2. Driving b lt r plac m nt 25

6.5.3.3. Driv with multipl rac pull ys 25

6.6. HEAT RECUPERATORS 25

6.6.1. Crossov r flow static r cup rator 25

6.6.2. Rotary r cup rator 25

6.6.3. H at pip r cup rator 26

6.7. ACCESSORIES 26

6.7.1. Control air locks 26

6.7.2. Ext rnal air intak grill s 26

6.7.3. Drip s parator 26

6.7.4. Sil nc r 26

6.8. TROUBLESHOOTING 26

6.8.1 . R duction in flowrat 26

6.8.2. Incr as in flowrat 26

6.8.3. R duc d xchang r ffici ncy 26

6.8.4. R duc d h at r cup rator ffici ncy 26

6.8.5. R duc d humidifi r ffici ncy 27

6.8.6. Abnormal nois l v l 27

6.9. MAINTENANCE AGREEMENT 27

7. SAFETY 27

7.1. SAFETY-RELATED FEATURES OF

AIR TREATIVENT UNIT 27

7.2. SAFETY NOTICES APPLIED TO THE

UNITS 27

7.3. PRACTICAL ACCIDENT—PREVENTION

TIPS 27

7.4. EC DECLARATTON OF COMPLIANCE 28

8. WARRANTY 29

9. UNIT INSPECTION SHEET 30

0. INTRODUCTION

This manual has b n compil d by TCF Srl to provid th

install r, Custom r and Us r with instructions int nd d

to nsur th prop r manag m nt and us of th Air

Tr atm nt Unit mod. ZAE and AZE-C, from d liv ry to

commissioning.

Th r comm ndations that follow ar int nd d to

nsur continuous op ration of th Air Tr atm nt Unit

and long machin lif .

Th proc dur s d scrib d b low should b follow d by

skill d p rsonn l with a good working knowl dg of air-

conditioning, syst ms ngin ring and air tr atm nt

units, v n though th unit can b op rat d by thos

unfamiliar with air tr atm nt thanks to th machin 's

simplicity of d sign.

DESCRIPTION OF AIR TREATMENT UNIT

1.1. COMPOSITION

In its most compl t v rsion, th unit, in its monoblock

or brok n down configuration, compris s:

-On or mor air lock intak s ction

-Filtration s ction

-R cov ry s ction

-H at xchang r s ction (h ating, cooling, post-

h ating)

-Humidifi r s ction

-V ntilation s ction (d liv ry, intak —outl t)

-Sil ncing s ction.

1.2. PERMITTED USE

TCF Air Tr atm nt Units ar d sign d xclusiv ly for

CIVIL AND INDUSTRIAL AIR TREATMENT

In th cas of CORROSIVE and/or EXPLOSIVE air flows

a numb r of sp cial t chnical modifications must b

mad at th d sign stag which, tog th r, adapt th

machin for th tr atm nt of sp cial typ s of flow.

Th Air Tr atm nt Unit must at all tim s b us d

strictly in accordanc with th d sign conditions

stablish d at th tim of contract in agr m nt with

th custom r. ANY OTHER USE SHALL CONSTITUTE

IMPROPER USE AND IS THEREFORE DANGEROUS.

THE MANUFACTURER MAY NOT BE HELD LIABLE

FOR DAMAGE CAUSED BY NON—STANDARD USE OR

ANY USE NOT ENVISAGED IN THE CONTRACT

2. CONTROL, PACKING, TRANSPORTATION

2.1. INSPECTION OF SUPPLY AT THE FIRM

Prior to shipping, ach TCF Air Tr atm nt Unit is

subj ct d to all th functional t sts list d on th attach d

UNIT INSPECTION SHEET (Form E.1.).

Th ch cks p rform d r gard:

- g n ral machin dim nsions

- corr ct ass mbly of th various parts and s ctions

- complianc with th various saf ty rul s in forc

- int grity of all th syst m‘s compon nt parts

- application of th id ntification, op ration and saf ty

notic s.

On compl tion of th Insp ction, th Chi f Insp ctor

appli s th EC mark d monstrating product complianc

with pr vailing Europ an Union machin dir ctiv s.

2.2. PACKING

Th Air Tr atm nt Units ar usually suppli d as fully-

ass mbl d monoblocks. Only if th custom r xpr ssly

r qu sts it can th units b brok n down into s v ral

s ctions to facilitat transportation and carriag through

narrow ap rtur s, stairs or corridors. Transportation of

th machin s, both monoblock and brok n down, can b :

- normal

- sp cial.

In th form r cas , TCF Srl do s not pack th machin . In

th cas of sp cial transportation, th packing r qu st d

is agr d at th tim of contract and is ntir ly for th

custom r's account.

Fragil compon nts suppli d s parat from th Unit,

such as humidifi rs, xchang rs, r cup rators, filt rs,

control boards, tc. ar always d liv r d pack d.

2.3. LOADING, TRANSPORTATION, UNLOADING

TCF Srl disclaims all liability for damag sustain d by th

Air Tr atm nt Units during loading, unloading and

transportation. W th r for r comm nd that sp cial

pr cautions b tak n, including:

- Th load must b firmly s cur d to nsur its int grity

during transportation

- Handling must b p rform d without x rting forc on

proj cting acc ssori s (hydraulic attachm nts, handl s,

hing s, air locks, prot ction roof)

- Do not ov rturn th s ctions as you may oth rwis

br ak int rnal supports, compon nts and damp rs

- Do not subj ct th Unit to viol nt impacts as you may

damag its int grity

- If a forklift truck is us d during th loading, unloading

and handling op rations, th forks of th truck must b

at l ast th sam l ngth as th unit to nsur stability

(fig. 1)

- if th Air Tr atm nt Unit is fitt d with a continuous

st l bas , handling may b accomplish d with a cran ,

using cabl s firmly s cur d to rods (suffici nt for th

str ss involv d) passing through th hol s provid d in

th bas .

If a cran is us d, proc d as shown in th illustration,

using spac rs to prot ct th structur (fig. 2).

- During transportation, prot ct th unit from

atmosph ric ag nts. Sp cial car must b tak n if th

unit is suppli d disass mbl d or d sign d for int rnal

us .

3. ASSEMBLY ON SITE

3.1. POST-TRANSPORTATION CHECK

Wh n th Air Tr atm nt Unit arriv s on sit , w

r comm nd you to mak a car ful insp ction of th

structur and th compon nt parts of th unit.

Should you com across damag sustain d during

transportation, you must r port it on th fr ight bill. Th

carri r must imm diat ly til a r port of th accid nt to

obtain comp nsation from th insuranc company

3.2. PRESERVATION ON SITE

In ord r to k p th Air Tr atm nt Unit in good and

ffici nt condition on sit , th following st ps must b

tak n first:

- Prior to installation, position th Unit and th

acc ssori s in a plac affording th b st possibl

prot ction against accid ntal knocks, dust and

atmosph ric ag nts

- Car fully cov r th inl ts and outl ts to pr v nt for ign

matt r from nt ring th unit and damaging th int rnal

compon nts

- Extract th pr -filt rs from th Unit and put th m in a

prot ct d plac to pr s rv th ir filtration ffici ncy

This is why th sup rior ffici ncy filt rs ar d liv r d

pack d; th y must b k pt in th ir packag s until th

unit is put into s rvic

- Ch ck that th hydraulic conn ctions ar prot ct d by

th r l vant caps as th y w r on d liv ry to th TCF

plant. lf th y ar not, plug th m in ord r to prot ct th

xchang rs.

3.3. POSITIONING

3.3.1. Dim nsions of installation room

Th Air Tr atm nt Unit installation room must b of

suffici nt siz to p rmit asy insp ction, maint nanc

and compon nt r plac m nt.

Accordingly, th following dim nsions ar

r comm nd d [fig. 3):

- h at xchang r xtraction sid

Minimum distanc Lb = (B+O.2) m

wh r B = machin width (m)

- insp ction sid Minimum distanc Li = 1.2 m

lf you do not hav th minimum spac r quir m nts as

sp cifi d abov , th Unit doors can, on r qu st, b

fitt d using PVC clamps inst ad of hing s. In this cas

th minimum distanc will b Li = 0.7 m

3.3.2. Bas

Th p rman nt installation of th Air Tr atm nt Unit

may b mad :

- dir ctly on th floor (Hg. 4a)

- on a concr t b d (fig. 4b)

- on a st l s ction b d (fig. 4c)

- on a susp nd d bas (fig. 4d)

Both th floor and th b ds must b capabl of

withstanding th machin w ight to within th

r quir d saf ty margins.

Th Air Tr atm nt Unit must b position d on a

horizontal surfac so as to pr v nt:

- damag to th fan motor units caus d by un v n

w ights on th vibration damp rs

- malfunctioning of th cond nsat drains

- difficulty in op ning and closing th insp ction doors.

Th horizontal alignm nt of th support surfac must

b ch ck d with a SPIRIT LEVEL; adjustm nts may b

mad using STEEL SHIMS.

3.3.3. Vibration damping

In ord r to nsur ff ctiv prot ction against

vibrations, th Air Tr atm nt Unit must b install d as

follows:

- suitabl DAMPERS in mat rial d sign d to withstand

th w ight involv d must b plac d b tw n th

machin and th support surfac

- th Unit must not b fast n d dir ctly with scr ws but

by m ans of brack ts (fig. 5).

Ev n in th cas of susp nd d installation of th Unit, th

supports must not b scr w d dir ctly into th c iling;

vibration damping mat rial must always b plac d

b tw n th supports and th c iling (fig. 6).

It, for r asons conn ct d with incr as d prot ction,

spring-op rat d or rigid rubb r vibration damp rs ar

r quir d b tw n th machin bas and th support

surfac , th hydraulic conn ctions must b fitt d with

appropriat JOINTS.

3.4 ASSEMBLY OF SECTIONS

If th Air Tr atm nt Unit is brok n down into two or

mor s ctions. proc d as follows:

- Ch ck th modul ass mbly ord r on th TCF

working drawing.

- R mov th mat rial r quir d for ass mbly, suppli d

on d liv ry, from th contain r locat d insid on of

th insp ction doors.

- Cl an th st l s ctions at th point of conn ction of

th modul s and tit th SELF—ADHESIVE SEALING

STRIP provid d (fig. 7).

Th sam strip must also b fitt d to th duct

conn ction flang s.

- S t th individual s ctions s t by sid , using a SPIRIT

LEVEL to ch ck that th ass mbl d parts ar p rf ctly

align d and l v l. (fig. 8)

- Fast n th s ctions tog th r with scr ws in th hol s

provid d.

Th hol s ar locat d on th insid of th corn rs and,

in th cas of dim nsions gr at r than 1.3 m, also in a

midway position.

Th scr w-fast ning ar as can usually b acc ss d

from th insp ction doors. Oth rwis , you must

r mov th pan ls n xt to th ar a involv d.

Should th Unit b install d outdoors, in addition to th

st ps list d abov , th points of conn ction of th

individual modul s must also b s al d with

wat rproofing silicon (fig. 9).

Sp cial car must b tak n with th roofing to afford

prot ction against th l m nts: th two dg s will b

joint d by m ans of a bayon t syst m, assist d by

silicon tr atm nt or a sp cific s al (fig. 10).

4. CONNECTION TO SYSTEMS AND START-UP

4.1. CONNECTION TO DUCTS

At th points of conn ction to th air ducts, th Air

Tr atm nt Units hav a smooth or a flang d surfac .

In ord r to optimis th conn ction with th ducts, you

must:

- cl an th conn ction dg s b tw n duct and unit

- fit a s al to th flang s in ord r to pr v nt air

infiltration

- tight n th conn cting scr ws firmly

- tr at th joint with silicon to nhanc th s al.

If th conn ction is mad with rubb ris d canvas

joints, mak sur th y ar not taut on compl tion of

ass mbly so as to pr v nt damag or th transmission

of vibrations.

In ord r to nsur th tightn ss of th conn ctions and

th int grity of th unit structur , th w ight of th

ducts must und r no circumstanc s b ar down on th

unit. Th ducts must b support d by BRACKETS.

4.2. CONNECTION OF HEAT EXCHANGERS

In ord r to pr v nt damag to th xchang r at th

joint b tw n th st l manifold and th copp r

circuits, you must:

- Us a pip wr nch to apply forc in th opposit

dir ction wh n making th conn ction to th mains

pip (fig. 1.1)

- Fit brack ts to support th conn cting pip s.

Th w ight of th pip s must und r no circumstanc s

b ar down on th manifold.

4.2.1. Wat r xchang

In ord r to nsur an optimum h at xchang , you must:

- WASH th h at xchang r b for conn cting it to th

wat r mains

- onc install d in a workmanlik fashion, any air pr s nt

in th hydraulic circuit must b xp ll d using th

r l vant valv .

To allow asy xtraction of th xchang r during

maint nanc :

- th conn ctions to th mains must b mad in such a way

as to allow r moval of th xchang r

- ON-OFF VALVES must b install d to xclud th h at

xchang r from th hydraulic circuit

- A VALVE must b install d on th low r manifold to allow

compl t drainag , and a VALVE must b titl d to th

upp r manifold to v nt th air from th xchang r (fig. 12)

Th normal h at xchang in a h ating or cooling wat r

xchang r occurs in REVERSE CURRENT (fig. 13).

In ord r to pr v nt th formation of ic in th h ating

units in th pr s nc of particularly low outsid

t mp ratur s, an EQUICURRENT h at xchang syst m

may b provid d (fig. 14).

This configuration must b d t rmin d at th d sign stag

and not during installation, sinc an obvious r duction in

ffici ncy will r sult if a h at xchang r siz d for r v rs

curr nt h at xchang is us d for quicurr nt op ration.

Th diagram (Hg. 15) shows th "standard" installation of

a wat r-typ h at xchang r.

4.2.2. Dir ct xpansion xchang r

In ord r to p rmit op ration of th whol syst m, mak

sur that th h at xchang occurs in r v rs curr nt

b for )making th conn ctions to th h at xchang r (fig.

16).

Th cooling circuit must b compl t with all th

n c ssary flow control, filtration and saf ty d vic s; th

pip must b siz d to allow prop r circulation of th

compr ssor prot ction oil.

W r comm nd you prot ct th xchang r against

vibrations to pr v nt th lik lihood of ruptur at th joint

b tw n manifolds and copp r pip s.

In ord r to nsur corr ct op ration of th th rmal

xpansion valv , th bulb of th valv must b in p rf ct

contact with th intak lin and fitt d on th outsid of

th air flow so as not to b aff ct d by it.

Sp cial car must b tak n with th SIPHONING of th s

xchang rs to nsur th maximum h at xchang and

corr ct ntrainm nt of th oil in th circuit. Th diagram

in fig. 16 shows a siphoning syst m without division of

h ad.

Fig. 17 Syst m siphoning xampl with division of

cooling h ad.

Fig. 18 shows an incorr ct siphon syst m (a) and a

corr ct on (b), in th cas of installation of th

compr ssors at a point b low th vaporator.

4.2.3. St am xchang r

In ord r to pr v nt dang rous WATER HAMMERING that

could ruptur th xchang r and l ad to th scap of

st am und r pr ssur , you must:

- mak sur that th Air Tr atm nt Unit is l v l on

installation

- corr ctly siz th flow control d vic s and th

cond nsat drains

- nsur th corr ct angl of inclination of th pip s

comprising th st am circuit.

B for starting up th syst m mak sur that th h at

xchang r is corr ctly conn ct d to it (fig. 19)

TCF installs st am batt ri s with angl d or v rtical pip s

(fig. 19) to nsur corr ct drainag of th cond nsat and

pr v nt it from accumulating insid th syst m. In Air

Tr atm nt Units with this typ of xchang r sp cial car

must b tak n to nsur that th bas is l v l (s s ction

3.3.2.).

Th st am syst m must b compl t with all th

n c ssary r gulating, filtration and saf ty d vic s, which

must b corr ctly siz d.

Each h at xchang r must b fitt d with a cond nsat

drain, which must b ov rsiz d to allow drainag of th

gr at r quantity of cond nsat that is form d during

syst m start-up.

Provision must also b mad for th automatic shut-off of

th st am f d in th cas of fan motor unit stop.

4.3. CONNECTION OF HUMIDIFIER SECTIONS

4.3.1 . F d wat r

TCF r comm nds f ding th humidifi r s ctions with

wat r that has a TOTAL HARDNESS of b tw n 15°F and

25°F. B low 15°F th aggr ssiv n ss of th wat r could

damag th unit compon nts, and th us ful lif of th

r sins in th soft ning syst m would b drastically

short n d.

Ov r 25°F th ffici ncy of th humidifi r syst m would

quickly diminish du to th build-up of scal .

Indice

Altri manuali TCF Unità di trattamento dell'aria

TCF

TCF CV Series Manuale operativo e di manutenzione

TCF

TCF TXP Series Guida del prodotto

Manuali Unità di trattamento dell'aria popolari di altre marche

Klimor

Klimor EVO-S Manuale utente

Salda

Salda SMARTY XP Guida

BLAUBERG

BLAUBERG KOMFORT Roto EC S400 Manuale utente

Trenton

Trenton TPLP Series Manuale utente

Kemper

Kemper CleanAirTower Manuale utente

Daikin

Daikin DV PTC 14 Series Manuale utente

Haier

Haier HB2400VA1M20 Manuale utente

Webasto

Webasto BlueCool A-Series Manuale utente

RDZ

RDZ DA 701 Documento tecnico

Carrier

Carrier 39T Dimensioni e guida di installazione

Armstrong Air

Armstrong Air BCE5V Series Manuale utente

ActronAir

ActronAir CAY500T Manuale utente

Carrier

Carrier 40MBDAQ Manuale utente

Allied

Allied A93UH1E Manuale utente

Nortek

Nortek B6VMAI Manuale utente

TemperZone

TemperZone Econex Pro OPA 1410RLTM4FPQD Guida alla manutenzione e all'assistenza

RDZ

RDZ WHR 200 Documento tecnico

AAON

AAON H3 Series Manuale del proprietario