PUM(O,R,V) AND PUML INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR ROTARY HEAT EXCHANGERS ROTOR SIZE (460/500)

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1 PUM(O,R,V) AND PUML INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR ROTARY HEAT EXCHANGERS ROTOR SIZE (460/500)

2 2 Installation and maintenance Content Page 1. Description - Unit design Handling the heat exchanger, Inspection facilities Connection, Checks, Rotor seals Installation, Drive equipment, Speed controller To change the rotor bearings, sizes To change the rotor bearings, sizes (460/500) Maintenance Service schedule Instructions Packaging/Lifting/Transport... 14

3 Installation and maintenance 3 1. DESCRIPTION UNIT DESIGN DESIGN ROOM SIDE The following should be connected to this side: exh. air duct from premises supply air duct to premises Room side DIRECTION OF ROTATION The direction of rotation shall be such that a point on the exhaust air side of the rotor moves towards the purging sector. The location of the purging sector is shown by yellow tape on the heat exchanger casing. CONDITION ON DELIVERY Sizes Rotor Fig. 1:3 Centre beam Peripheral seal Inspection cover Purging sector Sizes Casing V-belt Yellow tape marks the location of the purging sector Fig. 1:1 Motor bracket Drive motor Inspection cover on request Fig. 1:4 Outdoor air side Sizes are always delivered with the one-piece casing and with the rotor installed in the casing as shown in Fig. 1:3. Sizes can be supplied either as one unit or as a split unit as shown in Fig. 1:4. Centre beam Sizes Fig. 1:2 Fig. 1:5 CAUTION! During the installation period, protect the heat exchanger against water and moisture. Take care not to damage the end surfaces of the rotor, since they are relatively sensitive to physical damage. Fig. 1:6 Sizes are always supplied with a split casing and sectorized rotor as shown in the figures above. See the Assembly instructions for assembling a heat exchanger of split design.

4 4 Installation and maintenance 2. HANDLING THE HEAT EXCHANGER, INSPECTION FACILITIES HANDLING THE HEAT EXCHANGER The heat exchanger can be handled by means of a forklift truck or a crane. Keep the packaging in place to protect the rotor until installation is to be carried out. Use the tubes in the outer corners of the casing for lifting size 300 or smaller heat exchangers (see Fig 2:1). For lifting size heat exchangers, use 4 lifting devices as shown in Fig. 2:2. Make sure that the heat exchanger will not fall over. Always mount the heat exchanger on a flat surface capable of carrying the load. NB! If to lift the unit in horizontal position, first insert styrofoam or wooden pieces between the rotor and casing center- and cross beams. This to support the rotor from vertical shearing. INSPECTION FACILITIES To allow for inspection and possible service work on the rotor, either an inspection section or a duct with inspection panel must be connected to the heat exchanger. If unit sections with good access facilities are connected directly to the heat exchanger, these sections may be used for inspection. Fig. 2:3 Inspection cover measuring at least 600 x 600 mm. Fig. 2:1 Fig. 2:2

5 Installation and maintenance 5 3. INSTRUCTIONS FOR ROTARY HEAT EXCHANGERS CONNECTION TO THE DUCTING AND AIR HANDLING UNIT Connect the supply and exhaust air ducts either directly to the casing or by means of a jointing system. For particulars of connection of the supply and exhaust air ducts and the direction of air flow, see the instruction plate on the room side of the heat exchanger. CHECKS BEFORE STARTING THE HEAT EXCHANGER Do not run the fans during the construction of the building if the heat exchanger is not running. Make sure that the appropriate filters have been installed. Check that no foreign objects, which may damage the end surfaces of the rotor, have been left in the supply and exhaust air ducts. Check that the rotor runs freely. Kanal Duct Kanal Duct Duct Kanal Duct Kanal ROTOR SEALS Check that the gap between the rotor and all rotor seals is between 1 and 1.5 mm. If necessary, adjust the seals as follows: Place a spacer, such as a piece of paper, between the rotor and the seal, push the seal against the spacer and then remove the spacer. 1 1,5 mm 1 1,5 mm Fig. 3:1 RUMSIDA Till denna sida anslutes frånluft från lokalerna tilluft till lokalerna ROOM SIDE The following should be connected to this side: exhaust air duct from premises supply air duct to premises RAUMSEITE Angeschlossen auf dieser Seite werden: Abluftkanal vom Raum Frischluftkanal zum Raum HUONEPUOLI Tälle puolelle liitetään: Poistolma huonetiloista Tuloilma huonetiloihin ca 8 mm ca 8 mm Peripheral seal Hub seal Fig. 3:3 Fig. 3:4 1 1,5 mm 1 1,5 mm ca 8 mm J Fig. 3:2 Instruction plate located on the room side of the heat exchanger. Centre-beam seal Sizes Fig. 3:5 Fig. 3:6 Centre-beam seal Sizes

6 6 Installation and maintenance 4. DRIVE EQUIPMENT SPEED CONTROLLER DRIVE EQUIPMENT The motor bracket of the exchanger and the drive motor with the V-belt pulley and power supply cable fitted are sometimes delivered in a crate. Determine the drive motor installation alternative that provides the best accessibility with the installation work has been completed. Remove the cover behind which the motor is to be installed. Fit the motor bracket and motor in position. Install the motor so that the motor shaft is horizontal and the belt pulley faces towards the corner of the casing as shown in the adjacent figure. Run the power supply cable to the motor through the most appropriate cable entry hole (see Fig. 4:2). Fit the V-belt. The V-belt has been secured around the rotor at the factory. Proceed as follows: Stretch the V-belt around the rotor and pully, and cut the belt to such a length that it can only just be prised over the edge of the pulley after the V-belt has been jointed. When in position, the V-belt will be automatically tensioned to the correct tension by the spring load on the motor bracket. After the system has been commissioned, check the direction of rotation through the inspection cover in the exhaust air duct: The rotor shall rotate so that a point on the exhaust air side of the rotor moves towards the purging sector. The location of the purging sector is shown by yellow tape on the heat exchanger casing. INSTALLATION OF SPEED CONTROLLER AND RUN OF CABLES Fig. 4:2 Sizes Alternative cable entries Location of speed controller Cable runs inside the casing, to one side of the covers Alternative cable entries Drive motor Location of speed controller Fig. 4:3 Sizes Fig. 4:1

7 Installation and maintenance 7 5. TO CHANGE THE ROTOR BEARINGS SIZES DRIVE EQUIPMENT Cross-brace End cover Fig. 5:1 Sealing strip Drive motor Centre screw Fig. 5:3 Rotor mount Rotor shaft A. Remove the end covers. Dismantle the cross-- brace and the sealing strips. Remove the drive belt from the motor pulley and lift out the motor after having unscrewed the screws that secure it. See Fig. 5:1. B. Back off the screws and remove the centre cover plates. See Fig. 5:2. C. Block up the rotor and remove the four screws in the rotor mount shown in Fig. 5:2. The rotor can now be withdrawn by rolling it out. See Fig. 5:3. Rotor mount Adjusting screw D. See Fig. 5:3. Back off the centre screw in one of the rotor mounts and extract the rotor shaft in the opposite direction. E. The worn bearings can now be tapped out of the rotor hub as shown in Fig. 5:4. Clean the bearing locations and the inside of the bearing casing to remove old grease and fit the new bearings. CAUTION! Chill the bearings to facilitate fitting! Fit the new bearings at their locations. Use an intermediate ring as shown in Fig. 5:5 to prevent damaging the bearings. Fig. 5:2 Centre cover plate Screws for securing centre cover plate Screws for securing rotor mount F. Roll the rotor back to its position inside the casing and refit the other components in the reverse order. G. Use the adjusting screws shown in Fig. 5:2 to adjust the sealing gap, approx. 8 mm clearance around the periphery of the rotor and tighten the screws to secure the rotor mount, see Fig. 5:2. Intermed. ring absorbs taps Fig. 5:4 Fig. 5:5

8 8 Installation and maintenance 6. TO CHANGE THE ROTOR BEARINGS SIZES (460/500) Access to the rotor from both the upper and lower unit connections is necessary in order to replace the bearings. Front panel Rotor mount Adjusting screw Fig. 6:4 Fig. 6:1 Corner piece Top panel Upright frame diagonal stay E. Back off the two screws in the rotor mounts and at the same time lift the rotor about 200 mm. Block up the rotor using two 450 mm long, 100 by 100 mm wooden studs between the casing centre beam and the rotor hub, lower the rotor. See Fig. 6:4 and 6:5. Back off the centre screw in one of the rotor mounts and extract the rotor shaft in the opposite direction. See Fig. 6:4. Corner piece Side panel Rotor mount Side panel Fig. 6:2 Rotor shaft B. Dismantle the upper casing components in the following order: First the diagonal stays, then the top panels, corner pieces, side panels and finally the upright frame. See Fig. 6:2. C. Remove the drive belt from the motor pulley. D. Back off the screws and remove the centre cover plate. See Fig. 6:3. Centre cover plate Rotor mount Fig. 6:5 Rotor mount Rotor shaft 450 mm long 100 by 100 mm wooden studs Screws for securing rotor mount Fig. 6:3 Screw for securing centre cover plate

9 Installation and maintenance 9 6. TO CHANGE THE ROTOR BEARINGS SIZES (460/500) F. When changing the rotor bearings, the seal ring must also be dismantled and replaced. The worn bearings can now be tapped out from the rotor hub as shown in Fig. 6:6. Clean the bearing locations and the inside of the bearing casing to remove old grease and fit the new bearings. CAUTION! Replace both the inner and outer sealing rings! Chill the bearings to facilitate fitting! Fit the new bearings at their locations. Use an intermediate ring to prevent damaging the bearings. See Fig. 6:7. Fig. 6:6 G. Lower the rotor back to its position and refit the other components in the reverse order. H. Use the adjustment screws, shown in Fig. 6:4, to adjust the sealing gap, approx. 8 mm clearance around the periphery of the rotor and tighten the screws to secure the rotor mount, see Fig. 6:4. I. Inject 20 g. of type MOLUB ALLOY 787 lubricant in each bearing. Fig. 6:7

10 10 Installation and maintenance 7. MAINTENANCE The rotor, seals and drive equipment are the main components of the heat exchanger that require inspection and service. The heat exchanger is accessible for service through two inspection covers extending over the entire end of the heat exchanger. ROOM SIDE The following should be connected to this side: exh. air duct from premises supply air duct to premises Room side Rotor Centre beam Peripheral seal Casing Fig. 7:1 V-belt Motor bracket DIRECTION OF ROTATION The direction of rotation shall be such that a point on the exhaust air side of the rotor moves towards the purging sector. The location of the purging sector is shown by yellow tape on the heat exchanger casing. Inspection cover Purging sector Yellow tape marks the location of the purging sector Drive motor Outdoor air side Centre beam MAINTENANCE SCHEDULE The intervals tabulated below are applicable to the heat exchanger on daytime operation only. If the actual operating conditions are very different, e.g. if conditions are dusty, if condensation occurs or if the operating time is longer, the intervals must be reduced. Maintenance of the heat exchanger will be greatly facilitated if the recommended supervisory and purging equipment is installed. Object Interval Maintenance work Face surfaces of the rotor 6 months Inspect and clean. Rotor bearings 12 months If the bearings need periodic greasing, check and lubricate. Rotor of split design 6 months (1 month applicable to the initial first period ) Check the clamping of the sectors. Seals 6 months Check and adjust the seal positions. Gap of 1.5 mm. Drive 6 months (1 and 3 months applicable to the initial first period ) Check the belt tension and adjust if necessary. Angle-drive gearbox 6 months Check the oil and grease content if the gearbox is fitted with a plug. See the instruction plate on the gearbox. For particulars of changing the oil or gre ase, see the instructions supplied for the angedrive gearbox. Supervisory and purging equipment 12 months Check the performance. Fig. 7:2 CAUTION! During the installation period, protect the heat exchanger against water and moisture. Take care not to damage the end surfaces of the rotor, since they are relatively sensitive to physical damage.

11 Installation and maintenance MAINTENANCE ROTOR Face surfaces Check that there is no dust deposit on the rotor faces. If necessary, clean by vacuum-cleaning or blowing clean with compressed air from the clean side towards the dustcoated side. If vacuum-cleaning or blowing with compressed air proves to be inadequate (greasy dust), clean the rotor surface as follows: Spray a grease solvent by hand onto the dust-coated surface, then blow clean with compressed air from the opposite side. As an alternative, the rotor may be flushed with lowpressure steam or water, provided that the condensate from the steam or the flushing water can be satisfactory collected. DRIVE BELT Fit a new drive belt if the existing one is damaged or worn. Tension the driving belt once a year. Shortening the drive belt IMPORTANT! Do not use methyl ethyl ketone, acetone or other aggressive solvents. N.B. File the screws so that they are flush with the underside of the belt lock. Bearings Units in sizes up to and including 300 are equipped with permanently lubricated bearings. The larger size units have bearings equipped with grease nipples for periodic lubrication. The normal lubrication intervals (12 months) and the recommended grease are specified on a separate lubrication plate. The grease nipple for each rotor bearing is located below the corresponding hub cap. The grease nipples on size units are located on the topside of the shaft mounting plates; the grease nipples on size units are located on the underside of the shaft mounting plates as shown in the figure 7:3 below. Location of grease nipple on size exchangers Fig. 7:4 Cut the belt as shown in the above drawing. Use a belt lock to join the belt ends. ANGLE-DRIVE GEARBOX The angle-drive gearbox may be filled with either oil or grease. Certain gearboxes have a threaded plug for topping-up and inspection. Check the oil or grease content of these gearboxes twice a year. Gearboxes that have no plug are permanently lubricated. When changing the oil or grease or topping up, use the same type of lubricant as that used for the gearbox previously. The type of oil or grease is specified on the gearbox. Adjust the quantity so that the gearcase will be half full. For particulars of other service on the angle-drive gearbox, see the instructions supplied. Fig. 7:3 Location of grease nipple on size exchangers Split rotor Particularly during the initial period, check that all rotor sectors are firmly clamped in position.

12 12 Installation and maintenance 8. SERVICE SCHEDULE Initial operating period Item Rotor of split design See page 15 (Assembly instruction 9331) Belt drive 11 Action Check the clamping of the rotor sectors. Check the drive belt tension and adjust as necessary.fl After 1 month of operation After 3 month of operation Date Initials Date Initials From... to.... Item See page Action Rotor face surfaces 11 Inspect and clean if necessary. Rotor bearings 7, 8, 9, 11 Inspect and lubricate as necessary. Rotor of split design 15 (Assembly instruction 9331) Rotor seals 5 Check the clamping of the rotor sectors. Check the seal gaps (1 1.5 mm) and adjust as necessary. Belt transmission 11 Check the belt tension and adjust as necessary. Angle-drive gearbox (version with drain plug) Supervisory and purging equipment 11 Check the lubricant level. Change the oil or grease in accordance with the instructions supplied with the angle-drive gearbox. 11 Check the performance. After 6 month After 12 month Date Initials Date Initials From... to.... Item See page Action Rotor face surfaces 11 Inspect and clean if necessary. Rotor bearings 7, 8, 9, 11 Inspect and lubricate as necessary. Rotor of split design 15 (Assembly instruction 9331) Rotor seals 5 Check the clamping of the rotor sectors. Check the seal gaps (1 1.5 mm) and adjust as necessary. Belt transmission 11 Check the belt tension and adjust as necessary. Angle-drive gearbox (version with drain plug) Supervisory and purging equipment 11 Check the lubricant level. Change the oil or grease in accordance with the instructions supplied with the angle-drive gearbox. 11 Check the performance. After 6 month After 12 month Date Initials Date Initials

13 Installation and maintenance SERVICE SCHEDULE From... to.... Item See page Action Rotor face surfaces 11 Inspect and clean if necessary. Rotor bearings 7, 8, 9, 11 Inspect and lubricate as necessary. Rotor of split design 15 (Assembly instruction 9331) Rotor seals 5 Check the clamping of the rotor sectors. Check the seal gaps (1 1.5 mm) and adjust as necessary. Belt transmission 11 Check the belt tension and adjust as necessary. Angle-drive gearbox (version with drain plug) Supervisory and purging equipment 11 Check the lubricant level. Change the oil or grease in accordance with the instructions supplied with the angle-drive gearbox. 11 Check the performance. After 6 month After 12 month Date Initials Date Initials From... to.... Item See page Action Rotor face surfaces 11 Inspect and clean if necessary. Rotor bearings 7, 8, 9, 11 Inspect and lubricate as necessary. Rotor of split design 15 (Assembly instruction 9331) Rotor seals 5 Check the clamping of the rotor sectors. Check the seal gaps (1 1.5 mm) and adjust as necessary. Belt transmission 11 Check the belt tension and adjust as necessary. Angle-drive gearbox (version with drain plug) Supervisory and purging equipment 11 Check the lubricant level. Change the oil or grease in accordance with the instructions supplied with the angle-drive gearbox. 11 Check the performance. After 6 month After 12 month Date Initials Date Initials From... to.... Item See page Action Rotor face surfaces 11 Inspect and clean if necessary. Rotor bearings 7, 8, 9, 11 Inspect and lubricate as necessary. Rotor of split design 15 (Assembly instruction 9331) Rotor seals 5 Check the clamping of the rotor sectors. Check the seal gaps (1 1.5 mm) and adjust as necessary. Belt transmission 11 Check the belt tension and adjust as necessary. Angle-drive gearbox (version with drain plug) Supervisory and purging equipment 11 Check the lubricant level. Change the oil or grease in accordance with the instructions supplied with the angle-drive gearbox. 11 Check the performance. After 6 month After 12 month Date Initials Date Initials

14 14 Installation and maintenance 9. INSTRUCTIONS PACKAGING/LIFTING/TRANSPORT Fig. 9.1 Packaging/delivery design with one piece rotor/casing Fig. 9.2 Packaging/delivery design with Fig. 9.3 segmented rotor/split casing On site the heat exchanger can be removed with a crane/ lifting wires or using a forklift truck.

15 Installation and maintenance 15 NOTES

16 FG_DC_9332GB_PUM (O,R,V)_IN-MA_ _R0 Copyright 2018 FläktGroup PUM (O,R,V) A HISTORY OF INNOVATION AND RELIABILITY With more than a century of accumulated industry experience, FläktGroup is in a unique position to deliver energy efficient components and solutions for integrated performance, reliability and quality. With modern manufacturing technologies, precise deliveries and technical support, FläktGroup is your partner fulfilling and surpassing industry standards and certifications.» Learn more on or contact one of our offices

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