ECONOVENT PUM Installation and maintenance instructions for rotary heat exchangers

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Colin Fox
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1 Plant: Heat exchanger designation: ECONOVENT PUM Installation and maintenance instructions for rotary heat exchangers

2 Contents Design, Condition on delivery Handling, Loads on 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 Maintenance Service schedule Instructions Packaging/Lifting/Transport Fläkt Woods 2588 GB Specifications are subject to alteration without notice

3 Design condition on delivery Design Condition on delivery ROOM SIDE The following should be connected to this side: exh. air duct from premises supply air duct to premises 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. Sizes Room side Rotor Fig. 1:3 Centre beam Inspection cover Peripheral seal 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 Outdoor air side Fig. 1:4 Sizes are always delivered with the one-piece casing and with the rotor installed in the casing as shown in Fig. 1:3. Sizes 150 and 240 can be supplied either as one unit or as a split unit as shown in Fig. 1:4. Centre beam Fig. 1:5 Fig. 1:2 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. Sizes Fig. 1:6 Sizes are always supplied with a split casing and sectorized rotor as shown in the figures above. the Assembly instructions for assembling a heat exchanger of split design. Fläkt Woods 2588 GB Specifications are subject to alteration without notice

4 Handling, loads on 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 240 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. Loads on the heat exchanger The heat exchanger must rest on a flat load-bearing surface. If other components, such as ducts or other sections of the air handling unit, are connected directly at the top of the heat exchanger, they must apply equal loads to the duct connection of the heat exchanger as shown in Fig. 2:3 below. On sizes inclusive, no load-bearing centre beam need be provided under the heat exchanger, provided that the load on each of the duct connections is not in excess of 100 kg. If the heat exchanger carries heavy components, the load-bearing centre beam must be designed to withstand the entire weight of the heat exchanger and the weights of the components mounted on the exchanger. The maximum permissible deflection of the load-bearing centre beam caused by the weight of the heat exchanger and any other components is 1 mm. Size Max. load per connection as shown in fig. 2:3, F, kg F F Fig. 2:1 Fig. 2:3 F Fig. 2:4 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. 2:2 Fig. 2:5 Inspection cover measuring at least 600 x 600 mm. Fläkt Woods 2588 GB Specifications are subject to alteration without notice

5 Connection Checks Rotor seals 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. Kanal Duct Kanal Duct 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. 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. Kanal Duct Kanal Duct 1 1,5 mm Fig. 3:1 1 1,5 mm Fig. 3:2 RUMSIDA Till denna sida anslutes frånluft från lokalerna tilluft till lokalerna ROOM SIDE The following should be connected to this side: exh. air duct from premises supply air duct to premises RAUMSEITE Auf dieser Seite werden Abluftkanal vom Raum bzw. Frischluftkanal zum Raum angeschlossen. J ca 8 mm Peripheral seal Fig. 3:3 Fig. 3:4 ca 8 mm 1 1,5 mm Centre-beam seal Sizes Fig. 3:5 Fig. 3:6 ca 8 mm Hub seal 1 1,5 mm Centre-beam seal Sizes Instruction plate located on the room side of the heat exchanger Fläkt Woods 2588 GB Specifications are subject to alteration without notice

6 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. Installation of speed controller and run of cables 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. 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 Fläkt Woods 2588 GB Specifications are subject to alteration without notice

7 To change the rotor bearings sizes Cross-brace End cover Centre screw Sealing strip Rotor mount Fig. 5:1 Drive motor Fig. 5:3 Rotor shaft A. Fig. 5:1. 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. Rotor mount Adjusting screw D. 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. 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. Fig. 5:2 Centre cover plate Screws for securing centre cover plate Screws for securing rotor mount B. Fig. 5:2. Back off the screws and remove the centre cover plates. 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. Fig. 5:3. Fig. 5:4 Intermed. ring absorbs taps Fig. 5:5 Fläkt Woods 2588 GB Specifications are subject to alteration without notice

8 To change the rotor bearings sizes 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 A. Fig. 6:1. Dismantle the front panels. Corner piece Top panel Upright frame diagonal stay Corner piece E. Fig. 6:4. 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. 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. Side panel Side panel Fig. 6:2 B. Fig. 6:2. 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. C. Remove the drive belt from the motor pulley. Rotor mount Rotor shaft Rotor mount Screws for securing rotor mount Fig. 6:3 Centre cover plate Screw for securing centre cover plate D. Fig. 6:3. Back off the screws and remove the centre cover plate. Fig. 6:5 Rotor mount Rotor shaft 450 mm long 100 by 100 mm wooden studs Fläkt Woods 2588 GB Specifications are subject to alteration without notice

9 To change the rotor bearings sizes 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. 7:1. 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. Fig. 7:2. 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. 7:1 Fig. 7:2 Fläkt Woods 2588 GB Specifications are subject to alteration without notice

10 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 the side exhaust air from the premises supply air to the premises Room side Rotor Centre beam Peripheral seal Casing Fig. 25: 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 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 6 months Inspect and clean. rotor Rotor bearings 12 months If the bearings need periodic greasing, check and lubricate. Rotor of split design 6 months (1 month Check the clamping of the applicable to the initial sectors. first period of operation) Seals 6 months Check and adjust the seal positions. Gap of 1.5 mm. Drive 6 months (1 and 3 Check the belt tension months applicable and adjust if necessary. to the initial first period of operation) Angle-drive gearbox 6 months Check the oil and grease content if the gearbox is fitted with a plug. 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 12 months Check the performance. purging equipment Centre beam Fig. 25:2 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. Fläkt Woods 2588 GB Specifications are subject to alteration without notice

11 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. Important! Do not use methyl ethyl ketone, acetone or other aggressive solvents. Bearings Units in sizes up to and including 240 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 26:1 below. Location of grease nipple on size exchangers 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 Fig. 26:2 N.B. File the screws so that they are flush with the underside of the belt lock. 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. 26:1 Location of grease nipple on size exchangers Split rotor Particularly during the initial period of operation, check that all rotor sectors are firmly clamped in position. Fläkt Woods 2588 GB Specifications are subject to alteration without notice

12 Service schedule Initial operating period Belt drive 6, 28 Check the drive belt tension and adjust as necessary. After 1 month of After 3 months of Date Initial Date Initials Belt transmission 6, 28 Check the belt tension After 1 month of After 3 months of Belt transmission 6, 28 Check the belt tension After 1 month of After 3 months of Fläkt Woods 2588 GB Specifications are subject to alteration without notice

13 Service schedule Belt transmission 6, 28 Check the belt tension Belt transmission 6, 28 Check the belt tension Belt transmission 6, 28 Check the belt tension Fläkt Woods 2588 GB Specifications are subject to alteration without notice

14 Service schedule Belt transmission 6, 28 Check the belt tension Belt transmission 6, 28 Check the belt tension Belt transmission 6, 28 Check the belt tension Fläkt Woods 2588 GB Specifications are subject to alteration without notice

15 Service schedule Rotor seals 35 Check the seal gaps (1 1.5 mm) Belt transmission 6, 28 Check the belt tension Belt transmission 6, 28 Check the belt tension Belt transmission 6, 28 Check the belt tension Fläkt Woods 2588 GB Specifications are subject to alteration without notice

16 Service schedule Belt transmission 6, 28 Check the belt tension Belt transmission 6, 28 Check the belt tension Belt transmission 6, 28 Check the belt tension Fläkt Woods 2588 GB Specifications are subject to alteration without notice

17 Service schedule Belt transmission 6, 28 Check the belt tension Belt transmission 6 28 Check the belt tension Belt transmission 6, 28 Check the belt tension Fläkt Woods 2588 GB Specifications are subject to alteration without notice

18 Instructions packaging/lifting/transport Packaging/delivery performance with one piece rotor/casing On site the heat exchanger can be removed with a crane/lifting wires or Packaging/delivery performance with split rotor/split casing Using a forklift truck Fläkt Woods 2588 GB Specifications are subject to alteration without notice

19 Fläkt Woods AB, SE Jönköping T F W SEFLE 2588 GB teleskop reklambyrå

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

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