OPERATION AND MAINTENANCE DOCUMENTATION ROTARY HEAT EXCHANGER equipped with cylindrical gearmotor with EURA DRIVES converter DTR ver.1 (06.2014) www.barbor.biz
TABLE OF CONTENTS: 1. GENERAL INFORMATION... 3 2. INTRODUCTION.... 3 3. INTENDED USE OF THE DEVICE.... 4 4. MAIN COMPONENTS OF THE EXCHANGER..... 4 5. HOUSING... 4 6. ROTOR. 5 7. DRIVE BELT...... 5 8. BEARINGS. 5 9. INDUCTIVE SENSOR... 5 10. GEARMOTOR....... 6 11. FREQUENCY CONVERTER....... 6 12. TECHNICAL PARAMETERS OF THE FREQUENCY CONVERTER..... 7 13. MANUAL FOR THE FREQUENCY CONVERTER... 7 14. ELECTRICAL ACTUATOR WIRING DIAGRAM.....8 15. NAMEPLATE...... 9 16. DESCRIPTION OF THE ROTARY HEAT EXCHANGER CODE....... 9 17. DIMENSIONS AND WEIGHT..... 11 18. PACKING...... 12 19. TRANSPORT... 12 20. UNLOADING.... 12 21. STORAGE...... 14 22. INSTALLATION AND COMMISSIONING.... 14 23. OPERATION..... 15 24. OHS INSTRUCTIONS RELATED TO THE OPERATION OF THE DEVICE... 16 25. WARNINGS.... 16 26. DECLARATION OF CONFORMITY...... 17 27. WARRANTY..... 17 28. WARRANTY LIMITATIONS.... 18 29. WARRANTY CARD...... 18 30. FAILURE REPORT SHEET....... 18 31. CONTACT..... 18 DTR ver.1 (06.2014) www.barbor.bi z 2
1. GENERAL INFORMATION The content of this documentation corresponds to the version of the equipment described herein. However, some differences may appear and it shall not be guaranteed that the equipment received is identical to the documentation. Other functions may also be available that are not described in this documentation. The information contained herein is regularly reviewed. Any updates to the information and other necessary changes will be introduced on an ongoing basis. The products of the BARBOR company were designed and produced in accordance with the ISO 9001:2008 Quality Standards. 2. INTRODUCTION This Operation and Maintenance Documentation (OMD) concerns rotary heat exchangers produced by the BARBOR Sp. z o.o. company. It contains a summary of the basic information relating to the construction, transport, installation, commissioning and operation of our equipment. The observance of the information contained herein will ensure their proper and failure-free functioning. However, the performance of these tasks must take place in accordance with the recommendations contained in this OMD. Failure to comply with the aforementioned recommendations may result in loss of warranty. Familiarising yourself with this manual and the use of the devices in accordance with the terms specified herein as well as compliance with all safety requirements form a basis for the proper and safe functioning of the devices. DTR ver.1 (06.2014) www.barbor.bi z 3
3. INTENDED USE OF THE DEVICE The device is intended to operate in ventilation and air-conditioning installations. DOKUMENTACJA 4. MAIN COMPONENTS OF THE TECHNICZNO-RUCHOWA EXCHANGER 5. HOUSING Frames and sheets of the housings are made of galvanised steel and do not require maintenance. On special request the housing may be powder- or wet-coated. DTR ver.1 (06.2014) www.barbor.bi z 4
6. ROTOR Rotor is the main element of the rotary heat exchanger. It consists of an alternately spooled corrugated and flat aluminium band, which creates air passage ducts. The rotor functions as an accumulation substance, which heats up in contact with blown off air in order to give off the heat after a turn and coming into contact with the in-blown clean air. 7. DRIVE BELT Depending on the size of the rotor two types of the drive belt are used. A round V-belt which is coupled by means of welding or metal clip is applied to the rotor of the size of Ø 2000 mm. A trapezoidal V-belt with perforations which is coupled in a loop by means of a metal clip is applied to the rotors with a diameter greater than Ø 2000 mm. 8. BEARINGS The device is equipped with high durability ball bearings designed for 100,000 hours of operation. They can operate at a temperature from -30 to +120 C. 9. INDUCTIVE SENSOR Inductive proximity sensor responds to the introduction of the metal in its operation zone. It cooperates with the RE rotation control module, signalling the motion stops. NPN sensor IHF-12OC-4B-2M with the operation zone of 4 mm is integrated in the device. Also, other NPN sensors can be used with a greater operation zone. DTR ver.1 (06.2014) www.barbor.bi z 5
10. GEARMOTOR A 3-phase cage induction motor was combined with a worm gear with the required reduction ration. The motor is adapted for AC power supply in 230/400V ( /Y) circuit at a frequency of 50Hz. In the case of purchase of a complete version of the product the motor connected to the 230V circuit is controlled by means of a one-phase frequency converter. 11. FREQUENCY CONVERTER Rotor speed can be controlled by changing the frequency of the motor supply voltage by means of the frequency converter. The converter produced by EURA DRIVES equipped with a rotor rotation control module (WATCH DOG function) is used for power supply of the actuator. Description of the power train operation The efficiency of the heat recovery or cooling exchanger is regulated by the standard control signal 0 10VDC, controlling the rotation speed of the rotor. The signal must be transmitted to the terminal strip of the frequency. It is also required that a voltage-free signal is transmitted to the converter, which initiates the operation of the actuator and activation of the inductive sensor (see point 14 ELECTRICAL DIAGRAM). Correct and incorrect operational status are signalled by means of the converter. In the event of an alarm, the power train and frequency converter must be subject to control. By default, a frequency converter, rotation control module and inductive sensor are mounted in the housing of the exchanger. An electrical connection between the converter and actuator motor are made by the manufacturer. Other connections are to be established by the installer. DTR ver.1 (06.2014) www.barbor.bi z 6
12. TECHNICAL PARAMETERS OF THE FREQUENCY CONVERTER Power supply of the inverter (L, N, PE) Power 230/240 V AC ; 50/60 Hz 0.2kW Output current 1.5A Control signal Signal for the system actuation Relay output ALARM Transistor output 0 10 V DC voltage-free contact 250 V AC; 2.5A / resistive load 24VDC, 50mA, voltage output readiness for operation 13. MANUAL FOR THE FREQUENCY CONVERTER A detailed description is available in the manual on the CD attached to the documentation. Control functions and signalling Circuit state Circuit power supply Circuit in operation Signalling and procedure On the display of the converter the min available actuator output frequency in Hz is cyclically shown, DO1 output is available (24VDC), terminals TB-TC closed On the display of the converter the actuator operation output frequency is shown in Hz, DO1 output is active (24VDC), terminals TB-TC closed WATCH-DOG (rotation control) Other Alarm On the display of the converter Err6 is shown, DO1 output is not active (0VDC), terminals TB-TC opened, actuator is not operating, deletion of the error by means of the STOP/RESET button after the cause of the failure is remedied On the display of the converter another error code is shown check the code in the manual of the converter and proceed according to the instructions Rotation control module operation After exceeding the threshold of 0..10V control signal, the control of operation of the actuator is started. In the case of absence of an impulse from the inductive sensor signalling its motion within 120s the driver enters the alarm state. The Alarm is deleted automatically on the converter once the cause of the failure is remedied. DTR ver.1 (06.2014) www.barbor.bi z 7
14. Electrical Actuator Wiring Diagram Actuator control 0..10VDC Actuator control START/STOP 230VAC actuator power supply Alarm output NC contact 24VDC output * Inductive sensor black blue brown Frequency converter *Converter ready for operation **The same terminal Motor-inverter cable connection made by the manufacturer, other electrical connections to be made by the installer Actuator motor of the rotary exchanger Additionally, the diagram is available on the attached CD. DTR ver.1 (06.2014) www.barbor.bi z 8
15. NAMEPLATE The nameplate shows the main technical details relating to the construction of the exchanger and determines the serial number and year of manufacture. The plate is located inside the housing on the operating side. It is very important to keep the information readable. 16. DESCRIPTION OF THE ROTARY EXCHANGER CODE I. Type of the housing: CR basic (standard) housing CP painted housing II. Accumulation substance material A aluminium H aluminium with absorbent coating III. Height of slats: 17 1.7 mm 19 1.9 mm IV. Rotor width: 200 200 mm 250 250 mm V. Diameter of the heat exchanger: min 200 mm max 2500 mm VI. Housing width: min 400 mm max 2650 mm DTR ver.1 (06.2014) www.barbor.bi z 9
VII. Housing height: min 400 mm max 2650 mm VIII. Division of the heat exchanger: V vertical H horizontal IX. Cleaning sector: 0 cleaning sector disabled F1 on the front side of the heat exchanger on the right side/on the front side of the heat exchanger at the top F2 on the front side of the heat exchanger on the left side/on the front side of the heat exchanger at the bottom R1 in the rear of the heat exchanger on the right side/ in the rear of the heat exchanger at the top R2 in the rear of the heat exchanger on the right side/ in the rear of the heat exchanger at the top X. Location of the motor: 1 at the bottom on the left side 2 - at the bottom on the right side 3 - at the top on the left side 4 - at the top on the right side XI. Actuator and control: 00 actuator and control disabled D0 actuator (gear motor, drive belt, pulley) DC actuator and control (gear motor, drive belt, pulley, frequency converter, inductive sensor, rotation control module) DTR ver.1 (06.2014) www.barbor.bi z 10
17. DIMENSIONS AND WEIGHT Rotor diameter Height Width Rotor width 200 mm Depth Rotor width 250 mm D H B A A Rotor width 200 mm Weight Rotor width 250 mm mm mm mm mm mm kg kg 500 600 700 325 375 49 55 600 700 800 325 375 56 63 700 800 900 325 375 63 71 800 900 1000 325 375 71 81 900 1000 1100 325 375 80 91 1000 1100 1100 325 375 86 98 1100 1200 1200 325 375 96 110 1200 1300 1300 325 375 119 135 1300 1400 1400 325 375 131 149 1400 1500 1500 325 375 143 163 1500 1600 1600 325 375 166 190 1600 1700 1700 325 375 179 207 1700 1800 1800 325 375 194 224 1800 1900 1900 325 375 212 244 1900 2000 2000 325 375 228 263 2000 2100 2100 325 375 245 283 2100 2200 2200 325 375 263 304 2200 2300 2300 325 375 283 327 2300 2400 2400 325 375 302 350 2400 2500 2500 325 375 321 374 2500 2600 2600 325 375 342 397 DIMENSIONS APPLY TO THE STANDARD HEAT EXCHANGERS, BUT DUE TO THE FLEXIBILITY OF THE MANUFACTURING PROCESS DIMENSIONS AND WEIGHT MAY BE CHANGED. DTR ver.1 (06.2014) www.barbor.bi z 11
18. PACKING During the transport the rotary heat exchanger is protected by a foil and packed in a wooden box. The box is equipped with a sticker detailing the code and product weight. 19. TRANSPORT Due to the size, weight and height of location of the centre of gravity, this section is very unstable. The manufacturer recommends to safeguard the rotary heat exchanger by appropriate fastening to the vehicle transporting the device. If the dimension of the section exceeds the height of the transporting vehicle, additional safeguards should be applied. TRANSPORT OF THE HEAT EXCHANGER IS POSSIBLE ONLY IN THE OPERATING POSITION! 20. UNLOADING Depending on the size and weight of the heat exchanger a crane or forklift should be used. In the case of use of the lift, protection of the device against damages and deformations by means of spacers inserted between the belts is necessary. In the case of transport by the lift, it is necessary to check the space between the openings in the transport frame. During the operation of lifting of the section, it is necessary to check the centre of gravity by lifting slightly (it must be above the fork). Unloading of the devices from the transport vehicle and moving them around the construction site must take place in accordance with the generally accepted OHS regulations. Immediately after the delivery of the device at the destination the condition of the packaging and product as well as completeness of the attached documents should be checked. Before lifting the heat exchanger, it is necessary to check its exact weight and the strength of the slings, as well as familiarise yourself with the data relating to the dimensions of the device attached to the OMD. DTR ver.1 (06.2014) www.barbor.bi z 12
ggg REMARKS CONCERNING UNLOADING BY MEANS OF A FORKLIFT AND CRANE ARE PRESENTED IN THE ILLUSTRATIONS BELOW Before lifting the heat exchanger, you must make sure if the forks are long enough. Lifting the heat exchanger with a crane. DTR ver.1 (06.2014) www.barbor.bi z 13
21. STORAGE The device should be stored in dry rooms sheltered against precipitation, free from dusts, gaseous and corrosive substances. The maximum relative humidity must not exceed 80% at 20 C. The ambient temperature should not be higher than +40 C and not lower than -20 C. The devices can be stored and transported only in one layer. Placing any other elements on them is not permissible. ANY DAMAGES RESULTING FROM IMPROPER STORAGE, TRANSPORT OR UNLOADING ARE NOT COVERED BY THE WARRANTY. 22. INSTALLATION AND COMMISSIONING Installation of the heat exchanger requires a well-leveled surface. With the drive belt removed it must be manually controlled if the rotor rotates freely without obstruction (the correct direction of the rotations of the rotor is marked with a black arrow on a white background, located on the rim of the rotor). Check if the heat exchanger surfaces are not blocked and free from dirt or if the slats are not damaged. Check the adhesion of the sealing brushes on the rotor to housing side plates of the rotary heat exchanger (set by default, but they can move during transport). Remove the screw securing the motor plate. Put the drive belt on the pulley of the gear, making sure that the belt is not slipping on the rotor (tension set by default). Check if the electric device rotates freely in the required directions. Cable openings are secured with a PVC tape. Make use of the appropriate ones by removing the tape and installing a rubber stuffing box in order to seal the openings on the wires. Rubber stuffing boxes for cable openings (8 pcs) are safeguarded and placed on the housing. DTR ver.1 (06.2014) www.barbor.bi z 14
Check if the power supply and control system of the heat exchanger is connected properly in accordance with the rotary heat exchanger actuator diagram. If required, make any necessary adjustments and, after launching the control unit, check if the rotor rotates in the correct direction. AFTER INSTALLATION IT IS NECESSARY TO CHECK THE " PERPENDICULARITY" OF THE HOUSING THAT AFFECTS THE DURABILITY OF THE ROTOR AND TIGHTNESS OF THE SECTION. COMMISSIONING OF THE ROTARY HEAT EXCHANGER CANNOT TAKE PLACE BEFORE IT IS INSTALLED IN THE VENTILATION CONTROL UNIT MEETING THE RELEVANT PROVISIONS OF THE EU DIRECTIVE (IN ACCORDANCE WITH ANNEX IIB OF THE MACHINERY DIRECTIVE 98/37/EC OF 22.06.1998) 23. OPERATION If dirty, the cleaning of the slat block should be carried out with compressed air or noncorrosive detergent. Compressed air flow should be directed in the direction opposite to the air flow. Particular attention should be paid to the condition of the drive belt and smooth and uninterrupted rotation of the rotor itself. The state of sealing brushes and power supply and control cables (if they have not become loose) should also be checked. In the event of blow-offs cable glands (stuffing boxes) must be sealed. Stretching of the drive belt during operation is a natural process, and therefore it is necessary to periodically check whether the too stretched belt does not slip on the rotor (check every three months). Due to the simplicity of the procedure shortening of the belts does not require elaboration. Check of individual components of the device should be preceded by general inspection with particular focus on the state of silicone seals and metal surfaces (in terms of possible corrosion centres in order to quickly eliminate the corrosion) Maintenance of ball bearings is not required. DTR ver.1 (06.2014) www.barbor.bi z 15
Under normal operating conditions the motor does not require maintenance (gear is filled once with grease for the entire period of the operation). Irrespective of this, it is recommended to regularly check the motor in order to prevent failures caused by dirt, humidity or vibrations. THE ROTARY HEAT EXCHANGER MUST BE CONTROLLED NOT LESS THAN EVERY 6 MONTHS. 24. OHS INSTRUCTIONS RELATED TO THE OPERATION OF THE DEVICE Device connecting and commissioning procedures should take place under conditions corresponding to the applicable regulations, especially in the scope of operation of electrical equipment. Connecting procedures can be performed only by qualified persons. The mains voltage cannot be connected if the device is not connected to the protective system. The performance of repair and maintenance works without shutting down the power grid is forbidden. The operation of the device with any cover removed or with inspection doors opened is prohibited. The persons performing the maintenance or repair works or service the device must hold appropriate qualifications and obtain qualification certificate laid down in the Ordinance of the Ministry of Mining and Energy on the qualifications of persons employed in the operation of power equipment. 25. WARNINGS There are dangerous voltages within the discussed devices. The device controls rotating mechanical parts which pose a threat to life and health. Failure to observe this warning or to comply with the instructions contained in this manual may result in death, serious injuries or substantial property damages. DTR ver.1 (06.2014) www.barbor.bi z 16
Only properly qualified employees can operate the device. These employees must be thoroughly familiar with all safety instructions, conditions and method of installation, device operation and measures that allow to keep the device in proper condition contained in this manual. Proper and safe operation of the device is based on appropriate transport, installation and operation in line with regulations and proper maintenance. Access to the device by children and third parties should be prevented. The device must be used only in accordance with its intended use specified by the manufacturer. Any unauthorised modifications or use of spare parts and accessories which are not recommended by the product manufacturer may cause an electrical shock or other bodily injuries. This manual should be carefully stored in the vicinity of the device and made available to all users of the device. 26. DECLARATION OF CONFORMITY The rotary heat exchangers manufactured by our company, although they meet the definition of machines, cannot be stand-alone devices. A heat exchangers fulfils its function only when it is built in the ventilation control unit. In accordance with Directive 98/37/EC Chapter 1, Article 4, item 2, the aforementioned group of our products cannot bear the EC marking and does not require the declaration of conformity; however, BARBOR issues a declaration of conformity which is attached to the product documentation. 27. WARRANTY The product has a warranty for repair of faults in the construction and sub-assemblies for a period of 24 (twenty four) months from the date of its sale. The terms of the warranty are set forth in the Warranty Card. DTR ver.1 (06.2014) www.barbor.bi z 17
28. WARRANTY LIMITATIONS If upon the inspection it has been proved that the responsibility for a fault lies with the manufacturer, the warranty shall cover the replacement of the damaged components. The product warranty will be invalid if any part of any system or component has been manipulated. Any repair of damages arising from lack of maintenance or incorrect operation is excluded. 29. WARRANTY CARD A completed warranty card is attached to the product documentation. A complaint may be lodged only upon presentation of the warranty card. 30. FAILURE REPORT SHEET The sheet is available on the CD attached to the documentation. 31. CONTACT BARBOR Sp. z o.o. Skowarcz, ul. Klimatyczna 4 83-032 Pszczółki phone: +48 58 741 88 03 fax: +48 58 741 88 94 e-mail: barbor@barbor.biz web: www.barbor.biz DTR ver.1 (06.2014) www.barbor.bi z 18