Novenco Air Handling Units

Novenco Air Handling Units
Climaster ZCR – Installation and maintenance
918015-0 – GB
Important
This document is made available ‘as it is’. Novenco Marine & Offshore reserves the right to make changes without
prior notice due to further development of the product.
Copyright © 2014, Novenco Marine & Offshore A/S. All rights reserved.
Trademarks
Novenco® is a trademark of Novenco A/S.
Hi-Pres® is a trademark of Novenco Marine & Offshore A/S.
Other trademarks appearing in this document are the property of their respective owners.
Novenco Climaster ZCR
1. General Introduction
2. Handling
2.1 Weight
2.2 Assembled units
3. Reception on Site
4. Storage
5. Installation and Alignment of
Base Frame
5.1 Alignment of base frame
5.2 Pipe layout
5.3 Electric connections
5.4 Duct connection
5.5 Water trap
6. Description of Unit Casing
6.1 Panels
6.2 Doors
6.3 Cleaning
6.4 Leakage
6.5 Conditions near the air
handling unit
6.6 Surface treatment
6.7 Material description
7. Dampers
7.1 Mounting of damper
motors
7.2 Maintenance
7.3 Damper motors
8. Filters
8.1 Filter guard
8.2 Change of filter/cleaning
8.3 Life
8.4 Recommended final pressure losses for filters
8.5 Replacement filters
9. Rotary Wheel Type Heat
Exchanger
9.1 Drive system
9.2 Check of rotor position in
rotor casing
9.3 Adjustment of rotor
9.4 Purging Sector
MU 15244 0116
9.5
9.6
9.7
9.8
Rotor bearings
Belt drive
Cleaning
Inspection
10. Heating and Cooling Coils
10.1 Pipe connections
10.2 Cleaning
10.3 Demounting of heating
and cooling coils
10.4 Frost protection
10.5 Electric heating coil
10.6 Maximum thermostat
10.7 Overheat thermostat
10.8 Automatic control and
safety functions
10.9 Check of thermostats
10.10 Check of wire connections
10.11 Condensation
13. Motors for Fans
A. Parts List
A.1 Louvre damper SJD
A.2 Compact filters M6
A.3 Pocket filters G4
A.4 Pocket filters M5
A.5 Synthetic panel filters G3
A.6 Alu panel filters G2
A.7 Panel filters G4
A.8 ZCR 9/4 – Fan C2LF 180 M
A.9 Fan C2HB 250-M/630-M
B. Maintenance tools
C. EC-Declaration of conformity
11. Humidification
11.1 Ship steam
11.2 Steam humidifier
11.3 Compressed air/water
12. Fans
12.1 Storage
12.2 Electric connections
12.3 Start-up of fan
12.4 General inspection and
maintenance
12.5 Maintenance
12.5.1 Centrifugal fan
12.5.1.1 Demounting fan unit
12.5.1.2 Belt tension and belt
change
12.5.1.3 Fan bearings
12.5.1.4 Change of bearings
12.5.2 ZerAx Fans
12.5.2.1 Demounting fan unit
12.5.2.2 Mounting fan unit
12.5.3 Plug Fans
12.5.3.1 Demounting fan unit
12.5.3.2 Mounting fan unit
ZCR
3
Novenco Climaster ZCR
1. General Introduction
The instructions describe installation and maintenance of both unit
casing and all components, which
may be included in the unit. Therefore, components, which are not included in the current unit, will also
be described in the instructions.
In the table of contents all sections
are described and numbered, and
both installation and maintenance
instructions are collected under one
heading.
2. Handling
2.1 Weight
The total weight and dimension are
stated on the dimension drawing and
weight lists.
2.2 Assembled units
An assembled unit type ZCR can be
transported by crane in the hoisting
lugs mounted on the base frame, fig.
2.1
For horizontally moving the unit with
a forklift truck, always make sure
that the lifting forks are long enough
to reach the opposite side and properly beyond, fig 2.2, in order to avoid
damage to the bottom panel.
Fig. 2.1
Torsioning (twisting) of the unit must
be avoided in all cases. Spread-er
beams should be used to avoid excessive pressure on the unit casing.
If slings are used, special care
should be taken to avoid damaging
slings where they are subjected to
rubbing, against sharp edges, such
as roof edges, flanges, etc.
3. Reception on Site
On arrival to the erection site check
the unit for transportation damage,
also check whether the extent of
sup-ply is complete.
Fig. 2.2
When handling the unit, be careful
not to hit surface or outside connections.
4 ZCR
Notify the supplier of any damage or
defect immediately.
4. Storage
Units type ZCR are delivered packed
in plastic.
Important: For units with electric
heating coils, storage
must be at relative
moisture levels below
60% and at temperatures above 15 °C.
Outdoor storage of short duration
can be done with the units covered in
plastic. To avoid condensation it is
important that there is ventilation
under the cover.
Longer time of storage calls for removal of the plastic packing and for
indoor storage in dry and ventilated
locations.
Fans are to be manually turned once
a month, prior to turning the fan
mark the position of the impeller to
make sure it is not stopped in the
previous position.
For storage longer than 6 months, Vbelt drive should be loosened.
Air Handling Units are not to be used
as working platforms. If access to
the roof is unavoidable the roof
should be covered with sheet plywood. In addition protection should
be provided to junction boxes, door
handles, dampers etc. to avoid them
being used for climbing.
5 Installation of Base Frame
The air handling units are provided
with a base frame onto which the
sections are assembled, mounted
and fixed with bolts. The base frame
consists of two longitudinal girders
stabilized by transverse girder stiffeners.
The base frame is provided with demountable lifting devices.
The air handling units are normally
supplied assembled. If required the
air handling units may be supplied in
a number of sections for assembly
on site.
5.1 Alignment of Base Frame
The foundation for the air handling
unit must be level. During installation the base frame must be aligned
so that its four corners are level. This
is to avoid torsion of the base frame
and unit casing. Torsion of the unit
casing would affect the built-in components in a way they are not designed for. In air handling units with
a built-in enthalpy exchanger/rotary
wheel type heat exchanger an exact
alignment is particularly important.
Align the base frame by means of
base plates under the longitudinal
profiles each 1300 mm minimum.
Fasten the base frame to the foundation by means of bolts approx. each
1300 mm.
5.2 Pipe layout
Pipe layout must not hamper door
opening, inspection and operation of
the air handling unit.
Pipe inlets in panels are provided
with a seal on the inner sheet of the
panel. The seal is mounted in the
panel from the outside.
nents etc.) with approved cable
(moving parts, e.g. fan motors, with
rubber cable) and according to current regulations.
5.3 Electric connections
Cable inlets in panels must be provided with cable glands to ensure to
be air leakage-tight and against
damage of sharp edges.
5.4 Duct connection
Connect ducts to the inlet and outlet
openings of the air handling units by
means of LS-cleats, fig. 5.2.
Do not lead cable through the inspection doors. Cut hole for cable inlet with lock saw and lead cable
through cable glands as for example
shown on fig. 5.1
Outside
Inside
Fig. 5.1
PG
thread
Metric
thread
Cable diameter
PG16
M20
6.5 - 16.0
PG21
M25
9.0 - 20.0
PG29
M32
17.0 - 28.0
PG36
M40
23.0 - 34.0
PG42
M50
29.0 - 40.0
The flanged bushing with thread is
on the inner side of the panel while
the cable gland in the outside of panel protects the cable from the sharp
edge. Electric installations must be
performed by authorized personnel
and so that they protect against electric shocks.
Connect electric parts (fan motors,
damper motors, electric heating elements, automatic control compo-
Safety switches must be installed
according to appropriate regulations.
Fig. 5.2
Normally, it is not necessary to use
flexible connections for the duct connection (anti-vibration mountings
and flexible connections are built into the unit between fan and casing).
However, external flexible connections for mounting with LS-cleats
are available as accessories.
5.5 Water trap
Drains from “wet” sections (cooling
coils) must be provided with a water
trap. Novenco is able to supply a water trap made of AISI 316, fig. 5.3.
One-way
valve
Air
break
H
H
133
Fig. 5.3
The water trap is designed for negative pressure and is provided with a
ball so that it is tight also without being filled with water. Connect the water trap to the drain from the drip pan
ZCR
5
of the unit. All drains from drip pans
in the unit are with thread (1½” BSP
male).
In order to work, the height of the
water in the water trap (H-measurement) must be higher than the pressure height in the unit (Dp inside/
outside in the unit at the water trap).
Example.: Dp = 1300 Pa. The Hmeasurement must be at least 130
mm and to this must be added the increased pressure loss for fouling of
the filters and also 10 mm for safety:
minimal 300 Pa corresponding to 30
mm. This results in the fact that minimal H-measurement must be 160
mm. It is recommended to make the
H-measurement as high as possible.
For ZCR- fan coil unit with Ø32mm
drain pipe, use ZCN type water trap
made of PP.
6. Description of Unit Casing
The casing of the unit is constructed
of a frame enclosed by panels. The
frame is assembled by means of insertion joints and has soft rounded
edges. The unit casing is smooth inside ensuring easy cleaning.
with a width of socket spanner of 10
mm.
The outside diameter of the socket
spanner must be max. 14 mm in order to go through the hole in the outer sheet of the panel. This hole is
covered by a black plastic hole plug.
The end, top and bottom panels are
fastened to the frame from the inside
by means of sheet metal screws. The
panels are provided with adhesive
sealing strips (9 x 4,5 mm).
6.2 Doors
The access side is provided with
tight-fitting doors which are in principle constructed the same as the
panels.
The doors are provided with a mechanically attached rubber sealing
strip. The hinges are adjustable. By
loosening the screws with inside
hexagon head in the rear edge of the
door, the door can be adjusted vertically and horizontally. After the adjustment tighten the screws again.
6.1 Panels
Fig. 6.2
Fig. 6.1
The panels are 50 mm thick and consist of double-layer sheet steel with
intermediate mineral wool. All panels are screwed onto the frame
structure by means of self-tapping
sheet metal screws 6.3 x 13 mm,
6 ZCR
Fig. 6.3
Doors can be demounted by removing pintles in hinges.
The doors are provided with tongue
locks that are operated by means of
the 8 mm square keys supplied or
can be mounted with handles. The
doors open through 180° ensuring
easy access for inspection and servicing.
6.3 Cleaning
The inner surface of the Climaster
casing must be cleaned for dust and
other impurities, especially in front
of the filters. Cleaning is carried out
by means of a vacuum cleaner in order to remove all impurities so they
are not blown into the room.
6.4 Leakage
The sealing strips of the inspection
doors must be intact.
On removal and subsequent mounting of panels it is important that the
packings are leakage-free. Normally, it is necessary to replace the adhesive sealing strip.
Pipe and cable inlets must be leakage-free.
Check at intervals that duct connections and flexible connections are
leakage-free.
6.5 Conditions near the air handling
unit
Air intake must be kept free of foreign material (paper, leaves etc.).
Recommended cleaning intervals
(Please see the individual components as well):
Sheet steel part above 2mm to 4mm
thick are made of hot-dip galvanized
plate (275g/m2), coat thickness
20m each side.
General inspection: Once a month.
Minor internal cleaning: First time
after 1 month of operation. Afterwards every third month.
Filter check: First time after 1 month
of operation.
Afterwards every third month.
Check of remaining sections: Every
third month.
Thorough overhaul of the entire
unit: Once a year.
6.6 surface treatment
As standards, the sections, framework, and surfaces are coated with
Alu-Zinc.
When stainless steel sections are required, the framework and the panels or the parts of the panels facing
the inside of the ZCR air handling
unit are made of stainless steel quality AISI 316L.
6.7 Material description
Sheet steel parts up to 2mm thick
are made of Alu-Zinc coated sheet
steel, quality B500A AZ150, coat
thickness 20m each side.
Retainers
Sheet steel above 4mm thick are
made of hot-dip galvanized, coat
thickness min 65m each side.
Parts which are electrically galvanized (bolts, screws, etc.) have a coat
thickness of 10-15m.
For stainless steel parts quality AISI
316L is used.
Insulating material is Rockwool A5
with a volume weight of 70 kg/m3.
Sealing Material for fixed panels and
between sections:
Self-adhesive PVC foam strip 6.4 x
12mm.
7. Dampers
The damper consists of a number of
aluminium damper blades mounted
in synthetic bearings in a frame. The
movement of the damper takes place
by means of a coupling plate with
slots for regulating arms with rustproof pins mounted on the individual
damper shafts, fig. 7.1.
Shaft arm
Guide bearing
Coupling plate
Fig. 7.1
Inside and outside dampers are
mounted in/on the unit by means of
LS-cleats.
See appendix “A. Parts List” on
page 24.
7.1 Mounting of damper motors
The dampers on the unit are designed for mounting of Belimo
damper motors. One damper shaft
on each damper is provided with a
shaft extension 11,3/11,3 x115 mm
(stainless units) or Ø15 x 115 mm (aluminium zinc units) for direct
mounting of damper motor type FF/
SM/FM, fig. 7.2.
After electric connection of the
damper motor, adjust the movement
of the damper motor and damper
blades to each other as shown in the
installation instructions for the
damper motor.
Pivot screw
7.2 Maintenance
In practice the SJD damper is maintenance-free, but make sure that the
damper is kept clear of dust and dirt.
This applies to both air path and regulating mechanism outside the air
path.
The damper regulating mechanism
must always be well greased, e.g.
Fig. 7.2
Shaft extension
Guide pin
ZCR
7
with graphite grease, where moving
metal parts slide against each other.
Pay especially attention to this if the
air stream has a degreasing effect.
See appendix “A. Parts List” on
page 24.
7.3 Damper motors
Maintain damper motors according
to instructions from the motor suppliers.
If another type of damper motor is
used it is important to know the regulating moment of the damper.
The various regulating moments are
shown in below table.
Regulating Moments at 400 Pa
Fig. 8.1
AHU type
Moment Nm
ZCR-9/4
8
ZCR-9/6
8
ZCR-9/8
8
ZCR-9/13
8
ZCR-13/6
14
2 Pressure switch
ZCR-13/8
14
ZCR-13/12
14
The door of the filter section is provided with two hose connections
which are led to points of measurement on both sides of the filter. When
supplied, the manometer is mounted on the door of the filter section.
ZCR-18/8
14
ZCR-18/10
20
ZCR-18/12
20
ZCR-18/15
30
For coupled dampers the above values
should be multiplied by 2.
8. Filters
The air handling unit is provided with
one or several of the filter types
shown on this page. Fine filters of
high gravimetric efficiency are often
supplemented by a pre-filter of the
basic filter type.
The filters, marked with type, are inserted in retainers and fastened by
means of locking rails which press
the filter frame against the rubber
packing. The filters are released by
pushing the handles of the rails, fig.
8.1. However, panel type filters are
mounted in U-rails.
8 ZCR
8.1 Filter guard
Two types of filter guards are available, see fig. 8.2:
1 U-tube manometer
When starting up fill up with the
manometrical liquid supplied and
connect the hoses to the manometer.
Fig. 8.2
8.2 Change of filter/cleaning
All filters are disposable and are replaced when the recommended final
pressure loss has been obtained ex-
cept for AW filters which is washable.
8.3 Life
The life of the filters depends on the
operational process and dust concentration in the air.
Checking of the pressure drop
should take place regularly. It is advised not to extend the life by exceeding the recommended pressure
drops, as the air quantity and efficiency of the system is reduced.
Dust build-up in the filters can create unhygienic conditions in the system.
8.4 Recommended final pressure
drop for filters
Filter class
Final press drop
G4
150 Pa
M5-M6-F7
250 Pa
F8-F9
350 Pa
If a prefilter is combined with a fine
filter, use the following procedure:
when the total pressure loss above
both filters exceeds 400 Pa, change
the prefilter. If the pressure loss
above the fine filter alone exceeds
300 Pa, change this filter.
8.5 Replacement filters
Contact Novenco for ordering correct filters.
- Filter type order No.
Panel filters
9. Rotary Wheel Type Heat
Exchanger
Fig 9.2
Fig 9.1
Pocket type filter
ir
na
tur
Fig 9
sh
Fre
air
Fre
Aluminium filter
The rotary wheel type heat exchanger consists of a rotor and a drive system. The rotor has internal ball
bearings and is fastened to the casing by screws through an adjusting
disc (eccentric), a slot in the frame
and a disc at the end of the shaft fig.
9.1. and 9.2.
air
sh
Re
1881815LA
ir
na
tur
Re
1881815LB
Re
tur
na
ir
Fre
sh
air
1881815RA
Fre
sh
Re
tur
air
na
ir
1881815RB
Rotary wheel for ZCR 18/8 to 18/15
ir
na
tur
air
sh
Re
Fre
Location of brush seal, purging sector,
measuring taps and a drive system
Compact filter
sh
air
ir
na
tur
Fre
Re
94138LA
94138LB
Re
tur
Fre
na
Re
Fre
sh
sh
ir
air
94138RA
tur
air
na
ir
94138RB
Rotary wheel for ZCR 9/6 to 13/8
In ZCR 9/6 to 13/8 the brush strip
forming the seal along the circumference of the rotor is mounted on
the rotor whereas the brush strips
forming the seals between the top
and bottom air flows lengthwise and
crosswise of the rotor are mounted
on the frame. Only the rotor side opposite the purging sector is provided
with a brush seal. In ZCR 18/8 to 18/
15 all brush seals are mounted on
the frame. However, there is no
brush seal at the discharge side of
the fresh air.
ZCR
9
The purging sector and drive system
are located as shown on the sketches depending on the position of the
rotary wheel type heat exchanger.
9.1 Drive system
The drive system is as standard a
geared motor for constant rotor
speed.
The geared motor’s connection is
made as shown in the terminal box of
the motor. The geared motor is
maintenance-free.
Remove cover above adjusting
screw, fig. 9.3.
Loosen screw in shaft end and adjust
rotor by means of the adjusting disc
till gap between rotor and casing is
exactly the same along the whole circumference of the rotor, fig. 9.4.
In ZCR 9/4 up to and including 18/10
the wrench opening is 32 mm for the
adjusting disc.
In ZCR 18/12 and 18/15 the wrench
opening is 41 mm.
Prior to inspection and servicing,
stop fan and rotor before opening
doors.
After adjustment remount cover
above adjustment disc, fig. 9.3.
9.2 Check of rotor position in rotor
casing
Before leaving the factory the rotor is
aligned so that it runs correctly in the
rotor section. This alignment might
change in transit or during the handling and installation of the rotor
section. Before putting the unit into
operation, check that the gap (approx. 18 mm) between rotor and casing is exactly the same along the
whole circumference of the rotor
where the brush strip forms a seal
between the air flows.
Check at suitable intervals during
the working period that brush seals
everywhere fit tightly against the rotor surface.
9.3 Adjustment of rotor position in
rotor casing
The rotor is fastened to the casing by
screws through an adjusting disc
(eccentric), a slot in the frame and a
disc at the end of the shaft. Thus the
rotor position in the casing can be
adjusted, fig. 9.2.
Fig. 9.3
In ZCR 9/6 to 13/8 there is only an eccentric in the side at the purging sector. In ZCR 18/8 to 18/15 there are eccentrics in both sides.
If the gap is not exactly the same
along the whole circumference of
the rotor, it must be adjusted:
10 ZCR
Fig. 9.4
9.4 Purging Sector
In a rotary wheel type heat exchanger leakages between the fresh air
and discharge air ducts cannot be
completely eliminated.
By making sure that p11 < p22 and p12
< p21 transfer of polluted discharge
air to fresh air through leakages can
be avoided.
Owing to the rotation of the heat exchanger a certain amount of polluted
discharge air is mixed with the fresh
air where the heat exchanger travels
from the discharge air duct to the
fresh air duct. Therefore, the heat
exchanger is provided with a purging
sector, located where the rotor travels from the discharge air duct to the
fresh air duct, fig. 9.5.
The purging sector can be adjusted
into 7 positions, from position 0 to
position 6. When delivered the purging sector is set on position 0. In heat
exchangers where the fresh air duct
is located at the bottom, the rotor
must travel downward when looked
at from the access side. Adjust the
purging sector upwards, so that position 6 is the upper hole. The reverse is the case in heat exchangers
where the fresh air duct is located at
the top, here the rotor must travel
upward when looked at from the access side. Adjust the purging sector
downward and position 6 is thus the
bottom hole.
Sizes 9/4 – 13/8 are provided with
nine holes of which the two holes on
the other side of position 0 are not
used.
The purging sector must be adjusted
according to the pressure of the system: p22-p12 in accordance with the
below table.
Setting
of sector
Position 6
0 < p22 - p12 < 185*
Position 5
185 < p22 - p12 < 240
Position 4
240 < p22 - p12 < 355
Position 3
355 < p22 - p12 < 535
Position 2
535 < p22 - p12 < 1300
Position 1
Position 0
*
Differential
pressure [Pa]
1300 < p22 - p12
p22 - p12 < 0**
Imperfect purging at p22 - p12 < 150 Pa
** No purging at p22 - p12 < 0 Pa
9.5 Rotor bearings
The rotor bearings are ball bearings
which cannot be re-greased. When
the working lives of the bearings
have come to an end, they must be
replaced. The replacement should
be carried out by a serviceman.
9.6 Belt drive
The belt drive has an elastic belt
which does not require any maintenance. The elasticity of the belt is referred to as belt tension. The rotor
can be provided with a spare belt, if
ordered when ordering the unit.
Fig. 10.1
If the belt bursts, use the spare belt
and provide the rotor with a new
spare belt at the first opportunity.
This work should be carried out by a
serviceman as the belt has to be
welded together.
9.7 Cleaning
Even though the unit is provided with
filters dust may be accumulated on
the surface of the rotor from time to
time. In order to avoid a reduction of
Measuring tap - p12
Measuring tap - p22
Discharge air q11 - p11
the system performance the rotor
must be cleaned at suitable intervals. Access for cleaning of the rotor
is obtained by opening the inspection
doors opposite the filters and pulling
out the filters or - if the unit is provided with an inspection room type
DA - by opening the doors of the inspection room.
Clean the rotor by means of a vacuum cleaner with nozzle with a soft
brush or by blowing through the rotor with compressed air. If compressed air is used, purging must be
carried out from the clean side towards the dust-coated side. Finally,
vacuum clean and dry the unit.
9.8 Inspection
Inspection of rotor is recommended
when changing filters, especially if
the filters are damaged or very dirty.
Fresh air q22 - p22
10. Heating and Cooling Coils
The heating and cooling coils consist
of copper tubes with aluminium fins
housed in a aluzinc steel frame,
other materials available, depending
of specification. The medium is supplied and discharged through headers with connections, fig. 10.1, exFig. 9.5 Purging sector
ZCR 11
tended through the panel of the access side.
Assembly work close to the heating
and cooling coils must be carried out
with caution to avoid damage to the
fins.
10.1Pipe connections
Connection to the pipe system is
made by the pipe contractor.
Heating and cooling coils must always be connected in counter flow
(supply and discharge pipes are
marked with arrows) and so that the
expandability or own weight of the
pipe system does not load the pipe
connections of the coils.
If the connections of the heating and
cooling coils are designed as threaded pipes they must be secured to
avoid distortion and damage to the
internal pipe system of the coil, fig.
10.2.
Fig. 10.2
The cooling coil is provided with a
drip pan of stainless steel with drain,
1 ½” BSP - with thread, extended
through the base frame of the access
side. The drains must be connected
to a water trap. See fig. 5.3 on page 5.
10.2Cleaning
The heating and cooling coils must
be kept clean of dust and foreign material with a view to the hygiene and
heating/cooling efficiency.
Cleaning is effected by means of vacuum cleaning at the air inlet and, in
special cases, by means of compressed air from the air outlet side or
flushing with water.
12 ZCR
Cleaning must be performed cautiously as the aluminium fins are vulnerable to damage.
The cleaning interval depends on the
content of dust in the air.
Cooling coils:
Cooling coils are provided with drip
pan with drain through the base
frame for condensate extended
through the access side. Clean cooling coils by flushing with water, and
drip pan as well as drain must be
kept clean to avoid formation of algae.
In units with high air velocities an
droplet eliminator is mounted after
the cooling coil to catch droplets.
Remove dust and water at the bottom of the unit casing immediately
after cleaning; preferably by means
of a vacuum cleaner for dust and water.
Other components:
The components of the pipe system
for regulation and ventilation as well
as other components essential to the
operation of the heating/cooling
coils must be maintained in accordance with the instructions and their
proper function must be checked at
regular intervals.
10.3Demounting of heating and
cooling coils
If, during repair of the heating and
cooling coils, it is necessary to disassemble and later assemble pipe
connections, headers with threaded
connections must be retained to
avoid distortion and leakage of the
copper tubes of the coil, fig. 10.2.
When re-mounting a removed cooling coil it is very important to tighten
carefully round the cooling coil in order to avoid small air leakages with
high air velocities causing entrainment of condensate over the edges
of the drain system for the cooling
coil.
Cooling coils for direct expansion:
The same maintenance procedures
should be adopted as for water cooling coils, supplemented with the
cooling supplier's maintenance instructions for the pipe system and
associated components.
10.4Frost protection
Heating and cooling coils must be
protected against frost bursting.
This is obtained by a constant water
flow in the coils.
VM
VR
From boiler/water chiller
heat exchanger
V
KP61
Fig. 10.3
VM
VR
V
KP61
= Motor valve (3 way valve)
= Regulating and shut-off valve
= Shut-off valve
= Freezing thermometer
10.5Electric heating coil
Fig. 10.4
The electric heating coil, fig.10.4, is
composed of tube heating elements
of stainless steel mounted in a steel
frame and provided with a terminal
box with the necessary cable inlets.
Electrical connection is made in the
terminal box according to the wiring
diagram indicated in the box. Be
careful about connecting the wires to
the heating elements.
Note: Connect the thermostats direct to
the control current of the heating coil and
make sure the tube heating elements can
only operate when the fan is in operation.
10.6Maximum thermostat
The heating coil is provided with an
adjustable maximum thermostat
with a setting range from 30 to
110°C.
After cutting out the maximum thermostat resets automatically at falling temperatures.
10.7Overheat thermostat
The heating coil is provided with an
overheat thermostat (fire thermostat) with fixed setting at 110 °C and
for manual reset after cutting out.
10.8Automatic control and safety
functions
The automatic system must be so
designed that the heating coil can
only operate when the fan is in operation. If the maximum thermostat
cuts out it is only the voltage to the
heating elements that must be cut
off. - Operation is resumed automatically when the temperature is reduced by approx. 15° C. If the overheat thermostat cuts out, the fan
must stop and the other automatic
functions be neutralized. Before restarting the system, examine the
cause of the stop before activating
the reset switch of the thermostat.
In order to avoid unnecessary cutout of the overheat thermostat during planned off-periods the system
should be provided with automatic
controls for extended fan operation
for the purpose of cooling down the
heating coil.
Note: Minimum air velocity over standard
heating elements is 2 m/s with a view to superheating of the heating element, and the
thermostats must be connected direct to
the control current of the heating coil.
10.9Check of thermostats
When starting operation of the heating coil and at least once a year
check the function of the thermostats:
Set the maximum thermostat to
110° C and check that both maximum thermostat and overheat thermostat cut out at the same time.
If either thermostat fails to cut out,
contact a service engineer. After the
check reset the maximum thermostat.
10.10 Check of wire connections
Cut off the power supply of the electric heating coil. Check and adjust
wire connections to the heating element and thermostats at least once
a year.
Faint smell of burning on commissioning - mostly due to dust build-up
on the heating elements after a long
period of system stop and will normally disappear quickly. Other-wise,
check the electric heating coil thoroughly and also the function of the
overheat thermostat.
10.11 Condensation
When the electric air heating coil
have been out of operation for a long
period, small leakage currents may
arise caused by condensation in or
on the insulating material.
In order to give flash-over this accumulated condensation must be removed by successive increase of the
temperature of the heating unit. The
electric air heater has to be started
as follows:
The first time all heating elements
(for group by group) are switched in
for not more than 30 sec, then
switched off and after about one
minute switched in again for 30 sec.
This is repeated for some time, depending on how long time the heaters have been out of operation. Now
you switch in and off for respectively
longer and shorter periods, and after
about half an hour to one hour the air
heaters are ready for continuous operation. The cover of the connection
box must be removed.
As the condensation depends on the
relative degree of humidity of the air,
it must be considered how the
weather was in the period where the
heaters have been out of operation (a
warm and dry summer versus a cold
and wet summer). This will be a
guide as to the switching-in and -off
periods, but as a precaution it is better to start a little slower.
11. Humidification
Novenco air handling units type ZCR
can be provided with three humidification solutions.
- Ship steam
- Steam humidifier
- Compressed air/water
11.1 Ship steam
Steam provided by the ship can be
used for humidification. After filtered, the steam from the ship will be
directly sprayed into units by spray
nozzles. Therefore, make sure that
the steam is clean, harmless, and
drinkable.
11.2 Steam humidifier
When no steam source is available/
accessible in the ship, an electrode
steam humidifier can be employed
for producing steam out of water.
About water quality
The mode of operation of the steam
humidifier is based on the fact that
water contains minerals and is
therefore conductive. Normal feed
ZCR 13
water with a conductivity between
200 and 500 μS/cm at 15° C, is the
perfect one to use.
Note that the steam humidifier’s
performance depends on the water
quality very much. If the water quality is not within the above limits, the
unit cannot perform optimally. For
example, the electrodes could wear
out pretty fast or the steam production could be very low.
11.3 Compressed air/water
Without direct steam source at the
ship, the unit can be equipped with a
pneumatic atomizing nozzle to produce humidification out of a mixture
of compressed air and water.
lead cable through the inspection
doors. Cut hole for cable inlet with
locksaw and mount cable inlets as
for example shown on fig. 5.1
The cable has to be so long (approx.
1.5 x unit width) that the fan unit can
be pulled all the way out for inspection. After connection of the cable it
must be protected so it cannot touch
the fan.
If the motor is operated across a frequency converter, the connections
must be made according to the instructions of the frequency converter manufacturer. The motor must be
grounded.
12.3 Start-up of fan
As to the quality of water, make sure
that the water is clean, harmless,
and drinkable. The compressed air
must also be clean and harmless.
12. Fans
The air handling unit type ZCR can be
provided with 3 kinds of fans:
- Centrifugal fan;
- ZerAx fan;
- Plug fan.
1 Remove the transport protection.
These are marked with yellow
flex. Especially for ZerAx fan, remove two extra angles that secure
the vibration dampers, see below.
7 Check that air ducts are mounted
on the pressure sides of the fans.
A fan with direct access, i.e. without connection of an air duct, must
be fitted with a wire guard.
8 Check that a earthing connection
for the electrostatic potential in
the motor is mounted.
9 Connect the supply voltage.
10 Test run
Start the fans briefly and long
enough to check whether the fan
impeller rotates in the correct direction as indicated by the arrows
on the fan casings.
11Turn off the fan and reconnect the
supply voltage dependant on the
direction of rotation from the brief
start.
12 Check that no dampers close for
the air.
13Turn on the fans.
Note: Units with controls can take several minutes to start up.
14 Check that no abnormal mechanical sound and no surging occurs.
15 Check that the fan vibration level
is normal.
12.1 Storage
If the storage period exceeds three
months it is recommended to turn
the impeller regularly by hand.
For storage longer than 6 months, Vbelt drive should be loosened.
2 Check that the fan impellers rotate freely without touching the
housing.
The level should not exceed
7.1mm/s RMS.
12.2 Electric connections
- are made by authorized personnel
and according to current regulations
in the motor terminal box as shown
on the diagram on the inside of the
lid.
3 Check that all foreign bodies (paper, tools and similar) are removed from the air passages.
For centrifugal fan, level shall be
measured on fan bearing horizontally and vertically. the same
should be done on motor.
4 Check that electrical connections
meet current regulations.
Establish a lockable maintenance switch
on the outside of the air handling unit.
The motor must be connected with
approved rubber cable and according to current regulations. Do not
14 ZCR
5 Check that the belt tension and
alignment is correct (centrifugal
fan only).
6 Check that the motors are fastened.
For plug fan, level shall be measured near motor bearing horizontally and vertically.
For axial fan ZerAx, measurements are to be taken on the casing near front screw (guide vane
assembly) vertically and horizontally.
If the levels exceed 7.1mm/s RMS,
the fan should be stopped and balanced.
12.5 Maintenance
12.5.1 Centrifugal Fans
Note: Handle
Normally the fan is unprotected
(without belt guard or wire guard).
Fan handles are provided with a
bracket and a pad lock. Do not open
the door until the fan has stopped.
Do always keep the door locked, in
order to avoid unauthorised access.
Note: Be extraordinary cautious when
checking vibrations, as this is only possible with the fan section door open and
thereby direct access to rotating parts.
16 After 30 minutes of operation
check the vibration level again.
For centrifugal fan, also check
that the belt tension is correct. If
that is not the case, re-tighten the
belt.
17 Close the air handling unit.
Note: Always keep the doors to the unit
closed for safety reasons.
The unit is then in operation.
After a power failure, the unit is
started as normal.
12.4 General inspection and maintenance
Before opening the door to the fan
section, cut off the power supply to
the fan and set the maintenance
switch in position 0.
Open the door when the fan has
slowed down (min. 2 minutes).
Twice a year, check the fan operation, including whether abnormal
noises and vibrations occur.
Vibrations occurring during operation will normally be due to accumulations of dust or dirt on hubs and
blades, and will generally stop after
cleaning. If not, expert assistance
should be called in immediately, as
continued vibrations will shorten the
life of both blades and motor bearings
Motors are earthed to the base
frame of air handling unit.
Fig. 12.1
The fan unit consists of a double inlet
centrifugal fan, motor and V-belt
drive mounted on a frame with antivibration mountings, fig. 12.1
The fan unit is mounted in two transverse rails attached to the air handling unit.
The fan outlet opening is connected
to the outlet panel of the unit by
means of a flexible connection which
is fastened to the outlet panel by
means of two cleats fastened by
screws.
The outside frame of the fan unit is
on the access side attached to the
rails by means of two screws. On the
opposite side the outside frame of
the fan unit is attached to the rails by
means of two clips.
12.5.1.1 Demounting of fan unit for
servicing
Prior to opening the door to the fan
section, cut off the power supply to
the fan.
Open the door by handle, when the
fan has slowed down (min 2 minutes).
Remove screws on the access side
with which the outer frame of the fan
unit is attached to the rails.
Remove the two screws on the access side which hold the flexible connection attached to the outlet panel
of the unit.
Pull the fan out of the unit. Be aware
that the flexible connection is totally
clear of the hole in the outlet panel.
The fan unit is mounted on the bottom of the unit. The outer frame of
the fan unit is attached to the rails in
the access side by means of screws.
Opposite to the access side the outer
frame of the fan unit is attached to
the rails by means of two fittings.
The motor is mounted on two suspension rails each provided with a
set screw for tightening of the belts.
Access for inspection and maintenance of fan and belt drive is obtained by opening the inspection
door on the access side of the unit.
ZCR 15
12.5.1.2 Tensioning and Belt changing
Power transmission
Installation and maintenance instructions for Optibelt V-belt transmissions
Do not forget the normal safety
measures
Prior to working on/servicing the transmission, cut off the power supply and make
sure that the transmission can’t be
switched on again while work is taking
place.
V-belt pulley with TB bushes
Before installation check that all
components are undamaged.
Installation (please see page 20 as
well)
1 All shiny surfaces should be clean
and free of grease.
2 Hang belt pulley over shaft and after that mount bush.
3 Turn belt pulley until all threaded
holes are aligned with plain holes
in bush.
Fig. 12.2
4 Oil Allen screws prior to screwing
them into holes and tighten so
that belt pulley can still be moved
on shaft.
5 For correct centering of bush and
belt pulley, it is necessary to tighten Allen screws in several operations, a torque wrench is very useful for this purpose.
Fig. 12.3
6 Only tighten screws to torque values given for current bush, or it
cannot be removed later on without using force.
Fig. 12.4
TB bushes, Allen screws and tightening torques
Bush No.
TB 1008, 1108
Allen wrench
3
Number of screws
2
Tightening torques
5,7
TB 1210, 1215, 1310,
1610, 1615
5
2
20,0
TB 2012
6
2
31,0
TB 2517
6
2
49,0
TB 3020, 3030
8
2
92,0
TB 3525, 3535
10
3
115,0
TB 4040
12
3
172,0
TB 4545
14
3
195,0
TB 5050
14
3
275,0
16 ZCR
Horizontal alignment of shafts
Motor and machine shaft may have to be aligned with a machine spirit level.
Note!
Maximum misalignment 0.5°
Fig. 12.5
Vertical alignment and check of belt pulleys
Check the alignment of the pulleys by means of a guide rail.
Note!
After tightening screws in bushes check alignment and correct until it is in order.
Fig. 12.6
Installation of V-belts
Always place V-belts carefully on pulleys, do not force them over the edge of
the pulleys.
V-belts installed by force will often only work for a few weeks and then they
will have to be replaced again!
Fig. 12.7
Fig. 12.8
Tensioning of V-belts
The optimised values are calculated in connection with dimensioning of the
air handling unit and data sheets! The values in the table on page 21 presuppose that the number of belts is correct. If there are too many belts, the shaft
load is increased correspondingly! Align the motor parallel until the correct
belt tension Tmin/Tmax is reached. Rotate the transmission a few times before
checking the Tmin/Tmax values and adjust until the Tmin/Tmax values are correct. Check the belt tension the first time after 0.5 to 4 hours of operation under full load.
* Optikrik tension gauge, see instructions on pages 18 and 20.
ZCR 17
Maximum misalignment
When the belts are correctly tightened it is not certain that the belt pulleys
are aligned. Do not exceed the stated X1/X2 maximum values for misalignment.
Other pulley sizes are interpolated.
Pully diameter dd1, dd2 Max values X1, X2
112 mm
224 mm
450 mm
630 mm
900 mm
1100 mm
1400 mm
1600 mm
Fig. 12.9
Fig. 12.10
0,5 mm
1,0 mm
2,0 mm
3,0 mm
4,0 mm
5,0 mm
6,0 mm
7,0 mm
Inspection of belt transmission
Check the belt tension regularly, e. g. every three/six months and tighten as
required.
NB! This check is not necessary for RedPower maintenance free narrow V-belts.
Check the belt pulleys regularly for wear and tear, e. g. once a year and always
before installing new belts.
Changing belt pulleys with TB bushes (see page 20 as well).
1 Loosen and remove Allen screws. Now insert Allen screws in the threaded
holes intended for demounting, tighten until the belt pulley can be removed.
2 Remove TB bush and belt pulley.
** section and pulley groove template
Tension gauges
Rubber finger loop Pressure surface
Pocket clip
Indicator arm
Belt
Pressure spring
Fig. 12.11
OPTIK
RIK I
N
20
00
LBS.
600
Optikrik 0, I, II, III tension gauges (Fig. 12.11 and 12.12)
This tool is indispensable, if you want optimum life and efficiency of the belt
transmissions. At the same time the shaft load is optimised so that it corresponds with the values stated by Optibelt. If there are no computer calculation
or data sheet, you can find the maximum belt tension permitted by Optibelt
in the table on page 21.
50
100
150
Fig. 12.12
Fig. 12.13
18 ZCR
Optikrik 0, I, II, III tension gauges – operating instructions (Fig. 12.13)
1 Turn transmission a few times so that tension is distributed in the entire
belt before making measurements.
2 Place tension gauge on top of belt between belt pulleys, press indicator
arm fully onto the scale.
3 Do not touch tension gauge with more than one finger during measuring
process.
4 Now activate tension gauge by pressing a finger slowly on to the pressure
surface until a click is heard/felt, immediately release pressure after click.
5 Carefully lift tension gauge from belt and read belt tension at exact point
where top surface of indicator arm crosses scale.
6 Adjust belt tension until measured and stated values are identical, do not
forget to turn transmission a few times after each adjustment of belt tension.
This tension gauge is only used in multi-rib belt drives when the values exceed
what is measurable by means of Optikrik III.
1
2
3
4
5
Hang test hook (A) on belt between belt pulleys.
Turn second hook (B) over next belt and reset.
Pull handle until right test force on scale (C) is reached.
Now belt tension can be read as deflection depth on scale (D).
Adjust belt tension until measured and stated values are identical.
Fig. 12.14
Installation, see page 16 as well
Bush
TB 1008-3030
Bush
TB 3525-5050
Demounting, see page 16 as well
Bush
TB 1008-3030
Bush
TB 3525-5050
ZCR 19
Belt tension values
For Optibelt V-belts
Belt profile
Diameter of smallest pulley
(mm)
£ 71
> 71 £ 90
> 90 £ 125
>125 *
£ 100
SPA
>100 £ 140
XPA
>140 £ 200
>200 *
£ 160
SPB; 5V/15N;
>160 £ 224
XPB; 5VX/15NX
>224 £ 355
>355 *
£ 250
SPC
>250 £ 355
XPC
>355 £ 560
>560 *
£ 50
Z/10;
> 50 £ 71
ZX/X10
> 71 £ 100
>100 *
£ 80
A/13;
> 80 £ 100
AX/X13
>100 £ 132
>132 *
£ 125
B/17;
>125 £ 160
BX/X17
>160 £ 200
>200 *
£ 200
C/22;
>200 £ 250
CX/X22
>250 £ 355
>355 *
* belt tension values must be computer calculated
Tension gauges:
SPZ; 3V/9V
XPZ; 3VX/9NX
Optikrik 0
Optikrik I
Optikrik II
Optikrik III
20 ZCR
Area:
Area:
Area:
Area:
70 - 150 N
150 - 600 N
500 - 1400 N
1300 - 3100 N
Optibelt
Red Power
maintenance free
narrow V-belts
Installation
Remounting
new belts
same belt
Static tension Tmax
(N)
Optibelt
SK/VB
wrapped narrow and classical Vbelts
Installation
new belts
Control
Optibelt
Super TX
moulded cogged raw
edge V-belts
Installation
new belts
Control
250
300
400
200
250
300
200
250
350
150
200
250
250
300
400
200
250
300
400
500
600
300
400
450
350
400
500
250
300
400
400
500
600
300
400
450
700
850
1000
550
650
800
650
700
900
500
550
700
700
850
1000
550
650
800
1400
1600
1900
1100
1200
1500
1000
1400
1800
800
1100
1400
1400
1600
1900
1100
1200
1500
–
–
90
120
140
70
90
110
120
140
160
90
110
130
–
–
150
200
300
110
150
250
200
250
400
150
200
300
–
–
300
400
500
250
300
400
450
500
600
350
400
450
–
–
700
800
900
500
600
700
800
900
1000
600
700
800
The table does not replace a computer calculation or data sheet! The values can be
used when no computer calculation or data sheet with optimised values are available (see page 17), they are based on maximum power transmission and also state
maximum shaft load.
Range of application:
Narrow V-belts
Belt speed v = 5 to 42 m/s
Classical V-belts
Belt speed v = 5 to 30 m/s
12.5.1.3Fan bearings
AHU type
Novenco Fan
type
Max
RPM
Max
Power
kW
Shaft d
mm
Bearing
mfr.
ZCR9/4
C2LF-180-M
4000
3,5
14h8
SKF
6202-2RS1
Lifetime
ZCR9/6
C2HB-250-M
5600
5,4
20h8
SKF
YSA 205-2FK
8g / 4380h
ZCR9/8
ZCR13/6
C2HB-280-M
5230
7,5
25h6
SKF
YSA 206-2FK
10g / 4380h
ZCR13/8
C2HB-355-M
4000
11,7
30h6
SKF
YSA 207-2FK
13g / 4380h
ZCR13/12
ZCR18/8
C2HB-400-M
3500
13,6
30h8
SKF
YSA 207-2FK
13g / 4380h
ZCR13/12
ZCR18/10
C2HB-450-M
3200
20
35h8
SKF
YSA 208-2FK
15g / 4380h
ZCR18/10
ZCR18/12
C2HB-500-M
2800
23,5
35h8
SKF
YSA 208-2FK
15g / 4380h
ZCR18/12
ZCR18/15
C2HB-560-M
2500
28,4
40h8
SKF
SNL509N
C2HB-630-M
2100
31,4
45h8
SKF
BDB355CM
2700
5.5
D30
BDB355TM
3500
11
D35
ZCR18/15
ZCR13/8
ZCR13/12
ZCR18/8
ZCR13/12
ZCR18/10
ZCR18/10
ZCR18/12
ZCR18/12
ZCR18/15
ZCR18/15
Bearing
house
Bearing type
Clamping
ring
Bush +
Protection
washer
Greasing
22209 CCK/ 2 FRB 3.5/85
C3W33
H309
TSN509G
10g / 4380h
SNL510
22210 CCK/
C3W33
2 FRB 9/90
H310
TSN510G
11g / 4380h
SKF
SNL507TG
2207EK
FRB5.5/72
H307
TSN507G
8g/4200h
SKF
SNL508TG
2208EK
FRB8/80
H308
TSN508G
9g/3800h
BDB355XM
4500
22
D40
SKF
SNL509TG
2209EK
FRB3.5/85
H309
TSN509G
10g/4500h
BDB400CM
2500
7.5
D30
SKF
SNL507TG
2207EK
FRB5.5/72
H307
TSN507G
8g/4200h
BDB400TM
3200
15
D35
SKF
SNL508TG
2208EK
FRB8/80
H308
TSN508G
9g/3800h
BDB400XM
4100
30
D40
SKF
SNL509TG
2209EK
FRB3.5/85
H309
TSN509G
10g/3800h
BDB450CM
2200
11
D35
SKF
SNL508TG
2208EK
FRB8/80
H308
TSN508G
9g/3800h
BDB450TM
2900
18.5
D40
SKF
SNL509TG
2209EK
FRB3.5/85
H309
TSN509G
10g/4500h
BDB450XM
3600
36
D45
SKF
SNL510TG
2210EK
FRB9/90
H310
TSN510G
10.5g/4700h
BDB500CM
1900
11
D35
SKF
SNL508TG
2208EK
FRB8/80
H308
TSN508G
9g/3800h
BDB500TM
2500
22
D45
SKF
SNL510TG
2210EK
FRB9/90
H310
TSN510G
10.5g/4700h
BDB500XM
3200
45
D50
SKF
SNL511TG
2211EK
FRB9.5/100
H311
TSN511G
13g/4800h
BDB560CM
1700
11
D40
SKF
SNL509TG
2209EK
FRB3.5/85
H309
TSN509G
10g/4500h
BDB560TM
2200
30
D45
SKF
SNL510TG
2210EK
FRB9/90
H310
TSN510G
10.5g/4700h
BDB560XM
2800
55
D55
SKF
SNL512TG
2212EK
FRB10/110
H312
TSN512G
15g/4900h
BDB630CM
1500
15
D45
SKF
SNL510TG
2210EK
FRB9/90
H310
TSN510G
10.5g/4700h
BDB630TM
2000
30
D50
SKF
SNL511TG
2211EK
FRB9.5/100
H311
TSN511G
13g/4800h
BDB630XM
2500
55
D60
SKF
SNL513TG
2213EK
FRB10/120
H313
TSN513G
19g/4800h
12.5.1.4 Change of bearings
Demount the fan unit as described
previously.
Alternatively, acquire a detailed
guide.
12.5.2 ZerAx Fans
Slacken the V-belts, remove them
and pull off the belt pulley from the
fan shaft.
Support the fan shaft on the side
where the bearing is to be replaced.
12.5.2.1 Demounting fan unit
Demount the fan unit and pull it out
to service the fan or the motor as
shown below.
1 Cut off the power, and wait two
minutes before opening the
doors.
Note: The fans take a minimum of two
minutes to come to a complete halt.
2 Open the door to the fan section,
disconnect external wires into the
ZCR 21
junction box, mounted on the fix
panel as shown below.
7 Remove the M12 screws that fix
the fan on the bottom plate.
tions are available on www.novencogroup.com and are sent on request.
Note: Avoid exposing individual parts to
shocks when handling the fan. Shocks can
damage motor bearings and fan parts.
12.5.2.2 Mounting fan unit
1 Push the fan unit back in position.
2 Mount the inlet bell back.
3 Demount the fixed panel.
4 Remove the door post.
8 Be sure to remove the inlet bell
before moving the fan to the left as
shown below so that the motor
can be kept inside the housing.
3 Fasten all the screws.
4 Mount the earth wire back.
5 Mount the door post back.
6 Mount the fix panel back.
Inlet bell
7 Reconnect the wires to the junction box.
8 Close the door to the fan section.
Lock the door using the square
key.
5 Disconnect the earth wire.
The mounting of the fan unit is now
complete
9 Afterwards remove the screws on
the bottom rail, see the circled areas in above image. Then it is possible to pull out the fan along the
bottom rail. Please find proper
hand stacker and support to withstand the weight of the fan and
motor.
6 Remove the M8 screw that fixes
the fan to the panel.
Motor sizes
Weights [kg]
-71
11.0
-80
15.5
-90
24.3
-100
39.4
-112
46.9
-132
100.9
-160
139.2
-180
200.5
12.5.3 Plug Fans
The plug fan is a direct driven, single-inlet centrifugal fan with backward-curved blades mounted without fan housing.
The fan unit is mounted in a fan suspension configuration with vibration
dampers and on two transverse rails
fixed to the bottom of the chamber.
The unit consists of a fan wheel
mounted directly on the drive shaft of
a single-speed motor. The motor is a
standard base motor with connection in terminal box.
Maximum motor weights
The motor and fan unit can now be
serviced. ZerAx fans are serviced as
described in Novenco’s installation
and maintenance instructions, document no. 922950-0. The instruc-
22 ZCR
Figure 12.18
On the suction side the inlet funnel is
found mounted against the suction
chamber. A flexible hose isolates the
fan thus preventing vibrations from
spreading to the rest of the unit.
The motor and fan unit can now be
serviced.
Observe: Handles
2 Push and centre the fan unit in
front of the discharge panel. Keep
the flexible connection clear of the
panel opening when pushing the
fan unit past it.
Normally the fan is unprotected and handles must not be fitted on the door. The special square key is used for opening the door.
12.5.3.1 Demounting fan unit
Demount the fan unit to service it or
the motor.
1 Turn off the air handling unit, put
the safety switch in position 0 and
lock it.
2 Wait a minimum of two minutes
before opening the doors.
Note: The fans take a minimum of two
minutes to come to a complete halt.
3 Open the door to the fan section.
The door is opened using the
square key.
4 Remove the screws in the access
side. The screws fasten the outer
frame on the fan unit to the rails.
There are two screws in front of
and two behind the motor.
5 Release the fan unit from the discharge panel. Remove the two
screws on the access panel, which
fasten the flexible connection to
the panel. Keep the connection
clear of the panel opening when
pulling the fan unit past it.
6 Pull the fan out and support it appropriately.
7 Depending on the length of the
motor cable, pull the cable clear
of the fan casing to handle the motor.
12.5.3.2 Mounting fan unit
1 Place the fan unit on the rails in
the bottom of the section.
3 Fasten the fan unit with flexible
connection to the panel with the
two screws.
4 Mount the four screws holding the
fan unit to the rails in the bottom
of the section.
5 Close the door to the fan section.
Lock the door using the square
key.
The mounting of the fan unit is now
complete.
13. Motors for Fans
The fan motors are mounted before
leaving the factory but normally not
electrically connected.
Checking the Motor Bearings
The motors are meant to be operated
in dry or humid air at a normal ambient temperature. The motor bearings have to be lubricated as per the
instructions that accompany the motor. Replacements of bearings are to
be done in accordance with the motor manufacturer’s instructions.
See appendix “A. Parts List” on
page 24.
8 Demount the motor cable in the
terminal box.
ZCR 23
A. Parts List
A.1 Louvre damper SJD
Pos.
Description
Part no.
01
Clips
454328-0
02
Nylon disc
911738-0
03
Shaft arm
479270-0
04
Pilot bearing
479209-0
05
Quadrant
485983-0
06
Bearing with square hole
473349-0
07
Tightening handle
916273-0
08
Brush
916275-0
09
Bolt
916274-0
10
Operating lever
487216-0
A.2 Compact filters M6
Quantity
Size
Part no.
ZCR 9/4
Type
1
592x287x292
914271-0
ZCR 9/6
1
592x490x292
915971-0
ZCR 9/8
1
1
592x592x292
287x592x292
914270-0
914271-0
ZCR 13/6
2
592x490x292
915971-0
ZCR 13/8
2
592x592x292
914270-0
ZCR 13/12
4
592x592x292
914270-0
ZCR 18/8
3
592x592x292
914270-0
ZCR 18/10
3
3
592x592x292
592x287x292
914270-0
914271-0
ZCR 18/12
6
592x592x292
914270-0
ZCR 18/15
6
3
592x592x292
592x287x292
914270-0
914271-0
A.3 Pocket filters G4
Type
Quantity
Size
Part no.
ZCR 9/4
1
1
287x287x305
592x287x305
911532-0
911531-0
ZCR 9/6
1
1
287x490x305
592x490x305
911534-0
911533-0
ZCR 9/8
1
592x592x305
287x592x305
908268-0
908269-0
ZCR 13/6
2
490x592x305
911533-0
ZCR 13/8
2
592x592x305
908268-0
ZCR 13/12
4
592x592x305
908268-0
ZCR 18/8
3
592x592x305
908268-0
ZCR 18/10
3
3
592x592x305
592x287x305
908268-0
911531-0
ZCR 18/12
6
592x592x305
908268-0
ZCR 18/15
6
3
592x592x305
592x287x305
908268-0
911531-0
24 ZCR
A.4 Pocket filters M5
Type
Quantity
Size
Part no.
ZCR 9/4
1
1
592x287x305
278x287x305
911535-0
911536-0
ZCR 9/6
1
1
592x490x305
278x490x305
911537-0
911538-0
ZCR 9/8
1
1
592x592x305
287x592x305
910442-0
910440-0
ZCR 13/6
2
490x592x305
911537-0
ZCR 13/8
2
592x592x305
910442-0
ZCR 13/12
4
592x592x305
910442-0
ZCR 18/8
3
592x592x305
910442-0
ZCR 18/10
3
3
592x592x305
592x287x305
910442-0
911533-0
ZCR 18/12
6
592x592x305
910442-0
ZCR 18/15
6
3
592x592x305
592x287x305
910442-0
911535-0
A.5 Synthetic panel filters G3
Type
Quantity
Size
Part no.
ZCR 9/4
1
1
595x290x47
290x290x47
909691-0
911529-0
ZCR 9/6
1
1
494x494x47
392x494x47
913513-0
913512-0
ZCR 9/8
1
1
595x595x47
290x595x47
909689-0
909691-0
ZCR 13/6
3
392x494x47
913512-0
ZCR 13/8
2
595x595x47
909689-0
ZCR 13/12
4
595x595x47
909689-0
ZCR 18/8
3
595x595x47
909689-0
ZCR 18/10
3
3
595x595x47
595x290x47
909689-0
909691-0
ZCR 18/12
6
595x595x47
909689-0
ZCR 18/15
6
3
595x595x47
595x290x47
909689-0
909691-0
A.6 Alu panel filters G2
Quantity
Size
Part no.
ZCR 9/4
Type
1
1
594x288x48
288x288x48
910323-0
911530-0
ZCR 9/6
1
1
594x492x48
288x492x48
910324-0
910326-0
ZCR 9/8
1
1
594x594x48
288x594x48
910325-0
910323-0
ZCR 13/6
2
594x492x48
910324-0
ZCR 13/8
2
594x594x48
910325-0
ZCR 13/12
4
594x594x48
910325-0
ZCR 18/8
3
594x594x48
910325-0
ZCR 18/10
3
3
594x594x48
594x288x48
910325-0
910323-0
ZCR 18/12
6
594x594x48
910325-0
ZCR 18/15
6
3
594x594x48
594x288x48
910325-0
910323-0
ZCR 25
A.7 Panel filters G4
Type
Quantity
Size
Part no.
ZCR 9/4
1
1
592x287x48
287x287x48
919138-0
919446-0
ZCR 9/6
1
1
490x490x48
392x490x48
919447-0
919448-0
ZCR 9/8
1
1
592x592x48
287x592x48
919140-0
919138-0
ZCR 13/6
3
392x490x48
919448-0
ZCR 13/8
2
592x592x48
919140-0
ZCR 13/12
4
592x592x48
919140-0
ZCR 18/8
3
592x592x48
919140-0
ZCR 18/10
3
3
592x592x48
592x287x48
919140-0
919138-0
ZCR 18/12
6
592x592x48
919140-0
ZCR 18/15
6
3
592x592x48
592x287x48
919140-0
919138-0
A.8 ZCR 9/4 – Fan C2LF 180 M
Complete fan
Max. RPM
Max kW
Weight [kg]
Part no.
4000
3.5
6.7
917232-0
Impeller for fan
B
ØD
Weight [kg]
152
180
0.8
Shaft
L
Ød
ØD
Weight [kg]
354
14
15
0.43
26 ZCR
Bearing bracket
ØD
R
No. of arms
Weight [kg]
40
98
3
0.2
Bearing set
ØD
Ød
SKF code
Type
35
15
6202-2RS1
D
Type D has bearing on shaft,
locked with locking ring
A.9 Fan C2HB 250-M/630-M
AHU type
Fan type
Part no.
Max RPM
Max kW
Weight [kg]
ZCR 9/6
C2HB-250-M
917267-0
5600
5.4
20.4
ZCR 9/8
ZCR 13/6
C2HB-280-M
917268-0
5230
7.5
24.1
ZCR 13/8
C2HB-355-M
917269-0
4000
11.7
39.4
ZCR 13/12
ZCR 18/8
C2HB-400-M
917270-0
3500
13.6
57
ZCR 13/12
ZCR 18/10
C2HB-450-M
917911-0
3200
20
75
ZCR 18/10
ZCR18/12
C2HB-500-M
917271-0
2800
23.5
91.8
ZCR 18/12
ZCR 18/15
C2HB-560-M
917272-0
2500
28.4
147
ZCR 18/15
C2HB-630-M
917273-0
2100
31.4
183
Fan with frame type GTLZ-06
Impeller
Fan type
B
ØD
ZCR 9/6
Type
C2HB-250-M
191
255
ZCR 9/8
ZCR 13/6
C2HB-280-M
215
288
ZCR 13/8
C2HB-355-M
271
360
ZCR 13/12
ZCR 18/8
C2HB-400-M
304
405
ZCR 13/12
ZCR 18/10
C2HB-450-M
341
455
ZCR 18/10
ZCR 18/12
C2HB-500-M
380
510
ZCR 18/12
ZCR 18/15
C2HB-560-M
425
570
ZCR 18/15
C2HB-630-M
476
640
Shaft
Fan type
L
Ød
ØD
ZCR 9/6
Type
C2HB-250-M
519
20
20
ZCR 9/8
ZCR 13/6
C2HB-280-M
564
25
25
ZCR 13/8
C2HB-355-M
654
30
30
ZCR 13/12
ZCR 18/8
C2HB-400-M
709
30
35
ZCR 13/12
ZCR 18/10
C2HB-450-M
794
35
40
ZCR 18/10
ZCR 18/12
C2HB-500-M
864
35
40
ZCR 18/12
ZCR 18/15
C2HB-560-M
1034
40
45
ZCR 18/15
C2HB-630-M
1144
45
50
ZCR 27
Bearings
Fan type
Bearing
Type
ZCR 9/6
Type
C2HB-250-M
YSA205-2FK
YS
ZCR 9/8
ZCR 13/6
C2HB-280-M
YSA206-2FK
YS
ZCR 13/8
C2HB-355-M
YSA207-2FK
YS
ZCR 13/12
ZCR 18/8
C2HB-400-M
YSA207-2FK
YS
ZCR 13/12
ZCR 18/10
C2HB-450-M
YSA208-2FK
YS
ZCR 18/10
ZCR 18/12
C2HB-500-M
YSA208-2FK
YS
ZCR 18/12
ZCR 18/15
C2HB-560-M
22209-CCK/C3W33
H
ZCR 18/15
C2HB-630-M
22210-CCK/C3W33
H
Type S: Bearing set include bearing,
adapter sleeve and bearing damper.
Type YS: Bearing set include S-type
bearing set and YS-type plummer
block.
Type H: Bearing set include bearing, adapter
sleeve, guide ring and
plummer block.
Bearing specifications
Fan type
Make
Bearing
unit type
Bearing
house
C2HB-250-M
SKF
SYJ 505
YSA205-2FK
H 2305
C2HB-280-M
SKF
SYJ 506
YSA206-2FK
H 2306
10g / 4380h
C2HB-355-M
SKF
SYJ 507
YSA207-2FK
H 2307
13g / 4380h
Bearing type
Clamping
ring
Bush +
washer
Protection
Greasing
Lifetime
C2HB-400-M
SKF
SYJ 507
YSA207-2FK
H 2307
13g / 4380h
C2HB-450-M
SKF
SYJ 508
YSA208-2FK
H 2308
15g / 4380h
SYJ 508
C2HB-500-M
SKF
C2HB-560-M
SKF
SNL 509 N
22209-CCK/C3W33
2 FRB 3.5/85
H 309
TSN 509 G
10g / 4380h
C2HB-630-M
SKF
SNL 510
22210-CCK/C3W33
2 FRB 9/90
H 310
TSN 510 G
11g / 4380h
28 ZCR
YSA208-2FK
H 2308
15g / 4380h
B. Maintenance tools
Here is a list of tools required for maintenance of AHU.
Tools
Quantity
Pneumatic drill
1 pc
Allen wrench set
1 set
Hex socket set
1 set
Flexible extension
1 pc
Glue gun
1 pc
Cross point screwdriver
1 pc
Slot type screwdriver
1 pc
Rivet gun
1 pc
Plastic hammer
1 pc
Vacuum sucker
1 pc
Level bar
1 pc
Pipe tongs
1 pc
T-shape spanner (10mm)
1 pc
Scissor
1 pc
Hydraulic stacker
1 pc
ZCR 29
C. EC-Declaration of Conformity
In conformity with the EC Machinery Directive 2006/42/EC, Supplement II, A
Manufacturer: NOVENCO HI-PRES Air Handling Equipment (Wuxi) Co., Ltd.
Address:
No.1 Standard Building, District 2, Period 3, Wangzhuang Industrial Centre,
New District, Wuxi City, Jiangsu Province 214028, P.R. China
hereby declares that
Novenco air handling units type ZCR 9/3 – 21/21
a)
meet the requirements of the directives mentioned below provided that the products are installed in conformity
with the enclosed instructions. If the products are changed, this declaration will no longer apply.
Directives:
– EC Machinery Directive 2006/42/EC
– EMC Directive 2004/108/EC
– LVD 2006/95/EC
b)
are made in conformity with the following harmonized standards:
– EN ISO 12100-1, EN ISO 12100-2, EN ISO 12100-2/A1, EN 13857
– EN 60204-1
It is a precondition that Novenco’s installation instructions have been followed.
Naestved, 01.07.2013
Bjarne Soerensen
Director, R&D
Novenco Marine & Offshore A/S
30 ZCR
MU 15244 0116
Novenco Marine & Offshore develops and manufactures ventilation and re ghting systems that are
marketed and distributed world-wide through subsidiaries and agents.
The company was founded in Denmark
1947 and has become one of the
world-leading suppliers.
Novenco Marine & Offshore symbolises quality and
environmentally friendly products. The company is
certied according to ISO 9001 and
ISO 14001.
Novenco, ZerAx, 庉ₖ䱠, 庉㠖䱠 and
trademarks of Novenco A/S.
Hi-Pres,
诺克
NOVENCO
are registered
and 豸膌苇 are registered trademarks of
Novenco Marine & Offshore A/S.
豸膌苇
HI-PRES
Read more about Novenco Marine & Offshore on the
Internet.
Novenco Marine & Offshore A/S · Industrivej 22 · DK-4700 Naestved · Denmark · Tel. +45 70 12 42 22 · Fax +45 55 75 65 50
www.novenco-marine.com