TCF CV Series Manuel d'exploitation et d'entretien

INSTRUCTIONS, OPERATION

AND MAINTENANCE MANUAL

AIR EXHAUST UNITS

SERIES CV-CVM-CVMI-EV

TCF Termoventilatori Condizionatori Felsinea Srl

40057 Cadriano di Granarolo Emilia (Bologna), via Giuseppe di Vittorio 5

www.tcf.it

GENERAL INDEX

0. INTRODUCTION 2

1. DESCRIPTION OF THE EXHAUST AIR 2

UNIT

1.1 COMPOSITION 2

1.2 PERMITTED USE 2

2. CONTROL,PACKING,TRANSPORTATION

2.1 FACTORY INSPECTION OF THE SUPPLY 2

2.2 PACKING 2

2.3 LOADING,TRANSPORT,UNLOADING 2

3. PRESERVATION AND ASSEMBLY 3

ON SITE

3.1 POST-TRANSPORTATION CHECK 3

3.2 PRESERVATION ON SITE 3

3.3 POSITIONING 3

3.3.1 Base rame 3

3.3.2 Vibration damping 3

4. CONNECTION TO SYSTEMS AND START-UP

4.1 CONNECTION TO DUCTS 4

4.2 3-PHASE FAN MOTOR ASSEMBLY 4

CV MODELS

4.2.1 Electric motors 4

4.2.1.1 Connection or direct starting 4

4.2.1.2 Connection or star-delta starting 4

4.2.1.3 Dual speed three-phase motor 4

4.2.1.4 Permitted start-up time 5

4.2.1.5 Connection and protection accessories 5

4.2.2 Fan 5

4.2.3. Transmission 5

4.3 1-PHASE FAN MOTOR ASSEMBLY 6

CVM, CVMI, EV MODELS

4.3.1 Electric motors 6

4.3.1.1 3-speed ans 6

4.3.1.2 Single-speed ans 6

. MAINTENANCE 6

5.1 FOREWORD 6

5.2 FAN SECTION 7

5.2.1 Fan 7

5.2.2 Motor 7

5.2.3 Transmission (CV models) 7

5.2.3.1 Determining belt tension 7

5.2.3.2 Replacement o driving belt 8

5.2.3.3 Drive with multiple-race pulleys 8

5.3 ACCESSORIES 8

5.3.1 Control dampers 8

5.3.2 Fresh air inlet grilles 8

5.4 TROUBLESHOOTING 8

5.4.1 Reduction in low rate 8

5.4.2 Increase in low rate 8

5.5.3 Abnormal noise level 9

6. SAFETY 9

6.1 SAFETY-RELATED FEATURES OF 9

AIR-EXHAUST UNITS

6.2 SAFETY NOTICES APPLIED TO THE 9

UNITS

6.3 PRACTICAL ACCIDENT-PREVENTION 9

TIPS

7. WARRANTY 9

TCF Termoventilatori Condizionatori Felsinea Srl

40057 Cadriano di Granarolo Emilia (Bologna), via Giuseppe di Vittorio 5

www.tcf.it

0. INTRODUCTION

This manual has been compiled by TCF Srl to provide the

installer, customer and user with instructions intended to

ensure the proper management and use o the air-exhaust

units series CV, CVM, CVMI, EV rom the delivery up to the

commissioning.

The recommendations which ollow are intended to ensure a

continuous and durative operating li e o the air exhaust unit.

The procedures described below should be per ormed by

skilled personnel with a good knowledge o air-conditioning

systems design and operation, even though, thanks to the

unit’s simplicity o design, these could be carried out also by

those un amiliar with air handling.

1. DESCRIPTION OF THE AIR-EXHAUST UNIT

1.1 COMPOSITION

The air exhaust unit is made up rom:

•Return section possibly including one control

damper or grille

•Fan section

1.2 PERMITTED USE

TCF air exhaust units are designed exclusively or CIVIL AND

INDUSTRIAL AIR TREATMENT.

In case o CORROSIVE and/or EXPLOSIVE air lows, a number

o special technical modi ications must be made at the design

stage which, altogether, adapt the machine or the treatment

o special air lows.

The air exhaust units must at all times be used strictly in

accordance with the design conditions established at the time

o contract in agreement with the customer. ANY OTHER USE

SHALL CONSTITUTE IMPROPER USE AND IS THEREFORE

DANGEROUS. THE MANUFACTURER MAY NOT BE HELD

LIABLE FOR DAMAGE CAUSED BY NON-STANDARD USE OR

ANY USE NOT ENVISAGED IN THE CONTRACT.

2. CONTROL, PACKING, TRANSPORTATION

2.1 FACTORY INSPECTION OF THE SUPPLY

Prior to shipping, each TCF air exhaust unit is subject to all

the unctional tests listed on the attached UNIT INSPECTION

SHEET. The controls concern:

•General machine dimensions

•Correct assembly o the various parts and sections

•Compliance with the various sa ety rules in orce

•Integrity o all the system’s component parts

•Application o the identi ication, operation and

sa ety notices

On completion o the inspection, the Chie Inspector applies

the EC mark demonstrating product compliance with

prevailing European Union machine directives.

2.2 PACKING

Transportation o the machines may be:

-normal

-special

In the ormer case, TCF Srl does not normally pack the units.

In case o special transportation, the packing requested is

agreed at the time o contract and is entirely on the

customer’s charge.

Fragile components supplied separate rom the unit, such as

control boards etc., are always delivered packed.

2.3 LOADING,TRANSPORT,UNLOADING

TCF Srl disclaims any liability or damage occurred to the air

exhaust unit during loading, unloading and transportation.

We there ore recommend that precautions be taken,

including:

-The load must be irmly secured to ensure its

integrity during transportation

-Handling must be per ormed without exerting orce

on protruding accessories (hydraulic attachments,

handles, hinges, air locks, protection roo )

-Do not overturn the sections as you may otherwise

break internal supports, components and dampers

-Do not subject the unit to violent impacts as you

may damage its integrity

-I a orkli t truck is used during the loading,

unloading and handling operations, the orks o the

truck must be at least the same length as the unit to

ensure stability ( ig. 1)

-I the air exhaust unit is itted with a continuous

steel base rame, handling may be carried out with a

crane, using cables irmly secured to rods (su icient

or the stress involved) passing through the holes

provided in the base.

I a crane is used, proceed as shown in the illustration,

using spacers to protect the structure ( ig. 2).

-During transportation, protect the unit rom

atmospheric agents. Special care must be taken i

the unit is supplied disassembled or designed or

internal use.

TCF Termoventilatori Condizionatori Felsinea Srl

40057 Cadriano di Granarolo Emilia (Bologna), via Giuseppe di Vittorio 5

www.tcf.it

3. ASSEMBLY ON SITE

3.1 POST-TRANSPORTATION CHECK

Upon arrival o the air exhaust unit on site, TCF suggests the

customers to per orm an accurate check o the structure and

o the components.

Should any transportation damage be detected, this must be

noti ied on the delivery bill. The carrier must immediately ile

a report o the accident to obtain compensation rom the

insurance company.

3.2 PRESERVATION ON SITE

In order to keep the air exhaust unit in good and e icient

condition on site, the ollowing steps must be taken irst:

-prior to installation, position the unit and the

accessories in a place o ering the best possible

protection against accidental knocks, dust and

atmospheric agents

-care ully cover the inlets and outlets to prevent

oreign matter rom entering the unit and damaging

the internal components

3.3 POSITIONING

3.3.2 Base rame

The permanent installation o the air exhaust unit may be

made:

-directly on the loor ( ig. 3a)

-on a concrete bed ( ig. 3b)

-on a steel section bed ( ig. 3c)

-on a suspended base ( ig. 3d)

Both the loor and the beds must be capable o withstanding

the machine weight to within the required sa ety margins.

The air exhaust unit must be positioned on a horizontal

sur ace so as to prevent:

-damage to the an motor units caused by uneven

weights on the vibration dampers

-di iculty in opening and closing the inspection

doors

The horizontal alignment o the support sur ace must be

checked with a SPIRIT LEVEL; adjustments may be made

using STEEL SHIMS.

FIG. 3

3.3.2 VIBRATION DAMPING

In order to ensure e ective protection against vibrations, the

air exhaust unit must be installed as ollows:

-suitable DAMPERS must be placed between the

machine and the support sur ace, in material

designed to withstand the weight involved

-the unit must not be astened directly with screws

but by means o brackets ( ig. 5)

Even in case o suspended installation o the unit, the

supports must not be screwed directly into the ceiling;

vibration damping material must always be placed between

the support and the ceiling ( ig. 5).

TCF Termoventilatori Condizionatori Felsinea Srl

40057 Cadriano di Granarolo Emilia (Bologna), via Giuseppe di Vittorio 5

www.tcf.it

FIG. 5

4. CONNECTION TO SYSTEMS AND START UPS

4.1 CONNECTION TO DUCTS

At the point o connection to the air ducts, the air exhaust

units have a smooth or a langed sur ace.

In order to optimise the connection with the ducts, you must:

-clean the connection edges between duct and unit

-it a seal to the langes in order to prevent air

in iltration

-tighten the connecting screws irmly

-treat the joint with silicone to enhance the seal

I the connection is made with rubber canvas joints, make

sure they are not tightened on assembly completion, so as to

prevent damage or the transmission o vibrations.

In order to ensure the tightness o the connections and the

integrity o the unit, the weight o the ducts must under no

circumstances bear down on the unit. The ducts must be

supported by BRACKETS.

4.2 3-PHASE FAN-MOTOR ASSEMBLY CV MODELS

4.2.1 Electric motors

Be ore starting up the unit:

-inspect the motor CONTROL BOARD and check that

the motor protection devices are sized or the

maximum amperage, corresponding to the rated

value on the plate.

-The TERMISTORS, i present, must not be connected

to the power supply line o the electric motors since

otherwise they would be damaged irreparably

(operating voltage 1V)

-Check that the MAINS SUPPLY VOLTAGE is suited to

that o the motors as indicated on the relevant

plates

4.2.1.1 Connection or direct starting

The simplest electric motor start-up system is obtained by

connecting the motor directly to the supply line. However,

this method has limitations due to the high start-up current

(pick-up); this type o start-up is recommended or power

ratings up to 5,5kW or which TCF installs, as standard, 4-

poles 220/380 V three-phase motors.

The wiring diagrams are shown in ig. 6.

FIG. 6

4.2.1.2 Connection with star-delta starting

I the motor start-up current exceeds the value permitted by

the power supply, you may decide to choose or delta-star

starting.

For this purpose TCF installs dual voltage 400/690V motors

on its air exhaust units starting rom an output o 7,5kW, thus

allowing the motor to operate normally at 400V (delta

connection) and to start-up at 690V (star connection).

This arrangement reduces the starting current by

approximately 30% o the current involved in case o direct

starting.

FIG. 7

4.2.1.3 Dual speed three-phase motors

The diagram in ig. 8 shows the connection o a TWO-SPEED

MOTOR with two separate windings to the power supply.

TCF installs motors o this kind on the ollowing units:

-230/400V or power ratings up to 5,5kW

-400/690V or power ratings rom 7,5kW

This type o electric motor permits the delta-star connection

by means o a starter.

TCF Termoventilatori Condizionatori Felsinea Srl

40057 Cadriano di Granarolo Emilia (Bologna), via Giuseppe di Vittorio 5

www.tcf.it

The two-speed motors with a single DAHLANDER

commutable winding ( ig. 9) o er the advantage o

generating greater power than motors o the same size but

with separate windings.

4.2.1.4 Permitted start-up time

Because o the temperature increase, the start-up time o a

motor may not exceed the value shown in table 1.

The data re er to start-ups at exercise temperature, whereas

or cold start-ups such timings may be doubled.

4.2.1.5 Recommended connection and protection

accessories

For the sizing o cables and connections, please re er to the

motor nameplate data and to the laws in orce in the country

where the unit is installed.

FIG. 8

FIG. 9

4.2.2 Fan

Be ore start-up, carry out the ollowing checks:

-make sure that the an wheel is unctioning

correctly by rotating it manually

-check that any sa ety clamp, itted to prevent

damage during transportation, has been removed

rom the dampers ( ig. 10).

FIG. 10

sa ety clamps

4.2.3 Transmission

Be ore starting the air exhaust unit please check:

-the tension o the V-belts (section 5.2.3.1)

-that the pulleys are aligned (section 5.2.3.1)

-that the dowels, shown in ig. 20, in their possible

installation positions, are doing their unction o

securing the pulleys to the hubs

TCF Termoventilatori Condizionatori Felsinea Srl

40057 Cadriano di Granarolo Emilia (Bologna), via Giuseppe di Vittorio 5

www.tcf.it

FIG. 11

4.3 1-PHASE FAN MOTOR ASSEMBLY CVM, CVMI, EV

MODELS

4.3.1 Electric motors

Be ore starting up the unit:

-inspect the motor CONTROL BOARD and check that

the motor protection devices are sized or the

maximum amperage, corresponding to the rated

value on the plate.

-The thermal protections, i present, must not be

connected to the power supply line o the electric

motors since otherwise they would be damaged

irreparably

-Check that the MAINS SUPPLY VOLTAGE is suited to

that o the motors as indicated on the relevant

plates

4.3.1.1 3-speed ans

The scheme on ig. 12 shows the ‘code colour’ o the terminal

plate installed on the ans used or the EV and CVM series.

FIG. 12

WHITE ------------- COMMON

RED ------------- LOW SPEED

BLUE ------------- MEDIUM SPEED

BLACK ------------- HIGH SPEED

fan motor

STRIPED ___

The scheme on ig. 13 shows the connection o a an motor

actuated by the 3-speed selector type ‘6990’.

FIG. 13

WHITE -------------------------------

RED -------------------------------

BLUE -------------------------------

BLACK -------------------------------

fan motor

STRIPED ___

___________ 2

I _____

commuter

I I

PE N L

4.3.1.2 Single speed ans

The scheme on ig. 12 shows the ‘code colour’ o the terminal

plate installed on the ans used or the CVMI series.

FIG. 14

ORANGE

_________________

BLACK __________ I

STRIPED

___ I I

I I I

fan motor

PE N L

The scheme on ig. 15 shows the connection o a an motor

actuated by a “VVM” type speed controller.

FIG. 15

. MAINTENANCE

5.1 FOREWORD

TCF recommends that its customers carry out PREVENTIVE

MAINTENANCE on the air exhaust units in order to ensure a

long-term e iciency.

Such air exhaust units require little maintenance and have

been designed to make each operation as easy and sa e as

possible.

TCF Termoventilatori Condizionatori Felsinea Srl

40057 Cadriano di Granarolo Emilia (Bologna), via Giuseppe di Vittorio 5

www.tcf.it

5.2 FAN SECTION

5.2.1 Fan

In order to keep the an in per ect working order, WE

RECOMMEND YOU TO CHECK THE FOLLOWING AT LEAST

ONCE A MONTH:

-The cleanliness o the shell and wheel; remove any

deposits

-Damage and corrosion to the an components; in

case remedy with zinc-powder paint

-The tightness o the parts comprising the an section

-Seal o the vibration-damping joint itted to the an

supply mouth

-Cleaning and lubrication o any DAPO control air

locks. Lubrication o this part must be per ormed

every six months

-Absence o abnormal noises due to deterioration o

the bearings. I necessary, replace them. The ans

mounted on the TCF units are itted wither with

oilless

bearings

(design

lie

20.000 hours) or pedestal

bearings, depending on the operating conditions.

The pedestal bearings require periodic lubrication.

THE LUBRICATION INTERVALS show in table 2 are

subject to the environmental conditions and the

maximum temperature range during operation.

TABLE 2

Lubrication o an support bearings

5.2.2 Motor

In order to maintain the motor in per ect working order, TCF

recommends the FOLLOWING MONTHLY CHECKS:

-Cleanliness: remove any deposits

-Absence o abnormal noise due to deterioration o

the bearings

Power ul motors itted with grease nipples require

periodic lubrication. The greasing intervals, under

normal operating conditions, are shown in Table 3.

TABLE 3

Greasing o motor bearings

5.2.3 Transmission (CV models)

In order to ensure optimum drive e iciency and to avoid

damaging the an motor unit, the transmission must be kept

in per ect working conditions.

The ollowing must be CHECKED EVERY MONTH:

-The operating condition and dirtiness o the

transmission; remove any deposits

-Damage to the drive (cracks on belt and pulleys,

rayed belt edges, worn belts and pulleys). I

necessary, replace the damaged part(s)

-The per ect alignment o the transmission

-The tension o the belt (see section 5.2.3.1)

5.2.3.1 Determining belt tension

To alter the tension o the driving belts you must remove the

motor.

To acilitate this operation the motors are positioned on:

-guides

-belt-tensioning slides

in both cases it is easy to tighten or slacken the driving belt

by means o the lock nuts and adjusting screws.

In order to determine DRIVING BELT TENSION ( ig. 16), you

must:

-establish a centre distance (I) and block the drive

-using a spring-operated torque wrench, apply a

orce (P) on the midway point o the belt

(perpendicular to it) to obtain a de lection equal to

1/64 o the centre distance (approx. 16mm/m)

-check that the applied orce is within the values

indicated in table 5, i not, set a new centre distance

and repeat the test

TABLE 4

TCF Termoventilatori Condizionatori Felsinea Srl

40057 Cadriano di Granarolo Emilia (Bologna), via Giuseppe di Vittorio 5

www.tcf.it

FIG. 16

I the tension is not correct, the ollowing will occur:

-i the belt is slack, it will wear out rapidly and the

drive system will be ine icient

-i the belt is too tight, the motor and an bearings

will be damaged

whenever the belts are tightened, you must check that the

drive belts are aligned using an ordinary RULER ( ig. 17)

FIG.17

I the pulleys are o di erent thickness, you must check their

equivalence as shown in ig. 18 to ensure correct installation.

5.2.3.2 Replacement o driving belt

To REPLACE THE DRIVING “V” BELT:

-loosen the drive and remove the worn-out belt

-check the condition and wear o the pulleys and

replace them i necessary

-introduce the new belt without orcing; any orcing

could impair the transmission and shorten its

service li e

-align the drive and tension the belt

-check the belt tension a ter about 10 working hours

5.2.3.3 Drive with multiple-race pulleys

-in case o drives with several belts, the belts must be

replaced at the same time. This means that there

must not be belts presenting di erent states o wear

in the same transmission system

-the number o belts must always match the number

o races

-in this type o drive system, the belt slack must be

on the same side, as shown in ig. 19, be ore they are

tightened

FIG. 19

5.3 ACCESSORIES

5.3.1 Control dampers

The TCF control dampers o the SAL range do not require

particular maintenance. It is however recommended to veri y

the alignment o the gears and the smooth operation o the

ins. This could be damaged by the weight o ducts in case

they bear down o the dampers themselves, by de lecting

them (condition to be avoided).

5.3.2 Fresh air inlet grilles

They must requently be cleaned by deposits which obstruct

the air passage, jeopardizing the correct operation o the

whole installation.

5.4 TROUBLESHOOTING

The most common MALFUNCTIONS in air exhaust units are:

-reduced low rate

-increased low rate

-abnormal noise

5.4.1 Reduction in low rate

This is the result o an uncontrolled increase in resistance in

the aeraulic circuit which alters the an operating point.

The most requent causes are:

-blockage o the intake grille(s)

-ully or partially closed control air locks

-ine icient an motor unit drive

5.4.2 Increased low rate

I the sum o the resistances in the aeraulic circuits is less

than the value considered at the design stage, the most

common causes are:

TCF Termoventilatori Condizionatori Felsinea Srl

40057 Cadriano di Granarolo Emilia (Bologna), via Giuseppe di Vittorio 5

www.tcf.it

-incorrect setting o any mechanical low controls or

zone air locks

-open or partially closed inspection doors

5.4.3 Abnormal noise level

With regard to the an, the causes may be:

-worn-out or de ective bearings

-an o -balance

-oreign matter in the an wheel

With regard to the electric motor, the causes may be:

-worn-out or de ective bearings

-loose cooling an and/or an guard

-magnetic noise during requency reductions with

inverter (applications below 22Hz are not

recommended as a rule)

With regard to the drive system, the causes may be:

-slipping o belt

-worn belt

-misaligned pulleys

-pulley with play on key

in order to remedy the mal unctions listed above (and not the

entire air-conditioning system), CONSULT THE CHAPTER

RELATED TO THE MAINTENANCE (ch. 5) OR, IF THE

PROBLEM PERSISTS, CONTACT OUR TECHNICAL

DEPARTMENT.

6. SAFETY

6.1 SAFETY-RELATED FEATURES OF AIR EXHAUST

UNITS

TCF Srl has itted its air exhaust units with every possible

sa ety eature to prevent accidents, especially during start-up

and maintenance.

Some o the SAFETY FEATURES are listed below:

-INSPECTION DOORS THAT CAN ONLY BE OPENED

WITH A KEY are installed in the sections housing

rotating parts and drives

-the GRATES and HOUSINGS protecting rotating

parts and drives can only be removed with a key

-the outside o the structure has ROUNDED EDGES

-elimination o sharp-edged steel sheet parts inside

and outside o the unit

-use o SELF-TAPPING SCREWS WITH NON-

PROTUDING TIPS inside sections and panels

we always recommend to install, inside the an section, an

ELECTRIC ISOLATOR, which has the unction o preventing

the an-motor assembly rom getting started during

maintenance operations, thus jeopardising the sa ety o the

technician.

6.2 SAFETY NOTICES APPLIED TO THE EXHAUST

UNITS

The inspection doors o the air exhaust unit carry SAFETY

NOTICES drawing the operator’s attention to the danger

connected with moving parts and warning him to

disconnect the system power be ore opening the inspection

doors ( ig. 20).

FIG. 20

6.3 PRACTICAL ACCIDENT-PREVENTION TIPS

-Open the inspection doors only when the an is at a

standstill

-Be ore carrying out maintenance work on the an

motor unit, make sure that the motor cannot be

restarted by accident

-Be ore operating on the motor, make sure that it has

cooled down completely

-In order to protect your hands, use a lever to

remove the belts

-Block the an wheel be ore maintaining it, since

(especially when the belt is removed) the ‘updra t

e ect’ caused by the ducts could make it rotate and

cause injury

7. WARRANTY

TCF Srl guarantees its products or 12 months rom shipment

date.

The warranty covers the normal operation o the individual

components installed on our units, such as motors, ans, heat

exchangers, humidi iers and other parts.

It should be stressed that the warranty covers manu acturing

de ects in these parts, while their e iciency is categorically

excluded since this is determined by the characteristics o the

aeraulic and hydraulic systems and by the design, and does

not there ore all within our sphere o responsibility.

TCF there ore undertakes to replace any individual

component which mal unctions as rapidly as possible and

subject to stocks. The part should be sent ( reight costs pre-

paid) to our headquarters and the replacement part will be

sent ex-works.

Please note, too, that the warranty does not include the

service o our personnel or the replacement o the part on

site; this cost is entirely on the installer’s account.

On receipt o the returned material deemed to be de ective,

an inspection will be carried out to establish whether the part

reveals abnormalities justi ying application o the warranty.

I it is established that the de ect is due to external actors,

the replacement part will be charged to the customer.

It should urthermore be noted that the warranty shall not

apply in the case o tampering or in case the ailure is a

consequence o incorrect installation or connection.

On this behal , re erence will be made to the instructions

contained in this Installation, Operation and Maintenance

Manual which accompanies each o our machines.

TCF Srl

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