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Air quality Quality of life
Original Instructions
Installation Operations and Maintenance manual
CTAE
series
Incorporated in this manual there are the following documents:
Declaration of conformity •
Technical schedule •
Dimensional drawing •
Wiring diagrams •
RETAIN FOR FUTURE REFERENCE
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Table of Contents
Related Manuals for Vortice CTAE Series
Summary of Contents for Vortice CTAE Series
- Page 1 www.vorticeindustrial.com info@vorticeindustrial.com Air quality Quality of life Original Instructions Installation Operations and Maintenance manual CTAE series Incorporated in this manual there are the following documents: Declaration of conformity • Technical schedule • Dimensional drawing • Wiring diagrams • RETAIN FOR FUTURE REFERENCE...
- Page 2 Guarantee is limited by conditions and terms described in the “ ” supplied with the unit and bearing unit type and WARRANTY CERTIFICATE serial number. Support service performed by Vortice Industrial s.r.l. e-mail: info@vorticeindustrial.com...
- Page 3 O&M MANUAL - CTAE SERIES Quality Certification The quality of our products is documented through certificates that guarantee every phase of the company production process, from production to the management of materials, from production control to document management. Operating in this way, the process can be managed in a systematic way, as well as having the guarantee that all production activities are certainly carried out according to the procedures envisaged during the project, or in the technical documents.
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Page 4: Table Of Contents
O&M MANUAL - CTAE SERIES GENERAL INDEX 1. INTRODUCTION ....................................06 1.1 Preliminary information ..............................06 1.2 Aim and content of the manual ............................06 1.3 How to store this manual ............................... 06 1.4 Manual update ................................06 1.5 How to use this manual ..............................06 1.6 Potential risks ................................ - Page 5 O&M MANUAL - CTAE SERIES 6. MAINTENANCE ....................................29 6.1 Safety system ................................29 6.2 Electric motors, drives and centrifugal fans ........................30 6.3 Fans EC Brushless ................................ 31 6.3.1 Fans maintenance ..............................31 6.3.2 Cleaning and safety test ............................. 32 6.4 Air filters ..................................
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Page 6: Introduction
O&M MANUAL - CTAE SERIES 1. INTRODUCTION Air handling units should be installed and operated in accordance with requirements listed in this manual. Observing these simple instruc- tions carefully is a preliminary precaution in order to: • totally avoid or substantially decrease number of unit shutdowns for unforseen breakdowns;... -
Page 7: Potential Risks
O&M MANUAL - CTAE SERIES 1.6 Potential risks Any operation which can produce dangerous situations is indicated in this manual. It also contains precautionary measures for any specific case. CAUTION ! Any operation which can produce dangerous situations is indicated in this manual. It also contains precautionary measures for any specific case. - Page 8 O&M MANUAL - CTAE SERIES Whilst the unit has been designed to minimize any risk posed to the safety of people who will interact with it, it has not been technically possible to eliminate completely the causes of risk. It is therefore necessary to refer to the requirements and symbolism below:...
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Page 9: General Description Of Symbols Used
O&M MANUAL - CTAE SERIES 1.7 General description of symbols used Safety symbols combined in accordance with ISO 3864-2: BANNED A black symbol inside a red circle with a red diagonal indicates an action that should not be performed. WARNING A black graphic symbol added to a yellow triangle with black edges indicates danger. -
Page 10: Safety Symbols Used
O&M MANUAL - CTAE SERIES 1.8 Safety symbols used GENERAL RISK Observe all signs placed next to the pictogram. The failure to follow directions may create a risk situation that may be injurious to the operators and users. ELECTRICAL HAZARD Observe all signs placed next to the pictogram. -
Page 11: Limitations And Prohibited Use
O&M MANUAL - CTAE SERIES 1.9 Limitations and prohibited use The machine is designed and built exclusively for the uses described in this technical manual. Any other use is prohibited because it may pose a potential risk to the health of operators and users. -
Page 12: Safety
O&M MANUAL - CTAE SERIES 2. SAFETY 2.1 Safety integration principles The machine is designed and built to avoid any risk for health and people. Many project’s solutions have been carried out to avoid (where is possible) any kind of danger. -
Page 13: Trasportation And Handling
O&M MANUAL - CTAE SERIES 3. TRASPORTATION AND HANDLING 3.1 Receipt and inspection of the labels on the unit, and to take any possible precautions of the case. Not observing the rules reported on this manual can create dangerous situations. After receiving the unit, immediately check its integrity. The unit left the factory in perfect conditions; any eventual damage must be questioned to the carrier and recorded on the Delivery Note before it is signed. -
Page 14: Storage
O&M MANUAL - CTAE SERIES 3.3 Storage Unit should be stored under cover and ideally, should remain in their packaging. If for some reason the unit was already unpacked, follow these instructions to prevent damage, corrosion and / or deterioration: •... -
Page 15: Installation
O&M MANUAL - CTAE SERIES 4. INSTALLATION 4.1 Preliminary notice The AHU must be placed in a special area that can be made inside a technical room or outside in a covered area or not, depending on the structure on site. - Page 16 O&M MANUAL - CTAE SERIES • in case of overhead positioning, the individual support points must be realized in order to support the corresponding mass of the section in consideration of the unit’s height and in compliance with the safety limits for seismic risk. (Fig. F (concrete) – Fig. F (structure in metal profiles));...
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Page 17: Service Area Requirements
O&M MANUAL - CTAE SERIES 4.2 Service area requirements Area choosen for unit assembly must allow sufficient clearance space, around and on top of unit, for unit installation and further ordinary and extraordinary maintenance operations. Particularly important is the service area on the inspection and connection side, in order to allow panels to open completely and coils to slide out completely for extraordinary maintenance. - Page 18 O&M MANUAL - CTAE SERIES EXTERNAL JUNCTIONS SCHEME Fig. 5 INTERNAL JUNCTIONS SCHEME Fig. 6...
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Page 19: Coil Connections
O&M MANUAL - CTAE SERIES 4.4 Coil connections 4.4.1 Water coils The following requirements for water connections are also applicable for coils with other fluid, such as glicole solutions, diathermal oil, etc. The following minimal requirements are recommended for any type of installations. -
Page 20: Direct Expansion Coils
O&M MANUAL - CTAE SERIES 4.4.3 Direct expansion coils Instructions given at points a) and b) of paragraph 4.4.1. for water coils should be followed also in this case, bearing in mind that the best coil performance is always obtained with the counter-flow arrangement. In this case coil supply is evidently the one provided with the distribution header where the liquid line must be connected. -
Page 21: Hydronic Connections
O&M MANUAL - CTAE SERIES 4.5 Hydronic connections All connections should be made with the best available current workmanship practice according to the indicated dimensions of inlet and outlet diameters. Outlet connections should be complete with water traps and their height calculated on the basis of the maximum negative pressure existing at the drainage point. -
Page 22: Electrical Connections
O&M MANUAL - CTAE SERIES 4.8 Electrical connections The unit name plate (Fig. 1) and the literature supplied with the unit show the electric characteristics and the maximum full-load current input (FLA) of all electric motors and electric heaters, if any. - Page 23 O&M MANUAL - CTAE SERIES Electrical connection schemes Single speed motors L1, L2, L3 L1, L2, L3 Delta (Δ) connection Star (Y) connection Two speed motors - 2/4 poles or 4/8 poles Double polarity (Dahlander type) - Y/YY L1, L2, L3...
- Page 24 O&M MANUAL - CTAE SERIES Two speed motors - 4/6 poles Double winding - Y/Y L1, L2, L3 L1, L2, L3 Lower speed Higher speed (6 poles) (4 poles) One-phase motors MOTOR SWITCH BROWN WHITE ORANGE COMMON BLACK HIGH SPEED...
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Page 25: Plug-Fan / Brushless Fan Connections
O&M MANUAL - CTAE SERIES 4.8.3 Plug-fan / Brushless fan connections Power connections: from the electrical distribution / control panel, connect to the terminal board located on the brushless motor. The cable section is determined by referring to the following table. -
Page 26: Safety Devices On Doors
O&M MANUAL - CTAE SERIES 4.8.4 Safety devices on doors In the event that a door of the unit is opened where motors / fans or rotating parts are installed, the unit must immediately stop. Fan sections are equiped with a microswitch and/or a protection grid an inlet doors.In presence of a N.O. microswitch, connect it through an auxiliary contact in the circuit breaker;... -
Page 27: Unit Start Up
O&M MANUAL - CTAE SERIES 5. UNIT START UP 5.1 Preliminary checks Before starting the unit, it is necessary to carry out preliminary checks. Start-up operations must be performed in accordance with the instructions detailed in the previous paragraphs. Malfunctions or damage can occur due to lack of adequate care during shipment, transport or installation. -
Page 28: Air Filters
O&M MANUAL - CTAE SERIES d) Verify the actual current input and compare this value with data indicated on the unit name plate; in case actual current input is higher, it is necessary to check that: • motor-fan group rotates freely by hand;... -
Page 29: Dampers
O&M MANUAL - CTAE SERIES Glycol % in the solution Freezing point °C (by volume) 0 ° 10 % - 5,5 ° 20 % - 9,0 ° 30 % - 15 ° 40 % - 25 ° 50 % - 33 °... -
Page 30: Electric Motors, Drives And Centrifugal Fans
O&M MANUAL - CTAE SERIES 3. when internal lighting is installed, check that light turns on at safety intervention. (i.e. at doors opening in the previous example); 4. check correct positioning of all static (or passive) safety devices and that they are steadily fasten to the unit parts; in particular, protection of moving parts must be stable and should be possible to disassemble them only by using special tools. -
Page 31: Fans Ec Brushless
O&M MANUAL - CTAE SERIES SCREW “A” Fig. 9 At motor start up belts normally slide on pulleys for 1-2 seconds. Correct tension will avoid early wear out of belts (usually due to belts too loose) or overloading bearings of motor and fan (due to belts too tensioned). -
Page 32: Cleaning And Safety Test
O&M MANUAL - CTAE SERIES RISK OF INJURY • Keep out of the device hazard zone; • When working on the device, switch off the mains power and ensure that it cannot be switched back on; • Wait until the device stops;... -
Page 33: Humidifier Sections And Pumps
O&M MANUAL - CTAE SERIES 6.5 Humidifier sections and pumps 6.5.1 Water sumps, packs and nozzles Every 60 days open the bottom discharge and empty sumps, then wash with water jet in order to clean from dirt and mud deposited on the bottom;... -
Page 34: Unit Shut Down Precautions
O&M MANUAL - CTAE SERIES 6.8 Unit shut down precautions When unit is expected to be idle for long periods, it is recommended to use the following simple precautions: 1. disconnect power supply on the general electric panel and place a warning notice that unit is idle;... -
Page 35: Trouble Shooting
O&M MANUAL - CTAE SERIES 6.10 Trouble shooting Trouble Possible Cause How to solve Electric system failure Call electric maintenance Active safety fails to Replace component or call operate Electric components failure our Service Dirty filters Clean or replace filters... - Page 36 O&M MANUAL - CTAE SERIES Trouble Possible Cause How to solve Eccessive air volume See trouble 3 Droplets carryover Eccessive water flow on packs Adjust supply valve dawnstream pump Warn bearings on fan or motor Replace bearings Fan discharge isolator too...
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Page 37: Unit Record Book
O&M MANUAL - CTAE SERIES 6.11 Unit record book DATE CHECK OR TROUBLE RESULT INTERVENTION SIGNATURE... -
Page 38: Replacement Parts
O&M MANUAL - CTAE SERIES 7. REPLACEMENT PARTS 7.1 Unit identification AHU model is univoquely identified by the “Type” and “Series” indicated on the name plate, (Fig. 1) normally located on the external surface of the inspection panel of the fan section. -
Page 39: Raee Directive (Only Ue)
O&M MANUAL - CTAE SERIES The structure and the various components, if not usable, must be demolished and subdivided according to their nature; in particular steel and aluminum present in high quantities in the unit. All materials must be recovered or disposed of in compliance with the relevant national law. -
Page 40: Indicative Positioning Of Adhesive Signaling And Name Plate Of Identification
O&M MANUAL - CTAE SERIES 9. Indicative positioning of adhesive signaling and name plate of identification USCITA ACQUA WATER OUTLET ENTRATA ACQUA WATER INLET SCARICO DISCHARGE APPARECCHIATURE MACCHINE IN SOTTO TENSIONE MOVIMENTO HIGH VOLTAGE MACHINERY ISPEZIONE EQUIPMENT IN MOVEMENT FILTRI... - Page 41 O&M MANUAL - CTAE SERIES NOTES...
- Page 42 Reproduction, even partial, of the present manual and its figures is forbidden. VORTICE INDUSTRIAL S.r.l. reserves copyright according to applicable laws. VORTICE INDUSTRIAL S.r.l. shall have the right to introduce at any time whatever modifications necessary to the improvement of the product.
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