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KLIMA
AIR-WATER COOLER
Supplier information:
Homepage:
www.Klima.com
The Netherlands:
VDL Klima b.v.
Meerenakkerweg 30
5652 AV Eindhoven
P.O. Box 300
5600 AH Eindhoven
Telephone: +31 (0)40-2981818
Telephone service: +31 (0)40-2981858
Fax: +31 (0)40-2981800
E-mail info@klima.com
Supplier Belgium:
Klima Belgium n.v.
Leuvensesteenweg 49c
1932 Zaventem
Telephone: +32 (0)2-7206026
Fax: +32 (0)2-7203407
E-mail Klima.belgium@klima.com
Supplier Belgium:
Klima warmtetechniek n.v.
Buitenheide 4
3930 Hamont-Achel
Supplier France:
VDL Klima France s.a.r.l.
Chateau Rouge - 276
Avenue de la Marne
59708
Marcq-en-Baroeul
Telephone: +33 (0)320-65-91-65
Fax: +33 (0)320-65-91-60
E-mail Klima.france@klima.com
Publication: 27.03.2006
2
Table of Contents
1 General Information...........................................................................5
1.1 Product Information ........................................................... 5
1.2 Installation Parts ................................................................ 6
1.3 Prohibitions on (putting into) Operation ............................. 7
1.4 Guarantee.......................................................................... 7
2 Safety ................................................................................................ 8
2.1 General Safety................................................................... 8
2.2 Protection: ....................................................................... 10
3 Transport, Storage and Installation Site. ......................................... 12
3.1 Instructions for Transport and Hoisting ............................ 12
3.2 Transport and Packaging................................................. 13
3.3 Storage: ........................................................................... 13
3.4 Installation Siting:.............................................................14
4 Installation ....................................................................................... 15
4.1 Safety Measures and Facilities on the Heat Exchanger /
Installation. ...................................................................................... 15
4.1.1 Water side connections. .................................................. 15
4.1.2 Electrical connections: ..................................................... 15
4.1.2.1 Connection Regulations................................................... 16
4.1.3 Moving Parts.................................................................... 16
4.1.4 Open Without Danger ...................................................... 16
4.2 Preparation for Installation............................................... 17
4.3 Installation ....................................................................... 19
4.4 Tightening of the Bolts ..................................................... 19
5 Start-up............................................................................................20
5.1 Inspection before putting the unit into operation .............. 20
5.2 Air Inflow.......................................................................... 21
5.3 Filling and Venting. ..........................................................21
5.4 Re-tightening of the Bolts. ............................................... 21
5.5 Inspection after Start-up: ................................................. 21
5.6 Shut-Down of the Installation: .......................................... 22
6 Maintenance and Inspection:...........................................................23
6.1 Inspection ........................................................................ 23
6.2 Cleaning the Air-Water Cooler. ........................................ 24
6.2.1 Disassembly of the Air-Water Cooler............................... 24
6.2.1.1 Disassembly centrifugal fan. ............................................ 25
6.2.1.2 Disassembly Axial Fan. ................................................... 27
6.2.1.3 Disassembly of element from housing ............................. 28
6.2.2 Cleaning the Air-Water Cooler. ........................................ 29
6.2.2.1 Cleaning the element....................................................... 29
6.2.2.2 Cleaning the heat exchanger's air side. ........................... 29
6.2.2.3 Cleaning the Filters.......................................................... 29
6.2.2.4 Cleaning the Housing. ..................................................... 29
6.2.3 Assembly of the Air-Water Cooler.................................... 30
6.2.3.1 Assembly Centrifugal Fan................................................ 30
3
6.2.3.2 Assembly Axial Fan. ........................................................ 30
6.2.3.3 Assembly of the Element in the Housing ......................... 30
6.2.4 (Re)pressurizing the Heat Exchanger.............................. 30
7 Malfunctions .................................................................................... 31
7.1 Identification and Correction of Malfunctions. .................. 31
7.2 Safety Measures / Facilities: ............................................ 32
8 Customer Service: ...........................................................................33
8.1 Ordering Spare Parts:...................................................... 33
8.2 Complaints Procedure: .................................................... 33
9 Technical Specifications / Documentation ....................................... 34
4
1 General Information
Pictograms used in this manual
The general standards apply to symbols that are applied to the installation by
the owner.
This manual supplies information and instructions for the correct and safe
use of the unit.
Many accidents are the result of incorrect use.
Instructions in this manual must therefore always be followed.
The safety instructions must also always be observed when work is done on
the equipment.
The complete manual must be carefully read.
If, after reading this manual, questions still exist, you must contact the
supplier / contractor for more information.
The installation may NOT be put into operation before all
unclear issues have been resolved.
For exchanging heat between the airflow and a liquid (indirectly). The air to
be cooled flows (inner circuit) through a cooling battery filled with a coolant
liquid. A fan maintains the airflow.
Air/Water Coolers are used for cooling and channelling off excess heat
resulting from energy converted to heat by for example, electromotors,
generators transformers etc.
5
1.2 Installation Parts
Fig. 1 A few examples of Air/Water Coolers.
Fig 1
1. Housing
2. Element
3. Liquid in
4. Liquid out
5. Air in
6. Air out
6
1.3 Prohibitions on (putting into) Operation
Prior to using the unit, the user must have read and understood the
accompanying MANUFACTURERS STATEMENT (Guideline 89/392/EEC
art.4 paragraph 2 and Appendix II under B).
The materials used in the ventilator are in accordance with the VDMA 24169
norm.
Klima has advised on the choice of materials, the user remains responsible
for the media used with regards to corrosion.
1.4 Guarantee
Unless covered by a separate agreement, Klima guarantees the products
supplied by the company to be sound and in good working order, according
to the technical specifications, for a period of 6 months after being put into
operation, up to a maximum of 12 months after delivery.
The General Terms of Sale and Delivery can be requested from your
supplier.
Any damage and/or decrease in capacity due to non-observance of this user
manual are not covered by the guarantee.
The guarantee expires if any adaptations or changes are made to the heat
exchanger.
The equipment must always be inspected upon delivery for damage to the
equipment during transport.
The manufacturer must immediately be notified of any damage during
transport.
7
2 Safety
8
operation.
• The malfunctioning of a safety device must be reported
within sufficiently short space of time, as far as possible
using suitable technical means, in order to minimise the
chance that a dangerous situation occurs.
• As a rule fail safe procedures must be applied.
• The safety devices’ controls must as a rule operate
directly on the control mechanism concerned and not via
the software.
• Failure of the safety device must as far as possible result
in the devices and/or safety devices defaulting to a safe
state.
• Emergency shutdown facilities of the safety devices
must, as far as possible, be equipped with a system that
inhibits switching the equipment on again. A new start
command may only reactivate normal operations once
the emergency shutdown has been deliberately revoked.
The unit may only be fed with the mediums stated in the
technical specification sheet.
9
This manual describes other safety instructions than those
safety instructions related to the chapter in which they occur.
The complete manual must therefore be read to be aware of
all safety provisions and measures to be taken when using
this installation.
Inspect the clearance of the fan before using for the first time
or after maintenance.
After switching off the fan's motor it will take a little while
before the fan stops.
2.2 Protection:
For the protection of others, place the heat exchanger out of reach, in a
closed space, e.g. a boiler house, only accessible to authorized staff
acquainted with the safety requirements applying to the equipment stored
there.
If the heat exchanger is set up close to people, presenting a risk of burns,
insulation of the heat exchanger is mandatory.
10
The user must take care to provide adequate danger signs on exposed un-
insulated parts of the installation, which present risk of burns or other injury
and/or damage.
The fan's drive is protected.
If the cooler is set up close to people, presenting a risk of contact, the must
be shielded in accordance with Euro Norm EN 294. These protective
materials can be delivered by the manufacturer if requested.
11
3 Transport, Storage and Installation Site.
Fig 2
12
3.2 Transport and Packaging
3.3 Storage:
The unit must always be stored covered and dry.
Long-term storage from 2 to 24 months requires airtight sealing of the unit
adding an absorbent material e.g. silica-gel, or filling with inert gas.
If the ATEX 94/9/EG Guideline is applicable and the element
is filled with a flammable gas when operational then the
device must always be filled with an inert gas during transport
and storage.
Storage longer than 6 months requires inspection of the seals and possible
replacement before the unit is put into operation. For long-term storage each
ventilator’s fan must be turned 90° at least 1x per month. This prevents
bearing damage occurring to the ventilator’s electromotor.
13
3.4 Installation Siting:
General conditions on installation siting / location should satisfy:
• Sufficiently firm and level ground or construction, adapted to the load
that is expected.
• Sound construction and vibration-free installation of the unit.
• Protect if necessary against possible damage by e.g. internal transport.
• See the technical specification sheet for product-related information.
• Protection. For safety, see Chapter 2.2 under “Safety”.
• The location where the equipment is placed must have enough space
for installation, maintenance and cleaning. See the relevant chapters.
• Sufficient light and space for inspection and maintenance.
• The unit is anti seismic to maximum earthquake intensity in accordance
with Eurocode 8.
14
4 Installation
The assembly and start-up must be carried out by a suitably
qualified person appointed by the buyer or by a qualified
contractor.
The installation may only be operated, maintained and repaired
by authorised, trained and instructed personnel.
Refer to the manual for the unit in question for these safety
measures / facilities.
Prior to connecting the fan motor one must consult the wiring diagram in the
connector box. One must be very careful specially when connecting
pole reversible motors. Experience shows that many mistakes are
made when installing these motors.
The connection must be in accordance with local regulations. A thermal
safety switch for the motor is built into the electrical circuit of 3 phase motors
for which the setting corresponds to the maximum allowable current as
stated on the motor type plate. If the relay is incorrectly set then any damage
to the motor will not be compensated either by the manufacturer of the
electromotor or by VDL Klima b.v. How the unit is switched on, the thickness
of the wiring, type and settings of the safety measures, must be agreed on in
consultation with your contractor or power supplier. All electrical components
must be earthed, except for those components with double insulation.
15
4.1.2.1 Connection Regulations.
• The electrical equipment must be connected in compliance with Euro
Norm EN 60204-1.
• Local connection regulations (e.g. NEN 1010) must be complied with.
• Dangerous overload must be avoided by the use of over-current limiters
and such like control devices in the electrical system.
• Please refer to the electromotor’s User Manual for the connection
guidelines.
If the ATEX 94/9/EG Guideline is applicable and the air-water cooler is part
of the anti explosion protection, then any hatches and/or other parts that can
be opened must only be able to be opened using special tools or by applying
suitable safety measures. Neither may the ventilator(s) used contain any
parts that can be opened without using special tools or adhering to suitable
safety measures.
16
4.2 Preparation for Installation
General:
• Sufficient space for carrying out assembly, disassembly, maintenance,
cleaning, and other activities on the heat exchanger.
• There must be sufficient space on the side of the Air-Water Cooler that
the element is slid in/out of the housing to be able to assemble /
disassemble this same unit without mentionable problems (see fig 3.
The “LW1KD 1140 up to 1143" type cooler is shown here as an
example).
If ATEX 94/9/EG Guideline is applicable then there may be no
sparks, flames, electric arcs, high surface temperatures,
acoustic energy, optical radiation, electromagnetic waves or
other possible sources that could cause combustion in the
direct vicinity of the air-water cooler.
Fig 3
1. Element
2. Housing
17
Fig 4
• Remove the plastic caps from the connecting holes.
• Before the heat exchanger can be connected, the tubes must be clean
so that no pollutants can enter the unit.
• Before the heat exchanger can be connected, all tubes must be clean
so that no pollutants can enter the unit.
• The gaskets used must be suitable for the medium, temperature and
pressure to be applied.
• The foundation, construction and mounting must be sufficiently strong.
• Pressure impulses, pulsations and mechanical vibrations in the heat
exchanger should be avoided.
18
4.3 Installation
If the ATEX 94/9/EG Guideline is applicable and the element is
filled with a flammable gas then when shutdown the element
must be rinsed with an inert gas prior to disassembly to prevent
air mixing with the flammable gas.
19
5 Start-up
The assembly and start-up must be carried out by a suitably
qualified person appointed by the buyer or by a qualified
contractor.
The installation may only be operated, maintained and
repaired by authorised, trained and instructed personnel.
• The direction of the fan must be checked based on the directional arrow
on the housing or the motor.
20
The unit has been tested by Klima in accordance with the test
pressure stated on the type plate
21
5.6 Shut-Down of the Installation:
To shut down the heat exchanger the supply and return flows of the circuit
must be closed.
Normal operation is done with the on/off switch that is installed in the
installation with an "on" and "off" indication. For remote control, the switch
must be marked with a functional description.
The supplier of a third party must install a work switch enabling the main or
drive current to be switched off.
First, close the supply of hot medium and then, only when the
heat exchanger has cooled to the temperature of the cold
medium, close the supply of the cold medium.
Danger of freezing.
When an idle heat exchanger (filled with water or a water
mixture not of an anti-freeze type) is exposed to temperatures
below zero, the pipes may burst and deformation of the cover
and / or mantle may occur. If there is a danger of freezing all
the medium must be drained from the heat exchanger.
Danger of corrosion.
When the heat exchanger (filled with a medium) is idle for
over 48 hours, all the medium must be drained from the heat
exchanger.
Refer to chapter 3.3 for storage.
22
6 Maintenance and Inspection:
The assembly and start-up must be carried out by a suitably
qualified person appointed by the buyer or by a qualified
contractor. The installation may only be operated, maintained
and repaired by authorised, trained and instructed personnel.
6.1 Inspection
To guarantee a high degree of operational reliability regular inspection of the
equipment by the maintenance and operating personnel is necessary for the
following:
• Leakage.
• Pressure and temperature within the permissible limits.
• Presence of air in a system where a liquid medium is being used.
• If applicable, the presence of adequate condensate drainage.
• Torque of the bolts.
• Fouling of the fan and or motor and/or the heat exchanger (drop in
capacity).
• Vibrations / strange noises.
• General condition of the installation.
• Corrosion.
• Functioning of the safety devices.
23
• Temperature of the bearings max. 95°C (ambient temperature + 40°C).
• Temperature of the motor max. 135°C (ambient temperature +80°C).
• Torque of the bolts.
• Fins surface dirtied, damaged or blocked.
24
6.2.1.1 Disassembly centrifugal fan.
The electromotor is mounted on a mounting plate and then the fan is
mounted on the motors' shaft. Motor, fan and mounting plate are attached
to/on the housing as one unit. Disassembly of the fan or motor is therefore
done in reverse order. Use of a tackle here is advised (See Fig. 5).
Fig 5
1. Housing 5. Fan
2. Electromotor 6. Bolt
3. Shaft 7. Nut
4. Mounting Plate
25
Fan, fitted with a clamping bush.
Loosen all Allen screws. Place one or two screws in the disassembly hole(s).
Tighten the Allen screw(s) and fan and bush will come loose (See Fig. 6).
Fig 6
1. Electromotor
2. Fan
3. Clamping Bush
4. Allen Screw
5. Disassembly Hole
6. Assembly Hole
26
Fan, fitted with drawing plate.
Disassemble the locking plate. Then assemble a drawing plate to the boss
and pull the fan off the shaft by turning the central bolt (See Fig. 7).
Fig 7
1. Locking Plate
2. Drawing Plate
3. Boss Part
4. Fan
5. Shaft
6. Central Bolt
7. Locking Nut
27
6.2.1.3 Disassembly of element from housing
Fig 8
1. Housing
2. Element
3. Gasket
4. Flange frame
5. Gasket
6. Bolt
28
Proceed as follows:
• Close the supply and return flows of the circuit.
The element must be slide from the housing to carry out this task.
Refer to “Cleaning the Element” for further cleaning of the element.
29
6.2.3 Assembly of the Air-Water Cooler.
30
7 Malfunctions
31
Malfunction Possible cause Correction of the malfunction
Heat Gasket faces dirtied or Clean gasket faces. In case of
exchanger is damaged. damaged gasket faces, contact
leaking your supplier.
Defective gasket. Replace gasket.
Bolt tightened insufficiently. Check joints and re-tighten
carefully.
Defective tube. Contact your supplier.
The operating conditions Adjust the operating conditions.
deviate from those stated in
the technical specification
sheet.
External forces. Assemble the installation to be
stress-free.
32
8 Customer Service:
33
34