TCF ZAE Series Installation, Operation And Maintenance Manual

INSTALLATION,

OPERATION AND MAINTENANCE

MANUAL

AIR-HANDLING

UNITS

ZAE SERIES

1

TABLE OF CONTENTS

5.3.3. Control air locks 19

0. INTRODUCTION

1. DESCRIPTION OF AIR TREATMENT UNIT 4

1.1 COMPOSITION 4

1.2 PERMITI ED USE 4

2. CONTROL, PACKING, TRANSPORTATION 4

2.1 INSPECTION OF SUPPLY AT THE FIRM 4

2.2 PACKING 4

2.3. LOADING, TRANSPORTATION, UNLOADING 4

3. ASSEMBLY ON SITE 5

3.1 . POST-TRANSPORTATION CHECK 5

3.2. PRESERVATION ON SITE 5

3.3. POSITIONING 5

3.3.1. Dimensions of installation room 5

3.3.2. Base 6

3.3.3. Vibration damping 6

3.4. ASSEMBLY OF SECTIONS 7

4. CONNECTION TO SYSTEMS AND START-UP 8

4.1. CONNECTION TO DUCTS 8

4.2. CONNECTION OF HEAT EXCHANGERS 8

4.2.1 . Water exchanger 8

4.2.2. Direct expansion exchanger 9

4.2.3. Steam exchanger 10

4.3. CONNECTION OF HUMIDIFIER SECTIONS 10

4.3.1. Feed water 10

4.3.2. Hydraulic connections for cell block or spray
nozzle humidifiers 11

4.3.3. Humidification with cell block 11

4.3.4. Humidification with circulating pump 11

4.3.5. Ultrasonic, steam (submerged electrodes),
compressed air humidification 11

4.3.6. Steam humidification with submerged elements 11

4.4. DRAINAGE AND SIPHONING 11

4.5. FILTRATION SECTIONS 12

4.6. FAN MOTOR UNIT 13

4.6.1. Electric motors 13

4.6.1.1 . Connection for direct starting 13

4.6.1.2. Connection for star—delta starting 13

4.6.1.3. Dual speed three-phase motor 14

4.6.1.4. Permitted start time 14

4.6.1.5. Recommended connection and protection
accessories 14

4.6.2. Fan 15

4.6.3. Drive 15

5. INSPECTION 16

5.1. PRELIMINARY CHECKS 16

5.2. INSPECTION PROCEDURES 16

5.2.1. Power board 16

5.2.2. Flowrate check 16

5.2.3. Checking heat exchanger efficiency 17

5.2.4. Humidification system check 18

5.3. CORRECTION OF FLOW RESISTANCE
VALUES IN CIRCUITS AND ADJUSTMENT
OF FAN AlR—MOVlNG PERFORMANCE 18

5.3.1. Insufficient length of diverging duct section
between Unit delivery inlet and obstruction 18

5.3.2. Elbows 19

6. MAINTENANCE 20

6.1. FOREWORD 20

6.2. FILTRATION SECTIONS 20

6.2.1 . Reconditionable synthetic filters 20

6.2.2. Metal filters 20

6.2.3. Rotary filters 21

6.2.4. Reconditionable bag filters 21

6.2.5. Non-reconditionable medium/ high
efficiency filtration sections 21

6.2.5.1. Non-reconditionable bag filters 21

6.2.5.2. Absolute filters 21

6.2.5.3. Replacement load loss chart 22

6.2.6. Active carbon filters 22

6.3. HEAT EXCHANGERS 22

6.3.1 . Water exchangers 22

6.3.2. Extraction of heat exchanger 22

6.3.3. Steam exchanger 23

6.3.4. Direct expansion exchangers 23

6.4. HUMIDIFICATION SECTIONS 23

6.4.1. Humidification with spray nozzles 23

6.4.2. Humidification with cell block 23

6.4.3. Humidification with circulating pump 23

6.4.4. Ultrasonic, steam (submerged electrodes),
compressed air humidifiers 23

6.4.5. Steam humidification with submerged
elements 23

6.5. FAN SECTION 24

6.5.1. Fan 24

6.5.2. Motor 24

6.5.3. Drive 24

6.5.3.1. Determining belt tension 24

6.5.3.2. Driving belt replacement 25

6.5.3.3. Drive with multiple race pulleys 25

6.6. HEAT RECUPERATORS 25

6.6.1. Crossover flow static recuperator 25

6.6.2. Rotary recuperator 25

6.6.3. Heat pipe recuperator 26

6.7. ACCESSORIES 26

6.7.1. Control air locks 26

6.7.2. External air intake grilles 26

6.7.3. Drip separator 26

6.7.4. Silencer 26

6.8. TROUBLESHOOTING 26

6.8.1 . Reduction in flowrate 26

6.8.2. Increase in flowrate 26

6.8.3. Reduced exchanger efficiency 26

6.8.4. Reduced heat recuperator efficiency 26

6.8.5. Reduced humidifier efficiency 27

6.8.6. Abnormal noise level 27

6.9. MAINTENANCE AGREEMENT 27

7. SAFETY 27

7.1. SAFETY-RELATED FEATURES OF
AIR TREATIVENT UNIT 27

7.2. SAFETY NOTICES APPLIED TO THE
UNITS 27

7.3. PRACTICAL ACCIDENT—PREVENTION
TIPS 27

7.4. EC DECLARATTON OF COMPLIANCE 28

8. WARRANTY 29

9. UNIT INSPECTION SHEET 30

2

0. INTRODUCTION

This manual has been compiled by TCF Srl to provide the
installer, Customer and User with instructions intended
to e nsure the prope r manage me nt and use of the Air
Tre atme nt Unit mod. ZAE and AZE-C, from de live ry to
commissioning.
The recommendations that follow are intended to
ensure continuous operation of the Air Treatment Unit
and long machine life .
The procedures described below should be followed by
skilled personnel with a good working knowledge of air­conditioning, systems engineering and air treatment
units, even though the unit can be operated by those
unfamiliar with air treatment thanks to the machine's
simplicity of design.

3

DESCRIPTION OF AIR TREATMENT UNIT

2. CONTROL, PACKING, TRANSPORTATION

1.1. COMPOSITION

In its most complete version, the unit, in its monoblock
or broken down configuration, comprises:

- One or more air lock intake section

- Filtration section

- Recovery section

- Heat exchanger section (heating, cooling, post­heating)

- Humidifier section

- Ventilation section (delivery, intake—outlet)

- Silencing section.

1.2. PERMITTED USE

TCF Air Treatment Units are designed exclusively for
CIVIL AND INDUSTRIAL AIR TREATMENT
In the case of CORROSIVE and/or EXPLOSIVE air flows
a number of special technical modifications must be
made at the design stage which, together, adapt the
machine for the treatment of special types of flow.
The Air Treatment Unit must at all times be used
strictly in accordance with the design conditions
established at the time of 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

2.1. INSPECTION OF SUPPLY AT THE FIRM

Prior to shipping, each TCF Air Treatment Unit is
subjected to all the functional tests listed on the attached
UNIT INSPECTION SHEET (Form E.1.).
The checks performed regard:

- general machine dimensions

- correct assembly of the various parts and sections

- compliance with the various safety rules in force

- integrity of all the system‘s component parts

- application of the identification, operation and safety

notices.

On completion of the Inspection, the Chief Inspector
applies the EC mark demonstrating product compliance
with prevailing European Union machine directives.

2.2. PACKING

The Air Treatment Units are usually supplied as fully­assembled monoblocks. Only if the customer expressly
requests it can the units be broken down into several
sections to facilitate transportation and carriage through
narrow apertures, stairs or corridors. Transportation of
the machines, both monoblock and broken down, can be:

- normal

- special.

In the former case, TCF Srl does not pack the machine. In
the case of special transportation, the packing requested
is agreed at the time of contract and is entirely for the
customer's account.

Fragile components supplied separate from the Unit,
such as humidifiers, exchangers, recuperators, filters,
control boards, etc. are always delivered packed.

2.3. LOADING, TRANSPORTATION, UNLOADING

TCF Srl disclaims all liability for damage sustained by the
Air Treatment Units during loading, unloading and
transportation. We therefore recommend that special
precautions be taken, including:

- The load must be firmly secured to ensure its integrity

during transportation

- Handling must be performed without exerting force on

projecting accessories (hydraulic attachments, handles,
hinges, air locks, protection roof)

- 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

- If a forklift truck is used during the loading, unloading

and handling operations, the forks of the truck must be
at least the same length as the unit to ensure stability
(fig. 1)

- if the Air Treatment Unit is fitted with a continuous

steel base, handling may be accomplished with a crane,
using cables firmly secured to rods (sufficient for the
stress involved) passing through the holes provided in
the base.

4

If a crane is used, proceed as shown in the illustration,
using spacers to protect the structure (fig. 2).

- During transportation, protect the unit from
atmospheric agents. Special care must be taken if the
unit is supplied disassembled or designed for internal
use.

. ASSEMBLY ON SITE

3

3.1. POST-TRANSPORTATION CHECK

When the Air Treatment Unit arrives on site, we
recommend you to make a careful inspection of the
structure and the component parts of the unit.
Should you come across damage sustained during
transportation, you must report it on the freight bill. The
carrier must immediately tile a report of the accident to
obtain compensation from the insurance company

3.2. PRESERVATION ON SITE

In order to keep the Air Treatment Unit in good and
efficient condition on site, the following steps must be
taken first:

- Prior to installation, position the Unit and the

accessories in a place affording the best possible
protection against accidental knocks, dust and
atmospheric agents

- Carefully cover the inlets and outlets to prevent foreign

matter from entering the unit and damaging the internal
components

- Extract the pre-filters from the Unit and put them in a

protected place to preserve their filtration efficiency
This is why the superior efficiency filters are delivered
packed; they must be kept in their packages until the
unit is put into service

- Check that the hydraulic connections are protected by

the relevant caps as they were on delivery to the TCF
plant. lf they are not, plug them in order to protect the
exchangers.

3.3. POSITIONING

3.3.1. Dimensions of installation room

The Air Treatment Unit installation room must be of
sufficient size to permit easy inspection, maintenance
and component replacement.
Accordingly, the following dimensions are
recommended [fig. 3):

5

- heat exchanger extraction side
Minimum distance Lb = (B+O.2) m
where B = machine width (m)

- inspection side e Minimum distance Li = 1.2 m

lf you do not have the minimum space requirements as
specified above, the Unit doors can, on request, be
fitted using PVC clamps instead of hinges. In this case
the minimum distance will be Li = 0.7 m

3.3.2. Base

The permanent installation of the Air Treatment Unit
may be made:

- directly on the floor (Hg. 4a)

- on a concrete bed (fig. 4b)

- on a steel section bed (fig. 4c)

- on a suspended base (fig. 4d)

Both the floor and the beds must be capable of
withstanding the machine weight to within the
required safety margins.
The Air Treatment Unit must be positioned on a
horizontal surface so as to prevent:

- damage to the fan motor units caused by uneven

weights on the vibration dampers

- malfunctioning of the condensate drains

- difficulty in opening and closing the inspection doors.

.3.3. Vibration damping

3

In order to ensure effective protection against
vibrations, the Air Treatment Unit must be installed as
follows:

- suitable DAMPERS in material designed to withstand
the weight involved must be placed between the
machine and the support surface

- the Unit must not be fastened directly with screws but
by means of brackets (fig. 5).

The horizontal alignment of the support surface must
be checked with a SPIRIT LEVEL; adjustments may be
made using STEEL SHIMS.

Even in the case of suspended installation of the Unit, the
supports must not be screwed directly into the ceiling;
vibration damping material must always be placed
between the supports and the ceiling (fig. 6).

I

t, for reasons connected with increased protection,
spring-operated or rigid rubber vibration dampers are
required between the machine base and the support
surface, the hydraulic connections must be fitted with
appropriate JOINTS.

6

3.4 ASSEMBLY OF SECTIONS

If the Air Treatment Unit is broken down into two or
more sections. proceed as follows:

- Check the module assembly order on the TCF
working drawing.

- Remove the material required for assembly, supplied
on delivery, from the container located inside one of
the inspection doors.

- Clean the steel sections at the point of connection of
the modules and tit the SELF—ADHESIVE SEALING
STRIP provided (fig. 7).

Should the Unit be installed outdoors, in addition to the
steps listed above, the points of connection of the
individual modules must also be sealed with
waterproofing silicone (fig. 9).

Special care must be taken with the roofing to afford
protection against the elements: the two edges will be
jointed by means of a bayonet system, assisted by
silicone treatment or a specific seal (fig. 10).

The same strip must also be fitted to the duct
connection flanges.

- Set the individual sections set by side, using a SPIRIT
LEVEL to check that the assembled parts are perfectly
aligned and level. (fig. 8)

- Fasten the sections together with screws in the holes
provided.
The holes are located on the inside of the corners and,
in the case of dimensions greater than 1.3 m, also in a
midway position.
The screw-fastening areas can usually be accessed
from the inspection doors. Otherwise, you must
remove the panels next to the area involved.

7

4. CONNECTION TO SYSTEMS AND START-UP

4.1. CONNECTION TO DUCTS

At the points of connection to the air ducts, the Air
Treatment Units have a smooth or a flanged surface.
In order to optimise the connection with the ducts, you
must:

- clean the connection edges between duct and unit

- fit a seal to the flanges in order to prevent air
infiltration

- tighten the connecting screws firmly

- treat the joint with silicone to enhance the seal.

If the connection is made with rubberised canvas
joints, make sure they are not taut on completion of
assembly so as to prevent damage or the transmission
of vibrations.

In order to ensure the tightness of the connections and
the integrity of the unit structure, the weight of the
ducts must under no circumstances bear down on the
unit. The ducts must be supported by BRACKETS.

To allow easy extraction of the exchanger during
maintenance:

- the connections to the mains must be made in such a way
as to allow removal of the exchanger

- ON-OFF VALVES must be installed to exclude the heat
exchanger from the hydraulic circuit

- A VALVE must be installed on the lower manifold to allow
complete drainage, and a VALVE must be titled to the
upper manifold to vent the air from the exchanger (fig. 12)

4.2. CONNECTION OF HEAT EXCHANGERS

In order to prevent damage to the exchanger at the
joint between the steel manifold and the copper
circuits, you must:

- Use a pipe wrench to apply force in the opposite
direction when making the connection to the mains
pipe (fig. 1.1)

- Fit brackets to support the connecting pipes.
The weight of the pipes must under no circumstances
bear down on the manifold.

The normal heat exchange in a heating or cooling water
exchanger occurs in REVERSE CURRENT (fig. 13).

4.2.1. Water exchange

In order to ensure an optimum heat exchange, you must:

- WASH the heat exchanger before connecting it to the
water mains

- once installed in a workmanlike fashion, any air present
in the hydraulic circuit must be expelled using the
relevant valve.

8

In order to prevent the formation of ice in the heating
units in the presence of particularly low outside
temperatures, an EQUICURRENT heat exchange system
may be provided (fig. 14).
This configuration must be determined at the design stage
and not during installation, since an obvious reduction in
efficiency will result if a heat exchanger sized for reverse
current heat exchange is used for equicurrent operation.

The diagram (Hg. 15) shows the "standard" installation of
a water-type heat exchanger.

4.2.2. Direct expansion exchanger

Special care must be taken with the SIPHONING of these

exchangers to ensure the maximum heat exchange and

correct entrainment of the oil in the circuit. The diagram

in fig. 16 shows a siphoning system without division of

head.

In order to permit operation of the whole system, make
sure that the heat exchange occurs in reverse current
before)making the connections to the heat exchanger (fig.

16).

The cooling circuit must be complete with all the
necessary flow control, filtration and safety devices; the
pipe must be sized to allow proper circulation of the
compressor protection oil.
We recommend you protect the exchanger against
vibrations to prevent the likelihood of rupture at the joint
between manifolds and copper pipes.
In order to ensure correct operation of the thermal
expansion valve, the bulb of the valve must be in perfect
contact with the intake line and fitted on the outside of
the air flow so as not to be affected by it.

Fig. 17 System siphoning example with division of

cooling head.

Fig. 18 shows an incorrect siphon system (a) and a

correct one (b), in the case of installation of the

compressors at a point below the evaporator.

9

4

.2.3. Steam exchanger

TCF installs steam batteries with angled or vertical pipes

(fig. 19) to ensure correct drainage of the condensate and

prevent it from accumulating inside the system. In Air

Treatment Units with this type of exchanger special care

must be taken to ensure that the base is level (see section

3.3.2.).

The steam system must be complete with all the

necessary regulating, filtration and safety devices, which

must be correctly sized.

Each heat exchanger must be fitted with a condensate

drain, which must be oversized to allow drainage of the

greater quantity of condensate that is formed during

system start-up.

Provision must also be made for the automatic shut-off of

the steam feed in the case of fan motor unit stop.

4.3. CONNECTION OF HUMIDIFIER SECTIONS

In order to prevent dangerous WATER HAMMERING that
could rupture the exchanger and lead to the escape of
steam under pressure, you must:

- make sure that the Air Treatment Unit is level on
installation

- correctly size the flow control devices and the
condensate drains

- ensure the correct angle of inclination of the pipes
comprising the steam circuit.

Before starting up the system make sure that the heat
exchanger is correctly connected to it (fig. 19)

4.3.1 . Feed water

TCF recommends feeding the humidifier sections with

water that has a TOTAL HARDNESS of between 15°F and

25°F. Below 15°F the aggressiveness of the water could

damage the unit components, and the useful life of the

resins in the softening system would be drastically

shortened.

Over 25°F the efficiency of the humidifier system would

quickly diminish due to the build-up of scale.

10

4.3.2. Hydraulic connections for cell block or spray
nozzle humidifiers

4.3.5. Ultrasonic, steam (submerged electrodes),
compressed air humidification

The hydraulic connections must be arranged so as to
permit easy extraction of the evaporating block or the
distribution ramp.

The drain and overflow must be fitted with a siphon a not
connected directly to the drainage system pipe (section

4.4.). This operation is extremely important in order to
prevent tank overflows and resulting flooding of the unit
and the site of installation.

We recommend you install the following devices on the
hydraulic connection to the mains:

- a filter

- a pressure gauge

- a flow control valve that also allows exclusion of the
humidification system.

4.3.3. Humidification with cell block

Prior to start-up, check that the cell block is correctly
installed (section 6.4.2.).

At first-time start-up, check that the cell block is evenly
wetted; if you observe water jets on its surface, restore
the regular water flow by means of the tap.

For Air Treatment Units with the above-listed types of
humidification, you should consult the MANUAL supplied
with the humidifier.

4.3.6. Steams humidifier with submerged elements

In order to make the system operational, you must:

- Connect up the element electrically in accordance with

prevailing standards

- Connect the humidifier to the mains network; an on-off

valve must be included to exclude the humidification
section from the line

- Connect the overflow to the drain to prevent flooding in

the case of float malfunction.

4.3.4. Humidification with circulating pump

To avoid damaging the pump at first-time start-up, check
that:

- The hydraulic connection has been made properly, in
accordance with prevailing regulations

- The tank is clean and free of any residue resulting from
installation that could cause its blockage

- The water level inside the tank is kept at 20-30 mm
below the overflow.
Should a situation arise in which there is no water in the
tank, the pump motor would overheat and be irreparably
damaged. Conversely, if there is too much water in the
tank, an overflow may result, leading to flooding of the
unit and the installation room.

Before starting up the humidification system, you must:

- check the proper operation of the microswitch which, in

order to protect the element, interrupts the flow of
current when the water level drops below a permitted
level.

- check the setting of the float to prevent the overflow of

water from the tank.

4.4 DRAINAGE AND SIPHONING

Before positioning the Air Treatment Unit make sure you
have sufficient room to install the siphon and drainage
pipe.
The humidification and cooling exchanger sections of the
TCF Units are fitted with a threaded drain pipe projecting
laterally about 80 mm.

To allow the regular outflow of water every drain must be
fitted with a correctly sized SIPHON (fig. 22).

11

In order to prevent overflowing from the condensate
collection tank and resulting flooding of the machine and
the room in which it is installed, the siphon must be fitted
with a DRAIN VALVE to permit the removal of impurities
that settle on the bottom (fig. 23).

.5. FILTRATION SECTIONS

4

Check the correct installation of the prefilters located in
the relevant counter-frames with safety springs or guides.

The electrical connection and installation instructions for
the rotary filtration section are provided in the specific
manual provided. The instructions for introduction of the
reconditionable filtration diaphragm are set out in the
maintenance chapter (6.2.3.).

After removing the filters from the packing (in which they
are supplied to prevent deterioration during transport
and on site), place the bag, absolute and active carbon
filters in the relevant section, taking care to ensure rigid
assembly and perfect gasket tightness.
This operation must be performed about one hour after
the unit has been started up for the first time, when dust
and installation residue have been removed from the
ducts. In this way the non-reconditionable filtration
sections will be preserved.

On request, TCF supplies differential analogue pressure
gauges (fig. 25) or oil-column, gauges (fig. 26) of the types
shown.

I

n order not to undermine the operation of the drainage
system, pressurised siphons and siphons operating under
suction pressure must not be connected together.

THE WASTE PIPE (fig. 24) leading to the drainage
network:

- Must not be connected directly to the siphon in order to
absorb air or waste backflow and to permit direct visual
control of the correct outflow of waste water

- Must have a diameter larger than the drain pipe and a
minimum angle of 2% to ensure proper functioning.

Fig. 25

Fig. 26

12

4.6. FAN MOTOR UNIT

4.6.1.2. Connecting with delta—star starter

4.6.1. Electric motors

Before start-up:

- Inspect the motor control board and check that the
motor protection devices are sized for the maximum
amperage. corresponding to the rated value on the plate.
If the protection devices are sized for an amperage in
excess of the rated value, you must make sure that the
working range is sufficient.

- The thermistors (operating voltage 1 V) must not be
connected to the electric motor power supply line, as
otherwise they would be irreparably damaged

- Check that the mains supply voltage is suited to that of
the motors as indicated on the relevant plates.

4.6.1.1. Connection for direct starting

The simplest electric motor start—up system is obtained
by connecting the motor direct to the power supply.
However, this method has limitations due to the high
start-up current (pick-UD); this type of start-up is
recommended for power ratings of up to 5.5 KW at which
TCF installs 4 pole, 220/380 V three—phase motors as
standard.

If the motor start-up current exceeds the value permitted
by the power supply you may decide to opt for delta-star
starting.
For this purpose TCF installs dual voltage 380/660 V
motors on its Air Treatment Units starting from an output
of 7.5 KW, thereby allowing the motor to function
normally at 380 V (delta connection) and to start-up at
660 V (star connection).
This arrangement reduces the starting current to
approximately 30% of the current involved in the case of
direct starting.

The wiring diagrams are shown in fig. 27.

13

4.6.1.3. Dual speed three-phase motors

The diagram in fig. 29 shows the connection of a TWO­SPEED MOTOR with two separate windings to the power
supply. TCF installs motors of this kind on its Units:

- 220/380 V for power ratings up to 5.5 kW

- 380/660 V for power ratings over 7.5 kW.
This type of electric motor permits delta-star connection
with starter.

The two-speed motors with a single DAHLANDER
commutable winding (fig. 30) (side connection) offer the
advantage of generating greater power than motors of the
same size but with separate windings.

4.6.1.4. Permitted start time

With regard to the temperature increase. the start-up
time of a motor may not exceed the value shown in table

1. In the case of repeated starts with unchanging rated
power the temperature of the motor must be the same as
it was before the first start. Therefore, in order for the
values in the table to be valid. it is assumed that the motor
is cold.

4.6.1.5. Recommended connection and protection

accessories

Table 2 recommends, depending on the electric motor
installed in the Unit:

- the cross-section of the connecting cable, in copper or
aluminium

- the overload cut-out

- the fuse
lsp = starting current intensity
IN = rated current intensity

14

.6.3. Drive

4

Before starting the Air Treatment Unit, check:

- the tension of the “V“ belts (section 5.5.4.)

- that the pulleys are aligned (section 5.5.4.)

- that the dowels, shown in fig. 32 in their possible
installation positions, are doing their job of securing the
pulleys to the hubs.

4.6.2. Fan

Before start-up, carry out the following checks:

- make sure that the fan wheel is functioning correctly by
turning it manually

- check that any safety clamps fitted to prevent damage
during transportation have been removed from the
dampers (fig. 31).

4.6.4. Noise level

The computation and control of noise emissions has today
become particularly important, both during the design
and installation phases.
The sound pressure values of our machines are indicated
In our technical catalogues or can be supplied directly by
our Technical Department according to the requested air
moving characteristics.
Being therefore aware of the sound emissions produced
by the Unit, the Designer must make sure that, in treated
environments, maximum values laid down by current
regulations are not exceeded.
It must however be stressed that every environment has
its own acoustic characteristics which can considerably
affect sound pressure values of mechanical ventilation
systems. THE NOISE LEVEL DATA SUPPLIED BY US
SHOULD CONSEQUENTLY BE CONSIDERED AS A
CALCULATION BASE FOR MORE lN-DEPTH
CONSIDERATIONS WHICH TAKE INTO ACCOUNT THE
SYSTEM AND BUILDING STRUCTURE AS A WHOLE.

15

5. INSPECTION

5.1. PRELIMINARY CHECKS

- THE DELIVERY AND OUTLET HYDRAULIC
CONNECTIONS must be completed. Check the pressure
seal of the various circuits and the free passage they
afford to the carrying fluid

- THE INTAKE AND DELIVERY AIR-MOVING
CONNECTIONS must be completed. Check the tightness of
the lines against air leaks in both the main sections and
the various branches leading to the utilisation points

- THE EXTERNAL AIR INTAKES AND OUTLETS must
present entirely free passages. If the Units remain on site
for some time prior to inspection, make sure that the
passages have not become obstructed by foreign matter
and that the flow control locks are not in the fully or
partly closed position. TCF fits standard on outdoor
installations special "RAIN-SHIELDS" complete with leaf­collection net with a mesh size of 10 mm x 1 mm. It is
however advisable to check that these air intakes are free
of obstructions.
Similarly you must make sure that there are no air locks
in the closed position in the AIR DISTRIBUTION CIRCUITS
and that any safety systems installed, such as lire or
smoke gates, are not activated and blocking the air
passage

- THE CARRIER FLUIDS such as hot or superheated water;
steam, cooled water glycol mixtures or cooling gases must
be available in the actual conditions (temperature and
pressure) considered at the design stage

- THE POWER AND CONTROL BOARDS must be supplied
with the normal operating voltage

- OUTSIDE WEATHER CONDITIONS, DIFFERENT FROM
THOSE CONSIDERED ATTHE DESIGN STAGE, must be
assessed and made allowance for so as to ensure that the
inspection is reliable.

To make this check you must first take pressure readings
at the PRESSURE POINTS in front of and behind each
filtration section (on request, TCF can provide the
relevant attachments during manufacture)

- Compare the flow rate value obtained as described
above with the value obtained from the following
formula:
Q = 3600xSxV where:
Q = flow rate in m“/h
V = air velocity in Ws
S = passage area in m2
The velocity value "V" can be measured with hot-wire or
revolving-vane anemometers.
You must deduct from the front area of the grilles or
inlets the area lost through the presence of the conveying
fins in order to consider just the NET PASSAGE SECTION.
The area occupied by the fins can be obtained from the
technical specifications and is, on average, approximately
15% of the total area.

In order to take VELOCITY MB\SUREMENTS with the
HOFWIRE ANEMOMETER, holes of sufficient diameter to
allow the introduction of the telescopic probe must be
made in the ducts.
You should select straight duct sections at least 2.5
equivalent diameters in length or as far away as possible
from obstructions or points of probable turbulence. In
order to obtain reliable flow rate measurements, a
PERFORATED GRID must be made in the duct according
to the "point sampling" method shown in fig. 33.

5.2. INSPECTION PROCEDURES

5.2.1. Power board

Inspect the motor control board and check that the motor
protection devices are sized for the maximum amperage
corresponding to the rated value.
lf the protection devices are sized for an amperage in
excess of the rated value, you must make sure that the
working range is sufficient.

5.2.2. Flowrate check

- Using an oil or water column pressure gauge or an
analogue and/or digital gauge, check the FLOW
RESISTANCE in the various filtration sections and
consequently their fouling factor. The TREATED AIR
FLOW can be determined with a good degree of precision
on the basis of the filters' operating curve and the
working life considered at the design stage.

16

The more turbulent the air flow in the duct (evaluated by
broad deviations between one measurement and the
next) the denser the meshes in the sampling grid will be.
The REFERENCE MEASUREMENT is the arithmetic mean
of the measurements taken.

Using a REVOLVING-VANE ANEMOMETER a series of
VELOCITY MEASUREMENTS must be taken on the
external air intakes (if the Unit is configured for outside
air only) or at the intake grilles or delivery inlets.
The revolving-vane anemometer is not reliable for
measurements related to anemostatic or high-induction
diffusers.
The revolving-vane anemometer is recommended when
measurements are taken on a maximum of 2 or 3 intake
grilles so as to avoid summing together measurement
errors that would lead to an unacceptable calculation of
the hourly flow. It is therefore clear that, for
measurements on 4 or more diffusion inlets, the
reliability of the measurement is compromised and may
only be used as an approximate reference or as a rough
check on more accurate measurements made at one or
two positions on the intake duct

- The TCF Technical Department recommends you
double-check the flow rate results obtained as described
above, using the characteristic curve of the fan wheel
used (graph 1 shows an example):

- identify the curve corresponding to the fan's rpm.

- identify the curve corresponding to the absorbed power
at the shaft (P), previously calculated using the formula:

he CURRENT INTENSITY measurement of the fan motor

T
units under operating conditions should be made on the
remote control power switches inside the control board,
using an amperometer clamp.
Under no circumstances must the measurements be made
directly on the motor terminals since this is possible only
with the inspection door open, a condition that would
alter the length of the air circuit and therefore the
working point of the fans.

- Descend vertically from the point of intersection of the
power and rpm curves to obtain the FLOWRATE value on
the x-axes.

5.2.3. Checking heat exchanger efficiency

Check the EFFICIENCY OF THE HEAT EXCHANGERS by
measuring the temperature of the air and the carrier fluid
at the inlet and outlet with temperature gauges fitted with
telescopic contact probe. These measurements may be
made only after you have checked:

- correct connection to the distribution circuits (section

4.2.

- complete de-aeration of the circuits

- compliance of fluid temperature values with the design
values

- proper operation of the electronic adjustment

- correct opening and closing of the mixing valves and the
other exchanger control devices installed (diverter and
check valves, ON/OFF or modulating servomotors on air
locks, etc).

GRAPH 1

The AIR TEMPERATURE MEASUREMENTS must be made
with a telescopic temperature gauge through holes made
in the unit ducts or panels upstream and down-stream of
the exchangers to be checked.
The sensitive element of the temperature gauge must be
placed inside the duct or the Unit so that it is directly in
the path of the air flow, avoiding "dead zones" (e.g. by the
walls on the heat exchanger manifolds) which would
falsify the measurements (fig. 34).

On completion of the operation CLOSE THE HOLES made
with plugs.

17

5.2.4. Humidification system check

- Check that the humidification system is functioning
correctly, and particularly the exact humidistat or
regulator electrical connection to ensure that the system
comes into operation if the relative humidity in the
environment drops in relation to the set-point, and vice
versa. As with every other control feature, you must
therefore simulate different values on the regulators or
humidistats to check the activation of the pump, the
submerged electrode steam generator or any other
component involved in the treatment

- Check the correct siphoning of the drains (section 4.4.).

5.3. CORRECTION OF FLOW RESISTANCE VALUES IN

CIRCUITS AND ADJUSTMENT OF FAN AIR-MOVING
PERFORMANCE

MODIFICATIONS TO THE AIR-MOVING CIRCUIT may
sometimes be necessary during installation as a result, for
example, of dimensional or routing requirements that
cannot be anticipated at the design stage.
These modifications frequently result in increasing the
number and type of factors that affect fan performance.
Hence the need to approximate as realistically as possible
the SYSTEM CHARACTERISTIC CURVE, accurately
recalculating the new flow resistance values and
introducing e correction factor.
On the basis of its thirty years' experience in the field, TCF
Technical Department uses and recommends the SE
(SYSTEM EFFECTS) ADDITIONAL FLOW RESISTANCE
SYSTEM based on the charts developed by AMCA (AIR
MOVING AND CONDITIONING ASSOCIATION).
To calculate the additional flow resistance a graph is used
which presents a family of straight lines on logarithmic
velocity/flow resistance coordinates. Each line, which is
identified by a different letter of the alphabet, represents
an abnormal situation that determines an additional flow
resistance.

AMCA lists the adverse installation situations and
indicates the letter corresponding to the straight line in
the SE graph with which to determine the additional loss
factor. The flow losses Pa are calculated on the SE graph
as follows:

- enter the x-axis

• with the fan output velocity V if the obstruction is on the
delivery side

• with the fan input velocity V if the velocity refers to the
intake side

- ascend vertically to the straight line representing the
abnormal installation situation

- move horizontally to the y- axis to read off the Pa value.

5.3.1. Insufficient length of diverging duct section

between unit delivery inlet and obstruction

In the event that a given accessory has been installed at
such a distance from the delivery inlet as not to allow the
complete expansion of the air flow in the duct, abnormal
conditions quantifiable using the SE METHOD may arise.
In order for the air flow to expand and occupy the entire
duct section, a straight line distance is required equal to:
L>= 2.5 equivalent diameters (low/medium velocity ducts
L >= 6 equivalent diameters (high velocity ducts with V
>= 30 ITT/S)

Table 3 shows the value of the equivalent diameters for
rectangular ducts.

18

Table 4 shows the LETTER TO BE USED IN THE SE
GRAPH to determine the additional loss Pa in the case in
question.

PLN: Represents the percentage of the straight line

length required for complete expansion of the air
flow leaving the fan unit

Se: Area of the fan delivery inlet actually affected by

the air flow (value specified in manufacturer's
catalogue)

Sp: Area of fan delivery inlet.

TABLE 6

5.3.2. Elbows

The FLOW RESISTANCE connected with the presence of
elbows in the ducting depends:

- on their arrangement

- on the PLN value

- on the fan unit installed

T

able 5 shows the letter corresponding to the straight line
in the SE graph to be used to obtain the additional flow
resistance value Pa, depending on:

- the Se/Sp ratio

- the arrangement of the elbow (fig. 35)

- the PLN value.

5.3.3. Control air locks

Table 6 shows the MULTIPLIERS TO BE APPLIED TO THE
AIR LOCK FLOW RESISTANCE VALUES according to the
Se/sp ratio, should the locks be installed on the delivery
inlet. If the air locks are supplied by TCE consult the "SAL"
air lock technical bulletin.
Abnormal situations in relation to the reference standard
may also occur on the intake and are basically connected
with;

- the possible formation of eddies caused by curves in the
inlet conduit in conflict with the fan wheel rotation

- choking on the intake elbows

- the installation of containment housings around the fans

- more generally, the installation of accessories such as
drive protection guards, flow rate control locks, etc.
For all these evaluations and any others, all the AMCA
PUBLICATION 201 FANS AND SYSTEMS technical
documentation is available from the TCF Technical
Department. However, we would advise customers to
contact cur specialist personnel for a rapid, expert service
during inspection. The fan units will be adapted to the
new requirements by adjusting the drive ratios. In this
respect our Customer Service is always on hand to carry
out the necessary jobs.

19

TABLE 7 6

. MAINTENANCE

6.1. FOREWORD

TCF recommends that its customers carry out preventive
maintenance on the Air Treatment Units in order to
ensure long-term efficiency. These units require little
maintenance and have been designed to make each
operation as easy and safe as possible.

6.2. FILTRATION SECTIONS

The filtration sections require the most frequent
maintenance in order to:

- ensure that the air is filtered with the required efficiency
in the conditioned environment

- to prevent unit components from being damaged.

6.2.1. Reconditionable synthetic filters

These are cells measuring 50 or 1 O0 mm in thickness,
also known as PREFILTERS, which offer the advantage of
being reconditionable. The RECONDITIONING can be
performed using two different methods, depending on the
type of dust treated:

- In the case of DRY DUSTS, a compressed air jet is
directed against the filter in the opposite direction to
normal operation.

- In the case of WET DUSTS, the filtration diaphragm is
washed (without removing it from the frame), if
necessary using domestic detergents.
To avoid damaging the filter the temperature of the water
must not exceed 50°C. Do not use solvents or caustic soda.
Let the diaphragm dry by evaporation and refit it only
when it is perfectly dry.

20

TCF advises you to CHECK THE CONDITION OF THE
FILTERS ON A WEEKLY BASIS.

THE PREFILTERS MUST BE RECONDITIONED EVERY 7­20 DAYS depending on the type of environment being
conditioned. After 7-10 reconditioning operations, the
diaphragm deteriorates and its original characteristics
will be impaired; it should therefore be replaced.

6.2.2. Metal filters

These are filters of considerable strength and long service
life (especially if the mesh is stainless steel). You should
inspect them visually to decide when they need replacing.
THESE FILTERS MUST BE RECONDITIONED AT LEAST
ONCE A WEEK since they generally treat extremely
impure air (greasy and highly laden with particles).
The RECONDITIONING consists in washing the filters, if
necessary with solvents and caustic soda mixtures.
The filtration diaphragm may be dried with warm air or
compressed air.

6.2.3. Rotary filters

.2.4. Reconditionable bag filters

6

The rotary filters installed in the TCF Air Treatment Units
come complete with control board and differential
pressure switch.
The MAINTENANCE OPERATIONS to be performed
periodically are as follows:

- cleaning and lubrication of the gears: every 6 months

- drive chain tension check: every week

- replacement of fouled filtration diaphragm: if the
equipment spare has been consumed.

To replace the diaphragm, proceed as follows (fig. 35):

- stop the system by turning off the control board master
switch:

- after retrieving the check pin (1 ). extract the empty
clean filter roller (2) and replace the filtration diaphragm
(3)

- refit the full clean filter roller (2), check the correct
direction of air flow and make sure that the pin (1) has
been reintroduced on the reduction gear motor side

- roll out the clean filtration diaphragm until the end of
the dirty diaphragm hooks onto it

- using the manual control, rewind the whole of the dirty
filter onto the relevant roller (4)

- after retrieving the check pin (5), extract the dirty filter
miler (4) and remove the diaphragm

- after replacing and blocking the empty dirty filter roller
(4), fasten the clean diaphragm (3) to it using the spring

- make sure that the system functions correctly using the
manual control. If it does not, check the operations
performed

- lastly. set the control panel switch to automatic.

These are non-rigid filters with EU3-EU4 efficiency THEY
CAN BE RECONDITIONED using two different methods.

- With a vacuum cleaner, after removing the filter from
the Unit on the air inlet side.

- If this method is used the filter can be reconditioned
from 7 to 1 O times, after which the filter's efficiency and
accumulation capacity is impaired
If this method is not sufficient to remove impurities from
the filters, proceed as follows:

- extract the filters from the unit and, holding them with
the aperture uppermost, rinse them with a weak jet of
warm water (50°C max), letting the impurities run out at
the bottom through the filtration diaphragm

- let the filters dry thoroughly by evaporation before
refitting them. Do not use air jets to dry them.
In this way the filters can be cleaned 2-3 times, after
which the filter's characteristics will be compromised and
it will have to be replaced.

6.2.5. Non-reconditionable medium-high efficiency
filtration sections

This category includes BAG FILTERS with efficiency equal
to or in excess of EU5, and ABSOLUTE FILTERS.
They are characterised by an initial, clean filter loss and
by a final loss beyond which the filter loses its
accumulation capacity and original efficiency and must be
replaced. The filter must be replaced when it reaches a
loss level between the two points specified above. This
loss is fixed at the design stage on the basis of the
following considerations:

- it must not be high so as to prevent imbalances in the

system

- it must not be low to give the filters a sufficient service

life
THE REPLACEMENT LOSS CAN BE MEASURED WITH A
DIFFERENTIAL PRESSURE SWITCH. The recommended
values are shown in table 8.

6.2.5.1. Non-reconditionable bag—filters

These are filters with an efficiency of between EU5 and
EU9. THEY CANNOT BE RECONDITIONED as this would
damage their accumulation capacity and efficiency.
In order to preserve the filtration diaphragm for as long
as possible, the condition of the pre-filters must be
monitored carefully. Moreover, TCF recommends you
check the state of the gaskets on the frames and the
springs every week to prevent air passing the bag without
being filtered.

6.2.5.2. Absolute filters

These have an efficiency of between EU1O and EU14.
In order not to harm the very fine filtration capacity that
the filter in question is required to ensure, you must
check, on at least a weekly basis, the condition of the
gasket between filter and frame as well as the rigidity of
the assembly. ABSOLUTE FILTERS CANNOT BE
RECONDITIONED and must be replaced when the preset
loss has been reached.

21

6.2.5.3. Replacement loss chart

TABLE 7. Replacement loss

.3. HEAT EXCHANGERS

6

6.3.1. Water exchanger

In order to maintain an optimum water/air heat
exchange, the following MAINTENANCE OPERATIONS
must be performed regularly on the exchangers:

- At the beginning of each operating season, remove the

air present in the exchanger circuit using the relevant air
valve.

- At the beginning of each operating season, remove dust

and deposits from the finned block. Proceed as follows:

• use a jet of compressed air in the opposite direction to

the air flow during normal unit operation

• or wash the finned block with water, non-corrosive

components and a wire brush

- Remove any deposits from the condensate and drain

trap. This operation must be repeated every month in
order to prevent flooding of the machine and the room in
which it is installed.

6.2.6. Active carbon filters

The degree of deterioration of active carbon filters is
difficult to determine since it depends on the
concentration and type of aerosol in the air to be
deodorised. In order to maintain efficient deodorisation,
TCF recommends that the filters be replaced every 30-40
days.

TABLE 8
Capacity of active carbon filters to adsorb certain
substances

To avoid causing irreparable damage to the heat
exchangers, you must make sure that the primary fluid
will not risk freezing with the arrival of winter. For this
purpose TCF recommends the following steps:

- In the case of prolonged idleness of the heat exchanger

circuits, they should be completed drained

- Where an anti-freeze system based on heating elements

is provided to protect the exchanger, make sure that the
control board is constantly powered up

- On systems operating with anti—freeze, check its

efficiency and top up or replace as necessary.
ANTI-FREEZE LIQUID MUST NEVER BE INTRODUCED
INTO A CIRCUIT NOT SPECIFICALLY SIZED FOR THE
PURPOSE as it would impair pump operation and heat
exchanger efficiency.

6.3.2. Extraction of heat exchangers

Because there is frequently insufficient room for the
operator, it is not always possible to carry out the
necessary maintenance on the heat exchanger while it is
installed in the Air Treatment Unit.
In these cases the exchanger must be extracted and this
operation calls for the greatest care. To remove the
exchanger you must:

- make sure you have enough room for the removal and

temporary accommodation of the heat exchanger

- consider that an ordinary Cu/Al heat exchanger has a

mass of approximately 10 kg/m2 of frontal area per rank;
therefore, prepare supports if you think it necessary

- completely drain the heat exchanger

- remove the Unit panel covering the hydraulic

connections and the panel through which the exchanger
will be removed

- release the heat exchanger by undoing the relevant

clamps and extract it

- on completion of maintenance, restore the ideal

exchanger operating conditions.

22

6.3.3. Steam exchanger

With regard to general maintenance operations, follow
the steps described in 6.3.1.
In order to perform maintenance work on an Air
Treatment Unit with steam heat exchanger in absolute
safety, you must make provision for the automatic shut­off of the steam supply in the case of motor fan unit stop.

6.3.4. Direct expansion exchanger

With regard to general maintenance operations, follow
the steps described in 6.3.1.
TCF recommends you check, on at least a weekly basis,
that there are no gas leaks from the distribution heads. In
the event of gas leaks, the COOLING CHARGE would be
lost and the whole system compromised.

6.4. HUMIDIFIER SECTIONS

An efficient humidification system has a limited life that
depends on various factors, including:

- the type of operation (expendable, with circulation, cell
block, spray nozzles, steam, compressed air)

- the total hardness of the feed water (section 4.3.1)

- the dust concentration in the treated ain i.e. the Unit's
filtration efficiency.

- Check the condition of the distributor tube and, if

necessary, replace it

- Restore proper operating conditions before restarting

the humidification system.

6.4.3. Humidification with circulating pump

6.4.1. Humidification with spray nozzles

It is advisable to CHECK EVERYWEEK THAT THE SPRAY
NOZZLES FORM A REGULAR GONE-SHAPED JET.
In the case of scale you must:

- remove the malfunctioning nozzles from the distribution
ramp

- clean the nozzles on if they are damaged, replace them
with others that have the same characteristics

- restore proper working conditions prior to restarting
the humidification system.

6.4.2. Humidification with cell block

BEFORE EACH WORKING SEASON, in order to avoid
interruptions, you must visually check that the cell block
is evenly wetted; if you observe water jets on its surface
you must restore an even water flow by adjusting the
valve.
THE CELL BLOCK CANNOT BE RECONDITIONED.
When it is fouled you must replace it as follows:

- stop the electrical pump

- cut off the water feed using the relevant gate

- let the block dry completely, keeping the fan in
operation

- remove the frame housing the block by undoing the
securing screws and lift it out of the unit through the
inspection door

- extract the fouled block from the housing and replace it
with another of the same size. Take care with the
direction of fluid flow: the water which runs along the
veins of the block must intersect the air flow in reverse
current (fig. 36)

- AT THE START OF EACH WORKING SEASON, in order to

keep the humidification system in efficient condition, you
must check that the pump is working properly. lf it is not,
remove and clean it. If the pump still does not work
properly after cleaning, you must replace it.

- Make sure that the water level inside the tank is 20-30

mm below the overflow to avoid flooding and ensure the
pump has a sufficient water head. If the pump sucks in air,
it will overheat and sustain irreparable damage. If
necessary, adjust the float to maintain the correct water
level

- To prevent flooding of the machine and the installation

room, remove any scale and sludge that might obstruct
the drain every month.

6.4.4. Ultrasonic, steam (submerged electrodes),
compressed air humidifiers .

For Air Treatment Units with these types of
humidification system, consult the TECHNICAL MANUAL
supplied with the humidifier

6.4.5. Steam humidification with submerged heating
elements

In order to preserve the heating elements, maintain the
efficiency of the humidification system and prevent over­flows and flooding of the installation site, you must
perform the following steps at least once a month:

- check that the microswitch is working properly

- remove any deposits from the elements and the tank.

23

6.5. FAN SECTION

6.5.1. Fan

In order to keep the fan in perfect working order WE
RECOMMEND YOU CHECK THE FOLLOWING AT LEAST
ONCE A MONTH:

- The cleanliness of the screw and wheel; remove any
deposits

- Damage and corrosion to the fan components; remedy
with zinc-powder paint

- The tightness of the parts comprising the fan section

- Seal of the vibration-damping joint fitted to the fan
delivery inlet

- Cleaning and lubrication of any DAPO' control air locks.
Lubrication of this part must be performed every six
months.

- Absence of abnormal noise due to deterioration of the
bearings. if necessary, replace them. The fans mounted on
the TCF Units are fitted either with oilless bearings
(design life 2000 hours) or pedestal bearings. depending
on the operating conditions. The pedestal bearings
require periodic lubrication. THE LUBFIICATION
INTERVALS shown in Table 1 0 are subject to the
environmental conditions and the maximum temperature
range during operation.

TABLE 9
LUBRICATION OF FAN PEDESTAL BEARINGS

TABLE 10
Greasing of motor bearing

NOTE: The bearings must be greased more frequently in
harsh operating conditions.

6.5.3. Drive

In order to ensure optimum drive efficiency and to avoid
damaging the fan motor unit, the drive must be kept in
perfect working order.
The following must be CHECKED EVERY MONTH:

- The operating condition and dirtiness of the drive;

remove any deposits

- Damage to the drive (cracks on belts and pulleys, frayed

belt edges, worn belts and pulleys). lf necessary replace
the damaged part(s)

- Perfect alignment of the drive

- Belt tension (see section 6.5.4.).

6.5.3.1. Determining belt tension

To alter the tension of the driving belts you must move
the motor. To facilitate 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 of the lock nuts and adjusting screws.

6.5.2. Motor

In order to maintain the motor in perfect working order,
TCF recommends the FOLLOWING MONTHLY CHECKS:

- Cleanliness; remove any deposits

- Absence of abnormal noise due to deterioration of the
bearings.
Powerful motors fitted with grease nipples require
periodic lubrication. The greasing intervals, under normal
operating conditions, are shown in Table 11.

In order to determine DRIVING BELT TENSION, you must:

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

- using a spring-operated torque wrench, apply a force (P)

on the midway point of the belt (perpendicular to it) to
obtain a deflection equal to 1/64 of the centre distance
(approximately 16 mm/m)

- check that the force applied is within the values

indicated in table 12. Otherwise, set a new centre distance
and repeat the test.

TABLE 11

24

i

f the tension is not correct, the following will occur:

- if the belt is slack, it will wear rapidly and the drive
system will be inefficient

- if the belt is too taut, the motor and fan bearings will be
damaged.

Whenever the belts are tensioned, you must check that
the drive belts are aligned using an ordinary RULER. (fig.

38).

- introduce the new belt without forcing; any forcing

could impair the drive and shorten its service life

- align the drive and tension the belt

- check the belt tension after about 10 hours in service.

6.5.3.3. Drive with multiple race pulleys

- In the case of drives with several belts, the belts must be

replaced at the same time. This means that there must not
be belts presenting different states of wear in the same
drive system

- the number of belts must always match the number of

races

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

same side, as shown in Hg. 40, before they are tensioned.

If the pulleys are of different thickness, you must check
their equivalence as shown in fig. 39 to ensure correct
installation.

6

.5.3.2. Driving belt replacement

To replace THE DRIVING "V“ BEL`T:

- Loosen the drive and remove the worn belt

- Check the condition and wear of the pulleys and replace
them if necessary

6

.6. Heat recuperator

6.6.1 . Crossover flow static recuperator

Maintenance on this type of recuperator is confined to
CLEANING since it does not have any moving parts. To
clean the recuperator:

- remove the dust from the exchanger using a compressed

air jet and a wire brush

- remove grease deposits from the finned block with

warm water or steam and liposoluble household
detergents if necessary

- check the condensate drain every month and remove

any deposits.

6.6.2. Rotary recuperator

The heat exchange surface is self-cleaning. However, TCF
recommends:

- removing any residue with a compressed ai rjet or steam

- removing any deposits

- replacing the belt, if worn

- checking the physical condition and cleanness of the

drive every month.

25

6.8.1 . Reduced flow rate

6.6.3. Heat tube recuperator

Maintenance on this type of recuperator is confined to
CLEANING since it does not have any moving parts.
Proceed as follows:

- every month check drain operation drain and remove
any deposits V

- clean the finned block using either warm water with
liposoluble detergents if necessary, or a compressed air
jet in the opposite direction to the airflow during normal
Unit operation.

6.7. ACCESSORIES

6.7.1. Control air locks

TCF "SAL" control air locks do not require any particular
maintenance.
However, we recommend you check the alignment of the
gears and the movement of the fins, which must not in
any circumstance be deflected by the weight of the ducts.

6.7.2. External air intake grilles

This is the result of an uncontrolled increase in resistance
in the air moving circuit which alters the fan's operating
point. The most frequent causes are:

- excessively clogged filters

- formation of frost or ice on the front surface of the

prefilters in particularly damp and cold climates on Units
operating entirely with external air

- blockage of the intake grille(s) (especially external air

intake)

- fully or partially closed control air locks

- activation of the dampers

- deposits on cell blocks and heat exchangers

- inefficient fan motor unit drive.

6.8.2. Increased flow rate

If the sum of the resistances in the air-moving circuit is
less than the value considered at the design stage, the
most common causes are:

- incorrect setting of any mechanical flow controls or zone

air locks

- non-replacement of filters after ordinary maintenance

operations

- open or partially closed inspection doors.

These must be cleaned frequently to remove any deposits
obstructing the air passage which would comprise the
efficiency of the entire system.

6.7.3. Drip separator

Every month check that there are no deposits of dust or
scale that would impair separation efficiency Clean the
separator as follows:

- extract the drip separator from the Air Treatment Unit,
removing the panel and the screws

- completely dismantle the drip separator and clean each
single fin

- restore normal operating conditions, taking care not to
bend the fins during separator removal and reassembly.

6.7.4. Silencer

The silencers installed on TCF machines are of the
SOUNDPROOFED PANEL type.
They do not require any particular maintenance. Any dust
that forms on them should be removed with an ordinary
vacuum cleaner.

6.8. TROUBLESHOOTING

The most common MALFUNCTIONS in Air Treatment
Units are:

- reduced flow rate

- increased flow rate

- reduction in heat exchanger efficiency

- reduction in heat recuperator efficiency

- reduction in humidifier efficiency

- abnormal noise

6.8.3. Reduction in heat exchanger efficiency

The most common causes are:

- clogging of finned block

- formation of air bubbles inside the exchanger

- feed fluids at temperatures lower than the design

temperature

- malfunction or breakdown of control valve actuators

- water flow rate below design values.

For steam-operated exchangers:

- malfunctioning of condensate drains

- reduced supply steam pressure.

For cooling gas-operated exchangers:

- malfunctioning of expansion valve

- reduced cooling capacity due to working temperatures

different from those envisaged.

6.8.4. Reduction in heat recuperator efficiency

For crossover flow recuperators the causes may be:

- dust and dirt on the heat exchanger block

- clogging due to the presence of foreign matter between

the heat exchanger fins

- abnormal bypass of air on recuperator

For two-phase gas recuperators the causes may be:

- dust and dirt on the heat exchanger block

- clogging due to the presence of foreign matter between

the heat exchanger fins

- abnormal bypass of air on recuperator

- loss of cooling capacity due to accidental failure

26

For rotary recuperators the causes may be:

- dust and dirt on the heat exchanger block

- abnormal bypass of air on recuperator

- formation of frost on enthalpic recuperator in
particularly damp and cold climates

- broken rotor driving belt or blocked reduction gear
motor.

For twin exchanger recuperators the causes may be:

- dust and dirt on exchangers

- formation of air in the circuit

- blocked circulating pump.

6.8.5. Reduction in humidifier efficiency

Depending on the system used, the cause may be:

- scale clogging the spray nozzles

- scale on the cell block

- clogged lifting pump rotor and resulting reduction in
water flow rate

- clogged water filter

- malfunction of float.

6.8.6. Abnormal noise

7. SAFETY

7.1. SAFETY-RELATED FEATURES OF AIR
TREATMENT UNIT

TCF Srl has fitted its Air Treatment Units with every
possible safety feature to prevent accidents, especially
during start-up and maintenance.
Some of these 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

- on Units larger than our model 20, in which the operator

can enter the ventilation section for inspection purposes,
an ELECTRICAL KNIFE SWITCH is fitted standard inside
it. The purpose of the switch is to prevent the fan motor
assembly from being activated when someone is inside
the Unit

- the outside of the structure has ROUNDED EDGES

- elimination of sharp-edged steel sheet parts inside and

outside the Unit

- use of SELF·TAPPING SCREWS WITH NON-PROJECTING

TIP inside sections and panels.

With regard to the fan, the causes may be:

- worn or defective bearings

- fan off-balance

- foreign matter in fan wheel.

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

- worn or defective bearings

- loose cooling fan and/or fan guard

- magnetic noise during frequency reductions with
inverter (applications below 22 Hz are not recommended
as a rule).

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

- slipping of belt

- worn belt

- misaligned pulleys

- pulley with play on key.

In order to remedy the malfunctions listed above (and not
the entire conditioning system), CONSULT CHAPTER 6 ­MAINTENANCE OR, IF THE PROBLEM PERSISTS,
CONTACT OUR TECHNICAL DEPARTMENT

6.9. MAINTENANCE AGREEMENT

On request, TCF Srl is willing to study preventive and
annual maintenance agreements on its Air Treatment
Units so as to provide the customer with excellent
efficiency, purity and hygiene throughout the machine's
working life.

7.2. SAFETY NOTICES APPLIED TO THE UNITS

The inspection doors of the Air Treatment Unit carry
SAFETY NOTICES drawing the operator's attention to the
danger connected with moving parts and warning him to
disconnect the system power before opening the
inspection doors (Hg.41).

7.3. Practical accident-prevention tips

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

standstill

- Before carrying out maintenance work on the fan motor

unit, make sure that the motor cannot be restarted by
accident

- Before working on the motor; make sure that it has

cooled completely

- in order to protect your hands, use a lever to remove the

belts

- Block the fan wheel before carrying out maintenance

work on it, since (especially when the belt is removed)
the updraft caused by the ducting could make it turn and
cause injury

27

DECLARATION

T.C.F.srl

Customer

:

2004/108/CE

*

CEI EN 60204

-1

Mod. 03/13/08

Page 01/01

OF COMPLIANCE

Via G. Di Vittorio, 5 40057 Cadriano di Granarolo Emilia (BO) Tel. [phone] Fax [phone]

E-mails Uff. Comm.le: [e-mail] - [e-mail] - [e-mail] – [e-mail] Uff.Tecnico: [e-mail] - [e-mail]

The undersigned Daniele Negrini,
in quality of legal representative (managing partner) of Company

T.C.F. s.r.l. - via G. Di Vittorio, 5 - 40057 Cadriano di Granarolo E. (BO)

Declares that the following products:

Date: 11/09/2013

AIR HANDLING UNIT Mod. ZAE

Reference

Order n°

Construction year

is in compliance with the following Directives:

:

:

:

2006/42/CE
91/368/CEE
93/68/CEE
2006/95/CE

and to the following Norms:

EN 60335-1

and, in application to the Directives cited, has been equipped of mark.
The correspondent Technical Dossier is available in our headquarters.

Cadriano, DD/MM/YYYY

IT IS NECESSARY HOWEVER TO VERIFY THAT THE INSTALLATION AND

*

THE DRIVE ARE CARRY OUT TO YOU CORRECTLY AND IN THE RESPECT
OF DIRECTIVES EMC 2004/108/CE AND 2006/42/CE.

STAMP AND COMPANY OF DECLARING

28

8. WARRANTY

TCF Srl guarantees its products for 12 months as of the
delivery date.
The warranty covers the normal operation of the
individual components installed on our units, such as
motors, fans, heat exchangers, humidifiers and other
parts.
It should be stressed that the warranty covers
manufacturing defects in these parts, while their
efficiency is categorically excluded since this is
determined by the characteristics of the air-moving and
hydraulic systems and by the design, and does not
therefore fall within our sphere of responsibility.
TCF therefore undertakes to replace any individual
component that malfunctions as rapidly as possible and
subject to stocks. The part should be sent prepaid to our
headquarters and the replacement will be sent carriage
forward.
Please note too that the warranty does not include the
services of our personnel for the replacement of the part
on site; this cost is entirely for the installer's account.
On receipt of the returned material deemed to be
defective, an inspection will be carried out to establish
whether the part reveals abnormalities justifying
application of the warranty lf it is established that the
defect is attributable to external factors, it will be charged
to the customer.
It should further be noted that the warranty shall not
apply in the case of tampering or if the failure results
from incorrect installation or connection.
In this regards, reference will be made to the instructions
contained in this installation, Operation and Maintenance
Manual which accompanies each of our machines.

T.C.F. Srl

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