Instructions for the One-piece BCEA Air Handling Unit

Instructions for the One-piece BCEA Air Handling Unit 1. General 1.1 Description of the system The BCEA is a complete supply air and extract air unit. The unit is available in four sizes (004, 006, 009 and 014) and is equipped with filters, coil-type or rotary heat exchanger and fans. Space is provided for dampers. The air handling unit can be installed both indoors and outdoors. 1.1.1 Filters Class G3 short bag filters or Class F5, F7 or F8 long bag filters can be selected for the BCEA. Each filter section consists of one or several cassettes with throwaway type filter medium. The filter material is glass fibre and the cassette frame is as standard made of galvanized sheet steel. The cassettes run in slide rails made of aluminium-zinc coated sheet steel to Environmental Class M3. The cassettes are easy to withdraw from the filter section. The filter holder has sealing strips and an eccentric locking mechanism for effective air tightness. 1.1.2 Rotary heat exchanger, the Turbo The rotary heat exchanger is of Turbo design and has a temperature efficiency of up to 85% provided that the supply air and the exhaust air flows are equal. The heat exchanger is available in two widths: standard width or reduced width. 1.1.3 Coil heat exchanger The coil heat exchanger is of finned-tube design. Water mixed with anti-freeze agent is used as the heating medium. The heat exchanger has a temperature efficiency of up to 60%. The identification label of the control equipment is affixed on the front of the electrical equipment cubicle. It is of utmost importance that you quote the correct and complete designation and order number of your air handling unit whenever you get in touch with Swegon. 1.3 Specification The version, size and other particulars are specified in the documents supplied with the air handling unit. 2. Safety precautions The staff concerned shall read and understand the information presented in these instructions before they begin any work on the unit. If these instructions have not been followed, the manufacturer cannot assume warranty liability for any damage to the air handling unit or parts thereof caused by incorrect handling/installation by the purchaser or fitter. WARNING! The inspection doors on the discharge side of the fan must not be opened while the fan is operating. The door can otherwise fly open and cause personal injury. 3. Installation 3.1 Handling at the working site If the one-piece BCEA air handling unit has been ordered with base beams, the unit will be supplied on two transverse wooden beams bolted to the base beams. 1.1.4 BASIC Wing fans The BASIC Wing fans are of unique axi-centrifugal design. They have been developed with the focus on excellent power efficiency, low, uniform air flow, quiet operation and short overall length. The fans are easy to withdraw from the unit casing. The BASIC Wing is available with a direct drive or belt drive. Motors with or without frequency converter can be selected for the direct-driven fans. The BCEA can be supplied with or without the internal wiring and control equipment. The unit casing can be supplied in assembled condition or in parts for assembly at the installation site. 1.2 How to identify the air handling unit The air handling unit identification label and the motor rating label are affixed on the outside of the unit casing. Make sure that the lifting forks are long enough. The strength of the lifting wires restricts the load. L L A lifting wire spreader must be used. Specifications are subject to alteration without notice. www.swegon.se 1

If the unit is ordered without base beams, it will be supplied on a widen pallet. The air handling units are supplied packaged in plastic foil. The plastic foil packaging should remain on the air handling unit and its accessories until they are installed. This will protect the unit from damage during handling. We recommend one of the following lifting methods: 3.2 Mounting The air handling unit shall be mounted on a flat and firm supporting surface. The structure of the supporting surface must be designed to carry the weight of the air handling unit. When mounting the air handling unit and connecting the piping and wiring, see to it that all the inspection doors can be opened and that the internal components in the functional sections can be withdrawn from the unit casing to the extent required. When you install the water trap, the distance from the centre of the drain connection on the air handling unit to the floor surface must be at least 270 mm. A 1.2 metre wide, open walkway is required in front of air handling units with mounted electrical cubicle. The walkway can be narrower if system includes a smaller distribution box, however the walkway width should not be less than 800 mm. See the ELSÄK-FS 1999:5 directives for electrical safety. A minimum open space of 700 mm in front of the unit is required for inspection. See the following illustration. 3.3 Jointing additional air treatment sections (accessories), if required The separate additional air treatment sections can be jointed to the unit by means of bolts inside the framework or, if necessary, by means of bolts from the outside at the corners in the framework. The inside of the casing is accessible through the inspection door or by removing a wall panel. 1. Fit the sealing strips supplied onto the framework of one of the blocks. See Fig. 1 and 2. 2. Drive the guide pins supplied into the holes provided in corners of the framework of the same block. See Fig. 3. 3. Push the blocks together making sure that the guide pins in one block enter the holes in the corners of the next. See Fig. 4. 4. Bolting the blocks together from inside: Fit the bolt lug hooks with bolts in each corner and alternately tighten the bolts using a 6 mm Allen wrench. See Fig. 4. Bolting the blocks together from the outside, if required: Drill a 9 mm dia. hole at a 15 angle through each corner as shown in Fig. 5 and 6. Fit the bolt lug hooks with bolts in every corner and alternately tighten the bolts using a 6 mm Allen wrench. B 1200 B/2 700 Replacement of functional sections Servicing a unit with control cubicle fitted Servicing the heat exchanger General inspection and service B Sealing strip Fig. 1 Fig. 2 Guide pin Fig. 3 2 www.swegon.se Specifications are subject to alteration without notice.

3.4 Connection to the ducting Select an end connection with or without slip-clamp joints for the inlet or the outlet. Without slip-clap joints. Fig. 4 With slip-clamp joints. If you select an end connection without slip-clamp joint, connect the duct as shown in Alt. 1 in the illustration below. If you select an end connection with slip-clamp joint, connect the duct as shown in Alt. 2. Before you joint the adjacent components or duct pieces together, check that they are both vertically and horizontally aligned. Use a plastic mallet or a similar tool that won t damage the slip clamps when you hammer them into place. STANDARD DUCT 9 mm dia. holes at a 15 angle Alt. 1 Fig. 5 Viewed from above 9 mm dia. holes Alt. 2 Fig. 6 Viewed from the side Specifications are subject to alteration without notice. www.swegon.se 3

3.5 Electrical installation To be carried out by a qualified electrician in accordance with local regulations. The air handling unit does not have pre-punched holes for the cables. Drill holes through both sheet-metal skins and insulation preferably using a trepanning drill at a suitable location in the casing. Fit rubber cable glands in the holes in both the inner and outer skins of the casing to protect the cable. The cables run to the fans shall be sufficiently long to enable the fans to be withdrawn out of the unit casing for inspection and cleaning.the cables must not be arranged to pass through service and inspection doors or covers where they can obstruct servicing the unit in any way. We at Swegon recommend that you connect the fan motors across rubber cables that pass through cable glands arranged in the end walls of the air handling unit (see ELSÄK-FS 1999:5 and the figure below). The cable for the rotary heat exchanger is lead through the top panel.* *If the air handling unit is installed outdoors, the cables must not enter the unit through the roof of the unit. Cable entries should then be arranged from the backside or through intermediate section of the air handling unit. 3.6 Performance checks during commissioning When commissioning the air handling unit, the performance of the unit shall be checked and any adjustments made on the installation shall be carried out in accordance with the project design instructions. In Sweden, qualified staff must draw up special reports in accordance with directives governing performance checks of ventilation systems. Get in touch with your nearest Swegon representative for particulars as to who is qualified. 4. Maintenance 4.1 Regular performance checks The performance of the functions and the air flows shall be checked regularly. In Sweden, these checks have to be carried out at least at the intervals stipulated in directives governing performance checks of ventilation systems. Qualified staff shall check the performance of the unit. Get in touch with your nearest Swegon representative for particulars as to who is qualified. The air flow can be checked using a manometer that can be connected across hoses to measurement tappings on the inspection door of each fan. The manometer reading can be plotted in a conversion chart to determine the corresponding air flow. 5. Casing The one-piece air handling unit functions are integrated into a robust framework. The framework consists of torsionally rigid, form-rolled profiled members made of 1 mm thick aluminium-zinc coated sheet steel, to environmental class M3. The corner pieces are made of aluminium. The panels are made of aluminium-zinc coated sheet steel to environmental class M3. The panels are designed according to the sandwich principle: 0.7 mm thick sheet steel + 50 mm thick insulation + 0.7 mm thick sheet steel. The inspection doors are equipped with robust hinges and handles. The doors for accessing the fans/filters are equipped with a lock. 5.1 Insulation The BCEA has 50 mm thick fire-retardant thermal and condensation insulation as standard. The BC unit is also available with insulation that conforms to fire resistance class EI 30. 5.2 Tightness In terms of air leakage to the surroundings, the tightness of the unit casing of normal design conforms to class A in accordance with CEN Standard EN 1886. The casing is available in a special variant to class B. 4 www.swegon.se Specifications are subject to alteration without notice.

5.3 Thermal properties The BCEA unit casing conforms to Class T3 in accordance with CEN Standard EN 1886. 5.4 Acoustic properties The sound attenuating properties of the casing (db) measured according to EN 1886 directives are as follows: Octave band (Hz) 63 125 250 500 1000 2000 4000 8000 3 8 22 28 25 25 31 32 Airborne sound insulation (db) measured in accordance with ISO 140-3 for wall panels: Insulation Octave band (Hz) Rw 63 125 250 500 1000 2000 4000 Standard 20 13 26 43 51 54 59 37 EI 3023 14 25 43 51 54 59 37 Rw = weighted reduction figure. A measurement of the attenuation of the relevant wall panel. 6. Filters Class G3 short bag filters or Class F5, F7 or F8 long bag filters can be selected for the BCEA. Each filter section consists of one or several cassettes with throwaway type filter medium. The filter material is glass fibre and the standard cassette frame is made of galvanized sheet steel. The cassettes run in slide rails made of aluminium-zinc coated sheet steel to environmental class M3. The cassettes are easy to withdraw from the filter section. The filter holder has sealing strips and an eccentric locking mechanism for effective air tightness. Quantity of filter cassettes for each size, BCFC Unit size Cassette size 428 x 428 490 x 490 592 x 592 490 x 592 004 006 009 014 2 2 2 1 2 7. Damper (accessory) The BCEA one-piece air handling unit is designed with space to accommodate a damper, to be specified as an accessory. The damper has counter-rotating, torsionally rigid damper blades made of double aluminium-zinc coated sheet steel, to environmental class M3. The damper blades are journalled in nylon bearings and can be supplied with or without insulation (optional). The damper meets the provisions of tightness class 3 in accordance with EN 1751. On the size 004 units, the intake air damper can be mounted on the outside of the casing and in the size 006, 009 and 014 units it can be installed inside the casing. 8. Turbo Heat exchanger The Turbo rotary heat exchanger has high temperature and moisture recovery efficiency. The heat exchanger operates with a temperature efficiency of up to 85% provided the supply air and the exhaust air flows are equal. 8.1 Cooling energy recovery The high temperature efficiency of the heat exchanger can also be utilized for recovering cooling energy during the summer. If the indoor temperature is lower than the outdoor temperature, it is possible to operate the rotor at full speed to recover cooling energy from the exhaust air and transfer it to the supply air.two rotor widths 8.2 Två rotorbredder The standard rotary heat exchanger has a 250 mm wide rotor. If project design prerequisites don t call for achieving highest possible efficiency, a 200 mm wide rotor can be selected. This slender rotor also gives rise to a lower pressure drop. 8.3 Three variants Non-hygroscopic rotor. Is utilized for comfort ventilation. Hygroscopic rotor. Is utilized if the demands on moisture recovery are very high, and if it is desirable to obtain maximum cooling energy recovery. Anti-corrosion protected rotor. Is utilized in environments with aggressive atmosphere. The max. permissible temperature of the ventilation air is 40 C. 8.4 Design The heat exchanger rotor consists of alternate corrugated and flat strips of aluminium foil, that provide a large number of axial passages through which the air passes. The strips of foil are jointed together without the use of glue or a system of spokes. This method is patented and has been thoroughly tested. The bosses in the foil create turbulent currents in the air, which enable greater energy exchange and thus higher efficiency. Effective seals between the rotor and casing minimize leakage between the supply air and the exhaust air. Specifications are subject to alteration without notice. www.swegon.se 5

8.5 Speed control The speed of the heat exchanger is decisive for its temperature efficiency. The heat exchanger can be selected with a drive motor for constant or variable speed operation (speed control). If the rotor turns at constant speed, the temperature of the supply air cannot be kept constant at the set point. In order to restrict any undesirable rise in temperature, the heat exchanger should be equipped with speed control, to keep the temperature of the supply air at the set point. The speed controller varies the rotor speed steplessly from 0-12 rpm. The control box for speed control, purging operation and other functions is mounted by the drive motor. 8.6 Purging sector The heat exchanger of the BCEA is supplied with an adjustable purging sector as standard. The purging sector is supplied preset at its maximum setting and can at site be set to the correct angle depending on the differential pressures across P 1 P 3,, see the figure. The appropriate angle can be read in Table 1. The air flow through a correctly set purging sector can be read in Table 2. P1 P4 Table 2 Standard 250 mm wide rotor BCEA Air flow through the purging sector (m 3 /s) 004 0,03 006 0,04 009 0,06 014 0,09 Motor data P3 BCEA Air flow through the purging sector (m3/s) 004 0,02 006 0,03 009 0,05 014 0,07 Table 1 Pressure differential Angle P 1 P 3 (Pa) ( ) 1200 2 625 3 375 4 P2 270 5 200 6 150 7 125 8 105 9 95 10 Table 3 200 mm wide rotor (reduced width) 8.7 To adjust the position of the throttlingplates The air handling unit is equipped with throttling plates to ensure that purging operation through the heat exchanger will be as intended. These plates are used to preset the correct pressure balance inside the unit, enabling the purging air flow to pass in the right direcion. The throttling plates are supplied in unmounted condition and are to be fitted in the inner grooves provided in the extract air inlet of the unit. 9. Coil heat exchanger To INCREASE the negative pressure,slide the throttling plates inward. To DECREASE the negative pressure, slide the throttling plates outward. The coil-type heat exchanger is a finned-tube heat exchanger that uses water mixed with anti-freeze agent as the heating medium. The heat exchanger consists of copper tubes and profiled aluminium fins. The headers and water connections are made of steel. The connections have male threads. All the coil heat exchangers are equipped with individual venting and drain plugs as well as a connection for the probe of anti-frosting monitor. The downstream side of the heat exchanger can be fitted with a droplet eliminator for preventing condensate entrainment should the air velocity exceed 2.8 m/s. The pressure drop across the droplet eliminator is low. The extract air section is equipped with a sloping, stainless steel drip tray for collecting condensate. The drain connections are located on the inspection side. Free connections must be fitted with a type BCXZ-1-71-1 water trap. A pipework package can be used for interconnecting the extract air section with the supply air section. The pipework package includes a circulation pump, check valve, expansion vessel, safety valve, manometer, air purging valve, charging valve, throttling valve, pipe connection for a insertion sensor and two or more thermometers. The pipework package is insulated. Specify pertinent unit design and performance details when ordering. The coil heat exchanger can be included in a block. The specification for this component does not include the casing, i.e. the casing must be ordered separately. Heat exchanger BCEA size Rated output (kw) Current at rated output 004 014 0,04 0,45 A, single-phase 230V 6 www.swegon.se Specifications are subject to alteration without notice.

10. BASIC Wing fan 10.1 Common characteristics of the BCRW and BCRWR The Basic Wing is a fan of axi-centrifugal design. The fan has been developed with the focus on excellent power efficiency, low and uniform air flow, quiet operation and short overall length. The air velocity in the outlet duct is low (max. 6 m/s) and uniform. This enables minimal system losses. The low dynamic pressure (max. 22 Pa) also makes it possible to lower the total pressure in the system of ducting in comparison with a conventional centrifugal fan. The difference can be as much as 100 Pa. The less space is required in the fan room because functional sections and sharp duct bends can be fitted directly to the fan outlet without appreciable pressure losses. This also means a savings on energy since no pressure is needlessly lost. The standard fans have integrated airflow measurement equipment with a measurement inaccuracy of, ± 5%. Basic Wing is a patented product. 10.1.1 Design The fan is designed with any fan casing. The fan base consists of a construction of profiled steel sections. The fan can easily be withdrawn from the casing whenever needed. Rubber anti-vibration mountings and flexible connections are highly effective in isolating the fan from the unit casing. The flexible connections are available in two variants, standard woven plastic or aluminium coated glass fibre. Low outlet velocity and uniform air distribution pattern minimize system losses. Sharp duct bends can therefore be fitted directly to the fan outlet and give rise to marginal pressure losses only 10.2 BCRW fan, direct-driven A fan motor with frequency converter or a fan motor without frequency converter can be selected to drive the direct-driven BCRW fan. 10.2.1 Motor with frequency converter The motor with frequency converter makes it possible to adjust the speed and output to meet ongoing load conditions. This substantially reduces energy consumption, considerably reduces the need for maintenance and enables the fans to operate more quietly. The motor/frequency converter is equipped with factorywired cables for power and control. The fan can be switched in and out from remote normally open contacts. The fan speed is variably controlled by a 0-10 V signal from a remote instrument. These functions and alarm contacts are available for connection on the pre-wired control cable. The motor is a non-synchronous motor with integrated frequency converter and an EMC-filter. The motor and frequency converter are mutually compatible for optimum performance. The motor can withstand a max. permissible ambient temperature of 40 C. The motor has enclosure class IP 54. It is CE labelled and conforms to EMC requirements in accordance with CEN Standards EN 50081-1, EN 50082-2 and EN 61000-6-2. 10.2.2 Accessories Inverter for controlling the fan speed The inverter can be used for fan motors with integrated frequency converter and has two potentiometers for manually setting the speed of the fan. It can be utilized for two-speed control of one fan or for single-speed control of two fans. No separate power supply to the unit is required. The inverter has enclosure class IP20. It is equipped with fasteners for fitting it to a 35 mm DIN rail and is designed for installation inside a cubicle or the like. Cubicle containing equipment for controlling the fans The equipment cubicle is used for the fan motor with integrated frequency converter and is intended for controlling one fan motor. The cubicle has a selector switch for controlling two preset fan speeds and stop. LEDs are also provided for indicating that the air handling unit is in operation and for indicating alarms. No separate power supply to the cubicle is required. The cubicle is made of sheet steel with a painted finish and is designed for wall mounting. Its enclosure class is IP54. 10.2.3 Motors without frequency converter As an option, the fan motor is available without any integrated frequency converter. The motor speed can then be controlled from a remote frequency converter. The motor is a high-performance motor. The max. permissible ambient temperature of the motor is 40 C. Its enclosure class is IP 54. Specifications are subject to alteration without notice. www.swegon.se 7

10.3 BCRWR fan, belt-driven Standard single-speed motors or two-speed motors can be selected for the belt-driven BCRWR fans. If the need arises, the BCRWR can also be equipped with double motors. To ensure effective motor cooling, the ambient air temperature by the motor should not exceed 40 C. Both the fan and motor have bush-type belt pulleys that enable speedy belt replacement, for example, whenever a speed adjustment is necessary. The bearings are sized for 40,000 hours of operation. 10.3.1 Belt drive The belt drive is available in two variants: Standard, V-belt drive Poly-V belt drive 10.3.2 V-belts The efficiency of a correctly sized and installed V-belt drive is between 90% and 96%, depending on the output consumed to drive the fan (94-96% at outputs in excess of 3 kw). The belts have an estimated useful life of 25,000 hours, which is equivalent to 2.5 years, operating around the clock. This presupposes that the transmission is optimally sized and correctly installed. V-belts greatest advantages: Their cost price is low and they are universally available on the market. They can be used on all the sizes. 10.3.3 Poly-V belts Poly-V belts have a useful product life that is twice that of the narrow V-belts. Their design enables the use of smaller belt pulleys and larger transmission ratios; sizing the bearings limits our application. Greatest benefit: Better efficiency, 96-97%. They can be utilized on all the sizes. 11. Dimensions 11.1 BCEA, size 004 The damper is an accessory. A fan section without end connection is shown. Connection on casing Weight in kg Base beams Rotary heat exchanger Heat exch. coil Fan Casing** 250 mm 200 mm Belt-driven* Direct-driven Standard EI30 23 63 57 80 45 55 179 217 * Excl. motor and belt drive. ** Incl. Intermediate floor, filter spacer, fan wall spacer, filter holder and filter (F7). 8 www.swegon.se Specifications are subject to alteration without notice.

11.2 BCEA, size 006 The damper is an accessory. A fan section without end connection is shown. Connection on casing Weight in kg Base beams Rotary heat exchanger Heat exch. coil Fan Casing** 250 mm 200 mm Belt-driven* Direct-driven Standard EI30 40 85 77 118 65 80 235 288 * Excl. motor and belt drive. ** Incl. Intermediate floor, filter spacer, fan wall spacer, filter holder and filter (F7). 11.3 BCEA, size 009 The damper is an accessory. A fan section without end connection is shown. Connection on casing Weight in kg Base beams Rotary heat exchanger Heat exch. coil Fan Casing** 250 mm 200 mm Belt-driven* Direct-driven Standard EI30 44 127 115 157 89 120 286 351 * Excl. motor and belt drive. ** Incl. Intermediate floor, filter spacer, fan wall spacer, filter holder and filter (F7). Specifications are subject to alteration without notice. www.swegon.se 9

11.4 BCEA, size 014 The damper is an accessory. A fan section without end connection is shown. Connection on casing Weight in kg Base beams Rotary heat exchanger Heat exch. coil Fan Casing** 250 mm 200 mm Belt-driven* Direct-driven Standard EI30 47 180 161 213 110 155 360 445 * Excl. motor and belt drive. ** Incl. Intermediate floor, filter spacer, fan wall spacer, filter holder and filter (F7). 10 www.swegon.se Specifications are subject to alteration without notice.