flakt woods TopMaster Technical specifications

TopMaster Air Handling unit
Maintenance instructions

Fläkt Woods 8218 GB 2014.05.15 2 Subject to change without notice.
TopMaster Air Handling unit MAINTENANCE INSTRUCTIONS
Replacement parts
Replacement parts and accessories for this air
handling unit can be ordered from the nearest Fläkt
Woods AB sales office. When ordering replacement
parts specify their codes according to the spare parts
catalogue.
Filter
As dust is separated out in the filter the air resistance
increases resulting in a reduced air flow. Regular
filter replacement, with intervals determined by the
concentration of dust in the air, is therefore necessary.
The pressure drop can also be measured with the
manometer RDTZ-07.
It is a good idea to mark the scale of the pressure
gauge in red, just above the value for the recommended
final pressure drop. Order replacement filters and
replacement parts from your nearest sales office.
Order code:
Size 030
Extract air (F5) RTDZ-04-030-1-1
Supply air (F7) RTDZ-04-030-2-1
Size 050
Extract air (F5) RTDZ-04-050-1-1
Supply air (F7) RTDZ-04-050-2-1
Replacing a dirty filter (step by step)
1. Use a dust mask of class FFP2 at least.
2. Replace the filter by pulling the dirty one out.
Cleanthefiltercompartment.Checkthatthesealsare
undamaged before fitting a new filter.
Insert the new filter cassette carefully so as not to
damage the filter.
3. Pack the used filter in a dust-proof package.
4. Sort the filters for recycling.
Final pressure drop across the filter
Safety and General maintenance instructions
Air flow m3/s 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50
Supply air Pa 135 140 170 220 - - - -
Extract air Pa 115 120 125 135 - - -
-
Air flow m3/s 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50
Supply air Pa 130 140 150 160 175 190 200 215
Extract air Pa 115 120 125 135 145 155 170 180
Size 030
Size 050
Operation if the air handling unit
The customer is responsible for following and
documenting the agreed maintenance and care
measures. Follow the service schedule and fill in the
measures that have been undertaken.
Warning!
Before taking the air handling unit into
operation fit any unused connections
with protective mesh.
In addition, all electrotechnical and
mechanical safety devices must be
installed before taking the air handling
unit into operation.
Disposing of products and packaging.
Separate at source according to local regulations. Depending
on the product, the following should be removed when
disposing of it:
- Circuit boards, cables, coils, motors, sensors etc.
- Filters other than metal ones (cooker
hoods).
- Packaging material such as corrugated
cardboard, plastic and expanded
polystyrene.
- Everything else should be disposed
of as metal. However, it should be
noted that the unit also contains a vapour barrier, and
sometimes mineral wool enclosed between the internal
and external walls, which should be removed.
- Lightbulbsanduorescenttubes
• When the unit needs to be opened ensure that
the voltage to the unit is disconnected.
•Take care when opening the isolating valves for
the hot water to the air heater. There is a risk of
water hammer or steam discharge.
•When servicing or inspecting the unit, switch
off the main circuit breaker before opening the
inspection doors. Reset all safety devices before
restarting.
•The clearance in front of electric heaters and
electrical cabinets shall conform to applicable
electrical safety regulations.
•Use the control panel to stop the unit.
•The unit's hatches are fitted with locking
handles. Ensure that the unit is always left
locked, and that the keys cannot be accessed by
unauthorized persons.
•Do not open inspection hatches when the unit
is in operation.
Service must be carried out by an authorised service
company.

Fläkt Woods 8218 GB 2014.05.15 3 Subject to change without notice.
TopMaster Air Handling unit MAINTENANCE INSTRUCTIONS
Rotary heat exchanger Front areas
Check that the surface of the rotor is not coated with
dust. Clean by vacuuming or using compressed air.
Use the compressed air to blow away from the clean
side towards the dusty side.
If vacuuming or using compressed air is inadequate
(dustonagreasysurface),cleanthesurfaceoftherotoras
follows:
Spray a degreaser onto the dusty surface of the rotor,
thenblowcleanfromtheoppositesideusingcompressed
air.
Rotary heat exchanger
Size Length, mm
030 1955
050 1955
Important!
Do not use acetone or other
similar solvents.
The rotary heat exchanger is very important for the
operationandeconomyoftheunitandmustthereforebe
kept clean and in good condition.
Therotorisnormallyself-cleaningbecausetheairflow
is reversed when the rotor goes in and out of the centre
plane.
The rotor is also provided with a purging sector that
preventsextractairbeingcarriedintothesupplyairduring
rotation.
It is important for purging that extract air side has
a lower pressure (greater negative pressure) than the
supplyairside.Thereshouldbea0-20Pagreaternegative
pressure on the extract air side. This channels the air
leakageandpurgingflowguidedtowardstheextractair,
preventing a transfer to the supply air.
The operation of the rotor drive motor should be
checked atleast once every six months. Thedriveshaft is
lubricated for life.
The rotor shaft bearings are lubricated for life which
means that no lubrication is required.
Check that the belt is not broken or slipping.
Sealing strip
The rotary heat exchanger is fitted with a sealing strip
around the perimeter and against the centre plane in
order to reduce leakage between the supply air and
extract air sides. Check that the entire length of the
sealing strip is undamaged. Replace if necessary.
Replacing the drive belt
The rotor drive belt may need to be replaced due to
wear. The drive belt is welded. A replacement belt can
be supplied. Ensure that the belt is the correct length
according to the table below.
Wear protective gloves when replacing the belt.
Alternatively wash clean using low pressure steam
wherethecondensatecanbecollectedproperly.Thesame
applies to water at high pressure.
When using a high pressure spray the jet must be
directedatrightanglestothestructure.Thenozzleshould
be held about 50 mm from the surface of the rotor. An
appropriate maximum pressure is 80 bar.

Fläkt Woods 8218 GB 2014.05.15 4 Subject to change without notice.
TopMaster Air Handling unit MAINTENANCE INSTRUCTIONS
Remedial measures if there is a risk of
freezing
If the water freezes in a heat exchanger it will burst.
This means that water will run out of the system and
cause water damage. There is a risk of freezing in ven-
tilation systems at low outdoor temperatures in the
following cases:
The temperature of the heating medium is too
high.
There is a particular risk of freezing in the autumn and
spring. Adjust the water temperature to the outdoor air
temperature.
Oversized finned heat exchanger.
Lower the water temperature to increase the water flow.
The heat supply ceases or decreases.
If the supply of heat to the air heater can be expected
to cease or decrease significantly, the outdoor air
intake must be closed properly and all fans must be
stopped.
Air heater, water
Warning!
Warning - hot water!
NOTE!
Frost protection must not be set to
so low a temperature that there is
a risk of freezing. If the building is
to be left unheated for long periods
over the winter, the water must
be drained from both the pipework
and heat exchanger.
Cleaning
Despite effective air filters the fin surfaces are coated
with dust which prevents the air flow and impairs
heat transfer. The heat exchanger must therefore be
kept clean. This is best carried out using one or a com-
bination of the following alternatives.
1. Blowing clean using compressed air.
2. Vacuuming.
After cleaning remove all precipitated dust before
starting the fan.
Draining
Drain the unit through the pipe system.
Venting
Vent the heat exchanger through the pipe system.

Fläkt Woods 8218 GB 2014.05.15 5 Subject to change without notice.
TopMaster Air Handling unit MAINTENANCE INSTRUCTIONS
Electric air heater Water cooling coil, duct mounted
Electric air heater, water cooling coil, duct mounted
Units with an electric air heater may be installed in dry
rooms not subject to the risk of fire or explosion and in
garages where petrol is not normally filled.
The maximum air temperature downstream of the
heater is +40°C.
The air heater is fitted with two independent thermo-
stats.Oneoverheatprotectionthermostatwitha manual
reset, and one temperature limiting thermostat with an
automatic reset.
If the output air temperature from the heater exceeds
the set value for manual overheat protection, the heater
and supply air fan control circuit opens.
If the output air temperature from the heater exceeds
the set value for the automatic protection, the heater
controlcircuitopens.Whentheairtemperaturedropsthe
protection resets automatically.
Maintenance
Theelectric air heateris fittedwithtubularheatingrods.
Nomaintenanceisnecessaryapartfromperiodicperfor-
mance testing.
Checkthattheheatingrodsarenotcoatedwithdustas
this could lead to odours and in the worst case ignition.
If necessary clean by vacuuming or wiping.
Workontheductheater,suchasopeningthecover,may
only be carried out by a qualified installation engineer.
Overheating
If thermal overload protection with a manual reset has
tripped carry out the following.
1. Switch off the switch disconnector. Work on the air
heater, such as openingthecover, mayonly becarried
out by a qualified installation engineer.
2. Thoroughly investigate the reason that the thermal
overload protection tripped.
3. When the fault has been rectified reset the thermal
overload protection.
Cleaning
Despite effective air filters the fin surfaces are coated
with dust which prevents the air flow and impairs
heat transfer. The heat exchanger must therefore be
kept clean. This is best carried out using one or a com-
bination of the following alternatives.
1. Blowing clean using compressed air.
2. Vacuuming.
Aftercleaningremoveallprecipitateddustbeforestart-
ing the fan.
Clean the air cooler drainage tray as necessary. Also
check that the water trap is clean and filled with water.
Draining
Drain the unit through the pipe system.
Venting
Vent the heat exchanger by opening the plug at the top
of the heat exchanger a little.

Fläkt Woods 8218 GB 2014.05.15 6 Subject to change without notice.
TopMaster Air Handling unit MAINTENANCE INSTRUCTIONS
Maintenance
Inspect and clean the fan every six months. In environ-
ments with a high dust content in the supply air and/or
theextractair,themaintenance/careoftheunitmusttake
place more often.
The fan is accessible through the inspection door.
Fan
Temperature correction
The flow scale on the display instrument and flow
equation above apply for air at a temperature of
+20°C. At other air temperatures the flow must be
corrected using the equation:
q= q20 , m3/s where
(273 + t)
293
q = the actual air flow through the fan,
q20 = the air flow reading
t = prevailing temperature in °C
Important! Switch off the current
and wait for the impeller to stop
(about one minute) before inspec-
tion and service. The air handling
unit fans are driven directly. When
carrying out any work on these
the current to the unit must be
switched off.
NOTE! At the same flow the meas-
uring pressure at the supply air
fan and extract air fan is different.
Cleaning
Both the supply air and extract air fans should be
inspected and cleaned as necessary. Dust mainly col-
lects on the inside of the fan blades. The best way to
clean the impeller is using a vacuum cleaner fitted
with a soft dusting brush attachment. To prevent
imbalance in the fan, clean all fan blades carefully.
Following adjustment or cleaning check that the fan
runs without vibration.
Actions before startup
The fan must not be started with the dampers closed on
the inlet or outlet sides. The fan can be quickly switched
onwiththecoveropento determinetheimpeller’s direc-
tion of rotation. Before startup check that the impeller
rotates freely and that there are no foreign objects which
could be sucked in and damage the fan.
Lubricating the fan motor
The fan motor bearings are factory lubricated and main-
tenance-free.
Dismantling the fan/motor
1. Disconnect the motor/control cable.
2. Remove the filler plate with its seal and lift out the
fan/motor.
Air flow measurement
The TopMaster has measuring nipples for air flow
measurement. Using a measuring pressure Dp (Pa)
and a constant (k) the air flow (q) can be calculated
using the following equation:
NOTE! Where the unit is supplied
with flow control the test socket
is used for the pressuresensor
∆p
The measured pressure Dp, which is the difference
between the pressure in the fan outlet and the pressure
at the inlet cone, can be read off using a manometer
(pressure range up to 1,000 Pa) connected with a 4 mm
hose to two external nipples, see the illustration below.
The value of constant (k) is detailed in the Table below.
Iftheunitissuppliedwithflowcontroltheairflowcanbe
read off directly from the control panel.
Size 030 050
k extract air fan 56.6 36.8
k supply air fan 54.8 41.3
q=1000 (l/s)
1
kDpm
x x

Fläkt Woods 8218 GB 2014.05.15 7 Subject to change without notice.
TopMaster Air Handling unit MAINTENANCE INSTRUCTIONS
Service schedule
Applies from 20 ... ... ... to 20 ... ... ...
Symbol Action Month Date Action Date Action Date
Signed Signed Signed
3 month/9 month service 6 month service 12 month service
Filter
Rotary
heat exchang-
er
Fan
Casing
Checking pressure
drop and any filter
replacement .
General service.
Checking seals.
General service. General service.
Check door seals.
Internal cleaning as
necessary.
Cleaning impeller,
casing, unit casing.
Checking bearings.
Checking pressure
drop and any filter
replacement .
Cleaning rotor.
Checking pressure
drop and any filter
replacement .
Cleaning rotor.
Checking monitoring
equipment .
Symbol Filter 2
Symbol Roterande värmeväxlare
Symbol Fläkt
3
9
3
9
3
9
3
9
3
9
Symbol spjäll
Damper Checking operation
and gasket.
Replace gasket if
necessary.
Checking operation
and gasket.
Replace gasket if
necessary.
Checking operation
and gasket.
Replace gasket if
necessary.
Air heater
Air cooler
General service. Cleaning heat
exchanger and elec-
tric heating rods.
Cleaning heat
exchanger, electric
heating rods, drain-
age tray and casing.
Symbol luftvärmare
Symbol luftkylare
3
9
Air handling
unit
Cleaning Cleaning Cleaning
Symbol Aggregat
Silencer Cleaning as neces-
sary.
Cleaning as neces-
sary.
Cleaning as neces-
sary.
Symbol Ljuddämpare
3
9
Inspection intervals
The service schedule covers service and inspection
intervals for the components of an air handling unit.
The unit contains one or more of these components.
Delete components that are not applicable from the
service schedule.
Date and sign every service.
The length of the service interval is calculated on the
basisofapproximately2,000operatinghoursina12month
period for a normal air conditioning installation.
............................... In environments with a high dust
contentinthesupplyairortheextractair,maintenanceof
the air handling unit must take place more often.

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We specialize in the design and manufacture of a wide
range of air climate and air movement solutions.
Our collective experience is unrivalled.
We are constantly aiming to provide systems that
precisely deliver required function and performance as
well as maximum energy efficiency.
Fläkt Woods Group SA
18, avenue Louis Casaï, CH-1209 Geneva, Switzerland
Tel. [phone]
email info@flaktwoods.com www.flaktwoods.com
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FWG_TopMaster_Maintenance_SE 2014.05.15_8218 ©Copyright 2014 Fläkt Woods Group Condesign_ABS5953