KOJA Future S Troubleshooting guide

Future®Sairhandlingunit
Operation and maintenance
instructions
15 December 2020 version
www.koja.fi

FUTURE® S AIR HANDLING UNIT
OPERATION AND MAINTENANCE
INSTRUCTIONS
15 December 2020 Ver 1.7 (We reserve the right to changes without prior notice) 1
CONTENTS
1 General ........................................................................................................................................................... 3
1.1 Operating conditions ............................................................................................................................... 3
1.2 CEN standard classification ..................................................................................................................... 3
1.3 Sound level .............................................................................................................................................. 3
1.4 General safety instructions...................................................................................................................... 3
1.4.1 CE marking........................................................................................................................................ 6
1.4.2 Fire .................................................................................................................................................... 6
1.5 Declaration of conformity ....................................................................................................................... 7
1.6 Recycling and disposal instructions......................................................................................................... 8
1.7 Future® S series equipment and product code key................................................................................. 9
2 Installing the unit.......................................................................................................................................... 11
2.1 Space reserved for the unit ................................................................................................................... 11
2.2 Unit components in general .................................................................................................................. 12
2.3 Location of duct outlets and handedness of equipment ...................................................................... 13
2.4 Commissioning general instructions ..................................................................................................... 14
2.5 Maintenance general instructions......................................................................................................... 15
3 Fans............................................................................................................................................................... 16
3.1 Operating conditions ............................................................................................................................. 16
3.2 Safety..................................................................................................................................................... 16
3.3 Commissioning ...................................................................................................................................... 16
3.4 Maintenance.......................................................................................................................................... 16
4 Filters ............................................................................................................................................................ 18
4.1 Operating conditions ............................................................................................................................. 18
4.2 Safety..................................................................................................................................................... 18
4.3 Installation and commissioning............................................................................................................. 18
4.4 Maintenance.......................................................................................................................................... 19
4.5 Replacement of filters ........................................................................................................................... 19
4.6 Replacement of gasket .......................................................................................................................... 20
5 Post-heating coil ........................................................................................................................................... 21
5.1 Operating conditions ............................................................................................................................. 21
5.2 Safety..................................................................................................................................................... 21
5.3 Installing ................................................................................................................................................ 21
5.4 Commissioning ...................................................................................................................................... 21
5.5 Maintenance.......................................................................................................................................... 22
6 Heat recovery section, plate......................................................................................................................... 23
6.1 Operating conditions ............................................................................................................................. 23

FUTURE® S AIR HANDLING UNIT
OPERATION AND MAINTENANCE
INSTRUCTIONS
15 December 2020 Ver 1.7 (We reserve the right to changes without prior notice) 2
6.2 Safety..................................................................................................................................................... 23
6.3 Installing ................................................................................................................................................ 23
6.4 Commissioning and maintenance ......................................................................................................... 23
7 Heat recovery section, rotating.................................................................................................................... 24
7.1 Operating conditions ............................................................................................................................. 24
7.2 Safety..................................................................................................................................................... 24
7.3 Commissioning ...................................................................................................................................... 24
7.4 Maintenance.......................................................................................................................................... 25
7.4.1 Cleaning .......................................................................................................................................... 25
7.4.2 Adjusting rotor position.................................................................................................................. 26
7.4.3 First actions in case of an alarm when the rotor motor has stopped ............................................ 28
7.4.4 Replacement of drive belt .............................................................................................................. 28
7.4.5 Rotor removal................................................................................................................................. 29
8 Electric automation ...................................................................................................................................... 30
8.1 Safety..................................................................................................................................................... 30
8.2 Commissioning and maintenance ......................................................................................................... 30
8.3 Fans........................................................................................................................................................ 32
8.4 Temperature sensors............................................................................................................................. 32
8.5 Pressure transmitters ............................................................................................................................ 32
8.6 FxVent controller (accessory) ................................................................................................................ 33
8.7 HR damper actuators (accessory).......................................................................................................... 33
8.8 Safety switch (accessory)....................................................................................................................... 33
8.9 Heating coil pump group pump (pump group accessory) ..................................................................... 33
8.10 Heating coil pump group control valve (pump group accessory) ....................................................... 33
9 Other accessories ......................................................................................................................................... 34
9.1 Safety..................................................................................................................................................... 34
9.2 Water trap ............................................................................................................................................. 34
9.3 Fresh and exhaust air dampers (accessory) .......................................................................................... 34
9.4 Spare filters (accessory)......................................................................................................................... 34
9.5 Heating coil pump group (accessory) .................................................................................................... 35
9.5.1 Pump group installation ................................................................................................................. 36
9.5.2 Pump group commissioning and maintenance .............................................................................. 36
9.6 Preheating coil for the duct (accessory)................................................................................................ 37
9.6.1 Preheating coil installing, commissioning and maintenance ......................................................... 38
9.7 Cooling coil for the duct (accessory) ..................................................................................................... 38
9.7.1 Cooling coil installing, commissioning and maintenance............................................................... 39

FUTURE® S AIR HANDLING UNIT
OPERATION AND MAINTENANCE
INSTRUCTIONS
15 December 2020 Ver 1.7 (We reserve the right to changes without prior notice) 3
1 General
For efficient and economical ventilation system, the operation of the equipment must be monitored on a
regular basis, and the operation and maintenance instructions must be followed. The ventilation system must
be designed and implemented in accordance with the statutes and regulations in force.
The documentation of the ventilation system contain the operating principles of the plant and its subsystems,
operating programs, connection and control diagrams, location and layout drawings, and adjustment values
and operation and maintenance instructions for the equipment.
1.1 Operating conditions
The standard unit is designed for indoor installation. Ambient temperature must be over 0 oC. The air to be
handled must not be corrosive or poisonous, warmer than 40 oC or contain significant amounts of water
vapour or large particles.
CAUTION
The permitted operating conditions and any limitations must be checked from the section-
specific instructions.
1.2 CEN standard classification
Future® air handling unit complies with the CEN standard EN 1886 classification as follows:
•L2 leakage class for casing
•T3 heat transfer coefficient for casing.
1.3 Sound level
For the unit’s sound data, please refer to the design calculations supplied with the acknowledgment of order.
1.4 General safety instructions
WARNING
The ventilation unit includes sharp parts and hot surfaces.
WARNING
Observe general and section-specific safety instructions

FUTURE® S AIR HANDLING UNIT
OPERATION AND MAINTENANCE
INSTRUCTIONS
15 December 2020 Ver 1.7 (We reserve the right to changes without prior notice) 4
WARNING
The component manufacturer’s installation and operating instructions must be followed.
In case of a discrepancy between these instructions, follow the component manufacturer’s
instructions. For
detailed component manufacturer’s operating and maintenance
instructions, please refer to our website at
http://www.koja.fi/fi/rakennukset/tukimateriaalit/ilmankaesittelykoneet
WARNING
Before switching on the fan, make sure that the inlet and outlet of the fan section have
been connected to the ductwork or that the access to the rotating fan parts, such as the
impeller, through an inlet, outlet or access door has been prevented with protective
screens or by other appropriate manner. The service switch of the air handling unit must
be installed and in service when the unit is switched on. The damper section of the unit
must open before the fan starts.
WARNING
Do not keep extra objects on top of or inside the unit. Do not climb or walk on top of the
unit.
WARNING
The earthing continuity of the frame of the ventilation unit must be assured, and the frame
must be connected to the building’s earthing system before operation.
WARNING
The supply cables of the ventilation unit must be equipped with a correctly dimensioned
safety switch that can be used to stop the unit before starting any maintenance work. Upon
starting the unit, the safety switch of the unit must be installed and operating and the
access doors closed.
WARNING
The electric motors are serviced according to the manufacturer’s instructions. The
components must be de-energised and the impeller stopped for the duration of the
maintenance. Once opened, the rotors and stators of the EC motors may cause interference
in electrical devices, such as mobile phones and payment cards. Being in close proximity to
opened permanent magnet motors constitutes a danger to people with pacemakers.

FUTURE® S AIR HANDLING UNIT
OPERATION AND MAINTENANCE
INSTRUCTIONS
15 December 2020 Ver 1.7 (We reserve the right to changes without prior notice) 5
WARNING
Electrical connections must be made by a qualified and authorised electrician only. The
condition of the cables connected to the unit must be inspected visually before making any
electric
al connections and starting the unit. Before starting any installation and
maintenance work on the electrical device, make absolutely sure that the device is de-
energised. After switching off the power, wait at least five minutes to allow dangerous
voltages to discharge from the devices. Electrical devices should be inspected every six
months. Any deficiencies and faults must be rectified immediately.
WARNING
Due to functional reasons, fans/motors may start and stop automatically without warning.
This may happen, for example, after a power outage or malfunction.
WARNING
Do not use components other than those specified or approved by the equipment
manufacturer in the ventilation unit.
CAUTION
The unit must be installed in a space accessible only to qualified personnel. If the unit is
installed in a place where it is accessible to persons other than service personnel, the
handles of the access doors must be removed and locked in a safe place. Ensure during
installation, commissioning and maintenance that only qualified maintenance personnel
have access to the danger area.
CAUTION
The ventilation system and its maintenance routes must be designed and constructed so
that the ventilation unit can be serviced and repaired easily and safely. The National
Building Code of Finland 1009/2017, Section 24 of the Ministry of the Environment Decree
on the indoor climate and ventilation of buildings
CAUTION
The filters’ pressure difference values must under no circumstances exceed the
dimensioning pressure drop in the filters by more than two times. If the pressure difference
is exceeded, the components or structure of the unit may become damaged. The warranty
does not cover damages due to negligence in replacing the filters
CAUTION
If the unit is equipped with drainages for washing water, these must be plugged. If the
drainages are sewered, they must be equipped with a water trap.

FUTURE® S AIR HANDLING UNIT
OPERATION AND MAINTENANCE
INSTRUCTIONS
15 December 2020 Ver 1.7 (We reserve the right to changes without prior notice) 6
CAUTION
The fan models are not designed to be disassembled.
CAUTION
If the fan has to be replaced, the faulty fan is to be returned with a length of the wire
attached to the motor.
CAUTION
If the units have been in storage for an extended time, make sure that there is no moisture
in the link boxes of the motors.
1.4.1 CE marking
Future® S ventilation units are CE marked. The CE mark is attached to the machine plate on the switchboard
door. The manufacturer’s declaration of conformity and other documents relating to the safety of the unit
sections are supplied with the unit.
The ventilation system’s supplier and person responsible for taking the system into use must ensure that the
essential requirements relating to the safety of the unit are complied with and that the equipment
manufacturer’s instructions are followed. Electrical installations and their installation inspections and
measurements must be performed in accordance with standards SFS-EN 60204-1 and SFS 6000-6, and the
person responsible for taking the unit into use must compile the testing and installation documents.
1.4.2 Fire
In case of fire in the unit, do not use water, but a powder extinguisher or such. The materials used in the unit
do not produce harmful amounts of any hazardous gases when burning.

FUTURE® S AIR HANDLING UNIT
OPERATION AND MAINTENANCE
INSTRUCTIONS
15 December 2020 Ver 1.7 (We reserve the right to changes without prior notice) 7
1.5 Declaration of conformity
DECLARATION OF CONFORMITY
Manufacturer Koja Ltd
Address Lentokentänkatu 7
FI-33900 Tampere
Finland
Hereby declares that
Products FUTURE® S air handling unit series
a) conforms with the essential requirements of the directives listed
below, provided that the said products are installed in accordance
with the instructions supplied with the unit.
Machinery Directive 2006/42/EC
EMC Directive 2014/30/EC
Low Voltage Directive 2014/35/EC
Commission Regulation 1253/2014 implementing Directive 2009/125/EC
with regard to ecodesign requirements for ventilation units
The declaration only applies to the ventilation unit within the scope
during the time of delivery. If any changes are made to the products, this
declaration will no longer be in effect. A risk analysis according to the
Machinery Directive requirements has been conducted on the product.
b) has been manufactured according to the following harmonised
standards: SFS-EN ISO 12100, SFS-EN ISO 13857, SFS-EN 60204-1, EN
61000-6-1, EN 61000-6-3, EN 61000-6-4, SFS 6000-6, SFS-EN 13053
Technical file compiled by: Taneli Timlin
R&D Head of Technology, ventilation units
Address: Lentokentänkatu 7, FI-33900 Tampere, Finland
Date 07 December 2020
Signature Joonas Lius
Position Business Director

FUTURE® S AIR HANDLING UNIT
OPERATION AND MAINTENANCE
INSTRUCTIONS
15 December 2020 Ver 1.7 (We reserve the right to changes without prior notice) 8
1.6 Recycling and disposal instructions
WARNING
Observe general and section-specific safety instructions
WARNING
Before starting any disassembly work on the device, make absolutely sure that the device
is de-
energised. After switching off the power, wait at least five minutes to allow
dangerous voltages to discharge from the devices.
•Disconnect the device from other systems (ducts, heating network, cooling network, automation,
electrics).
•If the device consists of modules, remove the module fasteners
•Remove access doors
•Unwire components and disconnect cables
•Remove components
•Disassemble modules into parts if possible
•Sort and recycle loose parts and components according to the material recycling instructions.
The device consists of the following materials:
•Modules: Hot-dip galvanised steel plate, mineral wool, small amounts of plastic, rubber and
adhesive mass (corner brackets, handles, hinges and gaskets).
•Shut-off dampers: Hot-dip galvanised steel plate, polyurethane foam, small amounts of
silicone (gaskets).
•Filters: Hot-dip galvanised steel plate, fibreglass and plastic.
•Heat exchangers: Hot-dip galvanised steel plate, aluminium and copper.
•Fans: Hot-dip galvanised steel plate, composite, small amounts of rubber, electric
components.
•Switchboard: Painted steel plate
•Electric components (field devices, wiring, central components)
•Small amounts of plastic (e.g. pressure hoses, water traps)