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
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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
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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
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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
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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
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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
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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
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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)

FUTURE® S AIR HANDLING UNIT
OPERATION AND MAINTENANCE
INSTRUCTIONS
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1.7 Future® S series equipment and product code key
The equipment relating to Future® S series devices is selected unit-specifically during device dimensioning.
Device dimensioning forms a product code of the device, and this code defines the equipment included in
the device. Standard equipment in the device series include:
•EC fans
•Heat recovery (counterflow or rotating)
•Supply air filter ePM1 60% F7L
•Exhaust air filter ePM10 60% M5L
•Post-heating coil (water)
•Water drains and water traps
•Lifting brackets
•Adjustable base
•Electric automation centre with the following field devices installed and wired to terminal blocks:
oAir temperature sensors (5 pcs)
oAnti-freezing sensor for the heating coil
oHR damper actuators (counterflow HR) or HR control centre (rotating HR)
oHR defrost pressure-difference transmitters
oFilters’ pressure-difference transmitters
oSafety switch wired separately
The following accessories are available for the series:
•FxVent controller
•Fresh and exhaust air dampers
•Spare filters
•Heating coil pump group
•Air flow measurement
•Constant pressure control
•Fresh and exhaust air damper actuators
•Preheater
•Cooling coil

FUTURE® S AIR HANDLING UNIT
OPERATION AND MAINTENANCE
INSTRUCTIONS
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Figure 1.1: Future® S code key
The product code of the unit is available in the technical printout included in the unit delivery.

FUTURE® S AIR HANDLING UNIT
OPERATION AND MAINTENANCE
INSTRUCTIONS
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2 Installing the unit
Future® S ventilation unit is installed according to separate transport, storage, and installation instructions.
2.1 Space reserved for the unit
The space to be reserved for the unit depends on the selected model. Check the space required by the unit
from its dimensional drawing.
Figure 2.1: Example of the space to be reserved for the unit
NOTE! The locations of connections vary according to the unit’s handedness and model. Check the positions
of integrates from the unit’s dimensional drawing.

FUTURE® S AIR HANDLING UNIT
OPERATION AND MAINTENANCE
INSTRUCTIONS
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2.2 Unit components in general
The figure below describes the unit components on a general level.
Figure 2.2: Unit components in general
The components included in the unit vary according to the selected model.

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OPERATION AND MAINTENANCE
INSTRUCTIONS
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2.3 Location of duct outlets and handedness of equipment
The following is a general description of the handedness of the device series.
Figure 2.3: Handedness in general
Duct outlet locations are the same for all sizes of Future® S series units. Only the size and distance between
the ducts varies. Check the handedness of the unit from the unit’s dimensional drawing.

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OPERATION AND MAINTENANCE
INSTRUCTIONS
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2.4 Commissioning general instructions
(Figure shows –S500 Counterflow unit, Handedness – Left)
Before commissioning the ventilation unit, make sure that the unit has been installed and cleaned according
to the instructions, that the components and safety devices essential for the safe operation of the unit have
been installed properly, and that the flow rates have been adjusted.
The commissioning of the ventilation unit and the training of the operating personnel are usually carried out
by the supplier of the air-conditioning plant in question.

FUTURE® S AIR HANDLING UNIT
OPERATION AND MAINTENANCE
INSTRUCTIONS
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2.5 Maintenance general instructions
WARNING
Observe general and section-specific safety instructions
Before starting any maintenance and/or repair work, make sure that the work will not cause an unnecessary
disturbance to other activities in the building. Stop the unit and turn the safety switch to the zero position.
Make absolutely sure that the unit will not be started accidentally during maintenance.
After completing the maintenance and/or repair work, start the unit and make sure that all shut-off and
control devices as well as instruments are functioning.
The stated maintenance intervals are only guidelines. The intervals are determined by the utilisation rate of
the air-conditioning plant and the ambient conditions. The given intervals apply when the plant is used 8
hours a day in city air environment. The maintenance intervals are longer in cleaner environments (like the
countryside) and shorter in dirtier environments (like industrial areas).
It is advisable to have the unit serviced at the beginning (autumn) and at the end (spring) of the heating
season. Maintenance activities that can be performed by the plant’s own service personnel are cleaning, the
replacement of filters, belts and pulleys, and the lubrication of joints and bearings.
Repairs on unit sections and all installation and adjustment operations related to electricity or automation
require special expertise. Clean the unit with an ordinary detergent. Solvents must not be used in cleaning
sections that include aluminium parts (heat exchangers).
Spare parts mentioned in these instructions are available at Koja or the manufacturer in question. (Koja Ltd
reserves the right to changes without prior notice.)

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OPERATION AND MAINTENANCE
INSTRUCTIONS
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3 Fans
3.1 Operating conditions
The maximum permissible air temperature upstream of the fan is + 40 °C.
3.2 Safety
WARNING
Observe general and section-specific safety instructions
WARNING
An EC motor rotating freely generates voltage to the internal motor connections. These
voltages can be dangerously high. After the motor has stopped, wait at least five minutes
to allow dangerous voltages to discharge.
3.3 Commissioning
The fans’ EC motors are equipped with an integrated control unit. EMC requirements do not apply to the EC
motor power cabling. Nevertheless, it is advisable to use screened cable control wires. The bus conductors
must be screened and of the twisted pair type. Any control cable screens are connected on the EC motor end
only. The equipment must be protected against short circuits and the installations against overloading with,
for example, fuses.
•Make sure that the inside of the fan section and the fan are free from any loose parts, debris, etc.
that could get into the fan impeller.
•Check that the electrical cables are intact and routed to the motor flexibly and that the type of the
cable is correct.
•Check that the drive and fan operate freely by turning the impeller a couple of turns by hand.
•Make sure that the fan’s direction of rotation is correct.
•All filters, louvres, valves and other parts of the air-conditioning plant must be installed and pre-set
before long-term operation. The fan must not be started with the inlet and outlet dampers closed.
•If necessary, clean the fan casing and impeller with a brush, vacuum cleaner or damp cloth.
•Check the condition of the motor visually.
•Make sure that the access door gaskets are in place and intact. Close the access door and make sure
that every latch tightens properly.
•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.
3.4 Maintenance
•The recommended maintenance interval is 6 months.

FUTURE® S AIR HANDLING UNIT
OPERATION AND MAINTENANCE
INSTRUCTIONS
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•Make sure that the inside of the fan section and the fan are free from any loose parts, debris, etc.
that could get into the fan impeller.
•Check that the electrical cables are intact and routed to the motor flexibly and that the type of the
cable is correct.
•Check that the drive and fan operate freely by turning the impeller a couple of turns by hand.
•All filters, louvres, valves and other parts of the air-conditioning plant must be installed and pre-set
before long-term operation. The fan must not be started with the inlet and outlet dampers closed.
•If necessary, clean the fan casing and impeller with a brush, vacuum cleaner or damp cloth.
•Make sure that the fan’s direction of rotation is correct.
•Make sure that the access door gaskets are in place and intact. Replace, if necessary. Close the access
door and make sure that every latch tightens properly.
•Check that the fan is not making any extra noise.
•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.
Regular maintenance can be scheduled for the beginning and end of the heating season. It is advisable to
monitor the operation of the fan and, in particular, the drive between regular maintenances. During
commissioning of the air-conditioning plant, check the unit weekly to detect any possible need for repair.

FUTURE® S AIR HANDLING UNIT
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INSTRUCTIONS
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4 Filters
4.1 Operating conditions
•The operating temperature range is -40 °C ... +40 °C.
4.2 Safety
WARNING
Observe general and section-specific safety instructions
4.3 Installation and commissioning
The filters must be installed before test-running the unit. The filters are placed in the mounting grooves and
clamped with a clamping mechanism against the gasket.
• Check that the filters are intact and of the correct type.
• Check that the filters are tight against the frame gasket and that there are no leaks.
• Check that the filters are clamped in place.
• Check that the differential pressure gauge is intact and reset.
• Check that the differential pressure hoses of the filter section are intact and in their places.
At the installation stage, the pressure difference limits for the filter indicators must be set according to the
Future® dimensioning program documentation. The filter pressure difference values must under no
circumstances exceed the dimensioning pressure drop in the filter 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.