Vortice CTAE Series User manual

Air quality Quality of life
www.vorticeindustrial.com
[email protected]
Installation Operations and Maintenance manual
CTAE series
RETAIN FOR FUTURE REFERENCE
Incorporated in this manual there are the following documents:
Declaration of conformity •
Technical schedule •
Dimensional drawing •
Wiring diagrams •
Original Instructions

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O&M MANUAL - CTAE SERIES
Support service performed by Vortice Industrial s.r.l.
e-mail: [e-mail]
Reproduction, data storage and transmission, even partial, of this publication, in any form, without the prior written authorisation of the
Company, is prohibited. The Company can be contacted for all inquiries regarding the use of its products.
The Company follows a policy of continuous product development and improvement and reserves the right to modify specications,
equipment and instructions regarding use and maintenance at any time, without notice.
Declaration of conformity
We declare under our own responsibility that the below equipment complies in all parts with the CEE and EN directives.
The declaration of conformity is enclosed to the technical schedule enclosed with the unit.
This units has been designed in accordance with the following EU Directives:
• Directive 2006/42/CE of the European Parliament and of the Council of 17 May 2006 on machinery;
• Directive 2014/30/EU of the European Parliament and of the Council of 26 February 2014 on the harmonisation of the laws of the
Member States relating to electromagnetic compatibility (recast);
• Directive 2004/35/EU of the European Parliament and of the Council of 26 February 2014 on the harmonisation of the laws of the
Member States relating to the making available on the market of electrical equipment designed for use within certain voltage limits
(recast), and complies with “essential criteria for safety and health protection” therein specied.
Unit is therefore equipped with appropriate devices fully described in the technical literature supplied with the unit. Installer should carefully
connect and activate all safety components provided on the unit and check for their operation.
The plant or system, where this unit is assembled in, must similarly comply with EU Directives mentioned above.
End users, or any plant operators, should periodically check for proper operation and efciency of safety devices.
Non activating or removing or impeding operation of active safety devices, as well as removal of passive safety equipment, will cause imme-
diate loss of the Company liability with regard to any accidents or damages, direct or indirect, to persons or property, due to the Company
manufactured unit.
The Unit manual, provided with the unit, is completed by a TECHNICAL SCHEDULE reporting all essential unit construction and operational
data together with relevant DRAWINGS.
Upon unit delivery, the Company issues a “CONFORMITY DECLARATION” related to UE Directives and a description of “potential hazard
condition” and precautions adopted during construction to prevent these risks.
Transportation and handling, as well as operation of unit, should be carried out in accordance with instructions given in the present notes
and following pages, as well as technical literature supplied with the unit.
Guarantee is limited by conditions and terms described in the “WARRANTY CERTIFICATE” supplied with the unit and bearing unit type and
serial number.
Multiple instructions:
Consult the specic part
Read and understand
the instructions before
undertaking any work on
the unit

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O&M MANUAL - CTAE SERIES
FAC-SIMILE
FAC-SIMILE
FAC-SIMILE
FAC-SIMILE
Quality Certication
The quality of our products is documented through certicates that guarantee every phase of the company production process, from
production to the management of materials, from production control to document management.
Operating in this way, the process can be managed in a systematic way, as well as having the guarantee that all production activities are
certainly carried out according to the procedures envisaged during the project, or in the technical documents.
Documentation process serves to demonstrate that the activities are managed in a uniform manner and in compliance with the quality
standards.

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O&M MANUAL - CTAE SERIES
GENERAL INDEX
1. INTRODUCTION................................................................................................................................................................................. 06
1.1 Preliminary information.................................................................................................................................................. 06
1.2 Aim and content of the manual ...................................................................................................................................... 06
1.3 How to store this manual ............................................................................................................................................... 06
1.4 Manual update............................................................................................................................................................... 06
1.5 How to use this manual ................................................................................................................................................. 06
1.6 Potential risks ................................................................................................................................................................ 07
1.7 General description of symbols used............................................................................................................................. 09
1.8 Safety symbols used...................................................................................................................................................... 10
1.9 Limitations and prohibited use....................................................................................................................................... 11
1.10 Unit identication ......................................................................................................................................................... 11
2. SAFETY ............................................................................................................................................................................................. 12
2.1 Safety integration principles........................................................................................................................................... 12
2.2 Instructions for worker’s safety ...................................................................................................................................... 12
2.3 Check at receival ........................................................................................................................................................... 12
3. TRASPORTATION AND HANDLING.................................................................................................................................................. 13
3.1 Receipt and inspection .................................................................................................................................................. 13
3.2 Lifting and handling........................................................................................................................................................ 13
3.3 Storage .......................................................................................................................................................................... 14
3.4 Unpacking ..................................................................................................................................................................... 14
3.5 Personal protective equipment ...................................................................................................................................... 14
4. INSTALLATION .................................................................................................................................................................................. 15
4.1 Preliminary notice .......................................................................................................................................................... 15
4.2 Service area requirements............................................................................................................................................. 17
4.3 Section coupling and bolting ......................................................................................................................................... 17
4.4 Coil connections ........................................................................................................................................................... 19
4.4.1 Water coils ................................................................................................................................................................. 19
4.4.2 Steam coils ................................................................................................................................................................ 19
4.4.3 Direct expansion coils ................................................................................................................................................ 20
4.4.4 Electric heaters .......................................................................................................................................................... 20
4.5 Hydronic connections .................................................................................................................................................... 21
4.6 Water humidication connections .................................................................................................................................. 21
4.7 Air connections .............................................................................................................................................................. 21
4.8 Electrical connections.................................................................................................................................................... 22
4.8.1 Electric heaters .......................................................................................................................................................... 22
4.8.2 Electric motors............................................................................................................................................................ 22
4.8.3 Plug-fan / Brushless fan connections ........................................................................................................................ 25
4.8.4 Safety devices on doors ............................................................................................................................................ 26
4.8.5 Internal unit lighting .................................................................................................................................................... 26
4.8.6 Unit ground connection .............................................................................................................................................. 26
5. UNIT START UP.................................................................................................................................................................................. 27
5.1 Preliminary checks......................................................................................................................................................... 27
5.1.1 Checks before start-up ............................................................................................................................................... 27
5.1.2 Checks during unit operation...................................................................................................................................... 27
5.2 Safety system ................................................................................................................................................................ 27
5.3 Electric motors, fans and drives..................................................................................................................................... 27
5.4 Air lters ......................................................................................................................................................................... 28
5.5 Humidier sections and pumps...................................................................................................................................... 28
5.5.1 Drain sumps................................................................................................................................................................ 28
5.5.2 Packs and spraying nozzles ....................................................................................................................................... 28
5.5.3 Pumps......................................................................................................................................................................... 28
5.6 Coils............................................................................................................................................................................... 28
5.7 Dampers ........................................................................................................................................................................ 29

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O&M MANUAL - CTAE SERIES
6. MAINTENANCE .................................................................................................................................................................................. 29
6.1 Safety system ................................................................................................................................................................ 29
6.2 Electric motors, drives and centrifugal fans................................................................................................................... 30
6.3 Fans EC Brushless........................................................................................................................................................ 31
6.3.1 Fans maintenance ...................................................................................................................................................... 31
6.3.2 Cleaning and safety test ............................................................................................................................................. 32
6.4 Air lters ......................................................................................................................................................................... 32
6.5 Humidier sections and pumps...................................................................................................................................... 33
6.5.1 Water sumps, packs and nozzles ............................................................................................................................... 33
6.5.2 Water strainers............................................................................................................................................................ 33
6.5.3 Pumps......................................................................................................................................................................... 33
6.6 Coils .............................................................................................................................................................................. 33
6.7 Dampers ........................................................................................................................................................................ 33
6.8 Unit shut down precautions ........................................................................................................................................... 34
6.9 Summary schedule for periodical maintenance............................................................................................................. 34
6.10 Trouble shooting .......................................................................................................................................................... 35
6.11 Unit record book........................................................................................................................................................... 37
7. REPLACEMENT PARTS..................................................................................................................................................................... 38
7.1 Unit identication ........................................................................................................................................................... 38
7.2 Identication of the part to be replaced.......................................................................................................................... 38
7.3 Replacement parts ordering .......................................................................................................................................... 38
8. DISMANTLEMENT, MATERIALS’ DISPOSAL AND RECYCLING ...................................................................................................... 38
8.1 Unit disconnection ......................................................................................................................................................... 38
8.2 RAEE Directive (only UE).............................................................................................................................................. 39
9. INDICATIVE POSITIONING OF ADHESIVE SIGNALING AND NAME PLATE OF IDENTIFICATION ............................................... 40

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O&M MANUAL - CTAE SERIES
1. INTRODUCTION
Air handling units should be installed and operated in accordance with requirements listed in this manual. Observing these simple instruc-
tions carefully is a preliminary precaution in order to:
• totally avoid or substantially decrease number of unit shutdowns for unforseen breakdowns;
• increase component efciency and consequently conserve energy;
• increase component and unit life;
• decrease maintenance need and costs.
1.1 Preliminary information
The present manual is realized to allow the correct unit’s installation, the start up and maintenance.
The unit to which these instructions refer, has been designed for the uses that will be presented in the appropriate paragraphs and must only
be used for which it has been expressly sized (see TECHNICAL SCHEDULE), compatibly with its performance characteristics.
The Company will not be liable for claims for damage caused to persons, animals, material goods or property caused by improper instal-
lation, adjustment and maintenance or improper use. Any other use not specied in this manual is prohibited and doesn’t imply any com-
mitment or constraint for the manufacturer.
This document is intended to provide information only and does not form a contract with third parties.
The Company pursues a policy of constant improvement and development of its products and therefore reserves the right to change the
specications and the documentation at any time, without notice and without obligation to update existing equipment.
1.2 Aim and content of the manual
These instructions are intended to provide the information required for the selection, installation, use and maintenance of the unit.
They have been prepared in accordance with the European Union laws and with the technical standards in force at the date of issue of the
instructions. Observe the local safety regulations in force at the time of installation.
The instructions contain all the necessary information to prevent any reasonably foreseeable misuse.
1.3 How to store this manual
The manual must be kept in a suitable place with easy access for users and operators, protected from dust, damp and and easily accessible
to users and operators for any further consultation.
The manual must always accompany the unit during the entire life cycle of the same and therefore must be transferred to any subsequent
user.
1.4 Manual update
It is recommended that the manual is updated to the latest revision available.
If updates are sent to the customer they must be added to this manual.
The latest information regarding the use of its products is available by contacting the Company.
1.5 How to use this manual
The manual is an integral part of the unit.
Users or operators must consult the manual before performing any operation and especially so when transporting, handling,
installating, maintaining, or dismantling the unit in order to eliminate uncertainty and reduce risk.
In these instructions symbols have been used (described in the following paragraphs) to draw the attention of operators and
users to the operations that have a higher risk and which must be performed safely.

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O&M MANUAL - CTAE SERIES
1.6 Potential risks
Any operation which can produce dangerous situations is indicated in this manual.
It also contains precautionary measures for any specic case.
CAUTION !
Any operation which can produce dangerous situations is indicated in this manual. It also contains precautionary
measures for any specic case.
• All the units are provided with pictograms with danger warnings.
• All the units are safe, and it is forbidden to tamper with the machines or to remove security protections.
• To operate in total secure conditions it is helpful to have a technical preparation, and it is important to respect the proceedings illustrated
in this manual and eventual signallings afxed in critical places of the unit.
• The following dispositions must be respected during the installation, the start up, the use and maintenance of the unit:
• Do not start up the unit before its electric components are wired to the building’s electric plant;
• Do not start up the unit before the fan outlet is wired to a duct or protected with an accident prevention grid;
• Do not use the unit as a support for another machine;
• Do not use the unit as a platform;
• Do not use the unit as an equipment’s storehouse;
• Do not open inspection doors while the fan is working, especially near pressure sections;
• Do not leave inspection doors half closed, but check that handles and knobs are completely closed;
• Do not expose oneself to ultraviolet lamp’s light, which are situated in those sections where germicidal lamps are used.
• Wear individual security devices before working with the unit;
• Before unit’s start up check that all electrical devices are off. Especially, before opening inspection doors, check
that the fan is switched off and that no one can start it up without the knowledge of the technicist who is operating
on the machine;
• Always reassemble the protection grid of the fan section before the start up;
• Pay attention during lifting the machine, because its barycentre can be very unbalanced;
• Pay attention to lifting cables/hooks blocking;
• Pay attention to edges inside the unit;
• Pay attention to roof edges outside the unit;
• Pay attention to possible burns that heat coils can cause;
• Pay attention to possible burns that humidication system can cause;
• Pay attention to servo-controlled dampers which could suddenly close.

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O&M MANUAL - CTAE SERIES
Whilst the unit has been designed to minimize any risk posed to the safety of people who will interact with it, it has not been technically
possible to eliminate completely the causes of risk. It is therefore necessary to refer to the requirements and symbolism below:
LOCATION OF
RISK (if present) POTENTIAL RISK METHOD OF INJURY PRECAUTIONS AND PROTECTIONS
Mixing box with dam-
pers and actuators Crush Contact Remove voltage before any operation
Thermal heat
exchangers
Small stab wounds,
burns Contact Avoid any contact, use protective gloves
Electric heaters Electrocution,
severe burns
Contact,
Fire due to short circuit or
overheating of the heating
elements
Periodic check of the safety devi-
ces, adhesive warning signs on the
machine
Humidication with
steam producer,
nozzles
Electrocution,
severe burns Contact Use protective gloves and protective glasses
Plate / rotor heat
exchangers
Small stab wounds,
crush Contact Avoid any contact, use protective gloves
Fan and fan grids Cuts, eye damage,
broken bones
Insertion of sharp objects
through the grid while the fans
are operating
Never put objects through the
protection grids
External to unit:
unit enclosure
Intoxication,
severe burns
Fire due to short circuit or
overheating of the supply
cable external to unit
Size cables and mains protection
system in accordance with iee
regulations
Internal component:
electric cables and
metallic parts
Electrocution,
severe burns
Defect in the supply cable
insulation, live metallic parts
Adequate protection of power
cables, ensure correct earthing of
all metal parts

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O&M MANUAL - CTAE SERIES
1.7 General description of symbols used
Safety symbols combined in accordance with ISO 3864-2:
BANNED
A black symbol inside a red circle with a red diagonal indicates an action that should not be performed.
WARNING
A black graphic symbol added to a yellow triangle with black edges indicates danger.
ACTION REQUIRED
A white symbol inserted in a blue circle indicates an action that must be done to avoid a risk.
Safety symbols combined in accordance with ISO 3864-2:
The graphic symbol “warning” is qualied with additional safety information (text or other symbols).

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O&M MANUAL - CTAE SERIES
1.8 Safety symbols used
GENERAL RISK
Observe all signs placed next to the pictogram.
The failure to follow directions may create a risk situation that may be injurious to the operators and users.
ELECTRICAL HAZARD
Observe all signs placed next to the pictogram.
The symbol indicates components of the unit and actions described in this manual that could create an electrical hazard.
MOVING PARTS
The symbol indicates those moving parts of the unit that could create risk.
SHARP SURFACES
The symbol indicates components or parts that could cause stab wounds.
EARTH CONNECTION
The symbol identies Earthing connection points in the unit.
READ AND UNDERSTAND THE INSTRUCTIONS
Read and understand the instructions of the machine before any operations.
RECOVER OR RECYCLE MATERIAL

11
Fig. 1
O&M MANUAL - CTAE SERIES
1
2
3
4
5
6
7
8
9
LEGEND:
(1) CE Mark.
(2) Unit type and size.
(3) Serial number.
(4) Air ow, at standard conditions and
external available static pressure.
(5) External available static pressure.
(6) Unit’s total weight .
(7) Nominal power input, inductive plus
resistive.
(8) FLA, full load current according to
power input type.
(9) Main supply characteristics, up to three
different data for electric components
with different supply characteristics.
The “TECHNICAL SCHEDULE” provided with
the unit included all other technical details.
When corresponding with Vortice
Industrial, unit type and serial number
(point 2 and 3) must always be indicated.
1.9 Limitations and prohibited use
The machine is designed and built exclusively for the uses described in this technical manual.
Any other use is prohibited because it may pose a potential risk to the health of operators and users.
The unit is not suitable for operations in environments:
• excessively dusty or potentially explosive atmospheres;
• where there are vibrations;
• where there are electromagnetic elds;
• where there are aggressive atmospheres.
1.10 Unit identication
Each unit has a name plate, usually mounted on the external side of the unit, that provides key information regarding the machine and main
technical characteristics.
The rating plate may differ from the one shown below as the example is for a standard unit without accessories.
For all electrical information not provided on the label, refer to the wiring diagram.
Verify that the characteristics of the electric network comply with the data shown on the identication plate.
A facsimile of the label is shown below on Fig. 1 with the legend of the data included.
The product label should never be removed from the unit.

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O&M MANUAL - CTAE SERIES
2. SAFETY
2.1 Safety integration principles
The machine is designed and built to avoid any risk for health and people.
Many project’s solutions have been carried out to avoid (where is possible) any kind of danger.
Where there is no possibility to completely prevent or avoid dangers, please respect behavioural disposition indicated in the paragraph
1.6 “RESIDUAL RISKS” of this manual.
THIS UNIT IS NOT SUITABLE FOR OPERATION IN EXPLOSIVE ATMOSPHERE
2.2 Instructions for worker’s safety
• All the operations (discharge, assembly, moving etc.) must be effected after reading the following instructions. It is also important to
respect Safety Directive’s prescriptions and individual safety devices.
• Installation and machine’s start up must be effected by a qualied staff.
• Deactivate the appliance in case of failure or malfunction.
2.3 Check at receival
Air handling units are shipped without packing and, frequently, divided into different modular sections to be assembled on site.
It is recommended to check that sections are divided in the same way as indicated on unit assembly drawings and components are free
from damages due to trasportation.
The sections, upon their arrival on site, have a packaging that protects from dirt and atmospheric agents, but not from any impact.
Particularly it should be carefully checked that:
• fan-motor group rotates freely;
• antivibration isolators are not damaged;
• coil ns and threaded pipes are not damaged;
• dampers move freely;
• lters are correctly assembled and not damaged;
• external panels have no scratches or dents;
• no foreign matters are in the unit sections and their internal wall are clean.
Some types of lter cells, e.g. the absolute, bag or activated carbon types, can be shipped in a separate packing.
Any damages or lack of material should be immediately reported to the shipping agent and the Company should be
informed accordingly.
In case unit sections are stored outdoors before unit assembly, they must be adequately protected against possible
damages due to rain or foreign matters or dirt.

13
Fig. 2 Fig. 3
O&M MANUAL - CTAE SERIES
SPACER
LIFTING
HOLES
3. TRASPORTATION AND HANDLING
3.1 Receipt and inspection
of the labels on the unit, and to take any possible precautions of the case. Not observing the rules reported on this manual can create
dangerous situations. After receiving the unit, immediately check its integrity. The unit left the factory in perfect conditions; any eventual
damage must be questioned to the carrier and recorded on the Delivery Note before it is signed.
The company must be informed, within 8 days, of the extent of the damage. The Customer should prepare a written statement of any
severe damage.
Before accepting the unit check:
• The unit did not suffer any damage during transport;
• The delivered goods are conforming to what shown in the delivery note.
In case of damage or abnormalities:
• List the damage on the delivery note;
• Inform the Company of the extent of the damage within 8 days of receipt of the goods. After this time any claim will not be considered.
• A full written report is required for cases of severe damage.
3.2 Lifting and handling
Each unit section or single piece unit is provided with appropriate lifting points (lifting lugs or perimeter holes for lifting bars) clearly identied
in the structural base.
When unloading the unit, it is strongly recommended that sudden movements are avoided in order to protect the internal component of the
unit.
Lifting procedure to be followed in order to avoid any damages to side panels is schematically shown on Fig. 2; in smaller units, equipped
with feet, it is possible to proceed with the handling by means of forklifts, see Fig. 3.
It is important to keep the unit horizontal during the handling and lifting, avoiding absolutely to ip or tilt the sections.
Unit sections should be handled separately, before any assembly or coupling is made. After sections are assembled, it is NOT possible to
move the whole resulting unit.
Weight of each section or unit module, as well as the unit total weight, are shown in the technical documentation supplied
with the unit (DRAWING and TECHNICAL SCHEDULE attached).

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O&M MANUAL - CTAE SERIES
3.3 Storage
Unit should be stored under cover and ideally, should remain in their packaging. If for some reason the unit was already unpacked, follow
these instructions to prevent damage, corrosion and/or deterioration:
• Make sure that all the openings are well closed or sealed;
• To clean the unit, never use steam or other detergents that could damage it;
• The tools that are supplied for opening the electric box (if present) should be formally transferred to the person responsible of the plant.
3.4 Unpacking
Packaging (stretch lm for packaging, polystyrene etc.) could be dangerous and must be kept out of reach of children.
It is advisable to leave packaged units during handling and remove it before the installation.
The packaging must be removed carefully to prevent any possible damage to the machine.
The materials constituting the packaging may be different in nature (wood, cardboard, nylon, etc.).
We recommend to remove the protective lm from the panels after installing the AHU.
The packaging materials should be separated and sent for disposal or possible recycling to specialist waste companies
in order to reduce environmental pollution.
3.5 Dispositivi di protezione individuali
When operating and maintaining the unit, use the following personal protective equipment listed below as
required by law.
Protective footwear.
Eye protection.
Protective gloves.
Hearing protection.

15
A B C D
E E1
O&M MANUAL - CTAE SERIES
4. INSTALLATION
4.1 Preliminary notice
The AHU must be placed in a special area that can be made inside a technical room or outside in a covered area or not, depending on the
structure on site.
Prior to proceeding to AHU installation it is recommended to check the following:
• the structure (concrete or other) supporting the unit must be adequately designed for the unit static and operating weight; water mass
forecasted in unit sumps must also be considered; supporting base should have an horizontal surface, at and regular;
• The installation position must minimize the risks in the event of an earthquake or strong winds;
• Electric supply lines must be adequately sized according to the unit electric characteristics.
The positioning area for the unit can be obtained:
• directly on the oor (Fig. A)
• on a special concrete pedestal (Fig. B)
• on a pedestal in metal proles (Fig. C)
• on a hanging structure in metal proles (Fig. D)
In any case the following minimum requirements must be respected:
• The oor or pedestals must have suitable characteristics to support the mass of the unit in compliance with the required safety limits;
• The contact surface with the lower base frame of the unit must be sufciently smooth and hard in relation to the mass of the machine;
• The oor or pedestals must allow the construction of siphons on the discharges with the provided hydraulic components;
• The horizontality of the support surface must be checked and any corrections can be obtained using metal shims.
Special precautions must be taken in case of unit supplied splitted into sections and /or large dimensions where it’s not envisaged the
creation of a positioning place with a single and continuous surface:
• as well as at the begin and end of the unit, points of support must be made in correspondence with any intermediate junctions between
individual sections (detectable by the drawing of the machine and /or checked with our Technical Department)
(Fig. E (concrete) - Fig. E1(IPE beams));

16
L min ≥ 300 mm G
F F1
O&M MANUAL - CTAE SERIES
• in case of overhead positioning, the individual support points must be realized in order to support the corresponding mass
of the section in consideration of the unit’s height and in compliance with the safety limits for seismic risk. (Fig. F (concrete) – Fig. F1
(structure in metal proles));
• the surface of the support points must have a suitable width to allow positioning /approaching and assembly operations of the individual
sections during the installation phase (Fig. G);
• the contact surface with the base frame must be sufciently hard and smooth to allow positioning/approaching and assembly operations
in relation to the mass of the unit;
• the overall planarity of all the individual support points must be checked and if necessary corrected using metal shims.
READ AND UNDERSTAND THE INSTRUCTIONS
Before undertaking any task the operator must be fully trained in the operation of the machines to be used and their
controls. They must also have read and be fully conversant with all operating instructions.
All maintenance must be performed by TRAINED personnel and be in accordance with all national and local
regulations.
The installation and maintenance of the unit must comply with the local regulations in force at the time of the installation.

17
B+500 BB+500
Fig. 4
O&M MANUAL - CTAE SERIES
ACCESS AND CONNECTIONS SIDE
4.2 Service area requirements
Area choosen for unit assembly must allow sufcient clearance space, around and on top of unit, for unit installation and further ordinary
and extraordinary maintenance operations.
Particularly important is the service area on the inspection and connection side, in order to allow panels to open completely and coils to slide
out completely for extraordinary maintenance.
Fig. 4 shows minimum clearances requested.
The unit has to be installed such that maintenance and repair is possible. The warranty does not cover costs for the
provision of lifting apparatus, platforms or other lifting systems required to perform repairs during warranty period.
4.3 Section coupling and bolting
For unit delivered in separate sections, it is necessary to proceed to the total assembly on site, according to the overall drawings provided
with the unit.
1. Apply supplied self adhesive gasket along the perimetrical face of one of the sections to be coupled.
2. Position rst the heaviest section, then set beside the second one and embed it in the provided corner mortises.
3. Bolt sections together by means of holes provided in the proles and using M8 bolts supplied with the unit. Fasten gradually and
alternatively along the full perimeter (fastening couple 8-12 Nm/0,8-1,2 kgm) until gasket between proles is fully and uniformely pressed
(see Fig. 5 and Fig. 6).
Assembly of union bolts is carried out through inspection panels, or by disassembling side panels adjacent to union proles; as side
panels are secured on to proles by self-threading screws, highest care is required for re-assemblyng the same, in order not to break
panel seal gasket and not to dent panel surfaces.
In some cases it may be necessary to partially remove the coils and /or droplet eliminator to access to the junction plates.
4. Apply the sealing cord, supplied with unit, on the two sides and on top of the union perimeter.
(dimensions in mm)

18
Fig. 6
Fig. 5
O&M MANUAL - CTAE SERIES
EXTERNAL JUNCTIONS SCHEME
INTERNAL JUNCTIONS SCHEME

19
O&M MANUAL - CTAE SERIES
4.4 Coil connections
4.4.1 Water coils
The following requirements for water connections are also applicable for coils with other uid, such as glicole solutions, diathermal oil, etc.
The following minimal requirements are recommended for any type of installations.
a) Provide adequate supports for external circuit and thermal expansion joints with vibration isolators; avoid to load coil connections.
b) Position water pipes and water circuit devices not to impede coil slide out, inspection panel openings and access to any unit sections.
c) Avoid damages to coil connection solderings by fastening mechanical connections with care without applying any torsions to the same
especially when the exchangers are small.
Coil performance is normally rated for counter-ow circuit arrangement, consequently coils are provided with water
inlet at the bottom and downstream air ow, outlet at the top and upstream air ow.
This rule is ensured by following the applied plates indicating “Water in” and “Water out”.
Furthermore, water circuit should be provided with:
1) water drain to be positioned at the unit lowest point (obligatory);
2) vent valve at the circuit highest point to allow easy replenishment (recommended);
3) shut-off valves, on water inlet and outlet, to allow coil disassembly for extraordinary maintenance;
4) for hot water coils, water pump electric interlock with the fan cycling device or circuit bypass, to avoid damages resulting from overheated
stagnating air, during fan shutdown periods.
Installer must obviously guarantee the requested value of water ow.
4.4.2 Steam coils
For steam coils, follow same instructions given for water coils at points a), b), and c) of paragraph 4.4.1, paying attention to “Steam inlet”
and “Steam outlet” plates.
When realizing the steam circuit, installer should also take into consideration that:
1) steam coils are mounted in the section with an appropriate slope toward the outlet connection, this in order to facilitate a natural drainage
of condensate;
2) shut-off valves must be installed at steam inlet and outlet, to allow easy disassembly of coil, if necessary;
3) condensate should never build up inside coils headers or supply and discharge pipes; adequate slope of minimum 2% toward the boiler
should be provided for this purpose, in order to avoid water hammer at steam jet supply;
4) condensate from upsteam pipes should never ow through the coil; for this purpose a condensate drain valve should be provided at coil
inlet, to be connected to the return pipe to boiler;
5) condensate in the coil should be discharged through a condensate drain valve positioned downsteam coil;
6) in case a steam regulating valve of “on-off” type is installed and the air system can intake air at 0° C or less, it is recommended to provide
a steam pressure not less than 0.4 kg/cm2, in order to prevent coil from freezing up;
7) similarly to water coils, it is recommended to shut off steam supply when fan stops, in order to avoid overheated air from stagnating inside
unit, this can damage motors and bearings and impair honeycomb packages.

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O&M MANUAL - CTAE SERIES
4.4.3 Direct expansion coils
Instructions given at points a) and b) of paragraph 4.4.1. for water coils should be followed also in this case, bearing in mind that the best coil
performance is always obtained with the counter-ow arrangement. In this case coil supply is evidently the one provided with the distribution
header where the liquid line must be connected.
The refrigerant circuit must be made in accordance to the best state-of-the-art practice; in any case, the following recommendations are to
be followed:
1) coil is supplied with a holding charge of refrigerant or dehydrated nitrogen;
2) only refrigeration copper tubes should be used, tubes must be thoroughly cleaned, dehydrated and sealed until their use;
3) coil distributor should be cut only immediately before proceeding to brazing, which must be carried out in dehydrated nitrogen
atmosphere which must be forced inside tube to prevent undesired oxidation;
4) same criteria described in point 3) must be used when brazing liquid line to distributor;
5) refrigerant circuit must include appropriate controls and devices to guarantee proper system operation, coil is only a part of the system.
When sizing refrigerant circuit make sure that gas velocity is never lower then 2.5 m/s in the horizontal lines and
5 m/s in the vertical risers, this to guarantee oil return to compressor.
4.4.4 Electric heaters
Electric coils are also of the slide out type and consist of steel nned sheathed elements. Electric connections, including the ones to the
safety thermostat, should be made in the electric control panel located on the coil section panel and according to the electric diagram glued
inside. To avoid damages resulting from overheat, electric controls should include coil shut off during fan shutdown periods.
Make sure the power supply upstream of the unit is blocked with a switch.
Check that the main switch handle is padlocked and it is applied on the handle a visible sign of warning not to operate.
It must be veried that electric supply is corresponding to the unit electric nominal data (tension, phases,
frequency) reported on TECHNICAL SCHEDULE.
The power supply cables must be protected upstream against short circuits and overloads by a suitable device that
complies with current standards and laws.
The cable section must be commensurate with the calibration of the system-side protection and must take into account
all the factors that may inuence (temperature, type of insulation, length, etc.).
Power supply must respect the reported tolerances and limits: If those tolerances should not be respected, the warranty
will be invalidated.
When wiring the electric heater, make all the connections provided, also remember that the heater’s frame must always
be connected to the grounding system.
Before any service operation on the unit, be sure that the electric supply is disconnected.