USER MANUAL

KLIMA
AIR-WATER COOLER
Supplier information:

Homepage:
www.Klima.com

The Netherlands:
VDL Klima b.v.
Meerenakkerweg 30
5652 AV Eindhoven
P.O. Box 300
5600 AH Eindhoven
Telephone: +31 (0)40-2981818
Telephone service: +31 (0)40-2981858
Fax: +31 (0)40-2981800
E-mail info@klima.com

Supplier Belgium:
Klima Belgium n.v.
Leuvensesteenweg 49c
1932 Zaventem
Telephone: +32 (0)2-7206026
Fax: +32 (0)2-7203407
E-mail Klima.belgium@klima.com

Supplier Belgium:
Klima warmtetechniek n.v.
Buitenheide 4
3930 Hamont-Achel

Supplier France:
VDL Klima France s.a.r.l.
Chateau Rouge - 276
Avenue de la Marne
59708
Marcq-en-Baroeul
Telephone: +33 (0)320-65-91-65
Fax: +33 (0)320-65-91-60
E-mail Klima.france@klima.com

Publication: 27.03.2006

2
Table of Contents

1 General Information...........................................................................5
1.1 Product Information ........................................................... 5
1.2 Installation Parts ................................................................ 6
1.3 Prohibitions on (putting into) Operation ............................. 7
1.4 Guarantee.......................................................................... 7
2 Safety ................................................................................................ 8
2.1 General Safety................................................................... 8
2.2 Protection: ....................................................................... 10
3 Transport, Storage and Installation Site. ......................................... 12
3.1 Instructions for Transport and Hoisting ............................ 12
3.2 Transport and Packaging................................................. 13
3.3 Storage: ........................................................................... 13
3.4 Installation Siting:.............................................................14
4 Installation ....................................................................................... 15
4.1 Safety Measures and Facilities on the Heat Exchanger /
Installation. ...................................................................................... 15
4.1.1 Water side connections. .................................................. 15
4.1.2 Electrical connections: ..................................................... 15
4.1.2.1 Connection Regulations................................................... 16
4.1.3 Moving Parts.................................................................... 16
4.1.4 Open Without Danger ...................................................... 16
4.2 Preparation for Installation............................................... 17
4.3 Installation ....................................................................... 19
4.4 Tightening of the Bolts ..................................................... 19
5 Start-up............................................................................................20
5.1 Inspection before putting the unit into operation .............. 20
5.2 Air Inflow.......................................................................... 21
5.3 Filling and Venting. ..........................................................21
5.4 Re-tightening of the Bolts. ............................................... 21
5.5 Inspection after Start-up: ................................................. 21
5.6 Shut-Down of the Installation: .......................................... 22
6 Maintenance and Inspection:...........................................................23
6.1 Inspection ........................................................................ 23
6.2 Cleaning the Air-Water Cooler. ........................................ 24
6.2.1 Disassembly of the Air-Water Cooler............................... 24
6.2.1.1 Disassembly centrifugal fan. ............................................ 25
6.2.1.2 Disassembly Axial Fan. ................................................... 27
6.2.1.3 Disassembly of element from housing ............................. 28
6.2.2 Cleaning the Air-Water Cooler. ........................................ 29
6.2.2.1 Cleaning the element....................................................... 29
6.2.2.2 Cleaning the heat exchanger's air side. ........................... 29
6.2.2.3 Cleaning the Filters.......................................................... 29
6.2.2.4 Cleaning the Housing. ..................................................... 29
6.2.3 Assembly of the Air-Water Cooler.................................... 30
6.2.3.1 Assembly Centrifugal Fan................................................ 30

3
 6.2.3.2 Assembly Axial Fan. ........................................................ 30
6.2.3.3 Assembly of the Element in the Housing ......................... 30
6.2.4 (Re)pressurizing the Heat Exchanger.............................. 30
7 Malfunctions .................................................................................... 31
7.1 Identification and Correction of Malfunctions. .................. 31
7.2 Safety Measures / Facilities: ............................................ 32
8 Customer Service: ...........................................................................33
8.1 Ordering Spare Parts:...................................................... 33
8.2 Complaints Procedure: .................................................... 33
9 Technical Specifications / Documentation ....................................... 34

4
1 General Information
Pictograms used in this manual

Dangerous situation with possibility of personal injury as well

as damage to the equipment.

Reference to tips, comments and supplements with regard to

using the equipment.

If this symbol is stated on the type plate, then the apparatus

satisfies the ATEX 94/9/EG Guideline.

The general standards apply to symbols that are applied to the installation by
the owner.

This manual supplies information and instructions for the correct and safe
use of the unit.
Many accidents are the result of incorrect use.
Instructions in this manual must therefore always be followed.
The safety instructions must also always be observed when work is done on
the equipment.
The complete manual must be carefully read.
If, after reading this manual, questions still exist, you must contact the
supplier / contractor for more information.
The installation may NOT be put into operation before all
unclear issues have been resolved.

1.1 Product Information

Product : Air/Water Cooler.
Type : See Technical Specification Sheet or type
plate

For exchanging heat between the airflow and a liquid (indirectly). The air to
be cooled flows (inner circuit) through a cooling battery filled with a coolant
liquid. A fan maintains the airflow.
Air/Water Coolers are used for cooling and channelling off excess heat
resulting from energy converted to heat by for example, electromotors,
generators transformers etc.

5
1.2 Installation Parts
Fig. 1 A few examples of Air/Water Coolers.

Fig 1

1. Housing
2. Element
3. Liquid in
4. Liquid out
5. Air in
6. Air out

6
1.3 Prohibitions on (putting into) Operation

It is Prohibited to operate the Unit beyond Design

Conditions

The unit is designed according to the design parameters as stated in

the enclosed technical specification sheet. If these parameters are
exceeded then it is PROHIBITED to put the installation into operation
without prior consultation with the manufacturer.
Moreover, all continued use in such a non-design situation is
considered contrary to the regulations. The manufacturer is not liable
for any material damage or personal injury that results from further
use: this risk is solely the responsibility of the owner / user.

Prior to using the unit, the user must have read and understood the
accompanying MANUFACTURERS STATEMENT (Guideline 89/392/EEC
art.4 paragraph 2 and Appendix II under B).
The materials used in the ventilator are in accordance with the VDMA 24169
norm.

Klima has advised on the choice of materials, the user remains responsible
for the media used with regards to corrosion.

1.4 Guarantee
Unless covered by a separate agreement, Klima guarantees the products
supplied by the company to be sound and in good working order, according
to the technical specifications, for a period of 6 months after being put into
operation, up to a maximum of 12 months after delivery.
The General Terms of Sale and Delivery can be requested from your
supplier.
Any damage and/or decrease in capacity due to non-observance of this user
manual are not covered by the guarantee.
The guarantee expires if any adaptations or changes are made to the heat
exchanger.

The equipment must always be inspected upon delivery for damage to the
equipment during transport.
The manufacturer must immediately be notified of any damage during
transport.

7
2 Safety

2.1 General Safety

Physical injuries
Physical injuries can be caused by:
• Burning, by touching the heat exchanger, the motor or
other hot parts of the installation.
• Electrocution from contact with the electrical components
• Electrocution from touching live parts due to short
circuiting of the motor
• Maiming from contact with the rotating fan
• Sucking in or trapping of clothing
• Flying parts of the unit(breakage)
• Fire and explosion caused by the motor (ignition of the
medium).
• Unexpected release of steam
• The accidental release of a medium under pressure,
which presents a risk for burns and other injuries
because of the high pressure.
• Contact with chemicals that are released.
• Touching the fins (when disassembling the element) or
other pointed and/or sharp parts of the installation.

Damage to the equipment

Damage to the equipment can be caused by:
• External forces.
• Corrosion.
• Chemical corrosion.
• Erosion.
• Fatigue.
• Steam shock.
• Pressure / temperature too high.
• Impact load.
• Freezing.
• Transport
• Unexpected release of steam
• Imbalance of the fan (vibrations).
• Assembly errors of the motor installation.
• Assembly errors in the fan installation.
• Overheating of the motor (from overloading)

When applying the ATEX 94/9/EG Guideline

• The safety devices must operate independently of the
measuring and operating mechanisms necessary for

8
 operation.
• The malfunctioning of a safety device must be reported
within sufficiently short space of time, as far as possible
using suitable technical means, in order to minimise the
chance that a dangerous situation occurs.
• As a rule fail safe procedures must be applied.
• The safety devices’ controls must as a rule operate
directly on the control mechanism concerned and not via
the software.
• Failure of the safety device must as far as possible result
in the devices and/or safety devices defaulting to a safe
state.
• Emergency shutdown facilities of the safety devices
must, as far as possible, be equipped with a system that
inhibits switching the equipment on again. A new start
command may only reactivate normal operations once
the emergency shutdown has been deliberately revoked.

For transport see: the Instructions for Transport and Hoisting

If handled incorrectly, danger for physical injury and/or
damage to the equipment exists

Even after switching off the installation the heat exchanger

surface can still be hot.

The unit may only be fed with the mediums stated in the
technical specification sheet.

No fatigue analysis has been taken into account and therefore

the unit should only be used for static load.

A hot medium must NOT be allowed to flow through the heat

exchanger without a cold medium also flowing through the
heat exchanger. This is to prevent damage to the heat
exchanger.

If a cold medium is present in the heat exchanger but is

not flowing whilst a hot medium is flowing through the
heat exchanger, then the cold medium may start boiling
and the heat exchanger will be damaged.
Sudden changes in pressure and temperature must be
avoided.

The values stated in the technical specification sheet must not

be exceeded.

9
 This manual describes other safety instructions than those
safety instructions related to the chapter in which they occur.
The complete manual must therefore be read to be aware of
all safety provisions and measures to be taken when using
this installation.

Danger of freezing. When an idle heat exchanger (filled with

water or a water mixture not of an anti-freeze type) is exposed
to temperatures below zero, the pipes may burst and
deformation of the cover and / or mantle may occur. If there is
a danger of freezing all the medium must be drained from the
heat exchanger.

The fan's electrical components must be earthed to the

air/water cooler housing, except for those components with
double insulation.

The application of a operating switch in the main or driving

current, if safe maintenance of the fan cannot be guaranteed
during normal operation.

The fan is only suitable for transporting non-aggressive air

unless otherwise agreed with the customer (in writing).

Inspect the clearance of the fan before using for the first time
or after maintenance.

After switching off the fan's motor it will take a little while
before the fan stops.

The motors assembled by Klima are suited to working in

environmental temperatures between -20°C en +55°C. For
lower temperatures, if stated on the order, the motor can be
greased with special grease for operating temperatures down
to -40°C. For higher environmental conditions than +55°C it is
necessary to place the motor outside the airflow. A special
motor (suitable for higher temperatures) is also available.

2.2 Protection:
For the protection of others, place the heat exchanger out of reach, in a
closed space, e.g. a boiler house, only accessible to authorized staff
acquainted with the safety requirements applying to the equipment stored
there.
If the heat exchanger is set up close to people, presenting a risk of burns,
insulation of the heat exchanger is mandatory.

10
The user must take care to provide adequate danger signs on exposed un-
insulated parts of the installation, which present risk of burns or other injury
and/or damage.
The fan's drive is protected.
If the cooler is set up close to people, presenting a risk of contact, the must
be shielded in accordance with Euro Norm EN 294. These protective
materials can be delivered by the manufacturer if requested.

11
3 Transport, Storage and Installation Site.

3.1 Instructions for Transport and Hoisting

Use the hoisting facilities/crane hooks on the unit.
These hoisting facilities are only intended for hoisting the air-water cooler
prior to it being assembled to other equipment. The hoisting facilities may no
longer be used to lift and/or move the assembly once the cooler is
assembled with other equipment.
For global hoisting instructions, see Fig. 2.

Fig 2

12
3.2 Transport and Packaging

For transport see: the Instructions for Transport and Hoisting

Always use the appropriate hoisting facilities and equipment.

Respect the prescribed safety norms and regulations.

If handled incorrectly, danger for physical injury and/or

damage to the equipment exists

Any packaging must be removed carefully and disposed of in

an environmentally friendly way.

3.3 Storage:
The unit must always be stored covered and dry.
Long-term storage from 2 to 24 months requires airtight sealing of the unit
adding an absorbent material e.g. silica-gel, or filling with inert gas.
If the ATEX 94/9/EG Guideline is applicable and the element
is filled with a flammable gas when operational then the
device must always be filled with an inert gas during transport
and storage.

Storage longer than 6 months requires inspection of the seals and possible
replacement before the unit is put into operation. For long-term storage each
ventilator’s fan must be turned 90° at least 1x per month. This prevents
bearing damage occurring to the ventilator’s electromotor.

13
3.4 Installation Siting:
General conditions on installation siting / location should satisfy:
• Sufficiently firm and level ground or construction, adapted to the load
that is expected.
• Sound construction and vibration-free installation of the unit.
• Protect if necessary against possible damage by e.g. internal transport.
• See the technical specification sheet for product-related information.
• Protection. For safety, see Chapter 2.2 under “Safety”.
• The location where the equipment is placed must have enough space
for installation, maintenance and cleaning. See the relevant chapters.
• Sufficient light and space for inspection and maintenance.
• The unit is anti seismic to maximum earthquake intensity in accordance
with Eurocode 8.

14
4 Installation
The assembly and start-up must be carried out by a suitably
qualified person appointed by the buyer or by a qualified
contractor.
The installation may only be operated, maintained and repaired
by authorised, trained and instructed personnel.

4.1 Safety Measures and Facilities on the Heat

Exchanger / Installation.
Installation must be carried out in such a manner that all likely risks are
excluded.
To achieve this, the following points must at least be observed:
When installing the air-water cooler one should ensure that the installation
that the cooler is being assembled onto is shut down.

4.1.1 Water side connections.

Refer to the manual for the unit in question for these safety
measures / facilities.

4.1.2 Electrical connections:

If the ATEX 94/9/EG Guideline is applicable then the
manufacturer will under no circumstances bear the
responsibility for the electrical installation of the unit.

Prior to connecting the fan motor one must consult the wiring diagram in the
connector box. One must be very careful specially when connecting
pole reversible motors. Experience shows that many mistakes are
made when installing these motors.
The connection must be in accordance with local regulations. A thermal
safety switch for the motor is built into the electrical circuit of 3 phase motors
for which the setting corresponds to the maximum allowable current as
stated on the motor type plate. If the relay is incorrectly set then any damage
to the motor will not be compensated either by the manufacturer of the
electromotor or by VDL Klima b.v. How the unit is switched on, the thickness
of the wiring, type and settings of the safety measures, must be agreed on in
consultation with your contractor or power supplier. All electrical components
must be earthed, except for those components with double insulation.

15
4.1.2.1 Connection Regulations.
• The electrical equipment must be connected in compliance with Euro
Norm EN 60204-1.
• Local connection regulations (e.g. NEN 1010) must be complied with.
• Dangerous overload must be avoided by the use of over-current limiters
and such like control devices in the electrical system.
• Please refer to the electromotor’s User Manual for the connection
guidelines.

4.1.3 Moving Parts

The installation is equipped with moving parts like an electromotor that

drives a fan.
These moving parts must be shielded. See the Chapter "Protection".

4.1.4 Open Without Danger

If the ATEX 94/9/EG Guideline is applicable and the air-water cooler is part
of the anti explosion protection, then any hatches and/or other parts that can
be opened must only be able to be opened using special tools or by applying
suitable safety measures. Neither may the ventilator(s) used contain any
parts that can be opened without using special tools or adhering to suitable
safety measures.

16
4.2 Preparation for Installation
General:
• Sufficient space for carrying out assembly, disassembly, maintenance,
cleaning, and other activities on the heat exchanger.
• There must be sufficient space on the side of the Air-Water Cooler that
the element is slid in/out of the housing to be able to assemble /
disassemble this same unit without mentionable problems (see fig 3.
The “LW1KD 1140 up to 1143" type cooler is shown here as an
example).
If ATEX 94/9/EG Guideline is applicable then there may be no
sparks, flames, electric arcs, high surface temperatures,
acoustic energy, optical radiation, electromagnetic waves or
other possible sources that could cause combustion in the
direct vicinity of the air-water cooler.

Fig 3
1. Element
2. Housing

• For a heat exchanger with removable covers there must be sufficient

space available around the covers of the heat exchanger to facilitate
problem-free disassembly.
• For heat exchangers with removable covers ensure that there is
sufficient space so that the brushes for mechanical cleaning can be
used without problem. (see fig. 4, distance X).

17
Fig 4
• Remove the plastic caps from the connecting holes.
• Before the heat exchanger can be connected, the tubes must be clean
so that no pollutants can enter the unit.
• Before the heat exchanger can be connected, all tubes must be clean
so that no pollutants can enter the unit.
• The gaskets used must be suitable for the medium, temperature and
pressure to be applied.
• The foundation, construction and mounting must be sufficiently strong.
• Pressure impulses, pulsations and mechanical vibrations in the heat
exchanger should be avoided.

The design specifications stated in the technical specification

sheet must always be adhered to. If the user deviates from
these values, the responsibility rests with him.

18
4.3 Installation
If the ATEX 94/9/EG Guideline is applicable and the element is
filled with a flammable gas then when shutdown the element
must be rinsed with an inert gas prior to disassembly to prevent
air mixing with the flammable gas.

If the ATEX 94/9/EG Guideline is applicable then the safety

inspector must inspect and release the unit after rinsing.

If the ATEX 94/9/EG Guideline is applicable and the air heater

is part of a closed construction then the air-water heater must
be assembled gas-tight and tested with an inert gas. The closed
construction must also include a safeguard against
overpressure.

If the ATEX 94/9/EG Guideline is applicable then the air-water

cooler must be properly earthed.

• The instructions for transport and hoisting must be observed when

placing or moving the equipment.
• When assembling the piping all pipes/flanges must be mounted stress
free to the heat exchanger.
• Pipes must be able to expand. If necessary compensators must be fitted
to the pipes.
• Bolt-nut connections must be clean and lightly oiled.
• Gasket used for the piping: reinforced graphite gasket 1,5 mm.
• The cooler must be mounted, stress and vibration free, to the equipment
to be cooled.
• Any ducts must be mounted stress free to the cooler.

4.4 Tightening of the Bolts

The bolts on units with removable covers must be checked using a torque
wrench.

Refer to the manual for the unit in question for more

information on re-tightening the bolts.

19
5 Start-up
The assembly and start-up must be carried out by a suitably
qualified person appointed by the buyer or by a qualified
contractor.
The installation may only be operated, maintained and
repaired by authorised, trained and instructed personnel.

5.1 Inspection before putting the unit into operation

Refer to the accompanying documentation if inspection, control and/or safety
devices are built in.
As a rule, the safety devices in the system to guard against excesses in
pressure and temperature must be properly adjusted and tested before start-
up. The entire circuit must also be inspected to check whether all
connections have been properly made.
All relevant safety regulations must be observed both before and during
start-up.

The following instructions also apply when starting the fan:

• The suction and exhaust openings must be connected to a duct system.
• The suction and/or exhaust openings must be fitted with a protective
grid in the case of free suction and/or exhaust.
• There must be no foreign objects in the fan.
• Check if all bolts are properly tightened.
• Check that the fan is running freely (manually).

Utmost caution must be taken when inspecting that the fan is

running freely due to the extreme risk for physical injury if the
fan were to unexpectedly go live during inspection.

• Inspect -if applicable- the setting of grids, valves, appendages and

suchlike.
• Check the direction of the fan by applying current briefly.

Danger of maiming from contact with the rotating fan.

• The direction of the fan must be checked based on the directional arrow
on the housing or the motor.

N.B. Never turn on again immediately; always wait until the

fan and/or motor has completely stopped and never stop the
fan by hand.

20
 The unit has been tested by Klima in accordance with the test
pressure stated on the type plate

5.2 Air Inflow

Once all inspections have been carried out the fan(s) may be started and the
rest of the installation may be put into operation.

5.3 Filling and Venting.

For information on filling and bleeding the heat exchanger,

refer to the user manual for the unit used in the installation.

5.4 Re-tightening of the Bolts.

The bolts must be re-tightened after the unit has cooled down for the first
time.
Re-tightening must be done “diagonally” in at least four steps. See Chapter
4.4.

5.5 Inspection after Start-up:

After heating the heat exchanger for a certain period of time, all connections
must be inspected for leakage. In case of leakage, they must be repaired.
See Chapter 7.
Check whether the settings of the measuring and control devices reflect the
expected values.

Check after starting the fan for:

• Vibrations.
• Unusual sounds.
• Current consumption in relation to the motor's maximum allowable
amperage.

If any deviation is observed, the fan must immediately be

stopped and the deviation must be corrected.

If the ATEX 94/9/EG Guideline is applicable then any

deviation may be only corrected where this is not contrary to
the aforementioned guideline.

21
5.6 Shut-Down of the Installation:
To shut down the heat exchanger the supply and return flows of the circuit
must be closed.
Normal operation is done with the on/off switch that is installed in the
installation with an "on" and "off" indication. For remote control, the switch
must be marked with a functional description.
The supplier of a third party must install a work switch enabling the main or
drive current to be switched off.

First, close the supply of hot medium and then, only when the
heat exchanger has cooled to the temperature of the cold
medium, close the supply of the cold medium.

Danger of freezing.
When an idle heat exchanger (filled with water or a water
mixture not of an anti-freeze type) is exposed to temperatures
below zero, the pipes may burst and deformation of the cover
and / or mantle may occur. If there is a danger of freezing all
the medium must be drained from the heat exchanger.

Danger of corrosion.
When the heat exchanger (filled with a medium) is idle for
over 48 hours, all the medium must be drained from the heat
exchanger.
Refer to chapter 3.3 for storage.

22
6 Maintenance and Inspection:
The assembly and start-up must be carried out by a suitably
qualified person appointed by the buyer or by a qualified
contractor. The installation may only be operated, maintained
and repaired by authorised, trained and instructed personnel.

If the ATEX 94/9/EG Guideline is applicable then

maintenance may only be carried out after release by the
safety inspector.

If the ATEX 94/9/EG Guideline is applicable then dust

accumulation must be avoided with regards to excessively
high surface temperatures and/or dust explosions.

The owner must post warnings against environmental factors

that can pose a threat. Preferably using pictograms and/or
text.
The owner must enforce the wearing of protective clothing
and gloves by the personnel wherever necessary.

Maintenance, cleaning etc. must only take place on a

shutdown unit.

Special measures apply to a shutdown unit. See Chapter 5.5.

Depending upon operating conditions, maintenance should be carried out

every 1000 hours of operation or minimally 1x per year.

6.1 Inspection
To guarantee a high degree of operational reliability regular inspection of the
equipment by the maintenance and operating personnel is necessary for the
following:
• Leakage.
• Pressure and temperature within the permissible limits.
• Presence of air in a system where a liquid medium is being used.
• If applicable, the presence of adequate condensate drainage.
• Torque of the bolts.
• Fouling of the fan and or motor and/or the heat exchanger (drop in
capacity).
• Vibrations / strange noises.
• General condition of the installation.
• Corrosion.
• Functioning of the safety devices.

23
• Temperature of the bearings max. 95°C (ambient temperature + 40°C).
• Temperature of the motor max. 135°C (ambient temperature +80°C).
• Torque of the bolts.
• Fins surface dirtied, damaged or blocked.

6.2 Cleaning the Air-Water Cooler.

Description of maintenance:
Maintenance, cleaning, adjusting etc. must only take place on a shutdown
unit. If this is not possible then these activities must be able to be carried out
without danger.

6.2.1 Disassembly of the Air-Water Cooler.

If the ATEX 94/9/EG Guideline is applicable then parts may
only be disassembled or replaced by and at the manufacturer.

24
6.2.1.1 Disassembly centrifugal fan.
The electromotor is mounted on a mounting plate and then the fan is
mounted on the motors' shaft. Motor, fan and mounting plate are attached
to/on the housing as one unit. Disassembly of the fan or motor is therefore
done in reverse order. Use of a tackle here is advised (See Fig. 5).

Fig 5
1. Housing 5. Fan
2. Electromotor 6. Bolt
3. Shaft 7. Nut
4. Mounting Plate

25
Fan, fitted with a clamping bush.

Loosen all Allen screws. Place one or two screws in the disassembly hole(s).
Tighten the Allen screw(s) and fan and bush will come loose (See Fig. 6).

Fig 6

1. Electromotor
2. Fan
3. Clamping Bush
4. Allen Screw
5. Disassembly Hole
6. Assembly Hole

26
Fan, fitted with drawing plate.

Disassemble the locking plate. Then assemble a drawing plate to the boss
and pull the fan off the shaft by turning the central bolt (See Fig. 7).

Fig 7

1. Locking Plate
2. Drawing Plate
3. Boss Part
4. Fan
5. Shaft
6. Central Bolt
7. Locking Nut

6.2.1.2 Disassembly Axial Fan.

For more information on the axial fan, refer to the manual „KLIMA AXIAL
FAN“.

27
6.2.1.3 Disassembly of element from housing

This chapter contains a description of the disassembly of the

element from the housing. Refer to the manual for the unit in
question for disassembly of the element.
(See Fig. 8 for the parts. The example shown here is cooler
type “LW1KD 1140 up to 1143.)

If the ATEX 94/9/EG Guideline is applicable and the element is

filled with a flammable gas then when shutdown the element
must be rinsed with an inert gas prior to disassembly to prevent
air mixing with the flammable gas.

If the ATEX 94/9/EG Guideline is applicable then the safety

inspector must inspect and release the unit after rinsing.

Fig 8
1. Housing
2. Element
3. Gasket
4. Flange frame
5. Gasket
6. Bolt

28
Proceed as follows:
• Close the supply and return flows of the circuit.

First, close the supply of hot medium and then, only

when the heat exchanger has cooled to the
temperature of the cold medium, close the supply of the
cold medium.
• Wait until the heat exchanger has cooled down!
• Drain the medium (vent open)
• Where necessary mark the position of the parts to be disassembled.
• Remove the supply and return pipes and disassemble (remove) the
cover.

When disconnecting or disassembling the heat exchanger it is

possible that residual medium may seep from the heat
exchanger. To avoid damage to underlying parts or floor it is
necessary to catch the medium in, for example, a drip tray.

6.2.2 Cleaning the Air-Water Cooler.

6.2.2.1 Cleaning the element

Refer to the manual for the unit in question for information on

cleaning the element.

6.2.2.2 Cleaning the heat exchanger's air side.

Proceed as follows:

• Using a vacuum cleaner.

• Using compressed air blow in the opposite direction to the normal
airflow. Take care that the fins do not deform.

The element must be slide from the housing to carry out this task.
Refer to “Cleaning the Element” for further cleaning of the element.

6.2.2.3 Cleaning the Filters.

If any filters are built in these must be replaced or cleaned when they reach
their replacement date.

6.2.2.4 Cleaning the Housing.

If the housing needs to be cleaned care must be taken to avoid dirt falling on
or into the equipment being cooled.
To do so the housing is disassembled prior to cleaning.

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6.2.3 Assembly of the Air-Water Cooler.

6.2.3.1 Assembly Centrifugal Fan.

Fan, fitted with a clamping bush.
Clean and degrease all bare surfaces. Position the bush in the correct
position in the shaft and hand tighten the Allen screws in the assembly
holes.
Slide the boss with the bush on the shaft. Line them up.
Tighten the Allen screw completely.
Firmly tighten the Allen screws one by one.
Fill all holes with grease.
(See Fig. 6).

Fan, fitted with drawing plate.

Slide the fan onto the shaft (note the pin) and attach the fan using the
locking plate and nut and lock the nut.

Assembly of the fan/motor with mounting plate to the housing

Assembly of the fan/motor with mounting plate to the housing must be done
carefully to avoid damage to the fan. Mind the position of the junction box
during assembly and check that the fan is running freely before tightening
the bolts. (See Fig. 7).

6.2.3.2 Assembly Axial Fan.

For more information on the axial fan, refer to the manual „KLIMA AXIAL
FAN“.

6.2.3.3 Assembly of the Element in the Housing

• Make sure that all gasket faces are clean and undamaged.
• Always use new gaskets.
• Place the gasket.

6.2.4 (Re)pressurizing the Heat Exchanger.

If the ATEX 94/9/EG Guideline is applicable and the element is
filled with a flammable gas then prior to start-up the element
must be rinsed with an inert gas to prevent air mixing with the
flammable gas.

If the ATEX 94/9/EG Guideline is applicable then the safety

inspector must inspect and release the unit after rinsing.

For further information on (re)pressurizing the heat exchanger

refer to the user manual for the unit used in the installation.

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7 Malfunctions
7.1 Identification and Correction of Malfunctions.
If the ATEX 94/9/EG Guideline is applicable then only apply the following
instructions where this is not contrary to the aforementioned guideline.
Malfunction Possible cause
Heat There is air in the
exchanger installation.
has
insufficient
capacity.
The operating conditions
deviate from those stated in
the technical specification
sheet.
The heat exchanger is
fouled.
The connections have been
interchanged.
The fins are fouled and/or
damaged.
Imbalance of the fan
Fan malfunctioning /
damaged
Assembly error(s) in the
motor installation.
Assembly error(s) in the
ventilator installation.
Overheating of the motor
(from overloading)
Insufficient stability
Fan running in reverse
direction.
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Correction of the malfunction
Inspect the pipe work for
possible air pockets.
- Remove any air in the liquid.
- Then bleed the heat exchanger
thoroughly and if necessary fill
up the medium.
Adjust the operating conditions.
Clean the heat exchanger (see
Chapter: Cleaning the Heat
Exchanger).
Correct the connections.
Clean and/or realign fins.
Resolve the imbalance
Replace fan
Correct assembly error(s) in the
motor installation.
Correct assembly error(s) in the
ventilator installation.
Resolve the overload
Optimize stability
Change motor connection
according to description in
terminal box.
Malfunction Possible cause Correction of the malfunction
Heat Gasket faces dirtied or Clean gasket faces. In case of
exchanger is damaged. damaged gasket faces, contact
leaking your supplier.
Defective gasket. Replace gasket.
Bolt tightened insufficiently. Check joints and re-tighten
carefully.
Defective tube. Contact your supplier.
The operating conditions Adjust the operating conditions.
deviate from those stated in
the technical specification
sheet.
External forces. Assemble the installation to be
stress-free.

7.2 Safety Measures / Facilities:

Facilities must be provided (ladders, steps, cat ways etc.) to be able to safely
reach all places to make adjustments and to perform maintenance and
repairs.

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8 Customer Service:

8.1 Ordering Spare Parts:

When ordering spare parts it is important to provide the correct data.
One should at least state:
• Project and order number.
• Complete description of product / type (See Technical Specification /
type plate.)
• Required part (for name see documentation).

8.2 Complaints Procedure:

For complaints, requirements, or imperfections of the unit, please contact
Klima, or your supplier’s, service department.

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