Anda di halaman 1dari 40

AIR HANDLING UNITS USER MANUAL

www.systemair.com

CONTENTS
PREFACE............................................................................................................................................... WARRANTY ......................................................................................................................................... ACCEPTING DELIVERY ........................................................................................................................ DELIVERY, HANDLING AND STORAGE .............................................................................................. Delivery and handling................................................................................................................. Storage ........................................................................................................................................ ASSEMBLY........................................................................................................................................... Assembly of the AHU ................................................................................................................ Assembly of sections.................................................................................................................. INSTALLATION ................................................................................................................................... Placement.................................................................................................................................... Air duct connections................................................................................................................... Water connections...................................................................................................................... Tubing connections..................................................................................................................... Condensation drain pans............................................................................................................ Hot-cold water coil ..................................................................................................................... Steam coil ................................................................................................................................... Direct expansion type cooling coil............................................................................................. ELECTRICAL CONNECTIONS ............................................................................................................... Electrical connection .................................................................................................................. Assembly of automatic control field elements ......................................................................... CONTROLS AND INITIAL START-UP................................................................................................... OPERATION.......................................................................................................................................... Water circuit connections .......................................................................................................... Air filters ..................................................................................................................................... Heating coils ............................................................................................................................... Cooling coils................................................................................................................................ Heat recovery system with coil.................................................................................................. Rotary type heat exchangers...................................................................................................... Spray humidifiers........................................................................................................................ Steam humidifiers....................................................................................................................... Fans ............................................................................................................................................. Recommendations before start-up ............................................................................................ Water conditioning ..................................................................................................................... Electrical heaters ........................................................................................................................ Additional checks........................................................................................................................ Start-up Procedure...................................................................................................................... MAINTENANCE ................................................................................................................................... Tension of belts .......................................................................................................................... Maintenance of belts ................................................................................................................. Wheel adjustment ...................................................................................................................... Damper section........................................................................................................................... Filter section ............................................................................................................................... Coil section.................................................................................................................................. Fan section .................................................................................................................................. Motor section.............................................................................................................................. SAFETY................................................................................................................................................. MALFUNCTIONS.................................................................................................................................. 2 3 3 4 4 4 7 8 8 8 9 9 10 13 14 14 16 16 17 17 17 19 22 22 22 22 23 23 23 23 24 24 24 25 25 25 26 26 28 31 31 32 32 32 33 34 35 36 37

PREFACE We thank you for choosing the SYSTEMAIR air handling unit manufactured by SYSTEMAIR. The purpose of this document is to give users of the SYSTEMAIR Air handling unit information about equipment components and their properties, as well as information on transport, installation, start-up, operation, and maintenance. This document does not list the maintenance conditions required to extend the equipments useful life and increase its reliability in long lists that will exhaust the reader. Reliable and long lasting operation can only be achieved through the service of a competent engineer or a technician employed by the authorized maintenance firm. If he or she wishes to, the client can receive assembly, annual maintenance, and renovation services for the installation and operation services for their equipment. WARRANTY The SYSTEMAIR Air Handling Unit guarantees the conditions that are taken as understood and accepted by the customer. SYSTEMAIR guarantees the good quality of the equipment it manufactures. It undertakes to provide repair and replacement services and to make replacements and repairs as soon as possible in faults resulting from materials, in construction faults, and in structural faults that may arise even though the equipment is operated in compliance with conditions specified in the user manual, during the warranty period. SYSTEMAIR does not assume responsibility for direct damages arising from not being responsive. The functions that are within the scope of the warranty: Provided that the considerations that require attention regarding delivery, storage, handling, installation, operation, maintenance, safety and malfunctions are followed; malfunctions that are on the part of the manufacturing company regarding all mechanical and electromechanical components; malfunctions that are on the part of the manufacturing company regarding all electrical components inside the device are covered by the SYSTEMAIR warranty for 2 years from the date of delivery to the customer. Note 1: The warranty becomes invalid in the event that repairing the device without written authorization of the manufacturer or replacing components with those that are not original. Note 2: The warranty becomes invalid if the filters that are inside the device delivered by SYSTEMAIR are not replaced by SYSTEMAIR.
3

After having been tested at the main factory defected component(s), based on the type of malfunction, may be replaced or sent with a technician for assembly/repair. If the cause of malfunction falls within the scope of the warranty, any transportation and replacement costs regarding the device and the technician are assumed by the manufacturer, otherwise these costs should be paid by the customer. ACCEPTING DELIVERY Following the equipments arrival at your workplace and before signing the document of delivery, examine the equipment thoroughly while it is still on the vehicle; in case of any damages take note of said damages on the delivery document and in order to be able to make a claim, notify the final delivery firm responsible for the equipment and the insurance company, if any, by registered mail as soon as possible. Please notify SYSTEMAIR of the issue. In case of a problem, we recommend that you document the problem by taking photograph before unloading your equipment from the vehicle and have the driver prepare a report of damages. DELIVERY, HANDLING AND STORAGE 1. It must be ensured that the truck used for delivery will deliver the equipment in a safe manner. Special attention should be given to usable width, length, and height of truck bodies and a vehicle loading plan should be requested from SYSTEMAIR when necessary. Care must be taken to ensure that the truck is appropriate for the unloading site (The trucks maneuverability in the unloading site should also be taken into consideration.). 2. Units should be bound to the truck frame with thick ropes. Steel ropes should not be used for binding. For large units, it must be ensured that the units bottom casing is firmly fixed on the truck body. 3. At the points where the rope contacts the unit, wooden wedges, cardboard or other suitable material should be placed between the rope and the unit. 4. Before delivery, gaskets from wood, cardboard polystyrene or other suitable material should be placed between the units on the truck body. 5. Units should not be stacked during delivery, handling, or storage. 6. Care must be taken to ensure that the units are protected from the elements.
4

They should be covered with tarp. 7. Do not use coil connections, dampers or shafts (or any extended piece other than the main housing) as anchor points while carrying the unit to the platform. Use only the main housing to carry the unit to the platform. 8. Unit must not be tipped or overturned during handling or lifting. 9. During the removal of the units from the truck with a forklift, care must be taken to ensure that the load is distributed evenly on the forks and that the forks do not hit the panels or the base housing.

INCORRECT Figure 1 : Carrying the Sections

CORRECT

10. During the removal of the units from the truck using a crane/winch, care must be taken to ensure that the load is distributed evenly and steel rope should be used as sling. The places where the unit comes in contact with the rope should be protected. In the unloading of large units, a frame with hangers on all four corners as well as lock beams should be used to avoid damaging the equipment.

Figure 2 : Hauling the Sections

11. Do not pull, push or lift the AHU with the coil connections, dampers, shafts or the other parts of the unit.
5

Figure 3 : Do not carry from coil connections

12. In case another lifting method is used, proper lifting blocks should be placed underneath the unit to facilitate lifting. 13. Care and measures should be taken against severe bumps during the lifting or placing of the unit. 14. In case the units are dragged, pipe rollers or similar materials should be used or the unit should be slid on smooth surfaces.

Figure 4 : Air Hangling Unit Leg Detail

15. Care must be taken to ensure that all existing procedures and guidelines regarding loading and unloading are applied.

Storage 1. Care must be taken to ensure that the unit is carried safely particularly as it arrives at the work area on the transport vehicle. It must be ensured that the unit is shipped under a cover in wet weather. The units should be visually inspected against any damages incurred during transport. If damages have been found, please call your insurance company and transport company immediately. 2. While accepting the delivery of units in the field, check against the delivery note whether the pieces shipped separately from the unit (bag filters, highly sensitive air filters, electrical pumps) and fittings required for the assembly of main units (like screws, bolts, gaskets, etc.) have been sent in a separate box. Store these materials in a safe place. 3. Your unit will generally be wrapped within cling film when shipped out of our factory. Since your equipment will be at risk of corrosion in case water seeps inside the cling film during delivery and storage in the assembly area, measures should be taken to avoid this. Since the water left between the unit and cling film will combine with sunshine to create a corrosive effect, the cling film should be removed rapidly, the unit should be dried in natural air conditions and re-wrapped with cling film. If the dried unit can be stored in a secure and clean environment, it does not need to be wrapped in cling film. 4. Care must be taken to ensure that units are stored in a covered area without removing their packaging when storing them until the time of installation. 5. Care must be taken to prevent exposing unit sections which you carry to the field or assembly area to the elements, and to avoid excessive dust and contamination in the environment. Since air handling unit sections are not familiar to other assembly crews, they can be inadvertently used as toilets, framing or storage area for safe hand tools or valuable materials. These functions must be absolutely disallowed for work safety. 6. Units should not be stacked. They should not be walked on or loads placed on them. Panels, profiles or similar materials that can damage the units should not be propped against the units. 7. Units should not be placed in areas of heavy foot/vehicular traffic. Units extended pieces such as coil connections and damper shafts should be protected from the elements and from damages. 8. The units should be placed on wedges in the storage area. The units should be placed onto the base formed in the field assembly area.
7

ASSEMBLY Assembly of The AHU While the unit can be delivered in an assembled state, it can also be delivered in a disassembled state to facilitate transport, handling, and space allocation. Some sections may exceed the legal shipping dimensions of transport vehicles. When the unit is delivered in the form of disassembled sections, it should be assembled following the correct procedures. Assembly of sections a) Use a water gage to make sure the base is level. Your unit must be placed on an even surface. b) Sections should be placed in sequence, in the direction of air flow. c) Make sure the mounting site is clean and free from grease and oil. d) Wall clearances at the mounting site should be as specified below. e) The gasket that was sent for the section connection should be placed between the sections. Assembly should be made using bolts, nuts, and washers. (Figures 5-6)

Figure 5 : Flexline Section Connection


8

Note: Sections must be placed side by side before connection. Under no circumstances shall tools like vices be used during assembly to bring the sections closer.

Figure 6 : Air Handling Unit after assembly

INSTALLATION Placement To avoid problems, units should not be removed from their packages at during transport, and only opened when in their final position at the time of installation. Care should be taken to ensure that the surface on which the unit will be placed is capable of bearing the weight of the unit. The required clearances should be applied while placing the unit. The recommended clearances are specified below.

Figure 7 : Placement Clearances


9

Shock Absorbing Legs: The unit should be supported with shock absorbing legs before its final placement. (auxiliary part) Shock absorbing legs can be mounted with nuts as shown below.

Figure 8 : Shock absorbing legs

Air Duct Connections Ducts should be attached to air conditioners with flexible connections with a minimum width of 75 mm, made of flexible material. Connections should not be tight, and connectors should remain flexible so ducts will not be affected by vibrations after the installation.

Figure 9 : Air duct connections

To prevent excessive pressure drops and to guarantee optimum performance for the unit, duct connections should be made as shown in the above figure.
10

Tube supports shall include anti-vibration system.

Warning: Do not remove ducts during the units operation. The unit must not be started before the installation of the ducts.

Duct connections to damper in units should be made according to damper dimensions. Air leakage and unwanted resistance in front of the damper can arise from improperly made connections. These lead to improper air flow and pressure. Dampers designed by SYSTEMAIR are aluminum and mounted with hidden gear mechanisms. In case ducts are mounted on dampers on the air handling unit, there are available flanges suited to duct connection on the damper. Flanges on the damper should be used for flexible connection of your duct. Connections should be made without exerting the duct weight on the damper. The gear mechanism within the damper is concealed within the profile the drive shaft comes out of. Therefore, duct connections should be made as in the figure to prevent fittings (screw) from damaging the gear and locking the system. Damper flaps must not be moved manually. The motion must be effected by rotating the drive shaft.

INCORRECT Figure 10 : Damper Connections


11

CORRECT

As can be seen in the duct connection in Figure 9, duct weight should not be put on the air handling unit. Otherwise the panel (top panel) can be damaged due to the weight of the duct. Thus bearing elements should be used to bear the weight of the duct. Intakes of fresh air dampers in air handling units used in outdoor environments should be protected with hoods to prevent rain entering the unit. The inside of the hood should also be fitted with wire mesh to prevent foreign materials from entering the unit.

Figure 11 : Wire mesh

12

Water Connections Warning: Care should be taken to ensure that water connections are empty during placement and installation. After water connections are filled, antifreeze should be added in quantities indicated in the design specifications.

Figure 12 : Sample installation diagram

13

Tubing Connections All coils are manufactured with tubes extending outward and except for units that are manufactures in a disassembled state, plastic seals are placed around these tubes in order to prevent leakages from the air handling unit. Similarly the drain pan is manufactured to extend outward from the mounting base by a standard amount. Water and steam coils are externally connected as a standard. Tubes should be mounted to coils in a way that allows flexing. Installing the tubing While the tubing is being installed, care should be taken to ensure that the tubes that will supply the coil are connected without damaging the coils. - The entire tubing assembly should be carried independently of the coil. - All connections should be made to allow thermal expansion of pipes, and not to put strain on coil connections. Otherwise, the coil will be damaged. To this end, flexible connections should be used to absorb the vibration and expansion of the tubing between tubes and coils. Condensation Drain Pans Cooling sections are equipped with single or double discharge drain pans. Their drainage tubes should be fitted with siphons. An independent drainage system is recommended for drain pans with multiple discharges. The measurement H must always be larger than the bottom or top pressure generated by the fan. Drainage outlets should be discharged to the independent drainage works of the facility. Note: The siphon must always be filled with water before starting the unit to prevent air leaks or suction.
14

Figure 13 : The Drainage System

The height, R, should be at least equal to the formula value R= P + X (mm) 10

P= Fan Static Pressure (Pascal) X= Base Thickness of Main Unit (mm)


Figure 14 : Ball siphon

1234567891011-

Rubber piece Connecting element Nut Gasket Long bracket Water pipe Short bracket Rear pressure valve Valve main cover Valve ball Pressure lid

Figure 15 : Ball siphon assembly details


15

Hot - Cold Water Coil Air discharge from the tubing system should be at the tubing level and not the coil level. Any discharge at the coil level will only discharge the coil. If your unit operates with a fresh air intake or if the air temperature drops below +4C during the periods when you do not operate your unit, measures should be taken to prevent freezing of the coil. Be sure to contact the SYSTEMAIR After Sales Services Department regarding the issue. Note: It is recommended that thermometers and manometers be placed on water intakes and outlets of coils to enable flow measurement in the coil as well as possible adjustments. Complaints regarding coil capacity will only be taken into consideration after the instructions above have been fully applied. Steam Coil The most important point for steam coils is correct drainage. If the condensate water can not be removed properly, it may lead to knocking and resulting malfunctions in the coil. Condensate drainage pipes should be below the coil level. An air discharge valve should placed as close to the coil as possible. Place a steam trap or thermostatic relief valve on all outlet pipes of steam coils (as per the recommendations of the relief valve supplier).

Figure 16 : Lock Connection


16

Hot and cold water coils should be connected so that the hot and cold water intakes are at the bottom and hot and cold water outlets are at the top. In cooling coils, the water should be at the lowest possible temperature and the water intake should be at the bottom and the water discharge should be at the top. Direct expansion type cooling coil One of our authorized technical service points should be consulted to make tubing connections for DX type coils correctly. Note: Defrosting will be adjusted to the units operating conditions to prevent frosting that will damage the drainage and to provide protection against the damages resulting from water. If the installation has not been made according to the proper procedures, SYSTEMAIR will accept no responsibility. ELECTRICAL CONNECTIONS All electrical connections within the unit should be made with flexible cables. It is recommended that all cables passing through the air handling unit be equipped with cable protection. The power supply must be made within the following limits in case of malfunctions: Voltage tolerance limits: 10% Frequency tolerance limits: 2% Ground connection should be made with the connector with the smallest cross-section as indicated in the electrical diagram. The supply switch should be one level higher than the switch used on the unit. Cross-sections of supply cables should be determined by taking into account the voltage drops that may occur depending on distance. Unless clearly permitted by SYSTEMAIR, more then one system part (pumps, coils, etc.) should not be placed on one system, to avoid problems caused by microprocessor control. Since they are sources of electromagnetic potential, signal control cables should be kept apart from high current cables, power cables, and other cables. Especially in outdoor units, in order to avoid damages resulting from the voltage and electrical supply line, direct frequency strains on electrical equipments should be avoided and sudden spikes should be prevented in charging. Since the flow varies between systems, unless there are special instructions, passing a cable through the unit or drilling a hole in the unit is not recommended. All other electrical connections should be made in the same way.
17

We recommend that a protective element be placed on the electrical circuit, in case of short circuit, overload, or double phasing. (Thermal, Phase protection relay, fuse, etc.) Warning! Electrical connections must be made by a licensed electrician.

Warning!

Care should be taken to ensure that the grounding circuit is healthy.

The following electrical connection diagrams are for bipolar, 2/4 polar, 4/8 polar, 4/6 polar, and star delta connected motors.
2/4 and 4/8 pole connection CONNECTION 2/4 and 4/8 poles (DAHLANDER) 4/6 pole connection CONNECTION 4/6 poles Y- connection CONNECTION Y-

A M L V

: : : :

On Off On low speed On high speed

V1 : Auxilliary high speed on T : Time relay T : Thermal relay

18

Final Checks Before initial start-up, it is recommended that you check whether all of the above steps have been applied. The values of the accessories on the electrical drive panel of the motors, such as thermal contactor, signal lamp, and switch are proper. The direction of rotation of the fan is marked on the fan. If it rotates in the opposite direction, motor pole connections should be checked. After the motor is started, the current and voltage should be measures, and checked against rated values. Note: If the switch of the main unit is off, all connections must be checked before turning on the power to the unit. ASSEMBLY OF AUTOMATIC CONTROL FIELD ELEMENTS Mounting the Freeze Free Thermostat The freeze free thermostat is mounted between the heater and cooling coil and on the air intake surface of the cooling coil to prevent freezing of the coil in cold weather. The sensor probe of the freeze free thermostat must be mounted such that it will sense the entire surface of the coil. Hangers should be used at the bending points of the thermostat sensor, in order to prevent breaking the capillary tube. The sequence must definitely be as follows: first the heater, then the cooler and finally the drop eliminator. If the cooling coil is placed first, there is no protection against freezing and the cooling coil will freeze. Mounting the Mixing Section Damper Connection The exhaust must be adjusted according to fresh air to mixing damper return air and fresh air ratios. Flow Regulation with Frequency Converter If flow control with frequency converter is to be implemented in an air handling unit, the fan to which the frequency convector is to be connected should preferably be rare blade fans. This is because the operating points of fans with a large number of fans are unstable and unsuited to variable air volume applications. Mounting the Temperature and Humidity Sensor The temperature sensor is mounted close to the return fan. The humidity sensor should be placed in the region of return air, on the unit panel.
19

Mounting the Differential Pressure Switch The differential pressure switch is mounted in the section that is to be controlled through the microprocessor by reading the ambient pressure. Thus, the microprocessor creates the correct positive and negative pressure conditions by taking the required conditions into consideration. The pressure differential between the controlled room and the reference environment is checked with a 2 flexible transparent tube of diameter 4/7. The pressure switches can be places in several ways. These different layouts can be seen in the following figures. - Free ended tubes should be connected to the positive socket of the pressure key in the section. In case of negative section pressure, a ledge of few centimeters should be placed on the wall or ceiling. - The pressure switch should be placed at least 2 m above the floor, thus the best protection against external influences and impacts will be assures.

CORRIDOR

HALL

20

CORRIDOR

HALL

CORRIDOR

HALL

SUSPENDED CEILING

Figure 17 : Positioning the Differential Pressure Switch

21

CONTROLS AND INITIAL START-UP Water Circuit Connections Make sure that intakes and outlets of hot and cold water supply lines are hermetically connected. Check whether all fluid supply tubes are reinforced with manual cut-off valves and that these cut-off valves are open. Check the condensation pan discharge; if it has a spigot, make sure the spigot is open. Make sure the humidifier supply lines are connected to the main water supply. (Make the check by cutting off the main cut-off valve outside the air handling unit.) Electrical Power Supply Checks Check the three phase and ground connections. Check the power input voltages and frequencies within the limit of +/- 10%. OPERATION Water Circuit Connections Check whether the servomotors have been installed correctly according to their open and closed states. Check stroke settings. Check whether the flaps close fully. Check whether the flaps open and close fully upon demand. Check the spring return function in case of power failure. Air filters Make sure the correct filter has been installed. Check the position of the filter on the slides with respect to the direction of air flow. Fill the U tube manometer with liquid (water). Sensitive filters are shipped separately so they will not be contaminated during transport and start-up. Do not install them before the unit is cleaned by operating the fan. Adjust the pressure stat and filter pressure indicator (if any). Prefilters (reusable) The density of dirt should be checked by examining the pressure drop manometer. When the pressure drop reaches the figure specified for the filter (recommended
22

pressure is 250 Pa), the filters should be changed. Air filters should be cleaned depending on the results of the checks. Before changing the filters, the tightness of the frames should be checked and they should be resealed if necessary. The filter section should be cleaned. Care must be taken to ensure that no dirt remains in front of the filters. Bag Filters The density of dirt should be checked by examining the pressure drop manometer. When the pressure drop reaches the figure specified for the filter, the filter should be changed. (Unless bag filters are reusable, it is not recommended that you use them again.) Note: During initial start-up of the AHU, bag filters should be protected against the accumulated dust and dirt within the unit. Heating Coils Check connections against the project. Check for leakages in connections. Check whether the freeze-free thermostat has been placed and set correctly. Cooling Coils Check connections against the project. Check for leakages in connections. Check whether the PVC alfon (with globe valve) has been placed properly. Check whether the drop eliminators at the rear of the cooling coil have been placed properly (they may have shifted in place during transport). Heat recovery system with coil Check whether the system has been filled with the correct glycol. Check the rotating direction of the pumps. Take another look at the section containing the heating and cooling coils for other controls. Rotary type heat exchangers Check whether the direction of rotation of the rotor is correct.
23

Check the operation of the brake. Check and adjust the number of revolutions. Spray humidifiers Check connections against the project. Make sure the drop eliminators at the intakes and outlets have been positioned correctly. Make sure the pads (if any) have been placed on the slides correctly. Check whether the siphon has been placed correctly. Fill the water tank. When the water reaches the level indicated on the unit, the float valve should be shut off (5 mm below the funnel shaped overflow). Check whether it is functional. Check the direction of rotation and consumption of the pump. Check whether it conforms to the specifications on the label. Steam humidifiers Check whether the steam supply pipe has been mounted correctly. If the length of the tube is over 10 meters, an additional steam trap should be used. Check whether the filter has been installed. Mount the condensate water discharge pipe with or without pressure (depending on type). If pressure is low, install a special siphon for discharging the condensate water. Fans Remove the clamps placed on vibration absorbers for transport. Check whether the fan moves freely without being hindered by the body, flexible connections or cables. Rotate the fans manually to check whether they turn easily. Make sure there are no foreign substances in the fan section. Take particular care for connections of reversible polarity and adjustable speed electromotors. Check whether the intake damper (if any) works correctly. Check the tightness and adjustment of the belts, and readjust if necessary. (check the related chapter in the maintenance section). Check electrical connection and rotational direction of the fan.
24

Recommendations Before Start-up In cases where spring vibration dampers are used, care must be taken to ensure that spring fixing elements are removed. Some unit elements may slacken due to vibrations occurring during transport. Check all screws, nuts and especially rotating parts (wheels, bearings, etc) for tightness. Take care to ensure that cast body roller bearings are well lubricated. Take care to ensure that no foreign matter exists within the unit and ventilation duct and that there is no obstacle blocking the entry/exit of air. Note: In case the contractor adds another humidifier to the system, this should be done in such a way that it will never cause splattering of water or cause deposits (such as water conditioning salts etc.) on the coil . (Particularly in ultrasonic humidifiers) Water conditioning Unconditioned or improperly conditioned water causes mould, sediment and sludge, leading to corrosion or abrasion. An expert trained in water conditioning should be consulted to learn the method to be used for conditioning. The damages occurred due to corrosion are not covered by the warranty. SYSTEMAIR does not accept responsibility for damages that may result from inadequately conditioned or unconditioned water. Electrical Heaters Electrical heaters used in air handling units are used to maintain indoor temperature with fixed air flow and keeping the temperature at the desired value with cascade control. In variable air volume air handling unit applications, the application of cascade control that alters the number of resistances in the circuit can lead to dangerous results. This arises from the fact that, since there is no change in the power of each resistance, even if some of these are taken offline with the cascade breaker, the resistances that are online will overheat due to low volume, becoming incandescent and creating fire hazard. For this reason, cascading of the resistances used in variable air volume air handling units must be accomplished through serial connection of different numbers of resistances for each stage, or through an electrical control element which controls the powers of all resistances simultaneously.
25

Additional checks The condensation drain pan should be filled. The connections of the humidifiers with other units and their tightness should be checked. Air filters (bag, panel) should be installed. Care should be taken to ensure that filters have been fixed to the carcass frame correctly. The filtration material of filters should be correctly placed (the plain side should be opposite to the direction of flow). The differential pressurestat, if any, should be adjusted. Start-up Procedure After all the checks specified above have been completed, the unit may be started up according to the following procedure. a) The measurement of the voltage in the input installation and the current drawn by the motor (Amp.) should be compared to the values on the rating plate. Note: The motor power in our unit has been calculated with a predetermined safety margin. Compare the load drawn by the motor to the predicted load. b) STATIC EXTERNAL TEMPERATURE OF THE AIR HANDLING UNIT INSTALLATION SHOULD MATCH THE SPECIFICATIONS STATED IN THE ORDER. If there is a difference the design flow, pressure and motor values will be different. In this case, be sure to contact our technical service department. Note: The number of belts must always corresponds to the number of wheel channels. Note: Flow varies with the fan speed; pressure varies with the square of speed and power drawn varies with the cube of speed. If the system pressure is lower than the planned value, the flow speed with rise with the power drawn, which will cause overloading of the motor. This is important especially in forward inclined fans. For reverse inclined fans, the drawn power curve is almost identical to the return speed curve. Flow rate and rpm is directly proportional. V2 /V1 = (n2/n1) Ht2 / Ht1 = (n2/n1)2 Total pressure is proportional to the square of fan rpm. Pv2 / Pv1 = (n2/n1)3 The power drawn is proportional to the 3rd power of the fan rpm.
26

Start-up of Spray Humidifier Air Handling Units After the fan comes online and a check has been made to confirm air flow, the humidifier pump has to come online. If the humidifier pump comes online when there is no air flow, the drop eliminator can not perform its function completely and water will pass to other sections. Water flow from sprays should be observed a short time after the humidification pump has come online. If it is not observed, the direction mark on the humidification pump should be marked, and a check should be made to ensure that the pump is rotating in the right direction. A check should be made to see whether the specified amount of water is present in the humidification water pool. If water still does not come, the SYSTEMAIR After Sales Services Department should be contacted.
Caution! Do not operate the pump without water.

Start-up of Steam Humidifier Air Handling Units After the fan comes online and the unit is checked to see there is air flow, the operating signal must be sent to the steam humidifier controller. It will continue to operate proportionately/onoff until the humidity values set through the control card have been reached. If an error signal is seen on the control card display, it is recommended that you contact SYSTEMAIR Technical Service. The cleanliness of steam outlets should be checked periodically (80 hours). Start-up of the Rotary Type Heat Recovery Unit During installation, it is recommended that the heat recovery system be checked first. The distance between the frame of the rotor and wall surfaces should be equal and the rotor should be able to rotate. Afterward, the motor is shut off and the direction of rotation of the rotor is checked against the direction of the arrow on the unit. After it has been ascertained that the distances between the rotor frame and wall surface are the same, the hermetic bands around the rotor are adjusted by slowly rotating the rotor. After this step, the rotor is operated at maximum speed and the current drawn from the drive motor is checked. Finally, the tension of the belts and the operation of the spring loaded motor support is checked.
Warning! Since the rotor is one of the most expensive units within the air handling unit, its incorrect and incomplete installation, and incorrect handling will lead to costly repairs, thus great care should be taken and rules should be followed. If the rotor does not rotate due to a problem with the alignment made during installation, the rotor should be centered using a central screw. If problems still continue, the SYSTEMAIR After Sales Services Department should be contacted.
27

MAINTENANCE It is recommended that the following simple safety guidelines be kept in mind during maintenance of the AHU unit. Care must be taken to ensure that the technician conducting the maintenance; 1) Has been isolated against electricity (with isolation plates, rubber material, etc.). 2) He does not enter the unit until the fans are at a complete standstill. 3) He does not enter the unit until power is cut from the entire electrical installation. Similar maintenance is applied on many ventilation units. The following paragraphs contain the necessary basic information. The frequency of maintenance varies with the cleanliness of the units environment and its frequency of operation. Primarily, the fan selected for each system must deliver the design flow at the specified pressure. Every rise in unit pressure (such as the rise caused by dirt (etc) accumulating on filters or coils) creates a different operating condition and air flow. The following procedures must be implemented depending on the cleanliness of the environment and the equipments frequency of operation.

28

29

THE FOLLOWING CHECKS SHOULD BE CONDUCTED ONCE A YEAR: The Following Should be Checked: a) All electrical cables, tightness of all connections, b) Tightness of the screws and bolts in the ventilation section, c) Energy expenditure of motors, d) Vibration dampers and fan supports, e) Whether there is any indication of rust in the unit or accessories (the necessary cleaning and maintenance should be conducted). f) The shaft and wheels of the fan (The rust on the shaft should be cleaned by sanding and the shaft should be protected by coating with a layer of suitable varnish.) g) Seals on doors (should be replaced if necessary) h) Hinges should be checked, and necessary adjustments should be made in case of looseness. The Following Should be Cleaned: a) Nozzles and drain pan of the humidifier, b) Drain pan spouts and condensation drain pan, c) The fins of coils should be checked for any obstructions and the curves of drop eliminators, d) Blockage of the heat recovery section. e) The dirt level of cellulose filled evaporative humidifier padding should be checked. (It should be replaced if necessary.) f) The calcification level of the steam humidifier's steam cylinder and the condition of its electrodes should be checked. The steam cylinder should be replaced if necessary. The Following Should be Replaced: According to the indication of manometers and the differential pressurestat, coarse filters, bag filters and highly sensitive filters should be replaced.

30

Tension of Belts The correct tension in belts will prevent premature malfunction of bearings and wear and tear of belts. Thus, the tension of the belts should be measured.

Figure 18 : Check for Belt Tension

Maintenace of Belts Belts and wheels should be cleaned with a dry cloth. Belts should be cleared of oil, grease, and dust. Lubrication of belts is not recommended. If belts need replacement, the entire set should be replaced. Do not force the belts into the wheels, nut adjust the motor for assembly.
31

Wheel Adjusment The wheel adjustment can be measured using a steel ruler. Both edges of the wheel should be at the same level as the ruler. (Figure 19).

Figure 19 : Wheel Adjustment

Warning! Turning the unit on and off often will cause premature wear on the belts and wheels. Damper Section Check the operation of the damper and clean the damper. Clean the damper blades, and check the operation of bearings and gears. Check the damper in the OPEN" and "CLOSED" positions in this order. Contact our technical service department in case of problems. Only our technical service department is authorized for concealed gear damper design repairs. Filter Section General 1) Filters need regular maintenance. Maintenance frequency depends on the amount of dust in the air and upon operating conditions. 2) Neglecting filter maintenance may decrease air flow. For vibration free operation of the unit, it is essential that filters be given maintenance within design limits. Panel filters can be cleaned using one of the methods listed below: a) Washing with hot detergent water b) By spraying pressurized air from the clean side of the filter c) Using a vacuum cleaner from the dirty side of the filter d) Holding and the filter with the dirty side facing outward
32

Maintenance Frequency Filters should be checked every 15 days and given maintenance at least once in every four months. We would like to remind you that maintenance frequency depends on operation. Coil Section Cleaning 1) Coils should be cleaned at least twice a year. 2) Dust escaping from the filter form a layer on coil fins, affecting air flow and reducing the efficiency of heat transfer. 3) Coils must be kept very clean under all conditions. The best way to clean the coils is blowing air onto the fin; if this is not possible you may clean the fins by brushing softly without damaging them. The interior of the unit should also be cleaned after this operation. 4) Regularly empty the condensation pan of cooling coils and clear dirt and deposits. Freezing Risk Freezing leads to a surfeit of damages and destroys the coil in particular. All precautions should be made against freezing of the coil. Damages resulting from freezing are not covered by freezing. Measures to be taken to prevent decrease and/or stopping of the flow of hot water a) In cases where the flow of hot water decreases or stops, all air intakes and fans should be stopped. b) The freeze free thermostat should not be set too low. c) If for any reason the building can not be adequately heated in winter conditions, all air in the tubing and coils should be emptied. 1) Hot water coils: Make sure the water temperature is not too low and that the water circulation is regular. For example, a) Valves should be open b) There should be no air in the tubing 2) Steam coils: Make sure of the following:
33

a) b) c) d)

That there is steam pressure inside the coils That the boiler pressure is correct That the valves are open That the steam trap is functioning properly.

3) Cooling Coils: If the external temperature is lower than the freezing point of the water/glycol mixture, the cooling coil should be emptied. If only water is circulating within the coils, the coils should be emptied as soon as the outdoor temperature drops to 2C. Safety measures for preventing freeze of the unit coil in long standby periods If the unit must be kept on standby for an extended period of time, measures are taken in 2 ways to prevent freezing of the coil. A ) Adding ethylene glycol or other anti-freeze chemical to the water circuit B ) Removing the water within the circuit. Automatic control elements mounted on the unit (damper motors, pressurestats, thermostats etc) should be mounted using proper materials to avoid air leakage from the body. Control elements should be mounted such that they will not damage the mechanical operation of the unit. The recommendations stated above are not general rules. They vary depending on each systems operating setup. The system should be emptied using the method that is practicable. Fan Section Maintenance 1) Before starting the unit, make sure there are no unwanted objects within the unit, 2) Clean the interior of the unit with a vacuum cleaner, 3) If there is gas or dust in the air, rotors should be cleaned regularly, 4) Make sure the tension of the belts is correct; while slackness will cause slipping and excessive wear of belts, excessive tightness will exert excessive load on the motor and bearings. The belt tension control diagram should be examined for the generation of the correct tension. 5) If one of the belts is faulty, the whole set should be replaced. Otherwise, if only the faulty part were to be removed, since it will be new, therefore shorter and
34

tighter than the other parts, it will cause excessive strain. 6) Belts should be clean and free of grease. The best way to clean them is to wipe them with a dry and clean cloth. 7) Particles accumulating in rotors compromise the balance in the long run. 8) When the rotor needs to be replaced, we recommend that you summon one of our experienced engineers to repair the wheels. 9) Bearings and their supports should be cleaned and checked from time to time. While the frequency of this process depends on operating conditions, it should be conducted at least once a year on principle. 10) It is recommended that bearings be cleaned thoroughly and that all bearing components be checked. Checking the bearings Bearings should be checked on a regular basis during the units operation. Small tasks regarding the greasing or examination can be performed. We recommend that you consult the SYSTEMAIR After Sales Services department for further information. Motor Section Connection of the ground line The ground line should be connected at the most suitable location in the terminal box. Protection against short circuit, overload and double phase It is recommended that safety breakers be used to protect the electrical circuit (not for the motor), such as safety fuse that provides adequate protection for the installation. (Phase protection relay, thermal magnetic breaker, etc.) Start-up and stopping In squirrel cage motors, the starting current that occurs during the driving of the motor in the initial start-up rises to 3 or 7 times the nominal operating current. In case of star-delta start, the current is dropped to 1/3 of the current drawn in direct start-up. The start-up torque drops almost proportionally. Star-delta start-up is only used for motors above 5.5 kW.
35

Cleaning When there is excessive accumulation of dust inside the motor an on exhaust outlets, they should be cleaned by blowing clean air. Lubricating and cleaning the bearings Bearings are lubricated at the factory. Motor rollers are self-lubricated and enclosed type. They do not require additional lubrication. Fans equipped with cast body roller bearings should be periodically checked for lubrication, and lubricated if necessary. When you encounter a problem that causes concern, we recommend that you contact our Technical Service Department. Note: While useful life is 10 years for the unit (all models), the period of warranty against material and workmanship faults is 2 years.

SAFETY Make sure the power connection is off before responding in case of any malfunctions.

Take care to ensure that there is enough space at the back of your unit allowing the air to circulate.

Do not place items, etc. in a manner to block the flaps of air discharge louvers.

Do not drop in or insert any objects to the moving part (fan).

Do not operate the unit in a flammable (containing explosive gases) environment.


36

Make sure that there are no contracted connections after the assembly.

Remember to have the unit installed and operated by qualified employees. Make sure that your electrical wiring is appropriate to the unit. Make sure that there is no leakage or loose contacts at the electrical connections before operating the unit. Before operating the unit, make sure that it has a ground connection. The apparatus that will be used with the unit (switch, fuse, thermostat, etc.) should definitely be chosen from premium products that have quality certificates. Disconnect the power connections and inform the service in case of a malfunction. MALFUNCTIONS Malfunctions that occur in the air handling units can be divided into two groups, namely electrical and mechanical malfunctions. Having gained ground, the automation makes malfunctions occur because of or in connection with those two reasons. Therefore having comprehensive knowledge on both areas will help remedying the malfunctions easily and smoothly. Frequent malfunctions are summarized below. Fan motor malfunctions Drainage problems Noise problems Insufficient cooling or heating Malfunctions relating to electronic cards and related employees. Fan Motor Malfunctions Power issues and improper use might be the reasons of fan and fan motor malfunctions within the air handling units.
37

Drainage Problems Removing the intense water vapor requires draining. Many problems are encountered with these installations. Particularly hoses that are not connected properly, an improperly inclined installation or incorrect assemblies of internal units create this problem. Filters that are dirty and not cleaned cause problems and lead drainage problems. Additionally, taking account that the drainage problems can also occur at the external units of the devices that are using heat pump, this problem should be prevented through drainage application as well. Noise Problems Although air conditioning devices provide more comfortable, more convenient lifestyles, incorrect usage might cause even more discomfort. Ambient sound levels are considerably important and never should be overlooked. While selecting and using components that may cause high noise levels such as compressor, motor, and fan, sensitivity should be practiced against noise. Naturally, the location in which the air conditioning unit is to be placed and its purpose are significant criteria in determining the magnitude of the problem. Faulty installation and problems in rotating parts may lead to higher nose than is necessary. In this case the necessary measures must be taken and the malfunction of the related element should be repaired. Insufficient Cooling and Heating Depending on conditions such as system properties, operating conditions, and maintenance, there are some situations when consumers expectations can not be met even tough there is no technical malfunction. The leading cause of such situations is erroneous estimation and misinformation. The unit has been designed in the light of the information provided and will deliver the desired values at these conditions. Electronic Card and Element Malfunctions Air conditioning units are electronically controlled, therefore materials in the system such as contactors, solenoid coils and electronic cards may suffer malfunctions due to problems resulting from power issues. Yet the point which needs to be taken into consideration and resolved is determining whether these malfunctions result from mechanical problems. If there is a problem in the system that is caused by the main structure or by the system itself, rather than replacing the element in question, the main problem in the system should be resolved. The element should be replaced if deemed necessary.
38

Device Does Not Active!

Is it plugged?

Is the power outlet live?

Has the fuse blown?

Does the grid power meet the catalogue values?

Is there a general power outage?

Does power reach into the motor?

Is fan rotating direction correct?

Is there a jam at the fan scroll case?

Please consult our company if you still have problems provided that all operating conditions of the components under the "Operation" title are applied.
39

KS-KK 12/2012