AIR HANDLING UNIT INSTALLATION, OPERATION AND … · permission of DOGU IKLIMLENDIRME A.S., since operating at higher speeds may overload and damage the motor and fan. 3- Transportation

AIR HANDLING UNIT INSTALLATION,OPERATION AND MAINTENANCE INSTRUCTIONS

is a registered trademark of Dogu Iklimlendirme A.S

Venues Breathe with Dogu HVAC Systems!Dogu HVAC Systems which had started to produce ventilation and air-conditioning equipments in İzmir in 1999, produce two main segments as air outlet equipments and air handling units in accordance with European norms (DIN,EN). Dogu puts the devices on the market with ‘’Four Season’’ brand.

Dogu HVAC Systems which is in business within 45.000m² open area with 2 factory, has 120 different types of products. It brings new products to the sector producing Make-up Kitchen Hoods, Laminar Flow Ceiling, One Piece Square Ceiling Diffuser.

Our R&D journey started in 2004 with the first project of producing Make-up Kitchen Hood is followed by producing dozens of other new products that were designed by special software like Ansys Fluent® and Solidworks® today.

is a registered trademark of Dogu Iklimlendirme A.S

- Protect your unit against damage, shock and distortions.- Do not attemp to install and run the unit before reading the instructions in this booklet- Your unit’ s serial number is- Your unit’ s type is

MODELS

KKS 062 - 046

KKS 062 - 062

KKS 093 - 062

KKS 124 - 062

KKS 093 - 093

KKS 124 - 093

KKS 155 - 093

KKS 124 - 124

KKS 155 - 124

KKS 186 - 124

KKS 155 - 155

KKS 186 - 155

KKS 217 - 155

KKS 186 - 186

KKS 217 - 186

KKS 248 - 186

KKS 217 - 217

KKS 248 - 217

KKS 279 - 217

KKS 310 - 217

KKS 248 - 248

KKS 279 - 248

KKS 310 - 248

KKS 341 - 248

KKS 403 - 248

KKS 465 - 248

KKS 527 - 248

KKS 589 - 248

Air Handling Unit Installation, Operation And Maintenance Instructions

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CONTENTS Pages - INTRODUCTION ........................................................................................................................................... 3

- ABOUT AIR HANDLING UNITS .................................................................................................................. 3

- TRANSPORTATION AND STORAGE ......................................................................................................... 4

- INSTALLATION ............................................................................................................................................ 4 4.1 CONNECTION OF SECTIONS .............................................................................................................. 5

- CONNECTIONS ............................................................................................................................................ 6 5.1- DUCTING CONNECTIONS ................................................................................................................... 6 5.2- PIPING CONNECTIONS ....................................................................................................................... 9 5.3- CONDENSATE DRAIN LINES ............................................................................................................ 11 5.4- ELECTRICAL CONNECTIONS .......................................................................................................... 11

6-

7

8

9

SETTING UP OF COMPONENTS .............................................................................................................. 18 6.1- DAMPERS ........................................................................................................................................... 18 6.2- FILTERS .............................................................................................................................................. 18 6.3- COILS .................................................................................................................................................. 18 6.4- HUMIDIFIERS ...................................................................................................................................... 19 6.5- SUPPLY AND RETURN FANS ........................................................................................................... 20 6.6- ELECTRIC HEATER ........................................................................................................................... 20

- SAFETY ...................................................................................................................................................... 20 7.1- USE OF THE UNIT .............................................................................................................................. 21 7.2- OBSERVATION OF WARNING SIGNS .............................................................................................. 21 7.3- STAFF TRAINING ............................................................................................................................... 21 7.4- PREVENT OF COMMON DANGERS AND RİSKS ............................................................................ 22 7.5- RECOMMENDED SAFETY PRACTICES ........................................................................................... 22 7.6- THE HIDDEN DANGER ...................................................................................................................... 23 7.7- START UP ........................................................................................................................................... 24

- MAINTENANCE .......................................................................................................................................... 25

- BELT TENSION AND ALIGNMENT CONTROL ........................................................................................ 29

10

1

2

3

4

5

- CHANGE OF PULLEYS .......................................................................................................................... 31 10.1- MOUNTING OF PULLEYS ................................................................................................................ 31 10.2- REMOVAL OF PULLEYS ................................................................................................................. 31

11- LUBRICATION OF BEARINGS ............................................................................................................... 31

12- TROUBLESHOOTING ............................................................................................................................. 33 12.1- TROUBLESHOOTING CHART ......................................................................................................... 34

13- OPERATING LIMITS OF FANS............................................................................................................... 37

14- MOTOR TECHNICAL INFORMATION .................................................................................................... 41

APPENDIX-1 STARTER SELECTION TABLE ............................................................................................... 44

15- PRODUCING COMPANY ........................................................................................................................ 45

TABLE ............................................................................................................................................................. 45

16- WARRANTY ............................................................................................................................................. 46

17- DELIVERY REPORT ................................................................................................................................ 47

18- DECLERATION OF CONFORMITY ........................................................................................................ 48


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1- Introduction This manual is prepared as a guide to good practice in installation, operation and maintenance of air handling units manufactured by DOGU IKLIMLENDIRME A.S. The manual contains basic information and recommendations for proper and fail free operation of air handling units. Please read the instructions and warnings given in this manual and on the air handling unit before starting installation, operation and maintenance works and keep this manual near the unit, within easy reach of service personnel.

2- About Air Handling Units

WARNING: DOGU IKLIMLENDIRME A.S. air handling unit are only used for heating, ventilating and air conditioning purposes. Any other use is considered not in conformity with general provisions. The manufacturer is not responsible for damages resulting; the user will be the only responsible.

Standard units must not be used for handling of flammable gases. Spark-proof versions of rotating parts (fans, motors etc.) must be selected for this kind of applications, so air handling unit manufacturer should be informed while ordering the unit.

2.1 Operating Data2.1.1 Ambient Temperature Air handling unit components are suitable to be used at ambient temperatures between -20˚C and +40˚C and altitude of 1000m. Ambient temperature is the temperature of the air either inside or the outside of the unit. If the unit is to be used at ambient temperature and altitude other than stated above please consult to DOGU IKLIMLENDIRME A.S.

2.1.2 Power SupplyStandard power supply for air handling unit components such as motors, humidifier pumps, electric heaters, steam humidifiers etc. is 400V, 3ph, 50 Hz and for lighting 230V, 1ph, 50Hz. However customers may request other voltages while ordering the unit.

WARNING: Before starting electrical connections and selection of electrical components check if the mains power supply conforms to the data on the rating plates of electrical components. If there is any difference do not connect the devices.

2.1.3 Coils If not otherwise stated on the capacity label, maximum operating temperature and pressure:For hot and cold water coils: 90˚C, 10 barFor high temperature hot water coils: 150˚C, 15 barFor steam coils: 143˚C, 3 bar

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WARNING: Do not operate coils above the maximum temperature and pressure specified on the capacity label.

2.1.4 Motors And FansRated power, speed and current values of commonly used motors are given on pages 35 - 36 and maxi-mum speed and maximum installed power values of fans are given on pages 33 - 34 for information only. It is not permitted to operate fans and motors at higher speeds other than design speed, without written permission of DOGU IKLIMLENDIRME A.S., since operating at higher speeds may overload and damage the motor and fan.

3- Transportation And StorageAir handling units are inspected prior to dispatch for good condition and carefully loaded. Special care must be taken while unloading the units.

Air handling units are generally damaged during transportation and loading / unloading, especially when being lifted by a crane. Small units can be transported by hand-powered pallet truck or by forklift truck.

4- InstallationDuring final installation the requirements of EN 60204-1 do apply.

Before manufacturing air handling unit, the client should check the conditions at site to ensure that access routes are adequate for both size and weight of the unit sections. Air handling unit installation areas should also be checked. There should be sufficient space around the unit for servicing, maintenance and piping connections. Further, it must be ensure that the base is high enough from the floor to allow the condensate drain with necessary water trap.

WARNING: Always use the lifting holes on the base frame to lift the unit by a crane. Never lift the units by coil connections or by any other protrusions. While hoisting or lowering, proper lifting equipment (slings and spreaders properly selected on the ground of the size and weight of the section) should be used not to damage the unit. Ensure that slings do not damage the unit casing and protrusions such as coil pipe connections, door handles, drain connections etc. Safety precautions should also be taken not to tilt and not to drop the unit.

Fig. 1: Typical lifting equipment


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WARNING: Air handling units should be installed on a rigid and level surface. Correct alignment of the sections is essential to maintain a satisfactory airtight enclosure and to avoid distortion to the casing and components.

If the air handling unit is to be installed in a place where low vibration and noise is required such as hotels, hospitals etc it is recommended to install the unit on a floating concrete base, around which is filled with expanded polystyrene.

4.1 Connection Of SectionsFirst of all, transport the unit sections to the place where the unit will be installed. Check the sealing strips for any damage. Replace the strips if there is any damage. The order in which the individual sections are assembled can be determined from assembly drawings and by following identification labels on each section ( For example A1-A1, A2-A2 ). In order to reduce vibration, suitable anti-vibration strips may be placed under the base frame. To connect the sections, follow the instructions below.

4.1.1 Pent A Post Air Handling Units Once all sections are located in their place in the order they will be assembled, align the sections for air tightness and to easily fit the section connection bolts.

Fig. 2: Typical AHU concrete base

WARNING: Do not use excessive forces to align the sections, because it may deform the aluminum framework and casing.

Sections are locked together by special connection parts, bolts, and nuts. Section connection parts are mounted on the unit sections, bolts and nuts are fitted on the connection pieces.

First attach the base frame connection bolts on the base frame, and then section connection bolts and tighten the bolts gradually starting from the base frame.

4.1.2 Cold Bridge Free Air Handling Units Cold bridge free air handling unit sections are connected to each other through the holes on the facing surfaces of the sections and through the holes on the base frame, by means of bolts and nuts supplied within the unit. First attach the base frame connection bolts on the base frame, and then section connection bolts and tighten the bolts gradually starting from the base frame. And then fit the intermediate cover lids.

5- Connections5.1- Ducting ConnectionsReturn air, fresh air, exhaust air and supply air should be connected to the unit by flexible duct connectors. Air tightness should be maintained to achieve required air flow conditions. Poor ductwork connections to the unit and incorrect size, shape and arrangement of ductwork fittings can change airflow conditions.

5.1.1- Free Outlet ConditionsDischarging a centrifugal fan directly to atmosphere (Fig.3) is an inefficient method of discharge. It can be improved by the addition of a short duct length coupled to the fan outlet (Fig.4) or by the use of an expansion section (Fig.5) allowing the air to become less turbulent before being discharged. This is particularly important when grills or diffusers are being used at the discharge point as the manufacturers loss figures are based on a laminar flow air stream and turbulent air increases the losses.

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sealing strips

base frame connection

section connection


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5.1.2- Ducted Outlet ConditionsWith the outlet connected to the discharge duct by a flexible connector, which is desirable for noise and vibration isolation, it is important that the connector is correctly fitted. The fan outlet and the duct should not be misaligned (Fig.6) nor should the flexible connector be allowed to concertina. A smooth passage of air is desirable at all times. (Fig.7)

When discharging into a duct of larger cross-sectional area than the fan outlet, an expansion section with an included angle of 7-20ºC should be used. (Fig.8) The ideal configuration is with parallel length of ducting prior to the expansion section, allowing the air to become less turbulent before expanding. (Fig.9) The fan should never discharge directly into a duct with larger cross-section. (Fig.10)

The same criteria apply when discharging into a duct of smaller cross-sectional area then the fan outlet. A ducting section with an included angle of up to 45ºC should be used. Losses will again be minimized if a parallel section of ducting is used prior to the reducing section. (Fig.11) To achieve ideal conditions the length of parallel ducting in both cases should be equal to 8 impeller diameters. However parallel ducting of considerably shorter lengths can be used to advantage

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Extremely high losses occur when attempts are made to change the direction of the airflow close to the fan discharge. If this is necessary the installation should be carried out as in (Fig.12) and ever as in (Fig.13) A better solution is to have a parallel section of ducting prior to changing direction and it should be as long as can be accommodated. (Fig.14)

FAIR BAD BAD

Fig.13

Fig.14


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5.2- Piping ConnectionsCoils should be piped in counter flow arrangement to achieve required capacity. This arrangement requires that the entering heating or cooling fluid contacts the air leaving the coil. Water heating and cooling coils should be arranged with inlet connection at the lowest level on one side of the coil near downstream and water outlet connection on the same side but at high level near the upstream. This arrangement drives any air in the system into the upper part of the coil, where a manual air release valve should be fitted.

All coils connecting piping should be independently supported not to impose strain on the coil connections or circuitry. All coils connecting piping should be thermally insulated

WARNING: Use a pipe wrench to restrain the pipe connections of the coil when tightening the external pipe connections.

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5.3- Condensate Drain LinesMoisture condensed out of the airstreams on cooling / dehumidifying coils should be drained out of the unit, to prevent water damage in the air handling unit and ductwork system. Following precautions should be observed in piping of condensate drain lines.

- Condensate pipe connections to drain pan should not be less than the bore size of the pan outlet connec-tion.- A union or pipe coupling should be fitted at the pipe connections to the pan to permit easy disconnection to clean any dirt sediments. - The siphon (for positive and negative pressure applications) sent by the unit separately should be assem-bled according to its own installation instructions in the package.- If the drain pipe is to be long, drain line should be pitched with a gradient not less than 1 in 50.

5.4- Electrical ConnectionsElectric motor, starters, interconnecting cabling and any associated controls should be properly designed and selected to be suitable for the driven equipment or other electrical apparatus, to be safe and to comply with the requirements of Electricity Supply Authority. In case of the humidifier and frequency converter applications their own installation manuals should be used. For the other equipments the installation instructions and the wiring diagrams which stuck in the terminal box should be followed.

The equipments in the unit except lighting operate with 400V, 3Ph, 50Hz electric supply. Standard lighting equipment operates with 230V, 1Ph, 50Hz electric supply.

siphon for positive pressure

siphon for negative pressure

H(mm)=P10

H + 5

0 mm

H

1,5 x

H

1,5 x

H + 6

0

( ball type siphon )

P= maximum static pressure in unit, Pa

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Starter for centrifugal fans in the air handling units for single speed motors driving through V-belts are normally of the direct-on-line type. However the customer or Electric Supply Authority may require motors above 3kW to be operated by a star-delta starter, to reduce starting current.

CAUTION: To avoid the electric heater keep on running while the fan is not rotating, the wiring should be done similar to diagram shown at the right.

WARNING: Electrical installation and wiring works should be carried out by qualified and competent electricians, in accordance with all international, national and local regulations.- Thermal overload relay setting

a) Direct-on-line starting: The thermal overload relay should preferably be set to the motor full load current shown on the motor rating plate.b) Star-Delta starting: The thermal overload relay should preferably be set to the 0.58 x motor full load shown on the motor rating plate.After thermal overload relay settings is done it should be checked that thermal overload relay works properly at normal operating conditions, by operating motor on two phases.

Motor terminal markings- The terminal markings of motors conform to the international standards. Stator terminals are marked, U.V.W and the neutral terminal N.- Please check data on the rating plate. The voltage marked on the rating plate must be in agreement with the mains voltage.

The terminal board is normally equipped with 6 terminals. Details concerning the connection are given on the inside cover of the terminal box and / or on a diagram placed inside by the manufacturer. - Specifications require that all motors to be earthen properly. Special terminal in the terminal box should be used for this purpose.- To avoid the danger of overloading and operation on two phases, the motors should be protected either with fuses and thermal/thermo magnetic switches or electronic circuits. (See page 37)- If the electric heater will be used, electrical connections should be done according to the information on the heater label.The unit must be installed with a disconnecting device and over current relay on the site if it has not already equipped.

A Manual resetB Automatic reset


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The supply cable cross-section-area and length should be selected according to the;- Motor, lighting, electrical heater, etc power input and electrical supplyNOTE: All power and electrical supply values have indicated on the name plate of the unit and/or name plate of the equipment except the lighting. Electrical Supply of the lighting is 230V, 1Ph, 50Hz and the power input of the lighting is 100W as standard. Cable specification from the terminal box to lighting is H05V-K 2x0.75 - Cable installation conditions- International standards, local rules, regulations and standards and requirements of Electric Supply Authority.

5.4.1 Converter - Fed Operation Of MotorsWhen driving motors by a frequency converter, the following must be observed:- The fan motor must be suitable for operation with a frequency converter.- Rated speed of motor given on the rating plate should not be exceeded.- Maximum speed and maximum installed power values for fans given on pages 33 - 34 must not be exceeded.- Fan motor must be protected by PTC thermistor against overload and overheating.- Frequency converter must be overspeed protected. - Motor PTC thermistor must be wired to the frequency converter by shielded leads.- Assembly instructions of motor and frequency converter manufacturers must be referred.- If the operating point of the fan will exceed the design operating point of the fan, there is a risk of motor to overload and overheat. Please consult to DOGU IKLIMLENDIRME A.S., if the design operating point of the fan will be exceeded.

WARNING: At very low speeds for converter-fed operation, there is a risk of operation at mechanical resonance frequency. So, operation of motor at speeds lower than 300 rpm is not recommended.Programming, first operation and periodic control of frequency converters should be made by qualified personnel, according to manufacturer’s instructions.

Starter for centrifugal fans in the air handling units for single speed motors driving through V-belts are normally of the direct-on-line type. However the customer or Electric Supply Authority may require motors above 3kW to be operated by a star-delta starter, to reduce starting current.

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6- Setting Up Of Components6.1- DampersManually operated dampers can be adjusted to obtain the required air flow, by turning the control lever. After setting the desired location on locking quadrant, control lever must be tightened. Dampers can be equipped with the motor. Check that the blades turn back in closed position in case of power supply failure during operation. Care must be taken to ensure that the actuator does not attempt to push the damper blades beyond fully open or fully closed positions. All damper blades must be checked for free movement and for fully open and fully closed positions.

6.2- FiltersPanel filters and zigzag filters are normally fitted within the unit prior to shipping.

Bag filters are normally shipped in closed carton boxes to avoid any collection of dust and loss of efficiency prior to commissioning. Each bag filter is housed within a special holding frame with necessary locking spring to ensure proper sealing.

Automatic roll filters consist of basic frame dispensing unit for clean media, rewind unit for dirty media, drive system, roll filter media and control system. Normally filter media and control system are supplied loose for site installation. For assembly, filter media roll is mounted on the dispensing unit taken along the guide channel through working section and locked to the rewind unit. Differential pressure switch must be installed and connected to the control panel as shown on the circuit diagram.

Absolute filters are shipped in sealed carton boxes. While assembly, special care must be taken to ensure that each filter cell is properly sealed within the assembly frame with no possibility of air leakage.

Other type of filters such as active carbon filters, sand filters etc. will be supplied with manufacturer’s instructions along with the units.

Filters that shipped separately in the unit should be assembled after cleaning the inner surface by operating the fan. Before start-up, check if the filters have been installed.

6.3- CoilsAll coils are leak tested and checked prior to assembly. Fins are checked for proper condition. However, they must be checked once more and combed out if necessary, because they might be damaged during handling and installation. Do not remove plastic covers from coil pipe connections until the unit is ready for piping connections. Connections should be checked according to the project. Piping system should be checked for any damage and leakage. System layout should take into consideration of possible coil withdrawal.

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It Is Recommended That The Water Flow Is Shut Off When The Fan Is Switched Off. To Avoid The Overheating Of The Heating Coil, The Hot Water Pump And Water / Steam Valves Should Only Be Opened During The Operation Of Fan.

Supply Air Control: The Supply Air Temperature Of The Coil At The Suction Side Should Be Max. 40˚c, Otherwise The Overheating Danger Will Occur. check The Concentration Ratio Of The Antifreeze Before The Start-up Of The Cooling Coil. It Should Be Enough For The Claimed Operating Temperature Range. It Should Be Taken In To Account That The Increasing Concentration Ratio Of The Antifreeze Decreases The Performance Of The Coil.The Minimum Temperature Of The Chilled Water Should Be +20c, At Lower Temperatures Freezing Danger Will Occur.Antifreeze Is A Dangerous Chemical. The Safety Instructions Of The Antifreeze Manufacturer Should Be Taken In To Account.

Direct Expansion Coils Will Be Supplied With A Refrigerant Distributor Suitable For Brazed Connections. Refrigerant Pipe Work Must Include Necessary Shut Off Devices, Dehydrators, Solenoid Valves, Oil Traps Etc. Selection, Sizing, Installation And Setting Of Thermostatic Expansion Valve Should Be In Accordance With The Recommendation Of Condensing Unit Manufacturer.

Steam Coils: Special Care Should Be Taken For Collection And Disposal Of Condensate Within The Coils And To Prevent Entry Of The Condensate In The Main Into The Coil By Trapping It Independently On A Coil Bypass. Condensate Connections To The Steam Trap Must Be Of The Same Size As The Coil Outlet.

6.4- HumidifiersMat Type Or Steam Type Humidifiers May Be Assembled In The Unit. For The Piping And Wiring Instructions Please Refer To Humidifier Manufacturer’s Manual.

The supply water, overflow / drain piping should be done before the start-up of mat type humidifiers. The supply piping should have a valve for cutting off during the maintenance. Before start-up clean the water sump, close the drain valve and fill the sump with water. The float adjusts the water level. The distance between the water level and overflow pipe should be 5cm. The water level in the sump is very important so that if the water height is usually at low level the humidification performance will decrease. Check the rotation of the pump, the direction should be at clockwise. Change the connection of the 2 phases if the direction is opposite. Not to damage the pump do not operate dry.

Before the start-up of the steam humidifier, wiring and piping should be done, steam supply and drain hose should be connected to the steam distribution pipe.

Before start-up, piping system and hoses should be checked for any damage and leakage.

For further information about the humidifiers please refer to the humidifier manufacturer’s manual.


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6.5- Supply And Return FansVibration isolators, on which fan + motor assembly is mounted, are locked prior to shipping to avoid damage during transport.

WARNING: Once the unit is in position and duct connections are made, isolators must be released. It should be guaranteed that the fan move hasn’t locked.

Wiring work must be carried out in accordance with local standards. Type of start (direct-on-line or star/delta) should met with local electrical standards. Starters, controls, overload protecting devices, interlocks etc. should be provided as required. (See page 37) After the start-up, check that direction of rotation of the fan is correct.

6.6- Electric HeaterThe electric heater should be protected against humidity and water. Be sure that the electric heater automatically cuts off, if the air flow stops.

7- Safety DOGU IKLIMLENDIRME A.S. air handling units can be considered as safe machinery. By means of the compliance statement of the EEC and of the symbol “CE” on the unit, it is guaranteed that DOGU IKLIMLENDIRME A.S. air handling units fulfill the provisions for the safety and health, on the ground of Machinery Directive 98/37/EC and the European standards. The “CE” mark appears on every identification label of the unit.

In spite of all that, the unit can represent a danger, if it is utilized or serviced not properly or by staff not sufficiently trained, or if it is used not in conformity with general provisions. For this reason, we intend to explain to the user the concept of safety referring air handling units and to inform him of possible danger and consequent measures.

Internal area of the units near to the moving parts (fans, motors, pumps etc.) end electrical parts, hot sections (hot water and steam coils, piping, fittings and control devices) are considered as “danger zone”. In order to be able to access to these

areas, it is necessary to provide one self with the proper key tools. The operators are responsible for transport, installation, start up, service and maintenance including cleaning and repairing.

Possible hazards regarding to the air handling units are:- danger to the operator’s safety- damages to the unit- possibility to affect the efficiency of the unit work

isolator locking

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7.1- Use Of The UnitIn order to use the unit according to general provisions, proper instructions of transport, installation and use must be observed. Installation and start up of the unit must conform to the national standards having legal course in the country of the user. The user is responsible for compliance with standards. Besides it must be avoided any type of work that may compromise safety.

WARNING: Arbitrary changes on the unit made by the user or operator are not allowed and exclude the war-ranty of the manufacturer for the damages to things and persons.

The unit can be started up only by authorized persons and by the means of proper safety devices.

The installer is obliged to install the unit according to installation plans and conditions.

The staff in charge is obliged to signal immediately to the user any changes that may compromise safety. For this reason it is necessary to inspect the unit for eventual anomalies or damages at least once a week.

The user or operator never must dismount and deactivate safety devices; if these would be removed for extra maintenance, at the end of the operations they must be reinstalled.

For all operations of extra maintenance, the power source must be locked out and protected against unlock by anybody else.

7.2- Observation Of Warning SignsWarning signs should be placed on the unit, showing:- prohibition to repair or adjust while the unit is running- obligation to turn off the power before opening the access door- warning of coming into contact with electrical parts etc.

7.3- Staff TrainingInstallation, start up and maintenance works can be executed only by authorized and trained staff. This staff or people who, on behalf of the user, attend to control and make maintenance of the unit must be informed about possible hazards regarding:- electrical connections- piping connections- ducting connections- start up- maintenance

It is necessary to establish and to respect the responsibilities for the control and maintenance to guaranty safety.


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7.4- Prevent Of Common Dangers And RisksAir handling units are supplied with locked access doors as an option. So, unauthorized persons are not permitted to enter the sections which represent a danger.

The most important potential dangers for life and health are described below. The units are manufactured in conformity with machinery normative 98/37/EC. The user must take into consideration of dangers and risks described in this manual during operation and maintenance works.

7.5- Recommended Safety PracticesThis publication explains the proper use and installation of centrifugal fans in order to warn operating and maintenance personnel of the commonly recognized dangers associated with this equipment. In addition to follow the manufacturer’s installation instructions, care must be taken to ensure compliance with federal, state and local rules, regulations and standards.

Centrifugal fans in air handling units are located inside a casing, so accessibility to the fan is occasional or infrequent. For this reason, protective devices are offered as optional accessories only at specific user’s request. However as in case with other machinery involving moving parts, common sense and caution will preserve personnel safety.

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KIND OF DANGER

OR RISK

SOURCE OF DANGER

OR RISKDANGER OR RISK

Danger caused by moving parts Fans, electric motors, pumps Danger of hurting during repair

Danger caused by hot surfaces.Hot water and steam coils,

steam humidifiers, electric heaters,

electric motors

Danger of burning

Danger caused by pipe or hose

damage

Water and steam coils

Water and steam humidifiers

Danger of burning from hot water or steam. Danger of electric shock caused by water contacting electrical parts and

cables Risk of corrosion

Risk caused by mechanical resonance Vibration isolatorsRisk of damage or destruction of air

handling unit components

Risk caused by overspeed of fan External frequency converterRisk of damage of motor, fan and

ductworkRisk of excessive noise

The available optional guarding devices are:

1) Fan inlet and outlet guards: Centrifugal fans in air handling units are usually connected directly to duct-work which will prevent the contact with the internal moving parts. In case there is an exposed inlet or outlet which could represent a danger, suitable guards can be installed.

2) Drive guards: Safety guards should be used when drive systems are accessible by the personnel.

3) Limit switch: Cuts off the power supply of the fan motor when door opens. As the fan keeps on rotating, do not attempt to enter the unit within minimum 2 minutes, after opening the door.

Also supply disconnecting device and suitable warnings should be used. Maintenance personnel must engage the disconnecting device before starting any maintenance and repairs; do not forget to protect against unlock by anybody else.

7.6- The Hidden DangerIn addition to the dangers of rotation machinery, fans present another potential danger by virtue of their ability to draw in loose material. Solid objects passing through a fan represent potentially dangerous projectiles. Solid objects can cause fan failure by physically damaging the impeller blades. If the guard is removed for any reason, the fan must be disconnected and locked out. Where fans are installed over an occupied area, safety guards should be provided to prevent dropped objects from entering this area during installation and maintenance.

WARNING: Access doors to a fan or duct system must not be opened when the fan is running or coasting to a stop. After the unit has switched off, the impeller continues to run for approximately 1-3 minutes. The fan section is therefore still under pressure and the door must not be opened. Power shall be locked out prior to access into the fan section or ductwork. Even when locked out electrically, fans may cause injury or damage if the impeller is subject to “windmilling”. The impeller should be secured to physically restrict rotational movement. On the downstream or pressure side of the system, attempting to open the access door while the system is in operation, may result in an explosive opening. On the upstream or suction side, the inflow may be sufficient to draw in tools and clothing etc. and create a danger.

WARNING: Impeller must never be slowed down by hand or with objects.

The stroboscopic effect of certain lights in combination with certain fan speeds may cause a rotating assembly to appear stopped.Noise: At normal operating conditions, noise emission of air handling units does not (with duct connections made and service doors closed) exceed 70dB (A)

But at extreme operating conditions and depending on room acoustics, noise emission may be dangerous for health. Prolonged exposure at or above 85 dB (A) requires the use of hearing protection (ear plugs, ear muffs etc.)


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7.7- Start UpBefore operating air handling unit for the first time (or after an annual maintenance) the manufacturer’s instructions must be followed. In addition, the following check list must be completed:

- Ensure that all the sections of the unit are thoroughly cleaned. There is a possibility of collection of debris such as duct insulation materials, tapes, etc.- Ensure all electrical wiring is carried out in accordance with local standards and all components are provided with safety, protecting and isolating devices. (See page 37)- Remove all filters, install low efficiency filters such as gauze bags or throw away type filters, to keep the filters clean.- Clean water/steam/refrigerant coils and check pipe connections for any leakage and damages. Ensure that all the air in the system and in the coil is vented out. Check coil face free from debris.- Ensure all panels, if removed during installation, are in position and all service doors are closed.- Ensure that minimum water level is maintained in the humidifier. Check pipe connections and hoses for any leakage and damages.

7.7.1 Operation Of Fans:Before operating fans:- Check that pulleys are secure on shafts.- Check tightness of belts.- Check that all moving parts of the fan and motor are free to rotate.- Check that no loose materials are left near the fan inlet.- Check that direction of impeller rotation is correct. For this, momentarily energize the fan and see the direction of rotation.- Check that fan and motor pulleys are aligned.- Check if the bearings need lubrication.- Check that fan and motor are fixed tightly.- One of the most common causes of motor failure with forward curved blade fans is excessive air flow, due to overestimated system resistance. To overcome this type of failure, first start-up should be with the main system damper partially closed and to be opened when correct proportional air flow has been achieved by system regulation.- Check that flexible connections are firmly fixed and undamaged, duct connections are designed in accordance with acceptable engineering practices and with the manufacturer’s recommendations.- Check that thermal overload relay setting is correct.- Switch on the electric supply and allow fan to reach full speed. Check carefully for:• Excessive vibration• Unusual noise• Motor current and voltage valuesIf any problem is indicated, switch of immediately. Lock out the electrical supply, secure fan impeller if there is a possibility of wind milling. Check carefully for the cause of the problem and correct as necessary.After ensuring that there is not any problem, no leaks between joints and system is clean, stop the fan. Dispose low efficiency filters, install panel/bag/absolute filters as supplied. Restart the fan:

24 www.doguhvac.com


- Adjust damper position to obtain required air volume. Ensure that the air volume is within specified limits.- Check the motor current and ensure that it is in accordance with the motor rated data (on motor name-plate)- Check inlet-outlet temperatures across coils and adjust water/steam flows accordingly. Check the func-tioning of control devices.- Check the functioning of humidifier by adjusting the humidistat control.- Check the operation of heating coils by adjusting thermostat. Check the functioning of controls. (air flow switch, fan interlock, overheat protection, etc.)- Check the pressure drop across the filters and ensure that it is within limits.

During the first eight hours of running, operation of fan should be periodically observed and checked for excessive vibration and noise. Motor input current and motor and bearing temperatures should also be checked to ensure that they do not exceed manufacturer’s recommendations. Then the fan should be shut down to check the following items and to adjust, if necessary:- Belt drive alignment and belt tension- Bearing housing temperature- Fan and motor fixing boltsAfter start up and initial satisfactory operation of two weeks, it is recommended to have the following checks:- Belt drive alignment and belt tension- Motor running current- Bearing temperature immediately after stop. Bearing temperature should not exceed 70ºC. Lubricate if necessary. - Condition of filters- Condensate and drain, to see flow- Operation of control devices

WARNING: Investigate any changes to the fan. You may have more detailed explanation of problems and possible causes in “troubleshooting” section. Consult your manufacturer or other qualified consultant for questions concerning changes observed during periodic inspections.

- If excessive vibration is observed, stop the fan until the cause is corrected. Check for material build up on the impeller which causes an imbalance and leads to the fatigue failure or impeller.- Changes in the sound level of the fan may indicate troubleshooting is required.- If the motor temperature is high check cooling fan of the motor. It may be blocked or broken. Also check the input current. An increase in current may indicate that some major changes have been made in system.- High bearing temperatures usually caused by improper lubrication. If the cause of the problem is not easily seen, experienced personnel must examine the equipment before running it again.

8- MaintenanceA preventive maintenance program is an important aspect of an effective safety program. Maintenance works should be performed by experienced and trained personnel. Do not attempt maintenance unless electric supply has been locked out and the impeller has been secured. Before the maintenance operation, the safety precautions should be taken by locking out the main and maintenance switch and protecting against unlocking by anybody else.


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WARNING: During maintenance and repair works that will be done with an operator inside the unit a prominent ‘MAINTENANCE, DO NOT CLOSE THE DOOR’ sign must be placed on the service door.

Especially at the hygienic air handling units, filters, coils, (by disconnecting the flange connections), droplet eliminator and sound attenuators can be taken out from the service doors. Besides, all components can be taken out from the unit for cleaning and disinfection processes.

In general air handling unit do not require special attention other than routine cleaning and maintenance work. Frequency of maintenance depends on operating conditions. Following is the recommended maintenance schedule.

Once a week

- Check the conditions of filters every week. Clean, wash or replace if necessary.- Check the condition of drain for free flow

Once a month

- Check belt drive alignment and tension, adjust if necessary- Check the condition of float and valve in humidifier- Check the condition of access door hinges and seals lubricate hinges if necessary.

Once in six months

- Check the motor running current- Check fan and motor bearings for high temperature and noise- Check function of control devices.- Clean condensate drain pan, trap and drain line- Check air washer circulating pump and motor- Check the condition of inlet strainer of air washer- Check the condition of piping system for chilled/hot water or steam for leakage and damage.- Add chemicals if necessary.

Once a year

- Check the filter frame for proper sealing- Replace synthetic filter media in panel filters.- Check the controls and operation of automatic roll filters- Check the coils and fins. Wash with water spray, if necessary.- Check the coils for any leakage- Went the water coils- Replace belts- Check the tightness of the fan and the motor fixing bolts

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- Check motor and fan bearing lubrication- Check the operation of dampers- Check the condition of access door for easily opening and proper locking- Check the condition of valves and fittings on the piping system- Check all wiring, control and isolating devices, terminal connections, etc.After inspection and replacements, if necessary proceed in accordance with operation instructions, before running the unit again.

Following must also be noted about maintenance works:

A) Fan SectionsFor detailed information about lubrication of bearings, belt tension and alignment controls, changing of pulleys, see related sections in this manual.

B)Coil SectionsCoils should be cleaned to remove any accumulation of dust between the fins and tubes should be checked for any leakage. Cleaning process can be done in 3 ways;- vacuum cleaning- compressed air- water or steam spray (opposite to the air flow direction)

CAUTION: During the application, the water, steam or air pressure should not exceed 5 bars.

To clean the cooling coil at the hygienic air handling units, the coil can be reached from both sides by taking out the droplet eliminator from the service door by disassembling the by-pass sheet metal. With the same principle as there’s no droplet eliminator, the heating coil can be cleaned by reaching both sides from the service doors.

If it is required to withdraw the coil for cleaning and repairing, proceed as follows:- drain the water inside the coil- disconnect the coil from piping connections- remove the side panel- remove the bolts by which coil is fixed- withdraw the coil

To check for leakage in the tubes, - clean and dry the coil- fill water inside the tubes- see where the leakage is- drain the water inside the coil

After cleaning the coil, drain should be checked and the siphon should be cleaned.

CAUTION: Keep coils from freezing. When water inside coils is allowed to freeze, serious damage will be caused to the tubes. So, if there is a danger of freezing, anti-freeze chemicals should be added to the circulating water or if the coil will not be operated for a short time, some water circulation should be provided inside the tubes. If the coil will not be operated for a long time, it is recommended to drain to coil.

C) Filter SectionsCondition of the filters should be checked once a week. Dirty filters reduces the air flow and hence the capacity. A manometer, measuring filter pressure drop should be fitted to filter section. If other not stated on the unit, please use the recommended maximum pressure differentials for different kind or filters that are given on below table. When manometer reading shows these values, filters should be cleaned or replaced, and these values should not be exceeded. Synthetic or metallic filter media can be cleaned or washed. However it is recommended to replace synthetic media in every two years. New filters should be assembled in the right position that the rough and open side looks to the dirty air, smooth face to the clean air side.

If there’s gasket on the previous filter frame, to achieve the necessary tightness do not forget to apply the same media (absolutely same way) on the new filter after renewal.

Other type of filters such as throw away media, bag, absolute and roll filters must be replaced with new filters of same type, size and efficiency.

After opening the service door, the filters can be taken out by pulling aside.

Synthetic bag filter can be cleaned by vacuumed or compressed air besides can be washed with the sensitive detergent and warm water.

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FILTER GRADE INITIAL PRESSURE DIFFERENTIAL

RECOMMENDED MAXIMUM PRESSURE DIFFERENTIAL

G-2

G-3

G-4

25 Pa

40 Pa

50 Pa

150 Pa

150 Pa

150 Pa

Table 2: Pressure differentials for panel filters

FILTER GRADE INITIAL PRESSURE DIFFERENTIAL

RECOMMENDED MAXIMUM PRESSURE DIFFERENTIAL

G-4

F-5

F-6

F-7

F-8

65 Pa

55 Pa

60 Pa

115 Pa

165 Pa

150 Pa

250 Pa

250 Pa

250 Pa

350 Pa

Table 3: Pressure differentials for bag filters


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D) Humidifier sectionsHumidifier should be cleaned regularly. The period changes according to the operating conditions, air specifications and water quality. During periodic maintenance of humidifier, checks mentioned in its own manual should be performed. Piping system and hoses should be checked for leakage and damage.

E) Sound AttenuatorsSound attenuators can be taken out from the service door by unscrewing the components from the top and bottom panels. Attenuators can be cleaned by vacuumed or compressed air.

F) GeneralPeriodic checks should be made for thermal and acoustic lining and electrical insulation of the unit sections. Also connecting cables and control panels should be checked. Any metal surface which shows signs of deterioration should be cleaned.

Bolts, nuts and other assembling elements should be checked. Any missing bolts, nuts and screws should be replaced.

To clean the damper compressed air can be used. Do not lubricate the shaft of the damper.

Impurities on the droplet eliminator blades should be cleaned regularly. The period changes according to the operating conditions and the air quality. As cleaning media any de-scaler available on the market can be used.

For the best cleaning process of the droplet eliminator at the hygienic air handling units it should be taken out from the unit and disassembled by unscrewing. To clean the inner surface of the unit (after necessary components taken out) water / steam spray and cotton or directly wet cotton can be used by wiping.

9- Belt Tension And Alignment Control

Tension of the belt is adjusted at the factory. But after the first day operation and later approximately at one month intervals, belt tension should be checked and adjusted if necessary. To check the belt tension:- Measure centre distance of pulleys. (in meters)- Calculate belt deflection by using the following formulaBelt deflection (mm.) = centre distance (m.) x 16- Measure the force required to obtain the calculated belt deflection by using a belt tension checker. Place belt tension indicator on top of the belt and at the center of the span. Apply force at right angle to belt. - Compare the measured force with the values given on the following table. If the measured force is within the range, belt tension is satisfactory. If it is below the lower value, belt needs tensioning.

Before locking the motor is position, check the alignment of pulleys with a straight edge to conserve belt life as well as to eliminate the possibility of unnecessary noise.

If the belt is not tight enough, and if not corrected, could result in slippage causing loss of fan speed and belt failure through wear.

If the belt is too tight, and if not slackened somewhat could cause noise from excessive vibration, premature bearing failure and shorter belt life.

Efficiency is another reason to properly adjust belt tension. Excessive belt tension can create such a power demand as to actually overload a motor that otherwise would be quite adequate.

A belt should be just tight enough to avoid slippage.

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Belt section SPZ SPA SPB SPC

Small pulley diameter,

mm

56

to

95

1,3

to

2,0

100

to

130

2,0

to

2,5

80

to

132

140

to

200

112

to

224

236

to

315

224

to

355

375

to

560

2,5

to

3,6

3,6

to

4,6

4,6

to

6,6

6,6

to

8,7

8,7

to

11,7

11,7

to

15,3

13

to

20

20

to

25

25

to

35

35

to

45

45

to

65

65

to

85

85

to

115

115

to

150

Tensioning

force,

F

kg

N

DEFLECTION

CENTER DISTANCE

F

SMALLPULLEY


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10- Change Of Pulleys10.1- Mounting Of Pulleys- Clean and degrease smooth surfaces of bushing, pulley and shaft- Assemble bushing and pulley by aligning semi-threaded holes. Insert the screws loosely.- Insert the key on shaft, then slide pulley to desired position with screw heads to the outside. Tighten screws evenly and progressively. Never apply extreme tightening forces.

10.2- Removal Of Pulleys- Remove tightening screws- Insert one of the screws in the semi-threaded hole and tighten until bushing becomes loose on shaft.

CAUTION: Don’t use hammer or puller to remove the pulley. Don’t change pulleys without written consent of DOGU IKLIMLENDIRME A.S.; otherwise we take no responsibility for the consequences.

11- Lubrication Of BearingsBearings have to be controlled and cleaned regularly; have to be lubricated adequately to prevent direct metallic contact between rolling elements, to prevent wear and to protect bearing surfaces against corro-sion.

The fans with low shaft power are equipped with bearings in a rubber housing which absorbs a part of vibra-tion. When you change the bearing it is very important to change the rubber housing too. These bearings don’t need to be lubricated.

The fans with higher shaft power are equipped with bearings with cast iron support. The lubricant filled in a bearing gradually loses its lubricating properties during operation. Therefore it is necessary for grease to be replenished or renewed from time to time. The grease used is always lithium soap type suitable for all tem-peratures within the operating range.

Excess grease will cause the operating temperature to rise rapidly, particularly when running at high speeds. Therefore only the bearing should be completely filled, whilst the free space in the housing should be partly filled (between 30 and 50 %) Where bearings are to operate at very low speeds and must be well protected against corrosion, it is advisable to completely fill the housing.

Some of the bearings are prelubricated for life, that means grease life is tailored to the bearing life. Life of regreasable bearings can be increased by observing specified relubrication intervals; this can also com-pensate for other factors such as temperatures, ingress of liquids, speed, bearing size and mechanical load.

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CAUTION: For lubrication of bearings refer to the recommendations of fan and motor manufacturers.

12- TroubleshootingBefore checking the fan system, it will be necessary to shut down the fan. During inspection, the unit must be isolated electrically and all disconnect switches and other controls must be locked in the “off” position. Also, a prominent “DO NOT START” sign should be placed on control panel.

To find out the problem is an important step to correct it. By following the procedures outlined in this section, cause of the problem should be found.

Procedure for troubleshooting:a) Look at the troubleshooting chart to find the problem. Check probable causes.b) If the cause of the problem can not be found proceed through the “system checklist.c) If the problem still can not be solved, it is recommended to contact the “unit manufacturer”

System checklist

A systematic check of items listed below may identify the problem. See that:a) Impeller rotation is correctb) Pulleys are alignedc) Belts are not loose or too tightd) Belts and/or pulley are not worn.e) Flow surfaces of fan (impeller blades, housing and passages between inlets) are clean.f) Impeller and housing are not damaged.g) Coils, filters, ducts are clean.h) Fan outlet connections are correctly designed and installed.i) Variable inlet vanes are synchronised. If inlet vanes are not synchronised, there will be an unbalance flow between inlets causing thrust on bearing and low performance.j) Inlet vanes are correctly positioned for the designed operating conditionsk) There is no leak in the unit and ductwork. Some common leak sources are access doors, coil, duct joints, fan outlet connections etc.

If the cause of the problem still can not be found, consult air handling unit manufacturer. Manufacturer may need following information

a) Complete drawings including unit location, ductwork detail, model and size of the unit.b) Measured and design performance figures.c) System design calculationsd) Measured fan performance figures such as fan static pressure, air volume, current drawn, fan speed, air temperature and altitude etc.

12.1- Troubleshooting Chart

PROBLEM

NOISE

Impeller hits inlet

ring

Damaged impeller

Damaged inlet ring

Impeller not centered on shaft

Shaft loose in bearing

Impeller loose on shaft

Correct or change impeller

Correct or change inlet ring

Center the impeller

Tighten shaft

Tighten impeller

Belts too loose

Belts too tight

Belts wrong section

Belts worn

Belts oily or dirty

Belts length different (multibelt drives)

Drive systems hits drive guard

Fan, motor or motor base fixing bolts loose

Pulleys misaligned.

Variable speed pulleys not adjusted so each groove has different diameter.

Motor bearings damaged

Loose on support

Loose on shaft

Bearings worn or damaged

Bearings need lubrication

Foreign material inside bearing

Corrosion between shaft and bearings

Tighten bearings

Tighten shaft

Change bearings

Lubricate bearings

Clean bearings

Clean corrosion, if the shaft worn change shaft

Ductwork undersized for application

Fan size is too small for application

Check duct size and revise if necessary

Change size of equipment, revise if

necessaryCoil with insufficient face area

Worn or damaged impeller

Unbalanced impeller

Foreign material in fan housing or inside the unit

Change impeller

Balance impeller

Clean fan housing

Vibrating ductwork

Vibrating casing parts

Stiffen ductwork

Isolate vibrating parts properly

Vibrating parts not isolated from building

Obstruction in dampers, registers, grilles

Leaks in casing and ductworks

Sharp elbows

Sudden expansion or reduction in ductwork Install expansion/reduction sections with proper expansion/reduction angles

Check and remove any obstructions

Seal leaks

Remove sharp elbows, install elbows with proper radius and turning vanes

Registers and/or grilles undersized for application

Fan shaft bent

Belts too loose

Adjust belt tension

Install correct section belts

Change belts

Clean belts

Install correct belts.

Check drive system and drive guard.

Tighten bolts

Align pulleys

Adjust each groove to same diameter for required air flow

Change bearings

Correct or change shaft

Noise from drive

system

Noise from

bearings

High air velocity

Noise from impeller

Vibration

Rattling/whistling

SYMPTOMS POSSIBLE CAUSE OTHER CAUSES OR ACTION

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NO AIR FLOW

Motor is not

running

Motor is runni

ng but no

air flow

LOW AIR

FLOW

HIGH AIR

FLOW

HEATING

COIL

No heating

HEATING COIL

Low heating

Current is not

reaching motor

Current available

to motor

Fan is not running

Fan is running

Electric power failure

Motor bearing seized

Incorrect wiring to terminals

Faulty motor windings


Duct blockage


Filters are dirty or clogged

Coils are dirty or clogged

Fan rotation is not correct or impeller installed backwards

Belts are not tight or are greasyDrive belts are slipping

Duct resistance exceeds design criteria. Poor duct design

Dampers/registers closed

Access doors are loose. Duct joints are unsealed. Outlet duct system is not completed

High leakage on pressure side of the system

Drive system is wrong. Fan speed is low

Ducts are oversized or duct resistance overestimated.Access doors are loose. Duct joints are unsealed. Suction duct system is not completed.

Drive system is wrong. Fan speed is high

Supply voltage is low

Registers/grilles not installed

Filters are not installed

Power failure

Air lock

Automatic valve is closed

Isolating valves are closed

Boiler flow temperature is low

Regulating valves are partially closed

Pump failure. Thermostat failure. Time clock error. Fuel blockage. Blockage in coil or pipes

Thermostat failure, valve motor failure

Circuit valves are closed.

Thermostats should be adjusted. Boiler power is in adequate

Pumping power is not sufficient.Pipe sizing is not correct. Blockage in coil.

Boiler plant is off

Heating fluid is off or cold

Heating mains is coldHeating fluid flow rate is low

Filters are clean so low initial pressure differential

High leakage on suction side of the system

Motor current is excessive

Close balancing dampers or slow down fan by changing pulleysCheck access doors and duct joints. Seal leaks. Complete duct system

Consult manufacturer to check whether drive system is properly selected or not

Motor overloads. Check current drawn by motor

Install registers/grilles

Install filters

Regulate on dampers

Change or clean filters

Change or clean coils

Correct fan rotation, check that impeller is properly installed

Tighten belts, clean the grease

Check duct pressure losses and duct design

Adjust dampers/register for required air flow conditions

Check access doors and duct joints. Seal leaks. Complete duct system.

Consult manufacturer to check whether drive system is properly selected or not

Starter overload tripped

Control panel fault

Isolating switches off

Locate fault and restore power

Faulty wiring motor. Loose terminals.

Locate and correct fault.

Time clock error

SYMPTOMSPROBLEM POSSIBLE CAUSE OTHER CAUSES OR ACTION

Lack off correct lubrication

Motor internal wiring fault

Overheating or overloading incorrect electric supply

Tighten impeller, check the belts

Rubbish blocking duct

Tighten impeller

PROBLEM

Cooling fluid temperature is high

Insufficient coolant flow

Cooling coil is partially frozen

No air flow

Safety devices stops compressor

Safety devices stops compressor

Faulty thermostatic gear

AIR WASHER

Low

humidifying

COOLING OIL

No cooling

No cooling

ELECTRONIC

STEAM

HUMIDIFIER

No

humidifying

ELECTRONİC

STEAM

HUMIDIFIER

Low

humidifying

ELECTRICAL

HEATER

Low heat

Low water flow

Low water level in water pan

Water distribution system is clogged

Strainer is clogged

High air flow

Refrigeration plant cycles on-off Refrigeration plant capacity is insufficient. Circulating pump or compressor fault. Excessive heat gain in piping system.

Low load

Low suction temperature

Low air flow

Entering air temperature is too low

Thermostatic valve is closed

Power is not reaching elements or control valve

Electronic power failure

Heater elements faulty

Faulty thermostat gear

Steam supply rate is low

Steam cylinder and heating elements are scaled

Safety cut-out tripped

Humidistat calibration is not correct

Steam-trap faulty

Electric power failureMain contactor de-energized

Elements down to earthElement failure Elements disconnected / elements incorrectly wired / wrong voltageController cams faulty / wiring fault / equipment faultStep controller is stickingThermostat set is too low

Thermostat set is too low

Power is not available at controllerPower available at controller

Step controller faulty

Locate fault and restore powerSafety cut out tripped / poor duct design adjacent to heater causes areas of uneven air velocity and overheating of casing

Water treatment is insufficient

Heater elements faulty

Humidistat setting is not correctWater is not available in cylinder

Safety cut-out tripped

Control fault

Chilled water isolating valves are closed

Cooling thermostat setting is high

High pressure cut-out disconnects

Solenoid valve closed. Low pressure cut-out disconnects

Valves are partially closed or blockage in the system

Refer to “no cooling, safety device stops compressor” section

Refer to “ low air flow” section

Apply reheat or preheat

Unequal air velocity. Poor duct connections

Circulating pump or compressor fault

Blockage in system. Valves are closed. Leakage in piping

Float valve is off. Supply water is off.

Clean the system.

Clean the strainer

Refer to “high air flow” section

SYMPTOMS POSSIBLE CAUSE OTHER CAUSES OR ACTION

36 www.doguhvac.com


Water make-up failure or insufficient water level in cylinder. Water treatment is required to avoid scaling.

Control valves are not opening fully. Manual valves or partially closed

Manual valves or partially closed

Carry out maintenance or replacement

Thermostatic gear fault

Reset humidistat correctly

Check supply system

Water make-up failure or insufficient water levelin cylinder. Water treatment is required to avoid scaling.

Thermostatic failure. Circulating pump failure

Refer to “no air flow” section

Locate and correct fault

Fault in condenser. Fans or pumps stopped. Condenser blocked. Heat rejection is not taking place.

Suction temperature is too low. Low airflow. Entering air temperature is too low. Oversized coil or compressor.

13- Operating Limits Of FansWARNING: It is not permitted to operate fans at higher speeds other than design speed, without written permission of DOGU IKLIMLENDIRME A.S., since operating at higher speeds may overload and damage the motor and fan.

FAN TYPEADH

MAXIMUMINSTALLED

POWERkW

MAXIMUMSPEED

rpm

160L, 160R180L, 180R200L, 200R

200K225L, 225R

225K250L, 250R

250K280L, 280R

280K315L, 315R

315K315K1

355L, 355R355K

355K1400L, 400R

400K400K1

450L, 450R450K

450K1500L, 500R

500K500K1500K2

560L, 560R560K

560K1560K2

630L, 630R630K

630K1630K2710K

710K1710K2800K

800K1800K2900K

900K1900K21000K

1000K2

3344444

7.55.5115.511

18.57.515227.515221115301115303715

18.5304515

18.530452237552237553045753775

420040003800380034003400280030002500270021002400240018002000200016001800180014001500150012001300140014001100120013001300900

100011001100850900900750800800650700700600650


www.doguhvac.com 37

FORW

ARD

CURV

ED B

LADE

FAN

S, T

YPE

“ADH

”

38 www.doguhvac.com


FAN TYPEADH

MAXIMUMINSTALLED

POWERkW

MAXIMUMSPEED

rpm

180L, 180R200L, 200R

200K225L, 225R

225K250L, 250R

250K280L, 280R

280K315L, 315R

315K315K1

355L, 355R355K

355K1400L, 400R

400K400K1

450L, 450R450K

450K1500L, 500R

500K500K1500K2

560L, 560R560K

560K1560K2

630L, 630R630K

630K1630K2710K

710K1710K2800K

800K1800K2900K

900K1900K21000K

1000K2

2,233444

5.55.57.55.57.5117.511157.515221115301115303715

18.5303715

18.530452237552237553045753775

68006000680058006000460054004000470035004100450033003800400027003100350025002800320021002350265028001950210024002600160017002000230015001700200012001400165011001250150010001300

BACK

WAR

D CU

RVED

BLA

DE F

ANS,

TYP

E “R

DH”


www.doguhvac.com 39

FAN TYPEMAXIMUMINSTALLED

POWERkW

MAXIMUMSPEED

rpm

TLZ 160TLZ 180TLZ 200TLZ 225TLZ 250TLZ 280TLZ 315TLZ 355TLZ 400TLZ 450TLZ 500TLZ 560TLZ 630TLZ 710

TLZ 710TTLZ 800TTLZ 900T

TLZ 1000TT-HLZ 180T-HLZ 200T-HLZ 225T-HLZ 250T-HLZ 280T-HLZ 315T-HLZ 355T-HLZ 400HLZ 400RT-HLZ 450HLZ 450RT-HLZ 500HLZ 500RT-HLZ 560HLZ 560TT-HLZ 630HLZ 630TT-HLZ 710

T-HLZ 710THLZ 710T

T-HLZ 800THLZ 800T

T-HLZ 900THLZ 900T

T-HLZ 1000THLZ 1000T

3.53.5455

6.3799

1111

13.513.514222532403

3.545

5.25.67

7.5148

2010201435

12.540

12.51845184530703570

4250400038003400300027302200190017001500130012001000750850750650600

70006200620058004700370034002850360025003400210028002000280015502300130015002050120016501200160010651330

BACK

WAR

D CU

RVED

BLA

DE F

ANS,

TYP

E “R

DH”

BACK

WAR

D CU

RVED

BLA

DE F

ANS

40 www.doguhvac.com


MAXIMUMSPEED

rpm

MAXIMUMINSTALLED

POWERkW

MAXIMUMSPEED

rpm

TZAF 355BTZAF 355T1TZAF 355T2TZAF 400BTZAF 400T1TZAF 400T2TZAF 450BTZAF 450T1TZAF 450T2TZAF 500BTZAF 500T1TZAF 500T2TZAF 560BTZAF 560T1TZAF 560T2TZAF 630BTZAF 630T1TZAF 630T2TZAF 710BTZAF 710T1TZAF 710T2TZAF 800T1TZAF 800T2TZAF 900T1TZAF 900T2

TZAF 1000T1TZAF 1000T2

6.59

126.59

148.513

18.59.5132211

18.53511

18.540142245225033703575

300036504000270032003700240028503300210023002820195022002650155017002350137017002100130018001300160010501400

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14- Motor Technical InformationSiemens Low-voltage Three Phase Squirrel-cage Motors3000 rpm (2 pole) 400V, 3ph, 50 Hz, degree of protection IP55, class F insulation, 40 °C


www.doguhvac.com 41

TYPE SPEEDrpm

CURRENTA

EFFICIENCYµ, %

POWER FACTORCosØ

OUTPUT POWER

KW HP

1LA7 060-2AA601LA7 063-2AA601LA7 070-2AA601LA7 073-2AA601LA7 080-2AA601LA7 083-2AA601LA7 090-2AA601LA7 096-2AA601LA7 106-2AA601LA7 113-2AA601LA7 130-2AA601LA7 131-2AA601LA7 163-2AA601LA7 164-2AA601LA7 166-2AA601LA5 183-2AA601LA5 206-2AA601LA5 207-2AA601LA5 223-2AA601LA6 253-2AB601LA6 280-2AC601LA6 283-2AC60

0.180.250.370.550.751.11.52.234

5.57.51115

18.522303745557590

1/41/31/23/41

1.5234

5.57.5101520253040506075

100120

2820283027402800285528452860288028902905292529302940294029402940294529452960296529752975

0.500.681.001.361.732.403.254.556,107,80

10,3013,8020,0026,5032,5039,0053.0065.0078.0093.00

128.00150.00

63656671737779828486

86.588

89,59091

91,792,392.893,693.594.394.7

0.820.820.820.820.860.870.850.850.850.860.890.890.880.900.910.880.890.890,890.910.900.91

42 www.doguhvac.com


1500 rpm (4 pole) 50 Hz400V, 3ph, 50 Hz, degree of protection IP55, class F insulation, 40 °C

TYPE SPEEDrpm

CURRENTA

EFFICIENCYµ, %

POWER FACTORCosØ

OUTPUT POWER

KW HP

1LA7 060-4AB601LA7 063-4AB601LA7 070-4AB601LA7 073-4AB601LA7 080-4AA601LA7 083-4AA601LA7 090-4AA601LA7 096-4AA601LA7 106-4AA601LA7 107-4AA601LA7 113-4AA601LA7 130-4AA601LA7 133-4AA601LA7 163-4AA601LA7 166-4AA601LA5 183-4AA601LA5 186-4AA601LA5 207-4AA601LA5 220-4AA601LA5 223-4AA601LA6 253-4AA601LA6 280-4AA601LA6 283-4AA60

0.120.180.250.370.550.751.11.52.234

5.57.51115

18.522303745557590

1/61/41/31/23/41

1.5234

5.57.5101520253040506075

100120

13501350135013701395139514151420142014201440145514551460146014601460146514701470148014851485

0.420.560.761.031.451,862.553.404.706.408.20

11.4015.2021.5028.5035.0041.0055.0066.0080.0097.00

134.00160.00

55606065677277798282858687

88.590

90.591,291.892.993.493.894.394.6

0.750.770.790.800.820.810.810.810.820.830.830.810.820.840.840.830.840.860.870.870.870.860.86


www.doguhvac.com 43

1000 rpm (6 poles) 50 Hz 400V, 3ph, 50 Hz, degree of protection IP55, class F insulation, 40 °C

TYPE SPEEDrpm

CURRENTA

EFFICIENCYµ, %

POWER FACTORCosØ

OUTPUT POWER

KW HP

1LA7 063-6AB601LA7 070-6AB601LA7 073-6AA601LA7 080-6AA601LA7 083-6AA601LA7 090-6AA601LA7 096-6AA601LA7 106-6AA601LA7 113-6AA601LA7 130-6AA601LA7 133-6AA601LA7 134-6AA601LA7 163-6AA601LA7 166-6AA601LA5 186-6AA601LA5 206-6AA601LA5 207-6AA601LA5 223-6AA601LA6 253-6AA601LA6 280-6AA601LA6 283-6AA601LA6 310-6AA601LA6- 313-6AA60

0.090.180.250.370.550.751.11.52.234

5.57.51115

18.522303745557590

1/81/41/31/23/41

1.5234

5.57.5101520253040506075

100120

850835830920910915915925940950950950960960970975975978980982984988988

0.440.620.611.201.602.052.853.905.207.209.40

12.8017.0024.5031.5038.5045,5061.0069.0081.0099.00

136.00162.00

45566162676972747879

8058386

87.589.590.290.891.892.493.093.093.894.2

0.660.750.760.720.740.760.770.750.780.760.760.760.740.740.770.770.770.770.840.860.860.850.85

44 www.doguhvac.com


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15- Producing CompanyDOĞU İKLİMLENDİRME SAN. VE TİC. A.Ş I.T.O.B. O.S.B 10010 Sok. No:4 35473 Tekeli Menderes IZMIR TURKEYTel:+90 232 799 02 40Fax:+90 232 799 02 44

AUTHORIZED SERVICES ANKARAGÜVEN TEKNİKBEKİR YERLİKAYA 0.542.527.7878

ANTALYAREFSER LTD ŞTİAHMET ÖZDERESinan Mah. 1276 Sok. Palmiye Apt.No 4/2 Antalya0.242.31202440.532.2128109

IZMIRMERIDYEN HAVALANDIRMASABAHATTIN AKYAR5854 Sk.No:6 Karabağlar/İZMİR 0.232.2651009 TABLE

GUARANTEE PERIOD :2 YEARSPHYSICAL LIFE :10 YEARS


www.doguhvac.com 45

DEVICE CODE DEVICE MODEL

KS-1EA-1KS-2EA-2KS-3EA-3KS-4EA-4

HKS-5EA-5

HKS-6EA-6

HKS-7EA-7

KKS-S 093-093KKS-A 124-062KKS-S 124-093KKS-S 124-062KKS-S 093-093KKS-S 093-093KKS-S 124-062KKS-A 093-062KKS-S 155-124KKS-S 124-124KKS-S 062-062KKS-S 062-062KKS-S 093-093KKS-S 093-093

DEVICE CODE DEVICE MODEL

KS-12EA-12KS-13EA-13KS-14EA-14KS-15EA-15KS-16EA-16KS-17EA-17KS-18EA-18

KKS-S 155-155KKS-S 155-155KKS-S 124-093KKS-S 124-093KKS-S 093-093KKS-A 124-062KKS-S 093-093KKS-A 093-093KKS-S 155-155KKS-S 155-124KKS-S 124-093KKS-A 093-093KKS-S 093-093KKS-S 093-093

Warranty Certificate Midyat Hospital Air Handling Units And Celled Aspirators The FOUR SEASON brand air handling units and celled aspirators we manufacture which list is given below are under our guarantee against defects in material and workmanship for two years from date of consignment for given conditions below;

• The physical and technical faults which can occur due to failure to maintain devices good during storing them in worksite are out of our warranty scope. • Any transactions done to our devices without our service personnel will override our guarantee. • The burning motor etc. faults which are caused by voltage surges and wrongly done electrical installations are out of our warranty scope.• The spare part and service guarantee is given by our firm to devices we manufacture for 10 years.

Best regards,

46 www.doguhvac.com


Stamp-signature-date Stamp-signature-date

DELIVERY REPORTService / Delivery / Maintenance Form


www.doguhvac.com 47

FIRM

COMMISSIONING FAULT MAINTENANCE

FACILITY NAME

PHONE

NOTIFICATION DATE

DEPARTURE TO SERVICE DATE

SOLUTION DATE

..../..../201...

..../..../201...

..../..../201...

...... : ......

...... : ......

...... : ......

SERVICE SUPPLIED

VEHICLE LICENSE PLATE NUMBER SERVICE PERSONNEL RECIPIENT COMPANY REPRESENTATIVE

Service Type

Transaction Done In Service

DATE HOUR

IN WARRANTY OUT OF WARRANTY

SIGNATURE

DATE

SIGNATURE

DATE

OTHER

Warranty Condition

Description Of Solution

Customer Feedback (To Be Completed By Customer)

Suggestions For Improvements To Be Done (In-house)

17- Decleration Of Conformity

DECLARATION OF CONFORMITY

We, DOĞU İKLİMLENDİRME SAN. VE TİC. A.Ş.. headquartered at 10010 Sk. No:4 İTOB Organize Sanayi Bölgesi Tekeli Menderes - İZMİR – TURKEY hereby declares that the products KKS – S and KKS – H series AIR HANDLING UNITS manufactured at 10010 Sk. No:4 İTOB Organize Sanayi Bölgesi Tekeli Menderes - İZMİR – TURKEY (Tel: + 90 232 799 02 40, Fax:+ 90 232 799 02 44), with the brand name FOURSEASON complies with the essential requirements of the directives;- Machinery (MD) 98/37 EC,- Low Voltage (LVD) 73/23 EEC,and the standards applied in order to verify compliance with directives;EN 60204-1:1997 EN 292-1/2:1991EN 294:1992

Date of Issue: 26.04.2012

Name: Seçkin Tuncer ERDOĞMUŞ Title: General Coordinator Signature:

48 www.doguhvac.com



www.doguhvac.com 49

NOTES

www.doguhvac.com

FactoryITOB Organize Sanayi Bölgesi 10010 Sok.No: 4 35477 Tekeli / Menderes / Izmir / TURKEYTel: +90 (232) 799 02 40 Faks: +90 (232) 799 92 04

Istanbul AreaBarbaros Mah. Çigdem Sok. No:1 Agaoglu My OfficeKat: 4/18 Atasehir/Istanbul / TURKEYTel: +90 (216) 250 55 45 Faks: +90 (216) 250 55 46

Ankara AreaÇetin Emeç Bulvarı 1065 Cad. (Eski 2.Cad) 1309 Sok.No: B/4 Öveçler / Çankaya / ANKARA / TURKEYTel: +90 (312) 472 11 45 Faks: +90 (312) 472 11 46

0910

2015

Documents

AIR HANDLING UNIT INSTALLATION, OPERATION AND … · permission of DOGU IKLIMLENDIRME A.S., since operating at higher speeds may overload and damage the motor and fan. 3- Transportation