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INSTALLATION,

OPERATION

&

MAINTENANCE

MANUAL

INSTALLATION, OPERATION & MAINTENANCE MANUAL DOUBLE SKIN AIR HANDLING UNITS 'TW/TWH' SERIES Part Number:

DOUBLE SKIN AIR HANDLING UNITS 'TW/TWH' SERIES

Part Number: 801-031-62

INDEX

Contents

1. General remarks…………………………………………….…………… …………………….… 2

Page

2. Safety instructions………………………………………………………………………………… 2

3. Short description of units………………………………………… ……………………………… 3

4. Pre-installation checklist…………………………………….…………… ……………………… 4

5. Job site storage… ………………………………………………………………………………… 4

6. Preparing the unit site………………………………………… … ……………………………… 5

7. Transport…………………………………………………….…………… …………………….… 6

8. Installation……….………………………………………………………………………………… 7

9. Section assembly……… ………………………………………… ……… …………………… 11

10. Pre-start up check list……………… ……………………………… ………………………… 13

11. Start-up…… ….………………………………………………………………………………… 15

12. Air inlet/control section …………………………………………….…………… ………………35

13. Filter section ……………………………………………………… …………… ………………35

14. Cooler section ……………………………………………………….…………… ………………35

15. Heater section ……………………………………….…….…………… ……………………… 38

16. Heat recovery system … …………………………………………………………………… … 39

17. Humidifier section ………………………………………… … ……………………………… 39

18. Sound attenuator section………………………………………………….…………… …….… 39

19. Differential pressure switch with adjustable setting……….…………………………………… 40

20. Bulk head light ……………………………………….…….…………… ………………… … 45

21. Inclined tube manometer ……………………………………….…….…………… … ……… 46

22. Magnehelic differential pressure gauge …………………………………….…….………… … 46

23. Additional maintenance instructions for hygienic units ………………………………………… 49

24. Trouble shooting …………………………………… ……………………………………… 50-55

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS. THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

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1

- GENERAL REMARKS

Congratulation … You now own a central air handling unit made by ZAMIL AIR CONDITIONERS. Use this manual to secure/ensure a continuous and safety installation, start-up, operation and mainte- nance of your TW series air handling unit. This applies that your air handling unit needs to be checked and serviced in certain periods, so carefully review the procedures and detailed information discussed in the following pages of this maintenance manual to minimize installation, start up and maintenance difficulties.

2 - SAFETY INSTRUCTIONS

Note This maintenance instruction describes all functions and advantages of the units and secures a safety operation by the client/user, so far as known. Technical use and handling responsibility is of client/user. The maintenance staff/personal must be qualified technicians and trained in operating air handling units. Function control and maintenance to be done periodically. Should above instructions not followed up, warranty will be cancelled.

Observe Users Advice

up, warranty will be cancelled. Observe Users Advice O b s e r v e S

Observe Safety Instructions

Dangere S a f e t y I n s t r u c t i

Attentiona f e t y I n s t r u c t i o n

Noticet y I n s t r u c t i o n s Danger Attention

User information of this maintenance instruction and those given on units or components must be observed and followed up. Provision of unit may not be changed! Unauthorized changes impair function, safety and running life of unit.

Following signs of safety are content of this maintenance manual and to be observed.

indicates

a

potentially

hazardous

situation

which,

if

not

avoided, could result in death or serious injury.

… indicates a situation that may result in damage.

equipment or property

guides …

to useful further information and user advises.

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3 - SHORT DESCRIPTION OF UNITS

ZAMIL TW series air handling units are central-station air handlers consist of standardized unit components for variety of controlled-air applications. The unit may include a wide verity of modules according to the technical and functional requirements given by clients. (See our TW-air handling units’ catalogue for more details).

Generally, the TW-units module is provided with a module name plate/label which identifies the type of module, tagging information, the serial number…etc.

Sample of Fan Section Sticker

Sample of Coil Section Sticker

Sample of Section Identification labels

Sample of Fan Section Sticker Sample of Coil Section Sticker Sample of Section Identification labels -
Sample of Fan Section Sticker Sample of Coil Section Sticker Sample of Section Identification labels -
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4

- PRE-INSTALLATION CHECK LIST

TW series Air handling units can be shipped as individual modules, module sub-assemblies or a complete unit depends on the unit size, length, module function, and site space limitations. Units which shipped without a base rail are securely fixed to a wooden skid to facilitate handling. No skid is provided for units which have base rails.

AttentionNo skid is provided for units which have base rails. Receiving Check List Upon receipt of

Receiving Check List

Upon receipt of air handling, unit conduct a closely and a throughout inspection for damage which may have been caused in transportation.

At least inspect the following:

a. If the unit shipped in sections, make sure of the availability of all sections.

b. Inspect the external panels for any external damage.

c. Check all access doors to make sure that all hinges, handles, latches are not damaged.

d. Inspect the interior of each module for any internal damage.

e. Inspect the coil(s) for any damages to the fin surface and/or coil connections.

f. Manually rotate the fan wheel to ensure free movement of the shaft, bearings and drive.

g. Inspect the fan housing for any foreign objects.

h. Make sure of the availability of any item shipped as loose parts or spare parts. Any found damage must be reported within 14 days of receipt.

Resolving Shipping Damage

Attentionwithin 14 days of receipt . Resolving Shipping Damage Equipment is purchased F.O.B Fact ory, meaning

Equipment is purchased F.O.B Factory, meaning that the unit belongs to the customer the moment it leaves Zamil storing area and is the responsibility of receiving party to inspect the unit upon arrival at the destination before unloading or moving unit to its permanent location. If damage is noted or discrepancies found, the local Zamil sales representative should be notified immediately so that corrective action be taken.

Zamil is not responsible for shipping damage.

5 - JOB SITE STORAGE

If unit is to be stored for a period of time prior to installation, observe the following precautions:

a. Choose a dry storage site that is reasonably level and sturdy to prevent undue stress or permanent damage to the unit structure or components.

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b. Zamil highly recommends leaving units and accessories like filters cartoons in their skids / shipping packages for protection and ease of handling until installation.

c. Store the unit in clean location to protect motor, bearing, coils, filters…etc. from excessive dust.

d. Avoid storage in location where children play and/or public access.

e. Set the unit off ground if you store it in heavy rain area.

If unit is to be stored for an extended period of time the following maintenance procedure must be performed:

a. Fan wheel should be rotated by hand every two weeks to redistribute the bearing grease and to prevent bearing corrosion.

b. Each month bearings should be purged with new grease to remove condensation.

c. Belts should be removed or at least loosen, then prior to start- up, inspect and replace if necessary, reinstall/retention the belt.

d. All openings and access doors must remain sealed during storage.

e. Dampers must be cleaned and lubricated prior to start up.

f. Allow enough clearance around the unit to inspect periodically the equipment while in storage.

g. Do not stack units.

h. Do not pile other material on the unit.

6 - PREPARING THE UNIT SITE

a.

Ensure the total weight of the unit taken into consideration and can be supported by the installation site. (Weight report available with unit technical submittal).

b.

Sufficient space should be allowed for service access. (See page 10 for operation clearance).

c.

The floor or foundation must be level and the condensate drain at the proper height for proper coil drainage and condensate flow, to overcome standing water and wet surfaces inside the equipment which may cause odors and damage for the equipment and building material.

d.

Ensure there is an adequate height for condensate drain. (See page 9 for drain pan trapping).

e.

Ensure that the foundation of the mounting platform is level and large enough to include the unit dimensions. (Refer to the unit submittals for specific dimensions).

f.

Provide adequate lighting for maintenance personal to perform maintenance duties.

g.

Provide permanent power outlets in close proximity to the unit for installation and maintenance.

h.

Wiring the unit must be provided by the installer and must comply with all national and local electrical codes.

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7 - TRANSPORT

Lifting & Rigging

Notice7 - TRANSPORT Lifting & Rigging An experienced, reliable rigger should be selected to handle the

An experienced, reliable rigger should be selected to handle the unloading and final placement of the equipment.

Handle unit with care during installation to avoid damage due to twist- ing, bouncing or tilting. Rigger should be advised that the unit contains delicate components & is to be handled in upright position only.

The unit weight may be unevenly distributed, with more weight in the coil and fan areas. (Refer to the unit submittals for unit/module weights before preparing the unit for lifting).

Noticeunit/module weights before preparing the unit for lifting). Caution Attention To lift the unit use only

Cautionweights before preparing the unit for lifting). Notice Attention To lift the unit use only slings

Attentionbefore preparing the unit for lifting). Notice Caution To lift the unit use only slings which

To lift the unit use only slings which are capable to support the entire weight of the unit and spreader bars as applicable, (slings and spreader bars furnished by others).

Do not lift unit by coil connections or headers or other unit structural components.

Adjust as necessary the lifting slings for even unit lift. Failure to properly lift unit could result in death or serious injury or at least cause equipment and/or property damage.

As test, lift the unit approximately 50 cm to verify proper center of gravity lift point, to avoid dropping of unit, reposition lifting point if unit is not levelled. Failure to properly lift unit could result in death or serious injury or possible equipment of property damage.

Cautionor serious injury or possible equipment of property damage. Transportation By Means of Use: - High-lift

Transportation By Means of Use:

- High-lift

- Stacker trucks with squared timber

If a forklift truck is used, lift only from heavy end of skid.

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Trasnporation By Crane

DangerTrasnporation By Crane U n i t P l a c e m e n t

Unit Placement

AttentionBy Crane Danger U n i t P l a c e m e n t

Danger U n i t P l a c e m e n t Attention Keep

Keep area clear underneath suspended loads don’t step below. Personal injury!

Refer to the unit submittals and unit tagging for correct placement of all modules. If there are any discrepancies between the submittals and the unit tagging, access side and/or connection side, contact your local Zamil representative before going further.

Protect air handling unit against impact shocks, don’t let unit down on edges. Damage of unit!

8 - INSTALLATION

Foundation

- Foundation for the air handling unit shall be 50 - 100 mm each side, bigger than unit dimensions.

- Surface of foundation shall be levelled.

Height/design of foundation shall consider:

- Static requirements (weight of unit).

- Height of condensate siphon.

- Vibration-isolation.

- Solid sound conduction.

Monlithic Foundation Monolithic foundation is capable high demand to vibration-isolation.

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Strip Foundation

- At strip-foundation construction the unit bottom casing profile should be covered. - The intermediate foundation strips should match to unit sectional joint connections.

strips should match to unit sectional joint connections. Isolated Foundation In this case the foundation- plate

Isolated Foundation

In this case the foundation-plate (steel-reinforced) or as steel base frame is located on isolation vibrators, to prevent solid sound conduction. Pedestal below the isolation vibrators prevent that between floor area and foundation plate dust, mud can led to solid sound conduction. This foundation design prevents vibration and solid sound conduction.

design prevents vi bration and solid sound conduction. Vibration Isolation Notice For selection of vibrati on

Vibration Isolation

vi bration and solid sound conduction. Vibration Isolation Notice For selection of vibrati on isolator besides

Notice

For selection of vibration isolator besides the weight of units/foundation the load of air forces to be considered. The arrangement of equal vibration isolations must be symmetric to the unit thrust point. Steel spring-isolators need additional solid sound reducer.

Drain Height/

Foundation

Height To prevent excessive build up of condensate in drain pan, adequate trap

clearance must be provided beneath the unit.

Connection of condensate drain pipe with siphon to be made by client/user. Siphon must be counter pressure free. Prior start-up and after a long period of none-operation siphon must be filled with water.

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DESIGN OF SIPHON (CHW-cooler or DX-coil)

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Service and Maintenance Clearances (mm )

Provide adequate space for unit service access (fan shaft and coil removal, filter removal, motor access, damper linkage access etc.)

filter removal, motor access, damper linkage access etc.) ** Step in inside the unit for filter
filter removal, motor access, damper linkage access etc.) ** Step in inside the unit for filter

** Step in inside the unit for filter checking or replacement. At a minimum, the above clearance dimensions are recommended on one side of the unit for regular

service and maintenance. Refer to the technical submittal for locations of items such as filter access

doors, coil piping connection, motor location of unit for removal of panels.

Sufficient clearance must be provided on all sides

etc.

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9 - SECTION ASSEMBLY

9.1 - UNIT SECTION

Installation

If you use a pedestal base please consider beam in every position of unit sectional joints. For installation of individual unit section screws, washers and tape seals delivered to be used only. At hygienic version additional cover for sectional joints are delivered. After insert they are to be sealed by use elastic sealant (anti fungus silicon).

Section Assembly

TW TWH
TW
TWH
or 1.1 or 1.1 to be sealed by elastic sealing
or 1.1
or 1.1
to be sealed by
elastic sealing
   

Nos. per joint, each

Unit type – TW

TW 2-11

TW 14-26

TW 35-90

1

– Hexagonal screw M 8 x 80

4

8

-

1.1 Hexagonal screw M 8 x 120

4

8

12

2 – Spring washer A 8

4

8

12

3 – Cap nut, hexagonal M 8

4

8

12

4 – Self-adhesive seal tape

acc. demand

acc. demand

acc. demand

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Unit type – TWH

TWH 2-11

TWH 14-26

TWH 35-90

1

– Hexagonal screw M 8 x 80

4

6

-

1.1 Hexagonal screw M 8 x 120

4

6

-

2 – Spring washer A 8

4

6

-

3 – Cap nut, hexagonal M 8

4

6

-

4 – Joint gap cover

4

4

-

5 – Assembly clamp

-

2

-

6 – Hexagonal screw M 6 x 20

-

4

-

7 – Spring washer A 6

-

4

-

20 - 4 - 7 – Spring washer A 6 - 4 - Seal tape, near

Seal tape, near the profile edge on one of the opposite section-face- area. Connected sections are to be aligned (on foundation or pedestal) and to be pushed together up to 10 cm distance. Pull together (up to 1 cm distance) and again align the section. Finally fix all connecting screws & nuts as described before. By use of gripping belt/clamp pull now section tight together and fix the connecting screws. First down, then top.

and fix the connecting screws. First down , then top. Installation detail for head joint cap

Installation detail for head joint cap outside installation

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10 - PRE-STARTUP CHECK LIST

After unit is permanently positioned, complete the below pre-start up check list :

Filter Related Checks

1. Check to make sure the filter cartridge count is correct, if filter count is short, the exact number received should be noted on the fright bill at time of delivery.

2. Make sure that filters have been installed properly in their places.

3. Check to be sure that the filters called for are used, failure to use the filters that your Zamil air handler has been designed for can cause fan motor overload and/or cause the coils to become dirty and restrict air flow.

4. Filter access panels or doors should always be closed firmly to stop air by-pass around filter cartridges.

Fan Related Checks

5. Fan isolation shipping lock-down pieces should be removed.

6. If load points are not on same plane after supports are removed readjust isolators until elevation of load point are uniform.

7. Check motor mounting to make sure all nuts are tight.

8. Confirm that the motor voltage, phase, and power are compatible with wiring.

9. All electrical connections should be tight, complete and properly terminated.

10. Rotate manually the fan blower wheel(s) to make sure they should rotate freely in the proper direction and no parts are rubbing.

11. Check the fan for foreign bodies (tools, small components, etc.).

12. Check the alignment and parallelism of the pulleys and the V-belt tension and make sure that set screws are tight.

13. Check bearing-collar set screws on fan shaft and fan hub set screws for tightness. Loose collars and/or set screws will ruin the shaft quickly.

14. Do not operate fans with imbalance.

15. Inspect fan motor and bearings for proper lubrication, if necessary.

16. During fan start-up observe the rotation and if fan is operating reverse to the needed direction, which should correspond to the one indicated by the arrow, should the motor run in the wrong direction, interchange any two of the three electrical leads. Single-phase motors can be reversed by changing internal connections.

17. Supply and return fan drives are provided in the mid-speed adjustment range when variable speed sheaves are furnished. The motor sheave pitch diameter is field adju- stable for the required air flow. When final adjustments are complete the current draw of the motor should be checked and compared to full load amperage rating of the motor.

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18.

After supply fan is set, the return fan drives should be adjusted for proper pressurization of the building.

19. The maximum elongation of V-belts occurs in the first operation hours. Therefore it is highly recommended that after 30 minutes (full load) the V-belt shall be re-tensioned.

20. Sheaves with two or more grooves should be adjusted by the same number of ½ or full turns from closed position to insure the same pitch diameter so belts bear equal load. DO NOT FORCE BELT OVER THE GROOVES.

21. In case of a storage period over six months it will be necessary to clean the old grease and proceed with a re- greasing operation according to the quantities and types. (See Page 23-24 for details).

Coil Related Checks

Dampers Related Checks

General Checks

22. Ensure coil and condensate drain piping connections are complete.

23. Check the piping and valves for leaks.

24. Remove all foreign material from the drain pan and check the pan opening and condensate line for obstructions.

25. In case of DX-Coils ensure that the coil has been charged properly. Adjust the superheat setting.

26. If-for any reason, it is necessary to cut a hole in the unit casing, the hole should be cut through side panel (not through any access panel or door) and then carefully sealed.

27. Rotate damper shafts to test action, rough handling may have caused damper blades to bind.

28. If you select the damper motor make sure it is sufficient to operate the dampers, do not overdrive damper motors, this will deform dampers and/or linkage.

29. All maintenance panels are to be closed. Check all maintenance panels and locks for perfect position. Especially for all maintenance panels on pressure side of fan (positive pressure in the unit).

30. Prior final alignment unit installation position to be checked and levelled position.

31. Damages of coated outside of unit panels/casing to be cleaned from dirt, than treated with primer and re-painted with repair-colour-lacquer. For galvanized casing part the damaged points to be freed from rust (metallic bright) and mended with cold galvanizer.

32. Remove any debris from the unit interior.

33. Access door gasketing must not be removed or leakage of air and water could result.

34. Adjust the differential pressure switch – if any – per system requirements.

35. Check all screws, bolts, nuts electrical and piping connection for tightness.

36. After 24 hours operation re-check “start-up” items.

37. Leave this manual with the unit.

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11 - START-UP

11.1 - FAN SECTION

Assembly Motor and fan are built together as one function component on a common base frame, vibration free fastened to the unit casing. For power supply the local regulations to be observed. Main voltage must comply with the data given at motor name plate. Thermal over-current safety cut-outs are to be provided by client – unless the project specifications ask for, so far motor is not equipped with respective protective device, for example thermistor protectors, in motor winding. If thermal relays are used, they are to be set in accordance to values shown on motor name plate.

Maintenance and Inspection Services

Dangeron motor name plate. Maintenance and Inspection Services Attention Danger Prior opening of any maintenance panel,

Attentionmotor name plate. Maintenance and Inspection Services Danger Danger Prior opening of any maintenance panel, unit

Dangerplate. Maintenance and Inspection Services Danger Attention Prior opening of any maintenance panel, unit to be

Prior opening of any maintenance panel, unit to be switch-off!

Prior opening of any maintenance panel, unit to be switch-off!

Safety notes Before doing any maintenance operation on the fan, it's imperative to ensure that:

- The drive motor is disconnected from all electric terminals.

- The impeller has come to rest.

- The surface temperature has been checked to prevent burning.

- The impossibility of an uncontrolled running of the fan during the maintenance works.

- No debris of damage or dangerous materials is inside the fan. Only limited works may be carried out while in the operating condition and in observance of the safety and accident prevention. Regulations (for ex. measurement of vibration).

The non-observance of these points endangers life for the mainten- ance personal.

At inspection inside unit (fan section) high risk of accident is given by V-belt and fan-impeller.

Fan Impeller & housing checking 1- Light dust media, wear and dirt can be expected inside the housing and on the impeller (corrosion, abrasions, stickled materials), which can cause vibrations. Regular inspection and cleaning must take place. The intervals between them are to be fixed by the operator on accordance with individual operating conditions.

2-

Check concave sides for dirt and/or grease build-up.

3-

Check set screws and/or set collars of fan wheel and bearings for tightness.

4-

Check bearing mounting bolts for tightness.

5-

If fans are furnished with housing drains, make sure that holes in bottom are open.

6-

If housing access door is furnished be sure it is properly sealed and latched.

7-

Remove all debris from fan section and unit in general.

No high-pressure cleaners (steam rod cleaners) are to be used.

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Re-greasable Bearing Generally only proofed and low noise accuracy ball-bearings are built in with theoretical life-time of min. 200,000 operating hours. The V-belt drives pulleys to be calculated/chosen accordingly. Permissible bearing loads are not to be exceeded. Ball or roller bearings are greased at the factory and therefore ready to run at “start-up” however routine maintenance and inspection is required there after.

Normal operation of bearing is “cool or warm to touch”. High bearing temperature accompanied by excessive leakage of grease indicates too much grease. High temperature with no grease showing at the seals, particularly if the bearing seams noisy, indicates too little grease. If running discloses an excessive amount of grease in the bearings the grease fittings should be removed until the excess has escaped. Fan shafts should be coated to prevent corrosion yet check that dirt or debris build up is not accumulating which could affect balance. The re-lubrication intervals indicated in the diagram and tables 8 & 9 on page 24. Apply for fans with horizontal shaft and with temper- ature which do not exceed +60°C.

To consider the accelerated ageing of the grease by high temperatures, it's opportune to reduce by half the re-lubrication interval you can resume from the diagram and tables on page 24. For each 15°C of operating temperature augmentation of the bearing over +70°C (the max. admissible temperature for the grease mustn’t in any case be exceeded (see Table 8 on page 24). By temperatures below +70°C, the re-lubrication interval can be lengthened correspondingly (the re- lubrication interval should never be more than doubled and at least once yearly).

We recommend substituting completely the grease after two re- lubrications. The grease quantity and re-greasing interval depends from bearing type and RPM and are indicated in the tables and figures (See page 24).

Grease must be introduced through the grease nipple, after cleaning it, making the shaft rotate slowly during this operation.

The above data (especially the intervals), even though calculated with a safety factor, are in principle pure theoretical because of the eventual discrepancies between the input data and the actual conditions during the fan operation. For this reason, Zamil strongly recommend to make periodical controls on the bearings even though before the theoretical time of re-lubrication. In most cases, any flaws in the bearings can be detected by listening. When the bearings are normal, they generate a smooth and uniform sound. Loud and squeaking noise or other abnormal sounds imply that the bearings are worn out. A squeaking noise may also be caused by insufficient lubrication. Too small bearing cross-gap can cause a metallic noise. Dents on the outer race of the bearing can cause vibration, which in turn causes a smooth and clear sound. Intermittent sound implies a defective rolling surface. High bearing temperatures are usually a sign that the bearings are running abnormally. Too high temperature is harmful to the grease and bearing itself. High bearing

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- 16 -

temperature may be due to insufficient or excessive lubrication, impurities in the grease, overloading, bearing damage or too small a bearing cross-gap. Even a slight temperature change can be a sign of impaired operation if the operating conditions have not changed. Refilling with lubricant will normally cause a rise in bearing temperature lasting one or two days. Check the grease. A change of color or darkening is usually a sign that there are impurities in the grease.

After the bearing has been re-lubricated a number of times or if the grease has become caked, darkened or faded (compare with its original color), the grease should be replaced.

Check of V-Belt Tension

Correct belt tensioning can be determined as follows:

1. Measure belt length (upper length between pulleys) or calculate it by the formula.

length between pulleys) or calculate it by the formula.   2. According to table below detect
 

2.

According to table below detect power, “p” by which the indiv- idual belt is to be loaded in compliance with belt profile, active diameter, RPM of the small pulley, as well as ratio of transmission.

3.

At standstill pre-tension of belt shall have a deflection “f” of 1 mm per 100 mm belt length between pulleys when deflection power “p” arise at each belt.

Belt profile

Active pulley

   

Power “P” in kg to deflect V-belt RPM of small pulley

 
 

diameter

 

700

 

1450

 

2800

 

4000

dw

       
 

Transmission

 
 

up

to

1

3

1

3

1

3

1

3

x

SPZ

63

90

1.03

1.35

0.9

1.23

0.81

1.13

0.74

1.04

 

100

125

1.21

1.57

1.09

1.42

0.97

1.29

0.89

1.19

140

180

1.33

1.71

1.21

1.54

1.08

1.37

0.97

1.25

x

SPA

90

125

1.54

2.11

1.36

1.9

1.18

1.68

1.05

1.51

 

140

180

1.84

2.4

1.66

2.17

1.45

1.92

1.27

1.71

200

225

2.02

2.55

1.82

2.3

1.57

2

-

-

x

SPB

140

200

2.45

3.28

2.16

2.93

1.8

2.5

1.5

2.13

 

224

280

2.8

3.6

2.5

3.2

2

2.7

-

-

315

400

3.03

3.8

2.65

3.45

-

-

-

-

x

SPC

224

315

4

5.33

3.45

4.66

-

-

-

-

 

335

450

4.5

5.9

3.9

5

-

-

-

-

500

630

4.8

6

-

-

-

-

-

-

x nos. of belts.

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V-belt Replacement and Tension

V-belt Replacement and Tension Attention Danger When replacing V-belts the same belt profile should be used

AttentionV-belt Replacement and Tension Danger When replacing V-belts the same belt profile should be used again.

DangerV-belt Replacement and Tension Attention When replacing V-belts the same belt profile should be used again.

When replacing V-belts the same belt profile should be used again.

To replace V-Belt the axle spacing should be reduced until the new belt(s) can be easily fitted by hand. The re-tensioning of the belts should be done as follows:

TW units are equipped with parallel sliding rail for tension of V-belt. For tension of V-belt, safety screw of spindle at sliding rail to be unscrewed and spindle turned clock-wise until recommended V-belt tension is reached.

Possible elongation of new V-belt drives occurs to 80 % in the first 15 operating hours.

Therefore, in the beginning deflecting “fshall only be approx. 70% of the calculated value. After 50 operating hours recheck V-belts and re-tension them, if necessary.

1) When mounting reduce shaft distance, do not force belts into grooves by screw drives or something similar. 2) In case of multiple-groove belt drives replace always all belts simultane- ously. Care should be taken to ensure that belts have the same length (use sets only). 3) Pulleys shall be correctly flush.

Check of Flushing of Pulleys

shall be correctly flush. Check of Flushing of Pulleys For explosion hazardous plants only el ectrically

For explosion hazardous plants only electrically conductive V-belts may be used. Explosion hazard!

4) Regular checking of belt tension and re-tensioning in intervals of about 800 operating hours ensure high lifetime of belts.

Abnormal heating, excessive oscillations of the belt length between pulleys and noise are mainly reason of insufficient belt tensioning. Insufficient tensioning is leading to slip and pre-mature failure, as well.

Assembly of Pulley

as well. A s s e m b l y o f P u l l

V-BELT PULLEY WITH BUSH SYSTEM

At new pulleys all bright surface must be cleaned and degreased. Fit pulley and bush together and align the fixing holes. Grease screws slightly, fit them into the bolt hole and screw them slightly into the thread holes of the bush. Slide pulley with bush onto shaft, align it and tighten screws uniformly (for tightening torque refer to table, follows):

- 18 -
- 18 -

Torque - Schedule

Bush no.

 

Fixing screws

Max. tightening torque (Nm)

nos.

size

length

1108

2

¼”

½”

5.7

1210

2

3/8”

5/8”

20

1610

2

3/8”

5/8”

20

2012

2

7/16”

7/8”

31

2517

2

½”

1”

49

3020

2

5/8”

1 ¼”

92

3030

2

5/8”

1 ¼”

92

3535

3

½”

1 ½”

10

Dismanteling of Pulley

3535 3 ½” 1 ½” 10 Dismanteling of Pulley A d j u s t a

Adjustable V-Belt Pulley

u s t a b l e V - B e l t P u l

Attention

a- Remove the screws. b- Turn one of screw into pulley thread hole until pulley get loose from bush. c- Now take-off pulley/bush by hand. Don’t use tools or push by.

The theoretical life L10 can be guaranteed only if the diameter of the pulley respects a minimal value, i.e. if the permissible bearing loads are not exceeded. Always replace damaged/worn pulleys with new one of the same diameter.

If drive is equipped with an adjustable V-belt pulley, fan-rpm and consequently air volume can be varied within the regulating range.

When adjusting regulating pulley do not exceed maximum fan-rpm and admissible motor current consumption.

Damage of motor!

Zamil has already set the adjustable pulley to required diameter, according unit technical data. Variation of the air volumes can be made according to the following instructions:

Position of adjustable pulley

Increase active diameter

Decrease active diameter

On motor

Air volume increasing

Air volume decreasing

On fan

Air volume decreasing

Air volume increasing

Adjusting of New Active Pulley Diameter

volume increasing Adjusting of New Active Pulley Diameter When adjusting on a new active diameter proceed

When adjusting on a new active diameter proceed as follows (refer to example):

a) Determine adjustment:

Adjustment = Max. active dia. - New active dia. 4 x Regulating factor

b) Remove out adjusting screw (see picture).

c) By closing adjustable pulley find out max. active diameter. After this, open it to get the calculated rpm. (Adjustment should only be made in complete ¼ revolutions).

d) By doing so, a thread hole in the idle pulley is then matched automatically with the flattening of the fixed pulley. Turn in adjusting screw into this thread hole and tighten it strongly.

- 19 -
- 19 -
 

Adjustable pulley

 

Profile

   

SPZ

SPA

   

Outside

Outside

Active

Regulation factor

84

 

62

80

1.64

95

 

73

91

1.64

100

 

78

96

1.64

108

 

90

104

1.45

 

(108)

(76

102)

1.64

 

120

88

114

1.64

 

129

97

123

1.64

 

139

109

133

1.54

 

146

116

140

1.54

 

156

126

150

1.54

 

164

134

158

1.54

Example for Determination of Adjustment

How to Establish the Grease Quantity for Re-lubrication and Initial filling

Conditions:

Profile SPZ, adjustable pulley 100 mm outside diameter, max. active diameter (refer table above) = 96 mm regulating factor (refer table above) = 1.64 New determined act. Diameter = 83 mm Requested:

adjustment (nos. of revolution) Solution:

adjustment = 96 - 83 = 1.98 = 2 nos. revolution to open 4 x 1.64

1) Identify the fan, type and size. 2) In table (1) determine the technical bearing specifications:

- Bore.

- Unsplitted or splitted type if splitted, then check if it is of ball or roller type. 3) With fan and bearing data, enter tables from (2) to (6), where Ød corresponds to bore (internal bearing bore equal to shaft diameter where the bearing is set) to find the grease quantity for re- lubrication and 1st filling. 4) From table (7) find type and supplier of the grease. 5) To determine the re-lubrication time interval:

- For pillow block bearing see graph 1 with the correct parameters of shaft diameter and revolution velocity. - For splitted pillow block bearing with ball bearing see table (8), with roller bearing see table (9), entering the correct parameters of “bearing block” and revolution velocity.

- 20 -
- 20 -

Table (1)

- 21 -
- 21 -
- 22 -
- 22 -

Table (2)

Table (2) Table (3) Table (4) Table (5) Table (6) Table (7) - 23 -

Table (3)

Table (2) Table (3) Table (4) Table (5) Table (6) Table (7) - 23 -

Table (4)

Table (2) Table (3) Table (4) Table (5) Table (6) Table (7) - 23 -

Table (5)

Table (2) Table (3) Table (4) Table (5) Table (6) Table (7) - 23 -

Table (6)

Table (2) Table (3) Table (4) Table (5) Table (6) Table (7) - 23 -

Table (7)

- 23 -
- 23 -

Graph (1)

Graph (1) Table (8) Table (9) - 24 -

Table (8)

Graph (1) Table (8) Table (9) - 24 -

Table (9)

- 24 -
- 24 -

Bearing replacement 1- Dismantle all the eventual accessories mounted over the shaft, which can stand the substitution of the bearings. 2- Unlock the block cover releasing the bolts located on both sides. By mean of appropriate tools hold the shaft in order to avoid damages to the wheel and inlet cone. 3- Remove the locking rings from the bearing side (note that only one bearing is equipped with the locking rings) and the half sealing rings from the bottom and upper part of the block housing after have cleaned of the grease.

4- Slide out the bearings straightening the feather key of threaded ring placed on the bush; release the threaded ring from both sides using of punch and hammer. Place the bearings; tighten the bush by mean of the threaded ring and bend the feather key. 5- Mount the new seal ring inside the grooves located on the bottom part of the block. Grease the seal ring lips and place the greased group shaft/bearing over the block basement. Place the greased group shaft/bearing over the block basement. Mount one of more locating rings on the side of one bearing only (the other bearing will not be locked). Place the other seal ring, with the lips already greased, inside the upper part of the block. Grease the whole group having care to fill 1/3 of the available room. 6- Place the upper part of the block over the bottom part and tighten the bolts. Fill the bearing with the proper grease. Turn the wheel in order to check the correct rotation and to detect possible bad working on bearings and rotating parts. 7- Please note that an excessive amount of grease can cause a tempe- rature peak in the bearing, which in turn can damage the lubrication properties of the grease and lead to bearing damage.

Installation instructions for taper bushes

To assemble:

1-

Clean and degrease the bore and taper surfaces of the bush and the tapered bore of the pulley. Insert the bush in the pulley hub and

line up the holes (half thread holes must line up with half straight holes).

2-

Lightly oil the grub screws (bush sizes 1008 to 3030) or the cap screws (bush size 3535 to 5050) and screw them in, do not tighten yet.

3-

Clean and degrease the shaft. Fit pulley with taper bush on shaft and locate in desired position.

4- When using a key it should first be fitted in the shaft keyway. There should be a top clearance between the key and the keyway in the bore. 5- Using a hexagon socket wrench gradually tighten and grub/gap screws.

6- When the drive has been operating under load for a short period

(half to one hour) check and ensure that the screws remain at the appropriate tightening torque. 7- In order to eliminate the ingress of dirt fill all empty holes with grease.

To remove:

1- Slacken all screws. Depending on the size of the bush remove one or two. After oiling point and thread of grub screws or under head and thread of cap screws insert them into the jacking off hole(s) in bush.

- 25 -
- 25 -

2-

Tighten screw(s) uniformly and alternately until the bush is loose in the hub and pulley is free on the shaft.

3- Remove pulley/bush assembly from shaft.

Spare Parts Only original Zamil spare parts in accordance with the spare parts list are to be used. Zamil accepts no responsibility for damages resulting from use of other parts. Spare parts are suitable to be requested to Zamil having care to indicate on the order, job and the fan tag numbers. Referring the components of transmission groups as pulleys, bushes, V-belts and bearings are normally available on the market. However, our assistance service is always at disposal to supply parts directly from our stock. In case of heavy-duty application and when an eventual holding time for repair is suitable to originate major costs to your activity, Zamil suggests keeping available at your stock spare parts like:

Impeller.

Shaft.

Bearing block set or single block (if applicable).

Bearing set.

Pulleys.

V-belt set.

Couplings (if applicable).

11.2 - MOTOR 11.2.1 - Motor Identification (Name Plate)

- 26 -
- 26 -

11.2.2 - Checking the insulation

Attention11.2.2 - Checking the insulation This check is essential if the motor has been stored for

11.2.2 - Checking the insulation Attention This check is essential if the motor has been stored

This check is essential if the motor has been stored for longer than 6 months or in it has been in a damp atmosphere. This measurement is carried out with a megohmmeter at 500 volts D.C. (don’t use a magnetoelectric system). It is better to carry out an initial test at 30 or 50 volt and if the insulation is greater than 1 megohm, carry out a second test at 500 volt for 60 seconds. Insulation must be at least 10 megohms in cold state. If this value cannot be reached, and without exception if the motor may have been splashed with water, salt spray, kept in a very humid place or if it is covered in condensation, it is advisable to dehydrate the stator for 24 hours in a drying oven at a temperature of between 110 o and 120 o C.

If the motor cannot be placed in a drying oven:

-Switch on the motor, with the rotor locked; under 3-pahse A.C. voltage reduced to approximately 10% of the rated voltage, for 12 hours (use an induction regulator or a reduction transformer with adjustable outlets). For slip ring motors, this test should be performed with the rotor short- circuited. -Or supply it with D.C. current, with all 3 phases in series, and with the voltage at 1 to 2% of the rated voltage (use a D.C. Generator with independent excitation or batteries for motors less than 22 KW). -NB: The A.C. current should be monitored via a clamp ammeter, the D.C current with a shunt ammeter. This current by 5% of the original value for a 10 o deviation. While drying, all motor orifices must be clear (terminal box, drain holes).

Warningfor a 10 o deviation. While drying, all motor orifices must be clear (terminal box, drain

Attentionfor a 10 o deviation. While drying, all motor orifices must be clear (terminal box, drain

- 27 -
- 27 -

11.2.3

– Electrical

guidelines

11.2.3.1 – Maximum power of motors supplied directly (KW) from the mains

This extract from the C 15.100 standard indicates the limits tolerated for D.O.L. starting of a motor connected to the mains power supply.

starting of a motor connected to the mains power supply. *“other locations” include premises such as

*“other locations” include premises such as in the service industry, the industrial sector, general services to housing and the agricultural sector, etc. Prior inspection by the energy distributor is necessary for motors driving a machine with high inertia, motors with time-delay starting, and brake motors or reversed using reverse current.

11.2.4 - Supply connection

11.2.4.1 - Terminal box

Placed as standard on the top of the motor near the drive end for typed IM B3, B5, B14, the terminal box has IP 55 protection and is fitted with a cable gland. Warning: Even for flanged motor, the position of the terminal box cannot easily be modified as the condensation drain holes must remain at the bottom. Cable gland (NFC 68 311 AND 312 standards) The standard position of the cable gland (1) is on the right, seen from the motor drive end. When the non-standard position of the cable gland has not been correctly specified in the order, or is no longer suitable, the symmetrical construction of the terminal box enables it to be placed in any of the 4 directions except position 2 on flange –mounted motors (B5). A cable gland must never be opened upwards. Ensure that the cable entry radius of curvature prevents water from entering via the cable gland.

- 28 -
- 28 -

Note11.2.4.2 - Terminal block wiring diagram Attention All motors are supplied with a wiring diagram

11.2.4.2 - Terminal block wiring diagram

AttentionNote 11.2.4.2 - Terminal block wiring diagram All motors are supplied with a wiring diagram placed

Note 11.2.4.2 - Terminal block wiring diagram Attention All motors are supplied with a wiring diagram

All motors are supplied with a wiring diagram placed in the terminal box. All connectors required to make connections can be found inside the terminal box. Single speed motors are fitted with a block with 6 terminals conforming to the NFC 51 120 standard, identified in line with the IEC 34-8 (or NFC 51 118) standard.

- 29 -
- 29 -

11.2.4.3 - Direction of rotation

11.2.4.4 - Earth terminal

11.2.4.3 - Direction of rotation 11.2.4.4 - Earth terminal Attention 11.2.4.5 - Connection of power supply

Attention

11.2.4.5 - Connection of power

supply cables to the block

When the motor is powered by U1, V1, W1 or 1U, 1V, 1W from a direct supply L1, L2, L3, it turns clockwise when seen from the drive end. If any two of the phases are changed over, the motor will run in an anti-clockwise direction. (Make sure that the motor has been designed to run in both directions). Warning: Motor with backstop: Starting in the wrong direction will destroy the backstop (see arrow on motor housing). If the motor is fitted with thermal protection or space heaters, these should be connected to screw terminals or terminal blocks with labeled wires.

to screw terminals or terminal blocks with labeled wires. This is situated inside the ter minal

This is situated inside the terminal box; in some cases the earth terminal can be situated on one of the feet or on one of the cooling fins (round motors). It is indicated by the sign.

cooling fins (round motors). It is indicated by the sign. Cables must be fitted with connection

Cables must be fitted with connection suitable for the cable cross section and the terminal diameter. They must be crimped as instructed by the connector supplier. Connection must be carried out with connector resting on connector (see diagrams below):

- 30 -
- 30 -

If using cables without connectors, attach some calipers. If any nuts on brass terminal blocks are lost, they must be replaced by brass nuts, not ordinary steel ones. When closing the box, check that the seal is correctly positioned.

Notethe box, check that the seal is correctly positioned. 11.2.5 - Normal maintenance Checking after starting

11.2.5 - Normal maintenance

is correctly positioned. Note 11.2.5 - Normal maintenance Checking after starting After approximately 50 hours of

Checking after starting

After approximately 50 hours of operation, check that the fixing screws of the motor and the coupling device are tightened; and for chain or belt transmissions, check that the tension is correctly adjusted.

Cleaning

To ensure the motor can operate correctly, take steps to prevent dust and foreign bodies from clogging the cover grille and the housing fins.

Precautions: Check the motor is totally sealed (terminal box, drain holes, etc.) before carrying out any cleaning operation. Dry cleaning (vacuuming or compressed air) is always preferable.

Notecleaning (vacuuming or compressed air) is always preferable. 11.2.5.1 – Motor Greasing 11.2.5.1.1 - Type of

11.2.5.1 – Motor Greasing

11.2.5.1.1 - Type of grease

11.2.5.1.2 - Permanently

greased bearings

- Type of grease 11.2.5.1.2 - Permanently greased bearings When the bearings are not permanently greased,

When the bearings are not permanently greased, the type of grease is shown on the name plate. The standard grease is ESSO UNIREX N3 and we recommend its use for subsequent greasing. Avoid mixing greases.

For LS motor 180 MT and FLS (C) motors 132 M, the bearings defined enable long grease life and therefore lubrication for the lifetime of the machine. The grease lifetime according to speed of rotation and ambient temperature is shown on the following chart.

- 31 -
- 31 -

11.2.5.1.3 - Bearings without

grease nipples

11.2.5.1.4 - Bearings with

grease nipples

Notegrease nipples 11.2.5.1.4 - Bearings with grease nipples Attention 11.2.5.1.5 – Motor bearings maintenance

Attentionnipples 11.2.5.1.4 - Bearings with grease nipples Note 11.2.5.1.5 – Motor bearings maintenance 11.2.5.1.6 –

11.2.5.1.5 – Motor bearings

maintenance

11.2.5.1.6 – Checking bearings

11.2.5.2 – Servicing motor bearings

LS 180 L and LS 200 LT type motors are factory lubricated. Lubricant lifetime (in hours) under normal operation conditions is given in the table below for a machine with horizontal shaft operating at 50 Hz in ambient temperatures of 25 o C and 40 o C.

50 Hz in ambient temperatures of 25 o C and 40 o C. The bearings are

The bearings are factory lubricated

For LS motors > 200 LT (or on request for types 160,180,200 LT) and for FLS (C) and FLSB motors 160, the bearings are fitted with Tecalemit –Hydraulic grease nipples type M8 x 125.

with Tecalemit –Hydraulic grease nipples type M8 x 125. When you detect on the motor: -

When you detect on the motor:

- A noise or abnormal vibration. - Abnormal temperature rise in the bearing when it is correctly greased. The state of the bearings must be checked. Damaged bearings must be replaced as soon as possible to prevent worse damage to the motor and the driven equipment. When one bearing needs to be replaced, the other bearing must also be replaced. The seals should be changed as a matter of course when the bearings are changed. The free bearing allows the rotor shaft to expand (make sure it is identified during dismantling).

Bearings without grease nipple

Dismantle the motor; remove the old grease and clean the bearings and accessories with a degreasing agent. Fill with new grease: the new grease should fill 50% of the capacity of the bearing.

- 32 -
- 32 -

Bearings with grease nipple Always begin by cleaning the waste grease channel

When using the type of grease shown on the name plate, remove the covers and clean the grease nipple heads. When using a different type of grease, dismantle the motor and clean the bearing and accessories with a degreasing agent (carefully clean the grease feeder and outlet channels) in order to remove the old grease before re-greasing. To ensure bearings are correctly greased, fill the retainers, end shields and grease channels to capacity and fill the bearings to 30% of their capacity. Then turn the motor to distribute the grease.

Warningcapacity. Then turn the motor to distribute the grease. Note 11.2.6 – Preventive maintenance Too much

NoteThen turn the motor to distribute the grease. Warning 11.2.6 – Preventive maintenance Too much grease

11.2.6 – Preventive maintenance

Too much grease causes the bearing to overheat dramatically (statistics show that more bearings are damaged through too much grease than too little grease).

The new grease must be recently manufactured, of equivalent standard and must not contain any impurity (dust, water or other).

The diagram and table below give the recommended equipment to use and the ideal positions on the motor to take measurements of all parameters which can affect operation of the machine, such as eccentricity, vibration, winding, insulation, etc. This system allows the user both to monitor the performance of the equipment during use, and in the event of a fault to give measurements which will allow LEROY-SOMER to analyze and diagnose the causes quickly and efficiently, enduring the minimum downtime.

- 33 -
- 33 -

Cross-section of the power supply cables

The higher the current, the greater the voltage drop will be (NFC 15.100 standards or end user’s national standard). The voltage drop should therefore be calculated for the starting current to see if this is suitable for the application. If the most important criterion is the starting torque (or the starting time), the voltage drop should be limited to 3% maximum (the equivalent of a loss of torque of around 6 to 8%). The chart below can be use to select the conductors according to the length of the supply cable and the starting current, in order to limit the voltage drop to 3% maximum.

current, in order to limit the voltage drop to 3% maximum. For motors with flying leads,

For motors with flying leads, the cable should not be used for handling.

Fan motor replacement

1. Shut off motor power.

2. Disconnect and tag power wires at motor terminals.

3. Loosen motor to mounting rail attaching bolts. Loosen belt tensioning bolts as applicable.

4. Note belt position; remove and set aside belts.

5. Lift out motor with hoist suitable for the motor size and weight. Slide motor out on suitable temporary skids to avoid damage to cabinet or frame.

6. Reassemble by reversing above procedure. Be sure to reinstall belts in their original position. Use new belts as required. Do not stretch belts over sheaves. Review above for sheave alignment and belt tensioning discussed previously.

7. Reconnect motor leads and restore power. Check fan for proper speed and air flow.

- 34 -
- 34 -

12

- AIR INLET/CONTROL SECTION

12 - AIR INLET/CONTROL SECTION Attention Dampers Never start fan when damper are closed. Fan motor

Attention

Dampers

Never start fan when damper are closed. Fan motor must be locked by controls, accordingly.

Damage of equipment!

Maintenance Shaft of dampers are embed in plastic bearing sleeves. Normally they don’t require any maintenance. However it is recommended to check periodically connecting rods, bearing seat as well as fulcrums and if necessary to oil them. In case of heavy contamination we recommend to purge by compressed air and re-oil by use of resin-free oil.

13 - FILTER SECTION

13.1 - PRE-FILTER & BAG FILTER

Installation Filter inserts are supply separately in cartons in order to avoid damages/pollution during transport and installation of unit. First remove maintenance panel or open door of filter section. Now pull out (up to TW 26) the filter insert frame to fit-in the filter insert and fix them by locking wires. At walk-in unit TW 35 and bigger step into filter-section and fix as described before.

Maintenance

If no differential pressure gauge is installed filter must be inspected for contamination regularly (weekly) and change, if required. Except Alu. filters, all other filter-media are of throw-away media. Regeneration reduces in any case efficiency and is on risk of client. Filter of following sizes and quantities per each unit type are used.

Quantity of Filters / Sizes Model 24" x 12 " 24" x 20 " 24"
Quantity of Filters / Sizes
Model
24" x 12 "
24" x 20 "
24" x 24 "
No.
610 mm x 305 mm
610 mm x 508 mm
610 mm x 610 mm
TW 2
1
TW 3
1
1
TW 4
1
1
TW 6
2
1
TW 8
2
2
TW 11
4
TW 14
2
4
TW 17
6
TW 22
3
6
TW 26
9
TW 35
12
TW 47
16
TW 60
20
TW 73
9
20
TW 90
30

14 - COOLER SECTION

14.1 - COOLING COIL

Installation

In-/outlet connection should be connected in such way that coil is working to counter flow principle. All piping connection work should be tension free.

- 35 -
- 35 -

In order to facilitate repair, service and maintenance works, piping in front of heat exchangers must be easily removable or should be able to be swivelled off after loosening of cooling coil. Flow and return flow have to be closed by valves. Connect a drip-siphon to drain-connection of unit-drain pan. Connection to main drainage system must be counter-pressure-free or of open-type system. Design of siphon, refer to page 9.

Start-Up Prior to start-up check all connection for correct and tight assembly. For flanges check and re-tighten screws. As far as no automatic air vents are built-in, open all pipe-ventilation devices, prior filling of system. After finish of filling the system pressure rise the same and check for tightness. Prior start-up of fan the siphon to be filled up with water. After start of fan height of siphon to be checked, as no air may be sucked through or blown out.

Maintenance

as no air may be sucked through or blown out. Maintenance Attention Winter shutdown Essentially maintenance

Attention

Winter shutdown

Essentially maintenance works after start-up is restricted to check tightness of system and components, as well as cleanness for coil (tins). Dusty coil have a bad efficiency. At continuous operation, cleaning of coil should be done at least once yearly or at seasonal operation prior start of cooling period. For cleaning remove coil and if applicable drip-eliminator, after all connections are dismantled. Now unscrew drip eliminator, as well. Cleaning can be now done by use of pressed air or by spraying of water with detergent additives. After cleaning coil and drip- eliminator, if applicable, to be re-assembled.

Correct direction of drip-eliminator fins (vertical position) to be maintained.

Anti-freeze methods of coil protection

1. Close coil water supply and return valves.

2. Drain coil as follows:

a. Open vent.

b. Open coil drainage cock.

3. After coil is drained, connect line with a service valve and union from either nozzle to an antifreeze reservoir. Connect a centrifugal pump between the other header connection and the reservoir.

4. Fill reservoir with any inhibited anti-freeze acceptable to code and underwriter authority.

5. Open service valve and circulate solution for 15 minutes then check its strength.

6. If solution is too weak add more anti-freeze until desired strength is reached then circulate solution thru coil for 15 minutes or until concentration is satisfactory.

7. Stop pump drain coil to reservoir and close service valve.

8. Break union and remove reservoir and its lines.

9. Open coil and all needle valves (approximately 2 full turns) until spring.

- 36 -
- 36 -

Air drying method of coil

(unit and coil must be level for this method)

protection

1.

Close coil water supply and return main valves.

2.

Drain coil as described in procedures for anti-freeze methods of coil protection.

3.

Connect air supply or air blower to inlet header connection and close its drain connection.

4.

Circulate air and check for air dryness by holding mirror in front of coil connection. Mirror sill fog up if water is still present.

5.

Allow coil to stand for few minutes repeat step 4 until coil is dry.

Coil replacement

Attentionminutes repeat step 4 until coil is dry. Coil replacement 1. Disconnect piping. 2. Remove coil

1. Disconnect piping.

2. Remove coil connection cover panel.

3. On header end, remove screws holding air baffle to end panel’s on-air entering side.

4. On blind end, remove screws holding baffle to end panels.

5. Slide coil and baffles out of unit

6. Lift coil using lift points. Do not lift by header or center of coils.

7. Replace coil by reversion order of procedures listed.

PVC drip-eliminators are suitable up to air temperature of 80°C, only.

Material damage!

If necessary drain pan can be cleaned separately, as well. After re-assembly of integral parts, they can be pushed into via gliding guide mechanism.

Attentions, they can be pushed into via gliding guide mechanism. Prior start of cooling period heat

Prior start of cooling period heat exchanger to be checked for correct ventilation and system pressure, because otherwise if not available, the full cooling capacity cannot be obtained. If cooling media not mixed up with glycol, in winter freezing danger is given, so far air temperature could be below zero. In this case either:

- Cooling not needed empty system coil purge it with compressed air. - Add glycol according maximum ambient air temperature. Material damage!

14.2 - DX- DIRECT EXPANSION COILS SECTION

Installation Installation of refrigerant connecting piping is to be in such way, that service and maintenance works are not obstructed. We recom- mend to erect, fix the piping to top, on back side or if on mainten- ance side in space of webs/unit-profile, only. In this case mainten- ance panels can be removed without cutting the pipes. Connect a drip-siphon to drain-connection of unit drain pan. Connection to main drainage system must be counter-pressure-free or of open-type system. Design of siphon, refer to page 9.

- 37 -
- 37 -

Start-Up

Start-Up Attention Prior filling of system with fre on has to be checked for tightness (vacuumising).

Attention

Prior filling of system with freon has to be checked for tightness (vacuumising). Only trained personal are admissible (19L WHG or any other country law, valid). The user has to consider VBG 20, DIN 8975 or any other country regulation, valid.

Damage of environment!

Prior start up of fan the siphon to be filled up with water. After start of fan height of siphon to be checked as no air may be sucked through or blown out.

Maintenance Essentially maintenance works after start-up is restricted to check tightness of system and components, as well as cleanness for coil (tins). Dusty coil have a bad efficiency. At continuous operation, cleaning of coil should be done once 1 year or at seasonal operation prior start of cooling period.

For cleaning remove coil and if applicable drip-eliminator, after all connections are dismantled. Cleaning can be now done by use of pressed air or by spraying of water with detergent additives.

Attentionair or by spraying of wa ter with detergent additives. PVC drip-eliminators are suitable up to

PVC drip-eliminators are suitable up to air temperature of 80°C, only.

Material damage!

15 - HEATER SECTION

15.1 - HEATING COIL

Installation In-/outlet connection should be connected in such way that coil is working to counter flow principle. Normally, if not required special inlet of coil is on top, outlet in bottom. All piping connection work should be tension, free. In order to facilitate repair, service and maintenance works, pipings in front of heat exchangers must be easily removable or should be able to be swivelled off after loosening of heat exchangers. Flow and return flow have to be closed by valves.

Start-Up

Prior to start-up check all connection for correct and tight assembly. For flanges check and re-tighten screws. As far as no automatic air vents are built-in, open all pipe- ventilation devices, prior filling of system. After finish of filling the system pressure rise the same and check for tightness.

Maintenance

Same procedure as cooler, see cooler maintenance.

c e Same procedure as cooler, see cooler maintenance. Attention Bad vented coil and system interrupt

Attention

Bad vented coil and system interrupts circulation of water flow or give insufficient quantity. Freezing changer occurs at ambient temperature below zero!

- 38 -
- 38 -

15.2 - ELECTRIC HEATER

Installation

Power supply is to be made according to wiring diagram in terminal box of the heater or as per attached wiring diagram.

To protect other unit components against to high temperature and to away fire, the electric heat-exchanger is equipped with safety thermostat. The safety thermostat cut-off the heater by excess tempe- rature. Furthermore it is recommended to install suitable air flow control device and to interlock fan-motor operation with function of electric heater.

Means:

If fan motor stops by any reason electric heater switched-off also. - If electric heater switch-off by safety device, fan motor shall continue controlled by time relays, prior switching-off as well as.

-

Start-Up

Check all electric connection and function of safety devices.

Maintenance

Beside a periodically check of function no further maintenance work is required.

check of function no further maintenance work is required. Attention Prior opening of panel/door of electric

Attention

Prior opening of panel/door of electric heater section, the plant/unit to be switch-off.

Injury by burns (temperature) and voltage.

16 - HEAT RECOVERY SYSTEM

Please refer to attached manufacturer instructions.

17 - HUMIDIFIER SECTION

Air Washer:

Please refer to attached manufacturer instructions.

Steam Humidifier:

Please refer to attached manufacturer instructions.

18 - SOUND ATTENUATOR SECTION

Installation

Units

are

already

equipped

and

splitter

built-in.

No

further

installation needed.

 

Start-Up

Attenuator surface to be checked for damages and if needed to repair by paste over with fibre-glass mat.

Maintenance Besides check damage and inspection of dust to splitter surface (once a year), no further special maintenance required. Dust can be cleaned off by use of air jet (low pressure) or soft brush, manual.

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19 – DIFFERENTIAL PRESSURE SWITCH WITH ADJUSTABLE SETTING

Technical Data Max operation pressure: 10 kpa for all pressure ranges. Tolerance for upper and lower switching pressure: ± 15 %. Temperature range: Medium and ambient temperature from -20 °C to +85 °C. Storage temperature from - 40 °C to + 85 °C. Pressure connections: P1 for connection to higher pressure (designated +), P2 for connection to lower pressure (designated -). Electrical rating: Standard version: Max 1.5a (.4a)/250 vac, Low voltage version: Max .1a/24 CDC max. switching rate: 6 cycles/min. Arrangement of contacts: Break contact –NC operation contact NO operating contact no power supply line – COM.

19.1 – REPLACING DIFFERENTIAL PRESSURE SWITCH

Check the pressure switch to ascertain whether any damage is ascertain on the hosting. If the housing is leaky because of damage the pressure switch must not be used!

A) Mounting Position

You should mount the pressure switch vertically with pressure connections pointing downwards only then is it possible to drain

any condensation moisture which might occur.

to drain any condensation moisture which might occur. B ) Fixing with Screws To secure the

B) Fixing with Screws

To secure the device on the rear side of the housing, only use the sheet metal screws (3.5x8 mm) (usually supplied together with the

mounting brackets).

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- 40 -
Attention 19.2 - INSTALLING THE HOSES Under no circumstances must use long er screws! Otherwise,

Attention

19.2 - INSTALLING THE HOSES

Attention 19.2 - INSTALLING THE HOSES Under no circumstances must use long er screws! Otherwise, the

Under no circumstances must use longer screws! Otherwise, the base of the housing could be punctured resulting in the pressure switch leaking!

Do not tighten the screws so much that the base of the device is deformed. Otherwise, the pressure switch can be shifted out of position or leak.

Important: under no circumstances must the hoses be kinked pay particular attention to this point if you run the hoses over an edge. It is better to form one (1) loop as shown in the illustration. If the hoses are kinked the device cannot function accurately.

a) For the connection to the air handling unit

With the angled metal tube you can make a linear pressure connection

into the airflow or out of it if necessary. This allows very precise control of the coupling.

With the straight plastic nipples you can make a linear pressure connection to the air duct. In each case, the lead throughs are supplied with their own installation instructions. Install the lead – through as described in their instructions.

the lead – through as described in their instructions. b) For the connection to the pressure

b) For the connection to the pressure switch…

Two sockets are provided there for hoses with an internal diameter

of 6 mm connect the hose.

-With the higher pressure to socket P1 (white) which is located on the lower section of the housing.

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- 41 -

- With the lower pressure to socket P2 (grey) which is located on the lower section of the housing.

P2

which is located on the lower section of the housing. P2 P1 Run the hoses so

P1

Run the hoses so that nobody can trip over them. In particular, make sure by leading them that you run the hoses so as to prevent them from becoming loose when there are air movements, which would result in leaks at the connection.

After you have installed the hoses it is absolutely essential to check them for tightness of fit at the connection points and to make sure that they run without any kinks.

Otherwise it may happen that faults which occurred when the hoses were installed remain unnoticed leading to subsequent faults.

When you have done this, test the tightness of the hoses.

19.3 - ELECTRICAL CONNECTION

Warningthe tightness of the hoses. 19.3 - ELECTRICAL CONNECTION Caution Work on electrical installations must only

Cautiontightness of the hoses. 19.3 - ELECTRICAL CONNECTION Warning Work on electrical installations must only be

Work on electrical installations must only be carried out by specialists who are specifically trained for this purpose. If you are not a specialist yourself never undertake any work on electrical installations!

First, make sure that there is no power on the connection cable while you are working on the electrical connections! Otherwise, a possibly fatal electric shock may result and the conn- ected equipment may be damaged!

The connection cable can be run to the pressure switch from three sides according to choice the screw cable connection has a plug in design for this purpose.

The seal in the screw cable connection is designed for cables with alternative sheath diameters of 7 or 10 mm. Only use these sizes- otherwise the screw cable connection cannot seal adequately!

If you use a connecting cable

With a diameter of 7 mm you can line up the press nut the plain washer and the sealing ring directly on the cable.

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- 42 -
2 with a diameter of 10 mm you mu st first break the inner rubber

2 with a diameter of 10 mm you must first break the inner rubber

ring out of sealing ring. Then line up the press nut the plain washer and the sealing ring on the cable.

nut the plain washer and the sealing ring on the cable. a) The switching device In

a) The switching device

In the pressure switch is designed as a change over contact as can be seen from the wiring diagram. The rest position is shown in the drawing (pressure below the upper switching point).

In this instance pole three (com) closes to …

Pole 2 when the pressure is increasing (NO).

Pole 1 when the pressure is decreasing (NC).

(NO). • Pole 1 when the pressu re is decreasing (NC). Protect the feed line (to

Protect the feed line (to pole 3) by fuse either in the control system of along the line and do so with ….

3 max. 1.5 A/250 VAC if you are loading the contact with an

ohmic consumer; Max 0.4 A/250 VAC if you are loading the contact with an inductive consumer (such as a relay). Max 0.1 A/24 VDC if you are using the pressure switch in the weak current version with gold plated contacts.

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- 43 -

b) The connection

Are intended for crimp type sockets 6.3 mm. Make sure the crimp connection is perfect and that the cable lugs fit properly on the connections! If you do not have any crimp type sockets available you can also use the cable lugs, which are supplied with mounted screw terminals however, these are only intended for rigid copper wire! On flex it is either necessary to crimp on strand end sleeves and then you can also screw the strands on or to crimp cable lugs on directly as previously described!

19.4 – SETTING

lugs on directly as previously described! 19.4 – SETTING Warning Make sure that there is no

Warning

directly as previously described! 19.4 – SETTING Warning Make sure that there is no power on

Make sure that there is no power on the electrical connections before you carry out by settings on the pressure switch! Otherwise, it could be fatal if you accidentally touch the electrical connections or the metal adjusting screw while you are performing the settings!

Setting the pressure range. Use the setting button to set the pressure, which should trip the switch when the pressure is increasing.

Setting button

the switch when the pressure is increasing. Setting button When the pressure falls the switch returns

When the pressure falls the switch returns into its resting position as soon the pressure falls below the set switching differential.

19.5 - CLOSING THE SWITCH

Insert the screw cable connection into the place provided for this purpose on the housing, then place the housing cover in position and screw it down evenly on to the pressure switch.

Housing cover

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- 44 -

19.6 - TESTING THE SETTING

Do not operate the system until the housing is closed. Otherwise there is the possibility of a fatal electric shock if you accidentally touch the live parts!

Check the trip and reset pressures by slowly increasing the pressure and then allowing it to fall again. Important! Observe the maximum permissible operating pressure of 50 mbar which is indicated in the data sheet otherwise the pressure switch may be damaged!

20 – BULK HEAD LIGHT

the pressure switch may be damaged! 20 – BULK HEAD LIGHT Warning To replace a lamp

Warning

To replace a lamp

Make sure that the power supply to the lamp is OFF.

1- Unlock the holding wires.

su pply to the lamp is OFF. 1- Unlock the holding wires. 2- Install the lamp

2- Install the lamp into it’s proper place.

holding wires. 2- Install the lamp into it’s proper place. 3- Cover the lamp by the

3- Cover the lamp by the glass cover and tighten it by locking the holding wires.

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- 45 -

21

- INCLINED TUBE MANOMETER

21 - INCLINED TUBE MANOMETER Installation : Locate the manometer on a convenient vertical surface. Install

Installation:

Locate the manometer on a convenient vertical surface. Install gauge horizontally with self-drilling screws provided.

Filling:

Back out zero adjust knob until it stops: then turn in approximately two full turns so that there is room for adjustment in either direction. Remove the FILL plug and fill it with gauge fluid until fluid is visible in vicinity of zero on scale. Adjust for exact setting with zero knob and replace FILL plug.

Fittings with air filter:

Run the tube from the fitting on the discharge side of the filter to the left gauge connection (+). Remove paper from the red and green stickers and install adjacent to the indicating tube to show clean and dirty filter readings.

Maintenance:

Check oil level regularly to adjust zero knob as required. Be sure all pressure is removed by disconnecting tubing at top of the gauge before adjusting the zero knob.

22 - MAGNEHELIC DIFFERENTIAL PRESSURE GAUGE

the zero knob. 22 - MAGNEHELIC DIFFERENTIAL PRESSURE GAUGE Installation 1- Select a location free from

Installation

22 - MAGNEHELIC DIFFERENTIAL PRESSURE GAUGE Installation 1- Select a location free from excessive vibration and

1- Select a location free from excessive vibration and where the ambient temperature will not exceed 140 o F. Also, avoid direct sunlight which accelerates discoloration of the clear plastic cover, sensing lines may be run any necessary distance, long tubing lengths will not affect accuracy but will increase response time slightly. Do not restrict lines. 2- Magnehelic gauges are calibrated with the diaphragm vertical and should be used in that position for maximum accuracy. 3- Surface Mounting.

Locate mounting holes, 120 o apart on a 4 no. of 1/8” dia holes.

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- 46 -

4- To zero the gauge after installation. Set the indication pointer exactly on the zero mark, using the external zero adjust screw on the cover at the bottom. Note that the zero check or adjustment can only be made with the high and low pressure taps both open to atmosphere.

Operation

Positive Pressure:

Connect tubing (1/4” OD) from source of pressure to either of the two high pressure ports. Plug the port not used. Vent one or both low pressure ports to atmosphere.

Negative pressure:

Connect tubing (1/4” OD) from source of vacuum or negative pressure to either of the two low pressure ports. Plug the port not used. Vent one or both high pressure ports to atmosphere.

Differential pressure:

Connect tubing from the greater of two pressure sources to either high pressure port and the lower to either low pressure ports. Plug both unused ports.

No lubrication or periodic servicing is required, keep the case exterior clean. Occasionally disconnect pressure lines to vent both sides of gauge to atmosphere and re-set to zero.

Maintenance

Calibration Check:

Select a second gauge or manometer of known accuracy and in an appropriate range. Using short lengths of rubber or vinyl tubing, connect the high pressure side of Magnehelic gauge and the test gauge to two legs of a tee. Very slowly apply pressure through the third leg. Allow a few seconds for pressure to equalize, fluid to drain, etc., and compare readings. If accuracy unacceptable, filed re-calibration needed as the following procedure:

1- With gauge case, held firmly, loosen bezel, by turning

counter-clockwise. To avoid damage, a canvas strap wrench or similar tool should be used.

2-

Lift out plastic cover and “O’’ ring.

3-

Remove scale screws and scale assembly. Be careful not to damage pointer.

4-

The calibration is changed by moving the clamp. Loosen the clamp screw(s) and move slightly toward the helix if gauge is reading high and away if reading low. Tighten clamp screw and install scale assembly.

5-

Place cover and O-ring in position. Make sure the hex shaft on inside of cover is properly engaged in zero adjust screw.

6-

Secure cover in place by screwing bezel down. Note that the area under the cover is pressurized in operation and therefore gauge will leak if not properly tightened.

7-

Zero gauge and compare to test instrument. Make further adjustment as necessary.

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- 47 -
Warning Re-calibration or repair by the user is not recommended, consult factory for assistance. Trouble

Warning

Re-calibration or repair by the user is not recommended, consult factory for assistance.

Trouble shooting Tips:

Gauge won’t indicate or is sluggish

1. Duplicate pressure port not plugged.

2. Diaphragm ruptured due to overpressure.

3. Fittings or sensing lines blocked, pinched or leaking.

4. Cover loose or “O” ring damaged, missing.

5. Ambient temperature too low ( below 20 o F).

Pointer stuck-gauge can’t be zeroed.

1. Scale touching pointer.

2. Spring/magnet assembly shifter and touching helix.

3. Metallic particles clinging to magnet and interfering with helix movement.

4. Cover zero adjust shaft broken or not properly engaged in adjusting screw.

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- 48 -

23 - ADDITIONAL MAINTENANCE INSTRUCTIONS FOR HYGIENIC UNITS

Besides of cleaning of all components and devices, special attention must be given to the maintenance of filters. A permanent control of filters is imperative as well as replacement at maximum recomm- ended final filter pressure drop. Appearance and indication of defects shall be solved in due time.

Cleanness of plant

Further they shall be in consideration of experience of maintenance staff and ambient condition/influence of area, where unit is installed.

Air handling/conditioner unit Each filter stage should/must have their own filter gauge, for indication of filter-differential pressure drop. For clear and correct check of filter condition, each filter section shall be equipped with separate name plate, with indication of following:

filter class, type of filter-media, size/numbers of filter-inserts, nominal air volume (m 3 /h), initial pressure drop, recommended final pressure drop, date of last maintenance. Plant room and size of unit shall be designed in such way the reliability and demands of hygienic conditions of whole instalment are assured on high standard of government rules. For quick and easy dismantling/remove of unit components (purpose of maintenance) any piping system for unit should be dismantled easy, as well.

Air conditioning plant for OT-area

Switch-off is allowed for urgent maintenance or repair-works, only. However the time should be limited to short period and must be announced to hospital-management. General maintenance periods and works should be in accordance to hospital organisation rules for OT- area and agreed by technical management of hospital.

Fan Breakdown

agreed by technical management of hospital. Fan Breakdown Notice Power Failure Notice Hygienic Inspection Notice In

Notice

Power Failure

Noticemanagement of hospital. Fan Breakdown Notice Power Failure Hygienic Inspection Notice In case supply fan of

Hygienic Inspection

Breakdown Notice Power Failure Notice Hygienic Inspection Notice In case supply fan of overpressure system (+)

Notice

In case supply fan of overpressure system (+) breakdown, the exhaust fan shall be switched-off automatically, as well. In case exhaust fan of under pressure system (-) breakdown, supply fan shall be switch-off automatically, as well. In both cases electric interlock in control switch board is recommended.

Operation of plant, besides cooling system, must be secured by power failure. Use of emergency power diesel generator, recomm- ended.

All air conditioning plants/units to be inspected in view of hygienic after start-up periodically. Suggestion by hospital management.

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24 - TROUBLE SHOOTING

Problem

Probable Cause

Solution

Noise

Impeller hitting inlet ring

a. Impeller not centered in inlet ring.

b. Inlet ring damaged.

c. Crooked or damaged impeller.

d. Shaft loose in bearing.

e. Impeller loose on shaft.

f. Bearing loose in bearing support.

Impeller hitting cut-off

a. Cut-off not secure in housing.

b. Cut-off damaged.

c. Cut-off improperly positioned.

Drive

a. Sheave not tight on shaft (motor and /or fan).

b. Belts too loose. Adjust for belt stretching after 48

hours of operation.

c. Belts too tight.

d. Variable pitch sheaves not adjusted so each groove has

same pitch dia. (multi-belt drivers).

e. Misaligned sheaves.

f. Belt worn.

g. Isolation base shipping restraints not removed.

h. Belts oily or dirty.

Bearing

a. Defective bearing.

b. Need lubrication.

c. Loose on bearing supports.

d. Loose on shaft.

e. Seals misaligned.

f. Foreign material inside bearing.

g. Worn bearing.

h. Fretting corrosion between inner race and shaft.

Shaft Seal Squeal

a. Need lubrication.

b. Misaligned.

Impeller

a. Loose on shaft.

b. Defective Impeller. Do not run fan - Contact Zamil.

c. Unbalanced.

d. Worn as result of abrasive or corrosive material

moving through flow passage.

Housing

a. Foreign material in housing.

b. Cut-off or other part loose (rattling during operation).

Electrical

a. AC hum in motor or relay.

b. Starting relay chatter.

c. Noisy motor bearings.

d. Single phasing a 3 phase motor.

High Air Velocity

a. Duct work too small for application.

b. Fan selection too small for application.

c. Registers or grilles too small for application.

d. Heating or cooling coil with insufficient face area for

application.

Pulsation or Surge

Restricted system causes fan to operate at poor point of rating.

a.

b. Fan too large for application.

c. Ducts vibrate at same frequency as fan pulsations.

Rattles and/or Rumbles

a. Vibrating duct work.

b. Vibrating cabinet parts.

c. Vibrating parts not isolated from building.

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- 50 -

Insufficient Air Flow

Fan

a. Mechanical volume control device is improperly set.

b. Fan running backwards.

c. Cut-off missing or improperly installed.

d. Dirty fan blades.

e. Loose or slipping belts.

f. Fan speed too slow.

Duct System

a.

Actual system is more restrictive (more resistant to flow).

b. Dampers closed.

c. Registers closed.

d. Leaks in supply ducts.

e. Insulating duct liner loose.

Filters

a. Dirty or clogged.

Coils

a. Dirty or clogged.

Obstructed Fan Inlets

a. Elbows, Cabinet walls or other obstructions restrict air flow. Inlet obstructions cause more restrictive systems but do not cause increased negative pressure readings near the fan inlet(s).

No Straight Duct at Fan Outlet

a.

Fans which are normally used in duct system are tested

with a length of straight duct at fan outlet. If there is no straight duct at the fan outlet, decreased performance will result. If it is not practical to install a straight section of duct at the fan outlet, the fan speed may be increased to overcome this pressure loss.

Obstructions in High Velocity Air Stream

a. Obstruction near fan outlet.

b. Sharp elbows near fan outlet.

 

c. Improperly designed turning vanes.

d. Projections, dampers or other obstructions in part of

system where air velocity is high.

Cam High -Too Much Air Flow

System

a. Oversized duct work.

b. Access door open.

 

c. Registers or grilles not installed.

d. Damper set to by-pass coils.

e. Filter (s) none in place.

f. System resistance much lower than anticipated.

Fan

a. Fan speed too fast.

Incorrect Static

System, Fan or Interpretation of measurements

General Notes:

Pressure

The velocity pressure at any point of measurement is function of the velocity of the air and its density.

a.

 

b.

The static pressure measured in a "loose" or oversized

system will be less than the static pressure in a "tight" or undersized system for the same air flow rate.

c.

In most systems, pressure measurements are indicators

of how the installation is operating. These measurements are the result of air flow and as such are useful indicators

in defining system characteristics.

d. Field static pressure measurements rarely correspond with laboratory static pressure measurements unless the fan inlet and fan outlet conditions of the installation are exactly the same as the inlet and outlet conditions in the laboratory.

Static Pressure Low, CFM High

System

System has less resistance to flow than expected. This is a common occurrence. Fan speed may be reduce to obtain desired flow rate. This will reduce HP (operating cost).

a.

Fan

Backward inclined impeller installed backwards. HP will be high.

a.

b. Fan speed too high.

Static Pressure Low, CFM Low

System

a. Fan inlet and/or outlet conditions not same as tested.

Static Pressure High, CFM Low

System

a. Obstruction in system.

b. Dirty filters.

 

c. Dirty coils.

d. System too restricted.