instructions for assembly, operation and maintenance … for assembly... · introduction 1. general...

ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS /40

INSTRUCTIONS FOR ASSEMBLY,

OPERATION AND

MAINTENANCE OF AIR HANDLING UNITS


© Copyright Soko Inzinjering d.o.o. DDS January 2013 Information in this manual is subject to change or alterate without prior notice.

Warning, Hazardous Voltage: All work to be performed by trained personnel only. All electrical installation and servicing of the electrical components of this unit to be performed by qualified electricians only. Disconnect power supply before installation and servicing!


CONTENTS

Table of contents

INTRODUCTION ...................................................................................................................... 5

1. General ............................................................................................................................ 5

2. Safety Instructions ......................................................................................................... 5

3. Emergency Instructions ................................................................................................. 6

4. Maintenance and Cleaning Instructions ...................................................................... 6

ASSEMBLY .............................................................................................................................. 7

5. Delivery ............................................................................................................................ 7

6. Unloading and Transport ............................................................................................... 7

6.1 Unloading and Conveyance by Crane ........................................................................... 7

6.2 Unloading and Conveyance by Forklift Truck .............................................................. 7

7. Assembly and Installation ............................................................................................. 7

7.1. Installation of Section ................................................................................................ 7

7.2. Connection of Sections ............................................................................................. 9

7.3. Connection with Air Ducts ......................................................................................... 9

7.4. Pipe Connectors of Heater and Cooler .................................................................. 10

7.5. Connector for Condensate Drain ............................................................................ 10

7.6. Cleaning ..................................................................................................................... 11

7.7. Electric Power Supply .............................................................................................. 11

7.8. Protection of Motor................................................................................................... 12

MAINTENANCE ..................................................................................................................... 12

8. Air Dampers .................................................................................................................. 12

8.1. Putting into operational mode ................................................................................. 12

8.2. Maintenance .............................................................................................................. 13

9. Fan and Motor ............................................................................................................... 13

9.1. Putting into operational mode ................................................................................. 13

9.2. Maintenance .............................................................................................................. 15

9.3. Determining the tensile force of V-Belt for V-Belt transmission ......................... 16

9.4. Maintenance switch .................................................................................................. 17

10. Filters ......................................................................................................................... 18

10.1. Putting into operational mode ............................................................................. 18

10.2. Maintenance ........................................................................................................ 18

11. Silencers .................................................................................................................... 19

11.1. Putting into operational mode......................................................................... 19

11.2. Maintenance ........................................................................................................ 19

12. Heater – Heat Exchanger (warm water /hot water, steam) ................................... 19

12.1. Putting into operational mode ............................................................................. 19


12.2. Maintenance .......................................................................................................... 20

13. Electric Heater........................................................................................................... 21

13.1. Putting into operational mode ........................................................................... 21

13.2. Maintenance ......................................................................................................... 21

14. Cooler – Heat Exchanger (cold water, direct expansion cooler) ......................... 22

14.1. Putting into operational mode ........................................................................... 22

14.2. Maintenance ........................................................................................................ 22

CERTIFICATES - CONFIRMATION OF QUALITY ............................................................... 24

15. Certificate – CE mark .............................................................................................. 24

16. GOST R Certificate ................................................................................................... 28

17. GOST hygienic Certificate ....................................................................................... 31

18. GOST ATEX Certificate ............................................................................................ 34

19. EUROVENT CERTITA Certificate .................................. Error! Bookmark not defined.


INTRODUCTION

1. General

Attention This Instruction for assembly and maintenance should be read and observed by all persons having some influence on operation of Air Handling Unit. In case that some components are not described, individual instructions (require if necessary) shall be observed. Soko Inzinjering will not assume responsibility for any damage caused by non-observing this Instruction. In case of illegal modifications or interventions on the Unit, the manufacturer’s warranty will not be valid any more. The Air Handling Unit delivered by Soko Inzinjering is exclusively intended for air conditioning. Air conditioning means filtering, heating, cooling, humidifying, dehumidifying and transport of air. Soko Inzinjering expressly forbids any other type of use. Provide sufficient space for operation and maintenance of the Unit, in accordance with VDI 3803. The Air Handling Unit and all its parts must be stored in appropriate way, preventing damage or atmospheric influences. During the storage which exceeds 3 months, V-belt shall be removed and rotating parts of fan, motor, etc. shall be rotated once a month.

If the Air Handling Unit is delivered in separate sections, they shall be assembled in accordance with this Instruction for assembly and all protective devices shall be efficiently mounted. A person trained for handling the Unit is responsible for assembly on the spot and replacement of fixed parts, and shall also be responsible for issuance of the Certificate of Compliance. The Air Handling Unit can be set into operation only after the parts are assembled in compliance with this Instruction. All protective devices shall be mounted and checked Service switch must be mounted near the door of the ventilation section. Electric installation in accordance with regulations.

2. Safety Instructions

Danger Serious injures and material losses can be caused if the following instructions are not observed, as well as applicable safety regulations.

Access and work on the Unit is allowed only when the following requirements are met:

All devices are disconnected from electric power supply. Minimum waiting period for frequency converter is 15 minutes (due to residual

stress). Protection against subsequent switching in according to EN 60204 (e.g. block stop

switch for repairs – service switch.)

Use for intended

purposes

Necessary

space

Storing

Before

commissioning

Assembly


Wait until all rotating parts are stopped, especially the fan impeller, V-belt, motor, etc.

Heat exchangers shall cool to room temperature. Protective clothing shall be worn.

After the work is completed, the following requirements shall be met before setting the Air Handling Unit into operation:

Protective devices must be mounted and efficient as per JUS EN 294 (e.g. protective network).

Check that no person is present in dangerous zone (e.g. within the Unit).

Only trained personnel shall operate the device.

3. Emergency Instructions

In case of fire, immediately disconnect all devices from electric power supply. Close air dampers and fire flaps in order to prevent oxygen supply and prevent fire spreading. Carry out quickly antifire measures. Personal safety is more important than material safety.

Danger Serious bodily injuries even loss of life can be caused by inhaling smoke (combustion products). Used construction materials can produce toxic substances. Use protective breathing apparatus (gas mask or similar.)!

Explosion of high pressure vessels or pipelines caught by fire can cause serious bodily injuries and property damage. Do not approach dangerous (critical) area!

4. Maintenance and Cleaning Instructions

Air Handling Units are devices which require regular maintenance. Maintenance is carried out periodically in approximate time intervals depending on air pollution in accordance with VDI 6022. If the air is more polluted, the intervals between two maintenance interventions shall be shorter accordingly. Regular maintenance does not release the operator from performing daily checks of the operation of the Air Handling Unit.

Casing Clean dry foulness with industrial aspirator. Use moistened cloth if cleaning agent with lubricant and oil solution is necessary. Treat galvanised parts with protective spray. Regularly treat all moving parts such as door handles, hinges with lubrication

spray

Use only alcohol based disinfecting agent.

After maintenance and/or disinfecting measures, maintain sufficient cleanness before setting the Unit into operation again. Toxic or offensive smelling substances shall not come in contact with inlet air by which air-conditioned space is supplied.

In clean zones where, due to special circumstances, transmission from outlet to inlet air must not occur, all vital parts shall be leak-proof tested (e.g. using suitable test gas) once a year and after each servicing. Observe the manufacturer’s safety instructions. When it

Fire

Cleaning and

maintenance

Disinfection

Commissioning

Leak-proof test


is necessary, take measures in order to eliminate any leakage in consultation with the manufacturer.

ASSEMBLY

5. Delivery

When goods are received, they must be inspected in order to ensure that the delivery is undamaged and complete. Missing or damaged parts shall be immediately recorded on consignment note and acknowledged by the driver. Detailed description in respect of the procedure when damage is discovered is given in dispatch note. If such procedure is not carried out, responsibility for deficiencies will not be considered.

6. Unloading and Transport

The Air Handling Unit is delivered in individual sections which have their bases. Unloading and transport should be carried out by hoist or forklift truck.

Danger Fall of weight can cause serious bodily injuries or damage. Follow safety instructions for means of transport. Do not stay under the load when it is in the stage of floating.

6.1 Unloading and Conveyance by Crane Attention Use only suitable and approved means for lifting (ropes, chains, wire cables, sheaves)

according to national safety regulations for unloading and transport.

6.2 Unloading and Conveyance by Forklift Truck Attention When unloading and transporting the sections by forklift truck, the sections shall be transported either on their basic frames (bases) or on the pallet.

7. Assembly and Installation

7.1. Installation of Section

Attention The Air Handling Unit shall not be used for fulfilling construction requirements. If the section is misused, e.g. so that the section base will replace a part of the construction structure or bad distribution will endanger the section statics, all warranty obligations will fail. See Note in VDI 3803.

Mount the section on even and hard foundation. Any unevenness leads to nonparallelism of the section frames which are to be connected; it must be corrected by adequate support. Maximum tolerance in horizontal direction is s=0.5% (0.30 ).

Inspection

of goods

Base onto which the

sections are placed


Small floor unevenness (up to 50 mm) can be corrected by using the adjustable legs, which are an integral part of the AHU’s stand. The foundation shall be adjusted to construction requirements from the viewpoint of statics, acoustics and water drain.

Natural frequency of the support (bearing) structure, especially if it is of steel, must be adequately separated from the frequency of rotating parts such as fans, motors, compressors, etc.

1. Screw the adjustable feet 2. Adjust the height of legs in such

a way that the distance from the floor to the stand is H = 250mm and secure by tightening the nut (4a)

Check the arrangement of functional components and prepare drawings according to technical data before commencing the assembly.

Use sound deadened construction bases.

Neighbouring Unit which is of different weight can cause that the holes for connecting the sections are not aligned. In such case, align the holes during assembly by use of the hoist or other appropriate lifting equipment.

Important

Recommendation

Mounting of the

adjustable feet 1 2


7.2. Connection of Sections

All elements for connecting the sections, such as bolts, nuts, sealing tape, etc. are given as a part of the sections (usually in the fan section).

Sections are connected by bolts passing through inner part of profiles which form the section frame.

1 – Self-adhesive sealing tape 2 – Housing profile 3 - Profile for interconnecting the AHU’s sections with screw

The following shall be done in order to connect the sections: Attach the self-adhesive sealing tape along the edges of the profiles which form

the section frame. This is to be done on all joints of all sections being connected. Self-adhesive tape must be pressed between section profiles being connected.

If necessary, fix mutually the sections by clamps, so that connecting holes are aligned.

Connect the sections with bolts and nuts (mount the washers).

7.3. Connection with Air Ducts

Connection of air ducts with flexible connection on the sections of the Air Handling Unit must be realised so that it is free of any stresses. The length of flexible connection must not be used up to the maximum. The optimum length on which the flexible connection should be mounted is 115 mm.

1 – Profile of the AHU 2 – Flexible connection 3 – Air duct which is connected to the AHU

Important

Flexible

connection


7.4. Pipe Connectors of Heater and Cooler

When pipe water connections (inlet and outlet) of the heater and the cooler are close to each other, it must be provided that inlet and outlet connections are not mixed up (take into account that the exchangers are foreseen for counterdirectional water-air flow).

Attention Plan and adjust pipeline to be connected to exchanger section so that the exchanger be not exposed to pressure and stress due to large weight, vibrations, tensile forces, heat dilatation, etc. Use compensator if it is necessary. Provide couplings on service pipeline which will enable simple removal of the heat exchanger for the purpose of maintenance or replacement. The pipeline should be executed so that it does not disturb servicing of the entire Air Handling Unit.

When tightening the threaded connection on the coupling, it should be secured, e.g. by use of twist clamp so as to avoid pipe twisting or damaging. During the work, attention should be paid to connection with the coupling (flange) that the assembly be executed so that the exchanger is not exposed to pressure or stress.

7.5. Connector for Condensate Drain

Condensate drain is performed through the drain trap (U pipe) which is mounted on the very outlet of the Air Handling Unit. The height of U pipe must be appropriate in order to prevent suction of the drain condensate and its spraying in the air stream in the Air Handling Unit. Water must flow directly from the U pipe into side channel, and afterwards to the drains.

Connection of

exchangers

Connection of

drain trap


The height of the drain trap is defined according to the following:

p – total drop of pressure at the point of condensate drain.

Connect the drain trap to appropriate connection and charge it with water.

7.6. Cleaning

When assembly is completed and before start-up (activation), check the cleanness of all components in accordance with VDI 6022 and clean them, if necessary. Special attention shall be paid to removal of metal chips (residues) since they can cause corrosion.

7.7. Electric Power Supply

Attention

Installation, service and electric work to be performed only by skilled and qualified personnel!

Protect against water ingress over electric junctions in the weather leak-proof units. Inlet of the cable should be near the bottom or through waterproof cable of sufficient cross-section (use at least protection class IP65). Check all electric junctions (switch case, frequency converter, motor, etc.) whether they are fixed correctly and fix them if it is necessary (See DIN 46200).

Connect all electric components (e.g. electric heater, electric motor, etc.) in accordance with the manufacturer’s instructions, local electric regulations and general recommendations for protection against electromagnetic interference (earth work, cable length, cable protection).

Electric heating coils must be equipped with safety switch. The safety switch must be inspected for proper operation after initial installation and after long periods of downtime. During maintenance of the air handling unit, the electric heating coil has to be checked for dirt and cleaned if necessary.

Marking of junctions (e.g. electric heater, electric motor, etc.) is shown in the terminal box.

All electric nonconductive areas shall be jumper wire connected by same potential, e.g. separable section junctions, etc. Remove coating on the spots where ring eye meets equipotential bonding, so that the equipotential bonding is possible (metalic uninsulated surface). Do not use metal conduit gland screwing with plastic connector boxes.

Check every earthed cable, in order to make sure that they are correctly fixed and fix them, if necessary. Check galvanised tape used for earth works. Test resistance of earth works in compliance with EN 60204 and take all necessary precautionary measures.

Calculation of

drain trap height

In the zone of underpressure

H1 (mm) = p / 10

HS (mm) = p x 0.075

In the zone of

overpressure

H1 (mm) = 35 mm

H (mm) = (p /10) + 50

∆Ptot ≤ 1000 Pa

H1 (mm) = 100 mm

HS (mm) = 75 mm

∆Ptot ≤ 1000 Pa

H1 (mm) = 35 mm

HS (mm) = 150 mm

Equipotential

Bonding


7.8. Protection of Motor

Protection of the motor against overload is subjected to EN 60204 Provide motor safety switch and adjust the motor to rated current (see nameplate).

Higher adjusted value is not acceptable! Motor to be wired according to wiring diagram in junction boxes Electrical cables within the unit must be long enough that periodic tension adjustments

to belt and pulleys will not be hampered The motor with nominal power up to ~ 5.5 KW can be connected directly (Note: power

limitation is given by electric power distribution company, i.e. local supplier of electric power). Provide smooth commencement of operation when larger motors are used.

Motor Protection: 1. Through thermal contact (thermal contact in winding) direct driven fans through speed

controllable external rotor motors. The thermal contact used for motor protection, should be installed as to prevent a restart after a malfunction.

2. Through motor protection switch, with operation of fans with standard motor and belt-drive.

The motor should be protected from overloading through a protection switch. The thermal relays in the unit should be set with +10% of measured current, after adjustment of the equipment, but not exceeding the rated current of the motor.

Attention Damage caused by insufficient motor protection will not be covered with the manufacturer’s warranty.

MAINTENANCE

8. Air Dampers

8.1. Putting into operational mode

Danger Pay attention to the instructions on page 5.! When the risk of pinning exists, do not approach the area within the reach of air damper blades! Protective devices such as duct connections, protective grid, etc. should be mounted according to EN 294!

Attention Do not activate the fan before checking whether adequate air damper is open or the openness of the air damper is indicated by position switch. Provide control connection so when the air damper is close, adequate fan disengages immediately. Soko Inzinjering cannot assume responsibility for damage caused by irregular operation. If the air dampers are coupled, check synchronised movement and correct gear function, i.e. direction of rotation and final position of the air damper. Check the tightness of all bolts and connections.

In case of motor drive: Adjust linkage so that a 900 swing angle is guaranteed and shutters reach end position when closed.

Coupled air

dampers

Dampers with

motor drive


8.2. Maintenance

Every three months.

REGULARLY AS NECESSARY

Check for operation of air damper, defects, damage and corrosion.

x

Clean air damper, repair damage and remove corrosion. x Check efficiency of protective device. x Check for smooth moving of the blades. x Check adjustments x

Do not lubricate air dampers with gear wheel drive.

9. Fan and Motor


Danger Pay attention to the instructions on page 5.! Serious bodily injuries and material damage can be caused by fracture of the impeller blade. Exceeding the fan maximum speed, as specified in technical data, is not allowed. Do not activate the fan if irregular vibrations are present.

If the fan is started under free blow conditions, i.e. prior to connecting to ducting system, the current consumption may exceed the normal maximum (forbidden area of performance curve). The thermal protection of motor may be activated.

Remove safety equipment mounted for transport (striking wedges or similar) from the fan base. Avoid damaging of vibration insulation.

Attention Before the first activation, check whether it is necessary to clean the fan section, tubing system (is there pollution, tool, small parts, construction dust, etc.). Rotate the fan impeller to check for its smooth moving.

Check the connection of the pulleys with two V-belt slots (rim + elastic bush) together with motor and fan shafts.

Check the drive of the pulleys, adjust if necessary: tension of V-belt whether the slots of the pulleys are aligned so that V-belt is not stressed.

After 1 to 2 hours of continuous operation, repeat the above-said: retighten connection of the pulley with two V-belt slots (if necessary), retighten V-belt check if the slots of the pulleys are aligned.

Activate the motor for short time, in order to check if rotation direction corresponds to the direction shown by an arrow on the fan casing. If the fan rotates in incorrect direction, reversed two phases in accordance with safety instructions (for three phase A.C. motor).

After reaching operating speed of the fan, check the electric power consumption (with close inspection chamber). Measured values shall not exceed the nominal value on the

Maintenance

intervals

Important

Safety transport

equipment

Drive

Direction of rotation

Electric power consumption


nameplate. In case of exceeding, disengage immediately and check external pressure drop, airflows, rotation speed and direction of rotation. If phase currents are unequal, check motor power supply.

Attention The fan must not be operated outside the operation scope limited by the manufacturer. The manufacturer’s instructions shall be observed (take into account acceleration and deceleration).

During assembly of motor fan, e.g. replacement of bearings, the manufacturer’s specific assembly instruction must be observed.

1. Remove the upper two screws, and the lower two unscrew for about 5-6 mm.

2. The corresponding frequency converter,

which mark stands above, on the upper aluminum profile, set on the lower screws. Lean converter to the panel, return the top two screws and then all four screws firmly tighten.

Installation of frequency converters

mark of the corresponding converter

Remove

Unscrew


Note: ALL frequency regulators are always installed/ mounted at the factory, but are disassembled for safe transportation. Electrical diagrams for connecting frequency regulators are attached to the panel (hatched area in the figure 1.)

9.2. Maintenance

Every three months. Maintenance interval can be shorter, depending on whether the operation is continuous, or in some special conditions such as temperature exceeding 40 0C, presence of dust, etc.

Replacement, as well as adjustment of V-belts or pulleys should be performed without applying the force, since it can cause damaging. The fan motor bearings are permanently lubricated and cannot be lubricated subsequently. Standard greases used for lubrication are lithium-based greases and when they lose viscosity the bearing should be replaced.

Remove V-belt in case of disengagement for a longer period (more than 3 months) in order to avoid load of bearings. Replace the fan motor bearing before use if disengagement lasts for longer period (a year or more). Pay attention to the manufacturer’s instructions.

The fan motor bearings are permanently lubricated and cannot be lubricated subsequently (for motors with an axle height up to 160). Electrical motors with an axle height (180, 200, 225) are factory lubricated and it is impossible to further lubricate them without disassembling the motor, while electrical motors with an axle height 250 and above, have the option of lubrication. Standard greases used for lubrication are lithium-based greases and when they lose viscosity the bearing should be replaced.

FAN REGULARLY AS

NECESSARY

Check the fan for foulness, defects, damage, corrosion and couplings. x

Check bearings (noise). x

Lubricate bearings, observe the manufacturer’s instructions. x

Check impeller blades for: balance and vibrations. Adjust if necessary. x

Check for flexible coupling (leak, joints, stress …) x

Check vibration absorbers for function (stiffness, connections, …) x

Check safety of protective frame x

Clean the fan, repair any damage and remove corrosion, fix connections. x

Maintenance

intervals


ELECTRICAL MOTOR REGULARLY AS NECESSARY

Check electric motor for defects, damage, corrosion, heating and the direction of rotation.

x

Check motor bearings (noise). x Clean motor, repair any damage and remove corrosion; fix couplings.

x

Measure voltage, current, starting current and phase symmetricity.

x

Check the tightness of joints, supports in the assembly with the fan, fix if necessary.

x

V-belt transmission

Check V-belt transmission for defect, damage, wear-out, tension, V-belt position (whether it is aligned), functioning and tightness.

x

Replace a set of V-belts x

Adjust position of the fan and motor pulleys so that V-belt be aligned.

x

Adjust V-belt tension x

Clean V-belt transmission x

9.3. Determining the tensile force of V-Belt for V-Belt transmission

according to DIN 7753 Tension of V-belt should be measured and adjusted in accordance to certain technical requirements, using adequate measuring instruments. Measure the distance A of the fan and motor pulleys axes (in meters) Deviation S = A x 16 (mm) Apply sufficient force F on the V-belt in the middle of the distance A in order to obtain

deviation S Measure the applied force F Compare deformation force F with the tabular values. Use higher values in the stage of commencing the operation of new V-belt. After a few hours of continuous operation, test again the deformation force F and adjust it if necessary.

Force F [N] according to deviation S = 16 mm per 1 m of distance A

V-belt tension


TYPE OF PULLEY

DIAMETER OF SMALLER PULLEY ''d'' [mm]

DEFORMATION FORCE F [N]

SPZ 67 to 95

100 to 140 10 to 15 15 to 20

SPA 100 to 132 140 to 200

20 to 27 28 to 35

SPB 160 to 224 236 to 315

35 to 50 50 to 65

SPC 224 to 355 375 to 560

60 to 90 90 to 120

9.4. Maintenance switch

On all systems – AHUs which have one operational and one reserve motor are mounted maintenance switches by type: 1-0-2 , T0-4-8294/I1 – for motors up to 5,5kW; 1-0-2 , T3-4-8294/I2 - for motors from 5,5kW up to 11kW;

1-0-2 , T5B-4-8294/I4 - for motors from 11kW up to 18,5kW;

1-0-2 , T B-4-8294/I5 - for motors of 22kW

These switches are designed to turn off the motor in case of any intervention on the fan motor in the fan section as well as a posibility for motor selection - Operating / reserve. It is envisaged that the motor which is closer to the fan be reserve, a motor which is further away from the fan motor to be operating. For the selection of the operating motor, set the switch to position 1. In the case of operating motor failure, set the switch to zero, wait for all moving parts to stop, take off the belt buckle of the operating motor, set the belt on the reserve motor, set the switch to position 2 - reserve motor.

On systems where there is no reserve motor, the service switches type T0-2-15679/I1/SVB are mounted, which turns off the engine in case of any service intervention on the motor or inside of fan section.

Rukovanje

servisnim

prekidačim


10. Filters


Danger Pay attention to the instructions on page 5.!

Filters are fastened into a frame by tightening bolts. It is not allowed to destroy or damage filter segment. Check the position (seat) of filter in the frame.

It is necessary to monitor filter foulness; Adjustment of differential pressure switch on the side of servicing the Air Handling Unit is advisable.

FILTER CLASS RECOMMENDED FINAL PRESSURE DROP ON FILTER BEFORE REPLACEMENT

G1 – G4 200 Pa

F5-F7 400 Pa F8-F9 400 Pa H10-H14 500 Pa

It is necessary to follow the instructions for maintenance provided by the manufacturer.

10.2. Maintenance

Every three months.

Danger Pay attention to the instructions on page 5.!

Contact with foul filter (dust) can cause allergic reactions on skin, eyes or respiratory organs. When replacing filters, it is necessary to wear protective clothing, and if necessary protective mask. Avoid fouling of surrounding area and new filters when replacing the old ones.

Keep at least one set of spare filters in stock, and store them in a dry and dust-free area. Avoid fouling and possible damaging. Do not use filter after expiry of the life.


Check filters for cleanness, odour, defects, damage and corrosion.

x

Measure differential pressure drop on the filter. x Check the filter seat, tightness, fastening. x

Replace filters in case of extreme foulness, odour or damage, in case of reaching final pressure drop, or after time interval:

Replacement after 12 months Replacement after 24 months

An earlier filter replacement can follow construction works or reconstruction measures or due to inspection. Replacement of single filter element in a set is acceptable in case of damage provided that the last replacement does not date back longer than 6 months.

x

Pay attention to regulations related to environment protection when replacing the filter.

Filter installation

(in segments)

Supervision

Final resistance

of foul filter

Roll filters

Maintenance

intervals

Spare filters


11. Silencers


Danger Pay attention to the instructions on page 5.! It is necessary to check whether silencers are damaged or foul.

11.2. Maintenance

Every three months.

Danger Pay attention to the instructions on page 5.! The silencer largely requires low maintenance.


Check silencers for: cleanness, defects, damage and corrosion.

x

Clean silencers (see below), repair them and remove corrosion (if any), take contact samples if necessary.

x

Use vacuum cleaner for removal of surface dust particles.

Attention When cleaning, do not damage absorption material.

12. Heater – Heat Exchanger (warm water /hot water, steam)


Danger Pay attention to the instructions on page 5.! Do not use high temperature hot liquid when charging or bleeding, since there is a risk from burns. Do not touch very hot surfaces. Avoid contact with drained water when charging and bleeding for there is risk from poisoning and alkaline burns. Observe the manufacturer’s instructions.

Attention Do not exceed permissible nominal pressure (See design data sheet). In order to avoid freezing of heating coil: Add anti-freeze agents or fit safety frost thermostat on the side of air or water (depending on foreseen design of the Air Handling Unit). In order to avoid damaging of conditioning unit due to preheating, activate steam heater only when the fan is running. Provide protective sail switch (“air-prover”) and limit thermostat. Check correctness of inlet/outlet connections.

Supervision

Maintenance

intervals

Cleaning

Supervision


The system should be charged with the liquid intended for heating which by its composition corresponds to the design data sheet. Water quality shall be in accordance with JUS M.E2.011. Too high concentration of glycol leads to reduced heat exchange, and too low concentration of glycol leads to possible damage due to freezing. When charging, pay attention to design technical specifications so that installation cleaning, bleeding and charging be performed correctly (residual air in the exchanger can cause reduction of the capacity). After commissioning, check joints (connections) for leakage, and retighten them if necessary (See section 7.4).

12.2. Maintenance

Every three months.

Danger Pay attention to the instructions on page 5.! To avoid any skin burns do not touch hot surfaces and prior to commencement of works allow the exchanger to cool down to the surrounding temperature. Avoid any contact with discharged water when charging and bleeding, for there is a risk from poisoning and alkaline burns. Observe the manufacturer’s instructions.


Check the heater: hygienic conditions, defects on the air side, damage, leak-proof and corrosion.

x

Clean the heater on the air side (see below), repair damage, leakage and remove corrosion.

x

Check inlet/outlet connections for function. x Check anti-frost protection for function. x Clean the exchanger already mounted; when not accessible pull it out. Removed foulness must not enter into other sections. Remove foulness and foul water very carefully. Pay attention to the following: Avoid bending and damaging of the exchanger plate fins. Blow out the exchanger with compressed air in direction opposite to air flow. Do not use high pressure steam cleaners. Clean with water and low pressure. Use cleaning agents with pH value between 6 and 8 (when required). Frost protection thermostats are easily accessible and can be adjusted via a maintenance door. If frost protection thermostats are mounted in frames those are withdrawable. If the exchanger is out of operation for some time and above all if there is a risk of freezing, the exchanger must be emptied completely. Decontaminate discharged water in accordance with the manufacturer’s instructions.

Charging

After

commissioning

Maintenance

intervals

Cleaning

Cleaning

agents

Out of

operation


13. Electric Heater


Danger Pay attention to the instructions on page 5.! Do not touch heating elements in order to avoid skin burns. Every electric heater must be fitted with safety thermostat with manual reset. Dual thermostat (protective and operating) mounted directly in the air stream behind the electric heater: Operating – setting: 60 0C Protective (safety) – setting: 80 0C. Do not change set values.

Attention Electric heater can only be operated if airflow control is provided. Otherwise, due to insufficient cooling (preheating), electric heater, casing and other fixed parts can be damaged. Airflow must be monitored by measurements of differential pressure in the fan unit using differential pressure switch and sail switch. Functioning must be checked during commissioning (assembly).

Electric power consumption of should be checked by measuring all phases. For nominal values, see nameplate (technical data). If the nominal values are exceeded, Sokoinžinjering After-Sale Service must be notified.

13.2. Maintenance

Every three months.

Danger Pay attention to the instructions on page 5.! To avoid any skin burns do not touch heating elements and prior to commencement of works allow the heater to cool down to the surrounding temperature.


Check flow control, differential pressure switch and sail switch for function

x

Check operation of electric heater, hygienic conditions, defects, damage, corrosion and tightness of joints.

x

Clean electric heater, identify and repair damage and remove corrosion, tighten joints.

x

Check safety and operating thermostat for function (See previous “Commissioning”).

x

Protection

Recommendation

Flow control

Electric

power

consumption

Maintenance

intervals


14. Cooler – Heat Exchanger (cold water, direct expansion cooler)


Danger Pay attention to the instructions on page 5.! Avoid any contact with discharged water; when charging and bleeding, there is a risk from poisoning and alkaline burns. Observe the manufacturer’s instructions.

Attention Do not exceed permissible nominal pressure (See the design data sheet). In order to avoid freezing of the exchanger (if there is risk): Add anti-freeze agent or mount the exchanger in air stream behind the heater. Check inlet/outlet connections for function. The system cooler should be charged with liquid intended for cooling which by its composition corresponds to the design data sheet. Water quality shall be in accordance with JUS M.E2.011. Too high concentration of glycol leads to reduced heat exchange, and too low concentration of glycol leads to possible damage due to freezing. When charging, pay attention to design technical specifications so that cleaning, bleeding and charging be performed correctly (residual air in the exchanger can cause reduction of the capacity. After commissioning, check joints (connections) for leakage, and retighten them if necessary (See section 7.4). In case of with direct expansion cooler, cooling installation (including evaporator) is previously pressure tested by nitrogen to 25 bar, vacuumed and charged with cooling agent (Freon). Commissioning and maintenance of cooling installation are included in a specific instruction. Any intervention on the exchanger is permissible only when cooling installation is out of operation. In case of some incorrectness, contact our service.

14.2. Maintenance

Every three months.

Danger Pay attention to the instructions on page 5.! Avoid any contact with discharged water; when charging and bleeding, there is a risk from poisoning and alkaline burns. Observe the manufacturer’s instructions. Clean the exchanger when already assembled or when not accessible, move it out. Removed foulness must not enter joining unit parts. Remove foulness and foul water very carefully. Important points to watch: Avoid bending and damaging the exchanger plate fins. Blow out the exchanger with compressed air in opposite direction to air flow. Do not use high-pressure steam cleaners Clean with water and low pressure.

Supervision

Charging

Maintenance

intervals

Cleaning


MAINTENANCE REGULARLY AS NECESSARY

Check the exchanger: hygienic conditions, defects on air side, damage, leak-proof, and corrosion.

x

Clean the exchanger from air side (see below), repair damage, leakage and remove corrosion.

x

Check and if necessary clean condensate drain pan (drop eliminator pan).

x

Check and clean if necessary condensate drain and drain trap function.

x

Check water level in drain trap, refill if necessary. x

Check inlet/outlet connections for function. x Check anti-freeze protection for function x Check direct expansion for icing. x Drop eliminator Check drip eliminator for hygienic conditions, defects, damage, leak-proof and corrosion.

x

Clean and service drop eliminator: Pull out cassette, disassemble and clean profiles separately,

Repair damage and remove corrosion.

x

Use cleaning agents with pH value between 6 and 8 (when required). If the exchangers are out of operation for some time and above all if there is a risk of freezing, the exchangers must be emptied completely.

Cleaning

agents

Out of

operation


CERTIFICATES - CONFIRMATION OF QUALITY

15. Certificate – CE mark


16. GOST R Certificate


17. GOST Hygienic Certificate


18. GOST ATEX Certificate


«Soko Inzinjering» d.o.o.

Office Bulevard A. Carnojevica 125

11070 � New Belgrade, Serbia Phone +381(11) 785 00 60 Fax +381(11) 713 05 61

Factory Partizanska bb, Industrijska zona

22314 � Krnjesevci, Stara Pazova, Serbia Phone +381(11) 785 00 70

Fax +381(22) 391 340

eMail: [email protected] �� www.sokoing.rs �� www.sokoing.com

instructions for assembly, operation and maintenance … for assembly... · introduction 1. general...

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