AIR HANDLING UNITSUSER MANUAL

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CONTENTS

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PREFACE............................................................................................................................................... 3WARRANTY ......................................................................................................................................... 3ACCEPTING DELIVERY ........................................................................................................................ 4DELIVERY, HANDLING AND STORAGE .............................................................................................. 4

Delivery and handling................................................................................................................. 4Storage ........................................................................................................................................ 7

ASSEMBLY........................................................................................................................................... 8Assembly of the AHU ................................................................................................................ 8Assembly of sections.................................................................................................................. 8

INSTALLATION ................................................................................................................................... 9Placement.................................................................................................................................... 9Air duct connections................................................................................................................... 10Water connections...................................................................................................................... 13Tubing connections..................................................................................................................... 14Condensation drain pans............................................................................................................ 14Hot-cold water coil ..................................................................................................................... 16Steam coil ................................................................................................................................... 16Direct expansion type cooling coil............................................................................................. 17

ELECTRICAL CONNECTIONS ............................................................................................................... 17Electrical connection .................................................................................................................. 17Assembly of automatic control field elements ......................................................................... 19

CONTROLS AND INITIAL START-UP................................................................................................... 22OPERATION.......................................................................................................................................... 22

Water circuit connections .......................................................................................................... 22Air filters ..................................................................................................................................... 22Heating coils ............................................................................................................................... 23Cooling coils................................................................................................................................ 23Heat recovery system with coil.................................................................................................. 23Rotary type heat exchangers...................................................................................................... 23Spray humidifiers........................................................................................................................ 24Steam humidifiers....................................................................................................................... 24Fans ............................................................................................................................................. 24Recommendations before start-up ............................................................................................ 25Water conditioning ..................................................................................................................... 25Electrical heaters ........................................................................................................................ 25Additional checks........................................................................................................................ 26Start-up Procedure...................................................................................................................... 26

MAINTENANCE ................................................................................................................................... 28Tension of belts .......................................................................................................................... 31Maintenance of belts ................................................................................................................. 31Wheel adjustment ...................................................................................................................... 32Damper section........................................................................................................................... 32Filter section ............................................................................................................................... 32Coil section.................................................................................................................................. 33Fan section .................................................................................................................................. 34Motor section.............................................................................................................................. 35

SAFETY................................................................................................................................................. 36MALFUNCTIONS.................................................................................................................................. 37

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We thank you for choosing the SYSTEMAIR air handling unit manufactured by SYSTEMAIR.The purpose of this document is to give users of the SYSTEMAIR Air handling unitinformation about equipment components and their properties, as well as informationon transport, installation, start-up, operation, and maintenance. This document does notlist the maintenance conditions required to extend the equipment’s useful life andincrease its reliability in long lists that will exhaust the reader. Reliable and long lastingoperation can only be achieved through the service of a competent engineer or atechnician employed by the authorized maintenance firm. If he or she wishes to, theclient can receive assembly, annual maintenance, and renovation services for theinstallation and operation services for their equipment.

PREFACE

The SYSTEMAIR Air Handling Unit guarantees the conditions that are taken as understoodand accepted by the customer. SYSTEMAIR guarantees the good quality of the equipmentit manufactures. It undertakes to provide repair and replacement services and to makereplacements and repairs as soon as possible in faults resulting from materials, inconstruction faults, and in structural faults that may arise even though the equipment isoperated in compliance with conditions specified in the user manual, during the warrantyperiod. SYSTEMAIR does not assume responsibility for direct damages arising from notbeing responsive. The functions that are within the scope of the warranty: Provided thatthe considerations that require attention regarding delivery, storage, handling, installation,operation, maintenance, safety and malfunctions are followed; malfunctions that are onthe part of the manufacturing company regarding all mechanical and electromechanicalcomponents; malfunctions that are on the part of the manufacturing company regardingall electrical components inside the device are covered by the SYSTEMAIR warranty for2 years from the date of delivery to the customer.

Note 1: The warranty becomes invalid in the event that repairing the device withoutwritten authorization of the manufacturer or replacing components with those that arenot original.Note 2: The warranty becomes invalid if the filters that are inside the device deliveredby SYSTEMAIR are not replaced by SYSTEMAIR.

WARRANTY

Following the equipment’s arrival at your workplace and before signing the documentof delivery, examine the equipment thoroughly while it is still on the vehicle; in caseof any damages take note of said damages on the delivery document and in order tobe able to make a claim, notify the final delivery firm responsible for the equipmentand the insurance company, if any, by registered mail as soon as possible. Please notifySYSTEMAIR of the issue.In case of a problem, we recommend that you document the problem by takingphotograph before unloading your equipment from the vehicle and have the driverprepare a report of damages.

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ACCEPTING DELIVERY

After having been tested at the main factory defected component(s), based on thetype of malfunction, may be replaced or sent with a technician for assembly/repair.If the cause of malfunction falls within the scope of the warranty, any transportationand replacement costs regarding the device and the technician are assumed by themanufacturer, otherwise these costs should be paid by the customer.

1. It must be ensured that the truck used for delivery will deliver the equipmentin a safe manner. Special attention should be given to usable width, length,and height of truck bodies and a vehicle loading plan should be requested fromSYSTEMAIR when necessary. Care must be taken to ensure that the truck isappropriate for the unloading site (The truck’s maneuverability in the unloading siteshould also be taken into consideration.).

2. Units should be bound to the truck frame with thick ropes. Steel ropes should not be used for binding. For large units, it must be ensured that the unit’s bottom casingis firmly fixed on the truck body.

3. At the points where the rope contacts the unit, wooden wedges, cardboard or othersuitable material should be placed between the rope and the unit.

4. Before delivery, gaskets from wood, cardboard polystyrene or other suitable materialshould be placed between the units on the truck body.

5. Units should not be stacked during delivery, handling, or storage.6. Care must be taken to ensure that the units are protected from the elements.

DELIVERY, HANDLING AND STORAGE

They should be covered with tarp.7. Do not use coil connections, dampers or shafts (or any extended piece other than

the main housing) as anchor points while carrying the unit to the platform. Use onlythe main housing to carry the unit to the platform.

8. Unit must not be tipped or overturned during handling or lifting.9. During the removal of the units from the truck with a forklift, care must be taken

to ensure that the load is distributed evenly on the forks and that the forks do not hit the panels or the base housing.

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

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

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Figure 1 : Carrying the SectionsINCORRECT CORRECT

Figure 2 : Hauling the Sections

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

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

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Figure 3 : Do not carry from coil connections

Figure 4 : Air Hangling Unit Leg Detail

Storage1. Care must be taken to ensure that the unit is carried safely particularly as it arrives

at the work area on the transport vehicle. It must be ensured that the unit is shipped under a cover in wet weather. The units should be visually inspected against any damages incurred during transport. If damages have been found, please call your insurance company and transport company immediately.

2. While accepting the delivery of units in the field, check against the delivery notewhether the pieces shipped separately from the unit (bag filters, highly sensitiveair filters, electrical pumps) and fittings required for the assembly of main units (like screws, bolts, gaskets, etc.) have been sent in a separate box. Store these materials in a safe place.

3. Your unit will generally be wrapped within cling film when shipped out of our factory. Since your equipment will be at risk of corrosion in case water seeps inside the cling film during delivery and storage in the assembly area, measuresshould be taken to avoid this. Since the water left between the unit and cling filmwill combine with sunshine to create a corrosive effect, the cling film should beremoved rapidly, the unit should be dried in natural air conditions and re-wrappedwith cling film. If the dried unit can be stored in a secure and clean environment,it does not need to be wrapped in cling film.

4. Care must be taken to ensure that units are stored in a covered area without removing their packaging when storing them until the time of installation.

5. Care must be taken to prevent exposing unit sections which you carry to the fieldor assembly area to the elements, and to avoid excessive dust and contaminationin the environment. Since air handling unit sections are not familiar to other assembly crews, they can be inadvertently used as toilets, framing or storage area for safe hand tools or valuable materials. These functions must be absolutelydisallowed for work safety.

6. Units should not be stacked. They should not be walked on or loads placed on them. Panels, profiles or similar materials that can damage the units should notbe propped against the units.

7. Units should not be placed in areas of heavy foot/vehicular traffic. Units’ extendedpieces such as coil connections and damper shafts should be protected from theelements and from damages.

8. The units should be placed on wedges in the storage area. The units should be placed onto the base formed in the field assembly area.

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ASSEMBLY

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Figure 5 : Flexline Section Connection

Assembly of The AHUWhile the unit can be delivered in an assembled state, it can also be delivered in adisassembled state to facilitate transport, handling, and space allocation. Somesections may exceed the legal shipping dimensions of transport vehicles. When theunit is delivered in the form of disassembled sections, it should be assembled followingthe correct procedures.

Assembly of sectionsa) Use a water gage to make sure the base is level. Your unit must be placed on an

even surface.b) Sections should be placed in sequence, in the direction of air flow.c) Make sure the mounting site is clean and free from grease and oil.d) Wall clearances at the mounting site should be as specified below.e) The gasket that was sent for the section connection should be placed between

the sections. Assembly should be made using bolts, nuts, and washers.(Figures 5-6)

Note: Sections must be placed side by side before connection. Under nocircumstances shall tools like vices be used during assembly to bring thesections closer.

PlacementTo avoid problems, units should not be removed from their packages at during transport,and only opened when in their final position at the time of installation.

Care should be taken to ensure that the surface on which the unit will be placed iscapable of bearing the weight of the unit. The required clearances should be appliedwhile placing the unit. The recommended clearances are specified below.

INSTALLATION

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Figure 7 : Placement Clearances

Figure 6 : Air Handling Unit after assembly

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

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Figure 8 : Shock absorbing legs

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

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

Figure 9 : Air duct connections

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Tube supports shall include anti-vibration system.

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

Duct connections to damper in units should be made according to damper dimensions.Air leakage and unwanted resistance in front of the damper can arise from improperlymade connections. These lead to improper air flow and pressure.Dampers designed by SYSTEMAIR are aluminum and mounted with hidden gearmechanisms. In case ducts are mounted on dampers on the air handling unit, thereare available flanges suited to duct connection on the damper. Flanges on the dampershould be used for flexible connection of your duct. Connections should be madewithout exerting the duct weight on the damper.The gear mechanism within the damper is concealed within the profile the drive shaftcomes out of. Therefore, duct connections should be made as in the figure to preventfittings (screw) from damaging the gear and locking the system.Damper flaps must not be moved manually. The motion must be effected by rotatingthe drive shaft.

Figure 10 : Damper ConnectionsINCORRECT CORRECT

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

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Figure 11 : Wire mesh

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Water Connections

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

Figure 12 : Sample installation diagram

Tubing ConnectionsAll coils are manufactured with tubes extending outward and except for units thatare manufactures in a disassembled state, plastic seals are placed around these tubesin order to prevent leakages from the air handling unit. Similarly the drain pan ismanufactured to extend outward from the mounting base by a standard amount.

Water and steam coils are externally connected as a standard. Tubes should bemounted to coils in a way that allows flexing.

Installing the tubingWhile the tubing is being installed, care should be taken to ensure that the tubes thatwill supply the coil are connected without damaging the coils.

- The entire tubing assembly should be carried independently of the coil.

- All connections should be made to allow thermal expansion of pipes, and not to put strain on coil connections. Otherwise, the coil will be damaged.

To this end, flexible connections should be used to absorb the vibration and expansionof the tubing between tubes and coils.

Condensation Drain Pans

Cooling sections are equipped with single or double discharge drain pans.Their drainage tubes should be fitted with siphons.

An independent drainage system is recommended for drain pans with multipledischarges. The measurement “H” must always be larger than the bottom or toppressure generated by the fan.

Drainage outlets should be discharged to the independent drainage works of thefacility.

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Note: The siphon must always be filled with water before starting the unit toprevent air leaks or suction.

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Figure 13 : The Drainage System

The height, R, should be at leastequal to the formula value

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

R= + X (mm)P

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1- Rubber piece2- Connecting element3- Nut4- Gasket5- Long bracket6- Water pipe7- Short bracket8- Rear pressure valve9- Valve main cover

10- Valve ball11- Pressure lid

Figure 15 : Ball siphon assembly details

Figure 14 : Ball siphon

Hot - Cold Water CoilAir discharge from the tubing system should be at the tubing level and not the coil level.Any discharge at the coil level will only discharge the coil.

If your unit operates with a fresh air intake or if the air temperature drops below +4°Cduring the periods when you do not operate your unit, measures should be taken to preventfreezing of the coil. Be sure to contact the SYSTEMAIR After Sales Services Departmentregarding the issue.

Note: It is recommended that thermometers and manometers be placed on waterintakes and outlets of coils to enable flow measurement in the coil as well aspossible adjustments. Complaints regarding coil capacity will only be taken intoconsideration after the instructions above have been fully applied.

Steam CoilThe most important point for steam coils is correct drainage. If the condensate water cannot be removed properly, it may lead to knocking and resulting malfunctions in the coil.

Condensate drainage pipes should be below the coil level. An air discharge valve shouldplaced as close to the coil as possible. Place a steam trap or thermostatic relief valve onall outlet pipes of steam coils (as per the recommendations of the relief valve supplier).

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Figure 16 : Lock Connection

All electrical connections within the unit should be made with flexible cables. It isrecommended that all cables passing through the air handling unit be equipped withcable protection.

The power supply must be made within the following limits in case of malfunctions:• Voltage tolerance limits: ±10%• Frequency tolerance limits: ±2%Ground connection should be made with the connector with the smallest cross-sectionas indicated in the electrical diagram. The supply switch should be one level higherthan the switch used on the unit. Cross-sections of supply cables should be determinedby taking into account the voltage drops that may occur depending on distance.Unless clearly permitted by SYSTEMAIR, more then one system part (pumps, coils,etc.) should not be placed on one system, to avoid problems caused by microprocessorcontrol.Since they are sources of electromagnetic potential, signal control cables should bekept apart from high current cables, power cables, and other cables.Especially in outdoor units, in order to avoid damages resulting from the voltage andelectrical supply line, direct frequency strains on electrical equipments should beavoided and sudden spikes should be prevented in charging.Since the flow varies between systems, unless there are special instructions, passinga cable through the unit or drilling a hole in the unit is not recommended. All otherelectrical connections should be made in the same way.

ELECTRICAL CONNECTIONS

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Hot and cold water coils should be connected so that the hot and cold water intakes areat the bottom and hot and cold water outlets are at the top. In cooling coils, the watershould be at the lowest possible temperature and the water intake should be at the bottomand the water discharge should be at the top.

Direct expansion type cooling coilOne of our authorized technical service points should be consulted to make tubing connectionsfor DX type coils correctly.

Note: Defrosting will be adjusted to the unit’s operating conditions to preventfrosting that will damage the drainage and to provide protection against thedamages resulting from water. If the installation has not been made accordingto the proper procedures, SYSTEMAIR will accept no responsibility.

2/4 and 4/8 pole connectionCONNECTION2/4 and 4/8 poles(DAHLANDER)

4/6 pole connectionCONNECTION4/6 poles

Y-Δ connectionCONNECTIONY-Δ

A : On V1 : Auxilliary high speed onM : Off T : Time relayL : On “low speed“ T : Thermal relayV : On “high speed“

The following electrical connection diagrams are for bipolar, 2/4 polar,4/8 polar, 4/6 polar, and star delta connected motors.

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Warning! Electrical connections must be made bya licensed electrician.

Warning! Care should be taken to ensure that thegrounding circuit is healthy.

We recommend that a protective element be placed on the electrical circuit, in case ofshort circuit, overload, or double phasing. (Thermal, Phase protection relay, fuse, etc.)

Final ChecksBefore initial start-up, it is recommended that you check whether all of the abovesteps have been applied. The values of the accessories on the electrical drive panelof the motors, such as thermal contactor, signal lamp, and switch are proper.The direction of rotation of the fan is marked on the fan. If it rotates in the oppositedirection, motor pole connections should be checked.After the motor is started, the current and voltage should be measures, and checkedagainst rated values.Note: If the switch of the main unit is off, all connections must be checked beforeturning on the power to the unit.

ASSEMBLY OF AUTOMATIC CONTROL FIELD ELEMENTSMounting the Freeze Free ThermostatThe freeze free thermostat is mounted between the heater and cooling coil and onthe air intake surface of the cooling coil to prevent freezing of the coil in cold weather.The sensor probe of the freeze free thermostat must be mounted such that it willsense the entire surface of the coil.Hangers should be used at the bending points of the thermostat sensor, in order toprevent breaking the capillary tube. The sequence must definitely be as follows: firstthe heater, then the cooler and finally the drop eliminator. If the cooling coil is placedfirst, there is no protection against freezing and the cooling coil will freeze.

Mounting the Mixing Section Damper ConnectionThe exhaust must be adjusted according to fresh air to mixing damper return air andfresh air ratios.

Flow Regulation with Frequency ConverterIf flow control with frequency converter is to be implemented in an air handling unit,the fan to which the frequency convector is to be connected should preferably be rareblade fans. This is because the operating points of fans with a large number of fansare unstable and unsuited to variable air volume applications.

Mounting the Temperature and Humidity SensorThe temperature sensor is mounted close to the return fan. The humidity sensor shouldbe placed in the region of return air, on the unit panel.

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Mounting the Differential Pressure SwitchThe differential pressure switch is mounted in the section that is to be controlledthrough the microprocessor by reading the ambient pressure. Thus, the microprocessorcreates the correct positive and negative pressure conditions by taking the requiredconditions into consideration.

The pressure differential between the controlled room and the reference environmentis checked with a 2 flexible transparent tube of diameter 4/7.

The pressure switches can be places in several ways. These different layouts can beseen in the following figures.

- Free ended tubes should be connected to the positive socket of the pressure key inthe section. In case of negative section pressure, a ledge of few centimeters shouldbe placed on the wall or ceiling.

- The pressure switch should be placed at least 2 m above the floor, thus the bestprotection against external influences and impacts will be assures.

CORRIDOR HALL

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Figure 17 : Positioning the Differential Pressure Switch

CORRIDOR HALL

CORRIDOR HALLSUSPENDEDCEILING

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OPERATION

Water Circuit Connections• Make sure that intakes and outlets of hot and cold water supply lines are

hermetically connected.• Check whether all fluid supply tubes are reinforced with manual cut-off valves

and that these cut-off valves are open.• Check the condensation pan discharge; if it has a spigot, make sure the spigot is open.• Make sure the humidifier supply lines are connected to the main water supply.

(Make the check by cutting off the main cut-off valve outside the air handling unit.)

Electrical Power Supply Checks• Check the three phase and ground connections.• Check the power input voltages and frequencies within the limit of +/- 10%.

CONTROLS AND INITIAL START-UP

Water Circuit Connections• Check whether the servomotors have been installed correctly according to their

open and closed states.• Check stroke settings.• Check whether the flaps close fully.• Check whether the flaps open and close fully upon demand.• Check the spring return function in case of power failure.

Air filters• Make sure the correct filter has been installed.• Check the position of the filter on the slides with respect to the direction of air flow.• Fill the U tube manometer with liquid (water).• Sensitive filters are shipped separately so they will not be contaminated during transport

and start-up. Do not install them before the unit is cleaned by operating the fan.• Adjust the pressure stat and filter pressure indicator (if any).

Prefilters (reusable)• The density of dirt should be checked by examining the pressure drop manometer.

When the pressure drop reaches the figure specified for the filter (recommended

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pressure is 250 Pa), the filters should be changed.• Air filters should be cleaned depending on the results of the checks.• Before changing the filters, the tightness of the frames should be checked and

they should be resealed if necessary.• The filter section should be cleaned. Care must be taken to ensure that no dirt

remains in front of the filters.

Bag Filters• The density of dirt should be checked by examining the pressure drop manometer.

When the pressure drop reaches the figure specified for the filter, the filter should be changed. (Unless bag filters are reusable, it is not recommended that you use them again.)

Note: During initial start-up of the AHU, bag filters should be protected against the accumulated dust and dirt within the unit.

Heating Coils• Check connections against the project.• Check for leakages in connections.• Check whether the freeze-free thermostat has been placed and set correctly.

Cooling Coils• Check connections against the project.• Check for leakages in connections.• Check whether the PVC alfon (with globe valve) has been placed properly.• Check whether the drop eliminators at the rear of the cooling coil have been

placed properly (they may have shifted in place during transport).

Heat recovery system with coil• Check whether the system has been filled with the correct glycol.• Check the rotating direction of the pumps.• Take another look at the section containing the heating and cooling coils for

other controls.

Rotary type heat exchangers• Check whether the direction of rotation of the rotor is correct.

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• Check the operation of the brake.• Check and adjust the number of revolutions.

Spray humidifiers• Check connections against the project.• Make sure the drop eliminators at the intakes and outlets have been positioned

correctly.• Make sure the pads (if any) have been placed on the slides correctly.• Check whether the siphon has been placed correctly.• Fill the water tank.• When the water reaches the level indicated on the unit, the float valve should

be shut off (5 mm below the funnel shaped overflow). Check whether it is functional.• Check the direction of rotation and consumption of the pump.• Check whether it conforms to the specifications on the label.

Steam humidifiers• Check whether the steam supply pipe has been mounted correctly. If the length

of the tube is over 10 meters, an additional steam trap should be used.• Check whether the filter has been installed.• Mount the condensate water discharge pipe with or without pressure (depending

on type).• If pressure is low, install a special siphon for discharging the condensate water.

Fans• Remove the clamps placed on vibration absorbers for transport.• Check whether the fan moves freely without being hindered by the body, flexible

connections or cables.• Rotate the fans manually to check whether they turn easily. Make sure there are

no foreign substances in the fan section.• Take particular care for connections of reversible polarity and adjustable speed

electromotors.• Check whether the intake damper (if any) works correctly.• Check the tightness and adjustment of the belts, and readjust if necessary. (check

the related chapter in the maintenance section).• Check electrical connection and rotational direction of the fan.

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Recommendations Before Start-up• In cases where spring vibration dampers are used, care must be taken to ensure

that spring fixing elements are removed.• Some unit elements may slacken due to vibrations occurring during transport.

Check all screws, nuts and especially rotating parts (wheels, bearings, etc) for tightness.• Take care to ensure that cast body roller bearings are well lubricated.• Take care to ensure that no foreign matter exists within the unit and ventilation

duct and that there is no obstacle blocking the entry/exit of air.

Note: In case the contractor adds another humidifier to the system, this shouldbe done in such a way that it will never cause splattering of water or causedeposits (such as water conditioning salts etc.) on the coil . (Particularly inultrasonic humidifiers)

Water conditioningUnconditioned or improperly conditioned water causes mould, sediment and sludge,leading to corrosion or abrasion. An expert trained in water conditioning should beconsulted to learn the method to be used for conditioning.

The damages occurred due to corrosion are not covered by the warranty. SYSTEMAIRdoes not accept responsibility for damages that may result from inadequately conditionedor unconditioned water.

Electrical HeatersElectrical heaters used in air handling units are used to maintain indoor temperature withfixed air flow and keeping the temperature at the desired value with cascade control.In variable air volume air handling unit applications, the application of cascade controlthat alters the number of resistances in the circuit can lead to dangerous results. Thisarises from the fact that, since there is no change in the power of each resistance,even if some of these are taken offline with the cascade breaker, the resistances thatare online will overheat due to low volume, becoming incandescent and creating firehazard. For this reason, cascading of the resistances used in variable air volume airhandling units must be accomplished through serial connection of different numbersof resistances for each stage, or through an electrical control element which controlsthe powers of all resistances simultaneously.

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Start-up ProcedureAfter all the checks specified above have been completed, the unit may be startedup according to the following procedure.

a) The measurement of the voltage in the input installation and the current drawn bythe motor (Amp.) should be compared to the values on the rating plate.Note: The motor power in our unit has been calculated with a predeterminedsafety margin. Compare the load drawn by the motor to the predicted load.

b) STATIC EXTERNAL TEMPERATURE OF THE AIR HANDLING UNIT INSTALLATIONSHOULD MATCH THE SPECIFICATIONS STATED IN THE ORDER.If there is a difference the design flow, pressure and motor values will be different.In this case, be sure to contact our technical service department.

Note: The number of belts must always corresponds to the number of wheelchannels. Note: Flow varies with the fan speed; pressure varies with the squareof speed and power drawn varies with the cube of speed. If the system pressureis lower than the planned value, the flow speed with rise with the power drawn,which will cause overloading of the motor. This is important especially in forwardinclined fans. For reverse inclined fans, the drawn power curve is almost identicalto the return speed curve.

V2 /V1 = (n2/n1) Flow rate and rpm is directly proportional.Ht2 / Ht1 = (n2/n1)2 Total pressure is proportional to the square of fan rpm.Pv2 / Pv1 = (n2/n1)3 The power drawn is proportional to the 3rd power of

the fan rpm.

Additional checks• The condensation drain pan should be filled.• The connections of the humidifiers with other units and their tightness should be

checked.• Air filters (bag, panel) should be installed. Care should be taken to ensure that

filters have been fixed to the carcass frame correctly.• The filtration material of filters should be correctly placed (the plain side should

be opposite to the direction of flow). The differential pressurestat, if any, shouldbe adjusted.

Start-up of Spray Humidifier Air Handling UnitsAfter the fan comes online and a check has been made to confirm air flow, the humidifierpump has to come online. If the humidifier pump comes online when there is no air flow,the drop eliminator can not perform its function completely and water will pass to othersections. Water flow from sprays should be observed a short time after the humidificationpump has come online. If it is not observed, the direction mark on the humidification pumpshould be marked, and a check should be made to ensure that the pump is rotating in theright direction. A check should be made to see whether the specified amount of water ispresent in the humidification water pool. If water still does not come, the SYSTEMAIR AfterSales Services Department should be contacted.

Start-up of Steam Humidifier Air Handling UnitsAfter the fan comes online and the unit is checked to see there is air flow, the operating signalmust be sent to the steam humidifier controller. It will continue to operate proportionately/on-off until the humidity values set through the control card have been reached. If an error signalis seen on the control card display, it is recommended that you contact SYSTEMAIR TechnicalService. The cleanliness of steam outlets should be checked periodically (80 hours).

Start-up of the Rotary Type Heat Recovery UnitDuring installation, it is recommended that the heat recovery system be checked first. Thedistance between the frame of the rotor and wall surfaces should be equal and the rotorshould be able to rotate. Afterward, the motor is shut off and the direction of rotation of therotor is checked against the direction of the arrow on the unit. After it has been ascertainedthat the distances between the rotor frame and wall surface are the same, the hermeticbands around the rotor are adjusted by slowly rotating the rotor. After this step, the rotoris operated at maximum speed and the current drawn from the drive motor is checked. Finally,the tension of the belts and the operation of the spring loaded motor support is checked.

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Warning! Since the rotor is one of the most expensive units within the air handling unit, its incorrect and incomplete installation, andincorrect handling will lead to costly repairs, thus great care

should be taken and rules should be followed. If the rotor does not rotate due toa problem with the alignment made during installation, the rotor should be centeredusing a central screw. If problems still continue, the SYSTEMAIR After Sales

Services Department should be contacted.

Caution! Do not operate the pump without water.

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

The following procedures must be implemented depending on the cleanlinessof the environment and the equipment’s frequency of operation.

MAINTENANCE

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THE FOLLOWING CHECKS SHOULD BE CONDUCTED ONCE A YEAR:

The Following Should be Checked:a) All electrical cables, tightness of all connections,b) Tightness of the screws and bolts in the ventilation section,c) Energy expenditure of motors,d) Vibration dampers and fan supports,e) Whether there is any indication of rust in the unit or accessories (the necessary

cleaning and maintenance should be conducted).f) The shaft and wheels of the fan (The rust on the shaft should be cleaned by sanding

and the shaft should be protected by coating with a layer of suitable varnish.)g) Seals on doors (should be replaced if necessary)h) Hinges should be checked, and necessary adjustments should be made in case of

looseness.

The Following Should be Cleaned:a) Nozzles and drain pan of the humidifier,b) Drain pan spouts and condensation drain pan,c) The fins of coils should be checked for any obstructions and the curves of drop

eliminators,d) Blockage of the heat recovery section.e) The dirt level of cellulose filled evaporative humidifier padding should be checked.

(It should be replaced if necessary.)f) The calcification level of the steam humidifier's steam cylinder and the condition

of its electrodes should be checked. The steam cylinder should be replaced if necessary.

The Following Should be Replaced:According to the indication of manometers and the differential pressurestat, coarsefilters, bag filters and highly sensitive filters should be replaced.

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

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

Figure 18 : Check for Belt Tension

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

Warning! Turning the unit on and off often will cause premature wear on the belts and wheels.

Damper SectionCheck the operation of the damper and clean the damper. Clean the damper blades,and check the operation of bearings and gears. Check the damper in the “OPEN" and"CLOSED" positions in this order. Contact our technical service department in caseof problems. Only our technical service department is authorized for concealed geardamper design repairs.

Filter SectionGeneral1) Filters need regular maintenance. Maintenance frequency depends on the amount

of dust in the air and upon operating conditions.2) Neglecting filter maintenance may decrease air flow. For vibration free operation

of the unit, it is essential that filters be given maintenance within design limits.

Panel filters can be cleaned using one of the methods listed below:a) Washing with hot detergent waterb) By spraying pressurized air from the clean side of the filterc) Using a vacuum cleaner from the dirty side of the filterd) Holding and the filter with the dirty side facing outward

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Figure 19 : Wheel Adjustment

Maintenance FrequencyFilters should be checked every 15 days and given maintenance at least once in everyfour months. We would like to remind you that maintenance frequency depends onoperation.

Coil SectionCleaning1) Coils should be cleaned at least twice a year.2) Dust escaping from the filter form a layer on coil fins, affecting air flow and

reducing the efficiency of heat transfer.3) Coils must be kept very clean under all conditions. The best way to clean the coils

is blowing air onto the fin; if this is not possible you may clean the fins by brushingsoftly without damaging them. The interior of the unit should also be cleaned after this operation.

4) Regularly empty the condensation pan of cooling coils and clear dirt and deposits.

Freezing RiskFreezing leads to a surfeit of damages and destroys the coil in particular. All precautionsshould be made against freezing of the coil. Damages resulting from freezing are notcovered by freezing.Measures to be taken to prevent decrease and/or stopping of the flow of hot watera) In cases where the flow of hot water decreases or stops, all air intakes and fans

should be stopped.b) The freeze free thermostat should not be set too low.c) If for any reason the building can not be adequately heated in winter conditions,

all air in the tubing and coils should be emptied.

1) Hot water coils:Make sure the water temperature is not too low and that the water circulation isregular. For example,a) Valves should be openb) There should be no air in the tubing

2) Steam coils:Make sure of the following:

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a) That there is steam pressure inside the coilsb) That the boiler pressure is correctc) That the valves are opend) That the steam trap is functioning properly.

3) Cooling Coils:• If the external temperature is lower than the freezing point of the water/glycolmixture, the cooling coil should be emptied.• If only water is circulating within the coils, the coils should be emptied as soonas the outdoor temperature drops to 2°C.

Safety measures for preventing freeze of the unit coil in long standby periodsIf the unit must be kept on standby for an extended period of time, measures aretaken in 2 ways to prevent freezing of the coil.A ) Adding ethylene glycol or other anti-freeze chemical to the water circuitB ) Removing the water within the circuit.Automatic control elements mounted on the unit (damper motors, pressurestats,thermostats etc) should be mounted using proper materials to avoid air leakage fromthe body. Control elements should be mounted such that they will not damage themechanical operation of the unit.The recommendations stated above are not general rules. They vary depending oneach system’s operating setup. The system should be emptied using the method thatis practicable.

Fan SectionMaintenance1) Before starting the unit, make sure there are no unwanted objects within the unit,2) Clean the interior of the unit with a vacuum cleaner,3) If there is gas or dust in the air, rotors should be cleaned regularly,4) Make sure the tension of the belts is correct; while slackness will cause slipping

and excessive wear of belts, excessive tightness will exert excessive load on themotor and bearings. The belt tension control diagram should be examined for thegeneration of the correct tension.

5) If one of the belts is faulty, the whole set should be replaced. Otherwise, if onlythe faulty part were to be removed, since it will be new, therefore shorter and

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tighter than the other parts, it will cause excessive strain.6) Belts should be clean and free of grease. The best way to clean them is to

wipe them with a dry and clean cloth.7) Particles accumulating in rotors compromise the balance in the long run.8) When the rotor needs to be replaced, we recommend that you summon one of

our experienced engineers to repair the wheels.9) Bearings and their supports should be cleaned and checked from time to time.

While the frequency of this process depends on operating conditions, it should be conducted at least once a year on principle.

10) It is recommended that bearings be cleaned thoroughly and that all bearing components be checked.

Checking the bearingsBearings should be checked on a regular basis during the unit’s operation. Small tasksregarding the greasing or examination can be performed.

We recommend that you consult the SYSTEMAIR After Sales Services departmentfor further information.

Motor SectionConnection of the ground lineThe ground line should be connected at the most suitable location in the terminal box.

Protection against short circuit, overload and double phaseIt is recommended that safety breakers be used to protect the electrical circuit (notfor the motor), such as safety fuse that provides adequate protection for the installation.(Phase protection relay, thermal magnetic breaker, etc.)

Start-up and stoppingIn squirrel cage motors, the starting current that occurs during the driving of the motorin the initial start-up rises to 3 or 7 times the nominal operating current. In case ofstar-delta start, the current is dropped to 1/3 of the current drawn in direct start-up.The start-up torque drops almost proportionally.

Star-delta start-up is only used for motors above 5.5 kW.

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SAFETY

• Do not operate the unit in a flammable (containing explosivegases) environment.

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

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

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

• Make sure the power connection is off before responding in caseof any malfunctions.

CleaningWhen there is excessive accumulation of dust inside the motor an on exhaust outlets,they should be cleaned by blowing clean air.

Lubricating and cleaning the bearingsBearings are lubricated at the factory. Motor rollers are self-lubricated and enclosedtype. They do not require additional lubrication. Fans equipped with cast body rollerbearings should be periodically checked for lubrication, and lubricated if necessary.When you encounter a problem that causes concern, we recommend that you contactour Technical Service Department.

Note: While useful life is 10 years for the unit (all models), the period ofwarranty against material and workmanship faults is 2 years.

• Remember to have the unit installed and operated by qualified employees.

• Make sure that your electrical wiring is appropriate to the unit.

• Make sure that there is no leakage or loose contacts at the electrical

connections before operating the unit.

• Before operating the unit, make sure that it has a ground connection.

• The apparatus that will be used with the unit (switch, fuse,

thermostat, etc.) should definitely be chosen from premium products that

have quality certificates.

• Disconnect the power connections and inform the service in case of a

malfunction.

Malfunctions that occur in the air handling units can be divided into two groups,namely electrical and mechanical malfunctions. Having gained ground, the automationmakes malfunctions occur because of or in connection with those two reasons.Therefore having comprehensive knowledge on both areas will help remedying themalfunctions easily and smoothly.Frequent malfunctions are summarized below. • Fan motor malfunctions • Drainage problems • Noise problems • Insufficient cooling or heating • Malfunctions relating to electronic cards and related employees.

Fan Motor MalfunctionsPower issues and improper use might be the reasons of fan and fan motor malfunctionswithin the air handling units.

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MALFUNCTIONS

• Make sure that there are no contracted connections after

the assembly.

Drainage ProblemsRemoving the intense water vapor requires draining. Many problems are encounteredwith these installations. Particularly hoses that are not connected properly, animproperly inclined installation or incorrect assemblies of internal units create thisproblem. Filters that are dirty and not cleaned cause problems and lead drainageproblems. Additionally, taking account that the drainage problems can also occur atthe external units of the devices that are using heat pump, this problem should beprevented through drainage application as well.

Noise ProblemsAlthough air conditioning devices provide more comfortable, more convenient lifestyles,incorrect usage might cause even more discomfort. Ambient sound levels are consid-erably important and never should be overlooked. While selecting and using componentsthat may cause high noise levels such as compressor, motor, and fan, sensitivityshould be practiced against noise. Naturally, the location in which the air conditioningunit is to be placed and its purpose are significant criteria in determining the magnitudeof the problem. Faulty installation and problems in rotating parts may lead to highernose than is necessary. In this case the necessary measures must betaken and the malfunction of the related element should be repaired.

Insufficient Cooling and HeatingDepending on conditions such as system properties, operating conditions, andmaintenance, there are some situations when consumer’s expectations can not bemet even tough there is no technical malfunction. The leading cause of such situationsis erroneous estimation and misinformation. The unit has been designed in the lightof the information provided and will deliver the desired values at these conditions.

Electronic Card and Element MalfunctionsAir conditioning units are electronically controlled, therefore materials in the systemsuch as contactors, solenoid coils and electronic cards may suffer malfunctions dueto problems resulting from power issues. Yet the point which needs to be taken intoconsideration and resolved is determining whether these malfunctions result frommechanical problems. If there is a problem in the system that is caused by the mainstructure or by the system itself, rather than replacing the element in question, themain problem in the system should be resolved. The element should be replaced ifdeemed necessary.

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Device Does Not Active!

Is it plugged?

Is the power outlet live?

Has the fuse blown?

Does the grid power meet the catalogue values?

Is there a general power outage?

Does power reach into the motor?

Is fan rotating direction correct?

Is there a jam at the fan scroll case?

Please consult our company if you still have problemsprovided that all operating conditions of the componentsunder the "Operation" title are applied.

KS-K

K 12

/201

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