INSTRUCTIONS FOR ASSEMBLY, OPERATION AND MAINTENANCE OF AIR HANDLING UNITS

Transcription

1 INSTRUCTIONS FOR ASSEMBLY, OPERATION AND MAINTENANCE OF AIR HANDLING UNITS ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 1 /40

2 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! ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 2 /40

3 CONTENTS Table of contents INTRODUCTION General Safety Instructions Emergency Instructions Maintenance and Cleaning Instructions... 6 ASSEMBLY Delivery Unloading and Transport Unloading and Conveyance by Crane Unloading and Conveyance by Forklift Truck Assembly and Installation Installation of Section Connection of Sections Connection with Air Ducts Pipe Connectors of Heater and Cooler Connector for Condensate Drain Cleaning Electric Power Supply Protection of Motor MAINTENANCE Air Dampers Putting into operational mode Maintenance Fan and Motor Putting into operational mode Maintenance Determining the tensile force of V-Belt for V-Belt transmission Maintenance switch Filters Putting into operational mode Maintenance Silencers Putting into operational mode Maintenance Heater Heat Echanger (warm water /hot water, steam) Putting into operational mode ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 3 /40

4 12.2. Maintenance Electric Heater Putting into operational mode Maintenance Cooler Heat Echanger (cold water, direct epansion cooler) Putting into operational mode Maintenance CERTIFICATES - CONFIRMATION OF QUALITY Certificate CE mark GOST R Certificate GOST hygienic Certificate GOST ATEX Certificate EUROVENT CERTITA Certificate... Error! Bookmark not defined. ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 4 /40

5 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 nonobserving this Instruction. In case of illegal modifications or interventions on the Unit, the manufacturer s warranty will not be valid any more. Use for intended purposes Necessary space Storing Assembly Before commissioning The Air Handling Unit delivered by Soko Inzinjering is eclusively intended for air conditioning. Air conditioning means filtering, heating, cooling, humidifying, dehumidifying and transport of air. Soko Inzinjering epressly forbids any other type of use. Provide sufficient space for operation and maintenance of the Unit, in accordance with VDI The Air Handling Unit and all its parts must be stored in appropriate way, preventing damage or atmospheric influences. During the storage which eceeds 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 fied 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 (e.g. block stop switch for repairs service switch.) ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 5 /40

6 Wait until all rotating parts are stopped, especially the fan impeller, V-belt, motor, etc. Heat echangers 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 Fire In case of fire, immediately disconnect all devices from electric power supply. Close air dampers and fire flaps in order to prevent oygen 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 toic substances. Use protective breathing apparatus (gas mask or similar.)! Eplosion 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 approimate time intervals depending on air pollution in accordance with VDI 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. Cleaning and maintenance Disinfection Commissioning Leak-proof test 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. Toic 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 ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 6 /40

7 is necessary, take measures in order to eliminate any leakage in consultation with the manufacturer. ASSEMBLY 5. Delivery Inspection of goods 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 Base onto which the sections are placed 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. Maimum tolerance in horizontal direction is s=0.5% (0.3 0 ). ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 7 /40

8 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. Mounting of the adjustable feet 1 2 Important Recommendation 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. ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 8 /40

9 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 Important 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, fi mutually the sections by clamps, so that connecting holes are aligned. Connect the sections with bolts and nuts (mount the washers) Connection with Air Ducts Connection of air ducts with fleible connection on the sections of the Air Handling Unit must be realised so that it is free of any stresses. The length of fleible connection must not be used up to the maimum. The optimum length on which the fleible connection should be mounted is 115 mm. Fleible connection 1 Profile of the AHU 2 Fleible connection 3 Air duct which is connected to the AHU ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 9 /40

10 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 mied up (take into account that the echangers are foreseen for counterdirectional water-air flow). Connection of echangers Attention Plan and adjust pipeline to be connected to echanger section so that the echanger be not eposed 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 echanger for the purpose of maintenance or replacement. The pipeline should be eecuted 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 eecuted so that the echanger is not eposed to pressure or stress 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 drain trap ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 10 /40

11 Calculation of drain trap height The height of the drain trap is defined according to the following: In the zone of underpressure H 1 (mm) = p / 10 H S (mm) = p In the zone of overpressure H 1 (mm) = 35 mm Ptot 1000 Pa H 1 (mm) = 100 mm H S (mm) = 75 mm Ptot 1000 Pa H 1 (mm) = 35 mm H S (mm) = 150 mm p total drop of pressure at the point of condensate drain. Connect the drain trap to appropriate connection and charge it with water 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 Electric Power Supply Equipotential Bonding 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 crosssection (use at least protection class IP65). Check all electric junctions (switch case, frequency converter, motor, etc.) whether they are fied correctly and fi 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 bo. 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 boes. Check every earthed cable, in order to make sure that they are correctly fied and fi them, if necessary. Check galvanised tape used for earth works. Test resistance of earth works in compliance with EN and take all necessary precautionary measures. ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 11 /40

12 7.8. Protection of Motor Protection of the motor against overload is subjected to EN 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 boes 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 eternal 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 beltdrive. 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 eceeding 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 eists, 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. Coupled air dampers 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. Dampers with motor drive Check the tightness of all bolts and connections. In case of motor drive: Adjust linkage so that a 90 0 shutters reach end position when closed. swing angle is guaranteed and ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 12 /40

13 8.2. Maintenance Maintenance intervals Important Every three months. REGULARLY AS NECESSARY Check for operation of air damper, defects, damage and corrosion. Clean air damper, repair damage and remove corrosion. Check efficiency of protective device. Check for smooth moving of the blades. Check adjustments Do not lubricate air dampers with gear wheel drive. 9. Fan and Motor 9.1. Putting into operational mode Danger Pay attention to the instructions on page 5.! Serious bodily injuries and material damage can be caused by fracture of the impeller blade. Eceeding the fan maimum 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 eceed the normal maimum (forbidden area of performance curve). The thermal protection of motor may be activated. Safety transport equipment 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. Drive 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. Direction of rotation Electric power consumption 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 eceed the nominal value on the ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 13 /40

14 nameplate. In case of eceeding, disengage immediately and check eternal 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. mark of the corresponding converter Installation of frequency converters Remove 1. Remove the upper two screws, and the lower two unscrew for about 5-6 mm. Unscrew 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. ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 14 /40

15 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 Maintenance intervals Every three months. Maintenance interval can be shorter, depending on whether the operation is continuous, or in some special conditions such as temperature eceeding 40 0 C, 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. FAN Check the fan for foulness, defects, damage, corrosion and couplings. REGULARLY Check bearings (noise). Lubricate bearings, observe the manufacturer s instructions. Check impeller blades for: balance and vibrations. Adjust if necessary. Check for fleible coupling (leak, joints, stress ) Check vibration absorbers for function (stiffness, connections, ) AS NECESSARY Check safety of protective frame Clean the fan, repair any damage and remove corrosion, fi connections. The fan motor bearings are permanently lubricated and cannot be lubricated subsequently (for motors with an ale height up to 160). Electrical motors with an ale height (180, 200, 225) are factory lubricated and it is impossible to further lubricate them without disassembling the motor, while electrical motors with an ale 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. ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 15 /40

16 ELECTRICAL MOTOR REGULARLY AS NECESSARY Check electric motor for defects, damage, corrosion, heating and the direction of rotation. Check motor bearings (noise). Clean motor, repair any damage and remove corrosion; fi couplings. Measure voltage, current, starting current and phase symmetricity. Check the tightness of joints, supports in the assembly with the fan, fi if necessary. V-belt transmission Check V-belt transmission for defect, damage, wear-out, tension, V-belt position (whether it is aligned), functioning and tightness. Replace a set of V-belts Adjust position of the fan and motor pulleys so that V-belt be aligned. Adjust V-belt tension Clean V-belt transmission 9.3. Determining the tensile force of V-Belt for V-Belt transmission according to DIN 7753 V-belt tension 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 aes (in meters) Deviation S = A 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 ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 16 /40

17 TYPE OF PULLEY SPZ SPA SPB SPC DIAMETER OF SMALLER PULLEY ''d'' [mm] 67 to to to to to to to to 560 DEFORMATION FORCE F [N] 10 to to to to to to to to Maintenance switch Rukovanje servisnim prekidačim On all systems AHUs which have one operational and one reserve motor are mounted maintenance switches by type: 1-0-2, T /I1 for motors up to 5,5kW; 1-0-2, T /I2 - for motors from 5,5kW up to 11kW; 1-0-2, T5B /I4 - for motors from 11kW up to 18,5kW; 1-0-2, T B /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 T /I1/SVB are mounted, which turns off the engine in case of any service intervention on the motor or inside of fan section. ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 17 /40

18 10. Filters Putting into operational mode Danger Pay attention to the instructions on page 5.! Filter installation (in segments) 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. Supervision Final resistance of foul filter Roll filters Maintenance intervals 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-H Pa It is necessary to follow the instructions for maintenance provided by the manufacturer 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. Spare filters 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 epiry of the life. Check filters for cleanness, odour, defects, damage and corrosion. Measure differential pressure drop on the filter. Check the filter seat, tightness, fastening. Replace filters in case of etreme 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. REGULARLY AS NECESSARY Pay attention to regulations related to environment protection when replacing the filter. ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 18 /40

19 11. Silencers Putting into operational mode Danger Pay attention to the instructions on page 5.! Supervision Maintenance intervals It is necessary to check whether silencers are damaged or foul 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. Clean silencers (see below), repair them and remove corrosion (if any), take contact samples if necessary. REGULARLY AS NECESSARY Cleaning Use vacuum cleaner for removal of surface dust particles. Attention When cleaning, do not damage absorption material. 12. Heater Heat Echanger (warm water /hot water, steam) Putting into operational mode 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 eceed 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. Supervision Check correctness of inlet/outlet connections. ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 19 /40

20 Charging After commissioning 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.E Too high concentration of glycol leads to reduced heat echange, 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 echanger can cause reduction of the capacity). After commissioning, check joints (connections) for leakage, and retighten them if necessary (See section 7.4). Maintenance intervals 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 echanger 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. Clean the heater on the air side (see below), repair damage, leakage and remove corrosion. Check inlet/outlet connections for function. Check anti-frost protection for function. REGULARLY AS NECESSARY Cleaning Cleaning agents Clean the echanger 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 echanger plate fins. Blow out the echanger 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. Out of operation If the echanger is out of operation for some time and above all if there is a risk of freezing, the echanger must be emptied completely. Decontaminate discharged water in accordance with the manufacturer s instructions. ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 20 /40

21 13. Electric Heater Putting into operational mode Danger Pay attention to the instructions on page 5.! Do not touch heating elements in order to avoid skin burns. Protection Recommendation 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 0 C Protective (safety) setting: 80 0 C. 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 fied parts can be damaged. Flow control Electric power consumption Maintenance intervals 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 eceeded, Sokoinžinjering After-Sale Service must be notified 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 Check operation of electric heater, hygienic conditions, defects, damage, corrosion and tightness of joints. Clean electric heater, identify and repair damage and remove corrosion, tighten joints. Check safety and operating thermostat for function (See previous Commissioning ). REGULARLY AS NECESSARY ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 21 /40

22 14. Cooler Heat Echanger (cold water, direct epansion cooler) Putting into operational mode 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 eceed permissible nominal pressure (See the design data sheet). In order to avoid freezing of the echanger (if there is risk): Add anti-freeze agent or mount the echanger in air stream behind the heater. Supervision Charging 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.E Too high concentration of glycol leads to reduced heat echange, 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 echanger 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 epansion 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 echanger is permissible only when cooling installation is out of operation. In case of some incorrectness, contact our service. Maintenance intervals Cleaning 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 echanger 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 echanger plate fins. Blow out the echanger with compressed air in opposite direction to air flow. Do not use high-pressure steam cleaners Clean with water and low pressure. ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 22 /40

23 MAINTENANCE REGULARLY AS NECESSARY Check the echanger: hygienic conditions, defects on air side, damage, leak-proof, and corrosion. Clean the echanger from air side (see below), repair damage, leakage and remove corrosion. Check and if necessary clean condensate drain pan (drop eliminator pan). Check and clean if necessary condensate drain and drain trap function. Check water level in drain trap, refill if necessary. Check inlet/outlet connections for function. Check anti-freeze protection for function Check direct epansion for icing. Drop eliminator Check drip eliminator for hygienic conditions, defects, damage, leak-proof and corrosion. Clean and service drop eliminator: Pull out cassette, disassemble and clean profiles separately, Repair damage and remove corrosion. Cleaning agents Use cleaning agents with ph value between 6 and 8 (when required). Out of operation If the echangers are out of operation for some time and above all if there is a risk of freezing, the echangers must be emptied completely. ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 23 /40

24 CERTIFICATES - CONFIRMATION OF QUALITY 15. Certificate CE mark ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 24 /40

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31 17. GOST Hygienic Certificate ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 31 /40

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34 18. GOST ATEX Certificate ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 34 /40

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40 «Soko Inzinjering» d.o.o. Office Bulevard A. Carnojevica New Belgrade, Serbia Phone +381(11) Fa +381(11) Factory Partizanska bb, Industrijska zona Krnjesevci, Stara Pazova, Serbia Phone +381(11) Fa +381(22) ASSEMBLY, OPERATION AND MAINTENANCE INSTRUCTIONS Page 40 /40