KA Modular air handling units Installation, operation and maintenance manual | 2021-6-1-V-EN-2.
CONTENT 1. GENERAL INFORMATION.................................................................................................................................................................. 3 1.1 Information about manufacturer............................................................................................................................................................ 3 1.2 Unit naming.............................................................................................................
1. GENERAL INFORMATION 1.1 Information about manufacturer These instructions apply to all KA air handling units supplied by Systemair d.o.o., Slovenia. Manufacturer and supplier details: Systemair d.o.o. Špelina ulica 2 2000 Maribor Slovenija Responsible person: Anton Zupančič 1.2 Service and technical support: Systemair d.o.o. Brnčičeva 41c 1000 LJUBLJANA Slovenija tel: + 386 1 200 73 81 fax: + 386 1 423 33 46 e-mail: servis@systemair.
1.3 General description KA air handling units are modular devices that may be manufactured for a number of combinations of different cross section dimensions, functional unit assemblies, material combinations, sizes and types of control. Depending on the particular version, KA air handling units are designed for comfort ventilation, clean room ventilation, indoor pool ventilation, ventilation of industrial premises, and areas with an explosive atmosphere.
1.4 Declarations regarding the air handling unit DECLARATION OF CONFORMITY DECLARATION OF INCORPORATION The declaration of conformity is issued for the device supplied The declaration of incorporation is issued for a device supplied together with the control system and for which manufacturer also without a control system. makes first commissioning. The declaration of conformity for this device must be issued by the company which assigned the device and put it into operation.
1.5 Dangers and warnings • The intended use, operational conditions, inlet and outlet parameters, composition of the functions, dimensions, shape, place of installation, dimensions of shipment units, method of transport and handling at the place of installation, as well as the control system variant and other specifications, are determined and confirmed at the time of placing the order.
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Danger and warning symbols Warning – danger of injury due to rotating parts The frost protection cover must be freely removable - pay attention to the pipe installation! Warning – danger of contact with live electric components Safety chain on the inside of the door. Return the chain to the safety position before closing! Warning – hot surfaces Non-compliance with the instructions indicated in the warning signs may result in risk of injury and property damage.
1.8 Operation and control The unit shall be furnished for fully automatic operation. The modifications of parameters via the hand-held terminal buttons and screen must be limited in the control system. An alternative may be a controller linked to a central monitoring system that enables the selection of parameters via a PC, tablet or smart phone. Different implementations of the control system are available: • Air handling units manufactured in the factory without a control system.
Intended use and application options • KA air handling units are designed to transport and treat air in a temperature range from -20 ºC to +80 ºC. • At altitudes up to 1,000 m above sea level, the normal operating range of the fans and their electric motors is up to +40 ºC. • Units for comfort ventilation (KA HS ...) of premises such as offices, classrooms, hotels, shops, apartments and similar locations where a high level of comfort is required. • Hygienic-type air handling units (KA HH ...
2. INSTALLATION 2.1 Loading and transport Air handling units may be delivered as a single compact package (shipment unit) or in several compact packages (shipment units) to be assembled on site. They are delivered on transport pallets or on base frames. Loading, unloading and moving shipment units on site may be carried out with a forklift or a crane, by applying appropriate hoisting slings.
Delivery units with base frame Lifting brackets are provided for lifting on the base frame of each individual unit. For lifting, use suitable lifting straps and use brackets with sufficient lifting grip spacing or use spacer supports long enough to ensure that the straps do not press against the casing of the delivered unit. Caution The lifting brackets are only removed when the units are in place, just before joining. In the event of relocation, the brackets must be reassembled.
Storage before installation Until installation, air handling units must be stored indoors, in dry areas, or be protected against the elements or other damage in some other appropriate manner. Remove the plastic foil wrapping and cover the equipment with a waterproof canvas or similar cover, and ensure adequate clearance between the cover and the equipment casing.
Caution The minimum foundation height is determined by the elevation of the drain syphon for the sections (namely 150 mm). Mounting of unit without a foundation The foundation may be substituted by purpose-built legs with a level-adjustment screw system with an adjustment range of 30 mm. Due to siphon installation, there is also possibility of 250 mm base frame when feet or foundation is not an option.
Caution The foundation height for an outdoor unit should not be less than 500 mm. Design the foundation so as to protect the unit or sections thereof against sliding or tipping over under wind loads. To this end, carry out a check of wind forces. Upon joining and interconnecting individual compact units, affix the roof elements onto the air handling unit top according to the equipment design documents, and ensure that the joints are sealed against water.
2.3 Assembly 2.3.1 Joining of unit modules • Deliver the shipment unit to a location as close as possible to the mounting location. With a manual forklift, hoist the shipment unit so as to align its bottom with the foundation’s top surface. • Slide the shipment unit into its position on the foundation, using stripes or some other appropriate method. You may need to apply heavy or extra-heavy furniture hauling trolleys. Caution Fastening connections are not intended for pulling of modules together.
[2] Joining of corner reinforcements Fastening material For one connection following fastening material is always supplied: • 1x Screw DIN 933 Zn M10 x 40 • 1x Nut DIN 934 M10 Zn • 2x Washer DIN 9021 10,5 Zn The supplied material is the same whether it is a large or small reinforcement.
2.3.2 Mounting of roof Caution If possible, avoid walking on the roof with point force during installation. Use boards for more uniform force distribution Make sure that the screws are always screwed perpendicular to the drilling plane and that the correct torque is used. • Remove the protective foil from the roof and panels. • Apply the supplied 15 x 3 mm gasket 3 times in length to each part of the roof bent upwards in a “C” shape.
• Attach the sealing plates to the sides of the device where the two roofs meet and screw them on. Since the left and right pieces are different, make sure that the »L« from cover always looks in the other direction than »C« from the roof and the gap between the pieces of the roof is always covered. • Clean the roof of the drill chips and dirt accumulated during installation. 2.3.
2.3.4 Connection of piping Heat exchangers must be connected to the piping in a manner that enables the free opening of the service doors of adjacent sections and allows the dismantling and drawing out of heat exchanger components when necessary for maintenance or replacement purposes.
Connection of piping to hydraulic cyrcle To connect the unit to the hydraulic circuit, apply threaded joints (fittings) or flanged joints for a nominal pressure of 16 bar, depending on the piping size. For outdoor units with empty chamber, install the hydraulic circuit in the empty chamber next to heating or cooling coil . Observe the chapter above for pipe installation through the panels.
Example of hydraulic circle HW – heating coil CW – cooling coil 1 – circulation pump 2 – 3-way valve 3 – balancing valve 4 – termometer 5 – termometer (optional) 6 – venting valve 7 – ball valve 8 – drain valve Caution 3-way valve for cooling hydraulic cyrcle can be mounted on the inlet or outlet. It is important to instal it with the required flow direction.
2.3.5 Connection of syphons Caution Discharge pipes from the negative pressure or positive pressure syphons may not be connected directly to the sewage plumbing. The discharge of condensate into sewage plumbing must be arranged so that water condensate freely discharges into a funnel-shaped collector and from there into the sewage plumbing. In no event may a negative pressure syphon and a positive pressure syphon be connected to a common discharge pipe. The syphon should be installed outside the unit.
A quick calculation of the syphon height with respect to underpressure or overpressure in the condensation section: Pa+ > P0 Pa- < P0 ΔP Hmin Hmin Hmin / 2 Pa mm mm mm 200 30 30 15 400 50 50 25 600 70 70 35 800 90 90 45 1000 110 110 55 1200 130 130 65 Overpressure connection Drain over bottom panel Drain over side panel Hmin depends on the maximum overpressure (Pa +) in the condensation section.
Ball syphon The figure below shows an example of a syphon in disassembled form and a complete syphon on a single drain and with combined drains (exit over base frame). Caution The connection piece for direct connection to the device is not supplied by the manufacturer. The package includes a siphon and two reducing pieces DN 40/30. Caution It is important to watch how you turn syphon. The arrow on the cap should point in the direction of water outflow.
Overpressure connection Caution Shows direction of the drainage flow in overpressure section. When syphon is connected in overpressure, the plastic black button has to be removed. Drain over bottom panel Drain over side panel Hmin is a minimum of 60 mm regardless of the overpressure in the device. Underpressure connection Caution Shows direction of the drainage flow in underpressure section. Drain over bottom panel Hmin depends on the maximum underpressure (Pa -) in the condensation section.
2.3.6 Connection of electrical installation Electrical installations must be connected so as not to prevent or hinder the checking, servicing or replacement of functional components. Connection must be carried out in accordance with the design documents, the manufacturer’s guidelines and the provisions of the technical regulations and standards. The installer and user should be aware of the risks arising from lightning.
Connection of electrical installations with quick connectors between moduls Before mechanically connecting the device housing to the factory-fitted electrical control cabinet, control system elements and wiring, connect the electrical cables and wires using the quick connectors. All connectors where the connectors need to be connected are marked with a sticker. All cables, wires and also connectors are numbered. Connect the male and female part of the connector with the same number.
3. COMMISSIONING AND MAINTENANCE Caution The unit commissioning may only be carried out by a qualified professional. Before starting up the air handling unit, check all the electrical connections and unit control settings. 3.1 General instructions Before maintenance • • • • • • • • • • The power supply must be switched off completely and the service switch must be switched off and locked. Due to the frequency converter, it is necessary to wait at least 15 minutes.
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Caution Hygienic inspection is organized according to hygienic requirements. Cleaning the unit with cleaning agent always includes rinsing with water, drying and if necessary, disinfection. Inspection and cleaning of the component with added water droplet eliminator also includes inspection and cleaning of eliminator. 3.3 Fan Caution See also section 3.1 General instructions. 3.3.1 Electric motor connection and frequency converter set-up Caution The motor and frequency converter are factory set.
On figure below: Star connection Delta connection Delta-star connection up to 3 kW (left), 3 to 7,5 kW (middle), above 7,5 kW (right). Connection of the frequency converter power supply • Step 1: First, connect the grounding cable • Step 2: Connect electric supply cables to L1/L, L2 and L3/N. On figure below: • Connection of grounding cable (left), • Connection of ground cable, line power and motor wires (middle), • Three-phase and single-phase connection (right).
Cable length and cross-section The frequency converter has been tested with a given length of cable and a given cross-section of that cable. If the cross-section is increased, the cable capacitance - and thus the leakage current - may increase, and the cable length must be reduced correspondingly.
Wiring diagram 1,2 PE green/yellow Protective earth 3 L1 Black Power supply 4 L2 Black Power supply 5 L3 Black Power supply 6 NC White 1 Status relay, floating status contact, break for failure, contact rating 250 VAC / 2 A (AC1) / min. 10 mA; reinforced insulation on supply side and basic insulation on control interface side 7 COM White 2 Status relay, floating status contact, break for failure, contact rating 250 VAC / 2 A (AC1) / min.
Commissioning • Before checking the correct fan installation and operation, switch off the repair switch of the fan section in which you intend to intervene, or alternatively switch off the main switch on the air handling unit electric control cabinet, and lock the switch in the off position, to break the current supply circuit to the drive electric motor. • Prior to starting the electric motor, remove any mechanical interlocks on vibration isolators.
Caution Keep the inner and outer surface of the inspection glass clean. If you notice fouling, thoroughly clean the glass immediately. 3.4 Filter Caution See also section 3.1 General instructions. By appropriately setting the air handling unit control system, make sure that the relative humidity in the second filtering stage does not exceed 90% and the relative humidity in the first filtering stage or in the stage upstream thereof does not exceed 80% for three consecutive days.
592 x 287 3-2 4-2 5-2 2-3 3-3 4-3 5-3 6-3 2-4 3-4 4-4 5-4 6-4 7-4 8-4 592 x 592 2-2 4 - 1,5 3 - 1,5 SIZE 2 - 1,5 2-1 Number of filtering cells per cross section with different air handling unit sizes 1 1 2 2 1 1 2 2 3 2 2 4 4 6 6 8 1 287 x 592 1 1 1 2 2 3 1 287 x 287 592 x 490 1 1 1 1 1 2 2 2 8-5 9-5 10 - 5 3-6 4-6 5-6 6-6 7-6 8-6 9-6 10 - 6 6 6 8 8 10 3 6 6 9 9 12 12 15 2 3 3 4 4 5 287 x 592 2 2 2 2 287 x 287 1 1
Replace the filters: • • • • • Loosen the closing profiles, slide out the contaminated filter cassettes, clean the section casing if necessary, inspect the condition of the sealing tape on the sealing contact surface and repair or replace the tape if necessary, insert clean and undamaged filters. Caution For filter sections higher than 1900 mm, the door is divided by height. To replace the filters at the place of the partition profile, it is necessary to unscrew it and screw it back after replacement. 3.
3.4.3 Metal filter Caution See also section 3.1 General instructions and 3.4 Filter. See the values in the selection program data and on the nameplate.
3.4.4 Active charcoal filter Caution See also section 3.1 General instructions and 3.4 Filter. See the values in the selection program data and on the nameplate.
3.4.5 Absolute filter Caution See also section 3.1 General instructions and 3.4 Filter. See the values in the selection program data and on the nameplate. Absolute filters are always included and separately packaged.
3.5 3.5.1 Heat recovery units Plate heat exchanger Caution See also section 3.1 General instructions. See the values in the selection program data and on the nameplate. Commissioning • Prior to starting the section up, check the tightness of the threaded joints and tighten them if required. Also check the correct installation and connection of the control dampers with the damper electric motor drive, as well as the damper operation.
3.5.2 Rotary heat exchanger Caution See also section 3.1 General instructions. See the values in the selection program data and on the nameplate. Mount and install the heat exchanger in accordance with the manufacturer’s instructions, which are appended to these instructions. All the electrical installations and wiring must be carried out by an authorised and qualified professional in accordance with the heat exchanger manufacturer’s instructions and applicable regulations.
3.5.3 Run around coil Caution See also section 3.1 General instructions. See the values in the selection program data and on the nameplate. For Commissioning and maintenance of coils see also sections 3.7.2 Water heating coil and 3.7.3 Water cooling coil.
3.6 Control damper Caution See also section 3.1 General instructions. For standard item temperature stability check the values below: • Gear: -15 °C to +80 °C. • Sealing tape: -20 °C to +70 °C. Commissioning Control dampers are mounted on the casing from the outside or from the inside, depending on the project specifications, the customer’s requirements and the air handling unit version.
3.7 Heating and cooling coils Caution See also section 3.1 General instructions. We suggest that the piping is made in such a way that in the case of maintenance or replacement of the register, emptying the system and dismantling the piping is as easy as possible. Filling of water piping: • • • • Partially open the transfer medium supply valve and wait for the blade register to uniformly warm up / cool down. Fully open the transfer medium supply valve. Vent the system. Start the fan.
3.7.2 Water heating coil Caution See also section 3.1 General instructions and 3.7 Heating and cooling coils. In the event of high heating medium temperatures (above 70 °C), arrangements must be provided to protect the fan electric motor from overheating during unit idling; this is achieved by automatically shutting off the supply of the heating medium into the heating coil and continued operation of the fan for a certain period of time (3 to 5 min) after unit operation has stopped.
3.7.3 Water cooling coil Caution See also section 3.1 General instructions and 3.7 Heating and cooling coils. Be sure to install a properly sized syphon on the drain pipe to collect and drain the condensate. Instructions for the construction, installation and connection are given in section 2.3.5 – Connection of syphon. Check before Commissioning • The tightness of the threaded joints; tighten them if required, • the tightness of the piping joints.
3.7.4 Direct expansion (DX) Caution See also section 3.1 General instructions.
1 Splitting module 2 TXV 3 Temperature sensor 4 Capillary TXV 5 Pressure leveling line 6 Humidity indicator 7 mMagnetic valve 8 Drying cartridge 9 Rotolock valve 10 Collecting chamber Caution Connection of the cooling system and filling with coolant may only be carried out by a qualified professional. Connection should be made with copper pipes, which should be cleaned, dried and blown with dry nitrogen and plugged at both ends.
Medium draining • Shut off the isolating valves in the compressor-condenser section and evacuate Freon from the DX coil through the special valve (using the evacuation equipment in accordance with the Montreal Protocol). • Disassemble the thermostat valve insert. In the case quick couplings are being used, disconnect them; if not, unsolder the DX coil to allow its dismounting.
Maintenance Regularly check the soiling of the blades, and clean or replace the eliminator if necessary, as follows: • Slide the eliminator out. • Clean the blades with a scale removal agent. • Check the sealing and replace them if necessary. • Insert the eliminator back into the casing. 3.7.6 Steam heating coil Piping connection • Steam and air must move in a counterflow configuration. • Mount the steam heating coil in a vertical position – with the fin package tubing running vertically.
Check before commissioning • The tightness of the threaded joints; tighten them if required, • the proper functioning of the heating coil automatic anti-frost protection, before the heating coil is filled with the heat transfer medium, • the tightness of the piping joints, • the proper functioning of the automatic shut-off of the supply of heating medium into the heating coil at a heating medium temperature above 70 °C, to protect the electric motor against overheating, • the proper functioning of the autom
Maintenance In order to ensure smooth performance of heat exchangers, the following operations should be carried out regularly: • Check that the steam and water connections are leakage-free and that air joints are firmly mounted and leakagefree. • Check the venting fan operation. In the event of disturbances in the medium flow through the heat exchanger or the formation of air cushions, vent the piping system. • Check the operation of the heat exchanger automatic anti-frost protection.
Maintenance Once a month, check the following: • how well the electric connections are attached, • the installation of the temperature safety limiter and thermostat sensors, • the operation of the temperature safety limiter and safety thermostat, • the operation of the air flow control equipment, • the operation of the relays for starting the fan in advance and delayed stopping of the fan, • the proper mounting and attachment of the guards to protect against contact (the service cover, the connection box co
Connection • The indirect gas heating coil section must always be located in the positive pressure part of the air handling unit – downstream from the supply fan, to prevent the mixing of supply air and flue gases in the event of a heat exchanger defect. • The heat exchanger is installed into its casing on guide rails that facilitate its sliding out from the section in the event of defect or damage.
• In order to isolate the casing of the gas heating coil section from the noise and vibrations generated by the fan section upstream, apply a flexible connection made of a non-combustible material resistant to high temperatures. • In order to isolate vibrations generated by the fan section upstream of the gas heating coil section, apply spring vibration isolators. • In order to equalise the electric potentials of the fan upstream and the gas heating coil, apply a non-insulated Cu conductor.
3.8 Sound attenuator Caution See also section 3.1 General instructions. Every single splitter can be removed from the section. Commissioning In the case of cabling or joining sections, the removable panel on the section can be removed and the splitters removed. After the work is done, the splitters are returned and the section is restored to its original condition. Maintenance Splitters and section must be checked for dirt, damage and corrosion. In case of damage or soiling, cleaning is required.
3.9.2 Honeycomb humidifier Caution See also section 3.1 General instructions. Connection, commissioning and maintenance to be carried out according to the manufacturer‘s instructions. Be sure to install a properly sized syphon on the drain pipe to collect and drain the condensate. Instructions for the construction, installation and connection are given in section 2.3.5 – Connection of syphon.
Bleed-off factor With a given water quality, the bleed-off factor (f0) is determined by means of the water quality diagram. If the water bleed-off factor, fo, exceeds 2, the application of a direct water system is recommended, or the water quality should be improved. Direct water system: E = (V x 60 x 1.2 x (X2 - X1)) / 1000 Example calculation: O = fo x E V = 2.8 m3/s pH = 7.
Water piping connections: • shut-off valve (not included in scope of standard equipment) • 500 μm water filter (if the water contains coarse particles)* • solenoid valve (not included in scope of standard equipment – only for direct water) • constant flow rate valve (only for direct water) The extraction of water: In order to facilitate water bleed-off from the humidifier section under negative pressure, an appropriate negative pressure syphon must be provided.
Maintenance • Maintain the honeycomb humidifier section so as to prevent the growth and reproduction of microorganisms on any component of the air handling unit / ventilation system. • At a minimum, the water in the humidifier tank must meet the quality requirements for potable water. In order to avoid the build-up of lime deposits on the water droplet eliminator, total water hardness should not exceed 7°dH.
• Set the appropriate rate of the honeycomb humidifier bleed-off. To this end, carry out a chemical analysis of the supply water to obtain the necessary data, as follows: CaCO3 content (mg/l), Ca+ content (mg/l), HCO3- content (mg/l), pH value. From the water quality diagram (provided in the honeycomb humidifier manufacturer’s instructions), determine the bleed-off factor, f0.
3.10 Electric control cabinet Caution See also section 3.1 General instructions. The electric control cabinet consists of a connection part and a measuring part, which are mechanically separated from each other. It consists of the following basic elements: cabinet sinks, door with point closing and lock, elements for flow protection, separation and KS protection and measuring equipment.
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Tel: +386 1 200 73 50 Fax: +386 1 423 33 46 info@systemair.si www.systemair.com 66 systemair KA Modular Air Handling Units · Installation, operation and maintenance · version 2020-8-V-EN-003 Systemair d.o.o.
