INSTALLATION,

OPERATION
&
MAINTENANCE
MANUAL

DOUBLE SKIN AIR HANDLING UNITS

'TW/TWH & KW/KWH' SERIES
 Safety instructions 3

1. General remarks 4

2. Short description of units 4

3. Transport – Installation 5

4. Assembly – Start up - Maintenance 9

4.0 Casing 9

4.1 Fan section 13

4.2 Air inlet / Control section 20

Dampers 20

4.3 Filter section 21

Pre-/Fine bag filters 21

4.4 Heater section 22

PWW-heater 22

Electric heater 23

4.5 Cooling section 24

CHW-cooler 24

DX-cooler 25

4.6 Heat recovery system 27

4.7 Humidifier section 27

Air washer 27

Steam humidifier 27

4.8 Sound absorber section 27

4.9 Multizone section 27

5. Maintenance instruction for hygienic units 28

6. Trouble shooting 30

7. Programme of service for maintenance 33

-2 -
SAFETY INSTRUCTIONS

NOTE This maintenance instruction describes all functions and

advantages of the units and secures a safety operation by the
client/user, so far as known.
Technical use and handling responsibility is of client/user.
The maintenance stuff/personal must be technicians and trained
in operating air handling units (start-up protocol).
- Maintenance, repair works by trained personal, only.
- Function control and maintenance to be done periodically
and stated in sep. protocol.
Should above instructions not followed up, warranty will be
cancelled.

OBSERVE User information of this maintenance instruction and those given on

USERS units or components must be observed and followed up.
ADVICE Exceptionally those before transport installation, start up, re-start
and up keep.
Provision of unit may not be changed.!
Unauthorized changes impair function, safety and running life of
unit.

OBSERVE Following signs of safety are content of this maintenance manual

SAFETY and to be observed.
INSTRUCTIONS

Danger serves to prevent injuries the persons

Attention guides to damage of material and ambient

Notice guides to useful further informations

and user advises

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1. GENERAL REMARKS
Congratulation!You are now owner of double skin air handling unit
by CLASSIC AIR CONDITIONERS. This unit is desinged and
manufactured in observing all aspects of air condditioning and
static requirements.

Each unit needs a certain preventive maintenance to secure/ensure

a continuous and safety operation. This applies that your air hand-
ling unit needs to be checked and serviced in certain periods. Exact
detailed informations refer to following pages of this maintenance
manual.

2. SHORT DESCRIPTION OF UNITS

Zamil-Classic central air handling units consist of standardized

unit components. They are assembled to various air handling units
according technical and functional requirements given by clients.
Generally the units are shipped sectionally assembled. The casing
consists of Aluminum or rigid galvanized sheet steel profile
construction connected by glass reinforced polyamid corners.
Panels are of double skin design with incorporated none - combus -
tible insulation class A1 according to DIN 4102.
Thickness: - 30 mm
- 50 mm
Panel design: - outside 0,75 mm, coated RAL 9002
- inside 1,25 mm, galv. steel sheets

-4 -
3.TRANSPORT - INSTALLATION
ONE UNIT OR PART OF IT
Danger !
keep area clear underneath suspended loads
don’t step below Personal injury !

Attention !
protect air handling unit against impact shocks
don’t let unit down on edges
don’t load the unit on pointload only
don’t lift- up the unit on grasp to pipe or other unit structural
components
Damage of unit !

TRANSPORTATION
BY MEANS OF USE:
- high- lift
- stacker trucks with
squared timber

TRANSPORTATION
BY CRANE

-5 -
FOUNDATION - Foundation for the air handling unit shall be 50 - 100 mm,
each side, bigger than unit dimensions.
- Surface of foundation shall be levelled.

Height/design of foundation shall consider:

- static requirements (weight of unit)
- height of condensate syphon
- Vibration-isolation
- solid sound conduction

MONOLITHIC - monolithic foundation is capable high demand to

FOUNDATION vibration- isolation.

STRIP FOUNDATION - At strip-foundation construction the unit bottom casing

profile should be covered.
- The intermediate foundation strips should match to unit
sectional joint connections.

-6 -
POINT-LOAD - At point- load foundations the units bottom casing profile
FOUNDATION and sectional joints should be covered.
- The intermediate foundation load-points should match to unit
sectional joint connections.

ISOLATED FOUNDATION In this case the foundation-plate (steel-reinforced) or as steel base

frame is located on isolation vibrators, to prevent solid sound
conduction.
Pedestal below the isolation vibrators prevent that between floor area
and foundation plate dust, mud can led to solid sound conduction.
This foundation design prevents again vibration and solid sound
conduction.

SOLID SOUND For prevention/reduction of solid sound conduction soft material to

REDUCTION be used. As deep (soft material) the characteristic frequency as more
efficiency is given. The characteristic frequency of material should
be selected according critical frequency observed.
Mineralwool with characteristic frequency between 20 - 30 Hz is
useful in many cases.
Cork as insulation is not useful for fan excitated foundation, as the
rotary acoustic frequency is mostly same of characteristic frequency
of cork.

-7 -
VIBRATION For selection of vibration isolator besides the weight of units/
ISOLATION foundation the load of air force to be considered.
The arrangement of equal vibration isolations must be symmetric to
the unit thrust point.
Steel-spring- isolators needs additiona l solid sound reducer.

DRAIN-HEIGHT / Connection of condensate drain pipe with siphon to be made by

FOUNDATION-HEIGHT client/user.
Siphon must be counter pressure free.
Prior start-up and after a long period of none-operation siphon must
be filled with water.

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

Negative pressure (at suction side of fan pressure) Overpressure (at discharge side of fan)

AREA FOR SERVICE

AND MAINTENANCE

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4. INSTALLATION
4.0 UNIT SECTION

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

SECTION ASSEMBLY

or 1.1 or 1.1

to be sealed by
elastic sealing

Nos. per joint, each

Unit type – KW/TW KW 01-13 KW 16-50 KW 55-130

TW 2-11 TW 14-26 TW 35-90

1 – Hexagonal screw M 8 x 80 4 8 -
1.1 Hexagonal screw M 8 x 120 4 8 12
2 – Spring washer A 8 4 8 12
3 – Cap nut, hexagonal M 8 4 8 12
4 – Self-adhesive seal tape acc. demand acc. demand acc. demand

Unit type – KWH/TWH

1 – Hexagonal screw M 8 x 80 4 6 -
1.1 Hexagonal screw M 8 x 120 4 6 -
2 – Spring washer A 8 4 6 -
3 – Cap nut, hexagonal M 8 4 6 -
4 – Joint gap cover 4 4 -
5 – Assembly clamp - 2 -
6 – Hexagonal screw M 6 x 20 - 4 -
7 – Spring washer A 6 - 4 -

-9 -
SECTION ASSEMBLY Seal tape, near the profile edge on one of the opposite section-face-
area.
Connected sections are to be aligned (on foundation or pedestal) and
to be pushed together up to 10 cm distance.
Now fix the gripping belt/clamp around the section, pull together (up
to 1 cm distance) and again align the section.
Finally fix all connecting screws, nos. as described before, manual.
By use of gripping belt/clamp pull now section tight together and fix
the connecting screws. First down, than top.

- 10 -
Installation detail for head joint cap
outside installation

UNIT TOP SECTION

UNIT BOTTOM SECTION

- 11 -
START-UP Prior to start-up all maintenance panels are to closed. Check all
maintenance panels and locks for perfect position. Especially this is
to be done for all maintenance on pressure side of fan (positive
pressure in the unit).

ALIGNMENT OF Prior final alignment unit installation position to be checked and

PANELS/DOORS levelled position, proofed.

INSPECTION Damages of coated outside of unit panels/casing to be cleaned from

dirt, than treated with primer and re-painted with repair-colour-
lacquer. For galvanized casing parts the damaged points to be freed
from rust (metallic bright) and mended with cold galvanizer.

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4.1 FAN SECTION

ASSEMBLY Motor and fan are built together as one function component on a
common base frame, vibration free fastened to the unit casing. For
power supply the local regulations and/or VDE rules to be observed.
Main voltage must comply with datas given at motor name-plate.
Thermal over-current safety cut-outs are to be provided by client, so
far motor is not equipped with respective protective device, for
example thermistor protectors, in motor winding. If thermal relais
are used, they are to be set in accordance to values shown on motor
name-plate.
For maintenance and emergency function it is recommended to shut-
down the motor/unit for reasons mentioned before.

START-UP After finish of all mechanical and electric/power connection as first

step is correct rotation direction of fan- motor to be checked. Change
at rotation direction by exchange of 2-phases at motor.
The maximum elongation of V-belts occurs in the first operation
hours. Therefore it is highly recommended that after 30 minutes (full
load) the V-belt shall be retensioned (refer to item ''maintenance of
high efficiency narrow V-belts'').

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

Inspection of rotation can be done when fan section panel is opened!

Attention!
motor could be overloaded.
remain besides opened panel during period of inspection.

Inspection of rotation, when door closed

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

During inspection for start- up of fan-/motor aggregate following to

be controlled:
− fluttering of V-belt
− grazing of fan- impeller at fan casing
− noise of bearings
− unbalance of fan-impeller
At end of inspection switch-off fan-/motor-aggregate.

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MAINTENANCE/REPAIR Danger!
WORK FOR FAN-/MOTOR If no lockable repair-switch is provided/assembled, switch-off main-
AGGREGATE switch or remove fuses at switchboard.
Both provisions to be labelled at unit.

MOTOR Regarding maintenance of bearings refer to attached manufacturer

instructions. Lubrication instructions normally are given on motor
name plate.

FAN Bearing
Generally only proofed and low noise accuracy ball-bearings are
built in with theoretical life- time of min. 200,000 operating hours.
The V-belt drive pulleys to be calculated/choosen accordingly.
Permissible bearing loads are not to be exceeded.

V-belt tension

KW 01 - KW 02 are equipped with motor whip for tension of V-belt.

KW(H)03 - KW(H)130 & TW(H) 2- TW(H) 90 are equipped with parallel
sliding rail for tension of V- belt

For tension of V-belt, safety screw of spindle at sliding rail to be

unscrewed and spindle turned clock-wise until recommended V-belt
tension is reached (refer to item maintenance of high efficiency
narrow V-belt).

Attention!
Prior start-up all screws to checked and tighten!
Damage of material !

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 HIGH EFFICIENCY NARROW V-BELTS

Possible elongation of new V-belt drives occurs to 80 % in the first

15 operating hours.
Therefore, in the beginning deflecting ''f'' shall only be approx.
70 % of the calculated value.
After 50 operating hours recheck V-belts and retension them, if
necessary.

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

CHECK OF FLUSHING OF
PULLEYS

4) When replacing V-belts the same belt profile should be used

again.

EXPLOSION HAZARD 5) Danger!

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

6) Regular checking of belt tension and retensioning in intervals of

about 800 operating hours ensure high lifetime of belts. Abnormal
heating, excessive oscillations of the belt length between pulleys
and noise are mainly reason of insufficient belt tensioning.
Insufficient tensioning is leading to slip and premature failure, as
well.

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CHECK OF V-BELT Correct belt tensioning can be determined as follows:
TENSION
1. Measure belt length (upper length between pulleys)
or calculate it by the formula.

2. According to table below detect power, ''p'' by which the

individual belt is to be loaded in compliance with belt profile,
active diameter, RPM of the small pulley, as well as ratio of
transmission.

3. At standstill pretension of belt shall have a deflection "f'' of 1

mm per 100 mm belt length between pulleys when deflection
power ''p'' arise at each belt.

Belt profile Active pulley Power ''P'' in kg to deflect V-belt RPM of small pulley
diameter
dw
700 1450 2800 4000
Transmission i
up to 1 3 1 3 1 3 1 3
x SPZ 63 90 1.03 1.35 0.9 1.23 0.81 1.13 0.74 1.04
100 125 1.21 1.57 1.09 1.42 0.97 1.29 0.89 1.19
140 180 1.33 1.71 1.21 1.54 1.08 1.37 0.97 1.25
x SPA 90 125 1.54 2.11 1.36 1.9 1.18 1.68 1.05 1.51
140 180 1.84 2.4 1.66 2.17 1.45 1.92 1.27 1.71
200 225 2.02 2.55 1.82 2.3 1.57 2 - -
x SPB 140 200 2.45 3.28 2.16 2.93 1.8 2.5 1.5 2.13
224 280 2.8 3.6 2.5 3.2 2 2.7 - -
315 400 3.03 3.8 2.65 3.45 - - - -
x SPC 224 315 4 5.33 3.45 4.66 - - - -
335 450 4.5 5.9 3.9 5 - - - -
500 630 4.8 6 - - - - - -

x nos. of belts

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 V-BELT PULLEY WITH BUSH SYSTEM

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

Torque - Schedule

bush no. fixing screws max. tightening

torque (Nm)
nos. size length
1108 2 ¼'' ½'' 5.7
1210 2 3/8'' 5/8'' 20
1610 2 3/8'' 5/8'' 20
2012 2 7/16'' 7/8'' 31
2517 2 ½'' 1'' 49
3020 2 5/8'' 1 ¼'' 92
3030 2 5/8'' 1 ¼'' 92
3535 3 ½'' 1 ½'' 10

DISMANTELING OF PULLEY Remove the screws.

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

ADJUSTABLE V-BELT PULLEY

If drive is equipped with an adjustable V-belt pulley, fan-rpm and

consequently air volume can be varied within the regulating range.

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

- 17 -
 Manufacturer has already set adjustable pulley to required
diameter, according unit technical data.
Variation of the air volumes can be made according to the
following instructions:

Position of Increase active Decrease active

adjustable pulley diameter diameter
on motor air volume air volume
increasing decreasing
on fan air volume air volume
decreasing increasing

ADJUSTING OF NEW When adjusting on a new active diameter proceed as follows

ACTIVE PULLEY DIAMETER (refer to example):

a) Determine adjustment:
Adjustment = max. active dia. - new active dia.
4 x regulating factor

b) Remove out adjusting screw (see picture)

c) By closing adjustable pulley find out max. active diameter.

After this, open it to get the calculated rpm. (Adjustment should
only be made in complete ¼ revolutions, increase resp. decrease
calculated values.)

d) By doing so, a thread hole in the idle pulley is then matched

automatically with the flatening of the fixed pulley. Turn in
adjusting screw into this thread hole and tighten it strongly.

Adjustable pulley
Profile
SPZ SPA
Outside ∅ Outside ∅ Active ∅ Regulation
factor
84 62...80 1.64
95 73...91 1.64
100 78...96 1.64
108 90...104 1.45
(108) (76...102) 1.64
120 88...114 1.64
129 97...123 1.64
139 109...133 1.54
146 116...140 1.54
156 126...150 1.54
164 134...158 1.54

- 18 -
EXAMPLE FOR Conditions:
DETERMINATION OF profile SPZ, adjustable pulley 100 mm outside diameter, max.
ADJUSTMENT active diameter (refer table above) = 96 mm
regulating factor (refer table above) = 1.64
new determined act. Diameter = 83 mm
Requested:
adjustment (nos. of revolution)
Solution:
adjustment = 96 - 83 = 1.98 = 2 nos. revolution to open
4 x 1.64

- 19 -
4.2 AIR INLET/CONTROL DAMPERS 2.1 to 2.5
SECTION

INSTALLATION Electric connection of servomotor to be done in accordance to

manufacturer instructions.

Attention!
Never start fan when dampers are closed.
Fan motor must be locked by controls, accordingly.
Damage of equipment!

MAINTENANCE Shaft of dampers are embed in plastic bearing sleeves. Normally

they don’t require any maintenance. However it is recommended to
check periodically connecting rools, bearing seat as well as
fulcrums and if necessary to oil them.
In case of heavy contamination we recommend to purge by
compressed air and re-oil by use of resin- free oil.

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4.3 FILTER SECTION PRE-FILTER AND BAG FILTER 3.1 + 3.2

INSTALLATION Filter inserts are supply separately in cartons in order to avoid

damages/pollution during transport and installation of unit.
First remove maintenance panel and/or open door of filter section.
Now pull out (up to KW 25 / TW 26) the filter insert fra me to fit- in
the filter insert and fix them by spring.
At walk - in unit (KW 32 / TW 35 and bigger step into filter- section
and fix described before.
When using differential pressure gauge (standard- inclined gauge)
care should be taken for horizontal alignment.
Fix (+) connector to dirty air side and (- ) connector to clean air
side.
The pass through the unit panel is to be made air- tight.
Measuring points to be choosen in such way the influence of
dynamic factors are excluded.

START-UP After having checked whether filter- inserts are undamaged and are
correct fitted, the built-on filter-differential-gauge to be aligned
finally (see title installation). All unit parts/components are to be
cleaned from any rubbish and dust or coarse dirt. Fill- in measuring
liquid till zero position. After start-up of fan and set of designed air
volume indicate ''initial pressure drop point''.

MAINTENANCE When filter differential gauges indicates level of admissible final

pressure drop is obtained (for admissible final pressure drop refer
to unit technical data sheets) filter inserts to be changed.
If no differential pressure gauge is installed filter must be inspected
for contamination regularly (weekly) and change to techn.
experience and time recommended by manufacturer.
Beside perm. Alu - filter all other filter- media are of throw- away
media.
A regeneration reduce in any case efficiency and is on risk of
client. No guarantee.

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4.4 HEATER SECTION PHW-HEATING COIL 4.1 + 4.2

INSTALLATION In-/outlet connection should be connected in such way that coil is

working to counter flow principle. Normally, if not required
special inlet of coil is on top, outlet in bottom. All piping
connection work should be tension, free.
In order to facilitate repair, service and maintenance works,
pipings in front of heat exchangers must be easily removable or
should be able to be swivelled off after loosening of heat
exchangers. Flow and return flow have to be closed by valves. If
exchangers are not provided with ventilating and emptying
facilities, the customer has to provide respective lockable
connections. To avoid damages by freezing to heat exchangers,
frost protection sensors are to be provided behind preheaters so
that at temperatures below approx. +5°C the heating pump is
switched- in, heating valves are induced to open or outside air
dampers are induced to close.
The frost protection sensor should be equipped with a capillary
sensor (CT-standard approx. 3 m and 6 m) and shall be braced over
the coil face-area.

Attention!
Frost dangers occurs to the low tubes of coil first.
Brace capillary elements correspondingly.
Damage of coil!

However the kind of frost protection is determined by

client/supplier of plant.

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

MAINTENANCE Essentially maintenance works after start-up is restructed to check

tightness of system and components, as well as cleanness for coil
(tins) himself. Dusty coil have a bad efficiency. At continuous
operation, cleaning of coil should be done every 6 months or at
seasonal operation prior start of heating period. Cleaning can be
done by use of pressed air or by spraying of water with detergent
additives.
Remove of coil is possible, if all connections are dismantled.
Remove all coil by means of sliding out on unit glide mechanism.
Prior start of heating period, besides cleaning it is recommended to
check the freeze-protection thermostat as well as pressure level of
system and air- vents.

- 22 -
 Attention!
Bad vented coil and system interrupts circulation of water flow or
give insufficient quantity. Freezing changer accours at ambiant
temperature below zero !

ELECTRIC HEATER SECTION 4.3

INSTALLATION Power supply is to be made according to wiring diagram in

terminal box of the heater or as per attached wiring diagram.
To protect other unit components against to high temperature and
to away fire, the electric heat-exchanger is equipped with safety
thermostat. The safety thermostat cut-off the heater by excess
temperature.
Furthermore it is recommended to install suitable air flow control
device and to interlock fan-motor operation with function of
electric heater.
Means: - If fan-motor stops by any reason electric-heater
switched-off also.
- If electric -heater switch-off by safety device, fan-
motor shall continue controlled by time relais,
prior switching-off as well as.

START UP Check all electric connection and function of safety devices.

MAINTENANCE Beside a periodically check of function no further maintenance

work is required.

Attention!
Prior opening of panel/door of electric heater section the plant/unit
to be switch-off.
Injury by burns (temperature) and voltage.

- 23 -
4.5 COOLER SECTION CHW-COOLING COIL 5.1/5.3/5.5

INSTALLATION In-/outlet connection should be connected in such way that coil is

working to counter flow principle. Normally, if not required
special inlet of coil is on top, outlet in bottom. All piping
connection work should be tension, free.
In order to facilitate repair, service and maintenance works,
pipings in front of heat exchangers must be easily removable or
should be able to be swivelled off after loosening of cooling coil.
Flow and return flow have to be closed by valves. If cooling coil
are not provided with ventilating and emptying facilities, the
customer has to provide respective lockable connections.
Connect a drip - siphon to drain- connection of unit - drain pan.

Connection to main drainage system must be

counter-pressure-free or of open-type system (Gully etc.).
Description/design of siphon refer to page 8.

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

MAINTENANCE Essentially maintenance works after start-up is restructed to check

tightness of system and components, as well as cleanness for coil
(tins) himself. Dusty coil have a bad efficiency. At continuous
operation, cleaning of coil should be done once 1 year or at
seasonal operation prior start of cooling period.
For cleaning remove coil and if applicable drip-eleminator, after all
connections are dismantled. Now unscrew drip eleminator, as well.
Cleaning can be now done by use of pressed air or by spraying of
water with detergent additives. After cleaning coil and drip-
eleminator, if applicable, to be re-assembled.
Attention: Correct direction of drip-eleminator fins
(vertical position).

Attention!
PVC drip-eleminators are suitable up to air temperature of 80°C,
only.
Material damage!

- 24 -
 If necessary drain pan can be cleaned separately, as well.
After re-assembly of integral parts, they can be pushed into via
gliding guide mechanism.

Attention!
Prior start of cooling period heat exchanger to be checked for
correct ventilation and system pressure, because otherwise if not
available, the full cooling capacity cannot obtained. If cooling
media not mixed up with glycol, in winter freezing danger is given,
so far air temperature could be below zero. In this case either:
- cooling not needed empty system coil purge it with
compressed air
- add. glycol according max. ambient air temperature
Material damage!

DX- EVAPORATING SECTION 5.2/5.4/5.6

INSTALLATION Installation of refrigerant connecting piping is to be in such way,

that service- and maintenance works are not obstructed. We
recommend to erect, fix the piping to top, on back-side or if on
maintenance-side in space of webs/unit-profile, only. In these case
maintenance panels can be removed without cutting the pipes.
Connect a drip-siphon to drain-connection of unit-drain-pan

Connection to main drainage

system must be counter-pressure- free or of open-type system
(Gully etc.).
Description/design of siphon refer to page 8.

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

Prior start up of fan the siphon to be filled up with water. After

start of fan height of siphon to be checked as no air may be sucked
through or blown out.

- 25 -
MAINTENANCE Essentially maintenance works after start-up is restructed to check
tightness of system and components, as well as cleanness for coil
(tins) himself. Dusty coil have a bad efficiency. At continuous
operation, cleaning of coil should be done once 1 year or at
seasonal operation prior start of cooling period.
For cleaning remove coil and if applicable drip-eleminator, after all
connections are dismantled. Cleaning can be now done by use of
pressed air or by spraying of water with detergent additives.

Attention!
PVC drip-eleminators are suitable up to air temperature of 80°C,
only.
Material damage!

- 26 -
4.6 HEAT RECOVERY Please refer to attached manufacturer instructions.
SYSTEM

4.7 HUMIDIFIER SECTION AIR WASHER

Please refer to attached manufacturer instructions.

STEAM HUMIDIFIER
Please refer to attached manufacturer instructions.

4.8 SOUND ABSORBER

SECTION

INSTALLATION Units are already equipped and splitter built- in. No further
installation needed.

START UP Splitten surface to be checked for damages and if needed to repair

by paste over with fibre-glass mat.

MAINTENANCE Besides check a damage and inspection of dust to splitter surface

(once a year), no further special maintenance required. Dust can be
cleaned off by use of air jet (low pressure) or soft brush, manual.

4.9 MULTI ZONE SECTION For installation, start up and maintenance please refer to item
4.1 to 4.3 and 5.1 to 5.4.

- 27 -
5. ADDITIONAL MAINTENANCE INSTRUCTIONS FOR HYGIENIC UNITS
Cleanness of plant
Air handling/ conditioner unit
Besides of cleaning of all components and devices, special
attention must be given to the maintenance of filters. A permanent
control of filters is imperative as well as replacement at maximum
recommended final filter pressure drop. Appearance and indication
of defects shall be solved in due time. Intervals of
maintenance/inspections should be in period stated under item
''maintenance intervals'', page 34.
Further they shall be in consideration of experience of maintenance
stuff and ambient condition/influence of area, where unit is
installed.
Each filter stage should/must have his own filter gauge, for
indication of filter-differential pressure drop.
For clear and correct check of filter condition, each filter section
shall be equipped with separate name plate, with indification of
following: filter class, type of filter- media, size/nos. of filter-
inserts, nominal air volume (m3 /h), initial pressure drop,
recommended final pressure drop, date of last maintenance.
Plant room and size of unit shall be designed in such way the
reliability and demands of hygienic conditions of whole
installment are assure on high standard of government rules.
For quick and easy dismantling/remove of unit components
(purpose of maintenance) any piping system for unit should be
dismantled easy, as well.
Air conditioning plant for OT-area
Switch-off is allowed for urgent maintenance or repair-works,
only. However the time should be limited to short period and must
be announced to hospital- management. General maintenance
periods and works should be in accordance to hospital-organisation
rules for OT-area and agreed by technical management of hospital.
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FAN BREAKDOWN Notice!
In case supply fan of overpressure system (+) breakdown, the
exhaust fan shall be switched-off automatically, as well. In case
exhaust fan of underpressure system (-) breakdown, supply fan
shall be switch-off automatically, as well. In both cases electric
interlock in control switch-board is recommended.

POWER FAILURE Notice!

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

HYGIENIC INSPECTION Notice!

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

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6. TROUBLE SHOOTING

Failure Probable Cause Remedy

1. no air − motor does not run − switch on main switch

− check mains voltage on all motor phases
− check motor protective devices
− check control
− check frost protection

− motor running, but V- − mount new set of V-belts

belts broken

2. not enough air − dampers are not open − check and open all dampers of unit and duct
system

− filter dirty (see − install new filter

difference pressure
indicator)

− slip of belt drive too − retension belt drive

high

− check whether volume − check actuator whether electric power or

flow controllers are set controlled pressed air applies. If damage
to full air volume change.
− if motor out of order, burnt out/broken,
motor has to be changed
− fan turn in wrong
direction − change phase of 3-phase motors to that
rotation direction shall be varied

3. motor current − air volume too high − adjust air volume (V-belt drive/pulley)
consumption
too high − fan turn to the wrong − change phase of 3-phase motors to that
direction rotation direction shall be varied

− belt pulleys wrongly − check speed ratio and change drive

installed

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4. no heating − no voltage at heating − switch on main switch
(electrical register − check control
heater) − check overtemperature safety device

− voltage at heater ele- − check resistance of heater

ment, but no heating
5. no heating − no heating- media − check hot water generation
− check hot water pump

− valves do not open − check control

− check functioning of valves

− air in the heat exchanger − vent. heat exchanger

6. no cooling − no chiller water − check chilled water generation

− check chiller water pumps

− valves do no open − check control

− check valve for functioning

− air in the heat exchanger − vent. heat exchanger

7. water leakage − condensate drain − install siphon

in the cooler without siphon
section
− height of siphon too − enlarge height of siphon
low − observe maximum pressure losses

− no water in the siphon − fill siphon with water prior to start of

cooling period
− suctionside dampers
open only after start of − change control in such a way that fan starts
fan, so that the water is running only at opened suctionside dampers
drawn out from the
siphon

− eliminator does not work

correctly − clean fins of eliminator
− check fin direction, turn it if wrongly
installed

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8. water leakage − drip eliminator does not − clean eliminator
behind the work correctly − check fin direction, turn it if wrongly
airwasher installed

− nozzles dirty, they spray − clean nozzles

with water jet onto the
eliminator

− face velocity too low − check air volume and set it correctly

− air-washer humidifiers − air-washer operation only at nominal air

at lower fan speed, this volume, change control respectively
means face velocity too
low
9. no humidifica- − pump does not run − for failure remedy refer to item 1 ''motor
tion at washer does not run''

− pump runs, but no water − clean nozzles

or only few water is − clean filter sieve
coming − check water content of tub
− check maximum limitation of humidity
10. no humidifi- − refer to instructions of
cation with the respective
steam humi- manufacturers
difiers

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7. PROGRAMME OF SERVICE FOR MAINTENANCE

Acti- Maintained part Intervals of inspection / to be carried

vity maintenance
no. day week month year
1 − fan bearing 1x − inspection / check of
(maintenance- free) noises

− motor bearing 1x inspection / check of

(maintenance- free) noises

− V-belt drive (week of 1x 1x − re-tension of V-belt

start-up

− V-belt drive 1x − re-tension of V-belt

2 − damper 1x − check function,
oil bearings

− volume flow control 1x − clean slide rod

3 − filter 1x − check rate of diff.

pressure drop and/or
replace filter at
recommended final
diff. pressure drop
4 − heater 1-2 x − clean fins, vent.
piping/coil bleed prior
start of heating season
5 − cooler 1 x − clean fins, vent.
piping/coil, clean drip
eliminator fins, prior
start of cooling period
6 − washer-start up 1 x − check ph- value of
water
1x − check accumulation of
mud
− washer (maintenance)
waterhardness
up to 4° dH appr. − complete cleaning of
3x water
up to 8° dH appr. − complete cleaning of
6x water
8° dH appr. − complete cleaning of
1x water
8 − silencer 1 x − clean splitters
9 − housing 1 x − mend damages and
clean
− hygienic type − observe regulation of
local hygiene institute

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