Hygienic Air Handling Unit - ACS Klima · Air Handling Units are capable of regulating the air...

“ The Efficient Way of Air Handling Unit ”

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Package Type

Hygienic Air Handling Unit

Operation & MaintenanceManual

Thank you for choosing

ACS and CLIMACS brandPackage Type Hygienic Air Handling

Units.

In addition to “Air Handling Units Installation, Operation and

Maintenance Manual” supplied with each unit, this manual

contains instructions for the first installation, operation and

maintenance of the software automated system.

All the best...

IMPORTANT

All instructions and information given in the “ Air Handling Units Installation, Operation and Maintenance Manual ” are also valid for this package type hygienic

air handling unit. You can access all our manuals from the products menusin our web site www.acsklima.com

Besides providing heating, ventilation and air conditioning, Package Type Hygienic Air Handling Units are capable of regulating the air pressure of the hygienic area

both positively and negatively. Therefore, air handling units should not be shut down except for the periods of maintenance, cleaning or fault conditions.

Please keep in mind that shut down of the air handling unit may lead to the contamination risk in the hygienic location.

Due to hygienic and package type design of the unit, it should be installed on a level floor with sufficient strength to carry the load of the unit; the installation method

should allow easy cleaning and good drainage of condensed water. The installation location must be free of contamination sources such as chimney, dump, etc.

| Maintenance & Cleaning

MAINTENANCE & CLEANING

The instructions of the manufacturer should be followed prior

the operation for the first time (or after annual maintenance).

After that, below points should be checked:

For annual maintenance, shut down the air handling unit and turn off all motor switches, turn off the power.

Make sure that the all compartments are cleaned and no foreign object or material is left in the unit. Please check no duct isolation residues, tapes, nuts, hand tools are left behind.

Please check all the handles on doors and access panels.

If the unit is installed outside make sure that it is placed under an overhead shelter and check the joints of gaskets.

Duct connectionsand dampers

Cooling unitsand refrigerant check

Drainageand siphon check

Fan and motorconnections

Connections for allelectrical parts

and sensors

Door locksand hinges

Air tightness and pollutioncheck of filters

Water and refrigerantleakage control in heating,

cooling and DX exchangers.

In addition to check of connections;all notifications shown on the control panel must be carefully inspected and intervened.

| Air Filters & Panel Filters

The air delivered by the air handling units are cleaned by the filters

as the air passes through.

Failing to check the filters as instructed, may cause health risks

and faults in the unit; it also may cause to increased energy

consumption.

AIR FILTERS

Weekly checking and cleaning of the filters is necessary following the commissioning

of the unit. A drop in the pressure level is an indication of the filter pollution. The time

that a filter takes to get polluted depends on the operation duration of the unit as well

as the ambient weather condition and pollution where the unit is located, eg., city

and industrial regions. An optionally available automation system can be used to

detect and notify the pollution level of the filters.

If the unit is actively operated, change the front filters at least once per three to six

months depending on the pollution level of the ambient environment. Please take

care to insert the new filter correctly and check also the gaskets on filter skids; if worn

out change the gaskets and finally using clamping lever fix the filters in position to

provide air tightness.

PANEL FILTERS (FRONT FILTER)

Panel filters can be cleanedby one of the following methods:

Shaking and vacuum cleaning,

Compressed air,

Washing with warm water(not pressurized)

| 2nd & 3rd Stage Filters

2nd and 3rd STAGE FILTERS

Check if there is any pressure drop and inspect the condition of the gaskets on the

skids. The most significant indication of a filter pollution is the pressure drop.

Max Pressure Difference = 1.6 x Initial Pressure Difference + 40 Pa

When the max pressure drop is reached remove and renew the filter. Make sure that

the filter frame firmly sits on the outer cassette and check that the contact between

doors and filters is good.

Correct positioning and good sealing affect the filter performance.

"Please contact to ACS engineers to get

information on special filters "

BAG, MPACK AND HEPA type filters cannot be cleaned and reused. These should be changed

upon completion of life cycle

Ensuring the filter sealing

ATTENTION

Table 1: Pressure differences for panel (front) filters

FILTERCLASS

EU - 2

EU - 3

EU - 4

35 Pa

35 Pa

45 Pa

INITIAL PRESSUREDIFFERENCE

150 Pa

150 Pa

150 Pa

RECOMMENDEDMAX PRESSURE DIFFERENCE

FILTERCLASS

EU - 4

EU - 5

EU - 6

EU - 7

EU - 8

EU - 9

45 Pa

80 Pa

80 Pa

80 Pa

95 Pa

95 Pa

FILTERCLASS

150 Pa

200 Pa

200 Pa

200 Pa

300 Pa

300 Pa

RECOMMENDEDMAX PRESSURE DIFFERENCE

Table 2: Pressure differences for 2nd and 3rd stage filters

Note: ACS package type hygienic air handling units are supplied with automation system by which you can easily monitor the filters on touch sensitive panel screen.

| Air Dampers

AIR DAMPERS

Check that the rotation of the flaps is not obstructed.

Do not touch the body or flexible connections.

Remove the accumulated dust by compressed air.

If you observe any problem in opening or closing of the flapscall an authorized service.

STEAM TYPE HUMIDIFIERS

At the beginning of each season, clean the strainer in the steam feed of control valve.

Annually check the control valve, condensed water discharge system and dispersion pipe.

Humidifier boiler and electrodes should be checked at least once per year. If the water used in the system is not distilled water then the frequency of checks should be increased depending on the chemical composition of the water used.

Following the periodic checks of humidifier section the operation of the humidifier can be checked from the air handling compartments after humidifier. Looking towards air flow direction a steam increase should be observed.

Silencers chambers should be inspected carefully. If there the surfaces of the silencer chambers are damaged, the glass wool inside may be caught by the air flow and carried away towards the filters. This may damage the filters and pollute the ambient air.

(ACS, wraps the glass wool by a special fabric in order to minimize the risk.)

IMPORTANT

| Heaters, Coolers & Heat Recovery Exchangers

HEATERS, COOLERS AND HEAT RECOVERYEXCHANGERS

Cleaning of air inlet side should be checked at least once per year. Surrounding weather and environmental conditions may require more frequent checks. Remove the parts and clean them applying pressurized water in the opposite direction of air flow.

If the pollution is severe please check the condition of the filters.

Discharge the water inside the exchangers

Dismantle the exchanger and piping connections

Remove the side panel

Dismount the nuts fixing the exchanger

Remove the exchanger

Please follow below steps if water heat exchangers will be removed for cleaning and

maintenance:

Clean the surface and the fins of the exchanger

Charge the exchanger with water

Locate the leakage

Discharge the water

Using oxy-acetylene welding repair the small cracks or holes located on copper pipes

It may not be possible to repair the exchanger if the reason of leakage is cracks caused by

freezing, or if the leakage is between the fins.

Charge the exchanger with pressurized water to check welding.

Please follow below steps to locate leakage in water heat exchangers:

" Prevent freezing of water inside heat exchangers "

LOCATING LEAKAGE IN DX (REFRIGERANT CHARGED) HEAT EXCHANGERS:

After shutting down the unit and switching off the power, clean the surface of the exchanger by compressed air or water.

Straighten the bent fins by using a fin comb.

If ice is observed during operation let the ice melt down naturally and inform the technical service

If you think that there is a refrigerant leakage in the system please inform the technical service

If the water inside the pipes of exchanger freezes, this will severely damage the pipes. For this reason, if there is a risk of freezing the antifreeze should be added to circulating water. If you are planning to take the exchanger out of operation for a short period, at least, make sure the water inside the exchanger is partially circulated.

| Heaters, Coolers & Heat Recovery Exchangers

Some condensed water might be observed

in the return compartments of heat

exchangers that serve for cooling or heat

recovery. Please check the condensing water

drainage

Please clean by using either compressed air or water in the opposite direction to air flow.

You can also use a very soft brush.

Straighten the bent fins by using a special fin comb.

Air Flow Direction

| Fans

FANS

Make sure that the impeller is fixed on the motor shaft tightly.

Check if fan and motor rotate freely.

Make sure that there is no foreign object at the inlet of the fan.

Check the rotation direction of the fan. To do that, momentarily switch on and off the power then observe the rotation direction of fan.

Check that the motor shaft and fan inlet flange are aligned.

Check the motor and its connections.

Check that flexible connections are secured tightly and not damaged; duct connections are designed according to the recommendations of the manufacturer with acceptable engineering applications.

Check the setting of the motor protection switch is correct.

Switch on the power and let the fan to reach to its full speed.

Do not forget to observe below points!

x y

z

Excessive vibration

Proper lubrication Motor current and voltage values

Strange noise Axial alignment of motorand fan flange

| Fans

If any problem is observed shut down the unit immediately.

Switch off the power.

Secure the fan to prevent unintended rotation of the impeller.

Inspect the source of the problem carefully and rectify it if necessary.

The operation of the fan should be observed periodically for the first 8 hours of the operation.

Pay attention to excessive vibration or noise during this observation.

Check that the input current of motor and temperatures of the bearings are within the limits specified by the manufacturer.

Finally, switch off the fan to do below checks:

x y

z

Axial alignment of motorand fan flange

Bearing temperature Fan and motorfixing bolts

Fan speed should not be changed without consulting the firm. If a higher speed of

rotation is required the power rating of motor should be checked for required capacity.

The load on the bearings and fan must be recalculated by the manufacturer. Vibration

absorbing isolators should be checked once per year for damage

Annually check the balance of the fan. Clean dust on the suction funnel and rotor.

Accumulation of dirt on the rotor may impair the balance. If pollution is severe check the

filters and upgrade the filters if necessary. If the fan is equipped with a suction damper,

every three months check the suction damper for proper operation. To do that, switch

off the fan first then operate the suction damper and observe the operation of

servomotor, connections and flaps.

| Fans

MAINTENANCE PROGRAM

A protective maintenance program is an important part of an active safety program.

Maintenance works should be carried out by trained and experienced personnel.

Do not attempt to conduct any maintenance unless the power is switched off and

the fan is secured.

Package type hygienic air handling units are the kind of devices that directly relate

to human health. Therefore, except for routine cleaning and maintenance, the

works requiring a special attention must be performed only by the trained

personnel. Maintenance period varies depending on the operation conditions.

Recommended maintenance program is given below.

Warnings on filter pollution etc. will be given automatically and can be followed in

the screen of the systems equipped with the automation. The warning should be

followed carefully and necessary precautions must be taken immediately.

Ignoring these warnings may lead to an automatic shut down of the unit due to

self-protection.

Fan & Motor Balance

Motor and Support Fixing Bolts

Support and Cabinet Bolts

Cable Connection of Electric Motor

Motor Shaft and Fan Connection

Flexible Connections

Earthing

| Maintenance Program

Once Per Week:

Check the condition of filters. Clean, wash or change if necessary.

Check the level of pollution in the condenser heat exchangers, and wash if necessary.

Please keep in mind that above checks may be required more frequently depending on the climate and environmental conditions.

Once Per Month:

Check the operation of the fan and motor; adjust if necessary.

Check the injection nozzles and the humidifier valve.

Check water flow in the drainage pipe.

Check the condition of the entrance door hinges and the lid gaskets;lubricate the hinges if necessary.

Once Per Every Six Months:

Check the operation current of motor.

Check the fan and motor bearings for high temperature and noise.

Check the operation of control instruments.

Check condensed water tray, siphon and drainage pipe.

Check circulation pump and motor of the humidifier.

Check the condition of the strainer of the humidifier.

Check the condition of cold / hot water or steam pipe system.

Check lids, duct connections for air leakage (suction and blowing)and if a leakage is located take precautions immediately.


Once Per Year:

Check the isolation of the filter frame.

Change the synthetic wool in panel filters.

Check the heat exchangers and fins. Wash by water jet if necessary.

If any, straighten the bent fins by using a fin comb.

Check the heat exchangers for leakage.

Bleed the heat exchangers with water.

Check the tightness of the bolts fixing the fan and motor.

Check lubrication of motor and fan bearings.

Check the operation of the dampers.

Check the doors of the air handling unit for easy opening and closing.

Check the conditions of the fittings and valves in piping system.

Check all cabling, control and isolating apparatus and terminal connections etc.

In case a part is changed during a maintenance consult the relating section of the manual and follow the instructions to restart the unit.

Following the checks summarized above, if you still observe some problems such as the air flow rate is excessive or insufficient; or set temperature cannot be reached in the location; or intended pressure values cannot be reached in the location etc., please check outer systems (conditions and air tightness of ducts, VAVs - CAV - duct type heaters, operation of duct dampers, condition of surrounding environment). If you have any difficulty in detecting such problems you may call ACS engineers and technicians for support.

IMPORTANT WARNINGAll maintenance instructions and warnings above are essential for smooth operation of

the unit. Failing to follow the instructions or ignoring warnings notified on unit's screen

(the unit automatically logs the warnings) and continuing the operation may lead to

severe faults and make the warranty invalid.


Once Per Year: RECOMMENDED MAINTENANCE SPECIFICATION

Upon the end of warranty period, please check below points to cover in your maintenance contract when you sign a maintenance contract with a third party. Please do not make a maintenance contract with any person or company who are not qualified.

Hot and cold water heat exchangers to be washed with chemical agents. Air handling unit compartments to be cleaned with chemical agents.

All filters in the air handling unit to be checked, cleaned and if necessary replaced.

Air dampers to be checked and adjusted. Water inlet strainers and nozzles of the steam humidifier to be cleaned. Re-heater and pump (if any) flow directions to be checked. Droplet catcher to be checked DX heat exchangers to be checked and cleaned.

Refrigerant leakage test to be conducted in the cooling system. Condenser heat exchangers to be washed with chemical agents and the fans to be checked. Heat exchangers to be checked for leakage.

Motor and compressor current and voltage values to be measured.

Compressor oil to be checked. Overall operation and performance values to be retrieved. Hygiene of units to be provided by use of alcohol. Filters to be re-installed and checked for air tightness.

Freeze thermostat setting to be checked.

All site equipment (sensors) operation to be checked. Water tank of the steam humidifier to be checked and if necessary cleaned. Electrodes of the steam humidifier to be checked and if necessary renewed.

AD

JUS

TAB

LE D

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and

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S P

AG

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tem

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atur

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take

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UN

IT L

OC

AT

ION

:

Please note that the components in the picture are for illustration pupose only.Actual layout and numbers can be different.

37 8

2

HE

PA

FIL

TER

HY

GE

NIC

LO

CA

TIO

N

+ P

oziti

ve P

ress

ure

- N

egat

ive

Pre

ssur

eTR

AN

SM

ETE

R R

OO

MP

RE

SS

UR

E S

EN

SO

R

BLOWING TO THE LOCATION

DU

CK

TY

PE

HE

ATE

RB

LOW

ING

TO

TH

E L

OC

ATI

ON

( BO

AR

D R

EQ

UIR

ED

)

PA

CK

AG

E T

YP

EH

YG

IEN

IC A

IR H

AN

DLIN

G U

NIT

OP

ER

ATI

NG

RO

OM

EN

TRA

NC

EC

OR

RID

OR

IN F

RO

NT

OF

THE

DO

OR

4+ -

Lam

inar

flow

or

hep

a fil

ter

units

Panel frame and LCD screenair handling unit LCD control

Suc

tion

Inle

t

Suc

tion

Inle

t

Suc

tion

Inle

t

PT

- 10

0

PT

- 10

0

EX

HA

US

T

FRE

SH

AIR

INLE

T

HU

MID

ITY

SE

NS

OR

LOC

ATI

ON

RE

TUR

ND

UC

T

POWERAUTOMATION

HUMIDIFYNGSTEAM UNIT

BOARDMCC - DDC

Loca

tion

retu

rnV

av m

otor

Blo

win

gV

av m

otor

S c r e e n

1

1

1

11

1

13

3

32

2 4

34 M

BY

-PA

SS

RE

TUR

N P

IPE

UNIT

INFE

ED

PIP

E

SP

HE

RIC

AL

VA

LVE

DIR

T R

ETA

INE

R

RE

DU

CTI

ON

ELE

ME

NT

3-W

AY

VA

LVE

w/M

OTO

R

CO

NN

EC

TIO

N D

IAG

RA

M O

F TH

E 3

-WA

Y V

ALV

E w

/MO

TOR

If t

he

re is

a w

ate

r he

at

exchang

er

in t

he

sys

tem

, 3

-way

valv

e w

ill b

e u

se

56

910

14

1113

12

PRELIMINARY WORKS FOR THE COMMISSIONING OF THE UNIT(ACCORDING TO THE DIAGRAM ABOVE)

Cross Section andType of Cable

Implementation

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Cabling for location blowing and VAV motor (ratio adjusted)

Cabling for location return and VAV motor (ratio adjusted)

Cabling for pressure difference switch for HEPA filter (if any) pollution notification

Cabling for room pressure transmitter sensor

Cabling for the duct type heater (if any) according to power, stage and voltage(220V or 380 V)

Cabling for temperature limit thermostat of the duct type heater (if any)

Cabling for control panel screen, 24 V DC to control location of the unit

Data cabling for the screen, to the control location of the unit

Air handling unit MMC DCC main branch feeder (according to kW rating)

Earthing cabling separate from air handling unit MMC DCC main branch feeder

Pipe connection for water (of suitable hardness) supply to steam humidifier

Water inlet, outlet and 3-way valve connections if there is a water heat exchanger

Drainage connections for humidifier and cooling heat exchanger

Ethernet cabling between the air handling unit and the internet connection point of thecompany for software updates and remote diagnose

Wall installation of the screen case (supplied by ACS), at the control location of the unit.Screen cases are available for either surface mount or flush mount.Please send your preference previously.Receiving the units at site, transportation of the units to the location specified in theproject and making duct connections.

Implementation of cable trays to protect all cabling done by eitherACS or your electrician

All sensor connections between the unit and the control panel

Piping, welding and refrigerant charging works for cooling heat exchanger

Commissioning of the units, delivery of training and handing over to operators

3 x 0,75Halogen Free




___________Halogen Free



Cat 6

_____x_____Halogen Free

By the electricianof your company










By the plumberof your company



By the electrician orthe plumber of your

company

By your company

By your company

By your company

By ACS

By ACS

By ACS

Notes:

facebook.com/acsklima twitter.com/acsklima linkedin.com/company/acs-klima

Mimar Sinan Cad. No: 81 Karakuyu, Torbali / IZMIR / TURKEYTel : +90 (232) 866 20 50 | Fax: +90 (232) 866 22 23

[email protected]

www.acsklima.com

Hygienic Air Handling Unit - ACS Klima · Air Handling Units are capable of regulating the air...

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