Installation & Maintenance Service Manual

Installation & Maintenance Service Manual
ABCDEF
ABCDEF

IM
Issue 8a
May 2010
Installation and Maintenance Service Manual
for Air Handling Equipment
CONTENTS
Installation and
Maintenance Service Manual
for
Central Station and
Packaged A.H.U's
Index
Contents
Page
INTRODUCTION
1-3
Health & Safety, Safety Symbols, Receipt of Plant,
Off Loading, Unit Protection, Unit Storage,
Unit Positioning, Methods for Offloading
INSTALLATION
General, Location, Section to Section Joints,
Leakage Tested Units, Weatherproof Units,
Ductwork Connections, Pipework Connections,
Electrical Connections, Motor Wiring Diagrams,
Motor Starting Methods, Filters, Control Dampers,
Final Inspection
COMMISSIONING
General, Commissioning Checklist,
Anti-vibration Mounts, V-Belt Drives, Fan and Motor,
Refrigeration Systems, Control Systems,
Safety Interlocks, Warranty Claims
MAINTENANCE
General, Fans, Drive Gear, Belt Tensioning, Alignment,
Motors, Bearings, Filters, Coils, Humidifiers,
Legionella Check, Electric Heaters, Bulkhead Lights,
Refrigeration Systems, Specialised Equipment,
Maintenance Schedules
SERVICE CONTRACTS
FAULT FINDING
General Faults, Refrigeration System Faults
4-9
10 - 12
13 - 18
18
19 - 21
INTRODUCTION
INTRODUCTION
HEALTH & SAFETY
During installation, commissioning, operation
and maintenance of air handling units, operatives
may be exposed to hazards including, but not
limited to, rotating components, refrigerants and
high voltage electricity. If misused or handled
improperly, each of these items has the potential
to cause bodily injury or death.
It is the obligation and responsibility of all
personnel to identify and recognise these
inherent hazards, protect themselves and to
proceed with care and consideration to safety
when completing their tasks.
Failure to comply with any of these
requirements may result in serious damage to
the equipment or the property in which it is
located as well as resulting in personal injury or,
in extreme circumstances, death.
This manual is intended for use by authorised
operating and service personnel, who should
possess the appropriate training and skills to
enable them to perform their tasks competently
and safely.
It is essential that before performing any task,
the operative shall have read and understood this
manual together with any other documents
referenced.
The operative should also be familiar with and
comply with all governmental standards and
regulations relating to the task in hand.
SAFETY SYMBOLS
The following symbols are used to alert the
reader to potential hazards.
Notes
are intended to clarify or highlight
additional information.
Cautions
identify hazards that could lead to
damage of the equipment.
Warnings
indicate
potentially
hazardous
situations, which could result in
serious personal injury or death.
DANGER
Danger
Indicates imminently hazardous
situations, which could result in
serious personal injury or death.
H
Before commencing any activity, please
ensure that: All appropriate method statements and/or risk
assessments have been raised, served, are
in place and are adhered to prior to carrying
out any activity.
appropriate
Personal
Protective
The
Equipment (PPE) attire is worn relative to the
operation being carried out. (Refer to the
specific risk assessment.)
The unit supplied meets with the standards
written into the specification and is suitable for
the actual job application.
Adequate site plant and lifting gear is
available to lift and position the unit to the
manufacturers recommendations.
Electrical equipment is rated, connected and
earthed in accordance with I.E.E. Regulations
and local by-laws where appropriate.
Personnel do not enter the unit whilst the fan
is running.
The plant is fully isolated from the mains
supply and allowed to run down for a
minimum of five minutes before opening any
access door prior to the commencement of
any maintenance work.
Upon conclusion of maintenance work the
unit is left in a clean state with all access
doors and panels correctly fastened and
locked.
Fan and motor drive guards,
fan inlet guards and door
guards are not fitted unless
DANGER
specified. The fan and motor
are naturally guarded whilst in operation
by the unit panel work and therefore do
not come under the category of “open,
unprotected plant”.
RECEIPT OF PLANT
The
ensure
during
ensure
unit should be examined upon receipt, to
that no visible damage has occurred
transit, and the advice note checked to
that all items have been received.
If damage or delivery shortages are
discovered, the carrier should be immediately
informed. Dalair Limited should be notified within
three days of receipt, with a written confirmation
sent within seven days.
Dalair Limited can accept no responsibility for
damage by unloading from carrier or for
subsequent damage on site.
Page 1
INTRODUCTION
INTRODUCTION
OFFLOADING
UNIT STORAGE
The simplest method of offloading is by forklift
truck. If this is not possible, unit sections should
be lifted by crane, utilising the lifting holes or lugs
provided in the structural base frame. These are
provided for the facility of inserting lifting shackles
and nylon, web type slings.
If the unit is not to be installed immediately, it
should be stored in a clean, dry area. If stored
externally, it should be adequately protected from
the weather.
Dalair
Limited
should
be
notified of the method of
offloading in advance, as this
affects the way in which the
unit sections are loaded onto
the delivery vehicle.
Recommended methods of offloading are
shown on page 3.
Keep sections upright – DO NOT TILT.
Timber packs should be utilised to avoid
abrasion. Spacer bars should also be fitted,
where necessary, to prevent the slings from
slipping.
Where sections are fitted with
a
roof,
additional
timber
packing must be utilised to
ensure that the slings do not
bear on the roof structure and
that all forces are transferred
to the section framework.
Failure to utilise additional
timber packing will result
in damage to the roof.
Ensure that sections are offloaded onto a
prepared, flat sound base in an upright and
level position.
To prevent damage it is recommended that
the recipient obtain expert advice from a
craneage specialist.
Refer to general arrangement drawings for
section weights.
All lifting equipment is to be supplied by
others.
Avoid unnecessary jarring or rough handling.
It is important not to drop the units as this may
result in permanent damage to the internal
components.
During the storage period, it is advisable to
slacken the drive belts and to rotate the fan shaft
two or three turns every week to eliminate false
brunelling of the fan and motor bearings.
Before the unit is put into operation, the
grease in the bearings should be checked for
oxidation, a condition that is indicated by the
grease hardening and taking on the appearance
of varnish.
Fan and motor pulleys should be checked
periodically for rust and sprayed with penetrating
oil as a rust preventative.
In addition all dampers should be rotated and
lubricated as necessary.
UNIT POSITIONING
To alleviate the risk of damage, consideration
should be given to using the services of Dalair
Limited or a plant movement specialist when
moving unit sections into their final position.
The preferred method is by forklift or hand
pump trucks with timber packing to avoid
abrasion. Mechanical skates, rollers, pinch bars
and jacks may also be utilised as necessary, but
due care should always be taken to avoid
damage to the unit sections and finishes.
Where unit sections are fitted
with feet, it is essential that
adequate timber packing be
provided to ensure that all
forces are transferred through to the base
support channels. Failure to observe this
will result in damage/misalignment of the
support feet and unit section base frame.
UNIT PROTECTION
Unless otherwise specified, unit sections will
be delivered to site covered in “shrink wrap”
polythene, which should provide a more than
adequate level of protection against inclement
weather.
Should alternative methods of unit protection
be required, (i.e. timber, Corex, or flame
retardant materials), Dalair Limited should be
notified of the specific requirements at the precontract stage.
The removal and disposal of all protective
coverings is the responsibility of others.
Unit section
base frame
Timber pallet
or similar
Forklift
forks
Support
feet
During offloading and positioning, it is vital that the air handling
unit sections are kept upright on
their bases. They must not be
turned in any 90° or 180° plane otherwise
severe damage will occur. Any known
restrictions should be advised at precontract stage.
Page 2
INTRODUCTION
INTRODUCTION
METHODS FOR OFFLOADING
Page 3
INSTALLATION
INSTALLATION
GENERAL
Units should be installed in accordance
with good engineering practice and stand
upright and level.
The floor, foundation or supporting
steelwork should be rigid, flat and level. The
structure should be capable of supporting
the weight of the unit including water or
refrigerant in the coils.
Dalair Limited are not responsible for the
coordination of the supporting steelwork,
concrete plinths or the like.
LOCATION
The unit should be located away from building
flue stacks or exhaust ventilators to prevent
possible reintroduction of contaminated air through
the outside air intake.
Ensure that provision has been made in
the location of the unit to allow for the
removal of all plant items for service and
maintenance purposes.
Sufficient room should be allowed for access to: Fans & motors
Electric heater batteries
Filter bags, auto-rolls and panels
Coils and evaporative humidifiers, including
their removal for long term maintenance
Spray nozzles and pumps for spray coil modules
Heat exchangers
Thermal and desiccant wheels
Dagger plates
LEAKAGE TESTED UNITS
Air handling units are manufactured and
assembled to recognised industry standards and
they will normally achieve the air leakage test
classification specified when carried out in
accordance to the HVCA Specification Guides
DW143 and DW144.
However, due to the stresses, strains and forces
imposed during loading, transportation, off loading
and site positioning, the air handling unit structures
will move and panel seals will not always remain
fully intact.
It is therefore likely that re-sealing of the panels
and joints may have to be carried out on site for the
air-handling units to achieve the required leakage
classification. Door locking mechanisms may also
have to be adjusted.
Dalair cannot be held responsible for the units
failing a site leakage test if the above have not been
carried out correctly. However, Dalair will be
pleased to offer a service, at an additional cost, or
provide suitable advice for any remedial works as
required.
Section-to-Section Joints
Cleat and bracket detail
IMPORTANT CONSIDERATION
Sufficient clearance for U-traps
on
condensate
drain
and
overflow connections should
also be considered by the purchaser. (See
Page 5)
Intermediate
Bracket
SECTION-TO-SECTION JOINTS
Standard
Cleat
Ensure that sections or section assemblies are
positioned in their proper sequence and that the
unit handing and reference is correct.
Large
Cleat
Sections should be accurately aligned and
abutted prior to bolting together using the fixings
and gaskets provided.
All units have a corner gusset for bolting the
sections together. On larger units an intermediate
joining bracket is added.
Section-to-Section Joints
Jointing gasket and mastic seal detail
Incorrect installation will result in air leakage, air
blow marks to the unit casings and unacceptable
noise.
It is recommended that a mastic seal be
applied to the joint following assembly (See detail
opposite).
Page 4
Fixed
Panel
Jointing Gasket
Fixed
Panel
Mastic
INSTALLATION
INSTALLATION
WEATHERPROOF UNITS
Units or assemblies are weatherproofed in the
factory.
Prior to final assembly of sectionalised units,
the rubber gasket supplied should be fitted
between the section-to-section joints. (See page
4, Section-to-Section Joint sketches.)
A suitable outer sealant should then be
applied, followed by the fixing of roof strips,
supplied loose, to ensure a fully weatherproof
seal.
PIPEWORK CONNECTIONS
General
Pipework should be connected in accordance
with good engineering practice, and particular
care taken when connection is made to screwed
fittings on the unit.
All pipework must be adequately supported to
ensure that no additional load is borne by the unit.
Where supplied, ‘PN’ coil flanges
will be loosely fitted in reverse.
The correct fitting of all flanges
is to be under-taken, on site, by
others.
Roof joint strip detail
Coil Connections
Allowance for expansion and contraction should
be made when making connections to coils.
The bulb of the thermostatic expansion valve
for direct expansion coils should be securely
fitted to the suction line prior to any equalising
connection.
Steam coils should be supplied with a good
quality dry steam via the appropriate control
method, with a steam trap preferably of the
mechanical float type.
DUCTWORK CONNECTIONS
Ductwork may be connected direct to the air
handling unit, with the exception of units where
external spring isolators require a flexible
connection allowing a movement of 25 mm in any
direction.
Ductwork, steelwork and any
other services should not be
supported off the unit.
Each coil section should be individually
trapped. Vertical rising condense lines should be
avoided, unless pumped.
If a frost coil is not fitted then
appropriate action must be
taken to prevent the coils from
freezing. Please contact Dalair
Limited for further information
and advice.
Steam Humidification Modules
Please refer to the manufacturers installation
instructions, contact Dalair Limited for further
information.
Suggested methods of fixing ductwork
Condensate Drain Connections
All condensate drain connections must be
correctly trapped. Incorrect trapping can result in
flooding within the unit and consequent flooding
of the immediate area.
Drain lines should be a minimum of the same
size as the drain pan connection. They should
pitch downwards continuously, with a minimum
fall of 10mm per metre, to a tundish or other
form of air break. There must always be an air
break.
All drain lines should be insulated where
passing through any space where damage from
condensation drip might occur. Fittings with
cleanout plugs should be used at each change
of direction in the drain line.
Recommended condensate trap arrangements
are shown in the diagrams on Page 6.
Page 5
INSTALLATION
Condensate Drain Connections
ELECTRICAL CONNECTIONS
Electrical components should be connected
to the supply in accordance with the Institution of
Electrical Engineers (I.E.E.) Regulations and local
by-laws where appropriate.
Draw-through,
Negative Pressure: 'S' trap arrangement
In the case of three phase motors ensure that
the rotation of the motor corresponds with the
direction shown by the arrow on the fan frame.
Be sure that the electrical
fan motor is made using
containment materials, to
adjustment and also to allow
the anti-vibration mounts.
X
Y
MSP = Maximum suction pressure (in Pa)
(Based on ‘dirty’ filter conditions)
Dimension X = (MSP/10) + 50 (mm)
Dimension Y = X/2 (minimum)
For example if MSP = 1500Pa
connection to the
flexible cabling/
permit fan belt
for movement of
If safety-isolating switches are fitted to access
doors they must be wired through the
appropriate motor control circuits.
Provision should be made for the
installation of a fan run on
control to prevent residual heat
emanating from the heating
plant damaging components such as the
fan, motor, filters etc., when the unit is shut
down.
This objective may be achieved by: -
Dimension X = (1500/10) + 50 = 150 + 50 = 200mm
Dimension Y = 200/2 = 100mm
Overall trap height = X + Y = 200 + 100 = 300mm
Blow-through,
Positive Pressure: Running trap arrangement
A thermostat controlling the fan and ensuring
that the temperature within the unit does not
rise above 45°C in the event that air ceases to
flow,
Utilising a delay timer
Airflow switches
Motor Wiring Diagrams
Typical connection diagrams are shown below: -
Three Phase, Single Speed Motors
Y Connection
W1
W2
V1
V2
U1
U2
L3
L2
L1
L1
U1
X
U2
Y
Cables enter
from left
U1
W2
W1
L3
L1
U2
W1
W2
L3
V2
V1 L2
W2
V1
V2
U1
U2
L3
V2 L2
L2
Cables enter
from right
Cables enter
from left
W1
V1
L1
Cables enter
from right
MDP = Maximum discharge pressure (in Pa)
(Based on ‘dirty’ filter conditions)
� Connection
W1 W2
L3
V1 V2
L2
Dimension X = 50mm (minimum)
Dimension Y = (MDP/10) + 50 (mm)
L1
U1 U2
L1
W2
U1
Cables enter
from left
For example if MDP = 500Pa
Dimension X = 50mm
Dimension Y = (500/10) + 50 = 50 + 50 = 100mm
W1
L3
U2
V2
V1
L2
W1 W2
L3
V1 V2
L2
Overall trap height = X + Y = 50 + 100 = 150mm
Cables enter from
the left or the right
U1 U2
Cables enter
from right
Page 6
L1
INSTALLATION
INSTALLATION
Motor Wiring Diagrams
FILTERS
Three Phase, Two Speed Motors
The correct installation of air filters is an
important requisite in the satisfactory functioning
of any plant. It is necessary therefore to ensure
that each filter is intact before use and only then
installed in the manner recommended below.
Two separate windings Y/Y
1W 2W
L3
1V 2V
L2
L1
L1
1U 2U
L1
2U
1U
Low speed
1W 2W
2W
1V
1W
L3
L2
L3
2V
L3
L2
1V 2V
L2
High speed
Low speed
1U 2U
L1
High speed
Two separate windings �/�
1W 2W
L3
1U 2U
L1
2U
1U
Low speed
1W 2W
L2
L3
L3
2V
2W
1V
1W
L2
L3
1V 2V
L2
High speed
Low speed
1U 2U
L1
High speed
Dahlander-connection �/YY
Unless otherwise stated in our offer each filter
bank is supplied with a loose inclined gauge
manometer, which should be fitted in a horizontal
manner adjacent to the filters and connected
with the plastic tubes provided.
Spare Filters
1V 2V
L2
L1
L1
To establish a dirty filter condition and as an
aid to check the entire installation, a filter
measuring device is required to be fitted across
every bank of filters to enable accurate
measurement of the air pressure drop.
If stated in our offer, the AHU may have been
supplied with a spare set of filters. Any loose or
spare filters should be stored in a dry & clean
environment.
Should you require spare filter media then
please contact Dalair for information.
Auto-Roll Filters
Please refer to the manufacturers installation
instructions. Contact Dalair for further information.
1W 2W
L3
1V 2V
L2
L1
L1
1U 2U
Panel & Bag Filters
Side Withdrawal
L1
2U
1U
Low speed
2U
2W
1U
1W
1W 2W
1W
L3
1V
L2
2V
2W
L3
L3
2V
1V
L2
1V 2V
L2
Low speed
High speed
1U 2U
Filters are inserted by sliding them into rails
provided. Blanking elements, where necessary,
are factory fitted at the end of the rails by Dalair.
L1
High speed
Dahlander-connection Y/YY
1W 2W
L3
1V 2V
L2
L1
L1
1U 2U
L1
2U
1U
Low speed
2U
1W
1U
2V
2W
1W 2W
1V
L2
1W
L3
2W
L3
1V
2V
L2
L3
1V 2V
L2
High speed
Low speed
1U 2U
L1
High speed
Motor Starting Methods
Motor Power
Range
0.18 to 3 kW
4 to 5.5 kW
7.5 to 90 kW
DOL
Star/Delta
Inverter
Star
Delta
N/A
N/A
N/A
Star/Delta
Star
Delta
Delta
Recommended tightening torque
M5 = 4Nm, M6 = 7Nm and M10 = 14Nm
Page 7
INSTALLATION
INSTALLATION
FILTERS
Panel & Bag Filters
Front Withdrawal
Front withdrawal bag type filters are fitted by
inserting them squarely into the frames and are
retained by spring holding clips. Bag filters
should be inserted with the pockets in the vertical
position.
HEPA Filters
Front Withdrawal
These filters are generally supplied loose to
be fitted on site when the installation is complete.
Due to the high efficiency of these filters and the
often 'clean room' standards that they must
attain, the utmost care should be taken when
replacing these filters to ensure there is no
contamination of the system.
Carbon Filters
Carbon filters are supplied loose to be fitted on
site, when the installation is complete.
The filters must be stored in a clean, dry
environment and all packaging must remain in
place until the time of use. This type of filter has a
limited shelf life and, consequently, should be
regularly inspected and changed.
CONTROL DAMPERS
Dalair Limited only accepts responsibility for
damper actuators and linkages supplied as part
of the equipment order.
Where control damper actuators and linkages
are supplied and fitted by others, these items
should be set up in accordance with the control
manufacturers instructions.
Airflow control dampers may be operated with
pneumatic or electric actuators.
If it is necessary to use a linkage between the
damper actuator and the damper drive shaft,
they should be positioned a minimum of 350mm
and maximum 1200mm apart. The linkage may
be difficult to adjust on shafts that are less than
350mm apart and, if the shafts are more than
1200mm apart, the connecting linkage may lack
stiffness to operate the dampers.
Ensure that all spring return actuators have
stopped running and completed their stroke. If
not, loosen the connection and let the actuator
drive until the motor stops running. Adjust the
damper blades to the desired position and retighten the actuator connection.
After power has been supplied to the unit, the
dampers should be checked to ensure that they
operate freely and close tightly. Adjustment of the
linkage may be required.
Page 8
INSTALLATION
INSTALLATION
All dampers, actuators and
linkages must be checked
prior to applying power to
ensure
that
nothing
will
obstruct the operation of the dampers. Do
not overdrive damper actuators as this
may result in damage to the damper.
Typical linkage arrangements
Linkage adjustment
A linkage may be fitted between a control
damper and actuator either in situations where
the actuator cannot be fitted directly to the
damper drive shaft or between the fresh air and
return air dampers of two-way mixing boxes,
Initially, establish the direction of rotation of the
damper drive shaft(s) and the actuator.
If a spring return actuator is fitted, ensure that
it has completed its stroke.
Manually rotate the actuator to the position
that is required for the closed position of the
damper operated by the crank arm, then rotate
this damper to its mid stroke.
Where the direction of rotation is identical,
install the crank arms so that are parallel and at
the same angle.
When the direction of rotation is opposed,
install the crank arms so that they are parallel but
at 180° to each other.
At this stage the crank arm on the damper
shaft should be secured, but the crank arm on
the actuator should be free to rotate.
Attach the push rod between the ball joint
connectors on both crank arms and tighten the
ball joint screws only thumb tight.
Manually rotate the crank arm on the actuator
to drive the linkage and the damper shaft through
its full stroke, to ensure proper damper action.
Return the damper with the crank arm to it’s
closed position. Tighten and secure the crank
arm of the actuator. In the case of 2 way mixing
boxes, the damper driven directly by the actuator
should be manually rotated to the fully open
position prior to tightening the crank arm on the
actuator.
While pushing the damper operated by the
crank arm closed, tighten the ball joint screws to
secure the drive rod.
Run the actuator back and forth through its full
stroke and check for proper damper and linkage
operation. Adjust the linkage if required.
In some instances, e.g. the face and by-pass
damper of a plate heat exchanger, the damper
may be operated by a bracket attached directly
to one of the blades rather than a crank arm
fitted to a drive spindle. This type of linkage is
often more difficult to set up and adjust. In these
circumstances, Dalair Limited recommends the
use of a bracket fitted with a knuckle joint, which
makes provision for changes in the geometry of
the drive rod as the damper is opened and
closed.
1.
2.
3.
4.
Remote actuator, same direction of rotation
Remote actuator, different directions of rotation
Linked fresh air and return air dampers
Plate heat exchanger face & by-pass damper with
remote actuator showing knuckle joint
FINAL INSPECTION
After installation of the unit,
inspection should be carried out.
a
thorough
This should include inspecting the inside of
the unit and removing debris and tools, which
may have been left behind by on site contractors.
Fan impellers, scrolls and outlets should
similarly be inspected.
Ensure that transit protection fittings are
removed from the fan/motor base frame, all
bearings are adequately greased and that all
traps are primed.
Replace any panels, which may have been
removed and close all access doors, ensuring
that the door sealing gaskets have not been
damaged.
Page 9
COMMISSIONING
COMMISSIONING
GENERAL
ANTI-VIBRATION MOUNTS
The unit is supplied with access doors,
which should be closed whenever the unit
is in operation.
Before commissioning ensure that the
unit has been completely assembled, as
described in the installation section.
Remove the transit protection fittings
from the fan/motor base frame, which are
to be found adjacent to the four antivibration mounts.
Commissioning checklist
Unit received undamaged
Equipment received as ordered
Unit positioned and assembled in accordance
with installation instructions
Fan base shipping restraints removed
Anti-vibration mounts adjusted
Check electrical supply voltage
Check tightness of all electrical connections
Check alignment of fan and motor pulleys
Check taper lock bushes are tight
Check fan belt tension
Check any additional bearings and couplings
where fitted
Manually rotate fan impellers and motors to
ensure freedom of movement
Check and prime condensate drain traps
Check all filters are fitted
Energise momentarily to check correct fan
rotation
Check that all control system components,
such as fan run on timers, airflow switches,
etc., are wired correctly.
Check control damper operation
Check that ductwork is complete and that any
fire dampers installed downstream of the fan
are open
Check access panels, doors are fitted and
secure
Check fan motor current draw
Check all shaft bearings and belt tension after
24 hours of operation
Note that the motor and drive
are designed to operate against
a given system resistance. If
the system is not complete or
access doors and panels are open, the
motor rating will be exceeded and
damage to the motor may occur.
Do not operate fan motors in an
overload amperage condition.
Adjust each mount until the fan/motor base
frame is level. Adjustment is achieved by
releasing the locknut and screwing the central
levelling screw into the mounting. When the
equipment is level, tighten the locknut.
V-BELT DRIVES
Check the alignment of the pulleys and make
any adjustment that is necessary.
Clean protective oil or grease from pulleys or
belts and tension the belts to manufacturers
recommendation. (See the Maintenance section
for further detail).
FAN AND MOTOR
Ensure that both the fan and motor run freely.
Test run the fan, drive and motor to ensure that
the fan is rotating in the correct direction. Adjust
as necessary. When an inverter control is fitted,
the connections between the inverter and the
motor must be reversed. Check that all earth
connections are intact.
Check that the electrical current being drawn
by the motor does not exceed the manufacturers
recommendation quoted on the motor plate. If
the motor is found to be overloaded, check the
fan volume flow rate and the static resistance. If
either of these exceeds the quoted unit design by
more than 10% then contact Dalair Limited, as a
modification may be required.
Small motors are normally switched direct
onto the mains. This method of starting is
preferable for any size of motor as it gives the
highest torque and utilises the most cost effective
and least complicated starter. The only restriction
is that imposed by the Supply Authority due to
the limitation of the feeder circuit capacity.
NOTE: All motors up to 5.5 kW,
unless otherwise stated, are
assumed to be direct on line
starting.
Above this rating, provision is usually
made for star-delta starting. When the
Supply Authorities have a limit for stardelta starting, autotransformer starting is
used when the limit is exceeded.
Page 10
COMMISSIONING
COMMISSIONING
REFRIGERATION SYSTEMS
Commissioning Procedure
All
work
on
refrigeration
systems should be carried out
by an approved and qualified
refrigeration service engineer.
Prior to setting up the refrigeration
circuit the air volumes on the evaporator
must have been proven to be between
100% and 110% of design.
CAUTION! Refrigeration systems contain
gas at high pressure. Due care should be
taken when connecting or disconnecting
any components or gauge sets.
Run the main supply (evaporator) fan and
check running currents on all three phases. Set
the overload. Check the main supply (evaporator)
fan air volume.
Always ensure that the correct PPE attire
is worn and refer to the appropriate
COSHH data sheet, risk assessment and
method statement.
Isolate the compressor by its fuses/circuit
breakers and carry out a full controls and
functional check.
DANGER
Do not use a naked flame if refrigerant
gas is present in any appreciable quantity
in the local area.
Units are shipped with a holding charge of
refrigerant. This is NOT a full charge and
refrigerant will have to be added on site.
Service Valves
The liquid and suction line service valves are
shipped from the factory front-seated and closed
with the valve stem in the maximum clockwise
position. The discharge service valve is shipped
in the open position, and it will only be used if the
compressor requires service.
The liquid and suction line service valves have
a 1/4" male flare access port for evacuating,
charging and pressure checking the system.
NOTE! Never remove a cap from
an access port unless the valve
is fully back-seated with its
valve stem in the maximum
counter-clockwise
position
as
the
refrigerant charge will be lost.
ALWAYS USE A REFRIGERATION VALVE
WRENCH TO OPEN AND CLOSE SERVICE
VALVES.
Safety Features
Compressor motors are internally protected
against over current and excessive temperature
by a line-break motor protector.
Compressors are equipped with crankcase
heaters to discourage refrigerant migration into
the compressor sump during the off cycle. The
pump down, if present, positively closes the
evaporator during the off cycle, storing the
system charge in the high side and isolating the
compressor sump from refrigerant.
Once the above has been completed the
refrigerant system may be charged as follows: -
Initial Charging
CAUTION!
Where
fitted,
compressor crankcase heaters
must be energised for at least
24 hours prior to charging and
commissioning.
Isolate the compressor via its service valves
and shut the liquid line shut-off valves.
Attach a vacuum pump to the high-pressure
side of the system and pull the condenser and
associated pipework down to a vacuum.
Once a vacuum has been achieved connect
the liquid connection of a refrigerant cylinder to
this charging point and introduce liquid until the
pressure stabilises. This will give a charge to
enable vapour charging to take place with less
risk of overheating the compressor through lack
of suction gas cooling.
IMPORTANT!
This
must
be
carried out with the compressor
isolated by its fuses or circuit
breakers to avoid the possibility
of it starting as the pressure in the
system rises and the pressure switches
operate.
Disconnect the charging manifold and
connect across the compressor discharge and
suction ports. Open all the service valves.
Check the high and low-pressure switch
settings against the commissioning details.
Every unit is protected by both high and lowpressure controls mounted in the compressor
section/housing.
Every compressor is protected by an anticycle timer to prevent on/off cycling. These
timers must be set at a minimum of 6 minutes,
to allow a maximum of 10 starts per hour.
Page 11
COMMISSIONING
COMMISSIONING
Final Charging
CONTROL SYSTEMS
Switch the compressor on and charge with
vapour taking care to monitor the evaporating
and condensing temperatures at frequent
intervals. Also check that the compressor is
running cool. In the event of the compressor
body getting hot, stop charging and allow
compressor to cool.
Our warranty only extends to control systems
supplied and commissioned by Dalair Limited.
Charge each circuit to a full sight glass and to
the
correct
evaporating
and
condensing
temperatures.
Check the superheat and adjust each
expansion valve as necessary to obtain the
design superheat.
The evaporator air-on temperature must be to
design to be able to charge the system correctly.
Check the operation of both high and lowpressure switches. The low-pressure switch can
be checked by de-energising the solenoid valve.
The high-pressure switch can be checked by
switching off the condenser fans.
In the event that commissioning is undertaken
by others, the operational warranty for the control
system would then be the responsibility of others.
SAFETY INTERLOCKS
It is recommended that the user seek advice
from a control system specialist to ensure that
adequate safety features are provided to prevent
severe damage caused through malfunction or
component failure, e.g. damper malfunction or
failure or excessive pressure.
Consideration should be given to gas or
electrical heaters and modulating burners to
ensure that sufficient safety interlocks are
provided.
CAUTION!
Monitor
the
high
pressure constantly during this
test. If the pressure rises above
420 P.S.I (29 Bar) shut the
compressor down. Failure to do this may
result in the compressor internal relief valve
blowing which would then necessitate the
compressor being replaced.
Check that the controls operate correctly to
maintain the return/room air at the correct
temperature.
Note all details on the commissioning sheet
supplied and return one copy to Dalair Limited.
Proof of correct commissioning shall be
requested in the event of a warranty claim.
Replace all access connections, Schrader
caps and valve caps to ensure that refrigerant
loss cannot occur, and return any manual override switches to the 'AUTOMATIC' position.
WARRANTY CLAIMS
Any claim for inaccuracies in duty should be substantiated with a full commissioning report.
Proof of correct commissioning may be requested in the event of a warranty claim.
Page 12
MAINTENANCE
MAINTENANCE
GENERAL
General fan maintenance
A system of planned, regular maintenance
will return dividends by averting possible
costly repairs and unexpected periods of
down time. It is the owner’s responsibly to
provide the necessary maintenance of the
air-handling unit. If system failure occurs
due to improper maintenance during the
warranty period, Dalair Limited will not be
liable for any costs incurred to return the
unit to satisfactory operation.
(Common to all fan types)
The unit must be manually
isolated
from
the
electrical
supply
and
a
period
of
5
minutes
DANGER
allowed to elapse before any
access door is opened for the purpose of
general maintenance.
FANS
Units are generally fitted with belt driven,
centrifugal fans, with the motor and drive gear
located in the airstream.
Dependant upon the design criteria, other fan
types and drive arrangements may be supplied.
These include direct drive, axial, plug and duplex
fans. Extended shaft fans are used in situations
where the motor and drive gear are required to
be located out of the airstream.
Fans can be offered to meet the ATEX
directive where in-house certification is required.
Refer to the general arrangement drawings
for details of the type of fan and drive fitted.
Additionally, each fan has its own identification
plate, giving details of the manufacturer, fan size,
serial number and type.
Specialised and major servicing, such as the
replacement of a damaged fan impellor, is
beyond the scope of this manual. If it should
become necessary, please refer to the fan
manufacturer’s literature, which, if not included
with this manual, can be supplied upon request.
As a general rule, fans should be inspected at
least twice a year.
Any unusual noise or vibration when the fan is
running should be immediately investigated and
remedied, as this usually an indication of wear or
imbalance in the fan system.
Prior to carrying out any work on a fan it
is imperative that: The power supply to the motor is
switched off at the safety-isolating
switch.
A period of at least 5 minutes is
allowed for the fan impellor to come to
rest.
Precautions are taken to prevent the
accidental, uncontrolled running of the
fan during the maintenance work.
Access to the fan section is normally gained
by removing the quick release panel to the side
of the unit.
Inspect the fan blades and remove any build
up of dust by lightly brushing, using compressed
air or a vacuum cleaner. If the impellor is coated
with greasy dirt, it can be washed with a mild
detergent or solvent. Gentle handling is essential.
Steam or other high-pressure cleaners
must not be used.
Check the fan shaft and all bearings for signs
of over heating and wear. Lubricate as necessary
(See Bearings section, Page 15)
Fan bearings may be replaced easily,
although it may be necessary to remove small
fans entirely from the unit.
Inspect the flexible connection between the
fan and unit for damage or wear and replace if
necessary.
Duplex fans
Small duplex fans, i.e. two fans driven by one
motor, may share a common drive shaft. Larger
duplex fans generally have a flexible connection
fitted between individual fan shafts.
Where the connection between the fan shafts
is a “universal joint” type coupling, it should be
inspected for wear and greased as part of the
regular maintenance programme.
Where a “rubber tyre” type coupling connects
the fan shafts, it should be inspected for signs of
wear, (e.g. porosity or severe cracking), and
replaced as necessary.
Extended shaft fans
When motors are mounted out of the air
stream, the fan shaft and fan base steelwork are
extended to penetrate the unit casework.
Ensure that the fan shaft seal is intact and
adequately packed with grease.
Also check the condition of the rubber seals
surrounding the fan base penetrations for signs
of damage and replace if necessary.
Direct drive fans
Direct drive fans eliminate the need for belts
or pulleys as the motor is directly connected to
the impellor.
Where fitted to direct drive fans, the “rubber
tyre” type coupling connecting the motor and fan
shaft should be visually inspected for signs of
wear and replaced as necessary.
Page 13
MAINTENANCE
MAINTENANCE
Drive gear (Belt driven fans)
Ensure that the motor and fan pulleys are
aligned and taper lock bushes are tight.
The V-belt drives should be checked for wear
and tensioned to comply with the appropriate
motor manufacturers instructions.
Replacement belts should be of the same
specification and matching length as those
originally supplied.
Tensioning
Forces Table
Small pulley
Belt
diameter (mm)
Section
Force required to
deflect belt 16mm per
metre of span
Newton
(N)
Kilogramforce (Kgf)
SPZ
56 to 95
100 to 140
13 to 20
20 to 25
1.3 to 2.0
2.0 to 2.5
SPA
80 to 132
140 to 200
25 to 35
35 to 45
2.5 to 3.6
3.6 to 4.6
SPB
112 to 224
236 to 315
45 to 65
65 to 85
4.6 to 6.6
6.6 to 8.7
The high performance of modern belts,
particularly wedge, cannot be achieved without
correct tensioning.
SPC
224 to 355
375 to 560
Z
56 to 100
5 to 7.5
0.5 to 0.8
Incorrectly tensioned belts can substantially
shorten belt life and overload fan and motor
bearings shortening their life expectancy. Over
tightened belts can result in failure of the fan and
motor shafts and bearings, and can cause
nuisance tripping of the motor overload.
A
80 to 140
10 to 15
1.0 to 1.5
B
125 to 200
20 to 30
2.0 to 3.1
C
200 to 400
40 to 60
4.1 to 6.1
Where multiple belts are fitted, always replace
all belts as a set. Used belts will always be longer
due to stretching.
Belt Tensioning
To check for correct tension proceed as
follows: (1) Measure the span length.
85 to 115 8.7 to 11.7
115 to 150 11.7 to 15.3
Alignment
Good alignment of pulleys is important. Poor
alignment will result in belt flank wear.
(2) At the centre of the span apply a force at
right angles to the belt to deflect one belt
16mm per metre of span length.
(3) Compare this force with value in the
Tensioning Forces table.
Span length
Deflection 16mm
per metre of span
Correct
FORCE
Angled
Pulleys are correctly aligned
Shafts not in same plane
Shafts are parallel and in same
plane.
Corrected by resetting shafts
in the same plane.
If the measured force falls within the values
given the drive tension should be satisfactory. A
measured force below the lower value indicates
under tensioning.
A new drive should be tensioned to the higher
value to allow for the normal drop in tension
during the running-in period. After the drive has
been running for a few hours the tension should
be checked and re-adjusted to the higher value.
The drive should be subsequently tensioned
at regular maintenance intervals. Make adequate
provision for tensioning the belts during their life.
The minimum take-up allowance is given in
the table opposite. We recommend that a belt
tension indicator be purchased (Contact Dalair
Limited for further details).
Angled
Shafts not parallel
Corrected by resetting shafts
parallel. Ensure no deflection
is taking place in supporting
framework or shafts.
Page 14
Offset
Pulleys are offset
Corrected by moving either
pulley along the shaft until
aligned
MAINTENANCE
MAINTENANCE
MOTORS
BEARINGS
Check all motor wiring before starting up. The
cables should be capable of carrying the full load
current of the motor (see motor nameplate)
without producing over-heating or an undue
voltage drop under starting conditions. Terminal
screws and fixing bolts should be tight.
“Sealed-for-life” fan and motor bearings are
generally fitted as standard and consequently
maintenance is not required.
Ensure the starter is compatible with the
motor. Ensure the motor can be isolated from the
mains. Remove the fan cover and ensure that all
air-inlet holes are unobstructed. Clean any buildup of dirt and fluff from behind the fan and along
the ribs of the frame.
Motors fitted with ball and roller bearings are
dispatched with the bearing housings correctly
filled with grease, which under normal conditions
is sufficient to last at least two years. The annular
clearance between the shaft and bearing covers
is very small so that the bearing housing can
retain the grease and keep out dust and dirt.
Should the grease melt for any reason, leakage
will occur but, provided that the correct quantity
of the correct grease is used, no trouble should
be experienced.
Bearing lubrication can be conveniently
carried out when the motor is stripped for
periodic cleaning and inspection on a routine
basis. Over lubricating bearings, particularly on
high-speed motors, causes the bearing to run
extremely hot and the grease to become thin
and leak out.
BP Energrease LS3 is recommended for the
majority of applications as its lubricating
properties are retained over a wide temperature
range (-20°C to +120°C). Any other good grade
of lithium base grease with an i.p. penetration
185/250 may be used, such as Shell Alvaniar 3.
Other bearings should be regularly checked
and re-packed with a lithium based grease Shell
Alvaniar R3 Lithium +180°C, C3 as necessary.
Fan bearings are “lifelong” lubricated for
20,000 or 40,000 hours of operation. However, in
heavy-duty operational conditions, maintenance
intervals are to be established by the operator.
If no greasing intervals are specified, they lie
nominally above 8,000 operating hours. Hence
re-greasing must take place at least once yearly.
Depending upon operating conditions, it may
become necessary to re-grease several times,
as determined by the operator.
For motor bearings, please refer to the details
as explained in the adjacent motor section.
It may be more economical to replace motors
of small size that develop faults rather than to try
to change bearings.
FILTERS
Filters should be inspected at monthly
intervals under normal conditions or as indicated
by manometer reading, where fitted.
For typical dirty pressure drops, please refer
to the general assembly drawings or the
appropriate catalogue.
As a general guide panel filters would not
normally exceed 150Pa and bag filters would not
normally exceed 250Pa.
If there is any doubt as to whether the old and
the new grease will mix it is recommended that
the old grease is cleaned out and the bearing
recharged with new grease so that the complete
assembly including caps, is approximately 50%
full with the grease in close contact with the race,
and not merely smeared inside the bearing
cover.
BP Aeroshell No. 5 should be used for low
ambient temperatures down to – 40°C.
Rotation
It is essential that the direction of rotation of
the driving motor be checked. This check should
be a visual one of the direction of rotation of the
free shaft with the motor finally connected to the
supply. Reversal of rotation can easily be carried
out by changing over any two supply leads at the
starter. Where an inverter is fitted, the
connections must be reversed between the
inverter and motor.
Page 15
MAINTENANCE
MAINTENANCE
COILS
ELECTRIC HEATERS
Coils should be inspected every three months
to ensure that there is no build-up of dirt between
the fins. Any dirt found should be removed by
using a high-pressure air or steam jet.
In correctly filtered systems, no maintenance
is required other than periodic checking of the
fasteners and electrical connections for security.
Inspect and remedy any coil connection
leaks.
Coil freeze protection must be provided in
installations where any part of a water coil may
be subjected to temperatures of 0°C or lower.
If a coil is not in use, it is recommended that
the coil be completely drained and the inside of
the tubes be blown dry with compressed air.
Dalair Limited will not be responsible for water
coils damaged by freezing.
If nuisance tripping of an electric heater
occurs, the most likely cause is low air velocity
over the heater elements. This may be due to
dirty filters, too low a speed setting or user
adjustment to dampers remote from the unit.
Ensure that the thermal cut out switch is
sound and operating correctly.
BULKHEAD LIGHTS
HUMIDIFIERS
Always switch off and isolate before checking
or changing the lamp. Periodically check the
tightness of screw type lamps as these have a
tendency to work loose.
Check and maintain any water treatment that
may be appropriate. Clean any sediment from
the drain tray and connections and also clean
and repair any areas of corrosion.
Standard bulkhead lights
Check that the replacement lamp is the
correct type, paying particular attention to the
voltage and wattage.
Spray Coil/Washer Humidification Module
Check all nozzles on the spray tree and clean
as necessary in order to yield the full spray
pattern.
Incandescent lamps are type GLS, screw cap
type E27, 60W, 240V 50Hz.
Ensure that the pump inlet strainer is clean.
Check that the pump is handling the correct
volume of water and that it is operating smoothly
and quietly.
Check that there are no leaks, particularly at
the shaft seal. Ensure that the motor is not
overheating. Remove and clean all filters.
Check the tripping time for the motor overload
unit, and ensure that all controls are operating in
a satisfactory manner.
Wetted Cell Humidification Module
Inspect pump operation as described in the
previous section.
Ensure sump drainage is clear to allow the
flow of water under flushing cycles.
Wetted cell humidification systems must not
be supplied with softened water.
LEGIONELLA CHECK
At three monthly intervals take dip slide
samples of cooling coil, exhaust heat recovery
coil and humidifier condensate drip tray water
and send for analysis.
At three monthly intervals also take dip slide
samples of evaporative humidifier / cooler drains
/ water reservoirs under the requirements of the
legislation in relation to the Control of Bacteria in
Water Systems.
Fluorescent lamps are type PL, single turn,
two pin cap type G23, 9W, 240V 50Hz.
To replace a lamp, remove the diffuser by
unscrewing the two fixing screws. Remove the
old lamp and fit the replacement. Refit the
diffuser, ensuring that the gasket seal remains
intact. Do not over tighten the fixing screws. An
effective seal can be achieved with moderate
tightening of the screws.
Externally maintainable bulkhead lights
Older units are fitted with externally mounted
standard bulkhead lights mounted within a
purpose made, coated sheet steel box, hinged
on one side and secured with a retaining screw.
Remove the retaining screw and open the box
to gain access to the bulkhead light. Lamp
replacement is as described above.
Newer units are fitted with dichroic lamps
housed within polycarbonate terminal boxes.
Dependent on customer requirements, these
may be 240V or 12V. (12V lamps have a
transformer fitted within the terminal box.)
To replace the lamp, remove the terminal box
cover by unscrewing the four fixing screws. Grip
the sleeved lamp holder cover and put it out of
the terminal box to reveal the lamp. Remove the
old lamp and fit a new lamp of the same voltage.
Push the sleeved lamp holder cover back into
position and refit the terminal box cover, ensuring
that the gasket seal is remains intact.
If results are positive disinfect all associated
components of the air handling unit including all
drain trays, wash down sections and condensate
trap arrangements.
Page 16
MAINTENANCE
REFRIGERATION SYSTEMS
All
work
on
refrigeration
systems should be carried out
by an approved and qualified
refrigeration service engineer.
CAUTION! Refrigeration systems contain
gas at high pressure. Due care should be
taken when connecting or disconnecting
any components or gauge sets.
Always ensure that the correct PPE attire is
worn and refer to the appropriate COSHH
data sheet, risk assessment and method
statement.
Do not use a naked flame if refrigerant gas
is present in any appreciable quantity in the
local area.
Dirt should not be allowed to accumulate on the
condenser coils or other parts in the condenser air
circuit. Clean as often as necessary with a brush,
vacuum cleaner attachment or other suitable
means.
Condenser fan motors are generally equipped
with factory lubricated, sealed bearings and do
not require any maintenance.
A filter-drier is installed in the liquid line of
every system to prevent damage from dirt and
moisture.
When replacing a filter-drier do not allow it to
be exposed to the atmosphere for an extended
period of time, as once it absorbs moisture from
the atmosphere, it loses its effectiveness.
Refrigeration Shut Down Periods
Compressor Motor Burnout
(Clean-up Procedure)
When a hermetic motor burns out, the stator
winding decomposes forming carbon, water and
acid, which contaminate the refrigerant systems.
These contaminants must be removed from the
system to prevent repeat motor failures.
Determine the cause of the burnout and make
any necessary corrections.
Check control panel for blown fuses, welded
starter contacts, welded overload contacts or
burned out heater elements.
Check compressor terminal plate for burned
or damaged terminals and insulation, and
shorted or grounded terminals.
Check wiring for loose power connections.
Check for high or low voltage.
Close compressor suction and discharge
service valves and bleed refrigerant from
compressor. Save remaining refrigerant in
system.
Remove the suction and discharge shut-off
valve bolts and all other connections. Remove the
damaged compressor and replace with a new
compressor.
On severe motor burnouts, be sure that the
shut-off valves and suction or discharge lines are
not contaminated. If they are, they should be
thoroughly cleaned or replaced before being
connected to the replacement compressor.
Install a new liquid line filter-drier.
In the event of a shut down of the unit for
more than three weeks we recommend the
following actions: -
Evacuate and dehydrate the replacement
compressor and check to see that the oil is at the
correct level.
Shut down procedure
Place compressor in operation and, after a
period of four hours, check the compressor oil for
discolouration and/or acidity. If the oil shows signs
of contamination, replace the oil charge and filter
driers.
Pump down the compressor.
Shut the compressor service valves.
Isolate the compressor by its fuses, circuit
breakers or local isolators.
Start up procedure
Restore power to unit.
Open all service valves.
CAUTION!
Where
fitted,
ensure
compressor crankcase heaters are on
for at least 24 hours prior to starting
the compressor.
Switch the compressor on and check
refrigeration circuit readings.
NOTE! Never remove a cap from
an access port unless the valve
is fully back-seated with its
valve stem in the maximum
counter-clockwise
position
as
the
refrigerant charge will be lost.
ALWAYS USE A REFRIGERATION VALVE
WRENCH TO OPEN AND CLOSE SERVICE
VALVES.
Check the oil daily for discolouration and
acidity. If the oil remains clean and acid-free, the
system is clean. If the oil shows signs of
contamination change both the oil and the filterdrier. Repeat this procedure until the system is
clean.
SPECIALISED EQUIPMENT
For the maintenance of specialised
equipment, such as Indirect and Direct Gas
Burners,
Thermal
Wheels,
Desiccant
Dehumidifying Equipment and any other
equipment not detailed in this manual,
please refer to the original manufacturer’s
literature which will be supplied upon
request.
Page 17
MAINTENANCE
MAINTENANCE
MAINTENANCE SCHEDULE
Check last maintenance report and
intervening service reports. Pay particular
attention to items mentioned in the latter.
Routine maintenance
Generally clean the unit. Maintain all surfaces
as necessary treating any areas of corrosion.
Clean drain trays and repair any areas of
corrosion.
Check all access doors for leakage and
adjust locks if necessary. Replace any gasket
materials if required, especially on filter
modules.
Assess the fan and motor bearings. Check for
evidence of wear or overheating.
Monthly
Check condition of filters. Change if required.
2/3 Monthly
Check
all
electrical
connections
and
components for signs of overheating or arcing.
Check cleanliness of fin coil banks and heat
exchangers. Clean as necessary with soft brush
or vacuum.
Check fin coil banks and heat exchangers for
signs
of
contamination.
Disinfect
as
necessary.
Check fan belt tension and pulley/belt wear.
Use tensioning tables.
Check condition of filters. Change if required.
Check condensate drains are clear and
ensure that water can flow away freely.
Check drain trays for cleanliness. Wash with
diluted disinfectant solution and rinse.
Clean unit casing and action any rust spots.
Where fan shafts extend through A.H.U.
casework ensure that the shaft seal is intact
and adequately packed with grease.
Where fitted, filter manometer gauges should
be checked, topped up with manometer fluid
and zeroed as necessary.
Yearly
Tighten all electrical terminals within unit,
motors, heaters, compressors etc.
Inspect coil and vacuum coil faces to remove
dust.
Check filter rubber seals and replace if
necessary.
Inspect for corrosion and treat with rust
inhibitor prior to touching up with paint.
Check all earth connections.
Additional 2/3 monthly checks
for refrigeration systems
Check
evaporating
and
condensing
temperatures and suction and discharge
pressures.
Check evaporator superheats.
Check refrigerant charge level. If short of
refrigerant check for leaks, repair and
recharge.
Carry out routine leak test with suitable leak
detector with special reference to all screwed
joints and valves.
Check all pipework for signs of chafing or
damage.
Check compressor currents.
Check all capillary lines for signs of chafing or
fatigue.
Check the condition of all pipework including
vibration eliminators.
Check operation of safety pressure switches.
Recommended Spare Parts List
1 year schedule
4 sets of disposable filters
1 set of fan belts
1 belt tension Indicator
3 year schedule 12 sets of disposable filters
3 sets of fan belts
1 set of fan bearings
5 year schedule 20 sets of disposable filters
6 Monthly
Grease fans with extended lubrication points.
Lubricate locks and hinges and adjust as
required.
Check control damper blades for freedom of
movement.
Clean and lubricate damper blade bearings.
Check operation of damper actuators and
linkages through a complete operating cycle.
Adjust as necessary.
3 sets of fan belts
1 set of fan bearings
MAINTENANCE & SERVICE CONTRACTS
Should you require after sales support, then do not hesitate to contact the
Service & Maintenance department at our Head Office on 0121 556 9944
Page 18
FAULT FINDING
FAULT
General Faults
Symptoms
Possible Causes
Checks &
Corrections
Unit not operating
Main or local isolation
off
Check all isolators from
mains to unit
Fuse(s) failed
Check all fuses in
mains
Replace blown fuses
after correcting fault
Unit not switched on
Switch on
External interlock fault
Investigate and correct
Control MCB tripped
Re-set MCB after
investigating and
correcting fault
Loose wire in control
circuit
Investigate and tighten
wires
Fan motor overload
tripped
Re-set after
investigating power
wiring and MCB.
If it trips again, check
motor and contactor
Disconnect motor from
wiring to check winding
Motor runs but no
volume
Belts broken/drive
pulleys loose
Check drive belts and
pulley security
Replace damaged
belts
Water evident inside
AHU casing
Insufficient depth of
condensate trap
Check static differential
pressure at component
and rectify trap depth to
suit
Ensure multiple drain
traps are individually
trapped. Drain traps
must not be connected
to each other.
Blocked filters affecting
water seal in trap
Change filters
Check also for damper
malfunction on air inlet
AHU performance may
be above design
creating high air
velocity through cooling
coil and moisture carry
over
Re-check AHU
performance and
adjust as necessary
Also ensure that the
BMS control system,
where fitted, has been
set up and is operating
correctly
Humidification system
may be over
humidifying resulting in
excessive moisture
Investigate and if
necessary recommission the
humidification system
System design over
volume or pulleys
incorrectly selected
Isolate unit and refer to
Dalair Limited for
advice
Unit not operating
Power on
Motors constantly trip
out and running at
excessive current
Page 19
Notes
Check for loose wires
Do not link out without
customers written
consent
FAULT FINDING
FAULT
FINDING
Refrigeration System Faults
Symptoms
Possible Causes
Checks &
Corrections
Notes
Compressor not
operating
No power
Fuses/Circuit breaker
Check for loose wires
Internal klixon tripped
Loss of refrigerant
Overload
Too frequent cycling
Low pressure switch
tripped
Loss of refrigerant
Solenoid valve shut
Low evaporator airflow
Motor burn out
Insulation check
Replace compressor
Loss of oil
Check for signs of leak
Liquid entering
compressor
Expansion valve stuck
open
Broken valves
Replace compressor
Low evaporator airflow
Check and correct
Dirty evaporator
Clean
Expansion valve fails to
shut
Replace and re-set
Shortage of refrigerant
Leak on pipework or
components
Low head pressure
Air on condenser coil
too cold
Low condenser airflow
Condenser fan failed
Dirty condenser
Clean
System over-charged
Remove excess
refrigerant
Non-condensable
gases in system
Evacuate and recharge system
Noisy compressor
Low evaporating
pressure
High condensing
pressure
Page 20
Disconnect
compressor to check
wiring
Discard the excess
refrigerant safely and in
accordance with
bylaws.
FAULT FINDING
FINDING
FAULT
Refrigeration System Faults
Symptoms
Possible Causes
Checks &
Corrections
Compressor short
cycles
Shortage of refrigerant
Re-charge to design
Blocked filter drier
Replace
Low evaporating airflow
Check operation of fan
Check air filters
Faulty expansion valve
Replace and adjust
superheat
Broken or damaged
compressor valves
Replace compressor
Expansion valve too far
open
Re-adjust as necessary
Over-charged with
refrigerant
Reduce charge to
correct level
Broken suction or
discharge valve
Check and change as
necessary
Compressor ratio too
high
Check setting of high
and low pressure
switches and check
that all evaporator and
condenser fans are
operating properly
High suction
temperature
Reduce suction
temperature by TXV
adjustment or provide
de-superheating
Evaporating pressure
too high
Compressor running
hot
Page 21
Notes
Discard the excess
refrigerant safely and in
accordance with
bylaws
DALAIR HEAD OFFICE
BIRMINGHAM
DALAIR LIMITED – HEAD OFFICE
Southern Way, Wednesbury, West Midlands, WS10 7BU
Telephone: 0121 556 9944 Fax: 0121 502 3124, 0121 505 2106
Email: [email protected]
BIRMINGHAM
DALAIR LIMITED – TECHNICAL CENTRE
Dalair Limited, Blakeley Wood Road, Tipton, West Midlands, DY4 0QA
Telephone: 0121 556 9944 Fax: 0121 505 4902
Email: [email protected]
LONDON
DALAIR LIMITED
338 Euston Road, Regents Place, London, NW1 3BT
Telephone: 0208 544 8660 Fax: 0121 505 4902
Email: [email protected]
MANCHESTER DALAIR LIMITED
Metropolitan House, 16 Brindley Road, Old Trafford, Manchester M16 9HQ
Telephone: 0161 888 2224 Fax: 0161 888 2227
Email: [email protected]
GLASGOW
AIRESALES SCOTLAND LIMITED
The Mews, 19 Sandyford Place Lane, Glasgow, G3 7HS
Telephone: 0141 204 4750 Fax: 0141 204 4755
Email: [email protected]
BELFAST
W J HOGG & COMPANY LIMITED
1A West Bank Drive, Belfast, BT3 9LA
Telephone: 0289 077 8700 Fax: 0289 077 7508
Email: [email protected]
Email : [email protected]
Tel : 0700 4 dalair
Web : www.dalair.co.uk
Due to our policy of continued improvements in both design and performance,
we reserve the right to alter details without notification
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