KLS Ahu

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AIR HANDLING UNIT INSTALLATION,

OPERATION AND MAINTENANCE INSTRUCTIONS
PROTECT YOUR UNIT AGAINST DAMAGE, SHOCK AND DISTORTIONS.

DO NOT ATTEMP TO INSTALL AND RUN THE UNIT BEFORE READING THE INSTRUCTIONS IN THIS BOOKLET
YOUR UNITS SERIAL NUMBER IS ..............................................
YOUR UNITS TYPE IS
.A.O.S.B. 10008 Sokak No:5 35620 ili ZMR TRKYE

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1- HANDLING
Air handling units are inspected prior to dispatch for good condition and carefully loaded. Special
care must be taken while unloading the units.
Air handling units are generally damaged during transportation and loading / unloading,
especially when being lifted by a crane. Small units can be transported by hand-powered pallet
truck or by forklift truck. While hoisting or lowering, proper lifting equipment (slings and spreaders
properly selected on the ground of the size and weight of the section) should be used not to
damage the unit. Safety precautions should also be taken not to tilt and not to drop the unit.
Fig 1. Typical lifting equipment
2- INSTALLATION
During final installation the requirements of EN 60204-1 do apply.
Before manufacturing air handling unit, the client should check the conditions at site to ensure
that access routes are adequate for both size and weight of the unit sections. Air handling unit
installation areas should also be checked. There should be sufficient space around the unit for
servicing, maintenance and piping connections. Further, it must be ensure that the base is high
enough from the floor to allow the condensate drain with necessary water trap.
Air handling units should be installed on a rigid and level surface. Correct alignments of the
sections are essential to maintain a satisfactory airtight enclosure and to avoid distortion to the
casing and components. Once all sections are located, they can be easily aligned and locked
together. First of all, between the sides of the sections that shall be connected, a continuous foam
gasket must be adhered for airtight seal. (For pent-a-post units) Then the sections are pushed
towards one another. Sections are locked together by special bolts, nuts and stiffening parts.
Assembly parts, bolts, nuts and seals are placed in a bag inside of the unit.
First attach the bolts on the base frame, then section bolts and tighten both with the same order
and same torque gradually. Do not use excessive force to align the sections, because it may
deform the aluminium framework and casing.
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If the air handling unit is to be installed in a place where low vibration and noise is required such
as hotels, hospitals etc it is recommended to install the unit on a floating concrete base, around
which is filled with Styrofoam.

Fig. 2. Typical AHU concrete base
3- CONNECTIONS
3.1- DUCTING CONNECTIONS
Return air, fresh air, exhaust air and supply air should be connected to the unit by flexible duct
connectors. Air tightness should be maintained to achieve required air flow conditions. Poor
ductwork connections to the unit and incorrect size, shape and arrangement of ductwork fittings
can change airflow conditions.
3.1.1- Free Outlet Conditions
Discharging a centrifugal fan directly to atmosphere (Fig.3) is an inefficient method of discharge.
It can be improved by the addition of a short duct length coupled to the fan outlet (Fig.4) or by
the use of an expansion section (Fig.5) allowing the air to become less turbulent before being
discharged. This is particularly important when grills or diffusers are being used at the discharge
point as the manufacturers loss figures are based on a laminar flow air stream and turbulent air
increases the losses.
3.1.2- Ducted Outlet Conditions

With the outlet connected to the discharge duct by a flexible connector, which is desirable for
noise and vibration isolation, it is important that the connector is correctly fitted. The fan outlet
and the duct should not be misaligned (Fig.6) nor should the flexible connector be allowed to
concertina. A smooth passage of air is desirable at all times. (Fig.7)
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When discharging into a duct of larger cross-sectional area than the fan outlet, an expansion
section with an included angle of 7-20C should be used. (Fig.8) The ideal configuration is with
parallel length of ducting prior to the expansion section, allowing the air to become less turbulent
before expanding. (Fig.9) The fan should never discharge directly into a duct with larger crosssection. (Fig.10)
The same criteria apply when discharging into a duct of smaller cross-sectional area then the fan
outlet. A ducting section with an included angle of up to 45C should be used. Losses will again
be minimised if a parallel section of ducting is used prior to the reducing section. (Fig.11) To
achieve ideal conditions the length of parallel ducting in both cases should be equal to 8 impeller
diameters. However parallel ducting of considerably shorter lengths can be used to advantage.
Extremely high losses occur when attempts are made to change the direction of the airflow close
to the fan discharge. If this is necessary the installation should be carried out as in (Fig.12) and
ever as in (Fig.13) A better solution is to have a parallel section of ducting prior to changing
direction and it should be as long as can be accommodated. (Fig.14)

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FAIR
BAD
Fig.13
Fig.14

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3.2- PIPING CONNECTIONS
Coils should be piped in counter flow arrangement to achieve required capacity. This
arrangement requires that the entering heating or cooling fluid contacts the air leaving the coil.
Water heating and cooling coils should be arranged with inlet connection at the lowest level on
one side of the coil near downstream and water outlet connection on the same side but at high
level near the upstream. This arrangement drives any air in the system into the upper part of the
coil, where a manual air release valve should be fitted.
All coils connecting piping should be independently supported not to impose strain on the coil
connections or circuitry.
Use a pipe wrench to restrain the pipe connections of the coil when tightening the external pipe
connections.
All coils connecting piping should be thermally insulated.

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3.3- CONDENSATE DRAIN LINES
Moisture condensed out of the airstream on cooling / dehumidifying coils should be drained out
of the unit, to prevent water damage in the air handling unit and ductwork system. Following
precautions should be observed in piping of condensate drain lines.
- Condensate pipe connections to drain pan should not be less than the bore size of the pan
outlet connection.
- A union or pipe coupling should be fitted at the pipe connections to the pan to permit easy
disconnection to clean any dirt sediments.
- The siphon (for positive and negative pressure applications) sent by the unit separately should
be assembled according to its own installation instructions in the package.
-
If the drain pipe is to be long, drain line should be pitched with a gradient not less than 1 in 50.
3.4- ELECTRICAL CONNECTIONS

Electric motor, starters, interconnecting cabling and any associated controls should be properly
designed and selected to be suitable for the driven equipment or other electrical apparatus, to
be safe and to comply with the requirements of Electricity Supply Authority. In case of the
humidifier and frequency converter applications their own installation manuals should be used.
For the other equipments the installation instructions and the wiring diagrams which stuck in the
terminal box should be followed.
Starter for centrifugal fans in the air handling units for single speed motors driving through V-belts
are normally of the direct-on-line type. However the customer or Electric Supply Authority may
require motors above 3kW to be operated by a star-delta starter, to reduce starting current.
To avoid the electric heater keep on

running while the fan is not rotating, the
wiring should be done similar to
diagram shown at the right.
A Manual reset
B Automatic reset
CAUTION- Electrical installation and wiring works should be carried out by qualified and
competent electricians.
- Thermal overload relay setting
a) Direct-on-line starting: The thermal overload really should preferably be set to the motor full
load current shown on the motor rating plate.
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b) Star-Delta starting: The thermal overload really should preferably be set to the 0.58 x motor full
load shown on the motor rating plate.
After thermal overload relay settings is done it should be checked that thermal overload relay
works properly at normal operating conditions, by operating motor on two phases.
Motor terminal markings
- The terminal markings of motors conform to the international standards. Stator terminals are
marked, U.V.W and the neutral terminal N.
- Please check data on the rating plate. The voltage marked on the rating plate must be in
agreement with the mains voltage.
The terminal board is normally equipped with 6 terminals. Details concerning the connection are
given on the inside cover of the terminal box and / or on a diagram placed inside by the
manufacturer.
- Specifications require that all motors to be earthen properly. Special terminal in the terminal
box should be used for this purpose.
- To avoid the danger of overloading and operation on two phases, the motors should be
protected either with fuses and thermal/thermo magnetic switches or electronic circuits. (See
page 34)
- If the electric heater will be used, electrical connections should be done according to the
information on the heater label.

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4- SETTING UP OF COMPONENTS
4.1- DAMPERS
Manually operated dampers can be adjusted to obtain the required air flow, by turning the
control lever. After setting the desired location on locking quadrant, control lever must be
tightened. Dampers can be equipped with the motor. Check that the blades turn back in closed
position in case of power supply failure during operation. Care must be taken to ensure that the
actuator does not attempt to push the damper blades beyond fully open or fully closed positions.
All damper blades must be checked for free movement and for fully open and fully closed
positions.
4.2- FILTERS
Panel filters and zigzag filters are normally fitted within the unit prior to shipping.
Bag filters are normally shipped in closed carton boxes to avoid any collection of dust and loss of
efficiency prior to commissioning. Each bag filter is housed within a special holding frame with
necessary locking spring to ensure proper sealing.
Automatic roll filters consist of basic frame dispensing unit for clean media, rewind unit for dirty
media, drive system, roll filter media and control system. Normally filter media and control system
are supplied loose for site installation. For assembly, filter media roll is mounted on the dispensing
unit taken along the guide channel through working section and locked to the rewind unit.
Differential pressure switch must be installed and connected to the control panel as shown on the
circuit diagram.
Absolute filters are shipped in sealed carton boxes. While assembly, special care must be taken to
ensure that each filter cell is properly sealed within the assembly frame with no possibility of air
leakage.
Other type of filters such as active carbon filters, sand filters etc. will be supplied with
manufacturers instructions along with the units.
Filters that shipped separately in the unit should be assembled after cleaning the inner surface by
operating the fan. Before start-up, check if the filters have been installed.
4.3- COILS
All coils are leak tested and checked prior to assembly. Fins are checked for proper condition.
However, they must be checked once more and combed out if necessary, because they might
be damaged during handling and installation. Do not remove plastic covers from coil pipe
connections until the unit is ready for piping connectors. Connections should be checked
according to the project and the leakage should be taken in to account. System layout should
take into consideration of possible coil withdrawal.
It is recommended that the water flow is shut off when the fan is switched off. To avoid the
overheating of the heating coil, the hot water pump and water / steam valves should only be
opened during the operation of fan.
Supply air control: The supply air temperature of the coil at the suction side should be max. 40C,
otherwise the overheating danger will occur.
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Check the concentration ratio of the antifreeze before the start-up of the cooling coil. It should
be enough for the claimed operating temperature range. It should be taken in to account that
the increasing concentration ratio of the antifreeze decreases the performance of the coil.
The minimum temperature of the chilled water should be +20C, at lower temperatures freezing
danger will occur.
Antifreeze is a dangerous chemical. The safety regulations of the antifreeze manufacturer should
be taken in to account.
Direct expansion coils will be supplied with a refrigerant distributor suitable for brazed
connections. Refrigerant pipe work must include necessary shut off devices, dehydrators, solenoid
valves, oil traps etc. Selection, sizing, installation and setting of thermostatic expansion valve
should be in accordance with the recommendation of condensing unit manufacturer.
Steam coils: Special care should be taken for collection and disposal of condensate within the
coils and to prevent entry of the condensate in the main into the coil by trapping it independently
on a coil bypass. Condensate connections to the stream trap must be of the same size as the coil
outlet.
CAUTION: Do not operate coils above the maximum temperature and pressure specified on the
capacity label.
If not otherwise stated on the capacity label, maximum operating temperature and pressure:
For water coils (type:1) : 90C, 10 bar
For water coils (type:2) : 150C, 15 bar
For steam coils: 164C, 6 bar
4.4- HUMIDIFIERS
Mat type or steam type humidifiers may be assembled in the unit. For the piping and wiring
instructions please refer to humidifier manufacturers manual.
The supply water, overflow / drain piping should be done before the start-up of mat type. The
supply piping should have a valve for cutting off during the maintenance. Before start-up clean
the water sump, close the drain valve and fill the sump with water. The float adjusts the water
level. The distance between the water level and overflow pipe should be 5cm. The water level in
the sump is very important that if the water height is usually at low level the humidification
performance will decrease. Check the rotation of the pump, the direction should be at clockwise.
Change the connection of the 2 phases if the direction is opposite. Not to damage the pump do
not operate dry.
Before the start-up of the steam humidifier, wiring and piping should be done, steam supply and
drain hose should be connected to the steam distribution pipe.
For further information about the humidifiers please refer to the humidifier manufacturers manual.
4.5- SUPPLY AND RETURN FANS
Vibration isolators, on which fan + motor assembly is mounted, are locked prior to shipping to
avoid damage during transport. Once the unit is in position and duct connections are made,
isolators must be released. It should be guaranteed that the fan move hasnt locked.
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Wiring work must be carried out in accordance with local standards. Type of start (direct-on-line
or star/delta) should met with local electrical standards. Starters, controls, overload protecting
devices, interlocks etc. should be provided as required. (See page 34) After the start-up, check
that direction of rotation of the fan is correct.
4.6- ELECTRIC HEATER
The electric heater should be protected against humidity and water. Be sure that the electric
heater automatically cuts off, if the air flow stops.
5- SAFETY
KLS air handling units can be considered as safe machinery. By means of the compliance
statement of the EEC and of the symbol CE on the unit, it is guaranteed that KLS air handling
units fulfil the provisions for the safety and health, on the ground of Machinery Directive 98/37/EC
and the European standards. The CE mark appears on every identification label of the unit.
In spite of all that, the unit can represent a danger, if it is utilized or serviced not properly or by staff
not sufficiently trained, or if it is used not in conformity with general provisions. For this reason, we
intend to explain to the user the concept of safety referring air handling units and to inform him of
possible danger and consequent measures.
Internal area of the units near to the moving parts (fans, motors, pumps etc.) end electrical parts,
hot sections (hot water and steam coils, piping, fittings and control devices) are considered as
danger zone. In order to be able to access to these areas, it is necessary to provide one self
with the proper key tools. The operators are responsible for transport, installation, start up, service
and maintenance including cleaning and repairing.
Possible hazards regarding to the air handling units are:
-danger to the operators safety
-damages to the unit
-possibility to affect the efficiency of the unit work
5.1- USE OF THE UNIT
KLS air handling unit are used for heating, ventilating and air conditioning purposes. Any other use
is considered not in conformity with general provisions. The manufacturer is not responsible for
damages resulting; the user will be the only responsible.
Air handling units can be used between -30C and +60C ambient temperatures. If the unit is to be
used at special locations such as tropical regions, indoor pools etc. the operational limits must be
ascertained from the manufacturer.
CAUTION: Standard units must not be used for handling of flammable gases. Spark-proof versions
of rotating parts (fans, motors etc.) must be selected for this kind of applications, so air handling
unit manufacturer should be informed while ordering the unit.
In order to use the unit according to general provisions, proper instructions of transport, installation
and use must be observed. Installation and start up of the unit must conform to the national
standards having legal course in the country of the user. The user is responsible for compliance
with standards. Besides it must be avoided any type of work that may compromise safety.
Arbitrary changes on the unit made by the user or operator are not allowed and exclude the
warranty of the manufacturer for the damages to things and persons.
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The unit can be started up only by authorized persons and by the means of proper safety devices.
The installer is obliged to install the unit according to installation plans and conditions.
The staff in charge is obliged to signal immediately to the user any changes that may compromise
safety. For this reason it is necessary to inspect the unit for eventual anomalies or damages at
least once a week.
The user or operator never must dismount and deactivate safety devices; if these would be
removed for extra maintenance, at the end of the operations they must be reinstalled.
For all operations of extra maintenance, the power source must be locked out and protected
against unlock by anybody else.
5.2- OBSERVATION OF WARNING SIGNS
Warning signs should be placed on the unit, showing:
-
prohibition to repair or adjust while the unit is running

obligation to turn off the power before opening the access door
warning of coming into contact with electrical parts etc.
5.3- STAFF TRAINING

Installation, start up and maintenance works can be executed only by authorized and trained
staff. This staff or people who, on behalf of the user, attend to control and make maintenance of
the unit must be informed about possible hazards regarding:
-
electrical connections
piping connections
ducting connections
start up
maintenance
It is necessary to establish and to respect the responsibilities for the control and maintenance to
guaranty safety.
5.4- PREVENT OF COMMON DANGERS AND RISKS
Air handling units are supplied with locked access doors as an option. So, unauthorized persons
are not permitted to enter the sections which represent a danger.
The most important potential dangers for life and health are described below. The units are
manufactured in conformity with machinery normative 98/37/EC. If the user thinks to take further
measures to restrict every possible remaining danger, he will be able to recognize them by the
general description below:

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KIND OF DANGER
OR RISK
Danger caused by
moving parts
Danger produced by
electric contacts
Danger caused by hot
surfaces.
Danger caused by
pipe or hose damage
Risk caused by
overspeed of fan
Risk caused by
mechanical resonance
Risk of fail function or
programming
SOURCE OF DANGER OR RISK

Fans, electric motors, pumps
DANGER OR RISK
Danger of hurting
Electrical parts, electric wires
Danger of loosing one s life
Hot water and steam coils,

steam humidifiers
Water and steam coils
Water and steam humidifiers
Danger of burning
External frequency converter

Vibration isolators
External frequency converter
Danger of burning from hot water or steam

Danger of electric shock caused by water
contacting electrical parts and cables
Risk of corrosion
Risk of damage of motor, fan and ductwork
Risk of excessive noise
Risk of damage or destruction of air
handling unit
Risk of overspeed of fan ( see section
above risk caused by overspeed of fan )
Risk of mechanical resonance ( see section
above risk caused by mechanical
resonance)
5.5- RECOMMENDED SAFETY PRACTICES

This publication explains the proper use and installation of centrifugal fans in order to warn
operating and maintenance personnel of the commonly recognized dangers associated with this
equipment. In addition to follow the manufacturers installation instructions, care must be taken to
ensure compliance with federal, state and local rules, regulations and standards.
Centrifugal fans in air handling units are located inside a casing, so accessibility to the fan is
occasional or infrequent. For this reason, protective devices are offered as optional accessories
only at specific users request. However as in case with other machinery involving moving parts,
common sense and caution will preserve personnel safety.
The available optional guarding devices are:
1) Fan inlet and outlet guards: Centrifugal fans in air handling units are usually connected directly
to ductwork which will prevent the contact with the internal moving parts. In case there is an
exposed inlet or outlet which could represent a danger, suitable guards can be installed.
2) Drive guards: Safety guards should be used when drive systems are accessible by the
personnel.
3) Limit switch: Cuts off the power supply of the fan motor when door opens. As the fan keeps on
rotating, do not attempt to enter the unit within minimum 2minutes, after opening the door.
Also lockout switches and suitable warnings should be used. Maintenance personnel should
engage the lockout switch before starting any maintenance and repairs; do not forget to protect
against unlock by anybody else.

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5.6- THE HIDDEN DANGER
In addition to the dangers of rotation machinery, fans present another potential danger by virtue
of their ability to draw in loose material. Solid objects passing through a fan represent potentially
dangerous projectiles. Solid objects can cause fan failure by physically damaging the impeller
blades. If the guard is removed for any reason, the fan must be disconnected and locked out.
Where fans are installed over an occupied area, safety guards should be provided to prevent
dropped objects from entering this area during installation and maintenance.
Access doors to a fan or duct system must not be opened when the fan is running or coasting to
a stop. After the unit is switched off, the impeller continues to run for approximately 1-3 minutes.
The fan section is therefore still under pressure and the door must not be opened. The impeller
must never be slowed down by hand or by other objects. Power must be locked out prior to
access into the fan section or ductwork. Even when locked out electrically, fans may cause injury
or damage if the impeller is subject to windmilling. The impeller should be secured to physically
restrict rotational movement.
On the downstream or pressure side of the system, attempting to open the access door while the
system is in operation, may result in an explosive opening. On the upstream or suction side, the
inflow may be sufficient to draw in tools and clothing etc. and create a danger.
The stroboscopic effect of certain lights in combination with certain fan speeds may cause a
rotating assembly to appear stopped.
Noise: At normal operating conditions, noise emission of air handling units does not (with duct
connections made and service doors closed) exceed 70dB (A)
But at extreme operating conditions and depending on room acoustics, noise emission may be
dangerous for health. Prolonged exposure at or above 85 dB (A) requires the use of hearing
protection (ear plugs, ear muffs etc.)
5.7- START UP
Before operating fans for the first time (or after an annual maintenance) the manufacturers
instructions must be followed. In addition, the following check list must be completed:
- Ensure that all the sections of the unit are thoroughly cleaned. There is a possibility of collection
of debris such as duct insulation materials, tapes, etc.
- Ensure all electrical wiring is carried out in accordance with local standards and all
components are provided with safety, protecting and isolating devices. (See page 34)
- Remove all filters, install low efficiency filters such as gauze bags or throw away type filters, to
keep the filters clean.
- Check water/steam/refrigerant coils and pipe connections for any leaks. Ensure that all the air
in the system and in the coil is vented out. Check coil face free from debris.
-
Ensure all panels, if removed during installation, are in position and all service doors are closed.
Ensure that minimum water level is maintained in the humidifier.

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OPERATIONS OF FANS:
-
Check that pulleys are secure on shafts.
Check tightness of belts.
Check that all moving parts of the fan and motor are free to rotate.
Check that no loose materials are left near the fan inlet.
- Check that direction of impeller rotation is correct. For this, momentarily energize the fan and
see the direction of rotation.
-
Check that fan and motor pulleys are aligned.
Check that fan and motor are fixed tightly.
- One of the most common causes of motor failure with forward curved blade fans is excessive
air flow, due to overestimated system resistance. To overcome this type of failure, first start-up
should be with the main system damper partially closed and to be opened when correct
proportional air flow has been achieved by system regulation.
- Check that flexible connections are firmly fixed and undamaged, duct connections are
designed in accordance with acceptable engineering practices and with the manufacturer s
recommendations.
-
Check that thermal overload relay setting is correct.
Switch on the electric supply and allow fan to reach full speed. Check carefully for:
Excessive vibration
Unusual noise
Proper belt alignment
Proper lubrication
Motor current and voltage values
If any problem is indicated, switch of immediately. Lock out the electrical supply, secure fan
impeller if there is a possibility of windmilling. Check carefully for the cause of the problem and
correct as necessary.
After ensuring that there is not any problem, no leaks between joints and system is clean, stop the
fan. Dispose low efficiency filters, install panel/bag/absolute filters as supplied. Restarts the fan:
- Adjust damper position to obtain required air volume. Ensure that the air volume is within
specified limits.
- Check the motor current and ensure that it is in accordance with the motor rated data (on
motor nameplate)
- Check inlet-outlet temperatures across coils and adjust water/steam flows accordingly. Check
the functioning of control devices.
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-
Check the functioning of humidifier by adjusting the humidistat control.
- Check the operation of heating coils by adjusting thermostat. Check the functioning of
controls. (air flow switch, fan interlock, overheat protection, etc.)
-
Check the pressure drop across the filters and ensure that it is within limits.
During the first eight hours of running, operation of fan should be periodically observed and
checked for excessive vibration and noise. Motor input current and motor and bearing
temperatures should also be checked to ensure that they do not exceed manufacturers
recommendations. Then the fan should be shut down to check the following items and to adjust,
if necessary:
-
Belt drive alignment and belt tension
Bearing housing temperature
Fan and motor fixing bolts
AFTER TWO WEEK OPERATION

After start up and initial satisfactory operation of two weeks, it is recommended to have the
following checks:
-
Belt drive alignment and belt tension
Motor running current
- Bearing temperature immediately after stop. Bearing temperature should not exceed 70C.
Lubricate if necessary.
-
Condition of filters
Condensate and drain, to see flow
Operation of control devices
WARNING: Investigate any changes to the fan. You may have more detailed explanation of
problems and possible causes in troubleshooting section. Consult your manufacturer or other
qualified consultant for questions concerning changes observed during periodic inspections.
- If excessive vibration is observed, stop the fan until the cause is corrected. Check for material
build up on the impeller which causes an imbalance and leads to the fatigue failure or impeller.
-
Changes in the sound level of the fan may indicate troubleshooting is required.
- If the motor temperature is high check cooling fan of the motor. It may be blocked or broken.
Also check the input current. An increase in current may indicate that some major changes have
been made in system.
- High bearing temperatures usually caused by improper lubrication. If the cause of the problem
is not easily seen, experienced personnel must examine the equipment before running it again.

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6- MAINTENANCE
A preventive maintenance program is an important aspect of an effective safety program.
Maintenance works should be performed by experienced and trained personnel. Do not attempt
maintenance unless electric supply has been locked out and the impeller has been secured.
Before the maintenance operation, the safety precautions should be taken by locking out the
main and maintenance switch and protecting against unlocking by anybody else.
Especially at the hygienic air handling units, filters, coils, (by disconnecting the flange
connections), droplet eliminator and sound attenuators can be taken out from the service doors.
Besides, all components can be taken out from the unit for cleaning and disinfection processes.
In general air handling unit do not require special attention other than routine cleaning and
maintenance work. Frequency of maintenance depends on operating conditions. Following is the
recommended schedule maintenance.
ONCE A WEEK
-
Check the conditions of filters every week. Clean, wash or replace if necessary.
ONCE A MONTH
-
Check belt drive alignment and tension, adjust if necessary
Check the condition of float and valve in humidifier
Check the condition of drain for free flow
Check the condition of access door hinges and seals lubricate hinges if necessary.
ONCE IN SIX MONTHS

-
Check the motor running current
Check fan and motor bearings for high temperature and noise
Check function of control devices.
Clean condensate drain pan, trap and drain line
Check air washer circulating pump and motor
Check the condition of inlet strainer of air washer
Check the condition of piping system for chilled/hot water or steam
Add chemicals if necessary.
ONCE A YEAR
-
Check the filter frame for proper sealing
Replace synthetic filter media in panel filters.

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20/32

-
Check the controls and operation of automatic roll filters
Check the coils and fins. Wash with water spray, if necessary.
Check the coils for any leakage
Went the water coils
Replace belts
Check the tightness of the fan and the motor fixing bolts
Check motor and fan bearing lubrication
Check the operation of dampers
Check the condition of access door for easily opening and proper locking
Check the condition of valves and fittings on the piping system
Check all wiring, control and isolating devices, terminal connections, etc.
After inspection and replacements, if necessary proceed in accordance with operation

instructions, before running the unit again.
Following must also be noted about maintenance works:
A) Fan sections
For detailed information about lubrication of bearings, belt tension and alignment controls,
changing of pulleys, see related sections in this manual.
B) Coil sections
Coils should be cleaned to remove any accumulation of dust between the fins and tubes should
be checked for any leakage. Cleaning process can be done in 3 ways;
-
vacuum
compressed air
water or steam spray (opposite to the air flow direction)
During the application the water / steam / air pressure should not exceed 5 Bar.
To clean the cooling coil at the hygienic air handling units, the coil can be reached from both
sides by taking out the droplet eliminator from the service door by disassembling the by-pass sheet
metal. With the same principle as theres no droplet eliminator, the heating coil can be cleaned
by reaching both sides from the service doors.
If it is required to withdraw the coil for cleaning and repairing, proceed as follows:
-
drain the water inside the coil

disconnect the coil from piping connections
remove the side panel
remove the bolts by which coil is fixed
withdraw the coil
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21/32

To check for leakage in the tubes,
- clean and dry the coil
- fill water inside the tubes
- see where the leakage is
- drain the water inside the coil
- repair the small holes or cracks on the copper tubes by oxyacetylene welding.
Check with water if the welding is successful or not.
After cleaning the coil, drain should be checked and the siphon should be cleaned.
CAUTION: Keep coils from freezing. When water inside coils is allowed to freeze, serious damage
will be caused to the tubes. So, if there is a danger of freezing, anti-freeze chemicals should be
added to the circulating water or if the coil will not be operated for a short time, some water
circulation should be provided inside the tubes. If the coil will not be operated for a long time, it is
recommended to drain to coil.
C) Filter sections
Condition of the filters should be checked once a week. Dirty filters reduces the air flow and
hence the capacity. A manometer, measuring filter pressure drop should be fitted to filter section.
If other not stated on the unit, please use the recommended maximum pressure differentials for
different kind or filters that are given on below table. When manometer reading shows these
values, filters should be cleaned or replaced, and these values should not be exceeded.
(According to EN 779) Synthetic or metallic filter media can be cleaned or washed. However it is
recommended to replace synthetic media in every two years. New filters should be assembled in
the right position that the rough and open side looks to the dirty air, smooth face to the clean air
side.
If theres gasket on the previous filter frame, to achieve the necessary tightness do not forget to
apply the same media (absolutely same way) on the new filter after renewal.
Other type of filters such as throw away media, bag, absolute and roll filters must be replaced
with new filters of same type, size and efficiency.
Table 2: Pressure differentials for panel filters
FILTER GRADE
INITIAL PRESSURE DIFFERENTIAL
G-2
G-3
G-4
25 Pa
40 Pa
50 Pa
RECOMMENDED MAXIMUM PRESSURE

DIFFERENTIAL
150 Pa
150 Pa
150 Pa
Table 3: Pressure differentials for bag filters

FILTER GRADE
INITIAL PRESSURE DIFFERENTIAL
G-4
F-5
F-6
F-7
F-8
65 Pa
55 Pa
60 Pa
115 Pa
165 Pa
RECOMMENDED MAXIMUM PRESSURE

DIFFERENTIAL
150 Pa
250 Pa
250 Pa
250 Pa
350 Pa

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22/32

After opening the service door, the filters can be taken out by pulling aside.
Synthetic bag filter can be cleaned by vacuumed or compressed air besides can be washed with the
sensitive detergent and warm water.
D) Humidifier sections
Humidifier should be cleaned regularly. The period changes according to the operating
conditions, air specifications and water quality. During periodic maintenance of humidifier,
checks mentioned in its own manual should be performed.
E) Sound Attenuators
Sound attenuators can be taken out from the service door by unscrewing the components from
the top and bottom panels. Attenuators can be cleaned by vacuumed or compressed air.
F) General
Periodic checks should be made for thermal and acoustic lining and electrical insulation of the
unit sections. Also connecting cables and control panels should be checked. Any metal surface
which shows signs of deterioration should be cleaned.
Bols, nuts and other assembling elements should be checked. Any missing bolts, nuts and screws
should be replaced.
To clean the damper compressed air can be used. Do not lubricate the shaft of the damper.
Impurities on the droplet eliminator blades should be cleaned regularly. The period changes
according to the operating conditions and the air quality. As cleaning media any de-scaler
available on the market can be used.
For the best cleaning process of the droplet eliminator at the hygienic air handling units it should
be taken out from the unit and disassembled by unscrewing.
To clean the inner surface of the unit (after necessary components taken out) water / steam spray
and cotton or directly wet cotton can be used by wiping.

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23/32

7- BELT TENSION AND ALIGNMENT CONTROL
A simple Rule of thumb for checking belt tension is
illustrated at right.
When the bet is grasped as shown, a total deflection of
approximately 25mm (1) should be easily attained.
Excessive deflection is an indication that the belt is not
tight enough, and if not corrected, could result in
slippage causing loss of blower speed and belt failure
through wear.
Too small deflection indicates that the belt is too tight,
and if not slackened somewhat could cause noise from
excessive vibration, premature bearing failure and
shorter belt life.
Efficiency is another reason to properly adjust belt
tension. Excessive belt tension can create such a
power demand as to actually overload a motor that
otherwise would be quite adequate.
It goes without question however, that like all Rules of
thumb some judgement is necessary on the part of
person doing the adjusting.
A belt should be just tight enough to avoid slippage.
Before locking the motor is position, check the
alignment of pulleys with a straight edge to conserve
belt life as well as to eliminate the possibility of
unnecessary noise.

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8- CHANGE OF PULLEYS
8.1- MOUNTING OF PULLEYS
- Clean and degrease smooth surfaces of bushing, pulley and shaft
- Assemble bushing on pulley by aligning semi-threaded holes. Insert the screws loosely.
- Insert the key on shaft, then slide pulley to desired position with screw heads to the outside.
Tighten screws evenly and progressively. Never apply extreme tightening forces.
8.2- REMOVAL OF PULLEY

- Remove tightening screws
- Insert one of the screws in the semi-threaded hole and tighten until bushing becomes loose on
shaft.
CAUTION: Dont use hammer or puller to remove the pulley. Dont change pulleys without written
consent of KLS; otherwise we take no responsibility for the consequences.

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25/32

9- LUBRICATION OF BEARINGS
Bearings have to be controlled and cleaned regularly; have to be lubricated adequately to
prevent direct metallic contact between rolling elements, to prevent wear and to project bearing
surfaces against corrosion.
The fans with low shaft power are equipped with bearings in a rubber housing which absorbs a
part of vibration. When you change the bearing it is very important to change the rubber housing
too. These bearings dont need to be lubricated.
The fans with higher shaft power are equipped with bearings with cast iron support. The lubricant
filled in a bearing gradually loses its lubricating properties during operation. Therefore it is
necessary for grease to be replenished or renewed from time to time. The grease used is always
lithium soap type suitable for all temperatures within the operating range.
Excess grease will cause the operating temperature to rise rapidly, particularly when running at
high speeds. Therefore only the bearing should be completely filled, whilst the free space in the
housing should be partly filled (between 30 and 50 %) Where bearings are to operate at very low
speeds and must be well protected against corrosion, it is advisable to completely fill the housing.
Relubrication interval depends on the fan speed and bearing internal diameter and is calculated
by the following formula.
t = 10 x {14x106 / (n x d ) 4 x d }
t = relubrication interval ( h )
n = fan speed ( rpm )
d = Bearing inner diameter ( mm )
Above formula refers to a fan with ball bearings and working under normal operating conditions.
Relubrication intervals calculated according to the above formula are given on Table 4.
Table 4 Relubrication intervals (h)
FAN
SPEED
250
500
750
1000
1250
1500
1750
2000
3000
4000
5000
20
124420
61810
40940
30500
24240
20070
17080
14850
9630
7020
5460
25
111000
55000
36330
27000
21400
17660
15000
13000
8330
6000
4600
BEARING INNER DIAMETER (MM)

30
35
40
101040
93250
86940
49920
45920
42670
32880
30150
27910
24360
22260
20530
19250
17530
16100
15840
14370
13150
13400
12120
11040
11580
10430
9460
7320
6480
5770
5190
4510
3930
3910
3330
2820
45
81680
39940
26020
19070
14890
12110
10120
8630
5150
3410
2370
50
77190
37600
24400
17800
13840
11200
9310
7900
4600
2950
1960
60
69890
33740
21700
15670
12060
9650
7920
6630
3620
2110
1210
NOTE : It is not advisable to use relubrication intervals more than of 30000 hours.
If the fan works in particular conditions, relubrication intervals have to be corrected concerning
the temperature and surrounding factors, according to the following formula:
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tc = t x kT x kS
tc = corrected relubrication interval
kT = temperature correction factor
kS = surrounding correction factor
Temperature correction factor kT takes into account the reduction of relubrication interval when
bearing temperature raised over 70 C.
Table 5 : Temperature correction factors kT (for lithium soap grease)
TEMPERATURE OF BEARINGS ( C )
Temperature correction factor, kT
70
1
80
0.6
90
0.35
100
0.2
110
0.12
120
0.07
130
0.04
Surround factor kS considers in particular the external influences such as humidity, shocks and
vibrations
GREASE STRESS
Low
Medium
High
SURROUNDING FACTOR, kS
0.8
0.5
0.2
RELUBRICATION PROCEDURES
- If the relubrication intervals are shorter than 6 months, then it is recommended that the grease
fill in the bearing arrangement be replenished at intervals corresponding to 0.5 times the
relubrication intervals., the complete grease fill should be replaced after three replenishment at
the latest.
- If the relubrication intervals are longer than 6 months it is recommended that all used grease
be removed from the bearing arrangement and replaced by fresh grease.
- The 6 months limit represents a very rough guideline recommendation and may be adapted to
particular applications.
REPLENISHMENT
By adding small quantities of fresh grease intervals the used grease in the bearing arrangement
will be partially replaced.
Suitable quantities to be added are calculated by the following formula and are listed on
following table.
G = 0.005 x D x B
G = Grease quantity to be added when replenishing (g)
D = bearing outside diameter (mm)
B = total bearing width (mm)

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27/32

FRAME
CONTRUCTION
TYPE
FRAME
CONTRUCTION
TYPE
K2
FAN SIZE
250
G
3.9
280
315
d
25
FAN SIZE
560
630
G
d
17.4 50
G
5.6
355
400
d
30
710
800
G
d
23.1
60
G
6.8
450
500
d
35
G
8.4
560
630
710
800
d
40
G
9.9
900
1000
d
50
G
13.2
d
60
900
1000
G
d
33.6
60
RENEWING THE GREASE FILL

When the end of the relubrication interval t, has been reached, the used grease in the bearing
should be completely removed and replaced by fresh grease. As stated before, under normal
conditions, the free space in the bearing should be completely filled and the free space in the
housing filled to between 30 and 50 % with fresh grease. Great care should be taken to see that
contaminants are not introduced into the bearing or housing when relubricaton.
10- TROUBLESHOOTING
Before checking the fan system, it will be necessary to shut down the fan. During inspection, the
unit must be isolated electrically and all disconnected switches and other controls must be locked
in the off position. Also, a prominent DO NOT START sign should be placed on control panel.
To find out the problem is an important step to correct it. By following the procedures outlined in
this section, cause of the problem should be found.
Procedure for troubleshooting:
a) Look at the troubleshooting chart to find the problem. Check probable causes.
b) If the cause of the problem can not be found proceed through the system checklist
c) If the problem still can not be solved, it is recommended to contact the unit manufacturer
System checklist
A systematic check of items listed below may identify the problem. See that:
a) Impeller rotation is correct
b) Pulley are aligned
c) Belts are not loose or too tight
d) Belts and/or pulley are not worn.
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e) Flow surfaces of fan (impeller blades, housing and passages between inlets) are clean.
f) Impeller and housing are not damaged.
g) Coils, filters, ducts are clean.
h) Fan outlet connections are correctly designed and installed.
i) Variable inlet vanes are synchronised. If inlet vanes are not synchronised, there will be an
unbalance flow between inlets causing thrust on bearing and low performance.
j) Inlet vanes are correctly positioned for the designed operating conditions
k) There is no leak in the unit and ductwork. Some common leak sources are access doors, coil,
duct joints, fan outlet connections etc.
If the cause of the problem still can not be found, consult air handling unit manufacturer.
Manufacturer may need following information
a) Complete drawings including unit location, ductwork detail, model and size of the unit.
b) Measured and design performance figures.
c) System design calculations
d) Measured fan performance figures such as fan static pressure, air volume, current drawn, fan
speed, air temperature and altitude etc.

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29/32

PROBLEM
SYMPTOMS
POSSIBLE CAUSE
OTHER CAUSES OR ACTION
NOISE
Impeller hits inlet

ring
Damaged impeller
Damaged inlet ring
Impeller not centered on shaft
Shaft loose in bearing
Impeller loose on shaft
Belts too loose
Belts too tight
Belts wrong section
Belts worn
Belts oily or dirty
Belts length different (multibelt
drives)
Drive systems hits drive guard
Fan, motor or motor base
fixing bolts loose
Pulleys misaligned.
Variable speed pulleys not
adjusted so each groove has
different diameter.
Fan shaft bent
Motor bearings damaged
Loose on support
Loose on shaft
Bearings worn or damaged
Bearings need lubrication
Foreign material inside bearing
Corrosion between shaft and
bearings
Ductwork undersized for
application
Fan size is too small for
application
Coil with insufficient face area
Registers and/or grilles
undersized for application
Worn or damaged impeller
Unbalanced impeller
Foreign material in fan housing
or inside the unit
Vibrating ductwork
Vibrating casing parts
Vibrating parts not isolated
from building
Obstruction in dampers,
registers, grilles
Leaks in casing and ductworks
Sharp elbows
Correct or change impeller

Correct or change inlet ring
Center the impeller
Tighten shaft
Tighten impeller
Adjust belt tension
Adjust belt tension
Install correct section belts
Change belts
Clean belts
Install correct belts.
Noise from drive

system
Noise from
bearings
High air velocity
Noise from
impeller
Vibration
Rattling/whistling
Sudden expansion or
reduction in ductwork
Check drive system and drive guard.

Tighten bolts
Align pulleys
Adjust each groove to same diameter
for required air flow
Correct or change shaft
Change bearings
Tighten bearings
Tighten shaft
Change bearings
Lubricate bearings
Clean bearings
Clean corrosion, if the shaft worn
change shaft
Check duct size and revise if necessary
Change size of equipment, revise if
necessary
Change impeller
Balance impeller
Clean fan housing
Stiffen ductwork
Isolate vibrating parts properly
Check and remove any obstructions

Seal leaks
Remove sharp elbows, install elbows
with proper radius and turning vanes
Install expansion/reduction sections
with proper expansion/reduction angles

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PROBLEM
SYMPTOM
POSSIBLE CAUSE
NO AIR FLOW
Motor is not
running
Current is not
reaching motor
Electric power failure

Starter overload tripped
Control panel fault
Isolating switches off
Motor bearing seized
Incorrect wiring to terminals
Faulty motor windings
Locate fault and restore power

Faulty wiring motor. Loose terminals.
Locate and correct fault.
Time clock error
Lack off correct lubrication
Motor internal wiring fault
Overheating or overloading incorrect
electric supply
Tighten impeller, check the belts
Rubbish blocking duct
Current available
to motor
Motor is running
but no air flow
Fan is not running

Fan is running
LOW AIR FLOW
Drive belts are

slipping

Duct blockage
Filters are dirty or clogged
Coils are dirty or clogged
Fan rotation is not correct or
impeller installed backwards
Belts are not tight or are
greasy
Duct resistance exceeds
design criteria. Poor duct
design
Dampers/registers closed
Drive system is wrong. Fan
speed is low
High leakage on
pressure side of
the system
HIGH AIR FLOW
Access doors are loose. Duct

joints are unsealed. Outlet
duct system is not completed
Ducts are oversized or duct
resistance overestimated.
High leakage on
Access doors are loose. Duct
suction side of the joints are unsealed. Suction
system
duct system is not completed.
Drive system is wrong. Fan
speed is high
Motor current is
excessive
HEATING COIL
No heating
Boiler plant is off

Heating fluid is off
or cold
HEATING COIL
Low heating
Heating mains is
cold
Heating fluid flow
rate is low
Supply voltage is low

Registers/grilles not installed
Filters are not installed
Filters are clean so low initial
pressure differential
Power failure
Air lock
Automatic valve is closed
Isolating valves are closed
Boiler flow temperature is low
Regulating valves are partially
closed
Tighten impeller
Change or clean filters
Change or clean coils
Correct fan rotation, check that
impeller is properly installed
Tighten belts, clean the grease
Check duct pressure losses and duct
design
Adjust dampers/register for required air
flow conditions
Consult manufacturer to check
whether drive system is properly
selected or not
Check access doors and duct joints.
Seal leaks. Complete duct system.
Close balancing dampers or slow down
fan by changing pulleys
Check access doors and duct joints.
Seal leaks. Complete duct system
Consult manufacturer to check
whether drive system is properly
selected or not
Motor overloads. Check current drawn
by motor
Install registers/grilles
Install filters
Regulate on dampers
Pump failure. Thermostat failure. Time
clock error. Fuel blockage.
Blockage in coil or pipes
Thermostat failure, valve motor failure
Circuit valves are closed.
Thermostats should be adjusted. Boiler
power is in adequate
Pumping power is not sufficient.
Pipe sizing is not correct. Blockage in
coil.

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31/32

PROBLEM
SYMPTOM
AIR WASHER
Low humidifying
COOLING COIL
No cooling
Cooling fluid
temperature is
high
Insufficient
coolant flow
Cooling coil is
partially frozen
No cooling
ELECTRONIC
STEAM
HUMIDIFIER
No humidifying
ELECTRONC
STEAM
HUMIDIFIER
Low humidifying
Chilled water
isolating valves
are closed
No air flow
Faulty
thermostatic gear
Safety devices
stops compressor
POSSIBLE CAUSE
Low water flow
Blockage in system. Valves are closed.

Leakage in piping
Float valve is off. Supply water is off.
Clean the system.
Low water level in water pan

Water distribution system is
clogged
Strainer is clogged
High air flow
Refrigeration plant cycles onoff
Valves are partially closed or

blockage in the system
Low load
Low suction temperature
Low air flow
Entering air temperature is too
low
Poor distribution on cooling
coil
Thermostatic valve is closed
Cooling thermostat setting is

high
High pressure cut-out
disconnects
Safety devices
stops compressor
Solenoid valve closed. Low

pressure cut-out disconnects
Electronic power
failure
Heater elements
faulty
Power is not reaching

elements or control valve
Safety cut-out tripped
Humidistat setting
is not correct
Water is not
available in
cylinder
Heater elements
faulty
Control fault
Steam cylinder
and heating
elements are
scaled
Faulty thermostat
gear
Steam supply rate
is low
Clean the strainer

Refer to high air flow section
Refrigeration plant capacity is
insufficient. Circulating pump or
compressor fault. Excessive heat gain in
piping system.
Circulating pump or compressor fault
Refer to no cooling, safety device
stops compressor section
Refer to low air flow section
Apply reheat or preheat
Unequal air velocity. Poor duct
connections
Thermostatic failure. Circulating pump
failure
Refer to no air flow section
Locate and correct fault
Fault in condenser. Fans or pumps
stopped. Condenser blocked. Heat
rejection is not taking place.
Suction temperature is too low. Low
airflow. Entering air temperature is too
low. Oversized coil or compressor.
Thermostatic gear fault
Water make-up failure or insufficient
water level in cylinder. Water treatment
is required to avoid scaling.
Reset humidistat correctly
Check supply system
Safety cut-out tripped
Water treatment is insufficient
Water make-up failure or insufficient

water level in cylinder. Water treatment
is required to avoid scaling.
Carry out maintenance or replacement
Humidistat calibration is not

correct
Steam-trap faulty
Control valves are not opening fully.

Manual valves or partially closed
Manual valves or partially closed

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32/32

PROBLEM
ELECTRICAL
HEATER
Low heat
SYMPTOMS
Power is not
available at
controller
Power available
at controller
Element failure
Thermostat set is
too low
POSSIBLE CAUSE
Electric power failure

Main contactor deenergised
Locate fault and restore power

Safety cut out tripped / poor duct design
adjacent to heater causes areas of uneven air
velocity and overheating of casing
Step controller faulty
Thermostat set is too low

Elements down to earth
Step controller is sticking
Elements disconnected / elements incorrectly

wired / wrong voltage
Controller cams faulty / wiring fault /
equipment fault

TEL: 00 90 232 328 10 00
FAX: 00 90 232 328 10 80
www.klsklima.com.tr

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1/32

AIR HANDLING UNIT INSTALLATION,

PROTECT YOUR UNIT AGAINST DAMAGE, SHOCK AND DISTORTIONS.

.A.O.S.B. 10008 Sokak No:5 35620 ili ZMR TRKYE

AIR HANDLING UNIT INSTALLATION,

Fig 1. Typical lifting equipment

AIR HANDLING UNIT INSTALLATION,

which is filled with Styrofoam.

3.1.2- Ducted Outlet Conditions

AIR HANDLING UNIT INSTALLATION,

.A.O.S.B. 10008 Sokak No:5 35620 ili ZMR TRKYE

AIR HANDLING UNIT INSTALLATION,

.A.O.S.B. 10008 Sokak No:5 35620 ili ZMR TRKYE

AIR HANDLING UNIT INSTALLATION,

.A.O.S.B. 10008 Sokak No:5 35620 ili ZMR TRKYE

AIR HANDLING UNIT INSTALLATION,

.A.O.S.B. 10008 Sokak No:5 35620 ili ZMR TRKYE

AIR HANDLING UNIT INSTALLATION,

3.4- ELECTRICAL CONNECTIONS

To avoid the electric heater keep on

AIR HANDLING UNIT INSTALLATION,

.A.O.S.B. 10008 Sokak No:5 35620 ili ZMR TRKYE

AIR HANDLING UNIT INSTALLATION,

.A.O.S.B. 10008 Sokak No:5 35620 ili ZMR TRKYE

AIR HANDLING UNIT INSTALLATION,

AIR HANDLING UNIT INSTALLATION,

AIR HANDLING UNIT INSTALLATION,

AIR HANDLING UNIT INSTALLATION,

prohibition to repair or adjust while the unit is running

5.3- STAFF TRAINING

.A.O.S.B. 10008 Sokak No:5 35620 ili ZMR TRKYE

AIR HANDLING UNIT INSTALLATION,

SOURCE OF DANGER OR RISK

Electrical parts, electric wires

Danger of loosing one s life

Hot water and steam coils,

External frequency converter

Danger of burning from hot water or steam

5.5- RECOMMENDED SAFETY PRACTICES

.A.O.S.B. 10008 Sokak No:5 35620 ili ZMR TRKYE

AIR HANDLING UNIT INSTALLATION,

Ensure that minimum water level is maintained in the humidifier.

.A.O.S.B. 10008 Sokak No:5 35620 ili ZMR TRKYE

AIR HANDLING UNIT INSTALLATION,

Check that pulleys are secure on shafts.

Check tightness of belts.

Check that fan and motor pulleys are aligned.

Check that fan and motor are fixed tightly.

Check that thermal overload relay setting is correct.

AIR HANDLING UNIT INSTALLATION,

Check the functioning of humidifier by adjusting the humidistat control.

Belt drive alignment and belt tension

Bearing housing temperature

Fan and motor fixing bolts

AFTER TWO WEEK OPERATION

Belt drive alignment and belt tension

Motor running current

Condensate and drain, to see flow

Operation of control devices