SystemAir KA HSI-2-2-S-R-50F-TB2-L2 Installation, Operation And Maintenance Manual Download Page 1

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Modular air handling units

Installation, operation and maintenance manual

2020-8-V-EN-003

Summary of Contents for KA HSI-2-2-S-R-50F-TB2-L2

Page 1: ...KA Modular air handling units Installation operation and maintenance manual 2020 8 V EN 003 EN ...

Page 2: ...structions 28 3 2 Schedule for control and maintenance 29 3 3 Fan 30 3 3 1 Electric motor connection and frequency converter set up 30 3 3 2 Connection of EC fan 32 3 4 Filter 35 3 4 1 Bag or cassette filter 36 3 4 2 Dirty side removable cassette filter 37 3 4 3 Metal filter 38 3 4 4 Active charcoal filter 39 3 4 5 Absolute filter 40 3 5 Heat recovery units 41 3 5 1 Plate heat exchanger 41 3 5 2 R...

Page 3: ... fax 386 1 423 33 46 e mail servis systemair si 1 2 Unit naming The meanings of the different elements of the KA air handling unit code are provided in the following schematic KA HSI 2 2 S R 50F TB2 L2 S Standard H Hygienic P Corrosion resistant Execution Product name Width Hight Cross section H THOR 50 mm profile Profile type I Indoor O Outdoor Installation S Supply E Extract I In line D Double s...

Page 4: ... a steel base frame to which legs can be fitted if so required The thickness of the air handling unit casing wall is 50 mm Comfort units With a normal type of air handling unit all the interior and exterior casing walls are made of ZM coated galvanised steel sheet as the standard The whole bottom of the unit is sealed on the inside between the frame and panels The fastening material is of galvaniz...

Page 5: ...for a device supplied without a control system The declaration of conformity for this device must be issued by the company which assigned the device and put it into operation Caution The declaration of conformity or the declaration of incorporation shall be attached separately to each device If the customer makes changes or adds components to the device he must issue a new EC declaration of confor...

Page 6: ...the operating conditions determined in the confirmation of the order according to which the unit was manufactured Caution Any other use deviating from the so determined intended use relieves the manufacturer of any obligation or liability Systemair d o o the manufacturer of the KA air handling unit does not accept any liability in the event the directions indicated in these instructions are not ad...

Page 7: ...il section electric heat recovery section with rotary heat exchanger heating coil section gas heat recovery section with heat pipe exchanger condenser section silencer heating cooling circuit empty section spray humidifier section electric cabinet steam humidifier section with steam generator cooling coil section with water cooler steam humidifier section with system prepared steam cooling coil se...

Page 8: ...ponsible for moving pallets with modules Must have a forklift driving test and written permission from the system owner Crane driver Responsible for moving pallets and modules from the transport vehicle and to the place of operation Must have a crane driving test be mentally and physically able to operate the crane independently and prove to the system owner the required type of skill HVAC technic...

Page 9: ...tion of conformity for the entire unit and provides the CE label for the device 1 9 Annexes responsibility and intended use Drawings diagrams instructions for use maintenance and repairs The dimensions shape and technical data of the unit are made separately for each device They are printed on paper and delivered to the customer upon delivery of the device in a separate envelope or sent electronic...

Page 10: ...altitudes exceeding 1000 m above sea level and at temperatures in the range from 40 ºC to 60 ºC a reduction in the electric motor capacity should be taken into account in accordance with the instructions of the motor manufacturer In cases where the air temperature exceeds 60 ºC special versions of the fans and its electric motors should be applied When so requested air handling units suitable for ...

Page 11: ...e equipment during transport can only be carried out via the bottom base frame and transport pallet without applying any pressure on the casing Unloading and moving with a forklift The forklift forks must be long enough to avoid damage to the bottom surface of the shipment unit and to prevent the shipment unit from falling off the forks In the case of shipment units with base frames the forks must...

Page 12: ...s in order to prevent the stripes from pressing against the shipment unit casing Caution Place the lifting straps under the pallet on the outside of the support and secure them against slipping off the pallet High and short shipment units Some shipment units e g a section with a rotary heat exchanger a heat exchanger etc may be of significant height with very small length Extra attention should be...

Page 13: ...edge and the ceiling of the room in order to enable safe access to the cabinet In order to facilitate the assembly and joining of shipment units a clear space of at least 500 mm in width is also recommended at the back side of the unit Caution Where not practicable the method of joining shipment units must be specified in the order The access to shipment unit joining points from the inside the uni...

Page 14: ... foundation height observe all the factors that may affect the operation of the unit the mounting site the depth of snow cover requirements for the intake air quality the position of the intake and extract duct connections the types of connectors for heat exchanger piping the laying of electric cables etc Mounting of unit without a foundation The foundation may be substituted by purpose built legs...

Page 15: ...er sealing the joints against water is necessary in this case as well The joints between the intake and extract air ducting connections and the ducts must be watertight In cases when the intake air into and extract air out of the air handling unit run through ducts the joints between the duct connections and ducts must also be watertight For air handling units installed on the roof or at an elevat...

Page 16: ...oining surfaces connecting profiles Slide and press the shipment units together by means of slings We recommend slings with brackets applied so as to prevent damage to the casings Tighten the thread connections on all the joining elements 1 Joining of base frames This should always be the primary connection There are several options for joining you can use with your unit 1 Joining of base frames A...

Page 17: ...f vertical reinforcements Joining of connecting elements Fastening material For each connection the following fastening material is always supplied 1x Screw DIN 933 Zn M10 x 80 1x Nut DIN 934 M10 Zn 2x Washer DIN 9021 10 5 Zn Fastening material For each connection the following fastening material is always supplied 1x Screw DIN 933 Zn M8 x 40 1x Nut DIN 934 M8 Zn For each connection the following ...

Page 18: ...together with the supplied special screws with a rubber washer Fastening material For each connection the following fastening material is always supplied 1x Screw DIN 933 A2 M6 x 25 1x Nut DIN934 M6 A2 2x Washer DIN 9021 6 3 A2 Ø22 Ø6 7x3 EPDM Fasten the roof to the unit with the supplied special self tapping screws with a rubber washer Fastening material For each connection the following fastenin...

Page 19: ... to the ducting by means of flexible connections The flexible connections should always be almost fully stretched 50 90 In the case of a centrifugal fan the dimensions of the duct should be similar to those of the air outlet opening onto the fan in order to avoid or minimise losses due to turbulence In special cases e g with vertical duct runs buoyancy effects may induce an air flow that drives ro...

Page 20: ...is mounted through the hole as centrally as possible 3 An insulating tube is mounted on the pipe through the hole as shown in the table below see column Insulation The length of the tube must be at least 100 mm so that the pipe on the outside covers the panel flat and no insulation is visible The inner tube faces inside at least 50 mm 4 On the outside a rubber rosette is attached to the tube as sh...

Page 21: ...ir flow and vertical air flow The pump may be mounted in either the horizontal or in the vertical section of the piping however the pump axis must always be horizontal The control valve may be installed in the supply pipe or return pipe however the distance between the supply pipe and the return pipe and the distance between the control valve and the bypass pipeshould preferably not be less than 5...

Page 22: ... circulation pump 2 3 way valve 3 balancing valve 4 termometer 5 termometer optional 6 venting valve 7 ball valve 8 drain valve Caution 3 way valve for cooling hydraulic cyrcle can be mounted on the inlet or outlet It is important to instal it with the required flow direction ...

Page 23: ...re or underpressure may occur in the section where condensate drainage is required Pa P0 Section has overpressure Pa P0 Section has underpressure Caution In the case of separate drains at the cooling register and the water droplet eliminator the drains must be connected and only then a siphon installed The connecting pipes are not supplied by the device manufacturer Be sure to fill the siphon with...

Page 24: ...m 200 30 30 15 400 50 50 25 600 70 70 35 800 90 90 45 1000 110 110 55 1200 130 130 65 Overpressure connection Drain over bottom panel Drain over side panel Hmin depends on the maximum overpressure Pa in the condensation section Underpressure connection Drain over bottom panel Drain over side panel Hmin depends on the maximum underpressure Pa in the condensation section ...

Page 25: ... should point in the direction of water outflow In case of overpressure in the section look at the arrow Pa In case of underpressure in the section look at the arrow Pa Caution The siphon connection is suitable for a base frame of 125 mm at any time at overpressure but only if Hmin 60 mm In the case of a underpressure the height of the base of 125 mm corresponds to underpressure of 700 Pa or Hmin ...

Page 26: ...lack button has to be removed Drain over bottom panel Drain over side panel Hmin is a minimum of 60 mm regardless of the overpressure in the device Underpressure connection Caution Shows direction of the drainage flow in underpressure section Drain over bottom panel Drain over side panel Hmin depends on the maximum underpressure Pa in the condensation section ...

Page 27: ... power is provided for three phase current Sensors actuators and other external measuring equipment can be connected with a 0 75 m2 cable Power Current 1 5 2 5 4 6 10 16 25 35 50 70 95 kW 3p A mm2 mm2 mm2 mm2 mm2 mm2 mm2 mm2 mm2 mm2 mm2 1 5 2 3 100 m 165 m 265 m 395 m 3 4 6 33 m 84 m 135 m 200 m 335 m 530 m 4 5 6 8 30 m 57 m 90 m 130 m 225 m 355 m 565 m 6 9 25 m 43 m 68 m 100 m 170 m 265 m 430 m 5...

Page 28: ...he service switch must be switched off and locked Due to the frequency converter it is necessary to wait at least 15 minutes It is necessary to check whether all rotating parts are stationary fan belts rotary heat exchanger blinds It is necessary to check whether the temperature in the heat exchangers and hydraulic systems has adapted to the ambient temperature The PM motor shaft must be blocked E...

Page 29: ...X Carry out a functional test of the siphon X Cleaning X SOUND ATTENUATOR Inspection of soiling damage and corrosion X STEAM HUMIDIFIER Inspection of condensate draining from chamber X Cleaning if necessary Inspection of soiling damage and corrosion X Inspection of condensate draining X Cleaning with a cleaning agent X Desinfection if necessary Inspection of oper and cleanliness of the dirt traps ...

Page 30: ... a repair switch connect the electric motor to the mains supply via a device that allows the isolation of all the poles from the mains supply with a clearance of 3 mm between the contacts in the open state Integrate an automatic switch contactor and thermal guard in the electric motor energising circuit Electric motors up to 7 5 kW may be started directly their wiring is indicated on the motor nam...

Page 31: ...rt as possible to reduce the noise level and leakage currents Connect the motor cable screen armour to both the decoupling plate of the frequency converter and to the metal of the motor Same applies to both ends of metal conduit if used instead of screen Make the screen connections with the largest possible surface area cable clamp or by using an EMC cable gland This is done by using the supplied ...

Page 32: ...ication must have cable clamps at both ends for the best possible electrical contact Incorrect grounding Do not use cables with twisted ends They increase the array impedance at higher frequencies 3 3 2 Connection of EC fan Connection of Ziehl Abegg ECblue Connection of EBM paps 1 Cover of controller housing 2 Cable glands seal insert for two cables applicable only if necessary motor size D 3 x M1...

Page 33: ...xternal devices e g pot SELV Check before commissioning The mounting of the fan on the frame and the mounting of the electric motor on the tensioning bracket the parallelism of the motor drive shaft and of the fan shaft in the case of deviation adjust the electric motor by means of the tensioning bracket and once the adjustment has been completed firmly tighten all the screws the mounting of the r...

Page 34: ...ans changing the pulley on the motor and or the pulley on the fan In order to correct the pressure levels adjust the control dampers After remedying all the causes of incorrect operation measure the electric motor current again An electric current lower than or equal to the nominal current indicates the correct operation of the fan section For rooms with an excess supply air any failure of the int...

Page 35: ... Store new filters such that they are protected from dust and against damage Do not use filters whose shelf life as specified by the filter manufacturer has expired Only use filters that are in compliance with the EN 16890 1 standard as demonstrated by the manufacturer Handle contaminated filters in accordance with environmental protection regulations In the case of outdoor type air handling units...

Page 36: ...ame with one level the entire cross section filled with filter cassettes press the cassettes by means of the lock profile against the guide which has sealing tape applied repeat the procedure until the entire cross section of the section casing is filled check the connection of the pressure measuring hoses to the pressure measurement ports and connect the hoses if necessary Maintenance The filters...

Page 37: ...er frame insert the bag filter in such a way that the bags hang freely through the frame opening and are not compressed pinched or damaged in each frame corner insert a wire spring to press the filter bag against the sealing tape on the frame when installing and joining shipment units observe the rule of inserting the filters into the frame so as to ensure that the air flow presses them against th...

Page 38: ...e connection of the pressure measuring hoses to the pressure measurement ports and connect the hoses if necessary Maintenance Replace the filter cassettes slide out the filter cassettes drain clean the pan below the filter clean the section casing if necessary insert clean filter cassettes check the connection of the pressure measuring hoses to the pressure measurement ports and connect the hoses ...

Page 39: ...check the air tightness of the support plate filter frame joints check the air tightness of the filter cassette support plate joints Maintenance Replace the filter cassettes rotate the filter cassette in the direction of the arrow and pry it out of the support plate repeat the procedure to remove all the filter cassettes clean the section casing if necessary insert new cassettes in the opposite di...

Page 40: ...ress the compact filter frame seal against the filter frame absolute filters must be mounted in the absolute filter frame in the direction ensuring that air flow presses the filters against the seal air flow in the opposite direction is not allowed check the connection of the pressure measuring hoses to the pressure measurement ports and connect the hoses if necessary Maintenance Replace the filte...

Page 41: ...he air channels through the insert If the insert contamination consists of dry dust the insert can be cleaned without disassembly through the service openings With compressed air a maximum of 10 bar of pressure in this operation the use of personal protective equipment is obligatory If the insert contamination consists of greasy or sticky debris slide out the insert from the heat exchanger section...

Page 42: ...drive belt the operation of the motor drive and the settings of the frequency converter parameters the operation of the rotation monitoring magnet clean any debris from the section Parameters for setting the frequency converter VLT Micro Drive FC 51 Parameter Description Value 1 20 Motor power Motor data plate 1 22 Motor voltage Motor data plate 1 23 Motor frequency Motor data plate 1 24 Motor cur...

Page 43: ...ning valves at appropriate points In order to avoid the risk of condensate freezing on the fin package the medium temperature at the inlet of the heat exchanger in the extract air flow may not be less than 3 C Connect the hydraulic circuit in accordance with the design specifications and applicable safety regulations The hydraulic circuit must be fitted with an appropriately sized and installed ex...

Page 44: ... external dampers are fully open On the outside protect the control dampers with ducts or protection mesh if not factory protected Mount and start the motor drive in accordance with the manufacturer s instructions and electric control cabinet start up instructions The required capacity of the motor drive depends on the control damper size and on the pressure differential across the damper The requ...

Page 45: ...hermostat must be set to 5 C As the temperature drops below the set value the thermostat and automatic control system must carry out the following operations Stop the fan close the outdoor air intake control damper fully open the heating medium valve and start the circulation pump Caution In the case of air handling units that include a cooling coil preheater and reheater anti frost protection at ...

Page 46: ...ration In the event of disturbances in the medium flow through the heat exchanger or the formation of air cushions vent the piping system Check the operation of the heat exchanger automatic anti frost protection Periodically check the operation of the automatic shut off of the supply of the heating medium into the heat exchanger with the unit stopped Check the continued operation of the fan for 3 ...

Page 47: ...xchangers the following operations should be carried out regularly Check that the water connections are leakage free and that the air joints are firmly mounted and leakage free Check the venting fan operation In the event of disturbances in the medium flow through the heat exchanger or the formation of air cushions vent the piping system Check the adequacy of the cooling coil anti frost protection...

Page 48: ...e blade cleaning The thermal insulation of the evaporator extract pipe must provide a vapour barrier in accordance with applicable standards In installing the thermostat expansion valve follow the manufacturer s instructions install the valve on the horizontal pipe leg as close as practicable to the DX upstream of the pressure equalisation and at a proper inclination considering the pipe thickness...

Page 49: ... pressure protection switch according to the specified levels This also applies to the condensation pressure control switch the correct volume of Freon no droplets in the inspection glass the dry condition of the unit the inspection glass colour indicator dry wet in accordance with the manufacturer s instructions the correct evaporation and condensation pressure Upon commissioning make sure that t...

Page 50: ...in the direction opposite to the air flow direction If such cleaning proves insufficient disconnect the heat exchanger slide it out and wash with low pressure water or steam Do not use high pressure water or steam in order to avoid deforming the aluminium blades If washing with water the pressure thereof must not exceed 15 bar and the jet must be directed strictly parallel to the blades Exposure t...

Page 51: ... its internal surface Such operation may also result in markedly non uniform distribution of the outlet air temperature Subcooled condensate in the flooded heating coil section causes large stresses in the structure and water hammer This is particularly likely to occur at low inlet air temperatures As steam comes into contact with subcooled condensate steam bubbles abruptly collapse and cause impl...

Page 52: ...alve Caution Take care of possible very high medium temperature when draining Medium draining Close the steam supply valve and open the draining valve Once draining is finished open the steam valve once again to let all the condensate drain from the section until steam emerges Close the steam valve Let the draining valve open until the next restart Upon draining the heat exchanger dry the tube ban...

Page 53: ...es 3 7 7 Electric air heater Caution See also section 3 1 General instructions The connection of the electric air heater must be carried out by a qualified professional in accordance with the applicable regulations Connection commissioning and maintenance to be carried out according to the manufacturer s instructions Connection Any functional section containing temperature sensitive materials shou...

Page 54: ...as heating coil Caution See also section 3 1 General instructions The gas connection commissioning and maintenance of the gas burner may only be carried out by an authorized and professionally qualified person in accordance with the instructions of the gas burner manufacturer and in accordance with the approved design and applicable regulations 1 Thermal protection 2 Shut off ball valve 3 Gas filt...

Page 55: ...nd constructed in accordance with the applicable regulations laws and standards To facilitate obtaining consent from a chimney sweep service design documents should be drawn up for the stack including the solutions for the extraction and neutralisation of the flue gas condensate Connect the gas heater to the stack in accordance with the requirements applicable to stacks for gas fired installations...

Page 56: ...s to automatically stop the gas burner in the event the air temperature in the chamber above the heat exchanger exceeds approx 70 C the installation and operation of the safety thermostat temperature limiter the function of which is to stop the gas burner and block it in the event the air temperature around the heat exchanger exceeds approx 90 C in order to restart the gas burner manual interventi...

Page 57: ...least 100 C Be sure to install a properly sized siphon on the drain pipe to collect and drain the condensate Instructions for the construction installation and connection are given in section 2 3 5 Connection of siphon Commissioning The steam distributor is mounted into the air handling unit casing in such a manner so as to provide the required clear space around it and the required length of the ...

Page 58: ...eed off water O Water bleed off is necessary to maintain appropriate mineral and salt content levels in the humidifier section reservoir water 1 Moisturising panels 2 Water dividing profile 3 Water distribution pipes 4 Float 5 Float switch 6 Drain valve 7 Calving pipe 8 Water dividing module 9 Drainage control valve 10 Water pump 11 Water drainage pipe 12 Overflow drainage 13 Sihon 14 Droplet elim...

Page 59: ...version factor m3 s to m3 min 1000 conversion factor g min to l min Example calculation V 2 8 m3 s pH 7 1 Calcium concentration Ca2 100 mg l 100 ppm Bicarbonate concentration HCO3 100 mg l 100 ppm Inlet air humidity x1 2 g kg Outlet air humidity x2 9 g kg From the water quality diagram fo 0 3 E 2 8 x 60 x 1 2 x 9 2 1000 1 41 l min O 0 3 x 1 41 0 42 l min S 1 41 0 42 1 83 l min Commissioning On the...

Page 60: ...luded in scope of standard equipment only for direct water constant flow rate valve only for direct water The extraction of water In order to facilitate water bleed off from the humidifier section under negative pressure an appropriate negative pressure siphon must be provided Control Delta connection 230 V 1p 50 Hz Star connection 400 V 3p 50 Hz Wiring diagram for 3 phase pump ...

Page 61: ...esult in a fishlike odour Once there is no longer a demand for humidifying and the honeycomb humidifier section is shut down the water supply is shut off the air handling unit fan may not be stopped until the humidifier cassettes are dry The necessary prolonged time of operation of the air handling unit is 20 minutes at a minimum If the honeycomb humidifier is to be out of operation for at least 2...

Page 62: ... valve knob to the corresponding number to the left or to the right then check the bleed off water flow rate capture the bleed off water in a container of a known capacity not less than 1 litre and measure the container filling time Repeat this procedure until the correct bleed off rate is achieved Caution Keep the inner and outer surface of the inspection glass clean If you notice fouling thoroug...

Page 63: ...upply from Systemair d o o is the electric control cabinet itself the wiring between the air handling unit and the electric control cabinet and start up if so specified in the order confirmation In such an arrangement Systemair d o o does not carry out the mounting of the electric control cabinet or any required construction works penetrations cable trays laying of the power supply and control cab...

Page 64: ...o o Špelina ulica 2 SI 2000 Maribor Slovenia Tel 386 1 200 73 50 Fax 386 1 423 33 46 info systemair si www systemair com KA Modular Air Handling Units Installation operation and maintenance version 2020 8 V EN 003 ...

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SystemAir KA HSI-2-2-S-R-50F-TB2-L2, Installation, Operation And Maintenance Manual

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