ECE IOM Manual

Air handling and conditioning unit

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Contents

1. Checks at Design Stage

2. Checks at Order Stage

Summary of Contents for ECE IOM

Page 1: Table Of Contents
Contents 1. Checks at Design Stage 2. Checks at Order Stage 3. Delivery 4. Installation. 5. Commissioning. 6. Maintenance 7. Fault Finding...
Page 2 This manual contains advice for installers and users. General information about the range, construction and selection of ECE air handling/conditioning equipment can be obtained from the various sales publications, or by telephone. Certified individual unit data concerning dimensions, weights, component specification and performance, is issued with the order acknowledgement for each unit.
Page 3: Checks At Design Stage
1. Checks at Design Stage 1.1. Air Inlets and Discharges Whether ducted, or part of the Air Handling Unit, inlet and discharge connections to atmosphere such as Louvres, cowls, spigots etc. should be located and dimensioned so that flow restriction, short circulating, recirculation of vitiated air, pick up of contaminated air or nuisance discharge of exhaust air do not occur.
Page 4 1. Checks at Design Stage 1.2. Acoustics - Vibration Ensure space exists for incorporating attenuation of noise to atmosphere from outside air inlet and exhaust air discharge and on room side supply and extract ducts. Consider noise from casing radiation, flanking and breakout. Consider primary and secondary vibration isolation including service connections.
Page 5: Checks At Order Stage
WITHDRAWAL- SIDE/US/DS/T/B. FLEXIBLES OUT TO TENDER BY. FITTED MANOMETER(S). ISOLATING/FAN RAFT/FAN SECTION. RETURN DATE MAGNAHELIC(S). COMPUTE UNIT/PIPE CONNECTIONS. ORDER TO ECE CUSTOMER BY RADIANT HEAT FROM EAHB. ATTENUATING. IF ECE SELECTED. WHEN? ________________________________________ FLAME RESISTANT. ORDERS TO ECE BY CONSTRUCTION.
Page 6: Delivery
All units are fitted with a full perimeter bases to facilitate lifting, moving and installation. Unit wrapped ready for dispatch Units should be inspected and any external damage or short delivery reported to ECE. before unloading . We cannot accept responsibility for damage sustained during unloading from the delivery vehicle or on site.
Page 7 3. Delivery 3.2 Lifting 3.2.1. Cra ne long lifting stra p s 150m m m in. w id th 3.2.2 Cra ne 'H' fra m e short lifting stra p s 150m m m in. w id th 3.2.3 Fork lift...
Page 8 3. Delivery 3.3. Moving 3.3.1. Rollers 3.3.3 Skates 3.3.2 Toe Jacks...
Page 9: Installation
4. Installation 4.1. General Electrical wiring and controls, water, steam, gas and refrigerant piping, line fittings and controls should be installed In accordance with appropriate governing institute standard practice (I.E.E., C.l.B.S.E. etc.) and together with the electricity supply, water supply and drains should conform to the appropriate authority and all statutory regulations.
Page 10 4. Installation 4.2. Bases and foundations (cont'd) When foundations are uneven units will 'lozenge' if the installer attempts to use the joining bolts to pull non parallel faces together causing air leakage at joins, access doors will jam and not close after opening and duct connections will not be 'parallel' and will leak.
Page 11: Commissioning
5. Commissioning 5.1. Commissioning Fans - Motors - Drives Access is by hinged or lift off panels. Catches are hidden quarter turn cams, tool or key operated. Wiring to the motor(s) should be carried in flexible armoured conduit through screwed gland(s) fitted in hole(s) drilled by the installer/user.
Page 12 & belt(s) on site. remeasure volume recheck proportion and volumes to air terminal devices. ECE site operatives are available for changing belts and pulleys on site at extra cost if required. Notes; Rotating standby motors generate electricity even when isolated from the mains.
Page 13 5. Commissioning Commissioning Fans - Motors - Drives cont'd Anti Vibration Mountings Levelling screw Large cap Clamping area to support equipment Fixing/ Pressure levelling plate bolt Steel support Captive base moulded Ribbed into top cone Steel cap and body anti-skid Neoprene pads Slotted to absorb high...
Page 14 5. Commissioning 5.2. Commissioning - Servicing Filters Units are supplied with required filters fitted. After installation of the plant "Blow Through". Ensure the system filters are replaced by the installer at commissioning as follows. Filter Ratings - use this chart to ensure you have the correct type **If avoidance of pattern staining on surfaces is a priority use this standard or above Pa of Normally Used Filters...
Page 15 5. Com m issioning Filters (cont'd.) Commissioning - Servicing Type Retentivity Constant P.d. ka gas / kg carbon ins. W.G. Activated Carbon 0.1 - 0.4 0.45 Remove open side access doors (unless special access). Thoroughly clean system. Install temporary filters (gauze bags etc.) on inlet discharge points. Replace and close access doors.
Page 16 Hand operated with locking quadrant check:- Free action of the damper blades and arm before setting at the required angle. Motorised (motor not normally by ECE) Remove links and check: Motor bolts and platform tight Electrical supply and connections correct Motor operates freely and in correct direction.
Page 17 5. Commissioning Commissioning Coils General checks: Coils Installed in correct order for psychrometics. Fin conditions, comb out if necessary. Water coil checks: Air and water are in counter flow. Flow pipe work with drain cock fitted is to lowest connection. Return pipe work with vent is from highest connection.
Page 18 5. Commissioning Commissioning Coils - Condensate Drains Draw through units Blow through units with negative pressure - depression at trap Drain tray connection Drain tray Inlet Pipe Trap primed with water, fan off. Coil off. No difference in water levels Casing Unit Base Primed cleanable...
Page 19 5. Commissioning Commissioning Coils - Condensate Drains Blow through units with positive pressure at trap Trap primed with water, Drain tray fan off. connection Inlet Pipe Coil off. Drain tray No difference in water levels Casing Unit Base Primed cleanable 'U' bend trap Platform/Base Open Tundish...
Page 20 Commissioning Coils - Condensate Drain Faults Draw through Depression at coil off face = D Less than D Inadequate trap differential resulting in condensate drain tray overflow and flooding Depression at coil off face = D Height less than D Not draining into an open tundish but connecting to a full pipe resulting in condensate drain tray overflow...
Page 21 Commissioning Coils - Condensate Drain Faults Blow through Pressure at coil = P Height less than P Height less than P Inadequate trap differential resulting in priming water blow-out "splutter" and air leakage Pressure Height more than P at coil = P Not draining into an open tundish but connecting to a full pipe resulting in condensate drain tray overflow...
Page 22 Commissioning coils Draw through coils with condensate pump Open Tundish Drain tray Pump sump primed with water fan off Casing coil off HLFS No difference in water levels Unit Base LLFS Water level when LLFS switch stops pump Depth of priming water seal Platform/Base Level of opening in pipes Depression at...
Page 23 5. Commissioning Commissioning DX Cooling Coils Coils are normally of open header box construction (but may have split end covers supplied to order) are completely self supporting and designed to be fitted directly between or within the sections of the air handling unit.
Page 24 5. Commissioning Commissioning Chilled Water Cooling and LP Hot Water Heating Coils Guidelines for water circuits in C.W. Coolers and LPHW Heaters Bypass Circuit Tightly closing three-way valvesare required as the regulating valves. At nominal flow the pressure drop accross the valves (pv100), should range from approximately the same value to about double the value of the pressure drop accross the heating load branch at nominal flow.
Page 25 5. Commissioning Commissioning Chilled Water Cooling Coils Coils are normally of open header box construction (but may have split end covers supplied to order) are completely self supporting and designed to be fitted directly between or within the sections of the air handling unit.
Page 26 5. Commissioning Commissioning Hot Water Heating Coils Coils are normally of open header box construction (but may have split end covers supplied to order) are completely self supporting and designed to be fitted directly between or within the sections of the air handling unit.
Page 27 5. Commissioning 5.8.1 Commissioning Runaround Coils A TYPICAL PIPING ARRANGEMENT FOR RUNAROUND COILS AIR HANDLING UNITS SEPARATED Heat transfer medium water/glycol (minimum 15%, maximum 25%) Runaround systems are used for heat recovery only, coolth recovery is not a economically viable proposition. Air purger unit fitted with automatic air vent, safety valve...
Page 28 5. Commissioning 5.8.2 Commissioning Runaround Coils...
Page 29 5. Commissioning 5.8. Commissioning Runaround Coils - 5.8.3. Single Pressurisation Pump, Single Circulating Pump PRESSURISATION AND CIRCULATING PUMP SET AIR FLOW AIR FLOW SUCTION DISCHARGE Key to Numbers NOTE. Heat gains to water from pump and pipework plus heat gains to 1.
Page 30 5. Commissioning Commissioning Runaround Coils - 5.8.4. Single Pressurisation Pump, Twin Circulating Pumps with Flow Switch and Auto Changeover PRESSURISATION AND CIRCULATING PUMP(S) SET AIR FLOW AIR FLOW SUCTION DISCHARGE Key to Numbers NOTE. Heat gains to water from pump and pipework plus heat gains to 1.
Page 31 5. Commissioning 5.8.5 Commissioning Runaround Coils...
Page 32 5. Commissioning 5.10 Commissioning Steam Coils Coils are normally of open header box construction (but may have split end covers supplied to order) are self supporting and designed to be fitted directly between or within the sections of the air handling unit. When split cover plates are supplied these should be removed prior to connections being made, then replaced.
Page 33 5. Commissioning 5.11 Commissioning Electric Heater Batteries IF NOT PROPERLY INSTALLED AND CONTROLLED EAHB'S ARE DANGEROUS. THEY CAN CAUSE SERIOUS INJURY OR DEATH AND START FIRES. ASK YOUR LOCAL ELECTRICITY BOARD FIRE OFFICER AND ENGINEERS DEPARTMENT TO INSPECT YOUR INSTALLATION BEFORE USE. Access is by the access door clamped on the side of the unit.
Page 34 5. Commissioning 5.12 Commissioning Gas Fired Heaters Safety Notes:- Commissioning is recommended by our operatives, in any event gas piping, flue, electricity supply and controls should comply with gas safety, gas region, local authority, fire authority and insurance company regulations. Do not locate in presence of chlorinated or corrosive vapours, in areas of high risk i.e.
Page 35 Commissioning Electronic Steam Humidifiers General Humidifiers supplied for use with ECE units are electrode boilers which operate at atmospheric pressure and utilise standard water supplies provided the local regulations regarding connection of this type of equipment are observed. Should local regulations call for the use of a break tank to feed the unit, the speed at which the humidifier cylinder fills will be determined by the head pressure available.
Page 36 5. Commissioning 5.14 Commissioning Plate Heat Exchanger Before commissioning, ensure that the air streams can flow freely through the plate heat exchanger. If dampers are fitted, check their movement and correct adjustment. Furthermoremore check if installation has been carried out correctly and make sure the application limits (temperature, pressure difference, material etc.) cannot be exceeded PIC?
Page 37: Maintenance
6. Maintenance 6.1 Maintenance Schedule* Further Interval detailed instructions see section Item 1 mth 2 mths 3 mths 4 mths indicated Fan impeller cleaning Fan motor - cooling vents clear, bearings check Fan vee-belt drive, wear, tension, alignment Filter panels check, clean or renew as necessary Filter bag check, clean or renew as necessary:- Standard Fine...
Page 38 Spider arm bearing - Sealed ball races mounted in rubber, pre-greased and self align ing for service free use under normal duties. UNITS IN THE ECE RANGE FITTED WITH SPIDER ARM BEARINGS 450 - 630 up to 400 THLZ Duplex - 3 No.
Page 39 Maintenance Action (not already indicated in Schedule) FAN BEARINGS Plummer Block bearing - Sealed ball races, self aligning and mounted in cast iron supports, pre-greased with grease points. UNITS IN THE ECE RANGE FITTED WITH PILLOW BLOCK BEARINGS Extended shaft 'A' Frame NTH3 T1...
Page 40 6. Maintenance Maintenance Action (not already indicated in Schedule) FAN BEARINGS Direct Drive Fans - The impeller is keyed to the motor which is mounted on a support attached to the fan casing. Motor bearings are sealed ball races mounted in rubber, pre-greased and self aligning for service free use under normal duties.
Page 41 6. Maintenance Maintenance Action (not already indicated in Schedule) MOTOR BEARINGS Self aligning self oiling and spring loaded ball lubricators, use light machine oil. Pressure grease fittings and relief plugs, wipe down fitting, remove pressure plug (if fitted) and hardened grease.
Page 42 6. Maintenance Maintenance Action (not already indicated in Schedule) PLATE HEAT EXCHANGERS Only periodic visual checks are necessary. If dampers are fitted, test their movement. After initial 3-monthly inspection intervals, checks can be carried out every 12 months. Based on long experience, dirt build up inside the heat plate exchangers installed in air handling equipment is not expected.
Page 43: Fault Finding
7. Fault Finding Note: check for broken wires or loose cable shoes first, also at control panel ITEM OF CHECK FAULT EQUIPMENT NO AIR FLOW Motor connected CENTRIFUGAL Wiring to isolator (on?) - Fan motor stationery FANS Fuses intact - No current to motor Wiring to starter (on?) Starter wired properly Overloads holding in and correct size...
Page 44 7. Fault Finding Note: check for broken wires or loose cable shoes first, also at control panel ITEM OF CHECK FAULT EQUIPMENT NO HEAT cont'd All wiring connected ELECTRIC High temperature cut out button in HEATERS Continuity across H.T. cut out terminals cont'd Airflow switch making and breaking Voltage to airflow switch terminals...
Page 45 7. Fault Finding Note: check for broken wires or loose cable shoes first, also at control panel ITEM OF CHECK FAULT EQUIPMENT HIGH RH Humidistat or dewpoint stat too high/faulty COOLING No cooling COILS Coil fault (see above) cont'd Entering air temperature too high Insufficient cooling capacity (maybe start up, pull down time) Excessive fresh air or airflow Excessive moisture gain...
Page 46 7. Fault Finding Note: check for broken wires or loose cable shoes first, also at control panel ITEM OF CHECK FAULT EQUIPMENT HEAD PRESSURE TOO Refrigerant overcharge - vent excess charge REFRIGERATION Air in system - leak test, repair leak, evacuate and recharge HIGH Dirty Condenser- clean Malfunction of condenser fan (air cooled) - check head pressure...
Page 47 7. Fault Finding Fan Drive Belts Excessive oil Exposure to elements Belt forced over pulley rim Contact with obstruction Insufficient tension Stalled driven pulley Excessive slip Rough pulleys Substandard pulleys Excessive tension Shock load Foreign material Excessive dust Drive misalignment Worn pulley grooves Excessive vibration High ambient temperature...