Boreas Technologies Air Handling Unit Installation Commissioning Maintenance Manual
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Boreas Technologies Air Handling Unit Installation Commissioning Maintenance Manual

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  • Page 2 BOREAS 5 GENERATİON AIR HANDLING UNIT İnstallation Commissioning Maintenance Manual...

  • Page 3: Table Of Contents

    CONTENTS FİGURES ................................. 5 TABLES ................................6 General Considerations ......................... 7 Use ın Accordance wıth Instructions ..................... 7 Plant Room ............................ 7 Transport and Storage ........................7 Installation ............................. 8 Before Commissioning ........................8 Freeze Protection .......................... 9 Safety Warnings ............................. 9 Emergency Measures ..........................
  • Page 4 Connection of Condensate Outlet And Drainage Line ..............20 Electrical Connection ........................21 6.6.1 Air Handling Unit without Panel ..................21 6.6.2 Air Handling Unit with Panel ....................22 Rotary Heat Recovery Unit ......................22 Installation Connection for Evaporative Humidifier Section ............22 Installation Connection for High Pressure Humidifier Section ............
  • Page 5 7.7.2 Maintenance ........................35 Heat Pipe Heat recovery Heat Exchanger ................... 35 7.8.1 Initial Start-up ........................35 7.8.2 Maintenance ........................35 Rotary Type Heat Recovery Unit Heat Exchanger ............... 35 7.9.1 Initial Start-up ........................35 7.9.2 Maintenance ........................36 7.10 Plate Type Heat Recovery Unit Heat Exchanger................

  • Page 6: Fi̇gures

    Figure 2 Incorrect Stacking of Sections ......................8 Figure 3 Correct Carriage with Forklift ......................13 Figure 4 Incorrect Carriage with Forklift ......................14 Figure 5 Levelling the Air Handling Unit Using Chucks ................14 Figure 6 Service Clearance…………………………………………………………………………………………………………………...…15 Figure 7 Service Clearance………………………………………………………………………………………………………..…………..16 Figure 8. Section Connection Labels..........…….…….……………………………..…………..16 Figure 9 Sealing of Section Connection ..........………………..…………......16...

  • Page 7: Tables

    TABLES Table 1 Maintenance Check-list Spare Part Delivery / Customer Services / Repairs ........12 Table 2 List of Spare Parts ........................... 13 Table 3 Prooperties of Water to be Used in Humidification System ............23 Table 4 Wheel Tension Setting Table……………………..................25 Table 5 Vibration Reference Values ......................

  • Page 8: General Considerations

    BOREAS A.Ş. does not permit the use and operation of its Air Handling Unit for other purposes than that listed. Any malfunctions that arise from use for purposes other than that listed above are outside the scope of the warranty. Some examples are: using air handling unit sections as shelter, using air handling unit framework as scaffolding in construction sites, and using air handling unit sections as storage areas.

  • Page 9: Installation

    The service doors of chambers should be opened and closed once a month to avoid damage to seals. If the air handling unit includes a power or automation panel the board cover should be opened • to allow free ventilation.

  • Page 10: Freeze Protection

    commissioning be carried out by the BOREAS A.Ş. Technical Service or its authorized installation teams. It is suggested that the maintenance and repair circuit breaker be installed on the unit’s power supply line, and in close proximity to the unit. 1.6 F REEZE ROTECTION...

  • Page 11: Emergency Measures

    4.1.1 Filter Filters can be used optionally at the fresh air intake and return air intakes of the air handling unit. As these filters clean the air, they have a direct impact on the cleanliness and consequently the efficiency of the equipment within the unit.

  • Page 12: Heat Exchangers

    En 1886 tests, there will be risk of caving in unit panels. 4.1.2 Heat Exchangers The following types of heat exchangers can be used optionally in the BOREAS Air Handling Unit: Direct Expansion Refrigerant Heat Exchanger • •...

  • Page 13: Automation Or Power Panel

    4.1.4 Automation or Power Panel The automation system is offered as an option in the BOREAS Air Handling Unit. Since it contains all power and control equipment, the automation panel is sensitive to dust and ambient temperature. Therefore the panel should be checked every 2 months for dust accumulation and the correct temperature.

  • Page 14: Delivery

    ROM THE RUCK AND ANDLING The BOREAS Air Handling Unit is equipped with handling rings for connecting winch rings and transport holes for carriage by forklift. Persons should not stand below suspended loads during the carriage of Air Handling Unit sections.

  • Page 15: Unloading The Unit From The Truck And Carrying The Unit Using A Forklift

    5.1.2 Unloading the Unit From the Truck and Carrying the Unit Using a Forklift Make sure that the forklift forks pass through the forklift holes found on the unit legs and under the entire bottom section. Otherwise, the drainage pan and bottom covering panels located on the underside of the unit can be damaged.

  • Page 16: Assembly And Installation

    NSTALLATION OF THE The BOREAS Air Handling Unit must not be used as any structural part of the structure, in the section of the machinery room where it will be installed. If the unit is used in a way that is assumes functions such as the roof, wall, and load bearing system of the area where it is located, the product warranty becomes void.

  • Page 17: Section Connections In Unit

    Application of this seal is very important in terms of air leakage. • Care should be taken to ensure that the floor on which the air handling unit will be installed is level. •...

  • Page 18: Figure 9 Sealing Of Section Connection

    • Make sure that the clearances specified in Figure 6-7 be left to facilitate service work around the air handling unit. 3x30 mm EPDM seal must be applied to sections’ profile surfaces as shown in Figure 9. Make • sure profile surfaces have been cleaned of oil and dust before applying the seal.

  • Page 19: Duct Connection

    6.3 D ONNECTION Pipe bends for connection are found for duct connections on dampers and flanges. It is important for connections to be made over these bends. Before making the connection, 3x30 mm EPDM seal must be applied to these bends in order to prevent air leaks. Dampers and flanges must not be made to bear the load of ducts under any conditions.

  • Page 20: Heat Exchanger Connection

    6.4.1 Water Heating and Cooling Heat Exchanger The air handling unit may come with a water heating or water cooling heat exchanger depending on project selections. These need to be connected to the water installation for their water supply. The...

  • Page 21: Dx Heat Exchanger (Dx-Direct Expansion Heat Exchanger)

    WARNING: CAUTION! AN EXCLUSIVE DRAINAGE LINE MUST BE MADE FOR THE AIR HANDLING UNIT DRAINAGE CONNECTION. THE CONNECTION TO THE DRAIN MUST BE MADE NOT DIRECTLY, BUT THROUGH A SIPHON. THE AIR HANDLING UNIT MUST NEVER BE DIRECTLY CONNECTED TO THE SEWAGE LINE! 6.5 C...

  • Page 22: Electrical Connection

    The power supply is made within the terminal box. If the air handling unit includes the following sections which require power connection;...

  • Page 23: Air Handling Unit With Panel

    DCC panel. Therefore it is sufficient to connect only the main power supply to the panel. The distribution of power and signal to air handling unit sections is made over the panel. Cable connection terminals are used for cable conduit between air handling unit sections.

  • Page 24: Installation Connection For High Pressure Humidifier Section

    Systems where steam is generated and used with packaged steam units. (Figure 19) • The unit will be delivered with all connections pre-installed on the Air Handling Unit. Make the steam humidifier water supply connection according to the manufacturing firm’s instructions. If you can not find the user manual, contact BOREAS A.Ş.

  • Page 25: Final Cleaning

    Figure 19 Steam Humidifier Connection 6.11 F INAL CLEANING After all assembly work has been completed, all unit components should be checked against getting dirty. WARNING: THE INTERIOR OF THE UNIT MUST BE CHECKED FOR THE PRESENCE OF METAL SWARFS FOLLOWING THE FIELD INSTALLATION.

  • Page 26: Commissioning And Maintenance

    All provisions stated under the heading of 2. GENERAL SAFETY must be applied during the commissioning and maintenance of fans and motors. The following fan types and their lower versions can be used in the BOREAS Air Handling Unit. Backward Inclined Dense Blade Fans (Power Transmission via Belt and Wheel System) •...
  • Page 27 Check the alignment of the wheels. (Tolerance < 5 mm/m) o Check the tightness of bushing connections. Make sure all service doors of the air handling unit are closed. Make sure no one stands behind • the door during initial start-up in positive pressure sections.

  • Page 28: Maintenance

    : PLUG FAN SYSTEMS MUST BE USED WITH THE FREQUENCY INVENTER FOR WARNING CONTROL OF THE MOTOR’S FREQUENCY Installation Machine Good Acceptable Not Permissible Group Fixed, < 15 kW 0.7 mm/s 1.8 mm/s 4.5 mm/s Fixed, ≥ 15 kW 1.1 mm/s 2.8 mm/s 7.1 mm/s With Vibration Insulation...

  • Page 29: Air Filters

    Adjust belt tension 7.2 A ILTERS All provisions stated under the heading of 2. GENERAL SAFETY must be applied during the commissioning and maintenance of air filters. The following filter types can be used in the BOREAS Air Handling Unit:...

  • Page 30: Initial Start-Up

    The recommended filter replacement pressure values are given in Table 6. WARNING: PANEL FILTERS MUST BE INSTALLED ON THE UNIT DURING THE INITIAL START-UP OF THE AIR HANDLING UNIT! IT IS RECOMMENDED THAT BAG FILTERS BE INSTALLED FOLLOWING INITIAL START-UP.

  • Page 31: Heating Water Coil

    7.3 H EATING ATER All provisions stated under the heading of 2. GENERAL SAFETY must be applied during the commissioning and maintenance of heat exchangers. 7.3.1 Initial Start-up The heating system may be designed according to a 90-70°C etc. high temperature water regime. For this reason, use cold water during filling, purging, and air extraction procedures.

  • Page 32: Cooling Water Coil

    Periodic Maintenance of the Water Heating Heat Exchanger: Check whether the heat exchanger conforms to hygiene standards, and check for • accumulated dust, corrosion, and damages. • Purge air in the coil. • Check the inlet and outlet pipe lines for leakages. •...

  • Page 33: Direct Expansion Cooling Coil And Cooling System

    WARNING: IF THE HEAT EXCHANGER WILL NOT BE USED FOR A LONG TIME, PURGE THE WATER WITHIN THE HEAT EXCHANGER. OTHERWISE, THE WATER MAY FREEZE AND DAMAGE THE EXCHANGER. Periodic Maintenance of the Water cooling water coil: • Check whether the heat exchanger conforms to hygiene standards, and check for accumulated dust, corrosion, and damages.

  • Page 34: Maintenance

    • All unit connections must be completed before initial start-up. (Copper pipe connections, Expansion valve connections, etc.) Make sure gas cut-off valves are open. (Liquid Line, Suction Line, Discharge Line, Compressor • Input-Output) 7.5.2 Maintenance It is recommended that maintenance procedures be carried out every three months. These maintenance procedures are of critical importance for both cooling efficiency and the total efficiency of the system.

  • Page 35: Maintenance

    7.6.2 Maintenance The draining system should be checked once a month. Periodical Maintenance on the Draining System: clogging • Check whether the draining system conforms to hygiene standards, and check for corrosion, and damages. The water drainage time should be checked; if it is too slow, the pipe is clogged or there is a •...

  • Page 36: Maintenance

    7.7.2 Maintenance The drop eliminator should be subjected to periodical maintenance at every three months. Periodical Maintenance on the Droplet Eliminator: • Check whether the drop eliminator conforms to hygiene standards, and check for accumulated dust, corrosion, and damages. • The grime which forms on drop eliminator profiles should be cleaned using pressurized water.

  • Page 37: Maintenance

    • Check the tightness of the hermetic seals found in the central body of the rotor. Make sure it does not come into contact with the rotor surface in a way that will damage it. Check the rotor bearing, heed warnings set forth in the manufacturer firm’s user manual. •...

  • Page 38: Plate Type Heat Recovery Unit Heat Exchanger

    7.10 P LATE ECOVERY XCHANGER All provisions stated under the heading of 2. GENERAL SAFETY must be applied during the commissioning and maintenance of the plate type heat recovery heat exchanger. 7.10.1 Initial Start-up Make sure there are no dents or tears on the surface of the Aluminum plate. If there is tearing, •...

  • Page 39: Maintenance

    • Make sure that sufficient amounts of water (completely full) and glycol are added to the system. Make sure cut-off valves on the installation • are in the open position. Power the pump and check the direction of • rotation against the label indicating the direction of rotation.

  • Page 40: Initial Start-Up

    7.12.1 Initial Start-up • Make sure that power connections of the circulation pipe have been made as specified in the manufacturer firm’s user manual. Make sure that the water supply valve is in the open, the water overflow valve is in the open, the •...

  • Page 41: Maintenance

    • Make sure that the pump’s electrical connections are made in accordance with the information provided by the pump manufactuer. Make sure cut-off valves on the water installation are in the open position. • Bring the pump online. • 7.13.2 Maintenance It is recommended that maintenance procedures be carried out every month.

  • Page 42: The Electrical Heater System

    Periodical Maintenance on the Steam Humidifier System: Check steam hoses against leaks. • • Clean steam nozzles on diffusers. • Check the water supply line against leaks. WARNING: DO NOT OPEN THE SECTION DOOR, DO NOT INTERFERE WITH THE UNIT, DO NOT DISCONNECT STEAM HOSES WHEN THE STEAM HUMIDIFIER SYSTEM IS ONLINE! 7.15 T LECTRICAL...

  • Page 43: Silencer System

    Periodical Maintenance on the Electrical Heater System: Check whether the electrical heater conforms to hygiene standards, and check for • section accumulated dust, corrosion, and damages. • Make sure the air flow control, high temperature controls, and door position sensors are functional.

  • Page 44: Troubleshootıng

    Periodical Maintenance on the Silencer System: Check whether the silencer conforms to hygiene standards, and check for • section accumulated dust, corrosion, and damages. • Check silencer surfaces for tears, be sure to replace if there are any torn sections. •...

  • Page 45: Commissioning Request Form

    The fields that have been provided in the following form must be completed in full in order for the unit to be commissioned. Otherwise it will not be possible to commission and adjust the unit. BOREAS AIR HANDLING UNIT COMMISSIONING REQUEST FORM Dear Sir or Madam, Please send us the following form after properly fill out the fields below.
  • Page 46 5- Have the draining system of the unit been installed as indicated in the Installation, Commissioning and Maintenance Manual? 6- Are there any dents on the surface of the unit? Please photograph their locations, if any. 7- Has the waterworks that is required for heating and cooling been installed? Date of Commissioning Request: ………../………../20…..

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