Installation and Maintenance Instructions KLIMA Air Handling Units

1.0 COMMISSIONING 2.0 MAINTENANCE

Before commissioning the unit, ensure that all equipment has been It is the owner’s responsibility to ensure that the air handling
assembled in accordance with the installation procedure all instances equipment is maintained accordingly. In doing so, regular and
where the unit is in operation the access doors should remain closed; scheduled checks will decrease the possibility of unforeseen and
at no time, during maintenance or otherwise, should anyone be inside possibly costly repairs. Maintenance tasks should be taken care of by
a unit whilst it is in operation. a competent person, if system failure occurs due to improper
maintenance, Klima will not be held liable for the costs of restoring
1.1 Commissioning Checklist 4
a unit to its previous working condition.
For unit maintenance, please call KLIMA.
All equipment received is according to
specification/order.
2.1 Fans
Any damage to unit identified. Please refer to general arrangement drawings for details of the type
of fan and drive that is fitted. Maintenance guidelines for all fans are
Fan base shipping restraints / Fixing Brace beyond this manual, please contact Klima for specific concerns.
removed (if applicable). Before any work is carried out, please ensure that:
The correct installation procedure has been carried • The power supply to the motor is switched off.
out in accordance to Klima’s recommendations. • The fan impellor is at rest.
• Measures are taken to ensure that the accidental,
Fan and motor pulleys are aligned.
uncontrolled running of the fan is prevented during
Anti-vibration mounts are adjusted accordingly. maintenance work.
In general, fans should be inspected twice a year, and care should be
Check fan belt tension. taken to ensure that any unusual vibration or sound is investigated as
an urgent matter.
Rotate fan impellors and motors to ensure they
run freely. Access to the fan section is via hinged or lift-off panels. Cable entry
must be made through the apertures provided. Screwed glands with
Check any additional bearings and couplings cable restraint devices should be used.
(where fitted manually).

Condensate drain traps are checked.

2.1.1 General Fan Maintenance
• Access to the fan is normally gained by opening the
Check all filters are correctly fitted. hinged access doors, in some instances there will be a
turn mechanism (1/4 turn) to release and lift panels.
Ensure ductwork is complete.
• Care should be taken to remove any build up of dust
(a light vacuum or light brushing will normally take care
Check electrical supply voltage and tightness of
all electrical connections. of this) Do not use a steam or any other high pressure
cleaners.
Ensure control damper operation. • Inspect the connection between the fan and unit for any
damage or wear and tear.
Ensure access panels and doors are fitted properly
and secure. • In accordance with applicable standars access doors to the
fan modules are lockable. As such, it must be ensured that a
Check fan motor current draw. padlock is used to prevent access when fan is in operation,
or coming to rest (padlock supplied by others).

2.2 Fan and Motor

Care should be taken to ensure that the fan and motor run freely and
that the fan is rotating in the correct direction.
The electrical current being drawn by motors should not exceed the
manufacturers recommendations (specified on the motor plate). If
the current exceeds this, check the fan volume flow rate and the
static resistance.
Inverter should be calibrated to match the design and running
frequency that is provided on the datasheet of each specific unit.

2.3 V-Belt Drivers

Ensure the alignments of pulleys are correct and make any necessary
adjustments. It is important that any residue oil or grease from the
pulleys or belts is cleaned.
Belts should then be tensioned in accordance to the manufacturers’
recommendations. (See the Maintenance section for further detail).

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Installation and Maintenance Instructions KLIMA Air Handling Units

3.1.2 Belt Driven Fans Tensioning Forces Table

If there is a belt driven fan, ensure that the motor and fan pulleys are
Force required to deflect belt
aligned. V belt drives should be checked for wear and tear, and that 16mm per metre of span.
the tension complies with the motor manufacturers’ guidelines.
Belt Small pulley Newton Kilogram
Section dia. (mm) (N) force (Kgf)
Any replacement belts should be the same spec and length as the
ones originally supplied (for details, please refer to the manufacturers SPZ 56 to 95 13 to 20 1.3 to 2.0
100 to 140 20 to 25 2.0 to 2.5
literature).
SPA 80 to 132 25 to 35 2.5 to 3.6
140 to 200 35 to 45 3.6 to 4.6
3.1.3 Belt Tensioning
SPB 112 to 224 45 to 65 4.6 to 6.6
To check the correct tension of a belt drive, apply a force at right
236 to 315 65 to 85 6.6 to 8.7
angles to the centre of the belt span sufficient to deflect the belt
16mm for every metre of span length. SPC 224 to 355 85 to 115 8.7 to 11.7
Check this force with the tensioning forces table. 375 to 560 115 to 150 11.7 to 15.3

Fig. 11: Adjusting the drive belts. Z 56 to 100 5 to 7.5 0.5 to 0.8
A 80 to 140 10 to 15 1.0 to 1.5
B 125 to 200 20 to 30 2.0 to 3.1
C 200 to 400 40 to 60 4.1 to 6.1

3.1.4 Alignment
Good alignment of pulleys is important. Poor alignment will result in
belt flank wear.
Fig. 12: Alignment examples.

Correct (left)
Pulleys are correctly
aligned. Shafts are parallel
and in the same plane.

Angled (below)
Shafts are not in the same
plane.

Angled (left)
Shafts are not parallel.
Corrected by resetting
A new drive should be tensioned at a higher value to allow for the shafts parallel. Ensure no
normal drop in tension during the running period. When the drive deflection is taking place
in supporting framework
has been running for a few hours, tension should be rechecked &
or shafts.
adjusted to the higher value.
Care should be taken to tension the drive at regular maintenance
intervals. A belt tensioning indicator can be purchased to ensure Offset (left)
accuracy. Pulleys are offset.
Corrected by moving
either pulley along the
shaft until aligned.

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Installation and Maintenance Instructions KLIMA Air Handling Units

3.2 Bearings Gas Burner

The bearings that are fitted will be (unless otherwise specified) If a gas burner is intended to be used with low air on temperature
“sealed for life”, therefore consequence maintenance is not required. please discuss with Klima prior to order placement to ensure a
suitable component selection.
Fan bearings are lifelong; up to 40,000 hours of operation.
In cases of heavy duty operation, maintenance intervals are
to be established by the operator. 3.7 Heat Exchangers

3.3 Rotation
Isolation - Before commencing work
Ensure that the directions of rotation of the driving motor are make sure that the unit is electrically isolated from
checked and operating correctly. the mains unit and sufficient time has passed to allow the
fans to run down (5 minutes minimum).
3.4 Filters
When removing the filter access panels, pay attention to the airflow
The recuperator block is normally protected from dust and
direction marked on the panel, this must be replaced to the exact
contamination by upstream pre-filters. It is possible to clean the unit
position prior to being removed. Disposable filters should be checked,
with compressed air in the case of dust deposits or by spraying with a
and changed when they become fully laden with dust. Washable
mild detergent solution for grease deposits.
filters should be removed and washed in a mild detergent, flushed
with clean water and allowed to dry before refitting. Solvents, strong alkaline, acidic or any products that may be
aggressive to aluminium or plastics should not be used. Do not use
cleaning water over 50 deg C.
3.5 Humidifiers
Drain lines should be checked to ensure that they are unobstructed
Any areas of corrosion should be identified and repaired, any and free draining. Traps should be checked that they are fully primed
sediment from the drain tray and connections should also remain and functioning.
clean.
Drain pans should be flushed out periodically to remove
Spray Coil/Washer Humidifier Module. contamination, and chemical treatments may be used to provide
All nozzles should be checked and cleaned as necessary. protection between service visits.
Care should also be taken to ensure that the pump is handling the
correct volume of water and is in smooth and quiet operation. The
pump inlet strainer should also be clean.
Check for leaks, pay special attention to the shaft seal. If the unit contains a thermal wheel heat exchanger, please
Remove all filters and clean and ensure that the motor is not ensure that the rotation sensor is aligned with the sensing
overheating. studs, as this can become misaligned during
transport/installation thus causing a fault signal.

3.6 Coils
Water
Water coils should be connected to ensure that full counter flow 3.8 Legionella Check
exists i.e. - the entering airflow meets the return connection.
Legionella risk management should be undertaken by a competent person
All water coils should be connected with the flow at the bottom and
appointed by the duty holder in accordance with the latest edition of the
the return at the top unless otherwise advised. Drain and bleed valves
are located on the coil, others may be required in the system pipe- HSE approved code of practice L8 Legionnaires' disease, the control of
work depending on the installation. legionella bacteria in water systems.
Frost protection must be incorporated on shut down and fresh air
conditions to avoid coil freezing. Ideally, where the system is at risk of Particular attention should be given to:
frost damage, the addition of a proprietary antifreeze solution to the • Exhaust heat recovery coil.
water is recommended.
• Cooling coil.
Pipe-work connections should be made to the unit using appropriate
• Humidifier condensate drip tray water.
techniques, and must be independently supported. The connections
should be pressure tested. • Evaporative humidifier.
• Cooler drains.
DX • Water reservoirs.
Direct expansion coils must be fitted with a correctly sized
thermostatic expansion valve with an external equalising connection.
The expansion valve phial must be fitted between the suction header 3.9 Electric Heaters
connection and the equalising line. The recommendations of the TE An Air handling unit would normally require no heater maintenance.
valve manufacturer should be referred to when locating the phial and However a periodic check is advised to ensure that the fasteners and
adjusting the superheat. In all cases, settings should be in accordance electrical connections are operating correctly.
with the recommendations of the manufacturer of the refrigeration It is strongly recommended that an airflow switch is incorporated
equipment. within the control system with a fan run on timer (15 minutes) and
All cooling coil drains must be connected to the sloping drain with a an interlock provided between the heater contactor and fan motor
correctly sized trap running to an open tundish or similar. starter – to allow elements to cool on shutdown.

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Installation and Maintenance Instructions KLIMA Air Handling Units

3.10 Bulkhead Lights 3.13 Warranty

Ensure that lights are switched off and isolated before checking or KLIMA AHU has a 12 months parts and labour warranty.
changing the lamp.
This warranty is void if the equipment is modified without
authorisation, is incorrectly applied, misused, disassembled, or not
3.11 Specialist Equipment installed, commissioned and maintained in accordance with the details
Contact Klima for maintenance of specialised equipment that would contained in this manual and general good practice.
have been specified during design stage. A breakdown of the
component parts can be found on the design specification
documents, additional maintenance literature is available, please
contact Klima. This applies to any components not specifically
mentioned in this document.

3.14 After Sales

3.12 Maintenance Schedule
For technical assistance or further product information, including spare
It is important that maintenance checks are recorded and that the parts and replacement components, please contact the After Sales
schedule is always adhered to, in all cases, the previous report should Department.
be referred to.

Telephone 442 462 9538 E105

Particular attention to the items mentioned below should be
considered:
• Routine Maintenance. [email protected]
• Any areas of corrosion should be treated and all areas
of the unit should be cleaned.
• Any drain trays should be cleaned and repaired if
necessary.
• Check all access doors for leakage and if necessary,
locks should be adjusted and any replacement gasket
materials should be replaced as required.

Every 3 months
• Check filters and change/clean if required.
• Check fin coil banks and heat exchangers. If necessary
clean with a soft brush or vacuum. Also check for
signs of contamination.
• Check fan belt tensions and pulley/belt wear.
• Ensure condensate drains are cleaned clear and that
water can flow feely from unit.
• Clean unit casting and ensure that any corrosion is
addressed by treating.
• Filter magnahelic gauges should be checked and
topped up with fluid.

Every 6 Months
• Ensure all locks and hinges are lubricated and
adjusted as required.
• Check control dampers blades.
• Check operation of damper actuators and linkages
and adjust as necessary.

Annually
• All electrical terminals within the unit should be
tightened.
• Coil faces should be inspected and any dust removed.
• Thoroughly inspect the unit and its components for
erosion, acting immediately to treat/restore any
damaged areas.
• Check all earth connections.

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Installation and Maintenance Instructions KLIMA Air Handling Units

3.16 Service Chart

3 Month/9 Month Service 6 Month Service 12 Month Service

Symbol Action Date Action Date Action Date

Initials Initials Initials
Damper Air Check the damper 3 Check the damper Clean the damper.
recirculation section. performance. performance. Check the damper
Air recirculation performance.
section. 9

Filter. Check the pressure 3 Check the pressure Check the pressure drop
drop and change the drop and change the and change the filter if
filter if necessary. filter if necessary. necessary.
9

Rotary heat General inspection. 3 Clean the rotor. Clean the rotor.
exchanger. Check the seals. Check the monitoring
and purging equipment.
9

Plate heat General inspection. 3 Clean the heat Clean the heat
exchanger. Check the damper exchanger unit. exchanger unit, damper
performance. and casing.
9

Heat-pipe General inspection. 3 Clean the finned unit. Clean the finned unit,
exchanger. Check the damper damper, drain tray and
performance. casing.
9

Air heaters. General inspection. Clean the finned unit Clean the finned unit,
3
Air coolers. and the electric heater electric heater
Pipework package. elements. elements, drain tray &
casing. Inspect the
9 pipework package.

Humidifier Inspect the: Inspect the: Inspect the:

Casing, Casing, Casing,
Humidifier fills, Humidifier fills, Humidifier fills,
IHUMID
Droplet eliminator, 3 Droplet eliminator, Droplet eliminator,
Water filter, Water filter, Water filter,
Water tray, Water tray, Water tray,
Spray pipes and Spray pipes, Spray pipes,
Water flow. Water trap, Water trap,
Water flow and Water quality,
Constant-flow valve. Water flow and
9 Constant-flow valve.

Fans General inspection. General inspection. Clean the fan impeller,

3 casing, unit casing.
Check the bearings.
9

Belt drive General inspection. Check the belt Check the belt
3 tension. tension.

Casing Check that the doors

are tight. Clean the
inside if necessary.