ahu manual

Johnson Controls Marine 1

Air Handling Unit Manual

YORK Marine


Index

Introduction____________________________________________________________________ 4

TEST - PACKING - TRANSPORT ________________________________________________ 5

1.1 TEST __________________________________________________________________________ 5

1.2 PACKING _____________________________________________________________________ 5

1.3 TRANSPORT __________________________________________________________________ 5

1.4 PRELIMINARY CHECK _________________________________________________________ 6

INSTALLATION________________________________________________________________ 7

2.1 POSITIONING __________________________________________________________________ 7

2.2 SECTIONS CONNECTION________________________________________________________ 7

2.3 HYDRAULIC CONNECTION _____________________________________________________ 7

CONDENSATE DISPOSAL _________________________________________________________________ 7

HUMIDIFICATION ________________________________________________________________________ 8

COILS ___________________________________________________________________________________ 8

2.4 Electrical connections ___________________________________________________________ 9

MOTOR_________________________________________________________________________________ 9

SERVO-MOTOR _________________________________________________________________________ 9

ELECTRIC HEATER ______________________________________________________________________ 9

2.5 FAN____________________________________________________________________________ 9

2.6 FILTER_______________________________________________________________________ 10

2.7 AIR DUCTS CONNECTION______________________________________________________ 10

2.8 START-UP _____________________________________________________________________ 10

MAINTENANCE______________________________________________________________ 10

3.1 FILTER SECTION ___________________________________________________________ 10

3.2 COIL SECTIONS _______________________________________________________________ 11

3.3 Drip tray_______________________________________________________________________ 11

3.4 HUMIDIFICATION SECTION ___________________________________________________ 12

3.5 FAN SECTION ________________________________________________________________ 12


3.6 Dampers _______________________________________________________________________ 16

3.7 SPECIAL SECTION _____________________________________________________________ 16

3.8 VARIOUS CHECKS _____________________________________________________________ 16

PROBLEMS AND INCONVENIENCES ___________________________________________ 16


Introduction

The purpose of this manual is to provide the service and commissioning engineer with the necessary

knowledge of how to install a York Marine AHU and maintain its functions.

In order to secure the quality of installation and functions the contractor must have the guidelines of

this manual in mind.

Besides describing a correct installation, the manual draws attention to sources of concern.

It is imperative that the engineer familiarizes himself with the content of this manual to ensure a

reliable and efficient operation of the AHU, as York is unable to provide guarantee against damages

occurring during the warranty period if the cause is incorrect installation or use.


TEST - PACKING - TRANSPORT

1.1 TEST

Following tests are performed before the shipment:

DIMENSIONS CHECK

ASSEMBLED COMPONENTS CHECK

MOTOR - FAN PULLEYS BALANCING AND ALIGNMENT CHECK

FLEXIBLE JOINTS LOCKING ( IF NECESSARY )

GASKETS CHECK

SERIAL NUMBER AND NAME PLATE

1.2 PACKING

The unit is packed with air bubble nylon and all the projecting parts are protected.

1.3 TRANSPORT

We advise to pay particular attention to loading and unloading operations.

Projecting parts must not be used as grip points to move, load or unload the AHU.

During transport the AHU must be tightly fixed in order to avoid damages due to the load

movement.

The AHU can be delivered in separate sections to facilitate transport and positioning.

Holes in the base are made for tubes fixation in order to allow the lifting cables anchoring

when lifting with a crane.

The connection of the various sections composing th e unit is carried out by means of

galvanized bolts. The bolts are to be inserted in the holes in the connection frames. A sealing

gasket is placed on the section’s contact perimeter.

It is extremely important that the air handling unit is put on an appropriate flat base.


1.4 PRELIMINARY CHECK

When the unit is delivered, check that it has not been damaged during transport. The identification

label must show the correct AHU model and capacities.

The following should be checked:

A) FAN - MOTOR

Manually turn all the shafts to make sure they turn freely.

Clean the fan from any dirt before connecting to ducts and before testing the AHU.

Check that the fan blades have not been damaged.

Check the inspection doors and handles.

B) COILS

Check that manifolds, threading and flanges have not been damaged.

Check that coil fins are not damaged (crushed or crooked) or dirty. In this case restore parts and clean

the pad to avoid clogging.

C) FILTERS SECTION

Check that filters are inserted in their seats and are clean.

D) HUMIDIFICATION SECTION

Check the pump operation.

Check the valve or valve board.


Check steam generator if selected.

E) SECTIONS CONNECTION

Check that all the sections are perfectly connected with their screws.

Check the parts sealing (gaskets).

NOTE: THE FAN MUST NOT BE RUNNING AND THE MAIN SWITCH

MUST BE OFF BEFORE ANY INTERVENTION INSIDE THE MACHINE

INSTALLATION

2.1 POSITIONING

It is extremely important that the air handling unit is mounted on an appropriate solid flat base.

It is advisable to position the AHU so that normal maintenance is possible, leave sufficient space

on the service side.

2.2 SECTIONS CONNECTION

The connection of sections should be carried out with galvanised bolts inserted in holes on

the connection frames. A sealing gasket is p laced on the sections contact perimeter.

2.3 HYDRAULIC CONNECTION

CONDENSATE DISPOSAL

Coil and humidification sections are provided with a drip pan. The water trap ensures that

condensed water is lead away from the AHU, and also preventing air from entering the AHU from

the discharge connection.


HUMIDIFICATION

SHIP STEAM

Connect the steam pipe to the solenoid valve mounted on the steam humidification manifold.

Check that connections are made correctly and sealed.

STEAM GENERATOR

Mount the steam generator according to the manufacturer’s guidelines.

WATER/AIR SPRAY NOZZLE HUMIDIFICATION

Connect the supply pipes with water and air to the marked inlets on the valve board.

Before connecting make sure that connections are not damaged or dirty. Check the pipes and ensure

that they are mounted to satisfaction. Check the nozzle in the humidification section.

Close the manually operated regulating valves. Set pressure on the system. Adjust to the desired

pressure by opening the regulating valve, the pressure is shown on the manometers.

COILS

COILS SUPPLIED BY WATER should be connected following the rating plate details; the fluid

must run in counter-current compared to the air flow.

Avoid hydraulic connections and prevent the coil from being extracted.


STEAM COILS have pipes inclined towards the outlet manifold to facilitate the condensate disposal.

To avoid damages to the coil pay attention to the dimensioning and to the valves adjustment.

DIRECT EXPANSION COILS need adjustment devices and a circuit dimensioning in order to

ensure the oil circulation.

2.4 ELECTRICAL CONNECTIONS

MOTOR

Electric connections must be made according to norms and regulations. Check that the voltage and

the type of power supply correspond to the one shown on the motor name plate. Pay attention during

disassembly and reassembly of the terminal block cover that the gasket should be mounted in its

seat in order to prevent humidity from penetrating. Check the fan rotation direction, in case it is

incorrect invert two of the supply cable phases.

SERVO-MOTOR

SERVO-MOTOR use and maintenance, see manufacture guidelines.

ELECTRIC HEATER

Electric heaters have the circuit connection inside the heater panel. Remember to use a safety

thermostat for protection when mounting the electric heater.

2.5 FAN

Remove transport locks from the fan base frame and locks on other flexible joints.

Check pulleys alignment and electric connections by following the instructions given in the

maintenance programme, paragraph 3.4


2.6 FILTER

Bag and plan filters should be assembled in the unit approximately after half an hour of machine

operation to clean ducts from dust due to assembly operations.

CHECK THAT FILTERS ARE INSERTED IN THEIR

GUIDES OR FRAMES

2.7 AIR DUCTS CONNECTION

Operations to be carried out are the following:

Clean the flange and position the sealing gasket.

Tighten all the fixation screws.

Put duck tape around the connection to optimise the sealing.

Support ducts to avoid that the duct’s weight is supported by the AHU.

2.8 START-UP

After checking all components proceed to start-up. When starting-up the unit check:

Check dampers calibration.

Check the fan rotation direction.

Frequently check the belt’s tension during the first 24-48 hours.

Check the motor power supply.

Check that filters are inserted in their guides or on proper frames.

Check humidification system.

MAINTENANCE

All the panels can be removed by unscrewing the screws that fix them to the bearing frame.

3.1 FILTER SECTION

PLAN FILTERS

The plan filter is made of synthetic fibres.


Cleaning of the cells can be done with compressed air or by washing with water. When using

compressed air, be careful not to damage the filter by using a high pressure. The air stream must

be blown in the opposite direction then the air flow is through the filter.

The cleaning interval is approximately 15 days.

Check during operation if the interval should be increased or decreased. At start-up check

the filters more frequently.

BAG FILTERS

The high efficiency filtration is achieved by soft and rigid bag filters.

Bag filters cannot be regenerated therefore the filter must be replaced when dirty.

Bag filters are assembled on frames. To disassemble the filter remove the fixation springs and

slide the filter from the frame. Insert the new filter and secure with the fixation springs.

3.2 COIL SECTIONS

Check that the space between the fins is clean. If dirty use low pressure steam to dissolve and

clean fins and coil. Caution must be shown to avoid damaging or bending the fins.

The heating coil must be protected against freezing up, when not in use. Use an antifreeze

thermostat to secure the heating coil, or use a heating medium that does not expand when

exposed to frost.

3.3 DRIP TRAY

Regularly check that the condensed water can pass the drip tray outlet and water trap. Avoid

clogging of the water discharge pipe.


3.4 HUMIDIFICATION SECTION

WATER/ AIR NOZZLE HUMIDIFICATION

Frequently check the manometers to ensure correct pressure setting. Check the nozzles

operation with the fan not operating. If the nozzle is not working properly close the shut off

valves on the valve board, both lines. Unscrew the front of the nozzle and clean. Use compressed

air or metal wire of adequate diameter to clear openings.

HIGH PRESSURE STEAM HUMIDIFICATION

Check that the connections are tight-fitting and the solenoid valve is working. To clean the

high pressure steam nozzles, shut off the power and the solenoid valve closes. Dismount the

nozzles and clean with compressed air or metal wire with an adequate diameter.

3.5 FAN SECTION

FAN

Periodically check the centring of the impeller compared to the shaft and its fixation system.

Check there is no slipping of the impeller on the suction inlets.

Remove grease and dirt deposits on the impeller blades. During operation check the bearing

condition by listening to its noise level.

Check the lubricant condition. Radial bearings, lifetime lubricated, have been mounted in machines

where the power to the shaft is low. These bearings are due to work for a minimum operating

lifetime of 20,000 hours.

Fans, where the power to the shaft is higher, are provided with radial bearings housed in cast iron

supports with the possibility of greasing.

Types of grease for bearing lubrication.

Brand Type Base soap Operating temperature

FINA MARSON HTL 3 LITIO -30°C 120°C

SHELL ALVANIA FETT 3 LITIO -20°C 130°C

ESSO BEACON 3 LITIO -20°C 130°C

MOBIL MOBILUX 3 LITIO -30°C 130°C

BEARINGS REPLACEMENT WITHOUT FANS MONOBLOCK

SUPPORT

Remove possible accessories assembled on the fan shaft on both sides.


Hold, with an adequate device, the fan shaft, giving the possibility to carry out the

following operations, without damaging the impeller or the fan inlets.

Unlock the bearing eccentric ring, paying attention to unscrew the threaded grub fixing it.

By slight pushes make the bearing turn, for instance with a hammer or punches. Repeat

the operation for the other bearing and slide off the fan shaft rings.

Disassemble the dial that holds the bearings by unscrewing the fixing bolt on the fans

side.

Remove the bearings from the shaft, with the help of an extractor.

Reassemble the dials, pay attention to the new bearings that are equipped with rubber

dampers, these should also be replaced.

Insert the bearings equipped with dials in the fan shaft on both sides by approaching

the fan sides in correspondence to the fixation holes.

Insert the eccentric rings and fix them by tightening the threaded grubs.

Manually turn the impeller and make sure there are no anomalous tensions in its

movement or in the bearings movement.

These bearings are “lifetime” lubricated. Their theoretic life time is 20,000 hours, in

normal operating conditions. The temperatures range for these bearings range from

-30°C to +85°C.

BEARING REPLACEMENT IN THE FAN

MONOBLOCK SUPPORTS

Remove possible accessories assembled on the fan shaft on both sides.

Hold, with an adequate device, the fan shaft, giving the possibility to carry out the

following operations without damaging the impeller or the fan inlets.

Unlock the eccentric ring locking the bearing, paying attention to first unscrew the

threaded socket head screw fixing it.

Remove the elastic plugs from bearings cast iron supports.

Unscrew the fixation screws from the fan frame supports.

Remove bearings equipped with supports from the shaft, paying attention to carry out the

operation without damaging the shaft.

Remove bearings from cast iron supports by turning them on their axis, then extract them

from the support.


Insert the new bearings in the cast iron supports.

Insert them in the fan shaft.

Place the bearing supports on the fan frames, insert the elastic plugs.

Screws on bolts for the support fixation.

Observe the centring of the impellers compared to the fan inlet. Make sure that it is

rotating without friction.

Insert the bearing eccentric rings and tighten them in the shaft direction of rotation, lock them

by screwing the threaded socket head screw.

Manually turn the impeller and make sure there are no anomalous tensions in its

movement or in the bearings movement.

These bearings can be greased. The temperatures range for these bearings range from

-30°C to +110°C.

PULLEYS

The drive is composed by pulleys removable hub type, and “V” belts widely dimensioned.

In order to replace the pulley, follow these instructions:

DISASSEMBLY

Fully loosen all the threaded grub screws, which lock the pulley to the bushing .

Insert one of these grub-screws into the threaded extracting hole.

Tighten the grub-screw until the pulley loosens from the bushing.

Completely remove the pulley and the socket head screw from the shaft.

ASSEMBLY

Clean and degrease the socket head screw hole and the external surfaces and the conic

housing of the pulley. Insert the socket head screw in the pulley hub and align holes

(the half threaded holes must be aligned with half non threaded holes).

Slightly oil the threaded grubs and screw them on, but without tighten them fully.

Clean and degrease the shaft, insert the pulley and the socket head screw on the shaft till

the desired position is reached.

Using an Allen wrench gradually tighten the grubs to the pulley is completely locked.

After having operated the drive under load for a short time (from 24-48 hours), check

again the torque wrench setting.

With every change of pulley, check their alignment with figure


BELTS

Frequently check the belt’s tension during the first 24-48 hours. An over tensioning reduces the life

of belts and bearings. Keep the belts free from foreign materials that could cause slipping.

Periodically check the drive. Tension it when it slips. The belt should be shortened in the junction

point.

To check a drive tension, use the following procedure

Measure the free section length L.

Apply a force P in the centre of the free section.

Measure Fa and check this value with the one

obtained from the table below.

Fa absolute = L:100xE

Adjust the Fa value to the data read in Fa absolute.

Belt cross section Force applied (kg) Pulley diameter Belts flex. For 100mm of L

E(mm)

SPZ 2,5

71-90

90-125

>125

2,20

2,05

1,90

SPA 5,0

71-100

100-140

140-200

>200

3,20

2,75

2,55

2,45

SPB 7,5

112-160

160-224

114-355

>355

3,00

2,55

2,22

2,10

SPC 12,5

180-250

250-355

2,55

2,20


355-560

>560

2,00

1,90

TO ADJUST THE DRIVE BELT TENSION USE THE TENSION SCREW ON THE SLIDE CENTRAL

3.6 DAMPERS

Dampers made of galvanised sheet metal needs levers greasing every 3 months, while dampers

made of aluminium only need a normal cleaning.

3.7 SPECIAL SECTION

3.8 VARIOUS CHECKS

Periodically carry out the following controls

Check if panels, doors and connections have air leakage

Check electric cable condition, especially in the humidification sections

Check possible water leakage in hydraulic circuits

PROBLEMS AND INCONVENIENCES

CAPACITY

Fluid temperature: - Check the fluid temperature.

Regulation valve: - Check power supply to valve and the operations of the valve.

Hydraulic connection: - Check the coil connection.

LOW HUMIDITY

Dirty nozzles: - Clean the nozzles.

Dirty filter: - Clean or replace the filter.

Insufficient water level: - Check the hydraulic circuit.

HIGH NOISE LEVEL


Failed locking- damaged vibration damper- bearings for fan - motor section: - Close panel/door or

replace vibration damper, bearings.

Foreign body has entered the fan impeller: - Check and remove the foreign body.

Squealing due to ducts or air leakage from connections: - Check all joint.

PROBLEMS AND INCONVENIENCES

LOW AIR FLOW

The damper is not adjusted correctly: - Calibrate the damper.

The rotation of the fan is incorrect, belt is slipping: - Tighten the belts tension.

Dirty coils or filter: - Clean coils or filter.

Check duct work: - Clean duct work and open dampers in the duct system.

HIGH AIR FLOW

The damper is opened too much: - Calibrate the damper.

The filters are not fitted in their guide: - Check that filters are fitted correct in the guide.

Panel or inspection doors are opened: - Closed the inspection doors and panels.

Check duct system: - Check that all sections are calibrated correctly.

ELECTRIC MOTOR STOP

Safety device cuts motor out: - Check tension of belt.

Safety device cuts motor out: - Check that the fan impeller is not blocked.

Safety device cuts motor out: - Measure that the insulation resistance for each winding is ok.

Motor not running: - Check power supply and cable.

ahu manual

Documents

filter section

humidification section

fan section

sections connection

special section

york marine ahu

correct installation

quality of installation