1

TABLE OF CONTENTS
SECTION PAGE

INTRODUCTION ...................................................................................................................................3 NOMENCLATURE.................................................................................................................................4 PRE-INSTALLATION

RECEIVING .......................................................................................................................................................... 5 STORAGE ............................................................................................................................................................ 5 LONG-TERM STORAGE...................................................................................................................................... 5 HANDLING AND RIGGING .................................................................................................................................. 6

COMPONENTS ARRANGEMENT
PHYSICAL DIMENSION.. ................................................................................................................................... ..8 UNIT SHIPPING WEIGHTS (LBS)...................................................................................................................... 10 DISCHARGE ARRANGEMENTS ....................................................................................................................... 11 BLOWER ARRANGEMENT................................................................................................................................ 12 QUICK SERVICE ACCESS ................................................................................................................................ 12 COIL SECTION................................................................................................................................................... 12 FAN SECTION.................................................................................................................................................... 13 MOTOR LOCATION ........................................................................................................................................... 13

UNIT FEATURES AND ACCESSORIES

UNIT ASSEMBLY PLANNING ............................................................................................................................ 14 FAN BEARINGS ................................................................................................................................................. 15 VIBRATION ISOLATION..................................................................................................................................... 15

INSTALLATION
CLEARANCE 16 SECTION ASSEMBLY .16 CONDENSATE DRAIN TRAPS .......................................................................................................................... 17 DUCT CONNECTIONS....................................................................................................................................... 17 FAN SYSTEM ..................................................................................................................................................... 19 LEVELING FAN DECK ASSEMBLY .19 SHEAVES AND BELTS 20 GENERAL PIPING PARAMETERSWATER COILS .22 STEAM COILS ..23 DIRECT EXPANSION COILS .24 DAMPER ACTUATORS...................................................................................................................................... 25 ELECTRIC HEATER .25 DIFFERENTIAL PRESSURE GAUGE ..26 VFD .. ... ..27

OPERATION
START-UP PREPARATIONS ............................................................................................................................. 28 PRESSURE DROPS........................................................................................................................................... 29 OPERATING LIMITATION .......................................................................................................................... 30

MAINTENANCE
PERIODIC INSPECTION.................................................................................................................................... 31 ANNUAL INSPECTION....................................................................................................................................... 32 TROUBLESHOOTING CHART................................................................................................................. 33

INTRODUCTION
The Dunham-Bush Central Station Air Handling Units provide air conditioning at nominal capacities of 1200 to 640,000 CFM. The air handing unit has a design that allows hundreds of different configuration possibilities. Each unit is assembled to meet specific job requirements and can be shipped in sections or as a single assembly. This manual has been prepared as a guide for installing, operating and maintaining the DunhamBush central station air-handling units. Proper installation, operation and maintenance is essential to ensure lower first cost, longer equipment life and high overall operating efficiency. Dunham-Bush central station air-handling units are designed for cooling, dehumidifying (or humidifying), heating, ventilating and filtering. It is best suited for high-rise buildings, big industrial plants, hospitals, shopping centres, computer rooms and many other centralised systems. Its sectionalised design enable full lines of accessories to be attached to accommodate various applications. Every air-handlers is designed and tested by experienced engineers. It is fabricated with rigid galvanized steel frame work and thick gauge galvanized steel panel for rugged handling operation. It is subjected to rigid quality control standards to give the most efficient, reliable and economical performance possible.

MODULAR DESIGN

RETURN AIR FAN SECTION

ECONOMIZER

PREFILTER, COOLING COIL AND SUPPLY AIR FAN SECTION

BAG FILTER SECTION

DISCHARGE DAMPER

NOMENCLATURE
Each unit nameplate will carry the unit model designation. The following gives a sample nomenclature of Dunham-Bush air-handlers AH FS 100 H L

Air Handler Single Skinned AHD= Air Handler Double Skinned

AH=

L= Low Pressure Unit Up To 3.5 TSP M= Medium Pressure Unit Over 3.5 TSP

FS= AF= BF=

Forward Curved Wheel Air Foil Wheel Backward Curved H= Horizontal V= Vertical M= Multi Zone

Unit Size = Nominal CFM 100

PRE-INSTALLATION
RECEIVING
All units leaving Dunham-Bush factory have been thoroughly checked to ensure the shipment of quality products. We guarantee that all air-handlers are properly packaged. Cautions: Dunham-Bush Industries Sdn Bhd will not be responsible for any damages or loss parts in shipment or at the job site. Report any shipping damage to nearest DunhamBush office immediately. Carefully inspect all shipments immediately after delivery. When damage is evident, note this fact on the carrier's freight bill and request that the carrier send a representative to inspect the damage. This may be done by telephone or in person, but should always be confirmed in writing. The shipment should be unpacked in the presence of the agent so that the extent of damage or loss can be determined. The carrier's agent will make an inspection report and a copy will be given to the consignee for forwarding to the carrier with a formal claim. Do not report missing items until you have thoroughly checked the units because bolts, belts or other small item's might be packed inside the units.

STORAGE
If equipment is stored out-of-doors, special care should be taken to protect against moisture, corrosion and dust. Wheels should be covered to prevent unintended location by wind. Equipment, when stored under such conditions, must be periodically inspected to stop trouble from developing.

LONG-TERM STORAGE
If storing unit before installation, observe the following precautions, 1. The storage site should be level, rigid, and free of debris. If the site is in a heavy rain area, set the unit off of the ground. 2. Do not store the unit in a heavy traffic area or on a vibrating surface. Vibration can damage stationary bearings. 3. Monthly move the coverall, enter the fan section through the access door, and slowly rotate the fan and motor by hand. This operation prevents bearing corrosion by redistributing the bearing grease. 4. On no occasion should anything be stacked on top of the units. The elapsed time for the warranty prevails even though the units are in storage.

PRE-INSTALLATION
If your inspection indicates that the unit is ready for installation, move it to the desired location. Evaluate the job site by considering the following points: ( l.) Is the floor or foundation level enough to support the weight of the unit (the minimum foundation shall be 4 times the rotating mass of the fan and drives or about double of the units weight). Refer to table 1 to 5 (Page 8-10) for weight and dimensions. ( 2.) Is there sufficient space for making piping, draining and wiring connections, and this space accessible. ( 3.) Is there adequate space for servicing the unit, and for removing or opening the access doors. A minimum clearance equal to the width of the units must be provided on one side of the unit for removing the coil, shaft and wheel. ( 4.) How ductwork is to be done and is there enough space for ducting. In extreme cases when it is necessary to completely isolate any vibration from the airconditioner which can adversely affect any other nearby equipment, it is recommended that either one of the following methods be followed: ( 1.) Provide a separate floating plinth. ( 2.) Place the unit on a minimum 2.5" thick cork sheet. ( 3.) Support the complete unit on spring isolators. Request factory to provide correct spring isolators and mounting brackets at base units. For stringent quiet and vibration-free application, a good acoustical and vibration engineering practice has to be applied. Ideally, a heavy concrete slab should be used for floor mounted units, and main support beams for ceiling hung units. Long floor or ceiling spans should be avoided.

HANDLING AND RIGGING

Proper handling and rigging procedure should be exercised to prevent damages. Some units are completely assembled and should be handled carefully to avoid dropping or jarring. Others are shipped in a few sections or completely knock-down. Care is required in handling the individual parts. Fan wheels, casings, coils that are furnished with extra protective coatings must be handled with extreme care, as an injury to the coating can result in a break of continuity and this will destroy permanently the value of the protective covering for the metal. Any such rupture of coating, due to mishandling, is not covered by the guarantee.

PRE-INSTALLATION
Air handling units are shipped on strong plastic package or crate with sections bolted as determined by lorries or trailer size limitations. When lifting with slings, use spreader bars across the top of the units to avoid damaging panel or framework. Caution must be exercised to avoid damages to any sections. Check the weight of the units before rigging. Try to place the rigging cable such that the weight is evenly distributed. Lifting cables should not be attached to the extremities of the accessory sections without intermediate support at the basic units. The feet on the accessory section are provided for isolator mounting and not designed for rigging connections and must not be abused. All fan outlets are covered with cardboard. Remove it just prior to when the duct is connected to the unit.

The maximum permissible load is restricted by the lifting capacity of the slings

Suitable extension should be used in case when fork of the forklift is too short

FIGURE 1

COMPONENTS ARRANGEMENT
PHYSICAL DIMENSION
1.) HORIZONTAL TYPE

Note: For 2 panel add 2 at A, C, D. Add 2 at B for model up to 320 and 4 for model 420 onwards.
Model A B C D 12 34 49 26 1/2 22 46 50 30 32 48 54 34 40 58 60 36 1/2 48 68 60 38 64 74 62 43 80 76 66 49 100 76 66 56 120 92 66 56 150 92 70 70 180 102 78 72 240 120 86 80 1/2 270 128 86 84 320 146 86 84 420 154 122 96 86 520 154 122 108 1/2 86 640 184 126 108 1/2 90

2.) VERTICAL TYPE

Note: For 2 panel add 2 at A, B, H1 and H2. Add 2 at C for model up to 48 and 4 for model 64 onwards.
Model A B C H1 H2 12 34 25 1/2 52 22 46 29 57 32 48 33 67 40 58 35 1/2 72 48 68 40 1/2 73 64 74 41 1/2 84 1/2 41 1/2 43 80 76 45 94 45 49 100 76 49 105 49 56 120 92 49 105 49 56 150 92 54 124 54 70 180 102 59 3/4 131 3/4 59 3/4 72 240 120 68 150 1/2 70 80 1/2 270 128 68 154 70 84 320 146 70 159 75 84

3.) MULTIZONE TYPE

Note: For 2 panel add 2 at A, D, E and H2. Add 4 at B. Add 2 at C for model up to 120 and 4 for model 150 onwards. Add 2 at H1 for model 150 onwards.
Model A B C D E H1 H2 22 46 68 47 28 40 18 29 32 48 73 52 33 40 18 34 40 58 83 1/4 54 1/2 35 1/2 48 18 36 1/2 48 68 88 1/2 56 40 1/2 48 18 38 64 74 97 1/2 65 41 1/2 56 22 43 80 84 101 71 45 56 22 49 100 84 113 80 49 64 24 56 120 100 113 80 49 64 24 56 150 100 128 98 54 74 28 70 180 120 133 1/2 100 59 1/2 74 28 72 240 120 152 112 1/2 68 84 32 80 1/2 270 128 152 116 68 84 32 84 320 146 156 124 70 86 40 84 420 154 172 133 1/2 86 86 40 93 1/2 520 154 172 156 1/2 86 86 48 108 1/2 640 184 180 156 1/2 90 90 48 108 1/2

Notes: 1.) All dimensions are in inches. 2.) Spring type isolators are for standard fan of model AF 64 onwards and FS 80 onwards only, the rest will be rubber isolator mounting. 3.) L/H motor and R/H piping shown.

COMPONENTS ARRANGEMENT
PHYSICAL DIMENSION
4.) DIMENSIONS FOR ACCESSORY SECTIONS
FAN ONLY COIL MODULE EXTERNAL FACE AND BYPASS (See Note 4) INTERNAL FACE AND BYPASS

B
STANDARD MIXING BOX COMB. ANGLE FILTER MIXING BOX ANGLE FILTER SECTION

B E

B E B

A E E

BAG AND FLAT FILTER SECTION

DIFFUSER SECTION

SILENCER

Model A Fan Only Coil Module Face & By Pass (Opposed damper) Mixing Box (Parallel damper) External Internal Standard Comb. Filter

12 26 1/2 25 1/2 36

22 30 28 36

32 34 33 36

40 36 1/2

48 38

64 43

80 49 45 36

100 56 49 36

120 56 49 36

150 70 54 36

180 72 59 3/4 36

240

270

320

420 96 86 36

520

640

80 1/2 88 1/2 88 1/2 68 36 68 36 72 36

108 1/2 108 1/2 86 36 90 36 43 5/8 10 60 72 52 119 24 36 60 40 184

35 1/2 40 1/2 41 1/2 36 36 36

B 26 3/8 26 3/8 26 3/8 26 3/8 26 3/8 26 3/8 26 3/8 26 3/8 26 3/8 32 3/8 32 3/8 32 3/8 37 3/8 37 3/8 37 3/8 43 5/8 B B B 6 16 24 8 15 22 30 16 40 34 6 16 24 8 27 22 30 16 40 46 6 22 32 14 22 22 30 22 40 48 8 22 32 14 28 22 30 22 40 58 8 22 32 14 33 22 30 22 40 68 8 22 36 14 44 22 30 22 40 74 8 22 36 14 55 22 30 22 40 76 8 30 40 22 44 22 30 30 40 76 8 30 40 22 53 22 30 30 40 92 8 32 44 24 60 22 32 32 40 92 8 32 44 24 72 22 32 32 40 102 10 44 48 36 64 24 36 36 40 120 10 44 48 36 72 24 36 36 40 128 10 48 56 40 77 24 36 48 40 146 10 48 60 40 101 24 36 48 40 154 10 60 72 52 96 24 36 60 40 154

Damper E Section Width Damper Section Length B B B B

Angle Filter Bag & Flat Filter Section Diffuser Silencer Section Width

Notes: 1.) 2.) 3.) 4.)

All dimensions are in inches. For 2 panel add 2 at all dimensions. Except damper section width and length. Consult factory for dimensions of energy recovery unit. Bypass duct not included.

COMPONENTS ARRANGEMENT
5.)UNIT SHIPPING WEIGHTS (LBS)
Model Size 12 22 32 40 48 64 80 100 120 150 180 240 270 320 420 520 640

Basic Unit : FS Type Single Skin Horizontal Vertical 449 402 239 466 404 249 628 626 402 656 663 427 733 698 466 967 940 590 1022 1040 592 1065 1099 618 1114 1382 677 1190 1453 724 1470 1636 947 1582 1729 1020 1825 2039 2129 2549 1286 1380 1939 2138 2248 2684 1367 1450 2539 2810 1853 2653 2969 1937 2910 3872 4140 3690 4435 4850 2097 2712 2890 3026 4005 4300 3833 4592 5099 2181 2805 2990 4431 5320 3068 4598 5610 3181

5R 12 FIN Fan (See Note 3) Section Double Skin Horizontal Vertical

767 1001 737 489 998 610

5R 12 FIN Fan (See Note 3) Section

Basic Unit : AF Type Single Skin Horizontal Vertical 1013 989 636 1047 1045 657 1132 1140 692 1165 1199 718 1336 1604 899 1412 1675 946 1622 1788 1099 1734 1881 1172 1977 2241 2281 2751 1438 1582 2091 2340 2400 2886 1519 1652 2767 3038 2081 2881 3197 2165 3159 4227 4791 3939 4797 8632 2346 3848 3912 3295 4330 4890 4082 4954 5700 2430 3143 3632 5360 6248 3997 5526 6547 4109 7163 5335 7665 5709 8447 9193

5R 12 FIN Fan (See Note 3) Section Double Skin Horizontal Vertical

6330 6475 8371 9400

5R 12 FIN Fan (See Note 3) Section

6543 6621

Accessories Diffuser Section Coil Module with Drain Pan (without Coil) External Face and Bypass (without Duct) Internal Face and Bypass Flat and Bag Filter Section (without Filters) Angle Filter Section (without Filters) Combination Mixing and Filter Section (without Filters) Mixing Box Silencer (Couple with Silencer) 3 Rows Coil Only @ 12FPI. (See Note 4) 4 Rows 5 Rows 6 Rows 8 Rows Cartridge Filter Box 4595% Notes: 1.) 2.) 3.) 4.) 91 146 71 11 171 125 137 119 209 91 21 224 164 179 173 260 93 26 236 173 251 202 326 106 30 277 202 294 226 364 119 41 308 225 328 230 395 146 53 333 244 364 295 476 187 64 402 294 482 401 481 217 80 441 323 535 431 517 233 96 474 347 574 588 735 337 119 587 404 808 613 844 350 146 613 423 844 827 1015 1194 1194 690 254 895 597 1393 1303 1303 820 321 977 651 1629 1710 1865 1710 1865 835 364 912 444

1011 1102 628 189 827 552 683 221 857 575

1026 1119 684 746

1103 1233

2052 2237

91 200 34 39 47 52 65 16

119 263 47 51 61 68 85 22

173 277 56 65 78 87 109 32

202 325 66 78 94 105 132 36

225 360 77 91 110 124 156 48

244 390 94 112 135 153 194 54

294 470 109 130 158 179 229 81

401 517 129 154 188 214 274 96

431 555 149 180 220 251 322 122

587 881 185 224 272 311 398 130

613 920 227 275 334 382 489 148

1011 1100 1105 1142 284 346 421 483 620 208 322 395 481 550 730 230

1194 1193 361 444 541 624 804 270

1303 1302 423 523 639 740 956 390

1710 1864 1368 1492 470 583 712 825 555 693 849 987

1067 1281 432 576

All basic units weight are based on maximum motor frame size. Add 10 % for 2 panels. All basic unit weight are based on 5R 12FPI coil, correct with coil only weight if actual data required. For other fin series : 8FPI x 0.85, 10FPI x 0.92, 14FPI x 1.08.

10

COMPONENTS ARRANGEMENT
6.)DISCHARGE ARRANGEMENTS
A.) FAN SECTION ONLY
P1
AIR OUT

P1

P2
AIR IN

AIR OUT

P1

Q R

P2 S1

P2 AIR IN

R
S3

R
S1

AIR OUT

AIR IN

Horizontal Front

Top Inverted

Top

B.) SINGLE ZONE HORIZONTAL TYPE

P1
AIR OUT

P1

P2

AIR OUT

P1

Q R

P2

P2

AIR IN S1

R
S3

R
AIR IN

AIR OUT

S2
AIR IN

Horizontal Front

Top Inverted

Top

C.) SINGLE ZONE VERTICAL TYPE

AIR OUT

P1 S4 R AIR
OUT

P1 P2 S4 R
AIR OUT

P1

Q R

AIR OUT

P1

P2

Q R

P2 S1

P2 S1

AIR IN

AIR IN

AIR IN

Horizontal Front
Model

Horizontal Rear
Max. Motor Frame Size

Top Inverted

Top
Max. Motor Frame Size

Forward Curved Blower P1 P2 Q R S1 S2 S3

11 15/16 14 7/16

Backward Inclined Airfoil Blower S4 P1 P2 28 Q 16 R 16 S1 4 3/16 S2 11 1/8 14 7/8 16 S3 14 5/8 19 1/16 20 3/16 S4 6 3/16 4 3/16 5 4 9/16 5 1/16 5 1/16 5 5/8 5 1/8
9 11/16 9 11/16

12 22 32 40 48 64 80 100 120 150 180 240 270 320 420 520 640

9
15 13/16 15 11/16

15 7/8

9 1/8

10 3/8 11 3/8 13 1/2 16 16 16 19 22 3/8 25 1/8 28 1/8 28 1/8 31 1/2 35 3/8 39 5/8

4 3/16 4 3/16 4 3/16 4 3/16 4 3/16 4 3/16 5 3/4 5 3/4 5 3/4 5 3/4 5 3/4 6 1/4 6 1/4

9 5/8 10 3/4 11 3/4 12 3/4 12 3/4 12 3/4 16 1/2 16 16 3/4 18 3/16 18 3/16 20 5/16 22 1/8

4 3/16 5 4 7/8 4 1/2 5 1/2 7 7/8 9 5 3/8 5 7/8

D90L D100L D100L

D112M D132M D132M D160M D160M D180M D180M D180L D180L D200L D200L
D250SC D250MC D280SC

19 11/16 10 1/2 20 11/16 12 1/4

15 1/2 16 5/16 16 5/16 16 3/8 19 7/8 20 1/8 21 22 3/8 22 3/8 26 1/4 28 28 3/4

19 1/16 26 5/8 24 1/16 20 7/16 28 1/4 23 5/8 29 1/2 44 1/4 46 5/16 53 3/16

24 3/16 14 3/4 26 5/8 14 3/4 22 25 1/8 28 1/8 28 1/8 31 1/2 31 5/16 18 5/8 33 3/16 22 3/8 38 5/8 40 1/4 44 3/8 44 1/4

D112M 17 3/16 24 3/16 D132S 22 13/16

17 13/16 17 13/16 4 3/16 12 3/16 15 13/16

11 5/8 D132M 22 3/16 31 3/16 19 15/16 19 15/16 5 3/4 D160M 20 7/16 33 3/16 D160M D180M D180M 13 5/8 29 5/8 26 5/8 37 1/4 37 1/4 37 1/4 22 3/8 25 1/8 25 1/8 28 1/8 35 3/8 35 3/8 39 5/8 44 1/2 49 7/8 56 22 3/8 25 1/8 25 1/8 28 1/8 31 1/2 35 3/8 35 3/8 39 5/8 44 1/2 49 7/8 56 5 3/4

20 13/16 33 3/16

5 3/4 16 13/16 21 1/16 5 3/4 16 13/16 21 1/16 5 3/4 5 3/4 6 1/4 6 1/4 4 3/16 4 3/16 18 1/4 19 7/8 22 1/2 25 3/8

11 7/8 D180L 30 13/16 39 11/16 31 1/2 15 7/8 D200L 42 5/16 42 5/16 10 1/8 D200L 46 5/16 46 5/16 10 D200L 53 3/16 53 3/16 54 3/4 64 54 3/4 64 52 1/16 52 1/16

22 3/16 28 3/16 22 3/16 28 3/16 24 5/8 31 11/16 25 5/8 32 11/16

46 5/16 35 3/8 53 3/16 39 5/8

4 3/16 24 7/16

4 3/16 22 7/16 29 7/16

9 3/16

4 3/16 28 5/16 35 5/16

Notes: 1.) P2 is motor location. P1 & P2 can be inter charged to switch motor location. 2.) For other type of discharge arrangement, consult factory for dimensional details. 3.) Dimensions shown are for 1 panel unit. For 2 panel Add 1 at P1, P2, S1, S2, S3 (for 240 and above only) and S4 (for 64 and above only).

11

COMPONENTS ARRANGEMENT
BLOWER ARRANGEMENT
It is important to study the site layout and select the type of blower discharge pattern to suit the ductwork direction which will minimize noise and vibration. The selected blower discharge pattern should be specified in the purchase order (or order form) to the factory. Avoid field conversion of blower discharge pattern. If field conversion of the blower discharge pattern is required, contact factory or nearest Dunham-Bush representative and the field conversion should only carried out under the supervision of a factory authorised personnel. Figures and table on page 11give fan discharge arrangements and dimensions.

QUICK SERVICE ACCESS

Access panels are easily removable by turning door latch a quarter-turn and lifting off the panel. All access opening are lined with 1/8" thick neoprene gasket for airtight seal.

FIGURE 2: LATCH

COIL SECTION
Coil sections are integral with fan section for standard models up to size 180. For larger models, separate coil modules are provided to enable direct coupling to fan section or connection via flexible connectors, if desired. As an option, coil modules can be furnished with extended space to accommodate pre-heat and/or reheat coils.

DRAIN PAN
The drain pan is designed to effectively collect all the condensate and drain on either or both sides of the unit. The pan is of double-skinned sandwiched construction using heavy gauge galvanized steel with fiberglass in between. Option is available for stainless steel drain pan and other types of insulation material.

COIL
Standard coils are suitable for 250 psig working pressure and are tested under water with 350 psig air pressure. Following are also available as options for special applications: * 3/8" or 5/8" OD copper tubes - coils. * Copper fins or tinned copper fins - coils * Higher design working and test pressures * Custom made coils for heating or cooling * Direct-expansion coils air-cooled condensers or evaporators
12

COMPONENTS ARRANGEMENT
Table 7: Minimum Maximum Airflow (Cfms) For Cooling Only
Model Size Full Coil F.A.(ft ) No. Of Coil TH x FL Min. CFM Max. CFM 12 2.5 1 12x24 750 1500 22 5.0 1 16x36 1500 3000 32 6.6 1 20x38 1980 3960 40 8.3 1 20x48 2490 4980 48 10.1 1 20x58 3030 6060 64 13.1 1 26x58 3930 7860 80 16.1 1 30x62 4740 9480 100 19.4 1 36x62 5820 120 23.8 1 36x76 6990 150 30.3 1 46x76 8760 180 35.8 240 46.9 270 54.4 320 63.2 420 75.6 520 89.7 640 109.5

1 2 2 2 2 2 2 48x86 26x104 28x112 28x130 32x136 38x136 38x166 10830 14070 28140 16260 32520 18750 37500 22680 45360 26910 53820 32850 65700

11640 13980

17520 21660

Notes:

1. All coils performance are based on standard face area with nominal airflow and 12FPI for model 12 to 150. 10 FPI for model 180 to 640. 2. Water coils 44 F EWT and 10 F WTR temperature rise. 3. DX coils are R22 @ 40 F SST. 4. Since the final coil selection will seldom be at the above conditions, we recommend you refer to the Dunham-Bush Sales & Services computer coil program for all final coil selections.

FAN SECTION
FAN TYPES
Air Foil Fan Wheel (AF) Forward curved, or backward Forward Curved Fan Wheel (FS) inclined airfoil fans can be provided to suit the required applications. Forward curved wheels are constructed of galvanized steel and are tested in accordance with ARI Standard 430, suitable for external static pressure up to 5" w.g. Backward inclined wheels are of either aluminium or steel construction, wide structural members to provide maximum rigidity and are tested in accordance with ARI Standard 430, and suitable for external static pressure up to 6" w.g. Backward inclined airfoils wheels are of non-overloading characteristics. All fans are statically and dynamically balanced.

MOTOR LOCATION
There are two possibility of arrangements: on the left or right of the blower section. Unless otherwise specified to factory, the motor location provided is at the opposite side to the chilled water and drain piping connection (access panel will be done to facilitate service).

FIGURE 3: PLAN VIEW OF DISCHARGE

13

UNIT FEATURES AND ACCESSORIES

UNIT ASSEMBLY PLANNING
The Dunham-Bush modular central station air-handling units are available for draw-through application. Draw through air-handling units are available for low, medium or high pressure single zone applications in horizontal or vertical arrangement, for ceiling or floor mounting. Blow-through air handlers are available for multi-zone and single zone applications in horizontal arrangements for low, medium and high pressure applications.

TYPICAL ARRANGEMENT
FIGURE 4: MULTI-ZONE AIR-HANDING UNIT

BAG FILTER SECTION ELIMINATOR

REHEAT COIL

MIXING BOX SECTION PREHEAT COIL HUMIDIFIER SECTION ZONE DAMPERS DIFFUSER PLATE COOLING COIL

SPRING ISOLATORS

14

UNIT FEATURES AND ACCESSORIES

FAN BEARINGS
Fan bearings are of the self-aligning with regreasable ball bearings and selected for minimum 100,000 operating hours. Bearings are provided with optional extended lubrication lines which terminate on outside of unit casing for ease of periodic greasing.

VIBRATION ISOLATION
Spring isolators are standard for unit with internally mounted motor to provide excellent vibration isolation. For unit with externally mounted motor and drive package, external spring isolators or neoprene Pads are provided to isolate complete air handling unit. Fan and motor of standard unit are mounted on the same rigid, rugged steel frame. Fan discharge is connected to unit discharge by internal flexible duct connectors to further reduce vibration of unit.

FIGURE 5: VIBRATION ISOLATION AND DISCHARGE CONNECTION

15

INSTALLATION
CLEARANCE
When planning the placement of the unit, ensure adequate space for service access and connection of all required systems i.e. ( a.) Supply and return ductwork ( b.) Coil piping connection ( c.) Electrical power and control wiring ( d.) Trapped condensate drain connection ( e.) Routine services like filter and lubrication ( f.) Coil removal Recommended distance for typical service operations is minimum the width of the unit increased by 600mm. In case of section with special equipments (steam injection humidifier, etc) which may be attached to unit external, sufficient space shall be preserved.

SECTION ASSEMBLY
Sections are connected together as shown in Figure 6. Rig and align sections so that sides and tops are flush and joining lug are aligned. Places of contact of framework profiles should be covered with gasket around perimeter of unit frame, which has been assembled onto the section frame. Fasten the bolts and nuts provided following the instruction, which can be found on side of the section frame. In general, torque required to pull the joining lug shall be 353 lb-ft in order to compress the gasket which creates the frame seal.

Detail A

FIGURE 6 16

INSTALLATION
CONDENSATE DRAIN TRAPS
The condensate drain trap piping must be properly designed to insure the removal of condensate. Incorrect trapping can hold water in pan causing overflow. On blow through units, particularly, system air can escape down the drain with incorrect trapping. a.) On draw-through units (A) shall be equal to or greater than the coil section negative pressure at operating conditions. b.) On blow-through units (A) can be as small as 1 but (B) must equal or exceed the total static pressure in the coil section.

FIGURE 7: TYPICAL CONDENSATE PIPING

SIDE VIEW OF 'AH' DRAIN PAN

SLOPED TO DRAIN

A DRAIN LINE SLOPED 1/4" MIN PER FT

TO DRAIN B

DUCT CONNECTIONS
All intake and discharge air duct connections to the unit should be made with flexible material. The accessory flexible connectors may be used for this purpose. The flexible material should be installed so that it is sufficiently loose to prevent the transmission of vibration to the ductwork. Duct turns and transitions must be made carefully to hold the friction loss to a very minimum. Avoid short turns and duct elbows should contain splitters or turning vanes. Ductwork which is connected to the fan discharge should run in a straight line at least 1 fan diameters and should not be reduced in cross sectional area (See Figure 8). Figure 9 shows the recommended air discharge arrangement for an air duct turn made close to the unit. Notice that a duct should be in same direction as the fan rotation. Never deadhead the discharge into the flat side of a plenum. The air duct should never be unprotected to the elements when outside air is drawn into a unit. A hood or louvered assembly should be provided to keep rain and snow out of the unit. Also an expanded metal screen should be provided to keep birds and other animals out. Open return air ducts and free discharge openings should be protected with an expanded metal screen.

17

INSTALLATION
FIGURE 8: RECOMMENDED DISCHARGE DUCT ARRANGEMENT WHEN TURNS ARE REQUIRED

NOTE : MAKE TURNS IN THE SAME DIRECTION AS FAN ROTATION.

FIGURE 9: DUCT CONNECTIONS

18

INSTALLATION
Fan System
The fan section needs to be checked carefully before the unit is turned on. After removing all transportation protections (only in case when spring shock absorbers are installed) one should check if there are any objects near the fan, which could be sucked into the impeller after it is turned on. See Figure 10.

Figure 10

Leveling Fan Deck Assembly

After installation, check the fan deck to ensure that it is leveled with the foundation. The level may be corrected by loosening the cap screw (see Figure 11). To raise the level, turn the adjusting screw anti-clockwise, to lower, turn the screw clockwise. When the correct level is achieved, firmly tighten the cap screw.

Figure 11

19

INSTALLATION
SHEAVES AND BELTS
Factory-supplied drives are pre-aligned and tensioned. However, it is recommended that you check the belt tension and alignment before starting the unit. Always check the drive alignment after adjusting belt tension. To install sheaves on the fan or motor shaft, remove any rustpreventive coating on the shaft. Make sure the shaft is clean and free of burrs. Add grease or lubricant to bore of sheave before installing. Mount sheave on the shaft. To prevent bearing damage do not use excessive force. Place sheaves for minimum overhang. Each factoryassembled fan, shaft and drive sheave assembly is precision aligned and balanced. If excessive unit vibration occurs after field replacement of sheaves, the unit should be rebalanced. To change the drive ratio, reselect and replace the motor sheave, not the fan sheave. Make sure that fan shafts and motor shafts are parallel and level. The most common causes of misalignment are nonparallel shafts and improperly located sheaves. Where shafts are not parallel, belts on one side are drawn tighter and pull more than their share of the load. As a result, these belts wear out faster, requiring the entire set to be replaced before it has given maximum service. If misalignment is in the sheave, belts enter and leave the grooves at an angle, causing excessive belt and sheave wear. 1. Shaft alignment can be checked by measuring the distance between the shafts at 3 or more locations. If the distances are equal, then the shafts are parallel. 2. Sheave alignment: Fixed sheaves:To check the location of the fixed sheaves on the shaft, a straightedge or a piece of string can be used. If the sheaves are properly aligned, the string will touch them at the points indicated by the arrows in Figure 13. Adjustable sheaves: To check the location of adjustable sheave on shaft, make sure that the centerlines of both sheaves are in line and parallel with the bearing support channel. See Figure 13. Adjustable pitch drives are installed on the motor shaft. 3. Rotate each sheave a half revolution to determine whether the sheave is wobby or the drive shaft is bent. Correct any misalignment. 4. With sheaves aligned, tighten cap screws evenly and progressively. 5. With taper-lock bushed hubs, be sure the bushing bolts are tightened evenly to prevent sideto-side pulley wobble. Check by rotating sheaves and rechecking sheave alignment. When substituting field-supplied sheaves for factory-supplied sheaves, consider that fan shaft sheaves has been factory balanced with fan and shaft as an assembly. For this reason, substitution of motor sheave is preferable for final speed adjustment.

FIGURE 12: Determining sheave-shaft overhang 20

FIGURE 13: Sheave alignment

INSTALLATION
When installing or replacing belts, always use a complete set of new belts. Mixing old and new belts will result in the premature wear or breakage of the newer belts. Correct tensioning of V-belts drive is carried out as follows, 1. Fit the belts into the grooves and increase the centre distance until the belts are snug. (Note: Never lever belts over sheaves) 2. Tighten belts and equalize belt slack so that it is on the same side of belt for all belts. Failure to do so may result in uneven belt stretching. 3. As shown in Figure 14, measure the span length of the drive. Determine the deflection at the centre of the span by using (Span length / 64).

FIGURE 14

4. From table below, find the appropriate deflection force according to belt type. The deflection force for any V-belt should be within the minimum and maximum force shown in the table. When the tension drops to the minimum value, readjust to the maximum value. DEFLECTION FORCE K (Newton) SPZ SPA SPB Min. Max Min. Max Min. Max Min.

Cross Section Diam. Of smaller sheave (mm) 63-80 90-112 125-160 180-224 250-355 400-630

SPC Max

12 16 19 19 -

19 24 28 29 -

19 26 30 32 -

29 40 46 48 -

33 43 51 55

50 64 77 82

58 79 103

87 119 154

21

INSTALLATION
GENERAL PIPING PARAMETERS - WATER COILS
The following precautions should be noted with regard to the piping layout for hot water coils: ( 1.) All coils should be connected to provide adequate venting and drainage. ( 2.) Pipe all water coils for counterflow by connecting the inlet at the bottom and the outlet at the top. This arrangement ensures that for chilled water coils the coldest water meets the coldest air and that for hot water coils the warmest water meets the warmest air. ( 3.) Thermometers are recommended to provide temperature readings when coils are balanced. ( 4.) a. Plug cocks are used to manually adjust the water flow for a set pressure drop through the coil. b. The pressure drop is determined by connecting pressure gauges to the gauge cocks ( 5.) The leaving air temperature from the coil (in this piping layout) is maintained by automatically proportioning the amount of water flowing through the coil or through the by-pass. The water flow is regulated by a motorised 3 way mixing valve, controlled through a proportional remote bulb temperature controller. ( 6.) A gate valve and hose connection provided in the supply line dirt leg should be supplied when floor drains are remote in relation to the coil location. ( 7.) Water piping and coil section should be supported independently.

Figure 15: Water Coil Piping Layout

FLOW
AIR VENT PROPORTIONAL REMOTE BULB TEMP. CONTROL 3 WAY MIXING VALVE

RETURN

GATE VALVE

SUPPLY

GAGE COCK PLUG COCK THERMOMETER

DIRTLEG WITH GATE VALVE (7/8"OD MIN.)

22

INSTALLATION
GENERAL PIPING PARAMETERS -STEAM COILS (MEDIUM OR HIGH PRESSURE SYSTEM)
The following precautions should be noted with regard to the piping layout for steam coils: ( 1.) Return piping from coil to trap should be of at least the same size as the coil outlet connection. ( 2.) Steam piping and coil section should be supported independently. ( 3.) The sizing of control valves should be based on the steam load and not on the coil supply connection size. ( 4.) Thermostatic traps should be used for venting only. ( 5.) A strainer should be provided on the steam supply side of the control valve. ( 6.) Locate traps at least 12 inches below the coil return connection. ( 7.) Where handling outside air below 35F the following precautions must be followed: a. Proper draining is mandatory to avoid damage by freezing. b. Do not use overhead returns from coils. c. An immersion thermostat should be used to protect the coil. The device controls the outdoor air damper and fan motor when the steam supply fails or condensate temperature drops below a pre-set level. Thermostat is located in the return line before the dirt leg.

FIGURE 16: STEAM COIL PIPING LAYOUT

23

INSTALLATION
GENERAL PIPING PARAMETERS- DIRECT EXPANSION COILS
Each coil must be installed with the suction header on the entering air face of the coil and with the suction connection at the lower end. The orientation of the refrigerant distributor is not critical but the distributor tubes must not be linked or bent in a non-uniform configuration. Refer to Figure 17. An individual expansion device must be provided for each coil or each section of coil which contains a header suction connection. If the air flow through two or more coils is in parallel, as in a stacked coil bank, the suction piping must be installed in such a way that liquid from one coil suction header cannot reach another coil suction header. The bulb for the control valve must be attached to the header of the coil or section of coil fed by that valve and not to a common header. When two or more coils are Figure 17: DX Coil Piping Arrangement connected to a common suction line, never place the bulb on the common line. Thermostatic expansion valves are to be equipped with external equalizer tubes that are field connected to the suction line. The valve should be sized in accordance with the manufacturers recommendations, allowing approximately 35 psi pressure drop through the coil and distributor at full load. Do not oversize the valve. Follow the valve manufacturer's instructions on the location of the thermostatic bulb. Proper expansion valve operation is necessary in order to realize the rated coil capacity.

When a DX type coil is operated with a suction temperature below 32F, a build up of frost will occur on the finned surface. It is, therefore, not recommended to operate DX coils for air conditioning purposes at below freezing suction temperatures. If the full load operating point for the coil is selected at a "safe" temperature, a system analysis is required to check for the lowest probable suction temperature at light load conditions. Suction pressure controlled hot gas bypass valves are available from various control manufacturers to maintain an adequate minimum suction temperature.

24

INSTALLATION
DAMPER ACTUATORS
Damper sections are shipped fully assembled. Dampers have 90 degrees of travel from fully open to fully closed positions. All internal face and bypass damper sections, as well as the mixing box damper sections can be supplied with direct mounted damper actuators. The actuator is fitted with a universal spindle clamp for quick and easy mounting directly onto the damper spindle. The actuator is also supplied with an anti-rotation strap for fixing it in position. Release of the locking mechanism can be achieved manually or automatically by applying the supply voltage. The location of the anti-rotation strap shall be adjusted at site in order to adjust damper blade angle location to obtain the required air flow volume.

Figure 18 Anti-rotation strap Installation

ELECTRIC HEATER
The heater should be connected in a way, which will prevent it from turning on when the fan is not working. Besides when the work of the fan is stopped the power supply of the heater must be switched off. Every heating coil of the heater is separately wired to the terminal strip, which is placed at the side of the casing of heating component. Depending on the system of applied automatic control devices the regulation of heater power may be variable or stepped. The strip is equipped with terminals, which are used for connecting the ground and neutral conductor (the housing of the heater must be connected with the neutral or ground conductor) and terminals of thermostat protecting from excessive air temperature raise inside the heater, caused by the lack or decrease of the air flow. Operation of the thermostat is based on the properties of bimetallic element that opens the contacts of heater power supply circuit at the air temperature value of the thermostat capillary of 93oC. Contacts close again after the air temperature decreases and the thermostat is manually or automatically reset.

25

INSTALLATION
DIFFERENTIAL PRESSURE GAUGE
The optional differential pressure gauge is intended for measuring fan pressures, filter resistance, etc. In most circumstances, installation of filter gauge section is factory-completed. For fan section, the high pressure side at duct is site-installed. The typical installation is as shown in Figure 19. It is recommended to locate the static pressure tip downstream in a straight duct connected to the fan discharge where the flow is more uniform.

FIGURE 19: Pressure Static Tip Hock-up

26

INSTALLATION
VFD

27

START-UP PREPARATIONS
Start-up of the unit at the moment of putting the ventilating system into normal use must be performed only by properly qualified and trained personnel of installation and start-up team. Before the unit is started one should carefully perform some very important preparatory activities. ( 1.) Is the blower pulley properly mounted onto shaft. ( 2.) Is the motor rotation direction correct. ( 3.) Is belt tension normal and belt size correct. ( 4.) Are all bolts and nuts properly tightened. ( 5.) Is the belt adjustment normal. ( 6.) Is motorised damper functioning. ( 7.) Is thermostat, fan selector switch functioning. ( 8.) Is 3 or 4 way valve in proper condition. ( 9.) Are the air filters in place. ( 10.)Is fan wheel able to rotate free and clear when it is manually rotated. ( 11.)Is fan and motor bearings properly lubricated. ( 12.)Check that the fan and motor bearings do not run hot. ( 13.)Is insulation properly done. ( 14.)Steam injection humidifier Before shipment, the humidifier is cleaned and checked for leaks. As many elements can contaminate during transportation, they should be inspected and cleaned if necessary. Following activities should be performed, 1. Steam Supply System In most new installations, dirt may collect in the steam line during construction and connection of external pipework to the steam inlet. It is always advisable to flush this out before start-up. Check the condition of any strainer screens after flushing through, and clean as necessary. 2. All pressure gauges (applicable for system requires Pressure Reducing Station only) are fitted with a gauge cock to assist when calibration or maintenance is necessary. The gauges are protected from heat by the use of ring syphon tube and gauge cock. Fill the syphon pipe with water. 3. It is important that the steam supply to the humidifier is as dry as possible, and that the system is adequately drained of condensate. The pipework immediately upstream of the humidifier should be free of any low points where condensate could collect. 4. The steam supply to the humidifier should be maintained at a constant pressure to ensure that the design conditions are met. This may require the fitting of a pressure reduction station, as typically shown in Figure 22. Ensure that the main steam supply pressure does NOT exceed the maximum pressure stamped on the separator label 400kPa (58psi). 5. Initially, turn on the steam slowly in order to check for leaks both in the steam and condensate systems. 6. Make sure that the valve actuator is in the closed position before the system is energised. 7. Allow approximately 10 minutes for the humidifier to heat up, particularly the pre-heat tracer circuit, before the main valve is activated. 8. Set the running conditions required at the humidistat and high limit stat.

28

OPERATION
After the unit has been operated for quite so ( 1.) Is fan rpm and rotation correct.metime, do the following running check: ( 2.) ( 3.) ( 4.) ( 5.) ( 6.) ( 7.) ( 8.) ( 9.) Is motor running amps within the full load ampere. Is motor and fan getting too hot. Is there any air leakage from unit. Is the unit panel and fan housing sweating. Chilled water temperature inlet and outlet. Inlet and outlet chilled water pressure. Is unit vibrating excessively. Is the on/off design coil temperature being achieved by the units.

Take necessary action to rectify any abnormal, operating conditions. Contact Dunham-Bush office for any uncertainties.

PRESSURE DROPS
TABLE 8: CASING AND FILTERS ("WG)
SECTION 300 BASIC UNIT (VERT.) NO. COIL FACE AND BYPASS MIXING BOX WITH FILTERS T.A. MIXING BOX WITH CLEANABLE FLAT FILTER (HI-VEL) CLEAN V-TYPE FILTER (LO-VEL) T.A. V-TYPE FILTER CLEAN ELIMINATOR ASSEMBLY 0.100 0.020 0.059 0.030 0.028 0.040 0.011 0.024 STANDARD COIL FACE VELOCITY (FPM) 400 0.170 0.040 0.090 0.053 0.055 0.060 0.023 0.039 500 0.260 0.060 0.125 0.073 0.087 0.080 0.028 0.057 600 0.360 0.100 0.163 0.088 0.114 0.130 0.055 0.077

TABLE 9: AIR SIDE PRESSURE LOSS ("WG)

FACE VEL (FPM) 350 400 450 500 550 600 650 700 NOTE: 8 FINS/ INCH. HOT WATER, STANDARD STEAM 1 ROW(DRY) 0.035 0.047 0.059 0.073 0.088 0.105 0.125 0.143 2 ROW(DRY) 0.075 0.097 0.125 0.150 0.185 0.220 0.260 0.300 NON- FREEZE STEAM 1 ROW(DRY) 0.046 0.056 0.071 0.083 0.102 0.115 0.137 0.153 2 ROW(DRY) 0.082 0.103 0.128 0.154 0.184 0.215 0.247 0.281 4 ROW(WET) 0.304 0.376 0.452 0.536 0.620 0.712 0.800 0.908 CHILLED WATER, DX 6 ROW(WET) 0.456 0.564 0.678 0.804 0.930 1.068 1.200 1.362 8 ROW(WET) 0.604 0.752 0.904 1.072 1.240 1.424 1.600 1.816

29

OPERATION LIMITATION
In order for the units to perform smoothly and be long lasting, the following operating limitation has to be strictly abided to: TABLE 10
MODEL MIN CFM MAX CFM MAX MOTOR FRAME SIZE

FS

AF

12

750

1500

D90L

22

1500

3000

D100L

32

1980

3960

D100L

40

2490

5980

D112M

D112M

48

3030

6060

D112M

D132M

64

3930

7860

D132M

D132M

80

4740

9480

D160M

D160M

100

5820

11640

D160L

D160L

120

6990

13980

D160L

D160L

150

8760

17520

D180M

D180M

180

10830

21660

D180L

D180L

240

14070

28140

D200L

D180L

320

17490

34980

D200L

D200L

420

21240

42480

D250SC

520

26910

53820

D250MC

640

32850

65700

D280SC

30

MAINTENANCE
An air handling unit, as with any mechanical equipment, requires periodic maintenance. The following is a recommended "check list" to be used as a guide in establishing a maintenance program.

PERIODIC INSPECTION
( 1.) Check the fan motor and fan shaft to see that they are adequately lubricated. The shaft bearings are prefabricated and Zerk fittings are factory installed for relubrication. Shaft bearings should normally be relubricated once a year as a minimum for applications where the units operate in a generally clean, dry atmosphere. Bearings in units for outdoor or industrial applications may require relubrication two or three times a year or as often as once a month for severe conditions. Lubrication should be done when unit is not running and by means of a hand grease gun until grease goes through the bearing so that a bead of grease appears at the sear lip contacts. The most important time for lubrication is before any prolonged storage or shutdown to flush out any foreign material and to prevent moisture from entering the bearing. The recommended grease is lithium base water resistant type such as Alvania No. 3 by Shell Oil Company or its equivalent. The fan motor should be lubricated in accordance with manufacturer's recommendation or approximately every 5 years. Caution should be exercised when lubricating bearings to be sure that no foreign matter gets into bearings. ( 2.) Check the belts for proper tension and alignment at least once every six months. Proper belt tension depends on the center distance between pulleys and type of belt used. ( 3.) Check the pulleys and sheaves at least once every six months to make certain that set screws are properly tightened. ( 4.) To insure proper air cleaning efficiency, filters must be properly maintained. Dirty filters will reduce the air volume handled by the unit which will result in reduced unit capacity. The length of time between the replacement of throwaway filters or cleaning of permanent type filters is dependent upon the condition of the circulated air. A six week cycle is normal, however, more frequent servicing may be required. ( 5.) Check if heating coils of the heater are not damaged or have any contact with the elements inside the heating section. Check the correctness of electric connections according to the wiring diagram showing the connection of electrical heating coils. The bank of electric heater consists of a set of bare heating coils. During the work of the unit, when the heater is not working dust may deposit on heating coils. In the moment when the heater is turned on again high contamination may cause occurring of the smell of burned dust and even fire hazard. Electric connections, technical condition of heating elements and the level of their contamination should be controlled in equal (every 4 months) time intervals, especially before heating season starts. Possible contamination should be removed by means of vacuum cleaning. Functioning of protection preventing from the temperature rise should be checked as well.

31

MAINTENANCE
( 6.) Steam Injection Humidifier Before attempting any maintenance on this equipment, ensure that the assembly is fully isolated from the main steam supply. All electrical circuits must be isolated (fuses removed) or disconnected. Allow sufficient time for the whole unit to cool down. Consider what is or may have been in the pipeline. Ensure that any pressure is isolated and safely vented to atmospheric pressure before attempting to maintain the strainer.

1. Regularly clean the perspex window of the pressure gauges. Solvents should not be used to clean the perspex window as it may impair clarity. 2. Gauge cocks should always be opened and closed slowly to avoid pressure shocks to the gauges. 3. During recalibration the perspex window can be removed, using a narrow flat-faced screwdriver, placed in the slots on the edge of the glass. The pointer can be gently pulled off its spindle and replaced at the correct reading by gently pushing back on to the spindle. After calibration, push fit the window back into position. Refit the gauge to the system. 4. Maintenance can be completed with the strainer in the pipeline, once the safety procedures have been observed. It is recommended that a new gasket is used whenever maintenance is undertaken. Undo the strainer cap and remove the screen. Clean or replace as required and reassemble the strainer cap into the body, ensuring that the screen is located centrally.

ANNUAL INSPECTION
( 1.) If the unit is painted, check for evidence of corrosion or peeling. These areas should be properly cleaned and retouched. ( 2.) Tighten the blower wheel set screws. Inspect the wheels and housings for evidence of corrosion and retouch if necessary. ( 3.) Wash down the coil fin surfaces to eliminate dirt, lint or other foreign matter. If there is a particularly heavy accumulation of material, more frequent replacement or cleaning of filters is indicated. ( 4.) Check the motor and fan shaft bearings for evidence of wear. ( 5.) Check the drain pan and drain line to see that condensate is being properly drained and there are no restrictions in the line. ( 6.) Replace all belts showing evidence of wear. NOTE: It is recommended that all units be rebalanced to a minimum of "Quality Grade G6.3" if shaft or wheel is replaced.

32

TROUBLESHOOTING CHART
SYMPTOM Noise SOURCE 1. Impeller hitting inlet ring PROBABLE CAUSE Impeller not center (check shaft clamp). Inlet ring damaged or not adjusted. Shaft loose in bearing (check locking collar). Impeller loose on shaft (check shaft clamp). Bearing loose in bearing support (check mounting bolts). Sheave not tight on shaft (motor or fan). Belts hitting belt guard. Belts loose. Adjust after 48 hours operation. Belts too tight. Belts wrong cross section. Belts not "match" in length on multi-belt drive Variable pitch sleaves not adjusted so each groove has same pitch diameter (multi-belt drives). Misaligned sheaves. Belts worn. Motor, motor base or fan not securely anchored. Belts oily or dirty. Defective bearing. Needs lubrication. Loose on bearing support. Loose on shaft (check locking collar). Misalignment (check alignment binding). Worn bearing Fretting corrosion between inner race and shaft. Loose on shaft (check shaft clamp). Defective impeller. Do not run fan. Contact manufacturer. Unbalance. Foreign material on fan blades. Foreign material in housing. Inlet cones loose or not adjusted. Lead-in cantle not secure or is too rigid. AC hum in motor or relay. Starting relay chatter. Motor bearings. Single phasing a 3-phase motor. Bent. Undersized. May caused noise at impeller, bearings or sheave. Loose internal balance weights. Bearing alignment. Ductwork too small. Fan running too fast. Fan section too small. Static pressure lower the expected. Registers and grilles too small. Insufficient face area of heating or cooling coil.

2. Drive

3. Bearing

4. Impeller

5. Housing 6. Electrical

7. Shaft

8. High air velocity

33

TROUBLESHOOTING CHART
SYMPTOM Noise SOURCE 9. Obstruction in high velocity air stream may cause rattle or pure tone whistle PROBABLE CAUSE Dampers. Registers. Loose dampers or splitters. Grilles. Sharp elbows. Sudden expansion of duct work. Sudden contraction of ductwork. Turning vanes. Oversize ductwork. Parallel fan operation. Loose dampers or splitters. System instability. Ducts vibrate at same frequency as fan pulsation. Organ pipe action on long duct. Leaks in duct work. Registers or grilles. Excessive duct velocities. Vibrating ductwork. Flex connector too tight or touching. Vibrating cabinet parts. Vibrating parts not isolated from building. Forward curve impeller installed backward. Fan running backward. Impeller not centered with inlet cones. Fan speed too slow. Actual system is more restrictive (more resistance to flow) than expected. Dampers closed. Splitter rod disconnected. Registers closed. Leaks in supply ducts. Open duct seams. Insulating duct liner loose. Fire dampers closed. Dirty clogged (dirt, lint, snow, grass) Dirty or clogged (construction trash) Internal cabinet leaks in bulkhead separating fan outlet (pressure zone) from fan inlets (suction zone). Leaks around fan outlet at connection through cabinet bulkhead.

10.Pulsation or surge

11.High velocity through cracks holes or past obstructions 12.Rattles and/or rumbles

CFM low

1. Fan

2. Duct system

3. Filters 4. Coils 5. Recirculation

34

TROUBLESHOOTING CHART
SYMPTOM CFM low SOURCE 6. Obstructed fan inlets PROBABLE CAUSE Elbows, cabinet walls or other obstructions restrict air flow. Inlet obstructions cause restrictive systems but do not cause increased negative pressure readings near the fan inlet(s). Fan speed may be increased to counteract the effect of restricted fan inlet(s).(observe fan RPM limits). Fans which are normally used in duct systems are tested with a length of straight duct at the fan outlet. If there is no straight duct at the fan outlet, decreased performance will result. If it is not practical to install a straight section of duct at the fan outlet the fan speed may be increased to overcome this pressure loss. Observe fan RPM limits. Obstruction near fan outlet. Sharp elbows near fan outlet. Improperly designed or no turning vanes. Projections, dampers or other obstructions in part of system where air velocity is high. Oversized ductwork. Access door open. System not balanced. Resistance less than specified. Registers or grilles not installed. Dampers set to bypass coils. Filter(s) not in place. Backward inclined impeller installed backward (HP will be high). Variable motor sheave not adjusted. Fan speed too fast. The velocity pressure at any point of measurement is a function of the velocity of the air and its density. The static pressure at a point of measurement in the system is a function of system design (resistance to flow), air density and the amount of air flowing through the system. The static pressure measured in a "loose" or oversized system will be less than the static pressure in a "tight or undersized system for the same airflow rate. In most systems, pressure measurements are indicators of how the installation is operating. These measurements are the result of airflow and such are useful indicators in defining system characteristics. System has less resistance to flow than expected. This is a common occurrence. Fan speed may be reduced to obtain desire flow rate. This will reduce HP, conserve energy, and save operating costs.

7. No straight duct at fan outlet

8. Obstructions in high velocity air stream

CFM high

1. System

2. Fan

Static Pressure Incorrect

1. System fan or interpretation of measurements

2. System

35

kds

36