Dogu FourSeason KKS 062 - 046 Manual

AIR HANDLING UNIT INSTALLATION,
OPERATION AND MAINTENANCE INSTRUCTIONS
is a registered trademark of Dogu Iklimlendirme A.S

Venues Breathe with Dogu HVAC Systems!
Dogu HVAC Systems which had started to produce ventilation and air-conditioning equipments in İzmir in 1999,
produce two main segments as air outlet equipments and air handling units in accordance with European
norms (DIN,EN). Dogu puts the devices on the market with ‘’Four Season’’ brand.
Dogu HVAC Systems which is in business within 45.000m² open area with 2 factory, has 120 different types of
products. It brings new products to the sector producing Make-up Kitchen Hoods, Laminar Flow Ceiling, One
Piece Square Ceiling Diffuser.
Our R&D journey started in 2004 with the first project of producing Make-up Kitchen Hood is followed by
producing dozens of other new products that were designed by special software like Ansys Fluent® and
Solidworks® today.

is a registered trademark of Dogu Iklimlendirme A.S
- Protect your unit against damage, shock and distortions.
- Do not attemp to install and run the unit before reading the instructions in this booklet
- Your unit’ s serial number is
- Your unit’ s type is
MODELS
KKS 062 - 046
KKS 062 - 062
KKS 093 - 062
KKS 124 - 062
KKS 093 - 093
KKS 124 - 093
KKS 155 - 093
KKS 124 - 124
KKS 155 - 124
KKS 186 - 124
KKS 155 - 155
KKS 186 - 155
KKS 217 - 155
KKS 186 - 186
KKS 217 - 186
KKS 248 - 186
KKS 217 - 217
KKS 248 - 217
KKS 279 - 217
KKS 310 - 217
KKS 248 - 248
KKS 279 - 248
KKS 310 - 248
KKS 341 - 248
KKS 403 - 248
KKS 465 - 248
KKS 527 - 248
KKS 589 - 248
Air Handling Unit Installation, Operation And Maintenance Instructions
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CONTENTS Pages
- INTRODUCTION........................................................................................................................................... 3
- ABOUT AIR HANDLING UNITS .................................................................................................................. 3
- TRANSPORTATION AND STORAGE ......................................................................................................... 4
- INSTALLATION ............................................................................................................................................ 4
4.1 CONNECTION OF SECTIONS .............................................................................................................. 5
- CONNECTIONS............................................................................................................................................ 6
5.1- DUCTING CONNECTIONS ................................................................................................................... 6
5.2- PIPING CONNECTIONS ....................................................................................................................... 9
5.3- CONDENSATE DRAIN LINES ............................................................................................................ 11
5.4- ELECTRICAL CONNECTIONS .......................................................................................................... 11
6-
7
8
9
SETTING UP OF COMPONENTS .............................................................................................................. 18
6.1- DAMPERS ........................................................................................................................................... 18
6.2- FILTERS .............................................................................................................................................. 18
6.3- COILS .................................................................................................................................................. 18
6.4- HUMIDIFIERS...................................................................................................................................... 19
6.5- SUPPLY AND RETURN FANS ........................................................................................................... 20
6.6- ELECTRIC HEATER ........................................................................................................................... 20
- SAFETY ...................................................................................................................................................... 20
7.1- USE OF THE UNIT .............................................................................................................................. 21
7.2- OBSERVATION OF WARNING SIGNS .............................................................................................. 21
7.3- STAFF TRAINING ............................................................................................................................... 21
7.4- PREVENT OF COMMON DANGERS AND RİSKS ............................................................................ 22
7.5- RECOMMENDED SAFETY PRACTICES........................................................................................... 22
7.6- THE HIDDEN DANGER ...................................................................................................................... 23
7.7- START UP ........................................................................................................................................... 24
- MAINTENANCE.......................................................................................................................................... 25
- BELT TENSION AND ALIGNMENT CONTROL ........................................................................................ 29
10
1
2
3
4
5
- CHANGE OF PULLEYS .......................................................................................................................... 31
10.1- MOUNTING OF PULLEYS ................................................................................................................ 31
10.2- REMOVAL OF PULLEYS ................................................................................................................. 31
11- LUBRICATION OF BEARINGS ............................................................................................................... 31
12- TROUBLESHOOTING ............................................................................................................................. 33
12.1- TROUBLESHOOTING CHART ......................................................................................................... 34
13- OPERATING LIMITS OF FANS............................................................................................................... 37
14- MOTOR TECHNICAL INFORMATION .................................................................................................... 41
APPENDIX-1 STARTER SELECTION TABLE ............................................................................................... 44
15- PRODUCING COMPANY ........................................................................................................................ 45
TABLE ............................................................................................................................................................. 45
16- WARRANTY............................................................................................................................................. 46
17- DELIVERY REPORT................................................................................................................................ 47
18- DECLERATION OF CONFORMITY ........................................................................................................ 48

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1- Introduction
This manual is prepared as a guide to good practice in installation, operation and maintenance of air
handling units manufactured by DOGU IKLIMLENDIRME A.S. The manual contains basic information and
recommendations for proper and fail free operation of air handling units. Please read the instructions and
warnings given in this manual and on the air handling unit before starting installation, operation and
maintenance works and keep this manual near the unit, within easy reach of service personnel.
2- About Air Handling Units
WARNING: DOGU IKLIMLENDIRME A.S. air handling unit are only used for heating, ventilating and air
conditioning purposes. Any other use is considered not in conformity with general provisions. The
manufacturer is not responsible for damages resulting; the user will be the only responsible.
Standard units must not be used for handling of flammable gases. Spark-proof versions of rotating parts
(fans, motors etc.) must be selected for this kind of applications, so air handling unit manufacturer should
be informed while ordering the unit.
2.1 Operating Data
2.1.1 Ambient Temperature
Air handling unit components are suitable to be used at ambient temperatures between -20˚C and +40˚C
and altitude of 1000m. Ambient temperature is the temperature of the air either inside or the outside of the
unit. If the unit is to be used at ambient temperature and altitude other than stated above please consult
to DOGU IKLIMLENDIRME A.S.
2.1.2 Power Supply
Standard power supply for air handling unit components such as motors, humidifier pumps, electric
heaters, steam humidifiers etc. is 400V, 3ph, 50 Hz and for lighting 230V, 1ph, 50Hz. However customers
may request other voltages while ordering the unit.
WARNING: Before starting electrical connections and selection of electrical components check if the mains
power supply conforms to the data on the rating plates of electrical components. If there is any difference
do not connect the devices.
2.1.3 Coils
If not otherwise stated on the capacity label, maximum operating temperature and pressure:
For hot and cold water coils: 90˚C, 10 bar
For high temperature hot water coils: 150˚C, 15 bar
For steam coils: 143˚C, 3 bar

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WARNING: Do not operate coils above the maximum temperature and pressure specified on the capacity
label.
2.1.4 Motors And Fans
Rated power, speed and current values of commonly used motors are given on pages 35 - 36 and maxi-
mum speed and maximum installed power values of fans are given on pages 33 - 34 for information only.
It is not permitted to operate fans and motors at higher speeds other than design speed, without written
permission of DOGU IKLIMLENDIRME A.S., since operating at higher speeds may overload and damage the
motor and fan.
3- Transportation And Storage
Air handling units are inspected prior to dispatch for good condition and carefully loaded. Special care must
be taken while unloading the units.
Air handling units are generally damaged during transportation and loading / unloading, especially when
being lifted by a crane. Small units can be transported by hand-powered pallet truck or by forklift truck.
4- Installation
During final installation the requirements of EN 60204-1 do apply.
Before manufacturing air handling unit, the client should check the conditions at site to ensure that access
routes are adequate for both size and weight of the unit sections. Air handling unit installation areas should
also be checked. There should be sufficient space around the unit for servicing, maintenance and piping
connections. Further, it must be ensure that the base is high enough from the floor to allow the condensate
drain with necessary water trap.
WARNING: Always use the lifting holes on the base frame to lift the unit by a
crane. Never lift the units by coil connections or by any other protrusions. While
hoisting or lowering, proper lifting equipment (slings and spreaders properly
selected on the ground of the size and weight of the section) should be used
not to damage the unit. Ensure that slings do not damage the unit casing and
protrusions such as coil pipe connections, door handles, drain connections etc.
Safety precautions should also be taken not to tilt and not to drop the unit.
Fig. 1: Typical lifting equipment

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WARNING: Air handling units should be installed on a rigid and level surface. Correct alignment of the
sections is essential to maintain a satisfactory airtight enclosure and to avoid distortion to the casing and
components.
If the air handling unit is to be installed in a place where low vibration and noise is required such as hotels,
hospitals etc it is recommended to install the unit on a floating concrete base, around which is filled with
expanded polystyrene.
4.1 Connection Of Sections
First of all, transport the unit sections to the place where the unit will be installed. Check the sealing strips
for any damage. Replace the strips if there is any damage. The order in which the individual sections are
assembled can be determined from assembly drawings and by following identification labels on each
section ( For example A1-A1, A2-A2 ). In order to reduce vibration, suitable anti-vibration strips may be
placed under the base frame. To connect the sections, follow the instructions below.
4.1.1 Pent A Post Air Handling Units
Once all sections are located in their place in the order they will be assembled, align the sections for air
tightness and to easily fit the section connection bolts.
Fig. 2: Typical AHU concrete base

WARNING: Do not use excessive forces to align the sections, because it
may deform the aluminum framework and casing.
Sections are locked together by special connection parts, bolts, and
nuts. Section connection parts are mounted on the unit sections, bolts
and nuts are fitted on the connection pieces.
First attach the base frame connection bolts on the base frame, and
then section connection bolts and tighten the bolts gradually starting
from the base frame.
4.1.2 Cold Bridge Free Air Handling Units
Cold bridge free air handling unit sections are connected to each other
through the holes on the facing surfaces of the sections and through the
holes on the base frame, by means of bolts and nuts supplied within the
unit. First attach the base frame connection bolts on the base frame,
and then section connection bolts and tighten the bolts gradually
starting from the base frame. And then fit the intermediate cover lids.
5- Connections
5.1- Ducting Connections
Return air, fresh air, exhaust air and supply air should be connected to
the unit by flexible duct connectors. Air tightness should be maintained
to achieve required air flow conditions. Poor ductwork connections to the
unit and incorrect size, shape and arrangement of ductwork fittings can
change airflow conditions.
5.1.1- Free Outlet Conditions
Discharging a centrifugal fan directly to atmosphere (Fig.3) is an
inefficient method of discharge. It can be improved by the addition of a
short duct length coupled to the fan outlet (Fig.4) or by the use of an
expansion section (Fig.5) allowing the air to become less turbulent
before being discharged. This is particularly important when grills or
diffusers are being used at the discharge point as the manufacturers
loss figures are based on a laminar flow air stream and turbulent air
increases the losses.
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sealing strips
base frame connection
section connection

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5.1.2- Ducted Outlet Conditions
With the outlet connected to the discharge duct by a flexible connector, which is desirable for noise and
vibration isolation, it is important that the connector is correctly fitted. The fan outlet and the duct should
not be misaligned (Fig.6) nor should the flexible connector be allowed to concertina. A smooth passage of
air is desirable at all times. (Fig.7)
When discharging into a duct of larger cross-sectional area than the fan outlet, an expansion section with
an included angle of 7-20ºC should be used. (Fig.8) The ideal configuration is with parallel length of ducting
prior to the expansion section, allowing the air to become less turbulent before expanding. (Fig.9) The fan
should never discharge directly into a duct with larger cross-section. (Fig.10)
The same criteria apply when discharging into a duct of smaller cross-sectional area then the fan outlet. A
ducting section with an included angle of up to 45ºC should be used. Losses will again be minimized if a
parallel section of ducting is used prior to the reducing section. (Fig.11) To achieve ideal conditions the
length of parallel ducting in both cases should be equal to 8 impeller diameters. However parallel ducting of
considerably shorter lengths can be used to advantage

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Extremely high losses occur when attempts are made to change the direction of the airflow close to the
fan discharge. If this is necessary the installation should be carried out as in (Fig.12) and ever as in (Fig.13)
A better solution is to have a parallel section of ducting prior to changing direction and it should be as long
as can be accommodated. (Fig.14)
FAIR
BAD
BAD
Fig.13
Fig.14

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5.2- Piping Connections
Coils should be piped in counter flow arrangement to achieve required capacity. This arrangement requires
that the entering heating or cooling fluid contacts the air leaving the coil. Water heating and cooling coils
should be arranged with inlet connection at the lowest level on one side of the coil near downstream and
water outlet connection on the same side but at high level near the upstream. This arrangement drives any
air in the system into the upper part of the coil, where a manual air release valve should be fitted.
All coils connecting piping should be independently supported not to impose strain on the coil connections
or circuitry. All coils connecting piping should be thermally insulated
WARNING: Use a pipe wrench to restrain the pipe connections of the coil when tightening the external pipe
connections.

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5.3- Condensate Drain Lines
Moisture condensed out of the airstreams on cooling / dehumidifying coils should be drained out of the
unit, to prevent water damage in the air handling unit and ductwork system. Following precautions should
be observed in piping of condensate drain lines.
- Condensate pipe connections to drain pan should not be less than the bore size of the pan outlet connec-
tion.
- A union or pipe coupling should be fitted at the pipe connections to the pan to permit easy disconnection
to clean any dirt sediments.
- The siphon (for positive and negative pressure applications) sent by the unit separately should be assem-
bled according to its own installation instructions in the package.
- If the drain pipe is to be long, drain line should be pitched with a gradient not less than 1 in 50.
5.4- Electrical Connections
Electric motor, starters, interconnecting cabling and any associated controls should be properly designed
and selected to be suitable for the driven equipment or other electrical apparatus, to be safe and to comply
with the requirements of Electricity Supply Authority. In case of the humidifier and frequency converter
applications their own installation manuals should be used. For the other equipments the installation
instructions and the wiring diagrams which stuck in the terminal box should be followed.
The equipments in the unit except lighting operate with 400V, 3Ph, 50Hz electric supply. Standard lighting
equipment operates with 230V, 1Ph, 50Hz electric supply.
siphon for positive pressure
siphon for negative pressure
H(mm)= P
10
H + 50 mm
H
1,5 x H
1,5 x H + 60
( ball type siphon )
P= maximum static pressure in unit, Pa

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Starter for centrifugal fans in the air handling units for single speed motors driving through V-belts are
normally of the direct-on-line type. However the customer or Electric Supply Authority may require motors
above 3kW to be operated by a star-delta starter, to reduce starting current.
CAUTION: To avoid the electric heater keep on running while the fan is not rotating, the wiring should be
done similar to diagram shown at the right.
WARNING: Electrical installation and wiring works should be carried out by qualified and competent
electricians, in accordance with all international, national and local regulations.
- Thermal overload relay setting
a) Direct-on-line starting: The thermal overload relay should preferably be set to the motor full load current
shown on the motor rating plate.
b) Star-Delta starting: The thermal overload relay should preferably be set to the 0.58 x motor full load
shown on the motor rating plate.
After thermal overload relay settings is done it should be checked that thermal overload relay works
properly at normal operating conditions, by operating motor on two phases.
Motor terminal markings
- The terminal markings of motors conform to the international standards. Stator terminals are marked,
U.V.W and the neutral terminal N.
- Please check data on the rating plate. The voltage marked on the rating plate must be in agreement with
the mains voltage.
The terminal board is normally equipped with 6 terminals. Details concerning the connection are given on
the inside cover of the terminal box and / or on a diagram placed inside by the manufacturer.
- Specifications require that all motors to be earthen properly. Special terminal in the terminal box should
be used for this purpose.
- To avoid the danger of overloading and operation on two phases, the motors should be protected either
with fuses and thermal/thermo magnetic switches or electronic circuits. (See page 37)
- If the electric heater will be used, electrical connections should be done according to the information on
the heater label.
The unit must be installed with a disconnecting device and over current relay on the site if it has not already
equipped.
A Manual reset
B Automatic reset

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The supply cable cross-section-area and length should be selected according to the;
- Motor, lighting, electrical heater, etc power input and electrical supply
NOTE: All power and electrical supply values have indicated on the name plate of the unit and/or name plate
of the equipment except the lighting. Electrical Supply of the lighting is 230V, 1Ph, 50Hz and the power
input of the lighting is 100W as standard. Cable specification from the terminal box to lighting is H05V-K
2x0.75
- Cable installation conditions
- International standards, local rules, regulations and standards and requirements of Electric Supply
Authority.
5.4.1 Converter - Fed Operation Of Motors
When driving motors by a frequency converter, the following must be observed:
- The fan motor must be suitable for operation with a frequency converter.
- Rated speed of motor given on the rating plate should not be exceeded.
- Maximum speed and maximum installed power values for fans given on pages 33 - 34 must not be
exceeded.
- Fan motor must be protected by PTC thermistor against overload and overheating.
- Frequency converter must be overspeed protected.
- Motor PTC thermistor must be wired to the frequency converter by shielded leads.
- Assembly instructions of motor and frequency converter manufacturers must be referred.
- If the operating point of the fan will exceed the design operating point of the fan, there is a risk of motor
to overload and overheat. Please consult to DOGU IKLIMLENDIRME A.S., if the design operating point of the
fan will be exceeded.
WARNING: At very low speeds for converter-fed operation, there is a risk of operation at mechanical
resonance frequency. So, operation of motor at speeds lower than 300 rpm is not recommended.
Programming, first operation and periodic control of frequency converters should be made by qualified
personnel, according to manufacturer’s instructions.

Starter for centrifugal fans in the air handling units for single speed motors driving through V-belts are
normally of the direct-on-line type. However the customer or Electric Supply Authority may require motors
above 3kW to be operated by a star-delta starter, to reduce starting current.
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6- Setting Up Of Components
6.1- Dampers
Manually operated dampers can be adjusted to obtain the required air flow, by turning the control lever.
After setting the desired location on locking quadrant, control lever must be tightened. Dampers can be
equipped with the motor. Check that the blades turn back in closed position in case of power supply failure
during operation. Care must be taken to ensure that the actuator does not attempt to push the damper
blades beyond fully open or fully closed positions. All damper blades must be checked for free movement
and for fully open and fully closed positions.
6.2- Filters
Panel filters and zigzag filters are normally fitted within the unit prior to shipping.
Bag filters are normally shipped in closed carton boxes to avoid any collection of dust and loss of efficiency
prior to commissioning. Each bag filter is housed within a special holding frame with necessary locking
spring to ensure proper sealing.
Automatic roll filters consist of basic frame dispensing unit for clean media, rewind unit for dirty media,
drive system, roll filter media and control system. Normally filter media and control system are supplied
loose for site installation. For assembly, filter media roll is mounted on the dispensing unit taken along the
guide channel through working section and locked to the rewind unit. Differential pressure switch must be
installed and connected to the control panel as shown on the circuit diagram.
Absolute filters are shipped in sealed carton boxes. While assembly, special care must be taken to ensure
that each filter cell is properly sealed within the assembly frame with no possibility of air leakage.
Other type of filters such as active carbon filters, sand filters etc. will be supplied with manufacturer’s
instructions along with the units.
Filters that shipped separately in the unit should be assembled after cleaning the inner surface by
operating the fan. Before start-up, check if the filters have been installed.
6.3- Coils
All coils are leak tested and checked prior to assembly. Fins are checked for proper condition. However, they
must be checked once more and combed out if necessary, because they might be damaged during
handling and installation. Do not remove plastic covers from coil pipe connections until the unit is ready for
piping connections. Connections should be checked according to the project. Piping system should be
checked for any damage and leakage. System layout should take into consideration of possible coil
withdrawal.
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