Swegon SILVER M Assembly instructions

INSTALLATION –OPERATING - MAINTENANCE
AHU Swegon SILVER M
MANUAL
Swegon SILVER M - 2021.01.01

Contents
1. General 2 5. Commissioning, Service & Maintenance 14
These instructions are oriented to the current state of technology
at the time of their issuance. (Subject to modification)
1.1.
Intended utilisation
2
5.1.
Housing / Equipment
14
1.2.
Hazards
2
5.2.
Ventilator
14
2. Safety
3
5.3.
Belt drive (ventilator)
15
2.1.
Safety regulations
3
5.4.
Sound attenuator
16
2.2.
Markings and their use
3
5.5.
Filter unit
16
2.3.
Safety instructions
3
5.6.
Heat exchanger
17
3. Storage
and Transport
4
5.7.
Droplet seperator
18
3.1.
Site transport
4
5.8.
Cooling system
19
4. Installation
7
5.9.
Spray humidifier
20
4.1. Foundation / Base frame
7
5.10. Louver dampers 21
4.2. Equipment installation
7
5.11. Rotation heat exchanger 21
4.3. Structure-borne noise insulation
8
5.12. Plate heat exchanger 22
4.4. Potential equalisation / Grounding
8
5.13. Recuperative energy reclamation (KVS) 23
4.5. Frost protection
8
5.14. Direct lighted heat exchanger (burner chamber in the
4.6. Equipment attachment
9
airstream) 24
4.7. Ventilator installation / removal
9
5.15. Gas surface burner 25
4.8. Motor protection
10
5.16. Cleaning supplies 26
4.9. Electrical connection
10
5.17. Control Systems 26
4.10. Pocket type filter
11
6. Decommissioning 27
4.11. Heat exchanger connection
11
6.1 Decommissioning 27
4.12. Droplet separator
11
6.2 Dismantling and disposal 27
4.13. Steam heater connection
11
7 Emergency Measures 27
4.14. Refrigerant line connection
12
7.1 Fire prevention 27
4.15. Air duct connection
12
7.2 Leakage of harmful substances 27
4.16. Drainage line connection
12
8 Explosion Protection 28
4.17. Gas surface burner
13
8.1 Service, maintenance and repair 28
4.18. Direct lighted heat exchanger
13
8.2 Identification marking 28
8.3 Avoidance of ignition sources 29
9 System Component Service & Maintenance Table 30

INSTALLATION –OPERATING - MAINTENANCE
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SILVER M
INSTALLATION –OPERATING - MAINTENANCE
1. General
1.1. Intended utilisation
The equipment delivered by Huber & Ranner GmbH may be used
only for the conditioning of air. This applies to air filters, heaters,
coolers, humidifiers, dehumidifiers and conveyors. Any other usage
is specifically prohibited by Huber & Ranner GmbH.
The continuous observance of the existing installation, operating,
service and maintenance instructions is also considered integral to
intended utilisation!
Technical data
Technical specifications can be determined from the equipment
cards.
For technical related questions, please contact our customer service
department.
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
1.2. Hazards
The equipment should not be opened or accessed during
operation!
All rotating parts should be allowed to first come to a standstill.
Mechanical hazards
- Crushing injury to the hands on the suction-side doors
- Blowing open of doors with a pressure-side configuration
- Faulty damper switching (over or under pressure) can lead to
destruction of equipment components.
- The crushing of fingers when the air regulator and shut-off
dampers are moved.
- Never put hands in the vicinity of rotating parts, such as
ventilators, drive belts, WRG-rotors, etc.
- Loose or non-clinging pieces of clothing in the vicinity of the
suction openings and drive belts can lead to life threatening
injuries!
Hazards due to electrical energy
- Danger of short circuiting when connecting electrical
components.
- Due to high voltage and strong amperage, work should be
carried out only in a potential-free state.
- Due to static charge on the housing, proper grounding should
observed.
- All cables should be inspected for installation damage prior to
commissioning
- Explosion hazard when conveying an explosive atmosphere
(see Chapter 8: Ex-protection)
Hazard due to vibrations
Every operation has a critical turning speed range.
When operating in its range of resonance, the ventilator unit can
experience mechanical damage.
The range of resonance for turning speed regulated drives is to be
determined during commissioning, bridged over and recorded.
Hazard due to operating media/materials
- Refrigerant from direct evaporator or condenser may not
- be allowed to leak into the environment.
In the event of fire, poisonous gases and smoke (flammable
materials) can result, which must not be inhaled.
- Avoid bodily contact with brine when cleaning, filling or
emptying. Danger of poisoning and injury! Observe
manufacturer's information.
- Compressor oil can provoke allergic reactions if contacted or
swallowed. Avoid bodily contact
- When cleaning the equipment, care must be taken, that dust
from the filters or components is not inhaled, as allergens,
fungi and bacteria may be contained therein.
Hazard due to thermal influences
- Burn hazard from pipelines.
- Dangerous operating media include the electrical heater,
vapour humidifier and hot water.
- Freeze-burn hazard from cold parts (e.g. cold water lines,
refrigerant lines) and cold components (e.g. cooler, suction
chamber)

INSTALLATION –OPERATING - MAINTENANCE
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INSTALLATION –OPERATING - MAINTENANCE
2. Safety
2.1. Safety regulations
The climate control unit has been manufactured according to the
latest state of technology and approved safety related regulations.
None-the-less, hazard to life and limb of the user or a third party,
degradation of the equipment and other material assets can arise
due to improper utilisation or utilisation, for which the unit was not
intended.
The unit may be operated only in a technically faultless condition for
its intended purpose, with an awareness towards safety and
potential hazards. Faults, which can diminish operational safety,
must be immediately rectified.
Installation work and commissioning may be carried out exclusively
by trained specialist personnel. The manufacturer's warranty no
longer applies if servicing is not properly carried out.
Fundamental to the warranty is also the completion of a service
contract with a qualified specialist company and its verification by
means of protocol documentation.
The pressure devices built into the equipment are subject to
recurring inspection by a qualified specialist company for air
conditioning technology in accordance with the Industrial safety
regulations (BetrSichV).
The operating Instructions must be read carefully prior to
installation and commissioning by installers, commissioning and
operating personal. Only though adherence to these operating
instructions can mistakes be avoided and fault-free operation be
achieved.
If arbitrary or unauthorised modifications or alterations are
undertaken on the equipment, the manufacturer's warranty is no
longer valid.
The equipment is part of an air conditioning system and may be
operated only after installation of the entire system.
2.2. Markings and their use
This symbol indicates an immediate danger. Failure to follow these
instructions can result in injury to persons or damage to the
equipment.
"Environmental symbol" identifies the points, which could result in a
charge for the environmental pollution.
2.3. Safety instructions
In order to avoid overheating damage to the system, the steam heat
exchanger should be operated only with the ventilator running.
When using the temperature limiter, it must be observed that the
temperature monitor is adjusted ca. 5K lower than the safety
temperature limiter.
The allowable pressure level for the heat exchanger and associated
piping may not be exceeded.
Accessibility to safety relevant components must be guaranteed
over the entire serviceable life.
The electrical connection, as well as the servicing of electrical
components, may be carried out only by an electrician specialist.
The stipulations of VDE 100/DIN 57100 are especially applicable.
In conjunction with the initial connection and subsequent
inspections, the electrical connection bolts must be re-tightened.
Special regulations, such as building oversight guidelines for fire
protection regulations related to air conditioning systems, are
compulsorily prescribed and, for this reason, must absolutely be
adhered to.
Refrigerant (odourless and tasteless) suppresses atmospheric
oxygen and can lead to asphyxiation. In the event of a refrigerant
leak, the machine room should be accessed only with heavy duty
breathing protection equipment.
When disposing of refrigerant, environmental protection
regulations should be observed.
When the equipment is functioning in an explosion hazard
atmosphere, please observe Chapter 8!

SILVER M
INSTALLATION –OPERATING - MAINTENANCE
3. Transport and storage
Component sections or modules (few sections assembled as a
single module) of AHU are supplied on wooden blocks and
wrapped with foil covering. Do not remove foil covering before
assembly works start. Check the packaging for damages
immediately at the delivery as well as delivery completeness
according to project specification and transport slips.
AHUs, component sections or modules may be moved or
transported around the site or to assembly place only with
suitable transport tooling by qualified personnel.
If AHUs are going to be stored on site before assembling them in
place, they should be protected against weather conditions,
moisture, dust and damage. All oft he casing openings must be
protected by foil, to protect them from contamination.
Please note that the protective foil which touches directly
galvanized sheets, due to condensation can cause permanent
damage within one day on a galvanized sufrace (white
corrosion). If possible, avoid foil for covering AHU’s.
3.1. Site transport
All delivered AHUs have individual labelling according to order
specification.
Assembled component modules have to be transported in normal
working position. Do not transport modules tilted, upside down or
stacked on top of each other.
Before you move or lift single section or complete AHU check its
weight first and make sure if planned transport method is proper.
Use following transport methods for AHUs:
Method 1
Transport with forklift.
AHU stands on wooden blocks. Before lifting AHU make sure
the forks are longer than width of the unit.
Method 2
Transportation with eyebolts
- maximum suspension angle ‐ β=60° (α=120°)
- maximum weight of transportation section - 1700 kg
Method 3
Transportation with traverse and eyebolts
- maximum weight of transportation section - 2500 kg
NOTE: While transporting unit using traverse, eyebolts may only
be subjected to vertical loads.
NOTE: BEFORE EACH DELIVERY TRANSPORT METHOD MUST BE AGREED WITH AHUs SUPPLIER
During AHU transportation with a crane all safety rules must be obeyed. Only those cranes, load attachment devices, rigging,
etc. may be used for the transport of AHUs components, which are suitable and approved. The lift rig must not be able to damage the unit.
Lifting from the transport vehicle or the ground must be undertaken slowly and carefully. Jerking movement must be avoided.
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INSTALLATION –OPERATING - MAINTENANCE
Method 4
-Transportation with base frame eyes and traverse
only UB frame
- maximum weight of transportation section
- 8000 kg - <5000 kg "standard option"
‐ 5000 kg ‐ 8000 kg "heavy option" ”
Method 5
Transportation with base frame openings using
transport pipes and traverse
- only unit sections without eyebolts
Transport pipe length = unit width + 300 mm (150 mm each
side) - maximum section weight - 2500 kg
To transport the modules use pipes with appropriate marking,
dedicated to transport the particular module.
Transport pipes must be placed in correct base frame openings.
Transport pipes are included in delivery.
Method 6
Only when no transport eyebolts or transport pipes
are not available
Transportation with lifting straps - for transport sections without
base frame using traverse and non-slip mat.
- maximum weight of transportation section - 3500 kg
Modules where transport with non-slip mat is needed will be
properly marked.
For each transportation modules 4 non-slip mats pieces of 0,5 m
long are supplied. Non-slip mats have to properly disposed after
use.
Make sure that load is balanced when transporting with lifting
straps (centre of balance), avoiding moving of the load or tilting.
Before lifting the unit on place make a pre-lift on around 50 cm
to check centre of balance, correct lifting elements attachment
and stability of load.
On customer request it is possible to mark centre of balance on
each individual transportation section or module.
Marking centre of balance is charged extra and has to be
specified at the order.
NOTE: BEFORE EACH DELIVERY TRANSPORT METHOD MUST BE AGREED WITH AHUs SUPPLIER
During AHU transportation with a crane all safety rules must be obeyed. Only those cranes, load attachment devices, rigging,
etc. may be used for the transport of AHUs components, which are suitable and approved. The lift rig must not be able to damage the unit.
Lifting from the transport vehicle or the ground must be undertaken slowly and carefully. Jerking movement must be avoided.
5

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INSTALLATION –OPERATING - MAINTENANCE
4. Installation
4.1. Foundation / Base frame
Before positioning the housing module, the foundation and base
frame must be checked for stability and a secure seating of all
threaded connections. The support surface must be flat. Tolerance
to the horizontal max. 0.5%. Deflection of steel construction max.
1/1000 of the beam length. Irregularities can result in door-
twisting, leading to possible leaks and surface abrasion.
The support surface must be level, in order that draining of the heat
exchanger and tanks are warranted.
Prior to positioning, the foundation and base frame must be cleaned
and free of ice.
Position the equipment on a level and secure foundation.
Irregularities must be compensated for with appropriate base
supports.
The foundation surface should correspond to the equipment size. If
a strip foundation (concrete or steel beam) is used, the equipment
must be supported on the outer equipment frame. The minimum
support width is 55mm. In the case of strip foundations from a
device width of 2.0 m, cross beams or longitudinal beams are also
required at the start and end of the device and at the component
separation points. Supporting point spacing between the equipment
and the foundation should be maintained to a max. 1.2 m in length
and width, while a max. equipment floor loading of 100 kg/m²
should be heeded.
When determining the height of the foundation, the required siphon
height must be considered.
Freedom of movement of the doors, removability of assembly
elements and the fault-free sealing of assembly connections
depends upon exact alignment of the assembly.
Equipment must be protected against construction dust and
contaminants, as well as damage until commissioning!
When equipment pieces are standing next to each other, their
foundation must also be supported at the midsection!
4.2. Equipment installation
Accessibility for repair and service work must be warranted.
In addition, the pivot range of the doors must be kept clear; there
must not be any obstacles, such as cable or pipes, installed in front
of removable panels. The unit must be precisely aligned horizontally
and vertically with shims.
The equipment must be aligned horizontally and vertically by means
of base supports.
The dirt and soiling arising during transport, setup and installation
(especially drilling chips) must be removed as soon as possible.
We also recommend cleaning the interior prior to commissioning.
External installation
If a roof connecting frame is available, one should ensure that it is
insulated since condensation may occur.
The climate control unit in its weatherproof design is not a
replacement for a roof!
Roof framing and weatherproof equipment are not a substitute for
roofing!
External component impact points are to be caulked with the
durable elastic and weather resistant sealing compound as provided.
For roof units (weather resistant model), an additional tin roof, rain
covering will be provided.
Assembly of the rain covering will be carried out at the factory.
Larger pieces of equipment will be only pre-assembled, but must be
bolted together and weather stripped on-site.
Weather stripping will be carried out as follows:
Tape the sealing strip to the rain roof flange, caulk the durable
elastic sealing compound and cover with the loose profiles as
delivered. The covering profile is to be subsequently bolted to the
rain roof flange.
If the paint finish is damaged during installation, this must be
touched up.
Depending on the wind load, the air conditioner is safe and
structure-borne noise is decoupled when connected to the
substructure.

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INSTALLATION –OPERATING - MAINTENANCE
4.3. Structure-borne noise insulation
The equipment is to be installed, insulated from structure-borne
noise.
Regarding the foundation
In order to obtain structure-borne noise and vibration insulation,
the appropriate base supports (e.g. elastomeric stripping) must be
laid between the equipment base frame and the foundation,
whereby the manufacturer's information is to be observed. In
general, the equipment base should be supported under the face
sides and component attachment points and, if the component
length is greater than ca. 1.2 m, under the longitudinal side, as well.
Regarding ducting
The equipment is to be installed, decoupled, to the ducting system.
The decoupled ducting attachments for hygienic equipment must
not reveal any grooves or depressions.
4.4. Potential equalisation / Grounding
All non-conducting electrical attachment points must be bridged
over with a potential equalisation, e.g. flexible attachments,
ventilator motor unit. The entire assembly is to be grounded.
Sufficient lightning protection must be provided for outdoor
installation.
4.5. Frost protection
Frost protection capillary tubing must be evenly stretched over the
entire exchanger surface at the air outlet.
Care must be taken so that frost protection capillary tubing is not
buckled or damaged.

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INSTALLATION –OPERATING - MAINTENANCE
4.6. Equipment attachment
Installation material is provided. This is found in the marked
equipment modules.
In order to connect the equipment components, the following tasks
are to be carried out:
- Self-adhesive sealant is to be attached per section point to the
profile frames in two circular tracks on the equipment
component.
- Winch the equipment components together until they are
positioned exactly together
- Do not pull the equipment components together with the
attachment bolts. Deformation hazard!
- The bolts can then be secured. The equipment components are
to be connected with the prescribed equipment corner angles.
- For larger equipment depth, the modules should be connected
with additional centring threaded connections.
- The supplied pan connector (see diagram) must be installed on
site with unit widths between 2000 and 3000mm.
- For large pieces of equipment, the square tubing should be
additionally secured with connecting clamps
- The section points of the outer equipment components are to
be subsequently sealed with the sealing compound as
provided.
4.7. Ventilator installation / removal
Dismantling tracks with individual designs can be delivered as
accessories for the installation and removal of the motor or
ventilator, respectively.
For this, the motor will be transported by means of a trolley. The
drive motor can be placed on a lift wagon, for example, in front of
the unit.

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INSTALLATION –OPERATING - MAINTENANCE
4.8. Motor protection
Motors are to be protected from overload in accordance with DIN EN
60204 / DIN VDE 0113.
A motor protection switch is prescribed and should be adjusted to
the rated motor current value (see type data plate). A higher value is
not permitted!
Motors with a built in PTC thermostat detector are to be protected
via a PTC thermostat actuation device.
Generally, motors with a rated current up to 3 kW can be switched
on directly (observe performance limitations from the responsible
energy supplier). For larger motors, a star-delta-start or soft-start
is prescribed.
On-site safety precautions are to be taken to prevent overload,
short circuit, over or under current and excessively high ambient
temperatures.
Special care must be taken when connecting motors, especially on
equipment, for which the motors are outfitted with two turning
speed levels. Connections must be made in accordance with the
specifications on the type data plate and the connection plan on the
inside of the motor terminal box.
Protection fuses and automatic circuit breakers are not sufficient for
motor protection. The manufacturer's warranty no longer applies to
damage caused by insufficient motor protection.
4.9. Electrical connection
All electrical work must be performed exclusively by qualified
specialist personnel with unit power disconnected and protected
against be switched back on.
All electrical connections are to be made in accordance with valid
international, national and local regulations and guidelines, as well
as manufacturer's instructions.
In order to prevent damage, the connection diagram in the terminal
box must be respected.
Watertight sealing must be ensured when making electrical
connections. Connections from below or watertight threaded
connections (minimum protection type IP65) should have a sufficient
cable radius.
All electrical terminal connections (switching cabinet, frequency
converter, motor, etc.) should be checked for secure seating and re-
tightened if necessary (see also DIN 46200).
All electrical cables, which run throughout the housing, must be
affixed and prevented from being damaged.
In order to prevent overheating of the fan heater, the after-run time
of the fan must be observed. This should be adjusted between 6
and 8 minutes, depending on the size.

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INSTALLATION –OPERATING - MAINTENANCE
4.10. Pocket type filter
Pocket type filters are to be secured with fastening devices in the
mounting frame. For this, an air tight seating around the mounting
frame must be ensured.
Use the directions as provided with the filter for installing the
pocket type filter or channels, respectively, in the mounting frame.
For assembly, it must be observed that the pocket type filter is in its
correct position and that the filter surface will not pinch or clamp.
Damage or pressure marks on the filter surface are to be
avoided without fail, as otherwise the filter can rip during
operation and the filter category is no longer warranted.
Removable filters are to be installed sideways in the existing insert
tracks. It must be heeded that a seal is installed between the filters.
The continuous monitoring and cleaning of the filter is of great
importance and must be especially heeded, as a contaminated filter
will reduce air performance and, over a lengthy downtime,
represents an increased hygienic risk.
4.11. Heat exchanger connection
The heat exchanger is to be connected only in counter current flow,
as otherwise its performance can no longer be guaranteed.
Feed and return flow lines must be connected in such a manner that
no oscillation transfer and thermal stresses can occur.
Connections are to be made respective the „Feed line“, „Return line“
markings. Prior to making a connection, check sign positioning with
respect to the drawing and its function.
Flanges, connections and feed/return line shut-offs are to be
arranged in such a manner that the air filter can be removed without
excessive dismantling work.
A fault-free air bleeding and draining of the air heater and pipelines
is to be ensured by the user on-site.
When tightening the on site threaded connections on the heat
exchanger adapters, a pipe wrench should be used to carefully apply
a counter force, as the inner pipe may otherwise be twisted and
damaged.
In the event of frost hazard, the heat exchanger is to be protected
against freezing.
It must be assumed that residual water will remain in the heat
exchanger following normal drainage. For safety reasons, the heat
exchanger must additionally be purged with compressed air
(freezing hazard!).
4.12. Droplet separator
The detachable cover should be removed for installing or de-
installing the droplet separator.
Droplet separator cartridges are hung on the upper slide rail and the
lower guide rail and pushed into, or pulled out of the unit,
respectively.
When installing the cartridges, the air flow direction arrow should be
observed.
4.13. Steam heater connection
A safe condensate drainage must be continually ensured.
Controllability in partial load operation requires individual steam
registers to be outfitted with its own condensation drain.

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INSTALLATION –OPERATING - MAINTENANCE
4.14. Refrigerant line connection
The guidelines from the chapter, Heat exchanger connection, should
be observed.
Before connection, check whether the factory filled evaporator gas is
still present.
The maximum operating parameters (pressure, temperature, etc.)
may not exceed allowable factory specifications.
Because the pipeline system in use has a relatively small diameter, it
must be assumed that residual refrigerant will remain in the heat
exchanger following normal drainage. For safety reasons, the heat
exchanger must additionally be purged with compressed air.
4.15. Air duct connection
The air duct connection should be tension-free by means of elastic
supports. Under no circumstances may the elastic support
installation length represent the stretched length.
Air duct connection can also be accomplished with decoupled
profile frames.
During assembly, the grounding, the protective earth conductor
system and the potential equalisation must be professionally
installed.
4.16. Drainage line connection
In every situation where water build-up can occur during operation,
a siphon is to be installed in the immediate vicinity of the device in
order to ensure fault-free water drainage, to prevent odour build-
up and to avoid leaks or leak air intake from the condensation drain.
This applies to both the suction and the pressure sides.
We recommend using a ball siphon on the suction side and a normal
siphon (ball removed) on the pressure side.
The siphon height should be accurately determined, dependent
upon the pressure head.
Every siphon must empty freely over a collector line funnel.
Horizontal drainage lines must have a sufficient diameter and slope
gradient, as well as ventilation and bleed properties for fault-free
water drainage.
Other drain lines (e.g. cleaning tanks) are to be outfitted with
individual stop valves if these are connected to the drainage system.
The drainage lines should not be joined in front of the siphon or
stop valve.
Assembly and layout should be in accordance with the enclosed
siphon installation instructions.

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INSTALLATION –OPERATING - MAINTENANCE
4.17. Gas surface burner
The regulations and manufacturer's guidelines applicable to burners
and gas connections must be observed.
When installing the equipment, possible requirements from the
certifying authorities, all local regulations, as well as all demands
from the national equivalent to the DVWG and the technical
regulations for gas installation (TRGI) must be adhered to precisely.
4.18. Direct lighted heat exchanger
The burner must be secured to the prescribed burner attachment
plate.
The flame tube length for oil or gas burners must be adapted to the
warm air generator burner chamber in such a manner that the flame
exits the flame tube only after it is inside the burner chamber.
The heat exchanger must be built in with a natural incline towards
the condensation drain.
The regulations and manufacturer's guidelines applicable to the
burner, condensation drain, fresh air supply and chimney must be
observed.
Condensate must never remain in the heat register and must drain
freely at all times. Therefore, the condensate drain line must also be
connected.
The safety temperature limiter must be installed 50 cm to 100 cm
downstream from the fan heater in the flow direction.

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INSTALLATION –OPERATING - MAINTENANCE
5. Commissioning, Service & Maintenance
5.1. Housing / Equipment
General
Before opening the doors, the ventilator must be switched off, the
electrical power source disconnected and the system allowed to
come to a standstill (minimum 2 minute waiting period).
The pertinent directives and local regulations are applicable to the
electrical installation.
As a matter of principle, the accident prevention regulations must
be observed!
A functional inspection of safety measures should be regularly
carried out at the rated air volume!
The primary equipment operator is responsible to allow only those
persons to work on the equipment, who are familiar with the
fundamental regulations of occupational safety and accident
prevention, as well as these operating, service and maintenance
instructions, and who have been instructed in the handling of the
ventilator.
These operating instructions are to be permanently maintained at
the on-site location of the air conditioning unit deployment.
Commissioning
In order to put the system into service, the equipment must be
completely assembled with all media lines connected and all
electrical components properly cabled.
Close drain valves during operation.
Prior to switching on the system, an inspection of the protective
earth conductor must be carried out.
A functional inspection and performance measurement must be
carried out with a written protocol being established.
Maintenance
- All equipment chambers should be checked for contamination
and damage, and the chambers cleaned accordingly.
- Check the processes in free run-out.
- Check doors for leak-tightness and latches for freedom of
movement.
- Check duct connection attachments for leak-tightness.
After completing service and maintenance work, all points
applicable to commissioning when switching on the machine must
be adhered to.
5.2. Ventilator
Commissioning
Prior to commissioning the ventilators, the following prerequisites
must be fulfilled:
- Connection to the ducting system in place
- Discharge air and supply air lines open
- Ducting system and equipment chamber free of foreign objects
and contaminants
- Fan wheel checked for freedom of movement by manual spin-
up
- Transport protection has been removed
- All inspection doors are closed
- V-belt tension checked
- The max. speed must be set according to the nameplate on the
drive
- After installation of the motor and impeller, the overlap
dimension of nozzle and impeller must be adjusted correctly;
otherwise there will be a reduction in output. Refer to the
manufacturer’s documentation for the overlap dimension
based on the make, model and size or contact Huber & Ranner.
After completion, a test run is to be carried out to check
performance and direction of motor rotation.
Check ventilator turning direction against the directional arrow on
the housing by briefly switching on the system. In the event of an
incorrect direction of travel, electrical polarity on the motor must be
changed while observing safety regulations.
After obtaining ventilator operating turning speed, immediately
measure the power input from all three phases with doors closed.

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INSTALLATION –OPERATING - MAINTENANCE
The measured values must not exceed the rated values (hence, the
motor rated performance) depicted on the type data plate. Shut off
the unit immediately if an over-current situation exists. If a
dissimilar phase current exists, check the motor connection.
The manufacturer's specifications for maximum motor-ambient
temperature should be observed.
Any combination of frequency converter, motor and fan can vibrate
at one or multiple frequencies. These vibrations must be determined
during the commissioning process and suppressed with the
frequency converter.
Maintenance
- The ventilator should be cleaned as necessary in order to
prevent an out-of-balance condition.
- Check the bearing and re-lubricate as necessary. Re-
lubrication deadlines must be respected!
- Check the vibration damper for function.
- Check attachment bolts and re-tighten as necessary.
- If problems are detected (noises), check ventilator and motor
bearings.
- If problems are detected (vibrations), check the ventilator
running wheel without the v-belt for out-of-balance condition
(the running wheel must come to a rest in any position).
Removal from service
For lengthy periods of downtime, the ventilator should be turned 1x
per month in order to prevent one-sided loading of the bearing.
For periods of downtime longer than 3 months, the v-belt should be
removed in order to prevent spot-loading of the bearing.
Prior to re-commissioning bearings with a re-lubrication adapter,
remove the old grease and re-lubricate. The directives of the
ventilator manufacturer must be observed.
5.3. Belt drive (ventilator)
Commissioning
Prior to commissioning, check for correct tension and alignment.
Subsequent to commissioning, the v-belt drive should be run under
load. After ca. 30-60 minutes, the tensioning device should be
readjusted.
It must be heeded that the belt tension is checked after the first 50
operating hours, and re-tensioned as necessary.
The v-belt must neither be too taut nor too loosely adjusted, as this
can reduce the operating life of the motor and ventilator bearings.
Flat belts
A direct start-up must be avoided for flat belts. The belt can run off
of the drive due to sudden application of force.
Stretching of flat belts
Two thin measurement markings are located on the upper side of
the belt. The belt should be tensioned until the rated value of the
measurement marking gap is obtained (2% belt stretch).
The drive must be turned several times in order to check the tension
once again.
It must be heeded that the belt tension is checked after the first 100
operating hours, and re-tensioned as necessary.

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INSTALLATION –OPERATING - MAINTENANCE
Maintenance
- Check the belt drive for contaminants, damage and wear
- Check for secure attachment of the complete drive
- Replace only complete belt sets
- Check protection equipment for function
- Adjust alignment of the motor and ventilator plates
- Check belt tension and re-tension as necessary
5.4. Sound attenuator
Commissioning
Check the baffle for contaminants and damage.
Maintenance
- Check the baffle for contaminants and damage and carefully;
clean or repair with the proper tooling as necessary
Do not damage the surface.
5.5. Filter unit
General
Sufficient air filtering and regular filter changes will reduce the dust
content in the air and prevent contamination of the equipment and
ducting system. Excessive filter service usage degrades the air
quality due to odours. Moisture penetration of the filter must be
avoided for hygienic reasons.
The filter should be checked at regular intervals and replaced as
necessary, dependent upon operating conditions. As a rule, if the
manufacturer's prescribed pressure differential is exceeded, the
filter should be replaced. When replacing the filter, the leak-
tightness around the filter adapter frame should be checked.
Damage or pressure marks on the filter surface are to be avoided
without fail, as otherwise the filter can rip during operation.
Filter resistance can be determined by means of a differential
pressure measurement using an inclined-tube manometer, or
electronic manometer.
The pocket type filter is not reclaimable. When the final resistance is
reached, the pocket type filter must be replaced with a new one.
Replacement of individual filter elements is allowable only in case of
damage to the individual elements, and as long as the previous
replacement was no longer than 6 months back.
When replacing the filter insert, a breathing protection mask with a
P3 filter should be worn and the local environmental protection
regulations observed.
Dust laden filters pose an increased health risk.
Filters must be stored in a dry, dust-free environment. A filter
should no longer be used upon expiration of its minimum shelf life.
Commissioning
Filter inserts are secured in the mounting frame with tensioned
fastening clamps. Filter inserts elements must not be pinched or
clamped. Check the filter insert for an air-tight seat in the mounting
frame.
Prior to commissioning, the filter units must be checked for
damage.
Maintenance
- Check pocket type filters and frames for contaminants and
damage
- Check filter seat for leak-tightness and visually inspect for
damage
- Replace filter inserts with noticeable dust contamination,
odours or leakage.
- Replace filter inserts when the recommended final resistance is
reached
- Replace, at the latest, the 1st filter level after 12 months and
the 2nd filter level after 24 months.
Filter category
recommended final pressure
differential
G1-G4
150 Pa
F5-F7
200 Pa
F8-F9
300 Pa

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INSTALLATION –OPERATING - MAINTENANCE
Activated carbon filter
The cartridge is secured with a bayonet fitting. When replacing the
filter, remove the cartridge by turning it out of the frame.
In order to ensure a fault-free functioning of the filter cartridge, an
odour check following filtering should be carried out. If necessary,
the cartridge should be replaced.
Special filters
Special filters are serviced in accordance with the manufacturer's
service instructions.
5.6. Heat exchanger
General
In order to avoid freezing of the heat exchanger, an air-side, water-
side or condensate-side frost protection should be installed,
dependent upon the model.
In order to achieve an optimal temperature stratification
and/or to prevent potential freezing of units with multiple
heat exchangers, use of the piping in the Tichelmann
system is recommended. If this is not feasible, the hydraulic
compensation must take place with a regulating/shut-off valve.
The compensation must be carried out on site by the system
operator.
Do not use high-pressure water or high-pressure steam to clean the
heat exchanger. The lamella-fins can be damaged (exception is the
steel-galvanised heat exchanger with reinforced lamella-fins).
A still unavoidable amount of residual Stanzoil, left over from the
production process, will be present during the initial weeks of
operation.
Clean the heat exchanger while installed or, if it cannot be accessed,
it can be removed for cleaning. Removed contaminants must not be
allowed to seep into surrounding component parts. Contaminants
and dirty water should be carefully removed.
Use water only if the chamber or flooring can collect the water and
direct it away.
When cleaning copper or aluminium lamella-fins, compressed air is
used by carefully blowing against the direction of air flow.
The surface of the lamella-fin packets are cleaned with a brush (not
metal) or a vacuum cleaner. Hard or pointed cleaning utensils may
not be used.
Commissioning
The on-site piping is to be carefully cleaned prior to connection of
the heat exchanger.
Check to ensure the proper connection of the feed/return lines.
Give heed to counter current flow.
When the system is being filled, the heat exchanger is to be
carefully bled once it has reached the highest point of the system.
An improperly bled heat exchanger can form air pockets, which can
lead to a reduction in performance.
Check shut-offs and other fixtures for proper installation.
For filling, the following work is to be carried out:
- All shut-offs and regulating devices should be fully opened
- Open the prescribed bleeding devices, as long as automatic
bleeding devices are not provided.
- The system should be slowly filled from its lowest point.
- Gradually close the bleed valves at the various height levels, as
soon as air-free water is discharged.
- Switch on the primary and secondary pumps, check the turning
direction and operate the system for a longer period of time.
- Drive the regulating valve to the converse position (three-way
valve)
- Follow up control by re-opening the bleed valve
- Check system for leak-tightness

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INSTALLATION –OPERATING - MAINTENANCE
Frost protection
Frost protection is assured by means of a frost protection sensor,
which must be adjusted depending upon the percentage of glycol in
the media.
Percentage of
glycol
Setting value for
ethylene-glycol
Setting value for
propylene-glycol
20 %
-11 °C
-7 °C
30 %
-18 °C
-12 °C
40 %
-25 °C
-19 °C
The complete frost protection switching (e.g. mixing valve,
circulation pump, louver damper ventilator, heating supply) is to be
checked for function with available frost protection thermostats.
If the temperature near the unit can drop below 5°C, the frost
protection sensor must be installed inside or the exterior frost
protection capillary must be insulated.
The warm water supply to the heat exchanger must be assured even
after switching off of the RAC equipment.
Damage, which is the result of frost impact, is not covered as part
of our warranty responsibility.
Maintenance
- Allow the heat exchanger to cool down to the ambient
temperature
- Check lamella-fins for contaminants and clean as necessary
- Check lamella-fins and piping for damage and comb out
possible bent or warped fins.
- Check heat exchanger leak-tightness
- Check feed/return lines for function
- Check frost protection for function (thermostat by means of
coolant spray)
- Clean the condensation drain at the cooling radiator, check the
siphon for function and clean at the beginning of the cold
period, then refill
Removal from service
The heat exchanger must be completely emptied for longer periods
of standstill, especially with a freezing hazard. For this, first remove
the bleed air valve screw, then the drain plug. Subsequently blow
out each heat exchanger with compressed air for a complete
purging, as a residual amount of media can remain in the heat
exchanger following a free drainage.
5.7. Droplet separator
General
The droplet separator will bring its full effectiveness only after a
run-in period of ca. 4 weeks.
The droplet separator is to be cleaned by rinsing with water as
necessary. With large amounts of contamination, cleaning can be
done with a steam jet-spray unit.
An excessively contaminated and calcified droplet separator with a
plugged drip-mould can lead to a droplet run-off and increased
pressure loss.
The droplet separator, possibly located downstream from, and on
the air-outlet-side of the air cooler, as a rule contains lamella-fins
made of PPTV, which are temperature resistant up to +95°C.
Droplet separators are required only if the limiting speed will be
exceeded and a specific condensate volume is present.
When cleaning the droplet separator, remove the cartridges and
lamella-fins (remove bio-film).
During installation, heed air flow direction.
Commissioning
Check the droplet separator installation direction. The drip-mould
must indicate a direction opposite the air flow.
Maintenance
- Check the droplet separator and condensate tank for
contamination and damage; clean if necessary.

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INSTALLATION –OPERATING - MAINTENANCE
5.8. Cooling system
General
Because the cooling components in the RAC equipment have very
differing designs, it is not possible in this context to provide a
detailed description of the work related to commissioning, service
and maintenance. The individual operating instructions must be
observed.
Bodily contact with refrigerant must be avoided, as freezing of the
skin and limbs or damage to the eye retina can result. Equipment
for personal protection against the effects of refrigerant must be
used in accordance with regulations comparable to German VBG 20
(protective glasses, gloves, etc.)!
Modifications to the system may be carried out only by authorised
specialist personnel.
The loose filter dryer included in the delivery may be opened only by
the cooling system commissioning personnel and it must be
installed immediately, as air humidity can damage the filter dryer.
Commissioning
Maintenance
Depending on the operating mode and filling quantity, maintenance
should be carried out under a maintenance contract at least once a
year by a qualified specialist refrigeration company in accordance
with VDMA 24186, and in accordance with F-Gas Regulation (EU)
517/2014, preferably before the start of the cooling period. In
addition to the service and inspection work, further information
from the component manufacturer must also be observed.
According to the F-Gas Regulation (EU) 517/2014, the prescribed
intervals for leak tests depend on the type of refrigerant and the
refrigerant filling quantity.
The system filling quantity is converted to a CO2 equivalent:
Refrigerant filling quantity (t) * GWP = CO2 equivalent of the system
GlobalWarmingPotential:
R134a = 1.430 t/kg
R407c = 1.774 t/kg
CO2 equivalent
Frequency of control checks
from 5 t
annually
from 50 t
semi-annually
from 500 t
quarterly
Commissioning may be carried out only by a qualified cooling and
refrigeration specialist company. Inspection work
The checks or work tasks listed below can be carried out by the
operator.
- Clean lamella-fin surfaces in order to avoid excessive
condensation pressures. Contaminated surfaces lead to
performance loss. Do not damage piping or lamella-fins.
- Check the compressor oil level. The oil should cover at least
half of the viewing glass with the compressor switched off
- Check and clean condensation drain. Be aware of unusual
odours or operating conditions.

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INSTALLATION –OPERATING - MAINTENANCE
5.9. Spray humidifier
General
Switch on the pump only if the scrubber filled with water in order to
prevent damage to the slip-ring seal.
In order to warrant protection against a dry running condition, the
pump must switch off when the water level falls below 20mm above
the suction line.
Pull the floating switch cable in or out as appropriate.
The water quality must be hygienically faultless (germ-free).
The conductivity of the water must lie within the limits as set by the
manufacturer.
It must also be ensured that the condensate cannot return to the
drinking water network.
The conductivity of the water must be within the limit values
specified by the manufacturer.
The float valve must be set so that the fresh water supply shuts off
at a maximum water level 10 to 20mm below the overflow nozzle.
UV-radiation can be suitable for a continual air disinfection.
Chemical disinfection media (biocide) should be used only when
its harmlessness to health in operational concentrations can be
verified.
When using additives, it must be ensured that foam is not produced
when mixed with water.
Commissioning
Commissioning tasks are to be carried out in the following order:
- Clean any foreign objects from the spray humidifier tank
- Check the spray humidifier for proper condition as well as
possible visible damage (transport and installation damage).
- Check the nozzle support tubing and nozzles for firm seating
and direction (with or opposed to airstream)
- Inspect spray humidifier pump screen
- Fill water level to 20mm above suction pipe.
- Set dry running condition protection.
- Fill the system to ca. 10-20mm below the overflow nozzle
- Set the float valve (slide the float element and adjust the lever).
- Start equipment operation, initially on the air-side, then switch
on the spray humidifier.
- Check the pump turning direction.
- Set the pump motor over current actuator to rated current,
measure the power input and record in the protocol
- Check all pipe connections for leak-tightness and re-tighten
as necessary.
- Check the float valve for function.
- Set blow-down device
- Set possible biocide additives
- Operate the spray humidifier for ca. 2-3 hours and check for
function and leak-tightness
Subsequent to commissioning and within the first 700 operating
hours, a weekly germ-count should be made of the circulation water
and, as necessary, measures should be taken to improve the water
quality.
Maintenance
- Decalcification of entire spray humidifier
- Switch off the ventilator system, add in the lime solvent to the
circulation water and operate the circulation pump until the
lime is dissolved. Subsequently, thoroughly rinse and
neutralise the entire spray humidifier and clean the strainer.
- Decalcification of the humidifier nozzles and nozzle fittings,
under no circumstances may the nozzle bore holes be cleaned
with hard objects.
- Clean the droplet separator and flow straightener with water
(max. 50°C) or with a thinned formic acid, decalcify and
thoroughly rinse with water or clean with a steam jet-spray
unit
- Check the water quality
- Check float valve
- Clean and refill the integrated siphon
- The tank, pump and fixtures are to be emptied when operation
has ceased
- Check the spray humidifier pump for fault-free running and
water discharge.