WEGER WALTER GMBH DIWER EVO Series User manual

INSTALLATION AND
OPERATING MANUAL
FOR
WEGER AIR HANDLING UNITS
ENGLISH
Printed: 02/2015
Please read carefully and keep for future reference.

WEGER WALTER GMBH
HANDWER ERZONE, 5
I-39030 IENS/EHRENBURG (BZ)
ITALY
PHONE: [phone]
FAX: [phone]
E-mail: [email protected]
Website: www.weger.it
Always observe all relevant standards
and statutory regulations.
Subject to changes without prior notice

Installation and Operating Manual
Printed: 02/2015
TABLE OF CONTENTS
1. General information .................................................................................... 6
1.1. Unit series .......................................................................................................................... 6
1.2. ATEX units ......................................................................................................................... 7
2. Safety ........................................................................................................ 10
2.1. Intended use .................................................................................................................... 10
2.2. Statutory regulations ....................................................................................................... 11
2.3. Safety symbols and signal words ...................................................................................... 12
2.4. Safety instructions ........................................................................................................... 13
2.4.1. Risks during loading/unloading and transportation ......................................................... 13
2.4.2. Risks posed by doors ........................................................................................................... 13
2.4.3. Risks posed by fans .............................................................................................................. 13
2.4.4. Risks from electric power .................................................................................................... 14
2.4. . Risks posed by dampers, including air flow control and shut-off dampers ........................ 14
2.4.6. Risks from process chemicals / materials ............................................................................ 1
2.4.7. Risks posed by steam heaters ............................................................................................. 1
2.4.8. Risks from hot/cold components and media ...................................................................... 16
2.4.9. Risks from filter dust and other contaminants .................................................................... 16
2.4.10. Risk of explosion (ATEX units) ........................................................................................... 17
2.4.11. Risk of damage to property and the environment ............................................................ 17
2.5. Emergency procedures ..................................................................................................... 19
2. .1. Fire fighting .......................................................................................................................... 19
2. .2. Emergency procedures in the event of accidental release of hazardous substances ........ 19
3. Delivery of product .................................................................................... 19
3.1. Unloading / transport to location of installation ............................................................... 20

Installation and Operating Manual
Printed: 02/2015
3.2. Unloading by forklift truck or lifting trolley ....................................................................... 20
3.3. Unloading by crane .......................................................................................................... 21
3.4. Positioning by hand .......................................................................................................... 22
4. Installation of unit ..................................................................................... 22
4.1. Foundation / base frame .................................................................................................. 22
4.2. Structural vibration insulation .......................................................................................... 23
4.3. Installation of unit ............................................................................................................ 23
5. Assembly of unit ........................................................................................ 24
5.1.Preparation of unit assembly ............................................................................................. 24
5.2. Alignment of unit section ................................................................................................. 25
5.3. Connection of unit sections .............................................................................................. 25
.3.1. Connection with external corner brackets .......................................................................... 2
.3.2. Connection of unit sections from the inside with internal brackets ................................... 26
.3.3. Roof joint connections for outdoor units ............................................................................ 26
5.4. Alignment of doors .......................................................................................................... 27
.4.1. Adjustment of standard locking levers ................................................................................ 27
.4.2. Adjustment at locking lever – MFG 1 0 .............................................................................. 28
.4.3. Adjustment at hinge ............................................................................................................ 28
5.5. Dismantling of panels and panelling profiles ..................................................................... 29
5.6. Dismantling of frame profiles ........................................................................................... 29
5.7. Pre-assembled units ......................................................................................................... 29
6. Connections and operation ....................................................................... 31
6.1. Connection of heat exchanger .......................................................................................... 31
6.2. Connection of steam heater ............................................................................................. 32
6.3. Connection of refrigerant line ........................................................................................... 32
6.4. Condensate drain ............................................................................................................. 32
6.5. Air duct connections......................................................................................................... 32

Installation and Operating Manual
Printed: 02/2015
6.6. Multi-leaf dampers .......................................................................................................... 33
6.7. Electrical connections ....................................................................................................... 34
6.7.1 Holes for cables and glands .................................................................................................. 34
6.7.2. Motor connection ................................................................................................................ 3
6.8. Frost protection ............................................................................................................... 39
6.9. Potential equalization / earthing ...................................................................................... 39
6.10. Motor overload protection ............................................................................................. 39
6.11. Filters............................................................................................................................. 39
7. Commissioning and maintenance .............................................................. 40
7.1. Housing ........................................................................................................................... 42
7.2. Fan motor ........................................................................................................................ 42
7.2.1. Free-running wheels ............................................................................................................ 43
7.2.2. V-belt drive .......................................................................................................................... 4
7.2.3. Flat belt drive ....................................................................................................................... 47
7.3. Filters .............................................................................................................................. 48
7.4. Heat exchanger ................................................................................................................ 49
7.5. Humidifier ....................................................................................................................... 51
7. .1. Surface humidifier ............................................................................................................... 1
7. .2. Steam humidifier ................................................................................................................. 1
7. .3. Air washer ............................................................................................................................ 2
7. .4. Commissioning of contact humidifier ................................................................................. 2
7.6. Silencer ............................................................................................................................ 55
7.7. Multi-leaf dampers .......................................................................................................... 55
7.8. Weather guards ............................................................................................................... 55
7.9. Heat recovery unit ........................................................................................................... 56
7.9.1. Plate exchangers.................................................................................................................. 6
7.9.2. Closed-loop system (run around Coils) ............................................................................... 6

Installation and Operating Manual
Printed: 02/2015
7.9.3. Rotary heat exchanger (thermal Wheel) ............................................................................. 6
7.9.4. Heat tube ............................................................................................................................. 6
7.10. ATEX units ...................................................................................................................... 56
7.11. Test run ......................................................................................................................... 57
8. Shutdown and decommissioning ............................................................... 58
8.1. Prolonged shutdown / decommissioning .......................................................................... 58
8.2. Dismantling and disposal .................................................................................................. 58
9. Maintenance schedules for unit components ............................................ 56

Installation and Operating Manual Page 6
Printed: 02/2015
1. General information
The installation and operating manual forms part of the scope of delivery of your product and
must be filed near the unit where it is accessible at all times. All persons carrying out work on
the machine must have read this manual and adhere to all instructions. For work on unit
elements and built-in assemblies that are not covered in this document, refer to the separate
manual.
1.1. Unit series
WEGER produces units for a wide range of applications.
This manual applies to the following series:
Series:
DIWER EVO
DIWER EVO PU
DIWER EVO DP80
DIWER TE
DIWER TE PU
DIWER
DIWER PU
Design:
Series: Profile Panelling Insulation Sealing
DIWER EVO thermally decoupled with plastic frame Rock wool PUR foam
(sprayed on)
DIWER EVO PU thermally decoupled with plastic frame PU foam PUR foam
(sprayed on)
DIWER EVO DP80 thermally decoupled with plastic frame 40 mm rock wool +
40 mm PU board
PUR foam
(sprayed on)
DIWER TE thermally decoupled without plastic frame Rock wool Hollow seal
(clamped)
DIWER TE PU thermally decoupled without plastic frame PU foam Hollow seal
(clamped)
DIWER not decoupled without plastic frame Rock wool Hollow seal
(clamped)
DIWER PU not decoupled without plastic frame PU foam Hollow seal
(clamped)

Installation and Operating Manual Page 7
Printed: 02/2015
Model box details according to DIN EN 1886 (July 2009)
Series
Thermal
insulation
Heat bridge
factor
Housing
leakage
Mechanical
stability
Filter bypass
leakage
DIWER EVO DP80 T1 TB1 L1 D1 G1 – F9
DIWER EVO T2 TB2 L1 D2 G1 – F9
DIWER EVO PU T2 TB2 L1 D1 G1 – F9
DIWER TE T2 TB3 L1 D2 G1 – F9
DIWER TE PU T2 TB3 L1 D1 G1 – F9
DIWER T3 TB3 L1 D2 G1 – F9
DIWER PU T3 TB3 L1 D1 G1 – F9
Each of the above series is available in versions HG = hygiene; WF = weather-proof.
The models of the DIWER series are also available as an ATEX unit.
1.2. ATEX units
In accordance with the ATEX Directive 94/9/EC, units bearing the "Ex" mark (ATEX units) may
be operated in potentially explosive atmospheres as specified on the type plate and in the
technical data sheet.
Important!
Units bearing the "Ex" mark must not be modified or extended in any way without the
manufacturer's written consent.
ATEX units must not be operated near:
−High-frequency sources (e.g. transmitter stations)
−High-power light sources (e.g. laser light)
−Ionising radiation sources (e.g. X-ray machines)
−Ultrasound sources (e.g. ultrasonic echo devices)

Installation and Operating Manual Page 8
Printed: 02/2015
Already installed units must be upgraded to the relevant ATEX class. The following
components might be affected by such an upgrade:
- Electronic components (lamps, electric motors, switches, etc.) must be approved for
operation under ATEX conditions and labelled accordingly.
- The cabling of ATEX units must conform to the relevant standards. In particular, proper
potential equalization must be guaranteed.
- ATEX units for outdoor installation must be equipped with a suitable lightning
protection system and all metal parts of the construction (ladders, work platforms,
etc.) must be connected to a ground conductor.
- Depending on the processed air composition, one must take into account that
temperatures in the ducting of ATEX units might increase to 110 °C, which might be
sufficient to cause spontaneous ignition.
- In ATEX units for indoor installation, all electrically conductive parts must be properly
earthed (potential equalization) in order to prevent ignition by lightning strikes.
Possible ignition sources:
- Mechanically produced sparks caused by incorrectly operated fans
- Static electricity (caused by cleaning with conventional cloth)
- Hot surfaces
- Electrostatic charge of persons
- Lightning strikes
- Tools that do not conform to EN 1127-1
- Wiring
Non-compliance with the instructions below or with the applicable national and
international safety regulations might result in serious or e en fatal injury and damage to
property.
Do not commission ATEX units until the following requirements are met:
- Conditions of use in accordance with the purpose for which the unit is intended
- No substances nearby that are prone to spontaneous combustion e.g. pyrophoric
substances under EN 1127
- Constant and adequate ventilation of the installation site (mechanical equipment
room) in the case of ATEX units without a specified exterior Ex zone so that
unavoidable leakage to the exterior of the unit does not result in an explosive
atmosphere

Installation and Operating Manual Page 9
Printed: 02/2015
1.2.1. Explosion protection
The following instructions must be strictly adhered to:
- Ensure that there is no potentially explosive atmosphere near the machine (absence of
ignition sources)
- Use only tools that conform to EN 1127-1 in order to prevent sparks
- Prior to any maintenance or repair work, shut down the power supply to the unit.
Identification
The "Ex" rating plate of the unit is attached to the fan chamber!
The rating information distinguishes between inside (processed atmosphere) and outside
(atmosphere in room of installation). The air handling unit must only be operated under
conditions as specified on the "Ex" rating plate.
Example: the air handling unit is classified as follows (information on "Ex" rating plate:
Ex II 2G c IIB T4 inside ; Ex II 3G c IIB T3 outside
Codes:
Ex = Explosion protection (class)
I =Equipment group (underground)
II = Equipment category (above ground)
1 = Protection category 1 (zone 0)
2 = Protection category 2 (zone 1)
3 = Protection category 3 (zone 2)
G = Gas
IIA = Substances with low ignition susceptibility
IIB = Substances with medium ignition susceptibility
IIC = Substances with high ignition susceptibility
T1 = Max. surface temperature 4 0° C
T2 = Max. surface temperature 300° C
T3 = Max. surface temperature 200° C
T4 = Max. surface temperature 13 ° C
T = Max. surface temperature 100° C
T6 = Max. surface temperature 8 ° C
Gases and vapours are classified in three explosion groups (IIA, IIB and IIC), based on their
ignition susceptibility whereby substances in group IIA are less likely to explode than
substances in group IIC.

Installation and Operating Manual Page 10
Printed: 02/2015
2. Safety
The air handling unit has been designed and manufactured according to best engineering
practice and in compliance with the generally recognised safety standards. It meets all relevant
safety requirements. In the event of improper operation or operation for a purpose other than
the intended, there is however a risk of serious or even fatal injury to persons and a risk of
damage to the unit and other property.
In the interest of your safety and the safety of others, please carefully read these safety
instructions prior to assembling and commissioning the air handling unit!
The unit must only be operated for the intended purpose and if it is in proper working order.
The machine operator must be aware of all risks associated with the unit. Defects or faults that
might impair the safety of the unit must be eliminated without delay.
All work in connection with the assembly, installation and commissioning of the unit must be
carried out by specially trained technicians.
For work on unit elements and assemblies that are not covered in this document, refer to the
separate manual.
The pressure vessels integrated into the unit must undergo regular tests to be carried out by
an approved refrigeration contractor.
Before assembling, installing or commissioning the unit, all persons involved in these tasks
must have carefully read this installation and operating manual. A copy of this installation and
operating manual must be kept near the unit where it is accessible at all times. Compliance
with the instructions in this document ensures trouble-free operation of the unit.
The unit forms part of an air-conditioning plant and must only be operated after installation in
and in conjunction with the overall plant.
2.1. Intended use
All information on signs attached to the unit and all instructions in this manual must be strictly
adhered to.
The unit must only be used for the handling of air, including filtration, heating, cooling,
humidifying, dehumidifying and conveying. Any other use is strictly prohibited.

Installation and Operating Manual Page 11
Printed: 02/2015
2.2. Statutory regulations
It is the responsibility of the unit operator to ensure compliance with all relevant statutory
regulations, including the following standards:
DIN EN 378 - Refrigerating systems and heat pumps –. Safety and environmental
requirements - Obligation on owner to maintain a system logbook. It must cover the
following items:
•Details of all maintenance and repair work
•Quantity and type of refrigerant (new, reconditioned, recycled)
•Quantity of drained-off refrigerant
•Results of analyses of reconditioned refrigerant
•Origin of reconditioned refrigerant
•Modifications to unit, replacement of components
•Results of all routine checks and tests and exceptional events such as prolonged
standstill times
EU Regulation 2037/2000 on Ozone Depleting Substances and German Chemical
Ozone Layer Ordinance (ChemOzonSchichtV) – Obligation on unit owner to ensure
regular inspection and maintenance by specialist technician and minimum one annual
test for leakage, using suitable devices. Leaks must be repaired without delay.
Local hygiene plan – Where air handling units are operated in sensitive areas such as
medical facilities and clean room, all requirements laid down in the local hygiene plan
such as cleaning intervals, detergents and disinfectant specifications must be adhered
to.
VDI 6022 – Ventilation and indoor-air quality – Hygiene requirements for ventilation
and air-conditioning systems and units – Specific requirements for the operation and
maintenance of air-conditioning systems used in rooms frequented by people.
National water protection legislation – Compliance with disposal regulations for
cleaning water
Applicable waste management legislation – Filters must be disposed according to the
applicable waste management regulations.
Compliance with Ordinance on industrial Safety and Health.
Compliance with applicable personal protection equipment regulations.
Compliance with applicable statutory regulations regarding occupational safety and
explosion protection.

Installation and Operating Manual Page 12
Printed: 02/2015
2.3. Safety symbols and signal words
The safety instructions in this document are classified according to their probability of occurrence
and the damage they might cause. Based on this classification, they are accompanied by specific
signal words and symbols.
High risk; non-compliance results in serious or even fatal injury
Medium risk; non-compliance might result in serious or even fatal injury
Low risk; non-compliance results may result in minor injury
An exclamation mark on a red square indicates that there is a risk of damage to property and the
environment.

Installation and Operating Manual Page 13
Printed: 02/2015
2.4. Safety instructions
All work in connection with the assembly, installation and commissioning of the unit must be
carried out by specially trained technicians.
Protective equipment: Protective gloves, safety goggles, protective clothing, breathing apparatus
2.4.1. Risks during loading/unloading and transportation
- Risk of serious injury from dislodged loads.
Do not stand under suspended loads.
2.4.2. Risks posed by doors
- Risk of injury to hands from crushing by suction side doors:
Keep hands away from doors.
- Risk of injury from impact or crushing when pressure side doors are inadvertently
opened due to a failure of the door lock.
Only open the doors when the fan is not in operation.
2.4.3. Risks posed by fans
After a power failure, the fan is automatically restarted when the power returns!
- Risk of fatal injury from fan impeller:
Keep clear of the impeller. Remove all objects from the impeller range. De-energize
the unit and wait until the fan has come to a halt.
- Risk of serious or even fatal injury from fan suction catching clothing and hair:
Never wear loose clothing. Tie up long hair. De-energize the unit and wait until the fan
has come to a halt.
- Risk of fatal injury from rupturing impeller when maximum permissible operating
speed is exceeded:
Operate the fan only within the permissible operating speed range.
- Risk of fatal injury from fan impeller:
Before performing any maintenance work, shut down the fan and de-energize it.
- Risk of injury from cutting: while the unit is running, never reach into rotating fan parts
such as rotors, etc.
Wait until all rotating parts have come to a halt.

Installation and Operating Manual Page 14
Printed: 02/2015
2.4.4. Risks from electric power
- Risk of electric shock with possibly fatal consequences from contact with powered
components:
Before carrying out any work on the unit, always de-energize it.
- Risk of electric shock with possibly fatal consequences. Certain circuits, electrical parts
and electronic components of the fan might remain powered for a few minutes after
the unit has been disconnected from the power supply.
After shutting down the unit, wait for at least 2 minutes before starting work on or
near electrical components.
- Risk of electric shock with possibly fatal consequences from potential-free contacts
that might remain energized after the unit has been disconnected from the power
supply.
Only touch potential-free contacts after you have established that they are fully de-
energized!
- Risk of electric shock with potentially fatal consequences from contact with powered
components such as lighting devices of electrical parts, power sockets, MCR
equipment and safety circuits:
Only touch electrically powered components after you have established that they are
fully de-energized!
- Risk of electric shock from electrostatic charge of housing:
Earth the device.
- Risk of electric shock from short-circuits when connecting electrical components:
Prior to commissioning, check all cables for damage, in particular for damage to the
insulation; ensure that all cables are connected properly.
- Risk of electric shock during wet cleaning of powered unit:
Before cleaning the unit, de-energize it.
2.4.5. Risks posed by dampers, including air flow control and shut-off
dampers
- Risk of injury to fingers from crushing when dampers are operated:
Keep hands away from dampers.
- Risk of injury to hands by closing multi-leaf dampers:
Keep hands away from dampers; operate the unit only if it is fully connected to the
duct system.

Installation and Operating Manual Page 15
Printed: 02/2015
2.4.6. Risks from process chemicals / materials
According to DIN EN 375, the refrigerants used in the unit are classified in flammability and toxicity
class A1 (non-toxic, non-flammable)!
- Risk of poisoning, chemical burns and allergic reactions caused by process chemicals
such as anti-freeze agents, refrigerants, etc.:
Always observe the handling instructions of the manufacturer. Avoid skin contact with
process chemicals and take all necessary safety precautions (e.g. wearing of protective
gloves, eye protection, etc.).
- Risk of poisoning and chemical burns during filling, venting and emptying of brine
container:
Avoid skin contact with process chemicals and take all necessary safety precautions
(e.g. wearing of protective gloves, eye protection, face mask, etc.).
- Risk of poisoning from inhalation of toxic vapours released by fire:
Keep clear of danger zone and take all necessary safety precautions (e.g. wearing of
face mask, etc.).
- Risk of poisoning from refrigerant gases released at high temperature!
When carrying soldering or welding work on refrigerant circuit components, always
wear protective gloves and breathing apparatus with filter. If there is leakage, do not
smoke and keep naked flames away from unit.
- Risk of allergic reaction from contact (skin contact, inhalation, ingestion) with
refrigerant:
Avoid contact with refrigerant and take all necessary safety precautions (e.g. wearing
protective gloves and eye protection).
- Risk to health from refrigerant and cooling water splashes or spray mist:
Avoid skin and eye contact, do not inhale or ingest. For all work on the cooling water
circuit, wear protective gloves and eye protection!
2.4.7. Risks posed by steam heaters
- Risk of scalding by hot steam (>100°) released at high pressure:
When working on the steam piping system or the humidifier, ensure that there is no
steam pressure and that the system has fully cooled down.
- Risk of injury from burns caused by highly flammable descaling agents:
Protect descaling agents such as formic acid from heat and direct sunlight.
When cleaning the steam humidifier or its components and lines, keep ignition sources
away from the descaling agent;
do not smoke!

Installation and Operating Manual Page 16
Printed: 02/2015
- Risk of serious damage to eyes and chemical burns to skin from descaling agents:
When handling descaling agents, always wear safety goggles and protective gloves. Do
not inhale vapours and ensure proper room ventilation!
- Risk of serious eye irritation from descaling agents:
When handling descaling agents, always wear safety goggles!
2.4.8. Risks from hot/cold components and media
- Risk of injury from frostbite when touching cold components such as cold water lines,
refrigerant pipes, cooler or intake chamber. Pipelines pose a serious risk of injury from
scalding:
Keep clear of danger area and take suitable safety precautions, e.g. wearing protective
gloves. When the unit is shut down, ensure that there is no condensate left in the
pipes and that the heating medium supply line is closed.
- Risk of scalding from escaping hot water when fittings at the heat exchanger, the hot
water heater or the heat recovery unit are opened.
Before carrying out any work on the heat exchanger, close the shut-off valves in the
feed and return lines and let the unit cool down!
- Risk of injury from burns when touching heating, compressor, oil trap, vapour
humidifier, steam lance and any associated lines.
These parts remain hot for some time after the unit has been shut down!
2.4.9. Risks from filter dust and other contaminants
- Risk of poisoning by hazardous substances when inhaling dust released from dust filter
or other components:
Wear the personal protection equipment made available by the unit owner (protective
gloves, breathing apparatus with filter).
- Risk of poisoning by hazardous substances when coming into contact or inhaling
contaminants that collect in the unit:
Regularly clean the unit. Always wear protective clothing.

Installation and Operating Manual Page 17
Printed: 02/2015
2.4.10. Risk of explosion (ATEX units)
Risk of explosion:
- When conveying potentially explosive air and gases.
Keep ignition sources away from ATEX units. Only use tools conforming to EN 1127-1
to prevent sparks.
- From electrostatic charging of unit:
All electrical, non-conductive connections must be equipped with potential
equalization connections. The unit must be connected to an earthing conductor.
- From sparks produced by fan operated at a speed outside the permissible range in a
potentially explosive atmosphere.
Never exceed the maximum permissible fan speed.
- When the unit is shut down, the concentration level of the gas/air in the system
increases.
Keep all ignition sources away from the unit.
2.4.11. Risk of damage to property and the environment
Do not make unauthorised modifications to the unit. Only use original spare parts.
Operate the unit only with the permissible parameter settings.
Unloading and transport
- Serious damage to property from dropping loads;
please observe the instructions in section 3 "Delivery of product".
- Serious damage to heat exchanger connections, panelling and other mounted
components from force impact during moving of unit elements;
always move the unit elements by their base frame.
- Risk of damage to components from heavy impact, e.g. when attempting to dislodge a
part with a hammer, etc:
Components that rest on the foundation must only be moved by shifting.
Risks caused by fans
- Risk of mechanical damage to fan unit, due to critical input speed and operation within
resonance range:
The frequency range of the speed-controlled drives must be determined, bridged and
noted down during commissioning. Observe the instructions regarding overall pressure
increase, maximum permissible speed and direction of rotation of the fan in the fan
chamber.
- Risk of damage to fan due to excessive power to motor, resulting in excessive fan
speed:
Constantly monitor the power consumption of the motor.

Installation and Operating Manual Page 18
Printed: 02/2015
Risks from electric power
- Risk of damage to motor from insufficient motor protection, unsuitable safety fuses
and faulty automatic circuit breakers:
Protect the motor according to DIN EN 60204 / DIN VDE 0113.
Risk of damage from improper handling of dampers
- Risk of destruction of unit elements from incorrectly operated dampers
(underpressure or overpressure).
Monitor and test the damper regulation system.
- Risk of damage to unit and ducts as unit works against closed dampers:
Prior to performing a test run or starting the unit, close all unit doors and open the
dampers.
Risks in connection with process chemicals
- Risk of damage to the environment from process chemicals:
Observe information from manufacturer.
- Risk of damage to the environment from escaping refrigerant from direct evaporator
or condenser in the event of fire or leakage.
Constantly monitor the refrigerant levels in the unit.
- Risk of damage to the environment from anti-freeze agent.
Adhere to statutory disposal regulations.