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

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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)

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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