The installation and construction of the unit shall be carried out in strict accordance with GB50243-20 16 Code for Acceptance of Construction Quality of Ventilation and Air Conditioning Engineering.
1. Preparation before installation
(1) Be familiar with and review all relevant drawings, and check whether the unit placement position and foundation size meet the requirements.
(2) Confirm that the models and specifications of the equipment and attached accessories conform to the order contract and the physical quality is qualified.
(3) Prepare lifting and handling equipment, installation tools and other necessary materials.
(4) Coordinate the installation progress of civil engineering, water, electricity and air duct engineering to facilitate the smooth completion of the whole system.
2. Lifting and handling
(1) Do not open the outer packaging of the device until it reaches the final installation point. After reaching the final installation starting point, unpack the equipment and check whether there is any damage during transportation. If there is any damage, confirm it in time and lodge a claim with the transporter, and check whether the number of accessories is correct according to the product packing list.
(2) In order to prevent damage to the unit box during lifting and installation, when lifting with ropes, the ropes should be placed on the unit base. (See Figure 1- Schematic diagram of unit hoisting)
Combined air conditioner ">
Figure 1- Schematic diagram of unit hoisting
(3) When roller handling is adopted, at least three rollers with a length greater than the width of the device shall be used.
(4) Handle with care when hoisting and handling, and pay attention to safety.
3. The device is installed in place
(1) The installation of air conditioning unit has great influence on the operation and maintenance of equipment.
(2) The unit should be placed on a suitable foundation. The following two forms are recommended for installation foundation, and the foundation should be horizontally adjusted and have sufficient supporting strength. (See Figure 2- Schematic Diagram of Unit Installation Foundation)
Figure 2- Schematic Diagram of Installation Foundation of Device
(3) Sufficient maintenance space should be reserved around the foundation of the unit (see Figure 3- Schematic Diagram of Maintenance Space) for routine inspection and regular maintenance of the unit.
(4) When the unit is installed, all functional boxes shall be placed on the foundation according to the drawing order. For occasions with high earthquake-proof requirements, shock-absorbing pads should be placed between the unit and the foundation. Damping pads are generally natural rubber plates with a thickness greater than10 mm.
(5) If the unit is hoisted in the ceiling, the platform must be hoisted by equipment. The size of the platform must be larger than that of the unit, and the maintenance space should be considered. The levelness of the platform should be adjusted well, and the installation of the unit should be stable, and it cannot bear the weight of external water pipes and gas pipes.
(6) The inter-node connection of the unit is connected by bolts. First, stick a piece of polyethylene high foam plastic board in the middle of two sections, and its installation is shown in Figure 4- Schematic diagram of the connection and installation between sections, with the bolt spacing of 200mm, and then connect the unit base with bolts.
Figure 4- Schematic diagram of installation of inter-segment connection
(7) When the vertical unit is connected, the spacing between the self-tapping screws M6×20 connected between the frame and the unit base is 200mm. When the unit leaves the factory, the base of the unit has been connected with the upper frame. When installing, connect the lower frame with tapping screw M6×20. (See Figure 5- Schematic Diagram of Connection between Vertical Devices)
(8) When there is panel connection between positive pressure sections (usually fan sections and other functional sections), the distance between self-tapping screws M6×20 of connecting plates between sections is 200mm. (See Figure 6- Schematic Diagram of Positive Pressure Section Connection for details)
Figure 5- Schematic diagram of connection between vertical units.
Figure 6- Schematic diagram of connection between positive pressure parts
(9) If it is necessary to install or operate at the top of the unit, you must stand on the frame pole, not on the panel.
(10) The dry steam humidifier uses angle brackets and flanges to fix the humidifier body and nozzle on the humidifying section panel respectively, and its installation is shown in Figure 7- Schematic diagram of steam humidifier installation. The steam injection direction of the humidifier is reverse airflow, and a steam trap is installed at the steam outlet.
Figure 7- Schematic diagram of steam humidifier installation
4. Installation and connection of air duct
Please select the appropriate air duct according to the air volume and static pressure of the unit. Every air duct should be insulated, and the insulation material should have a moisture-proof layer to prevent moisture absorption.
(1) air volume control valve is installed in the air inlet and outlet ducts of the unit, which is convenient for system debugging and makes the air volume and air pressure appropriate. The air inlet and outlet of the unit, as well as the air inlet pipe and the air outlet pipe, shall be connected by soft connection.
(2) The unit shall not bear the weight of external pipes, and all air inlet and outlet pipes shall be supported and fixed.
(3) When installing pipelines, the space required for unit maintenance must be considered.
Note: Before connecting the elbow, the air outlet pipe should be kept at least twice the length of the air outlet, otherwise it will cause additional wind pressure loss.
5. Installation and connection of water pipes
All piping systems shall be installed in accordance with local regulations.
(1) The maximum service pressure of the surface cooler and hot water heater shall not exceed 1.6MPa, and the inlet and outlet pipes shall be connected by pipe threads or flanges, and the pipe threads shall be wound with raw material belts, and the water pipe connection form shall be "lower inlet and upper outlet". (See Figure 8- Installation Diagram of Inlet and Outlet Pipes of Coil)
Heater and surface cooler (single layer)
Heater and surface cooler (double layer)
Figure 8- Installation Diagram of Inlet and Outlet Pipes of Coiled Tube
(2) The maximum service pressure of the steam heater shall not exceed 1.4MPa, the steam inlet and outlet pipes shall be connected by pipe threads or flanges, the steam inlet shall be "upper inlet and lower outlet", and a steam trap shall be installed at the steam outlet. (See Figure 9- Schematic Diagram of Installation of Steam Inlet and Outlet Pipes of Steam Heater)
Steam heater (single layer)
Steam heater (double layer)
Figure 9- Schematic diagram of installation of steam inlet and outlet pipes of steam heater
(3) The inlet and outlet pipelines of the unit shall be equipped with regulating valves (except condensate drain pipes) so as to regulate the flow and cut off the water source during maintenance. Thermal insulation measures should be taken for the inlet and outlet pipelines of the unit. U-shaped water seal must be installed on each condensate drain pipe. For installation, see the schematic diagram of U-shaped water seal installation in Figure 2.
(4) Install pressure gauges and thermometers on the inlet and outlet pipes of the unit to monitor whether the water system is normal.
6. Wire laying and connection
(1) All wires must be laid in accordance with local power regulations. Before laying wires, please check whether the power supply and wires used meet the requirements according to the parameters on the nameplate of the unit.
(2) The power connection port of the unit is located at the access door side of the fan part. When connecting, connect the power cord isolated by the switch from the site to the motor junction box of the unit.
(3) Wiring of electric heating coil
Ⅰ. Configure electrical appliances and wires according to the electrical heating wiring diagram and schematic diagram of the unit and connect them correctly. The metal shell of the electric heating coil must be well grounded.
Ⅱ. The electric heating controller must be connected with the temperature relay signal in the electric heating coil to ensure that the electric heating power supply will be automatically cut off when the air temperature in the unit is too high.
ⅲ. The electric heating controller should interlock the fan and electric heating to ensure that the electric heating power supply cannot be connected when the fan stops.
Debugging:
1. Preparation before debugging
Before the normal operation of the unit, the following contents shall be checked:
(1) The system shall be correct, unobstructed and free from water leakage;
(2) The power cord should be connected correctly, firmly and reliably;
(3) The wind system is safe, reliable and correct, and the pipeline is clean;
(4) Confirm that the fixing plate on the compression spring damper on the fan base has been removed (see Figure 10- Schematic diagram of removing the fan fixing plate);
(5) Whether there are any construction relics in the fan casing;
(6) Turn the fan pulley by hand to see whether the impeller touches the wind shell and whether the rotation is flexible;
(7) The fan should rotate correctly.
Figure 10- Schematic diagram of removing the fan fixing plate
2. Start and close the device
(1) Usually, the box structure of the unit is designed according to the working pressure. Attention should be paid to the position of the inlet and outlet regulating valves of the unit when starting, so as to prevent the excessive pressure difference between the inside and outside of the unit from causing permanent deformation of the unit box and even damaging the unit. (different manufacturers)
(2) When supplying water to the unit, open the air valve first to discharge the air in the pipeline.
(3) When the fresh air temperature is lower than 2℃, it is necessary to turn on the preheating coil or take other corresponding protective measures to prevent the coil in the unit from freezing and cracking.
(4) For units with humidification function, the fan should be turned on first, and then the steam should be turned on; When stopping, turn off (water) steam first, and then turn off the fan.
(5) Start the unit program: first supply water (steam) to the surface cooler or heater, and then start the fan motor.
(6) After shutdown in winter, turn off the fan first, and then cut off the power supply, so as to avoid freezing crack of the coil.
(7) Before the operation of clean air conditioning system, temporary filters (such as non-woven fabrics) should be set at the entrance of return air and fresh air and in front of coarse and medium efficiency filters to protect the system. The detection and adjustment of clean air conditioning system should be carried out after the system is thoroughly cleaned and operated for more than 24 hours to achieve stability.
Maintenance:
1. Fan drive system
When the unit is running, always pay attention to whether the fan is in good condition, and regularly check the belt tightness and bearing conditions.
(1) Adjustment of belt tension: Proper belt tension is very important for preventing fan vibration and reducing belt wear and noise. The user should check the tension of the belt every week and make necessary adjustments according to the following steps:
A loosen the four fixing bolts of the motor, tighten/loosen the adjusting bolts, and move the motor;
B. Use your fingers to act in the direction perpendicular to the belt in the middle section, and adjust the tension of the belt to make it produce the corresponding deflection distance (see Figure 1 1- pulley calibration and schematic diagram of belt tension);
C. retighten the fixing bolts of the motor.
(2) Belt pulley correction: The fan belt pulley and the motor belt pulley should be placed on the same plane, otherwise it will cause excessive energy loss and shorten the service life of the belt. After each belt adjustment, check whether the positions of the two pulleys are correct. As shown in figure 1 1, put a ruler on the same side of the two pulleys and check the straightness. If it is not correct, loosen the fixing screw of the fan pulley, slide the fan pulley along the fan shaft, and adjust the angle by loosening the motor on the motor chassis until the straightness is ≤2mm.
Figure 1 1- Schematic diagram of pulley calibration and belt tension
note:
1. The adjusted belt and pulley shall meet the requirements of straightness and tension at the same time.
2. After the new belt is used for the first time for a total of 24 hours, the tension of the belt must be checked and adjusted appropriately. If the adjustment is improper or not, the service life of the belt will be greatly shortened, and in serious cases, the belt will break.
3. Belts are consumables. Generally, it is normal for new belts to wear after 1 year. At this time, the new belt should be replaced as needed. When driving multiple belts, replace the belts in the same group at the same time.
(3) Bearing lubrication: After the unit runs for a period of time, according to the usage of bearing re-lubrication cycle, it is necessary to check the lubrication of fan bearings and add appropriate amount of grease as needed (the amount of grease injection is added until new grease is extruded). In the following cases, lithium-based grease No.3 (ZL-3) must be used (Shell grease should be used as much as possible):
1. When the unit is in normal operation, the grease should be replaced every 7000~8000 hours in a good environment with the operating temperature lower than 60℃.
2. When the unit is in normal operation, the lubricating grease should be replaced every 3000~3500 hours in a good environment with the operating temperature of 60~70℃ in the unit.
3. When the unit is running normally and the relative humidity in the unit is more than 85%, replace the grease every 2000~2500 hours.
Note: When re-lubricating, clean the nozzle; After adding grease, cover the plastic cover of the grease injection hole of the bearing seat to prevent foreign matter from polluting the grease.
2. Cleaning/replacement and use of air filter
(1) The filter should be cleaned/replaced in the following cases:
A. Before starting the machine for the first time;
B. After the unit runs for 3 months (shorten the time appropriately according to the working environment on the unit);
C. The filter section is equipped with a resistance monitoring device. When the resistance of the filter reaches the final resistance. When the filter material of the filter is non-woven, it can be cleaned 1-2 times; For the metal mesh filter, it can be cleaned and used repeatedly.
(2) Cleaning method of the filter element: soak the filter element in proper soap or detergent or water, and gently rub it. Rinse with clean water and dry before reassembling.
(3) The high-efficiency filters (including secondary high-efficiency filters and activated carbon filters) shall be unpacked and installed at the site after the clean room and purified air conditioning system are thoroughly cleaned and the system has been continuously debugged for more than 12 hours. Before installation, the filter shall not be deformed, separated, broken or damaged. Pass through immediately after installation, the direction must be correct, and the periphery and interface of the installed high-efficiency filter should be tight.
Regularly check the dust accumulation of the filter screen of the unit. When the filter reaches its final resistance, it needs to be scrapped or replaced. Workshop staff need to record the pressure difference between the middle and primary efficiency every day. When the pressure difference between the intermediate effect and the initial effect is higher than the initial value 1.5 times, the filter is blocked and needs to be cleaned. When the pressure difference between the intermediate and primary filters is lower than the initial pressure difference, it is necessary to check whether it is damaged. If it is damaged, it needs to be replaced in time.
3. The surfaces of surface coolers and heaters should be cleaned or purged regularly to remove surface dust.
4. After the surface cooler and heater work for 2-3 years, chemical cleaning should be adopted to remove the scale in the pipeline.
5. Regularly check the lubrication part of electrical equipment and transportation drive of air conditioning unit.
6. When the unit stops, if the surface cooler and heater will be at a temperature below 0℃, in order to prevent the surface cooler and heater from freezing and cracking, drain the internal water, close the fresh air valve, or add antifreeze, such as ethylene glycol solution, to the pipeline.
Drainage procedure:
Ⅰ. Close the inlet and outlet pipe valves;
Ⅱ. Slowly open the bleeder valve on the reflux pipe of the device;
Ⅲ. Slowly open the drain valve on the water inlet pipe of the unit;
Ⅳ. Drain all water to be stored. (When reinstalling, it must be wrapped with raw material tape and tightened).
3. Air conditioning box
1) Carefully check the box for deformation, condensation and air leakage, and solve the problems immediately when found;
2) Clean the box.
3) Whether the insulation and casing of connecting pipes are in good condition.
4) Whether the doors and locks are in good condition and whether there is air leakage.
4. Other moving parts
1) fan:
A. Whether the fixing bolts of impeller, volute and bracket are loose;
B bearing temperature is normal (no more than 70 degrees);
C continuously running equipment should be oiled (greased) once a month.
2) Motor:
There is running current and the temperature rise is normal;
B bearing temperature is normal;
C. Whether the blades, shields and bottom corner bolts are firm;
D fully sealed bearings should be refueled once a year, and other bearings should be refueled once a year in March;
E. Stop using it for a period of time before starting it, and check the insulation.
3) Whether the soft connecting canvas is damaged and whether the fixing screws are loose.
4) Whether the fixing bolts of the shock absorber are loose and the elasticity can be restored.
5) Whether the clapboard, silencer and pillar are in good condition and deformed.
6) Whether the air valve opening is appropriate and whether the fixing screws are loose.
7) Whether the condensed water drainage is smooth.
5. Maintenance and overhaul of the motor
1) Daily inspection: In daily use, always keep the motor clean and do not block the air inlet of the motor, so as not to reduce the air intake and affect the heat dissipation effect. Keep the electrical contacts clean and have good contact.
2) Operation inspection: During the operation of the motor, always pay attention to whether the load current meets the requirements of the nameplate, whether the temperature rise of the motor meets the technical conditions, and whether the bearing leaks oil and heats up.
Precautions:
1. The supply air temperature of the unit shall not exceed 80℃ (heating). If it exceeds this temperature, you should ask our company when ordering, so as to adopt high-temperature bearings and motors with special requirements.
2. The temperature and flow rate of water supplied to the heat exchanger shall meet the relevant requirements: softened water shall be used for water supply, and the inlet temperature of cold water is about 7℃ and the flow rate is 0.5 ~ 2m/s; Generally, the inlet temperature of hot water is about 60℃ and the flow rate is 0.5 ~1m/s.
3. When starting the unit, pay attention to control the working current of the motor in the unit within the rated current value by adjusting the air volume control valve in the air duct system, and it is not allowed to run with excessive air volume or current.
4. When the unit leaves the factory, there is no water in the coil. If the user installs the unit in a low temperature environment in winter, and the air conditioning system has no time to supply hot water for heating, do not pump water into the water pipe system and the coil in the unit.
5. When the ambient temperature or the inlet air temperature of the unit is ≤2℃, the water pump system shall not stop continuously supplying hot water of not less than 60℃ to the coil in the unit, and the water flow shall not be less than1m/s. ..
6. When the ambient temperature or the air inlet temperature of the fresh air unit is ≤2℃, a preheating device shall be set at the air inlet of the unit, and a closed regulating valve and an anti-freezing switch shall be installed at the new air inlet of the system, which shall be interlocked with the fan.