COSTRUZIONI AREAULICHE

Via M. da Besozzo 16 Monza (MI) 20052

Tel. 039 - 2025660 Fax 039 - 2025668

Installation, Operation and Maintenance Manual

Safety
Troubleshooting
INDEX
1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL
1.1 SHIPPING
1.2 OFF LOADING
1.3 SHORT DELIVERY / DEFECTS
1.4 INSTALLATION
1.5 ASSEMBLY
1.6 SETTING UP OF COMPONENTS
1.6.1 DAMPERS
1.6.2 FILTERS
1.6.3 HEAT EXCHANGER COILS
1.6.4 HUMIDIFIERS
1.6.5 SUPPLY AND RETURN FAN ASSEMBLY
1.6.6 ROOF CANOPY
1.7 DRIVE
1.7.1 BETS TENSION
1.7.2 CHANGE OF PULLEY
1.8 MAINTENANCE
1.8.1 ONCE IN A WEEK
1.8.2 ONCE IN A MONTH
1.8.3 ONCE IN SIX MONTHS
1.8.4 ONCE IN A YEAR (PREFERABLY AT THE START OF SEASON)
1.8.5 FILTERS
1.8.6 HEAT EXCHANGER COILS
1.8.7 SUPPLY AND RETURN FAN ASSEMBLY
1.8.8 CLEANING OF DOUBLE SKIN PANELS
2 SAFETY
2.1 TERMINOLOGY
2.2 OPERATION SAFETY
2.3 USE OF THE UNIT IN CONFORMITY TO GENERAL PROVISIONS
2.4 MEASURES OF THE USER/OPERATOR, OBSERVATION OF THE SIGNPOSTS (WARNINGS)
2.5 STAFF TRAINING
2.6 USE OF THE UNIT
2.7 BEHAVIOUR IN CASE OF DAMAGE
2.8 MEASURES TAKEN BY MANUFACTURER
2.9 PREVENTION MEASURES ARE TO TAKEN BY INSTALLER OR THE PERSON IN CHARGE
OF INSTALLING CONTROL AND STURT-UP DEVICES
2.10 RECOMMENDED SAFETY PRACTISES
2.10.1 PERSONNEL SAFETY
2.10.2 THE HIDDEN DANGER
2.10.3 START UP CHECK LIST
2.10.4 AFTER 2 WEEKS OPERATION
2.10.5 WARNING SIGNS
2.10.6 ROUTINE MAINTENANCE
3 TROUBLESHOOTING
3.1 PROCEDURE FOR TROUBLESHOOTING
3.2 SAFETY PRECAUTION
3.3 MASTER TROUBLESHOOTING CHART
3.4 SYSTEM CHECK LIST
3.5 ADDITIONAL INFORMATION (FAN MANUFACTURER’S ANALYSIS)
3.6 CONCLUSION

APPENDIX
 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

1. INSTALLATION, OPERATION AND MAINTENANCE MANUAL

1.1. SHIPPING

Units are normally shipped Ex-Works. They are inspected prior to despatch for
goods condition and carefully loaded in containers with no crating/boxing. Hence, in
case of transit damage, the forwarder must be informed immediately. All claims must
be directed to the forwarding/insurance agents and SAIVER take no responsibility.

When units are shipped FOB port, they are either containerised or crated and
delivered FOB to forwarders. Immediately upon receipt on site, inspection should be
made and any damages must be reported by telex to SAIVER as well as to the
forwarding/insuring agents within 24 hrs of receipt.

1.2. OFF LOADING

Special care must be taken to ensure that

units are offloaded from the containers.
Rough handling can result in damage to
aluminium frame work and double skin
panels. It is possible to lift the sections by
slings or by forklift.
Slings, preferable nylon, must be place
around the structural base frame as shown in
fig 1.2-1.
fig 1.2-1

Before lifting the section, It must be

ensured that the slings are properly
located so they don't slide from
their slot ( see fig 1.2-2 and fig 1.2-
3).

fig 1.2-3

fig 1.2-2

If everything is all right, then the section can be elevated

and taken away ( see fig 1.2-4 ).

fig 1.2-4

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 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

In the case in which is utilised a lifting tube, it must be inserted into the specific hole
as shown in fig 1.2-5.

fig 1.2-5
Then the sling, which is equipped with a particular loop, must be connected to the
tube as shown in fig 1.2-6 and fig 1.2-7.

fig 1.2-6 fig 1.2-7

After that, the section can be lifted ( see fig 1.2-8 and fig 1.2-9 ).

fig 1.2-8 fig 1.2-9

It is necessary to utilise slings opportunely sized on the ground of the section weight.

The larger and heavier units should be lifted using a forklift with sufficiently long
extended forks to prevent damaging the underside of the unit.

It is strongly recommended that offloading and installation operation are carried out
by specialists with necessary equipment and proper tools. SAIVER cannot accept
responsibility for any damage sustained during offloading and installation.

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 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

1.3. SHORT DELIVERY/DEFECTS

All items must be checked against purchase order, SAIVER drawing and the packing
list for correctness and any claims for non compliance or short supply or any
manufacturing defects must be reported to SAIVER by telex within three days of
receipt.

1.4. INSTALLATION

Prior to installation, it must be ensured that adequate access exists for connecting all
supplies, disposal of condensate/overflows, inspection, maintenance and for
replacement of renewal parts such as filters, belts, bearings etc.
Installation of units must be in accordance with good engineering practise. Structural
base for the units must be level and rigid.

Further it must be ensured that the base is

high enough from the floor to allow the
installation of condensate drain with
necessary trap for easy flow as show in fig
1.4-1. It is suggested to take advice for
locating the suspension points for ceiling hung
units.

fig 1.4-1

1.5. ASSEMBLY

Units are normally designed to make best use of containers ( shipping ) volume in
two or more sections depending on the design of units. However all the sections are
externally marked and their sequence of assembly can be easily identified from the
enclosed drawings.
Once all the sections are located, they can be easily aligned and locked together.

First of all, between the sides of the sections that shall be connected, it must be
inserted a continuous foam gasket for airtight seal as illustrated in fig 1.5-1.

Push the sections towards one another, making sure that they are lined up with one
another.

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 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Consequently the sections are locked together by stainless steel bolts located in
factory predrilled assembly holes ( see fig 1.5-2 and fig 1.5-3) into the corner
brackets on the inside of the frame. Make sure that they are firmly in position.

Necessary stainless steel bolts and foam gaskets are supplied in a bag, normally
located within the respective section.

fig 1.5-2 fig 1.5-3

It must be noted that, during installation and assembly, there is a possibility of

misalignment if individual sections are not carefully handled. Do not use excessive
force to align because it may deform the aluminium structural framework.

In the case it is not possible to access the inside of the casing, the connection can
be made either by opening an inspection door or by removing a wall panel.

While SAIVER take no responsibility for consequences due to mishandling etc, will
try to assist to ensure that units are properly installed. In case services of factory
personnel are required for assembly the same can be provided at extra cost.

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 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

1.6. SETTING UP OF COMPONENTS

Duct connection: when duct flanges are connected to damper frames, it must be
ensured that the fixing bolts are of correct length and do not obstruct the movement
of damper lever/linkages.

1.6..1. DAMPERS

All dampers must be checked for free movement prior to proceeding further.

1) Manually operated dampers can be adjusted to obtain the required airflow, by

loosening the bakelite knob and then turning the control lever. Bakelite knob
must be tightened after setting up at the desired location on locking quadrant.

2) Motorised dampers are supplied with the linkage rod for connection to the
actuator. It must be ensured that the actuator motors ( not supplied by SAIVER )
are rigidly fixed to the structural framework of the unit and not to the double
skinned panels. Care must be taken to ensure that the actuator does not attempt
to push the damper beyond fully open or fully closed positions.

1.6..2. FILTERS

Check the type and quality of filters is in accordance with the drawing.

1) Panel Filters: with flat or corrugated media are normally fitted within the unit prior
to shipping.

2) Bag Filters: along with pre-Filters ( if any ) are normally shipped in closed carton
boxes, as supplied by filter manufacturer, to avoid any collection of dust and loss
of efficiency prior to commissioning. Each Bag Filter is housed within a special
holding frame with necessary locking spring to ensure proper sealing. A bank of
such special frames ( quantity depends on the type and air flow ) is assembled
within the peripheral aluminium framework of each Bag Filter Section. Entire
assembly along with Pre-Filter must be locked with four springs to ensure no
leakage of air.

3) Automating roll Filters have two headers, one houses the clean spool, while the
other dirty spool, which is driven by a geared motor and chain drive actuated by
differential pressure ( D.P. ) switch. Normally filter media and D.P. switch are
supplied loose for site installation. For assembly, filter media roll is mounted on
the clean spool header, taken along the guide channel through working section
and locked to the dirty ( driving ) spool. D.P. switch must be installed and
connected to the control panel as shown in the circuit diagram.

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 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

4) Absolute Filters are shipped in sealed carton boxes, as supplied by filter

manufacturer. They are housed in a special purpose made of aluminium frame
with corner brackets and locking devices for each cell. While assembly special
care must be taken to ensure that each filter cell is properly seated within the
assembly frame and perfectly sealed against the neoprene foam gasket with no
possibility of air leakage.

5) Other type of Filters such as Actuated Carbon, inertial ( sand ) Filters, if installed,
will be supplied with manufacturer's instructions along with the units.

1.6..3. HEAT EXCHANGER COILS

All coils are leak tested and checked prior to assembly. Fins are checked for proper
condition prior to shipping. However during handling and installation they might be
slightly bent and hence they must be checked and combed out if necessary. Do not
remove plastic protective covers from the header connections until the system is
ready for hook up. System layout should take into consideration of possible coil
withdrawal. All connecting pipework must be properly insulated.

1) Water Coils: system design, pipe connections and valve arrangement must be in
accordance with good engineering practice. Flow and return connections are
clearly identified on the unit panels and pipe work must be connected accordingly,
preferably through flexible couplings to avoid transmission of any vibration from
the piping to coil. Excessive tightening torque might damage the coils. Pipework
must be supported independently to the coil and/or the unit.

Use a pipe wrench to restrain the pipe

connections of the heat exchanger when
tightening the external pipe connections
(see fig 1.6-1).

Plugged drain and vents are provided for fig 1.6-1

each coil and their use must be limited to
the respective coil. They must not be used for draining or venting the other part
of the system. Sufficient antifreeze chemicals must be added to the circulating
water in cooling coils, when there is a possibility of they being exposed to
temperatures below 2°C.

It is recommended that the water flow is shut off when the fan is switched off.

Normally, each heating coil should be provided with its own circulation pump. This
ensures an even circulation of the water in the air heater, regardless of the
position of the control valve; and provides the following important benefit:
appreciably less risk of freezing, due to the fact that the water velocity in the coil is
always sufficiently high.

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 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

2) Direct Expansion Coils: all direct expansion coils will be supplied with a
refrigerant distributor suitable for brazed connections. No expansion valves are
supplied by SAIVER. The refrigerant pipe work must be design and installed in
accordance with good engineering practise and include necessary shut-off
devices, dehydrators, solenoid valves, oil traps etc. Selection, sizing, installation
and setting of thermostatic expansion valve should be in accordance with the
recommendation of Condensing Unit manufacturer. Flow of nitrogen gas must be
maintained through the coil while brazing to avoid formation of oxide film inside,
which might clog the suction strainers affecting on the system operation
adversely.

3) Steam Coils: these are similar to that of water coils, but in addition special care in
take for collection and disposal of condensate within the coils. Condensate
connections to the steam trap must be of same size as the coil outlet. Care must
be taken to prevent entry of condensate in the main into the coil by trapping it
independently on a coil bypass. The steam trap is normally sized 3 times the
design flow.

4) Condensate Drains: All chilled water coils must be individually trapped and
connected to drain with adequate pitch for easy flow. It is recommended to install
a trap as shown in fig 1.4-1. Depending on the ambient temperature and plant
location, it is recommended to insulate the condensate drain pipework.

5) Electric Heater Batteries: If not properly wired and controlled electric Heater
Batteries can be dangerous by causing serious injury or fires or even DEATH.

Electric Heater Batteries are supplied in the form of sheathed elements assemble in
aluminium framework. Double skinned panels are normally drilled for cable entry.
Prior to connecting, heater battery assembly must be checked for conformity to
local regulations. All wiring must be in accordance with local standards. In order
to protect the elements from overheating and possible START OF FIRE, an
airflow switch with necessary control must be installed to cut the power supply
OFF to the heater elements.

Heater Battery must be interlocked with fan motor. Power supply must be
SWITCHED OFF prior to removal of access door and not be switched ON
until the access cover is replaced.

1.6..4. HUMIDIFIERS

Check the type of humidifier and ensure that the necessary Water/Steam/Electric
power supplies are available for connection.

1) Electric Pan Humidifier contains an electric resistance or a bank of resistance in

the form of sheathed elements, normally suitable for 3 phase power supply. All
wiring must be carried out in accordance with local standards with necessary
controls. Connect water supply with shut-off valves. Ensure that overflow is
connected to the drainage with a necessary trap.

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 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Important

Check and clean if necessary the terminal screws etc, to ensure that there is no
short circuiting between the resistance and the cover plate or the humidifier body.

2) Steam ( Pan ) Humidifier must be connected to the steam supply with shut-off
valves, inlet strainer, solenoid valve etc. Condesate drain must be complete with
a trap.

3) Steam ( Injection ) Humidifier is normally supplied with inlet strainer, modulating

valve, condensate trap, steam injection manifold with condensate collector and
discharge pipe. Ensure that the supply steam pressure is maintained within the
limits marked on the modulating valve assembly and connected with a shut-off
valve.

4) Air Washer is a closed circuit humidification system complete with water sump,
inlet strainer, centrifugal pump assembly, isolating valves, water distribution
system made of nylon tubes and self cleaning adjustable nozzles. Feed/Make-up
water supply must be connected to the float valve with a shut-off valve. Overflow
and drain connection must be complete with a trap. A common drain line may be
used for overflow and drain connections, provided a shut-off valve is installed to
isolate the drain connection. Connect power supply to the pump motor in
accordance with local standards with necessary controls. Check the pump
impeller for free rotation.

5) Electronic Steam Humidifiers are packaged type and manufactured by others.

Please refer to manufacturer instructions for details on installation and
maintenance.

6) Eliminators: There is a remote possibility of eliminator blades being displaced

from their position during the transit/installation. In case of such occurrence, they
must be set in position, which is a simple operation. Further it must be ensured
that no foreign matter obstruct the airflow through the eliminator.

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 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

1.6..5. SUPPLY AND RETURN FAN ASSEMBLIES

Anti-vibration mounts, on which fan & motor assembly is

suspended, are locked prior to shipping to avoid damage during
transit ( see fig 1.6-1 ). Once the unit is in position and fan outlet
is connected to ductwork, A.V. Mounts must be released.

fig 1.6-2

Check the type and voltage of motor. If information is made available, cable entry
holes through the double skinned panels can be factory drilled. However it is a simply
operation to carry out the same on site, but ensure that no holes drilled and no
connections are made through access door. It is recommended to use flexible
armoured conduit between the panel and motor terminal box. All conduiting/wiring
must be carried out in accordance with local standards.
Check the type of start ( direct on line/star delta ) meets with the local electrical
regulations. Provide starter/controls/overload protecting devices/interlocks as
required.
Manufacturer instruction, which are supplied along with the motor, must be carefully
studied and followed. Duct work must be connected and insulated in accordance with
good engineering practise. Depending on specified noise levels, attenuators are to
be selected and installed as per the recommendations of acoustic specialists. It is
recommended to protect all lining and attenuation materials with smooth perforated
metallic sheets to avoid migration of fibres into occupied areas/blockage and
subsequent replacement of filters frequently.

Belt driven fans must be checked as illustrated in Chapter 3.4.

1.6..6. ROOF CANOPY

Normally roof canopy is supplied loose to avoid damage during transit for assembly
and installation on site. When units are supplied with bottom inlet and/or discharge, it
must be ensured that proper flashing is carried out around base frame to avoid
possible ingress of water.

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 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

1.7. DRIVE

1.7..1. BELT TENSION

The belts must be correctly tensioned to

ensure good contact with the pulley. If
c/c
insufficiently tensioned, the belts may
L
slip, and if excessively tensioned, the
motor and fan bearings may be P1
overloaded.
When correctly tensioned ( see fig 1.7-
1 ), the belt deflection L will be 15 mm
per metre of distance between centres
c/c when a force P1 ( N ) is applied and fig 1.7-1
P < P1 < 1.5 P , where the force P is
dependent on the belt type as shown in Table A.

The deflection should be measured preferable by means of tensiometer.

Table A
Force P
Belt section diameter of 0 ÷ 10 m/s 10 ÷ 20 m/s 20 ÷ 30 m/s
smaller pulley (N) (N) ( N)
( mm )
SPZ 67 ÷ 95 12 ÷ 18 10 ÷ 16 8 ÷ 14
> 96 19 ÷ 26 17 ÷ 24 15 ÷ 22
SPA 100 ÷ 140 22 ÷ 32 18 ÷ 26 15 ÷ 22
> 141 33 ÷ 48 27 ÷ 40 23 ÷ 34
SPB 160 ÷ 265 38 ÷ 56 32 ÷ 50 28 ÷ 42
> 266 57 ÷ 72 51 ÷ 64 43 ÷ 58
SPC 224 ÷ 355 72 ÷ 102 60 ÷ 90 50 ÷ 80
> 356 103 ÷ 132 91 ÷ 120 81 ÷ 110

1.7..2. CHANGE OF PULLEYS

SAIVER take no responsibility for the consequences, if the pulleys are changed
without their written consent.

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 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

1.8. MAINTENANCE

In general air handling unit do not require special attention other then routine
cleaning and maintenance work. Following is the recommended schedule of
maintenance, when units operate at normal conditions. However actual conditions of
use/operation will dictate the interval of checking/replacement of the filters, belts etc.

1.8..1. ONCE IN A WEEK

• Check filter condition at weekly intervals. Clean, wash or renew/replace if

necessary.

1.8..2. ONCE IN A MONTH

• Check fan belt tension and adjust if necessary.

• Check the condition of spray nozzles and float valve in air washer.

• Check the condition of drain for free flow.

• Check the condition of resistance in electric Pan Humidifier.

• Check the condition of access door hinges and lubricate if necessary.

1.8..3. ONCE IN SIX MONTHS

• Check the fan motor running current.

• Check function controls and their effect on A.H. Unit components.

• Check fan and motor bearings.

• Check electric heater battery elements.

• Add water and flush condensate drain pan, trap and drain line.

• Check circulating pump and motor in air washer.

• Check the condition of inlet strainers.

• Check the condition of chilled/hot water.

• Add chemicals if necessary.

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 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

1.8..4. ONCE IN A YEAR ( PREFERABLY AT THE START OF SEASON )

• Check the operation of dampers.

• Check the filter frame for proper sealing.

• Replace synthetic media in panel filters.

• Check the access doors for easy operation and proper locking.

• Check the controls and operation of Roll Filters.

• Check the coils and fin condition. Wash with water spray, if necessary.

• Check the condition of all insulating, regulating valves etc in the system.

• Vent the water coils.

• Check motor and fan bearing lubrication.

• Replace belts.

• Check all wiring, controls, isolating devices, terminal connections etc.

While attending to the above maintenance schedules, following must be noted.

1.8..5. FILTERS

It is important to check the condition of filters once a week. When the pressure drop
across the filter exceed the maximum pressure drop given in SAIVER drawing, the
filter must be attended immediately. Dirty filters reduces the air flow and hence the
capacity. Do not operate the system without filters. In case the media is synthetic or
metallic, they can be cleaned or washed. However it is recommended to replace
synthetic media once in every year and metallic media once in every two years.
Other filters such as Throw Away Panels, Bag, Absolute, Roll Filters must be
replaced with new cells of identical media and efficiency.

1.8..6. HEAT EXCHANGER COILS

It is recommended to drain the water when the system is shut down. In case required
coils can be withdrawn as follows:

• Disconnect the coil from the water connection.

• Remove the side ( Doubled Skin ) panel.

• Remove the bolts by which coil frame is fixed to the unit frame.

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 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

• Withdraw the coils. coil can be reinstalled by the following the above procedure in
reverse.

1.8..7. SUPPLY AND RETURN FAN SECTIONS

Bearing lubrication

Normally fans are fitted with grease packed ball bearings Series: SY and type: UCP
with minimum anticipated running life of ( see Table B ):

Table B
Fan with speed up to 1000 RPM 25000 hrs
Fan with speed between 20000 hrs
1500 ÷ 2000 RPM
Fan with speed between 15000 hrs
2000 ÷ 3000 RPM

Fans normally installed for high pressure /heavy duty application will have Series:
2300 ball bearings housed in plummer block type: SNA. The recommended intervals
are as follow ( see Table C )

Table C
BEARING FAN SPEED ( RPM )
HOUSING 500 1000 1500 2000 2500 3000
SNA 607 25 25 18 17 13 10
SNA 608 25 25 18 15 12 9
SNA 609 25 25 18 14 11 8
SNA 610 25 21 16 12 8 5
SNA 611 25 18 15 11 7 3
SNA 612 25 17 13 9 4 -
SNA 613 25 17 12 8 2 -
SNA 615 25 15 10 5 1 -
SNA 616 25 13 8 2 - -
SNA 617 25 12 6 1 - -
(hrs x 1000)

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 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Impeller removal

For some reason, if it is required to take the impeller out for cleaning, following
procedure is recommended:

Forward Curved Fan

• Loosen motor mounting bolts and remove the motor.

• Remove belts and bearings.

• Loosen the fan fixing screw and withdraw the shaft.

• Unbolt the flexible connection on fan discharge.

• Turn the fan assembly by 90.

• Take out the impeller from the fan discharge opening. Handle carefully while
cleaning, to avoid any damage to blades.

Backward Curved Fan

• Loosen motor mounting bolts and remove the motor.

• Remove belts and bearings.

• Unbolt and remove the flange of bearing supporting ring frame.

• Remove the aluminium inlet cone.

• Withdraw the impeller along with the shaft.

• Inlet cones and impellers are made of aluminium. They must be handled carefully.

1.8..8. CLEANING OF DOUBLED SKIN PANELS

All panels are double skinned and they can be easily detached from the framework
by removing screw with simple hand tools. They can be cleaned or washed. However
it must be ensured that they are completely dry prior to refixing. Do not drop any
heavy weights or sharp edge tools etc. It might damage the plasticised finish or
puncture the aluminium panels.

NOTE

If any further information is required, please contact SAIVER, who will be very
pleased to assist.

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 SAFETY

2. SAFETY

The SAIVER air handling units can be considered a safe machinery.

By means of the compliance

statement of the EEC and of the
symbol “CE” on the unit, it is
guaranteed that the SAIVER air
handling units fulfil the provisions
for the essential health and safety
requirements laid down in Annex I
of Machinery Directive 98/37/CE .

The “CE” mark appears on every

identification label of the unit ( see
fig 2.1-1 ). fig. 2.1-1

In spite of all that, the unit could represent a danger, if it is utilised or serviced not
properly by staff not sufficiently trained.
We, like manufacturer of the unit, intend to explain to the user, by an exhaustive
chapter, the concept of safety referring to air handling unit and to inform him of
possible dangers and consequent measures.
Observe also the general standards for the safety and the accidents’ prevention
coming from the following indications!

2.1. TERMINOLOGY

It is considered “danger zone” internal area of the unit close to the movement parts
and the electrical parts.
In order to be able to access to these areas, it is necessary to provide oneself with
the proper key tool to deactivate the safety devices.

The operators are responsible for transport, installation, start up, service and
maintenance, including cleaning and troubles repair.

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 SAFETY

2.2. OPERATION SAFETY

SAIVER air handling units are safe because they are built in accordance with good
engineering practise.
Nevertheless, the units could represent a hazard if they are used, by an untrained
staff, improperly or not in conformity with general provisions. The more common
hazards are:

• danger to operator’s safety.

• damages to the unit.
• possibility to compromise the efficiency of unit work.

2.3. USE OF THE UNIT IN CONFORMITY TO GENERAL PROVISIONS

SAIVER air handling units are able to fan, to heat, to cool, to filter, to humidify.
Any other use is considered not in conformity with general provisions. The
manufacturer is not responsible for damages resulting; the user will be the only
responsible.
In order to use the unit according to general provisions proper instructions of
installation, exercise and transport must be observed.

Installation and start up of the unit must satisfy the national standards having legal
course in the country of the user. The user is responsible for compliance with
standards.

Besides, it must be avoided any type of work that may compromise safety.

Arbitrary transformations of the unit by user or operator are not allowed and exclude
the warranty of the manufacturer for the damages to things and persons.

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 SAFETY

2.4. MEASURES OF THE USER/OPERATOR, OBSERVATION OF THE

SIGNPOSTS (WARNINGS)

Signposts are placed on the unit, showing:

1) prohibition to repair or adjust during motion ( fig 2.4-1 )

2) obligation to turn off the power before opening the access door ( fig 2.4-2 )
3) warning of coming into contact with electrical parts ( fig 2.4-3 )

TURN OFF THE POWER

DON REPAIR OR ADJUST BEFORE OPENING
DURING THE MOVEMENT

fig 2.4-2 fig 2.4-3

fig 2.4-1

This signpost and the other warnings regarding the unit must be absolutely observed.

2.5. STAFF TRAINING

The unit can be started up and serviced (routine maintenance + corrective

maintenance) only by authorised and trained staff. This staff must be informed about
possible hazards regarding:

• electrical connections
• piping connections
• ducting connections
• start up

These operations can be executed only by trained persons.

People who, on behalf of the user, attend to control and to the extraordinary/ordinary
maintenance of the unit.

It is necessary to establish and to respect the responsibilities for control and

maintenance to guaranty safety, without confusing competencies.

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 SAFETY

2.6. USE OF THE UNIT

The unit can be started up only by means of proper safety devices.

The installer is obliged to install the unit according to installation plans and conditions.

Only authorised persons must operate on the unit.

The staff in charge is obliged to signal immediately to the user any changes that may
compromise safety. For this reason it is necessary to inspect for eventual anomalies
or damages at least once a week.
The user or operator never must dismount and deactivate safety devices; if these
would be removed for extra maintenance, at the end of operations they must be
reinstalled.

For all operations of extra maintenance, the power source must be locked out.

2.7. BEHAVIOUR IN CASE OF DAMAGES

If it is necessary to make maintenance, the fan must be switch off, isolated and
allowed to rundown.

2.8. MEASURES TAKEN BY MANUFACTURER:

Essential Health & Safety requirements laid down in annexe I of EEC

MACHINERY DIRECTIVE 98/37/EC
Applicable points of EEC Measures taken: Ref. to harmonised
MACHINERY DIRECTIVE procedure
1.1.4 Lighting Inspection zone in order to UNI EN 292
provide maintenance and start-
up provided with lighting
1.1.5 Design of a unit in Design of a multi-section unit UNI EN 292
order to handling with basement for lifting by
forklift or rope; locking of
vibration isolators during
transport conditions stated on UNI EN 292
1.3.2 Risk of breakage Operation
during functioning the as-built drawing; frequency
of maintenance listed in the
instruction handbook
1.3.3 Risk due to surfaces Casing tested till 400 mm of UNI EN 292
and projection of objects pressure, fan dimensioning
within operation limits, mesh for
no ducted fan and warnings
described in the maintenance
and operation handbook
1.3.4 Risk due to surfaces, Sharp corner of extruded UNI EN 292

18
 SAFETY

edges and corners minium profiles rounded off to

6mm ray
1.3.7 Prevention measures Access door open able with a UNI EN 292
against moving elements special tool ; written warning
1.3.8 Estimated prevention fitted on the access door.
measures against moving Optional measures are to be
elements required during commercial
1..41.1 General agreement and stated on the
requirements as-built drawing
1.4.2.1 Fixed protection
1.5.1 Risk due to electric Wiring diagrams inside motor UNI EN 292
power terminal box. CEI EN 60204-1
(see also paragraph 2.9)
1.5.6 Risk of fire Fire-retardant polyurethane or UNI EN 292
mineral wool panels type
sandwich
1.5.7 Risk of explosion Should any risk of explosive UNI EN 292
atmosphere, supply of electric
motor and explosion-proof fan
occur
1.5.8 Risk due to noise Noise level stated on the as- UNI EN 292
built drawing data sheet.
Should not such noise meet
given conditions, both required
for machine room and other
room, measures will be taken
as follows:
- additional insulation into
section
- silencer on the supply fan
section
1.5.9 Risk of vibration Fans and motors mounted on UNI EN 292
basement isolated by vibration
isolators and flexible
connections on fans
1.5.14 Risk of being Access door provided with UNI EN 292
imprisoned inside the unit hinges which allow opening
from the inside
1.6.1 Maintenance of the See Installation, Use and UNI EN 292
unit Maintenance handbook
1.6.4 Workman corrective Design according to SOP 003; UNI EN 292
maintenance see chapter “Safety” in the
handbook for a safety
maintenance
1.7.0 Warning device Written warning in proximity to UNI EN 292
electrical and rotating parts
1.7.2 Warning about further Written warnings near pipe UNI EN 292
risks connections
1.7.3 Marking Marking on metal name plate UNI EN 292
displayed on the outside the fan

19
 SAFETY

section access door.

Operation conditions and
overall dimensions stated on
the as-built drawing.
1.7.4 Information for use Installation, Use and UNI EN 292
Maintenance handbook, As-
built drawings and possible
attached schemes form an
integral part of ‘Information for
use’.

2.9. PREVENTION MEASURES ARE TO TAKEN BY INSTALLER OR THE

PERSON IN CHARGE OF INSTALLING CONTROL AND START-UP
DEVICES

Essential Health & Safety requirements laid down in annexe I of EEC

MACHINERY DIRECTIVE 98/37/EC
Applicable points in EEC Measures to take: Ref. to
MACHINERY DIRECTIVE harmonised
1.2.1 Safety and reliability of Control system, Start-up and procedure
UNI EN 292
control system Stopping according to standards CEI EN 60204-1
1.2.2 Control device in force
1.2.3 Start-up
1.2.4 Emergency stopping
device
1.2.5 Operation modal Should not start-up and stopping UNI EN 292
selector switch devices be in proximity to the CEI EN 60204-1
unit, it shall be provide with an
additional lockable isolating
switch placed outside the air
handling unit, near the fan
section access door in order to
guarantee safe maintenance.
1.5.1 Risk due to electrical Grounding of an electric motor UNI EN 292
power according to standards in force CEI EN 60204-1

20
 SAFETY

2.10. RECOMMENDED SAFETY PRACTISES

This publication explains the proper use and installation of centrifugal fans in order to
warm operating and maintenance personnel of the commonly recognised dangers
associated with this equipment. In addition to following the manufacturer' s installation
instructions, care must be taken to ensure compliance with federal, state and local
rules, regulations codes and standards.

2.10..1. PERSONNEL SAFETY ACCESSORIES

Centrifugal fans in air handling unit are located inside a casing opportunely sealed so
accessibility to these fans is occasional or infrequent. For this reason, protective
devices are offered as optional accessories only at specific user' s request.
However as in the case with other machinery involving moving parts, common sense
and caution will preserve personal safety.

The available guarding devices are:

1) Lockout switches and suitable warnings. In such cases, maintenance personnel

should engage the lockout switch before undertaking any maintenance or repairs.

2) Inlet and outlet guards. Centrifugal fans are

usually connected directly to ductwork which
will prevent the contact with the internal
moving parts. In case there is an exposed
inlet or outlet which could represent a
danger, It can be installed a suitable guard
as the one represented in fig 2.10-1.
fig 2.10-1: inlet or outlet
3) Drive guards. A typical centrifugal fan drive
guard on centrifugal fan
guard may vary with the arrangement.
Safety guards shall be used when drive systems are accessible to personnel
( see fig 2.10-2).In restricted areas, omission of the back cover may be
acceptable.

fig 2.10-2: drive guard- centrifugal fan

21
 SAFETY

2.10..2. THE HIDDEN DANGER

In addition to the dangers of rotating

machinery, fans present another
potential danger by virtue of their
ability to draw in loose material.
Solid objects passing through a fan
represent potentially dangerous
projectiles. Solid objects can cause
fan failure by physically damaging
the impeller blades.
Whatever there is the possibility of
fig 2.10-3: special purpose intake
solid objects being drawn into a
remote intake, the intake shall be screen
guarded at all this times. In the event
the guard is removed for any reason, the fan must be disconnected and locked out.

Where fans are installed over an occupied area, safety guards should be provided to
prevent dropped objects from entering this area during installation and maintenance.

Access doors to a fan or duct system should not be opened with the fan in operation
or coasting to a stop. Power shall be locked out prior to access into a fan or ductwork.
Even when locked out electrically, fans may cause injury or damage if the impeller is
subject to "wind milling". The impeller should be secured to physically restrict
rotational movement.
On the downstream (or pressure) side of the system, realising the door with the
system in operation may result in an explosive opening. On the upstream (or suction)
side the inflow may be sufficient to draw in tools and clothing, etc, and create a
danger.
The access door in air handling unit is always locked out by a special lock and to
open the door it is necessary a key so it is impossible to open it by chance.

The stroboscopic effect of certain lights in combination with certain fan speeds may
cause a rotating assembly to appear stopped.

22
 SAFETY

2.10..3. START UP CHECK LIST

Before putting any fan into operation the manufacturers'instructions must be

followed. In addition, the following check list must be completed.

• There is possibility of collection of debris such as duct/insulation materials, tapes

etc used during installation of the system. Hence it must be ensured that all the
sections of the unit are thoroughly cleaned. In case units are supplied with
peraluman panels, polythene protective film must be peeled off and it must be
ensured that no traces of film is left loose within the unit.

• Ensure all panels, if removed during installation, are in position.

• Ensure all electrical wiring in carried out to local standards and all components
are provided with safety, protecting and isolating devices.

• Remove all filters including panel filters: install low efficiency filters such as gauze
bags or a set of throw away type filters.

• Ensure all dampers are opened.

• Check water/steam/refrigerant coil connection for any leaks. Ensure that all the
air in the system and coil is vented out. Check coil face free from debris.

• Add water in the condensate drain pan to prime the trap and ensure free flow of
water into the drain.

• Ensure that minimum water levels are maintained in electrical Pan Humidifier/Air
Washers.

Fan start up

1) Screw out security nuts of antivibration mounts.

2) Lock out the primary and secondary power sources.
3) A complete inspection shall be made of all the ductwork and the interior of the
fan. Make certain there is no foreign material which can be drawn into or blown
through the fan or ductwork. Eyes should be protected against undetected
foreign material through the use of safety goggles or other appropriate means.
4) Make sure the foundation or mounting arrangement and the duct connection are
adequately designed in accordance with recognised acceptable engineering
practises and with the fan manufacturer' s recommendations.
5) Check and tighten all hold-down (securing) bolts.
6) Check the fan assembly and bearings for proper grounding to prevent static
electricity discharge.
7) Spin the impeller to determine whether it rotates freely and is not grossly out of
balance.
8) Inspect impeller for proper rotation for the fan design.
9) Check all set screws and tighten, if necessary.

23
 SAFETY

10) Check belt drive or coupling alignment; use recommended belt tension.
11) Check the belt drive for proper sheave selection and make sure they are not
reversed ( excessive speeds could develop ).
12) Properly secure all safety guards.
13) Secure all access door to the fan and ductwork.
14) Momentarily energise the fan to check the direction of rotation.
15) Switch on the electrical supply and allow the fan to reach full speed.
Check carefully for:

a) Excessive vibration
b) Unusual noise
c) Proper belt alignment
d) Proper lubrication
e) Proper amperage and voltage values

If any problem is indicated, SWITCH OFF IMMEDIATELY.

Lock out the electrical supply, secure the fan impeller if there is a potential for
windmilling ( impeller turning due to a draft through the system ).Check
carefully for the cause of the trouble and correct as necessary.

Even if the fan appears to be operating satisfactory, shut down after a brief period
and recheck items 5) through 12) as the initial start up may have loosened
the bolts and set screws.

• After ensuring that there are no leaks between joints of section and system is
clean, stop the fan. Dispose off low efficiency filters. Install Panel/Bag/Absolute
filters, as supplied.

• Restart the fan. In case of a stand-by fan and motor are supplied, ensure that no
short circuiting of air occurs.

• In case fan is connected to a stand by motor for automatic change over, do not
touch the terminal of stand by motor, even though motor is idle. Ensure that belts
are removed and the power is isolated.

• Adjust dampers position to obtain the rated air volume.

• In case fans are supplied with variable pitch pulley ( up to 7.5 kW ), adjust the
same to the desired position.

• Ensure that the air volume are within the specified limits.

• Check the motor current and ensure the same is within the rated ( name plate )
data.

• Check ON-OFF temperature across coils and adjust water/steam flows

accordingly. Check the functioning of controls.

• Check the functioning of humidifier by adjusting the humidistat control.

24
 SAFETY

• Check the operation of heater batteries by adjusting thermostat. Check the

functioning of controls such as air flow switch, fan interlock, over heat protection
etc.
• Check the pressure drop across the filters and ensure that the same is within the
limits.

The fan has been put into operation but, during the first eight hours of running, it
should be periodically observed and checked for excessive vibration and noise. At
this time checks should also be made of motor input current and motor and bearing
temperatures to ensure that they do not exceed manufacturer' s recommendations.

After eight hours of satisfactory operation, the fan should be shut down to check the
following items and adjust, if necessary ( lock-out power ).

1) All set screws and hold-down bolts

2) Drive coupling alignment
3) Belt drive alignment
4) Bearing housing temperature
5) Belt drive tension

After twenty-four hours of satisfactory operation the fan should be shut down ( locked
out ) and the drive belt tension should be readjusted to recommended tension.

2.10..4. AFTER 2 WEEKS OPERATION

After start up and initial operation of approximately 2 weeks, it is recommended to

have the following checks.

• Bearings temperature immediately after stoppage. This is not to exceed 70°C;

Lubricate if necessary.

• Belt tension.

• Pulley alignment.

• Motor running current.

• Filter condition.

• Condensate and drain to see flow.

• Operation of controls.

25
 SAFETY

2.10..5. WARNING SIGNS

A preventive maintenance program is an important aspect of an effective safety

program. Investigate any changes to the fan. Refer to Chapter 3 “troubleshooting”,
for a more detailed explanation of investigating procedures. Consult your
manufacturer or other qualified consultant with question concerning changes
observed during periodic inspections.

1) Excessive vibration: if excessive vibration is observed stop the fan until the cause
is corrected. Check for material build-up on impeller. Generally this will show up
as material flaking off the fan impeller and causing an imbalance which may lead
to fatigue failure of the impeller.

2) Noise: changes to the sound level may indicate troubleshooting is needed.

3) High motor temperatures: check that cooling air to the motor has not been
deviated or blocked by dirty guards or similar obstacles. Check the input
amperage. An increase in amperage may indicate that some major changes has
been made in the system.

4) High bearing temperatures: this condition is usually caused by improper

lubrication; this can be either "over", "under" or "unsuitable" lubrication. In any
case if the cause of the trouble is not easily seen, experienced personnel must
examine the equipment before it is put back in operation.

26
 SAFETY

2.10..6. ROUTINE MAINTENANCE

Maintenance should be performed by experienced and trained personnel. Do not

attempt maintenance unless the electrical supply has been locked out or tagged out
and the impeller has been secured.

a) Under normal circumstances, handling clean air, the system should require
cleaning only about once a year. However, the fan and the system should be
checked at regular intervals to detect any unusual accumulation.

b) The fan impeller should be especially checked for build-up of material or dirt
which may cause an imbalance with resulting undue wear on bearings and belt
drives. A regular maintenance program should be established as needed to
prevent material build up.

c) Periodic inspection of the rotating assembly must be made to detect any

indication of weakening of the rotor because of corrosion, erosion, or metal
fatigue.

27
 TROUBLESHOOTING

3. TROUBLESHOOTING

A preventive maintenance program is an important aspect of an effective safety

program. It is fundamental to keep any part of the system controlled in order to point
out promptly any changes to the right working.
In any case it is suitable to consult the manufacturer or other qualified consultant with
question concerning changes observed during periodic inspections.

3.1. PROCEDURE FOR TROUBLESHOOTING

1) Look in the "Master Troubleshooting Chart" for an index tag which

corresponds to with the apparent problem.
2) Check each of the probable causes listed.
3) If the cause of the trouble is not found proceed through the "System
Checklist".
4) If the problem has still not be solved, it is now advisable to contact the
representative of fan manufacturer. He should be given the results of the
"System Checklist" and some "additional information" which are particularly
interesting for the manufacturer.
5) The fan manufacturer or his representative will analyse the information
submitted (as outlined on page 31 ).With this information and, if necessary, an
on-site inspection he should be able to explain why the system is not achieving
its design performance and may recommend changes in the system or the fan
installation which will overcome the problem.

3.2. SAFETY PRECAUTION

Before checking the fan and system it will be necessary to shut down the fan. During
inspection the fan must be electrically isolated and all disconnect switches and
others controls locked in the "OFF" position. Where this in location remote from the
fan, prominent "DO NOT START" signs should also be in place.

3.3. MASTER TROUBLESHOOTING CHART

See Appendix

28
 TROUBLESHOOTING

3.4. SYSTEM CHECKLIST

Poor system performance may arise from a number of causes including:

• improper installation or assembly of the fan

• damage in handling or transit
• system design error
• deterioration of the system
• faulty controls
• poor fan selection
• a combination of several factor

A systematic check of items listed should identify the problem or problems and allow
suitable corrective action to be taken.

SYSTEM CHECKLIST

A) While the impeller is coasting to

a stop, see if it is rotating in the
proper direction (see fig 3.4-1 )

B) Make certain the impeller is of

the correct rotation for the
housing and not installed
backwards. [ Fan manufacturer
describe the rotation of
centrifugal fan impeller as being
"clockwise" or
"counterclockwise" when viewing
the DRIVE SIDE ( see AMCA
Standards 2406 ) ].
fig 3.4-1: type of centrifugal fan
impeller
C) If the fan is belt driven:
1) are the drive pulley (motor sheave) and the driven pulley (fan
sheave) in alignment ? Improper alignment of the sheave can
cause excessive power (high amperage) and squealing belts (see
fig 3.4-2 ).

fig 3.4-2

29
 TROUBLESHOOTING

2) are the belts loose ? Loose belts can cause slipping, leading to
squealing and/or low fan speed along with hot sheaves, bearings,
shafts and motor. Belts should be tensioned to the belt
manufacturer's recommendations. Tension of the drive belts should
be adjusted for stretching after the first forty-eight hours of
operation. Caution! excessive belt tension will reduce fan and
motor bearing life (see fig 3.4-3).

fig 3.4-3

3) are the belts and/or sheaves worn ? If so, an immediate

replacement could save down time at a later date. Replacement
belts should be a new set of matched belts.
D) Check the flow surfaces (passages between the inlets, impeller blades
and inside of housing) for cleanliness. A millimetre build-up of dirt on the
flow surfaces could impair fan performance.
E) Are there any gouges, tears, holes, erosion or corrosion in the impeller
blades, rims or backplate; inlet and/or housing ? If so, report the
approximate size and location to the fan manufacturer.
F) Is any foreign matter trapped in the impeller, housing or ductwork (loose
insulation, papers, ice, etc) ? If so, remove.
G) Are coils, heaters, filters, ducts, etc dirt laden ? If so, clean or replace.
Remove any non-essential obstruction to flow in elbows, shutters,
transformations, dampers, bird-screens, etc.
H) Have all the parts supplied with the fan been installed ?
I) Are there any obstruction to flow near the fan inlets ? Objects such as
pipes, ductwork, columns, belt guards, belt drives, etc could adversely
affect the output of the fan.
J) Are the fan outlet connections correctly designed and installed ? Duct
takeoffs, or obstructions in the fan outlet could adversely affect the output
of the fan.
K) See fig 3.4-4 for typical inlet-impeller relationships. A few simple
measurements as indicated on fig 3.4-4 can tell the manufacturer if a
problem exists in this area (several measurement should be taken around
the entire inlet circumference).

30
 TROUBLESHOOTING

fig 3.4-4: typical inlet-impeller relationships

D) Are turning vanes installed in elbows close to the fan inlet or discharge ?
E) If the fan is equipped with variable inlet vane or inlet damper control,
check the operation as follows:
1) Do not rely on the control arm position alone for locating the
position of the vane/damper blades without first checking visually to
see that the vane/damper position agrees with the position of the
control arm.
2) If the unit is double width fan equipped with variable inlet vanes or
damper control, both inlet vanes/dampers must be synchronised
(the inlet vanes/dampers must be in the same relative position with
respect to the impeller on both inlets). If the inlet vanes/dampers
are not synchronised, there will be an unbalance flow between
inlets resulting in deficient air performance, unbalance thrust on
bearing and/or a surge condition in the fan.
3) Make certain that variable inlet vanes are of the proper rotation with
respect to the impeller. As the vanes close, they should cause the
entering air to spin in the same direction as the impeller.
4) Are the inlet vanes/dampers correctly positioned for the designed
operating conditions ? If not, the desired pressure-volume of the
fan will not be realised (see fig 3.4-5).

fig 3.4-5: typical normalised inlet vane control

pressure volume curve
D) Insp

31
 TROUBLESHOOTING

ect any ductwork or plenums approaching the fan inlets for the possibility
of inducing swirl of air into the inlet (see fig 3.4-6 ).

fig 3.4-6: typical forced inlet vortex

After completing the above steps and securing the fan, remove all OUT signs on
disconnected switches and override systems and put the unit back into
operation.

D) Inspect the entire system including the fan, fan plenum and all ductwork
for leaks. Leaks may be detected by sound, smoke, feel, soapy solution,
etc. Some common leak sources are access doors, coils, duct seams, fan
outlet connection etc which must be sealed.

32
 TROUBLESHOOTING

3.5. ADDITIONAL INFORMATION ( FAN MANUFACTURER'S ANALYSIS )

If the cause of the trouble has still not be found after completing the "system
checklist", the fan manufacturer should be consulted.

The fan manufacturer will review the information provided concerning the system and
apply his own special knowledge and experience to the problem.

To make a complete analysis of the problem, in addition to the results of the "system
checklist", the manufacturer will need:

A) Complete plans (drawings) including all ductwork, location, size, model

and manufacturer of all fans, motors, coils, dampers, etc. with all pertinent
dimensions for the complete system as actually installed. The original
engineering drawings may not be representative of the actual installation.
B) If the problem is failure of the process or system to achieve design
performance the measured performance figures and design performance
figures should be supplied.
C) A copy of the system design calculations.
D) A copy of the specifications and any addendum.
E) If a separate air performance test has been conducted on the installed fan,
a statement of measured fan performance along with a copy of the test
data, the type of test and instrumentation, and the location of the flow rate
pressure determination should be supplied.

A statement of fan performance should contain:

1) fan total pressure rise or fan static pressure

2) flow rate
3) power (amperage)
4) fan speed
5) gas density

Among other actions he will:

1) Access the probable accuracy of the field performance measurements.

2) Check whether the fan selection is correct for the application.
3) Examine the system drawings (plans) in order to individualise any
eventual change in the system performance curve in respect to the
system design calculations or the original fan selection.
4) Make the appropriate corrections.

33
 TROUBLESHOOTING

3.6. CONCLUSION

By intelligent application of the procedures outlined in this manual it should be

possible to find the cause of performance problem in any air moving system.

Identification of problem associated directly with the fan may require the assistance
of the fan manufacturer.

Recognition of the cause of the trouble will usually be a major step towards curing it.
Corrective measures may include alterations to the system, modification to the fan
outlet or inlet connections, adjustments to the fan etc. in many cases an increase in
the fan speed may be decided upon but it is extremely important that the fan shall
not be operated above its catalogued maximum speed or the maximum speed
recommended by the manufacturer.

The information obtained through the checklists in this manual should also help in
allocating responsibility for the necessary corrective action. In most cases, if the
troubleshooting procedure has been followed carefully and impartially it will be
apparent whether the system has been built and installed in accordance with the
design drawings, whether the fan was properly selected, or the fan is not performing
up it its published ratings.

34
 APPENDIX: MASTER TROUBLESHOOTING CHART
PROBLEM SOURCE PROBABLE CAUSE
NOISE A-1 IMPELLER HITTING INLET RING a) impeller not centred in inlet ring
b) inlet ring damaged
c) crooked or damaged impeller
d) shaft loose in bearing
e) impeller loose on shaft
f) bearing loose in bearing support
A-2 IMPELLER HITTING CUT OFF a) cut-off not secure in housing
b) cut-off damaged
c) cut-off improperly positioned
A-3 DRIVE a) sheave not tight on shaft ( motor and/or fan )
b) belts hitting belt tube
c) belts too loose. Adjust for belt stretching after 48 hours
operating
d) belts too tight
e) belts wrong section
f) belts not "matched" in length on multi-belt drive
g) variable pitch sheaves not adjusted so each groove has same
pitch diameter ( multi-belt drives )
h) misaligned sheaves
i) belts worn
j) motor, motor base or fan not securely anchored
k) belts oily or dirty
l) improper drive selection
A-4 COUPLING a) coupling unbalanced, misaligned, loose or may need lubricant
A-5 BEARING a) defective bearing
b) needs lubrication
c) loose on bearing support
d) loose on shaft
e) seals misaligned
f) foreign material inside bearing
g) worn bearing
h) fretting corrosion between inner race and shaf
A-6 SHAFT SEAL SQUEAL a) needs lubrication
b) misaligned
PROBLEM SOURCE PROBABLE CAUSE

A1
 APPENDIX: MASTER TROUBLESHOOTING CHART
NOISE A-7 IMPELLER a) loose on shaft
b) defective impeller. Do not run the fan. Contact manufacturer
c) unbalance
d) coating loose
e) worn as result of abrasive or corrosive material moving through
flow passages
A-8 HOUSING a) foreign material in housing
b) cut-off or other part loose ( rattling during operation )
A-9 ELECTRICAL a) lead-in cable not secure
b) AC hum in motor or relay
c) starting relay chatter
d) noisy motor bearings
e) single phasing a 3 phase motor
A-10 SHAFT a) bent
b) undersized. May cause noise at impeller, bearing or sheave.
c) if more than two bearings are on shaft, they must be properly
aligned.
A-11 HIGH AIR VELOCITY a) duct work too small for application
b) fan selection too small for application
c) register or grilles too small for application
d) heating or cooling coils with insufficient face area for application
A-12 OBSTRUCTION IN HIGH VELOCITY GAS a) dampers
STREAM MAY CAUSE RATTLE, OR b) registers
PURE TONE WHISTLE c) grilles
d) sharp elbows
e) sudden expansion in duct work
f) sudden contraction in duct work
g) turning vanes
A-13 PULSATION OR SURGE a) restricted system causes to operate at poor point of rating
b) fan too large for application
c) ducts vibrate at same frequency as fan pulsation
A-14 GAS VELOCITY THROUGH CRACKS, a) leaks in duct work
HOLES OR PAST OBSTRUCTIONS b) fins on coils
c) register or grilles
PROBLEM SOURCE PROBABLE CAUSE
NOISE A-15 RATTLES AND/OR RUMBLES a) vibrating duct work

A2
 APPENDIX: MASTER TROUBLESHOOTING CHART
b) vibrating cabinet parts
c) vibrating parts not isolated from building
INSUFFICIENT AIR B-1 FAN a) forward curved impeller installed backwards
FLOW b) fan running backwards
c) cut-off missing or improperly installed
d) impeller not centred with inlet collar(s)
e) fan speed too slow
B-2 DUCT SYSTEM a) actual system is more restrictive (more resistance to flow ) than
expected
b) dampers closed
c) registers closed
d) leaks in supply ducts
e) insulating duct liner loose
B-3 FILTERS a) dirty or clogged
B-4 COILS a) dirty or clogged
B-5 RECIRCULATION a) internal cabinet leaks in bulkhead separating fan outlet ( pressure
zone ) from fan inlets ( suction zone )
b) leaks around fan outlet at connection through cabinet bulkhead
B-6 OBSTRUCTED FAN INLETS a) elbows, cabinet walls or other obstructions restrict air flow. Inlet
obstructions cause more restrictive systems but do not cause
increased negative pressure readings near the fan inlet(s).Fan
speed may be increased to counteract the effect of restricted fan
inlet(s)
B-7 NO STRAIGHT DUCT AT FAN OUTLET a) fans which are normally used in duct system are tested with a
length of straight duct at the fan outlet. If there is no straight duct
at the fan outlet, decreased performance will result. If it is not
practical to install a straight section of duct at the fan outlet, the
fan speed may be increased to overcome this pressure loss.
B-8 OBSTRUCTIONS IN HIGH VELOCITY AIR a) obstruction near fan outlet
STREAM b) sharp elbows near fan outlet
c) improperly designed turning vanes
d) projections, dampers or other obstruction in part of system where
air velocity is high
PROBLEM SOURCE PROBABLE CAUSE
TOO MUCH AIR C-1 SYSTEM a) oversized duct work
FLOW b) access door open
A3
 APPENDIX: MASTER TROUBLESHOOTING CHART
c) registers or grilles not installed
d) dampers set to by-pass coils
e) filter(s) not in place
C-2 FAN a) backward inclined impeller installed backwards ( power will be
high )
b) fan speed too fast
STATIC D-1 SYSTEM, FAN OR INTERPRETATION OF general discussion:
PRESSURE MEASUREMENTS The velocity pressure at any point of measurement is a function of
WRONG the velocity of the air or gas and its density.
The static pressure at a point of measurement in the system is a
function of system design ( resistance to flow ), air density and the
amount of air flowing through the system.
The static pressure measured in a "loose" or oversized system will
be less than the static pressure in a "tight" or undersized system for
the same flow rate.
In most systems, pressure measurements are indicators of how the
installation is operating. These measurements are the result of air
flow and such are useful indicators in defining systems
characteristics.
Field static pressure measurements rarely correspond with
laboratory static pressure measurements unless the fan inlet and
fan outlet conditions of the installation are exactly the same as inlet
and outlet conditions in the laboratory.
Also see D-2 through D-6, E-2, F-1, and G-1, for specific cases.
static pressure low, D-2 SYSTEM a) system has less resistance to flow than expected. This is a
flow rate high common occurrence. Fan speed may be reduced to obtain
desired flow rate. This will reduce power ( operating cost ).
D-3 GAS DENSITY a) pressure will be less with high temperature gases or high
altitudes
D-4 FAN a) Backward inclined impeller installed backwards. Power will be
high
b) fan speed too high
PROBLEM SOURCE PROBABLE CAUSE
static pressure low, D-5 SYSTEM a) fan inlet and/or outlet conditions not same as tested. See
flow rate low general discussion ( D-1 ).
Also see B-1 through B-8.

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 APPENDIX: MASTER TROUBLESHOOTING CHART
static pressure D-6 SYSTEM a) obstruction in system
high, flow rate low b) dirty filters
c) dirty coils
d) system too restricted
Also see B-1 through B-8.
POWER HIGH E-1 FAN a) backward inclined impeller installed backwards
b) fan speed too high
E-2 SYSTEM a) oversized duct work
b) face and by-pass dampers oriented so coil dampers are open at
the same time by-pass dampers are open
c) filter(s) left out
d) access door open
E-3 GAS DENSITY a) calculated horse power requirements based on light gas ( e.g.
high temperature ) but actual gas is heavy ( e.g. cold start up )
E-4 FAN SELECTION a) fan not operating at efficient point of rating. Fan size or type may
not be best for application
FAN DOES NOT F-1 ELECTRICAL OR MECHANICAL Mechanical and electrical problems are usually straightforward and
OPERATE are normally analysed in a routine manner by service personnel. In
this category are such item as:
a) blown fuses
b) broken belts
c) loose pulleys
d) electricity turned off
e) impeller touching scroll
f) wrong voltage
g) motor too small and overload protector has broken circuit

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 APPENDIX: MASTER TROUBLESHOOTING CHART

PROBLEM SOURCE PROBABLE CAUSE

PREMATURE G-1 BELTS, BEARINGS, SHEAVES, general discussion:
FAILURE IMPELLER, HUBS, ETC. Each fan component is designed to operate satisfactory for a
reasonable life time. Fan intended for heavy duty service are made
especially for that type of service. For example, Class I fans are
intended for operation below certain limits of pressure and outlet
velocity. Class II fans are designed for higher operating limits ( see
AMCA standards 2408 ).Not all components are limited by the
same factors, e.g. limiting factors may be power, round per
minutes, temperature, impeller tip speed, torque, corrosive
atmospheres, expected life, etc.
Also see A-3, A-5, A-6.
G-2 COUPLINGS see item A-4
G-3 SHAFT also see A-10

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