KRUEGER KAH, Operation & Maintenance Manual

Page 1: ...Krueger 1401 N Plano Rd Richardson TX 75081 972 680 9136 kruegerinfo krueger hvac com www krueger hvac com Model KAH Installation Assembly Start up and Service Instructions OPERATION MAINTENANCE GUIDE...

Page 2: ...by accessing the Krueger website at www krueger hvac com Operating service personnel maintain responsibility for the applicability of these documents to the equipment If there is any question regardin...

Page 3: ...e General Requirements Inspect Parts Fan Segment Operating Adjustable Motor Base Checking Belt Tension Aligning Sheaves Belt Replacement Tensioning Sheave Alignment for Top Mount Lubrication UVC Emitt...

Page 4: ...d materials This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question IMPORTANT READ BEFORE PROCEEDING SAFETY...

Page 5: ...the AHU to ensure compliance with the safety requirements However the individual operating or working on any equipment is primarily responsible for Personal safety safety of other personnel and the eq...

Page 6: ...pletely Do not remove the functional bolts from the seismic isolators as shown in Figure 1 right Ensure the damper linkage is tight and is in the correct power off position If the return air dampers a...

Page 7: ...in Figure 3 right mounted under the internal fan assembly For thrust restraint adjustment procedures if applicable refer to the service manual Prepare the fan isolators for operation using the followi...

Page 8: ...otation SECTION 2 START UP OPERATION CONTINUED FIGURE 4 COUNTERBALANCE LOCKED INTO PLACE FOR SHIPPING FIGURE 5 COUNTERBALANCE UNLOCKED FOR START UP CAUTION Do not be operate this AHU until after start...

Page 9: ...365 7290 21 N A ATLI 1 32X32 20400 00 N A ATZAF 1 36X36 19701 70 N A EPFN 3 365 7290 21 N A ATLI 1 36X36 28049 90 N A ATZAF 2 36X36 19367 80 N A EPFN 1 402 8869 55 N A ATLI 1 40X40 39236 40 N A ATZAF...

Page 10: ...2 182 1821 92 N A MPQN 1 165 1518 58 N A MPQS 3 182 1821 92 N A MPQN 2 165 1518 58 N A MPQS 1 200 2185 80 N A MPQN 3 165 1518 58 N A MPQS 2 200 2185 80 N A MPQN 1 182 1821 92 N A MPQS 3 200 2185 80 N...

Page 11: ...rs usually measure outside air This can be provided with one or two pairs of positive or High and negative or Low pressure tube connections Connect and respectively to the and ports of the transducer...

Page 12: ...g Automation System BAS The output signal corresponds directly to flow through the damper The BAS compares this signal to the design CFM setpoint as determined by the particular mode of operation of t...

Page 13: ...ut the economizer cycle In this arrangement the 25 damper would be for monitoring nominal airflow through the first 25 down to 3 75 and the 75 damper would be for monitoring the remaining 75 100 Sensi...

Page 14: ...ationary airflow sensing device and air straightening section The integral air monitoring station shall incorporate pressure sensing ports built into the sensing device and shall control the minimum a...

Page 15: ...ide Air and Exhaust Air Dampers 1 Position the damper blades so that they will be closed with the power off which will be the dampers spring return position Note if the damper shaft is rotated clockwi...

Page 16: ...h door They are located on three edges of each door top latch side bottom Figure 19 on page 28 The spacers should be left in place until the AHU is placed in its final location and multiple skid AHUs...

Page 17: ...ueger hvac com SECTION 2 START UP OPERATION CONTINUED FIGURE 16 HORIZONTAL WHEEL Elevation View Plan Top View Supply Fan Supply Fan Cooling Coil Cooling Coil Heating Coil Heating Coil Filter Filter Ac...

Page 18: ...hands and objects away from the moving parts activate the AHU and confirm the wheel rotation The wheel rotates clockwise from the pulley side 4 If the wheel has difficulty starting turn the power off...

Page 19: ...lock bearings on the wheel using a NLGI grade 2 consistency mineral oil lithium or lithium complex base grease 4 Before start up make sure the wheel turns by hand and does not bind All contact between...

Page 20: ...ls are adjusted correctly the seal gap will vary that much as the wheel turns but it should never be touching the wheel surface 6 If the unit is supplied with an adjustable purge determine the proper...

Page 21: ...inspected and tested at the factory however different conditions at the job site including controls that have been added at the time of installation require careful testing and final adjustment for sa...

Page 22: ...tractor customer who requested start up and do the following Ensure the AHU and system is capable of design airflow for gas heat start up Ensure reliable power is available Verify the following Verify...

Page 23: ...balance report Set the bypass damper if provided Airflow proving switch for main supply fan installed and operational Check with the control technician two minute post purge programmed in AHU controll...

Page 24: ...able 6 on page 28 10 Visually check that the high temperature safety limit is set for a 200 230 F range The limit switch is typically mounted behind the burner control panel 11 Connect a 0 15 gas pres...

Page 25: ...is intermittent Pilot continues to burn after ignition transformer is de energized 11 Using the signal generator cycle the burner to check capacity modulation Observe valve damper actuator operation...

Page 26: ...20 200 U UL 10 10 1 R RIGHT S Stainless B 200 or 208 3 60 B 120 B 4 20 mA C 25 250 F FM 25 25 1 C 277 1 60 C 0 135 30 300 R IRI D 230 or 240 3 60 35 350 E 380 3 60 40 400 F 440 3 50 45 450 G 460 3 60...

Page 27: ...A 5 NA 5 N A 5 N A 5 N A 18 N A 18 050 N A 14 N A 27 N A 27 N A 27 N A 27 N A 27 50 N A 5 NA 5 N A 5 N A 5 N A 18 N A 18 060 N A 27 N A 27 N A 27 N A 27 N A 27 N A 27 60 N A 6 NA 6 N A 6 NA 6 N A 19...

Page 28: ...00 NA 1 00 NA 1 00 NA 1 00 50 NA 1 00 NA 1 00 NA 1 00 NA 1 00 NA 1 00 NA 1 00 60 NA 1 00 NA 1 00 NA 1 00 NA 1 00 NA 1 00 NA 1 00 75 NA 1 00 NA 1 00 NA 1 00 NA 1 00 NA 1 25 NA 1 25 85 NA 1 00 NA 1 00 N...

Page 29: ...ano Rd Richardson TX 75081 972 680 9136 kruegerinfo krueger hvac com www krueger hvac com SECTION 2 START UP OPERATION CONTINUED FIGURE 29 TYPICAL WIRING DIAGRAM Connect Signal Generator here for test...

Page 30: ...500 61 69 0 75 7 000 57 64 0 86 7 500 53 60 0 98 8 000 50 56 1 1 8 500 47 53 1 23 9 000 46 50 1 38 10 725 38 8 43 2 2 DF 60 DF 75 6 000 91 0 44 6 500 84 0 52 7 000 78 0 6 7 500 73 91 0 68 8 000 68 85...

Page 31: ...mage or nuisance thermal cutout tripping 2 The maximum air inlet temperature for open coil heaters is 100 F and for finned tubular heaters 80 F 3 Sufficient working space must be provided per paragrap...

Page 32: ...ections maximum KW per sq ft should be calculated as follows SECTION 2 START UP OPERATION CONTINUED Electrical Installation 1 Follow the wiring diagram on the inside of the terminal box 2 Supply conne...

Page 33: ...fe to use If a less than 10 megohms is achieved replace any damaged elements or ceramic insulators prior to operation 3 Ensure filters are clean and airflow is at the minimum requirement or greater pr...

Page 34: ...etal tab on access doors that provide access to moving parts This mechanical protection from moving parts is required by UL 1995 Always replace RED metal tab on access doors that provide access to pre...

Page 35: ...ration On multiple belt adjustable pulleys check the pitch depth to insure identical belt travel power transfer and wear Adjustable motor bases are provided for belt adjustment Sheaves If optional adj...

Page 36: ...ouling and microbial growth X Visually inspect the dehumidification coils for cleanliness and microbial growth Clean when fouling is observed X Visually inspect drain pans and other adjacent surfaces...

Page 37: ...on fan wheels and shafts may adversely affect the balance of the fan assembly Refer to the information later in this section to replace the fan and fan assembly components Checking the Fan Check the f...

Page 38: ...NUM FAN MOTOR BASE MOTOR BASE SUPPORT RAILS DRIVE SIDE FIG 1 PARALLEL MISALIGNMENT FIG 4 PARALLEL ALIGNMENT FIG 5 DRIVE SIDE FIG 2 SECTION 3 MAINTENANCE CONTINUED Notes 1 The sheaves should be centere...

Page 39: ...belt span Apply a force on the plunger and perpendicular to the belt span until the bottom of the large O ring is even with the top of the next belt or with the bottom of a straight edge laid across...

Page 40: ...ualize the load across the entire belt width thereby reducing wear and extending belt life Figure 39 right shows how to align a synchronous drive properly using a straightedge or shows how to use a pi...

Page 41: ...ut of the belt s start raising the base in 1 2 increments using the adjustment screws on both ends 7 As the belts start to tighten check for parallel misalignment by placing a straight edge across the...

Page 42: ...SALIGNMENT SECTION 3 MAINTENANCE CONTINUED FIGURE 45 SEALED BEARING LUBRICATION Verify the type of bearings before lubricating them as shown below Sealed not to be relubricated in the field as shown i...

Page 43: ...her extended lube lines enabling lubrication of both fan bearings from one side of fan as shown in Figure 49 right or optional external lube lines For AHUs 42 tall and above extended lube lines and ex...

Page 44: ...to the three tables below for the proper lubrication intervals for the bearings listed earlier in this section NOTE The bearing on the split pillow blocks is 1 3 full when only one side of bearing is...

Page 45: ...rical terminations 2 Conduit fittings and clamps for damage or looseness 3 Operating amperage and compare the number to the number listed on the AHU nameplate Keep Motor Bearing Lubricated Bearing gre...

Page 46: ...e 0 1 Low Temperature 1 0 TABLE 14 MOTOR BEARING LUBRICATION INTERVAL MULTIPLIER NEMA IEC FRAME SIZE RATED SPEED RPM HOURS 10 000 6 000 3 600 1 800 1 200 900 UP TO 210 INCL 132 2 700 5 500 12 000 18 0...

Page 47: ...fter a door has been opened and closed Three Types of Lamps Three different types of UV lamps are used in AHUs V Mod V Ray and V Max Grid V Mod Lamps Install the two pronged lamps into the slotted fix...

Page 48: ...move filter frame end cover as shown in Figure 57 and 58 right 3 Remove old filters if present 4 Make sure gaskets at both ends of the side load filter tracks are in place The gaskets are normally fou...

Page 49: ...st one another Always apply the air from the air leaving side of the coil 6 On heavily soiled coils use a safe commercial grade coil cleaner 7 Follow the safety and mixing instructions as noted on or...

Page 50: ...by normal airflow drain pan and outlet 8 Add ample amount of cleaning agent to drain line and trap 9 Allow cleaner to stand for time required by manufacturer s instructions 10 Flush with clean water...

Page 51: ...from the face off the wheel Wash the segments in a 5 solution of non acid based coil cleaner see material list or alkaline detergent and warm water Allow segments to soak in solution until grease and...

Page 52: ...el drive motor bearings are pre lubricated and no further lubrication is necessary The wheel drive pulley is secured to the drive motor shaft by a combination of either a key or D slot and setscrew Th...

Page 53: ...carefully 5 With the wheel out wash the media carefully with water Once clean allow the media to dry out for several hours or days if necessary 6 Reinstall using the reverse procedure Run the unit It...

Page 54: ...ay be easier to install half the belts from the inboard side and half from the outboard See Figure 65 right Alternative Installation Method 1 Set motor to mid position of adjustment range and mark bas...

Page 55: ...e loosen the seal Tek screws as shown in Figure 66 right 3 Move the seal away form the wheel surface until no more rubbing is noticed A typical large diameter wheel will have a flatness variation of 1...

Page 56: ...adjusted and don t need further adjustment the AirLoop labyrinth seals should be verified prior to start up and adjusted if needed See Figure 68 below As illustrated in Figure 67 right the correct adj...

Page 57: ...ink belt which allows installation or replacement without using special tools Innergy tech recommends checking the belt after a month of operation and every three months through a general maintenance...

Page 58: ...alignment and belt tension X Check belt tension X Lubricate fan bearings Ball Bearing Table 4 2 Roller Bearing Table 4 3 Split Pillow Block Table 4 4 See OM Tables Check condition of extended lubricat...

Page 59: ...ne in or on any AHU The only exception is when the AHU is provided with hight temperature gas heat venting WARNING Rotating parts and electrical shock hazards exist Lock out and tag out the fan motor...

Page 60: ...and Diffusers Grilles VAVs and MITs Other items through which airflows or which offer obstruction to airflow While differences in temperature and humidity may cause air movement it may be considered v...

Page 61: ...nges vary The technician should have one or more instruments to cover the range of 0 8 inches of water as shown in Figure 71 right Before using the inclined manometer ensure the instrument is level an...

Page 62: ...indicates the difference between two pressures or between a single pressure and atmosphere when one side is open to atmosphere If a U tube is filled to the halfway point with water and air pressure i...

Page 63: ...of the kinetic energy in the fluid and is known as the velocity pressure VP VP is always exerted in the direction of air flow The relationship between the velocity and the VP may be expressed by the f...

Page 64: ...to the threaded holes in bushing Hand tighten it against the sheave web 6 Tighten each cap screw gradually and evenly in rotation to push the sheave off the taper of the bushing Tap lightly with a ham...

Page 65: ...n rotation to the torque value as shown in Table 16 right There must be a gap between the bushing flange and sheave hub when installation is complete Adjusting Sheave 1 Before belts are installed chec...

Page 66: ...the pitch diameter 0 2 Seven turns are required to adjust the sheave from the minimum to the maximum pitch diameter 5 Put slight finger pressure on the face of the adjustable flanges near the split 1...

Page 67: ...central sleeve over the key 4 Clean and remove any burrs from the shaft from the sheave to end 5 Slide the sheave off of the shaft Installing Sheave 1 Loosen set screws on adjustable flange s of new...

Page 68: ...Unit SP across fan Unit CFM Pressure drop of water across cooling coil PSIG Air pressure drop across cooling coil Temperature differential across cooling coil Motor voltage and amperes For fan or mot...

Page 69: ...to run through the control panel All wiring must be in accordance with Krueger published specifications and must be performed only by qualified Krueger personnel Krueger will not be responsible for d...

Page 70: ...MUST MEET LOCAL CODES SAFETIES 50 60 HZ J REMOVE JUMPER WHEN CONNECTING SAFETIES 2 5 SS1 XOO OOX OFF HAND AUTO CONTROL POWER OPTION PANEL OR LTC OPTION 2 CONTROL POWER UP TO 4 100VA TRANS LOW TEMP RES...

Page 71: ...gerinfo krueger hvac com www krueger hvac com FIGURE 81 FULL VOLTAGE STARTER CONTINUED M1 MOTOR 3PH T3 T2 OL1 T1 ALTERNATE OL1 USED WITH CT1 2 3 WHEN MOTOR FLA IS GREATERTHAN 80 AMPS TERMINAL POINT RE...

Page 72: ...NNECTIONS FOR PROPER SEE TRANSFORMER CONNECTION DIAGRAMS 2L2 X1 FU1 L2 FU1 T1 2L3 L3 C ABC AB B GFI B ABD 2KVA AC S N A A A AB B L SWITCH LIGHT SERVICE 2KVA TRANSFORMER TRANSFORMER 150VA OR 500VA LINE...

Page 73: ...EMOTE DEVICE BY OTHERS NOTES M1 MOTOR 3PH 2T3 2T2 OL1 2T1 ALTERNATE OL1 USED WITH CT1 2 3 WHEN MOTOR FLA IS GREATERTHAN 80 AMPS ALTERNATE OL1 OL1 CT3 CT2 CT1 M1 MOTOR 3PH DISC2 FU3 M2 MOTOR 3PH 2T3 OL...

Page 74: ...om KAH Operation Maintenance Guide Page 74 of 88 SECTION 5 WIRING DIAGRAMS CONTINUED FIGURE 83 TRANSFORMER ENCLOSURE WIRING DETAIL SHOWN OPEN LOAD WHITE HOT LINE WHITE HOT X2 B N L A L B L A S 1 B N L...

Page 75: ...ger hvac com www krueger hvac com FIGURE 84 TRANSFORMER WIRING DIAGRAM SWITCH B L AB B B LOAD GFI A S SERVICE LIGHT A A A N A LINE X1 FU2 2L2 FU1 L2 1 ABD 6 C AC E 3 1 ABC SEE TRANSFORMER TRANSFORMER...

Page 76: ...Plano Rd Richardson TX 75081 972 680 9136 kruegerinfo krueger hvac com www krueger hvac com KAH Operation Maintenance Guide Page 76 of 88 SECTION 5 WIRING DIAGRAMS CONTINUED FIGURE 85 UV CONTROL PANEL...

Page 77: ...uide Page 77 of 88 Krueger 1401 N Plano Rd Richardson TX 75081 972 680 9136 kruegerinfo krueger hvac com www krueger hvac com FIGURE 86 GAS HEAT SINGLE PHASE 1500VA TRANSFORMER WIRING DIAGRAM SECTION...

Page 78: ...Rd Richardson TX 75081 972 680 9136 kruegerinfo krueger hvac com www krueger hvac com KAH Operation Maintenance Guide Page 78 of 88 SECTION 5 WIRING DIAGRAMS CONTINUED FIGURE 87 UV CONTROL PANEL WIRIN...

Page 79: ...24 vac control relay used to seal in its coil and provide interlocking means to the UV lights If all doors are closed all the SW1 s will allow C1 to energize as long as power is available By selectin...

Page 80: ...hardson TX 75081 972 680 9136 kruegerinfo krueger hvac com www krueger hvac com KAH Operation Maintenance Guide Page 80 of 88 SECTION 5 WIRING DIAGRAMS CONTINUED FIGURE 89 GAS HEAT THREE PHASE 1000VA...

Page 81: ...Guide Page 81 of 88 Krueger 1401 N Plano Rd Richardson TX 75081 972 680 9136 kruegerinfo krueger hvac com www krueger hvac com FIGURE 90 GAS HEAT THREE PHASE 500VA TRANSFORMER WIRING DIAGRAM SECTION 5...

Page 82: ...dson TX 75081 972 680 9136 kruegerinfo krueger hvac com www krueger hvac com KAH Operation Maintenance Guide Page 82 of 88 SECTION 5 WIRING DIAGRAMS CONTINUED FIGURE 91 TYPICAL WIRING DIAGRAM FOR ELEC...

Page 83: ...e Guide Page 83 of 88 Krueger 1401 N Plano Rd Richardson TX 75081 972 680 9136 kruegerinfo krueger hvac com www krueger hvac com FIGURE 92 TYPICAL WIRING DIAGRAM FOR CONTROL TYPE FULL SCR SECTION 5 WI...

Page 84: ...cond l s Length Feet Ft 0 3048 Meters m In es In 25 4 Millimeters mm Weight Pounds Lbs 0 4538 Kilograms kg Velocity Feet Second Fps 0 3048 Meters Second m s Pressure Drop Feet Of Water Ft 2 989 Kilopa...

Page 85: ...KAH Operation Maintenance Guide Page 85 of 88 Krueger 1401 N Plano Rd Richardson TX 75081 972 680 9136 kruegerinfo krueger hvac com www krueger hvac com NOTES...

Page 86: ...Krueger 1401 N Plano Rd Richardson TX 75081 972 680 9136 kruegerinfo krueger hvac com www krueger hvac com KAH Operation Maintenance Guide Page 86 of 88 NOTES...

Page 87: ...KAH Operation Maintenance Guide Page 87 of 88 Krueger 1401 N Plano Rd Richardson TX 75081 972 680 9136 kruegerinfo krueger hvac com www krueger hvac com...

Page 88: ...1401 N Plano Rd Richardson TX 75081 Tel 972 680 9136 Fax 972 497 0450 www krueger hvac com kruegerinfo krueger hvac com KAH Operation Maintenance Guide 04 2015 Krueger 2015 All Rights Reserved...