INSTALLATION,

OPERATION
&
MAINTENANCE
MANUAL

DOUBLE SKIN AIR HANDLING UNITS

'TW/TWH' SERIES
Part Number: 801-031-62

INDEX
Contents

Page

1. General remarks.......2
2. Safety instructions....2
3. Short description of units.....3
4. Pre-installation checklist......4
5. Job site storage.....4
6. Preparing the unit site.......5
7. Transport.......6
8. Installation.....7
9. Section assembly.........11
10. Pre-start up check list........13
11. Start-up......15
12. Air inlet/control section ...35
13. Filter section ....35
14. Cooler section ...35
15. Heater section .......38
16. Heat recovery system .......39
17. Humidifier section .......39
18. Sound attenuator section.......39
19. Differential pressure switch with adjustable setting.....40
20. Bulk head light .........45
21. Inclined tube manometer ..........46
22. Magnehelic differential pressure gauge .......46
23. Additional maintenance instructions for hygienic units ...49
24. Trouble shooting .....50-55

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

-1-

1 - GENERAL REMARKS
Congratulation You now own a central air handling unit made by
ZAMIL AIR CONDITIONERS. Use this manual to secure/ensure a
continuous and safety installation, start-up, operation and maintenance of your TW series air handling unit.
This applies that your air handling unit needs to be checked and
serviced in certain periods, so carefully review the procedures and
detailed information discussed in the following pages of this
maintenance manual to minimize installation, start up and
maintenance difficulties.

2 - SAFETY INSTRUCTIONS
Note

This maintenance instruction describes all functions and advantages

of the units and secures a safety operation by the client/user, so far as
known.
Technical use and handling responsibility is of client/user.
The maintenance staff/personal must be qualified technicians and
trained in operating air handling units.
Function control and maintenance to be done periodically.
Should above instructions not followed up, warranty will be
cancelled.

Observe Users Advice

User information of this maintenance instruction and those given on

units or components must be observed and followed up.
Provision of unit may not be changed!
Unauthorized changes impair function, safety and running life of
unit.

Observe Safety Instructions

Following signs of safety are content of this maintenance manual

and to be observed.
.. indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.

Danger
.. indicates a situation that may result in equipment or property
damage.
Attention
..guides to useful further information and user advises.
Notice

-2-

3 - SHORT DESCRIPTION OF UNITS

ZAMIL TW series air handling units are central-station air handlers consist of
standardized unit components for variety of controlled-air applications. The unit
may include a wide verity of modules according to the technical and functional
requirements given by clients. (See our TW-air handling units catalogue for more
details).
Generally, the TW-units module is provided with a module name plate/label
which identifies the type of module, tagging information, the serial
numberetc.

Sample of Fan
Section Sticker

Sample of Coil
Section Sticker

Sample of Section
Identification labels

-3-

4 - PRE-INSTALLATION CHECK LIST

TW series Air handling units can be shipped as individual modules,
module sub-assemblies or a complete unit depends on the unit size,
length, module function, and site space limitations.
Units which shipped without a base rail are securely fixed to a
wooden skid to facilitate handling. No skid is provided for units
which have base rails.

Attention

Receiving Check List

Upon receipt of air handling, unit conduct a closely and a

throughout inspection for damage which may have been caused in
transportation.

At least inspect the following:

a. If the unit shipped in sections, make sure of the availability of
all sections.
b. Inspect the external panels for any external damage.
c. Check all access doors to make sure that all hinges, handles,
latches are not damaged.
d. Inspect the interior of each module for any internal damage.
e. Inspect the coil(s) for any damages to the fin surface and/or
coil connections.
f. Manually rotate the fan wheel to ensure free movement of the
shaft, bearings and drive.
g. Inspect the fan housing for any foreign objects.
h. Make sure of the availability of any item shipped as loose
parts or spare parts.
Any found damage must be reported within 14 days of receipt.

Resolving Shipping Damage

Equipment is purchased F.O.B Factory, meaning that the unit belongs

to the customer the moment it leaves Zamil storing area and is the
responsibility of receiving party to inspect the unit upon arrival at the
destination before unloading or moving unit to its permanent
location.
If damage is noted or discrepancies found, the local Zamil sales
representative should be notified immediately so that corrective
action be taken.
Zamil is not responsible for shipping damage.

Attention

5 - JOB SITE STORAGE

If unit is to be stored for a period of time prior to installation,
observe the following precautions:
a. Choose a dry storage site that is reasonably level and
sturdy to prevent undue stress or permanent damage to the
unit structure or components.
-4-

b. Zamil highly recommends leaving units and accessories

like filters cartoons in their skids / shipping packages for
protection and ease of handling until installation.
c. Store the unit in clean location to protect motor, bearing,
coils, filtersetc. from excessive dust.
d. Avoid storage in location where children play and/or
public access.
e. Set the unit off ground if you store it in heavy rain area.
If unit is to be stored for an extended period of time the following
maintenance procedure must be performed:
a. Fan wheel should be rotated by hand every two weeks to
redistribute the bearing grease and to prevent bearing corrosion.
b. Each month bearings should be purged with new grease to
remove condensation.
c. Belts should be removed or at least loosen, then prior to startup, inspect and replace if necessary, reinstall/retention the belt.
d. All openings and access doors must remain sealed during
storage.
e. Dampers must be cleaned and lubricated prior to start up.
f. Allow enough clearance around the unit to inspect periodically
the equipment while in storage.
g. Do not stack units.
h. Do not pile other material on the unit.

6 - PREPARING THE UNIT SITE

a. Ensure the total weight of the unit taken into consideration
and can be supported by the installation site. (Weight report
available with unit technical submittal).
b. Sufficient space should be allowed for service access. (See
page 10 for operation clearance).
c. The floor or foundation must be level and the condensate
drain at the proper height for proper coil drainage and
condensate flow, to overcome standing water and wet
surfaces inside the equipment which may cause odors and
damage for the equipment and building material.
d. Ensure there is an adequate height for condensate drain. (See
page 9 for drain pan trapping).
e. Ensure that the foundation of the mounting platform is level
and large enough to include the unit dimensions. (Refer to the
unit submittals for specific dimensions).
f. Provide adequate lighting for maintenance personal to
perform maintenance duties.
g. Provide permanent power outlets in close proximity to the
unit for installation and maintenance.
h. Wiring the unit must be provided by the installer and must
comply with all national and local electrical codes.

-5-

7 - TRANSPORT
Lifting & Rigging
An experienced, reliable rigger should be selected to handle the
unloading and final placement of the equipment.

Notice
Handle unit with care during installation to avoid damage due to twisting, bouncing or tilting. Rigger should be advised that the unit contains
delicate components & is to be handled in upright position only.
The unit weight may be unevenly distributed, with more weight in the
coil and fan areas. (Refer to the unit submittals for unit/module weights
before preparing the unit for lifting).

Notice

To lift the unit use only slings which are capable to support the
entire weight of the unit and spreader bars as applicable, (slings and
spreader bars furnished by others).

Do not lift unit by coil connections or headers or other unit

structural components.

Caution

Attention

Adjust as necessary the lifting slings for even unit lift. Failure to
properly lift unit could result in death or serious injury or at least
cause equipment and/or property damage.
As test, lift the unit approximately 50 cm to verify proper center of
gravity lift point, to avoid dropping of unit, reposition lifting point if
unit is not levelled. Failure to properly lift unit could result in death or
serious injury or possible equipment of property damage.

If a forklift truck is used, lift only from heavy end of skid.

Caution

Transportation By Means of Use:

- High-lift
- Stacker trucks with
squared timber

-6-

Trasnporation By Crane

Keep area clear underneath suspended loads

dont step below. Personal injury!

Danger

Refer to the unit submittals and unit tagging for correct placement of
all modules. If there are any discrepancies between the submittals
and the unit tagging, access side and/or connection side, contact your
local Zamil representative before going further.

Unit Placement

Protect air handling unit against impact shocks, dont let unit down
on edges.
Damage of unit!

Attention

8 - INSTALLATION
Foundation

- Foundation for the air handling unit shall be 50 - 100 mm each side, bigger than
unit dimensions.
- Surface of foundation shall be levelled.
Height/design of foundation shall consider:
- Static requirements (weight of unit).
- Height of condensate siphon.
- Vibration-isolation.
- Solid sound conduction.

Monlithic Foundation
Monolithic foundation is capable high demand to vibration-isolation.

-7-

Strip Foundation

- At strip-foundation construction the unit bottom casing profile should be covered.

- The intermediate foundation strips should match to unit sectional joint connections.

Isolated Foundation In this case the foundation-plate (steel-reinforced) or as steel base frame is
located on isolation vibrators, to prevent solid sound conduction.
Pedestal below the isolation vibrators prevent that between floor area and
foundation plate dust, mud can led to solid sound conduction.
This foundation design prevents vibration and solid sound conduction.

Vibration Isolation

Notice

Drain Height/
Foundation Height

For selection of vibration isolator besides the weight of units/foundation the

load of air forces to be considered.
The arrangement of equal vibration isolations must be symmetric to the unit
thrust point.
Steel spring-isolators need additional solid sound reducer.

To prevent excessive build up of condensate in drain pan, adequate trap

clearance must be provided beneath the unit.
Connection of condensate drain pipe with siphon to be made by client/user.
Siphon must be counter pressure free.
Prior start-up and after a long period of none-operation siphon must be filled
with water.
-8-

DESIGN OF SIPHON (CHW-cooler or DX-coil)

-9-

Service and Maintenance

Clearances (mm )

Provide adequate space for unit service access (fan shaft and coil
removal, filter removal, motor access, damper linkage access etc.)

** Step in inside the unit for filter checking or replacement.

At a minimum, the above clearance dimensions are recommended on one side of the unit for regular
service and maintenance. Refer to the technical submittal for locations of items such as filter access
doors, coil piping connection, motor location...etc. Sufficient clearance must be provided on all sides
of unit for removal of panels.

- 10 -

9 - SECTION ASSEMBLY
9.1 - UNIT SECTION
Installation

If you use a pedestal base please consider beam in every position of

unit sectional joints.
For installation of individual unit section screws, washers and tape
seals delivered to be used only. At hygienic version additional cover
for sectional joints are delivered. After insert they are to be sealed by
use elastic sealant (anti fungus silicon).

Section Assembly

TW

TWH

or 1.1
or 1.1

to be sealed by
elastic sealing

Nos. per joint, each

Unit type TW
1 Hexagonal screw M 8 x 80
1.1 Hexagonal screw M 8 x 120
2 Spring washer A 8
3 Cap nut, hexagonal M 8
4 Self-adhesive seal tape

TW 2-11

TW 14-26

TW 35-90

4
4
4
4
acc. demand

8
8
8
8
acc. demand

12
12
12
acc. demand

- 11 -

Unit type TWH

1 Hexagonal screw M 8 x 80
1.1 Hexagonal screw M 8 x 120
2 Spring washer A 8
3 Cap nut, hexagonal M 8
4 Joint gap cover
5 Assembly clamp
6 Hexagonal screw M 6 x 20
7 Spring washer A 6

TWH 2-11
4
4
4
4
4
-

TWH 14-26
6
6
6
6
4
2
4
4

TWH 35-90
-

Seal tape, near the profile edge on one of the opposite section-facearea.
Connected sections are to be aligned (on foundation or pedestal) and
to be pushed together up to 10 cm distance. Pull together (up to 1 cm
distance) and again align the section.
Finally fix all connecting screws & nuts as described before.
By use of gripping belt/clamp pull now section tight together and fix
the connecting screws. First down, then top.

Installation detail for head joint cap

outside installation

- 12 -

10 - PRE-STARTUP CHECK LIST

After unit is permanently positioned, complete the below pre-start up
check list :
Filter Related Checks

1. Check to make sure the filter cartridge count is correct, if

filter count is short, the exact number received should be
noted on the fright bill at time of delivery.
2. Make sure that filters have been installed properly in
their places.
3. Check to be sure that the filters called for are used,
failure to use the filters that your Zamil air handler has
been designed for can cause fan motor overload and/or
cause the coils to become dirty and restrict air flow.
4. Filter access panels or doors should always be closed
firmly to stop air by-pass around filter cartridges.

Fan Related Checks

5. Fan isolation shipping lock-down pieces should be

removed.
6. If load points are not on same plane after supports are
removed readjust isolators until elevation of load point
are uniform.
7. Check motor mounting to make sure all nuts are tight.
8. Confirm that the motor voltage, phase, and power are
compatible with wiring.
9. All electrical connections should be tight, complete and
properly terminated.
10. Rotate manually the fan blower wheel(s) to make sure
they should rotate freely in the proper direction and no
parts are rubbing.
11. Check the fan for foreign bodies (tools, small components,
etc.).
12. Check the alignment and parallelism of the pulleys and the
V-belt tension and make sure that set screws are tight.
13. Check bearing-collar set screws on fan shaft and fan hub
set screws for tightness. Loose collars and/or set screws
will ruin the shaft quickly.
14. Do not operate fans with imbalance.
15. Inspect fan motor and bearings for proper lubrication, if
necessary.
16. During fan start-up observe the rotation and if fan is
operating reverse to the needed direction, which should
correspond to the one indicated by the arrow, should the
motor run in the wrong direction, interchange any two of
the three electrical leads. Single-phase motors can be
reversed by changing internal connections.
17. Supply and return fan drives are provided in the mid-speed
adjustment range when variable speed sheaves are
furnished. The motor sheave pitch diameter is field adjustable for the required air flow. When final adjustments are
complete the current draw of the motor should be checked
and compared to full load amperage rating of the motor.
- 13 -

18. After supply fan is set, the return fan drives should be
adjusted for proper pressurization of the building.
19. The maximum elongation of V-belts occurs in the first
operation hours. Therefore it is highly recommended that
after 30 minutes (full load) the V-belt shall be re-tensioned.
20. Sheaves with two or more grooves should be adjusted by
the same number of or full turns from closed position
to insure the same pitch diameter so belts bear equal
load. DO NOT FORCE BELT OVER THE GROOVES.
21. In case of a storage period over six months it will be
necessary to clean the old grease and proceed with a regreasing operation according to the quantities and types.
(See Page 23-24 for details).
Coil Related Checks

22. Ensure coil and condensate drain piping connections are

complete.
23. Check the piping and valves for leaks.
24. Remove all foreign material from the drain pan and check
the pan opening and condensate line for obstructions.
25. In case of DX-Coils ensure that the coil has been charged
properly. Adjust the superheat setting.
26. If-for any reason, it is necessary to cut a hole in the unit
casing, the hole should be cut through side panel (not
through any access panel or door) and then carefully sealed.

Dampers Related Checks

27. Rotate damper shafts to test action, rough handling may

have caused damper blades to bind.
28. If you select the damper motor make sure it is sufficient
to operate the dampers, do not overdrive damper motors,
this will deform dampers and/or linkage.

General Checks

29. All maintenance panels are to be closed. Check all

maintenance panels and locks for perfect position.
Especially for all maintenance panels on pressure side of
fan (positive pressure in the unit).
30. Prior final alignment unit installation position to be
checked and levelled position.
31. Damages of coated outside of unit panels/casing to be
cleaned from dirt, than treated with primer and re-painted
with repair-colour-lacquer. For galvanized casing part
the damaged points to be freed from rust (metallic bright)
and mended with cold galvanizer.
32. Remove any debris from the unit interior.
33. Access door gasketing must not be removed or leakage
of air and water could result.
34. Adjust the differential pressure switch if any per
system requirements.
35. Check all screws, bolts, nuts electrical and piping
connection for tightness.
36. After 24 hours operation re-check start-up items.
37. Leave this manual with the unit.

- 14 -

11 - START-UP
11.1 - FAN SECTION
Motor and fan are built together as one function component on a
common base frame, vibration free fastened to the unit casing. For
power supply the local regulations to be observed. Main voltage must
comply with the data given at motor name plate. Thermal over-current
safety cut-outs are to be provided by client unless the project
specifications ask for, so far motor is not equipped with respective
protective device, for example thermistor protectors, in motor winding.
If thermal relays are used, they are to be set in accordance to values
shown on motor name plate.

Assembly

Maintenance and Inspection Services

Prior opening of any maintenance panel, unit to be switch-off!

Danger

Attention

Danger
Fan Impeller & housing checking

Safety notes
Before doing any maintenance operation on the fan, it's imperative to
ensure that:
- The drive motor is disconnected from all electric terminals.
- The impeller has come to rest.
- The surface temperature has been checked to prevent burning.
- The impossibility of an uncontrolled running of the fan during the
maintenance works.
- No debris of damage or dangerous materials is inside the fan.
Only limited works may be carried out while in the operating
condition and in observance of the safety and accident prevention.
Regulations (for ex. measurement of vibration).
The non-observance of these points endangers life for the maintenance personal.
At inspection inside unit (fan section) high risk of accident is given by
V-belt and fan-impeller.
1- Light dust media, wear and dirt can be expected inside the
housing and on the impeller (corrosion, abrasions, stickled
materials), which can cause vibrations.
Regular inspection and cleaning must take place. The intervals
between them are to be fixed by the operator on accordance with
individual operating conditions.
2- Check concave sides for dirt and/or grease build-up.
3- Check set screws and/or set collars of fan wheel and bearings for
tightness.
4- Check bearing mounting bolts for tightness.
5- If fans are furnished with housing drains, make sure that holes in
bottom are open.
6- If housing access door is furnished be sure it is properly sealed
and latched.
7- Remove all debris from fan section and unit in general.
No high-pressure cleaners (steam rod cleaners) are to be used.
- 15 -

Re-greasable Bearing

Generally only proofed and low noise accuracy ball-bearings are

built in with theoretical life-time of min. 200,000 operating hours.
The V-belt drives pulleys to be calculated/chosen accordingly.
Permissible bearing loads are not to be exceeded.
Ball or roller bearings are greased at the factory and therefore ready
to run at start-up however routine maintenance and inspection is
required there after.
Normal operation of bearing is cool or warm to touch.
High bearing temperature accompanied by excessive leakage of
grease indicates too much grease.
High temperature with no grease showing at the seals, particularly if
the bearing seams noisy, indicates too little grease.
If running discloses an excessive amount of grease in the bearings
the grease fittings should be removed until the excess has escaped.
Fan shafts should be coated to prevent corrosion yet check that dirt
or debris build up is not accumulating which could affect balance.
The re-lubrication intervals indicated in the diagram and tables 8 & 9
on page 24. Apply for fans with horizontal shaft and with temperature which do not exceed +60C.
To consider the accelerated ageing of the grease by high temperatures,
it's opportune to reduce by half the re-lubrication interval you can
resume from the diagram and tables on page 24. For each 15C of
operating temperature augmentation of the bearing over +70C (the
max. admissible temperature for the grease mustnt in any case be
exceeded (see Table 8 on page 24). By temperatures below +70C, the
re-lubrication interval can be lengthened correspondingly (the relubrication interval should never be more than doubled and at least once
yearly).
We recommend substituting completely the grease after two relubrications.
The grease quantity and re-greasing interval depends from bearing type
and RPM and are indicated in the tables and figures (See page 24).

Grease must be introduced through the grease nipple, after cleaning

it, making the shaft rotate slowly during this operation.
The above data (especially the intervals), even though calculated with a
safety factor, are in principle pure theoretical because of the eventual
discrepancies between the input data and the actual conditions during
the fan operation. For this reason, Zamil strongly recommend to make
periodical controls on the bearings even though before the theoretical
time of re-lubrication.
In most cases, any flaws in the bearings can be detected by listening.
When the bearings are normal, they generate a smooth and uniform
sound. Loud and squeaking noise or other abnormal sounds imply that
the bearings are worn out. A squeaking noise may also be caused by
insufficient lubrication. Too small bearing cross-gap can cause a
metallic noise. Dents on the outer race of the bearing can cause
vibration, which in turn causes a smooth and clear sound. Intermittent
sound implies a defective rolling surface. High bearing temperatures are
usually a sign that the bearings are running abnormally. Too high
temperature is harmful to the grease and bearing itself. High bearing
- 16 -

temperature may be due to insufficient or excessive lubrication,

impurities in the grease, overloading, bearing damage or too small a
bearing cross-gap. Even a slight temperature change can be a sign of
impaired operation if the operating conditions have not changed.
Refilling with lubricant will normally cause a rise in bearing
temperature lasting one or two days. Check the grease. A change of
color or darkening is usually a sign that there are impurities in the
grease.
After the bearing has been re-lubricated a number of times or if the
grease has become caked, darkened or faded (compare with its original
color), the grease should be replaced.
Correct belt tensioning can be determined as follows:
1. Measure belt length (upper length between pulleys) or calculate it by
the formula.

Check of V-Belt Tension

2. According to table below detect power, p by which the individual belt is to be loaded in compliance with belt profile, active
diameter, RPM of the small pulley, as well as ratio of transmission.
3. At standstill pre-tension of belt shall have a deflection f of 1 mm
per 100 mm belt length between pulleys when deflection power
p arise at each belt.
Belt profile

x SPZ
x SPA
x SPB
x SPC

Active pulley
diameter
dw
up
63
100
140
90
140
200
140
224
315
224
335
500

to
90
125
180
125
180
225
200
280
400
315
450
630

Power P in kg to deflect V-belt RPM of small pulley

700
1450
2800
4000
1
1.03
1.21
1.33
1.54
1.84
2.02
2.45
2.8
3.03
4
4.5
4.8

3
1.35
1.57
1.71
2.11
2.4
2.55
3.28
3.6
3.8
5.33
5.9
6

Transmission
1
3
0.9
1.23
1.09
1.42
1.21
1.54
1.36
1.9
1.66
2.17
1.82
2.3
2.16
2.93
2.5
3.2
2.65
3.45
3.45
4.66
3.9
5
-

1
0.81
0.97
1.08
1.18
1.45
1.57
1.8
2
-

3
1.13
1.29
1.37
1.68
1.92
2
2.5
2.7
-

1
0.74
0.89
0.97
1.05
1.27
1.5
-

3
1.04
1.19
1.25
1.51
1.71
2.13
-

x nos. of belts.
- 17 -

V-belt Replacement and

Tension

When replacing V-belts the same belt profile should be used again.
To replace V-Belt the axle spacing should be reduced until the new belt(s) can
be easily fitted by hand. The re-tensioning of the belts should be done as
follows:
TW units are equipped with parallel sliding rail for tension of V-belt.
For tension of V-belt, safety screw of spindle at sliding rail to be unscrewed
and spindle turned clock-wise until recommended V-belt tension is reached.

Possible elongation of new V-belt drives occurs to 80 % in the first 15

operating hours.
Therefore, in the beginning deflecting f shall only be approx. 70% of the
calculated value.
After 50 operating hours recheck V-belts and re-tension them, if necessary.

Attention

1) When mounting reduce shaft distance, do not force belts into grooves by
screw drives or something similar.
2) In case of multiple-groove belt drives replace always all belts simultaneously. Care should be taken to ensure that belts have the same length (use
sets only).
3) Pulleys shall be correctly flush.
Check of Flushing of Pulleys

For explosion hazardous plants only electrically conductive V-belts may be

used.
Explosion hazard!
Danger
4) Regular checking of belt tension and re-tensioning in intervals of about
800 operating hours ensure high lifetime of belts.
Abnormal heating, excessive oscillations of the belt length between pulleys and
noise are mainly reason of insufficient belt tensioning. Insufficient tensioning
is leading to slip and pre-mature failure, as well.
V-BELT PULLEY WITH BUSH SYSTEM
Assembly of Pulley

At new pulleys all bright surface must be cleaned and degreased.

Fit pulley and bush together and align the fixing holes.
Grease screws slightly, fit them into the bolt hole and screw them
slightly into the thread holes of the bush.
Slide pulley with bush onto shaft, align it and tighten screws
uniformly (for tightening torque refer to table, follows):
- 18 -

Torque - Schedule
Bush no.
1108

nos.
2

1210
1610
2012
2517
3020
3030
3535

2
2
2
2
2
2
3

Dismanteling of Pulley

Fixing screws
size

Max. tightening torque (Nm)

length

3/8
3/8
7/16

5/8
5/8

5/8
5/8
7/8
1
1
1
1

5.7
20
20
31
49
92
92
10

a- Remove the screws.

b- Turn one of screw into pulley thread hole until pulley get loose
from bush.
c- Now take-off pulley/bush by hand. Dont use tools or push by.

The theoretical life L10 can be guaranteed only if the diameter of

the pulley respects a minimal value, i.e. if the permissible bearing
loads are not exceeded. Always replace damaged/worn pulleys
with new one of the same diameter.
Adjustable V-Belt Pulley

Attention

If drive is equipped with an adjustable V-belt pulley, fan-rpm and

consequently air volume can be varied within the regulating range.
When adjusting regulating pulley do not exceed maximum fan-rpm
and admissible motor current consumption.
Damage of motor!
Zamil has already set the adjustable pulley to required diameter,
according unit technical data.
Variation of the air volumes can be made according to the
following instructions:

Position of adjustable pulley

On motor
On fan
Adjusting of New Active Pulley
Diameter

Increase active diameter

Air volume increasing
Air volume decreasing

Decrease active diameter

Air volume decreasing
Air volume increasing

When adjusting on a new active diameter proceed as follows

(refer to example):
a) Determine adjustment:
Adjustment = Max. active dia. - New active dia.
4 x Regulating factor
b) Remove out adjusting screw (see picture).
c) By closing adjustable pulley find out max. active diameter.
After this, open it to get the calculated rpm. (Adjustment should
only be made in complete revolutions).
d) By doing so, a thread hole in the idle pulley is then matched
automatically with the flattening of the fixed pulley. Turn in
adjusting screw into this thread hole and tighten it strongly.
- 19 -

Adjustable pulley
Profile
SPZ
Outside
84
95
100
108

SPA
Outside

(108)
120
129
139
146
156
164
Example for Determination of
Adjustment

Active
62...80
73...91
78...96
90...104
(76...102)
88...114
97...123
109...133
116...140
126...150
134...158

Regulation factor
1.64
1.64
1.64
1.45
1.64
1.64
1.64
1.54
1.54
1.54
1.54

Conditions:
Profile SPZ, adjustable pulley 100 mm outside diameter, max.
active diameter (refer table above) = 96 mm
regulating factor (refer table above) = 1.64
New determined act. Diameter = 83 mm
Requested:
adjustment (nos. of revolution)
Solution:
adjustment = 96 - 83 = 1.98 = 2 nos. revolution to open
4 x 1.64

How to Establish the Grease

Quantity for Re-lubrication and
Initial filling
1) Identify the fan, type and size.
2) In table (1) determine the technical bearing specifications:
- Bore.
- Unsplitted or splitted type if splitted, then check if it is of ball
or roller type.
3) With fan and bearing data, enter tables from (2) to (6), where
d corresponds to bore (internal bearing bore equal to shaft
diameter where the bearing is set) to find the grease quantity for
re- lubrication and 1st filling.
4) From table (7) find type and supplier of the grease.
5) To determine the re-lubrication time interval:
- For pillow block bearing see graph 1 with the correct
parameters of shaft diameter and revolution velocity.
- For splitted pillow block bearing with ball bearing see table
(8), with roller bearing see table (9), entering the correct
parameters of bearing block and revolution velocity.

- 20 -

Table (1)

- 21 -

- 22 -

Table (2)

Table (3)

Table (4)

Table (5)

Table (6)

Table (7)

- 23 -

Graph (1)

Table (8)

Table (9)

- 24 -

Bearing replacement

Installation instructions for

taper bushes

1- Dismantle all the eventual accessories mounted over the shaft,

which can stand the substitution of the bearings.
2- Unlock the block cover releasing the bolts located on both sides.
By mean of appropriate tools hold the shaft in order to avoid
damages to the wheel and inlet cone.
3- Remove the locking rings from the bearing side (note that only one
bearing is equipped with the locking rings) and the half sealing
rings from the bottom and upper part of the block housing after
have cleaned of the grease.
4- Slide out the bearings straightening the feather key of threaded ring
placed on the bush; release the threaded ring from both sides using of
punch and hammer. Place the bearings; tighten the bush by mean of
the threaded ring and bend the feather key.
5- Mount the new seal ring inside the grooves located on the bottom part
of the block. Grease the seal ring lips and place the greased group
shaft/bearing over the block basement. Place the greased group
shaft/bearing over the block basement. Mount one of more locating
rings on the side of one bearing only (the other bearing will not be
locked). Place the other seal ring, with the lips already greased, inside
the upper part of the block. Grease the whole group having care to fill
1/3 of the available room.
6- Place the upper part of the block over the bottom part and tighten the
bolts. Fill the bearing with the proper grease.
Turn the wheel in order to check the correct rotation and to detect
possible bad working on bearings and rotating parts.
7- Please note that an excessive amount of grease can cause a temperature peak in the bearing, which in turn can damage the lubrication
properties of the grease and lead to bearing damage.

To assemble:
1- Clean and degrease the bore and taper surfaces of the bush and the
tapered bore of the pulley. Insert the bush in the pulley hub and
line up the holes (half thread holes must line up with half straight
holes).
2- Lightly oil the grub screws (bush sizes 1008 to 3030) or the cap
screws (bush size 3535 to 5050) and screw them in, do not tighten
yet.
3- Clean and degrease the shaft. Fit pulley with taper bush on shaft
and locate in desired position.
4- When using a key it should first be fitted in the shaft keyway.
There should be a top clearance between the key and the keyway
in the bore.
5- Using a hexagon socket wrench gradually tighten and grub/gap
screws.
6- When the drive has been operating under load for a short period
(half to one hour) check and ensure that the screws remain at the
appropriate tightening torque.
7- In order to eliminate the ingress of dirt fill all empty holes with
grease.

To remove:
1- Slacken all screws. Depending on the size of the bush remove one or
two. After oiling point and thread of grub screws or under head and
thread of cap screws insert them into the jacking off hole(s) in bush.
- 25 -

2- Tighten screw(s) uniformly and alternately until the bush is loose in

the hub and pulley is free on the shaft.
3- Remove pulley/bush assembly from shaft.

Spare Parts

Only original Zamil spare parts in accordance with the spare parts list are
to be used. Zamil accepts no responsibility for damages resulting from
use of other parts.
Spare parts are suitable to be requested to Zamil having care to indicate
on the order, job and the fan tag numbers. Referring the components of
transmission groups as pulleys, bushes, V-belts and bearings are
normally available on the market. However, our assistance service is
always at disposal to supply parts directly from our stock. In case of
heavy-duty application and when an eventual holding time for repair is
suitable to originate major costs to your activity, Zamil suggests keeping
available at your stock spare parts like:
Impeller.
Shaft.
Bearing block set or single block (if applicable).
Bearing set.
Pulleys.
V-belt set.
Couplings (if applicable).

11.2 - MOTOR
11.2.1 - Motor Identification (Name Plate)

- 26 -

11.2.2 - Checking the insulation

Attention
This check is essential if the motor has been stored for longer than 6
months or in it has been in a damp atmosphere.
This measurement is carried out with a megohmmeter at 500 volts D.C.
(dont use a magnetoelectric system). It is better to carry out an initial
test at 30 or 50 volt and if the insulation is greater than 1 megohm, carry
out a second test at 500 volt for 60 seconds. Insulation must be at least 10
megohms in cold state.
If this value cannot be reached, and without exception if the motor may
have been splashed with water, salt spray, kept in a very humid place or
if it is covered in condensation, it is advisable to dehydrate the stator for
24 hours in a drying oven at a temperature of between 110 o and 120oC.
If the motor cannot be placed in a drying oven:
-Switch on the motor, with the rotor locked; under 3-pahse A.C. voltage
reduced to approximately 10% of the rated voltage, for 12 hours (use an
induction regulator or a reduction transformer with adjustable outlets).
For slip ring motors, this test should be performed with the rotor shortcircuited.
-Or supply it with D.C. current, with all 3 phases in series, and with the
voltage at 1 to 2% of the rated voltage (use a D.C. Generator with
independent excitation or batteries for motors less than 22 KW).
-NB: The A.C. current should be monitored via a clamp ammeter, the
D.C current with a shunt ammeter. This current by 5% of the original
value for a 10o deviation. While drying, all motor orifices must be clear
(terminal box, drain holes).

Warning

Attention

- 27 -

11.2.3 Electrical
guidelines
11.2.3.1 Maximum power of
motors supplied directly (KW)
from the mains

11.2.4 - Supply connection

11.2.4.1 - Terminal box

This extract from the C 15.100 standard indicates the limits tolerated
for D.O.L. starting of a motor connected to the mains power supply.

*other locations include premises such as in the service industry,

the industrial sector, general services to housing and the agricultural
sector, etc.
Prior inspection by the energy distributor is necessary for motors
driving a machine with high inertia, motors with time-delay starting,
and brake motors or reversed using reverse current.
Placed as standard on the top of the motor near the drive end for typed
IM B3, B5, B14, the terminal box has IP 55 protection and is fitted
with a cable gland.
Warning: Even for flanged motor, the position of the terminal box
cannot easily be modified as the condensation drain holes must
remain at the bottom.
Cable gland (NFC 68 311 AND 312 standards)
The standard position of the cable gland (1) is on the right, seen from
the motor drive end.
When the non-standard position of the cable gland has not been
correctly specified in the order, or is no longer suitable, the
symmetrical construction of the terminal box enables it to be placed
in any of the 4 directions except position 2 on flange mounted
motors (B5).
A cable gland must never be opened upwards.
Ensure that the cable entry radius of curvature prevents water from
entering via the cable gland.

- 28 -

Note

11.2.4.2 - Terminal block

wiring diagram

All motors are supplied with a wiring diagram placed in the

terminal box.
All connectors required to make connections can be found inside
the terminal box.
Single speed motors are fitted with a block with 6 terminals
conforming to the NFC 51 120 standard, identified in line with the
IEC 34-8 (or NFC 51 118) standard.

Attention

- 29 -

11.2.4.3 - Direction of rotation

When the motor is powered by U1, V1, W1 or 1U, 1V, 1W from a

direct supply L1, L2, L3, it turns clockwise when seen from the drive
end. If any two of the phases are changed over, the motor will run in
an anti-clockwise direction. (Make sure that the motor has been
designed to run in both directions).
Warning: Motor with backstop: Starting in the wrong direction will
destroy the backstop (see arrow on motor housing).
If the motor is fitted with thermal protection or space heaters, these
should be connected to screw terminals or terminal blocks with
labeled wires.

11.2.4.4 - Earth terminal

This is situated inside the terminal box; in some cases the earth
terminal can be situated on one of the feet or on one of the cooling
fins (round motors). It is indicated by the sign.

Attention
11.2.4.5 - Connection of power
supply cables to the block

Cables must be fitted with connection suitable for the cable cross
section and the terminal diameter.
They must be crimped as instructed by the connector supplier.
Connection must be carried out with connector resting on connector
(see diagrams below):

- 30 -

If using cables without connectors, attach some calipers. If any nuts

on brass terminal blocks are lost, they must be replaced by brass nuts,
not ordinary steel ones. When closing the box, check that the seal is
correctly positioned.

Note

11.2.5 - Normal maintenance

Checking after starting
After approximately 50 hours of operation, check that the fixing screws
of the motor and the coupling device are tightened; and for chain or belt
transmissions, check that the tension is correctly adjusted.

Cleaning
To ensure the motor can operate correctly, take steps to prevent dust and
foreign bodies from clogging the cover grille and the housing fins.
Precautions: Check the motor is totally sealed (terminal box, drain
holes, etc.) before carrying out any cleaning operation.
Dry cleaning (vacuuming or compressed air) is always preferable.

Note

11.2.5.1 Motor Greasing

11.2.5.1.1 - Type of grease
11.2.5.1.2 - Permanently
greased bearings

When the bearings are not permanently greased, the type of grease is
shown on the name plate. The standard grease is ESSO UNIREX N3 and
we recommend its use for subsequent greasing. Avoid mixing greases.
For LS motor 180 MT and FLS (C) motors 132 M, the bearings
defined enable long grease life and therefore lubrication for the lifetime
of the machine. The grease lifetime according to speed of rotation and
ambient temperature is shown on the following chart.

- 31 -

11.2.5.1.3 - Bearings without

grease nipples

LS 180 L and LS 200 LT type motors are factory lubricated.

Lubricant lifetime (in hours) under normal operation conditions is
given in the table below for a machine with horizontal shaft operating
at 50 Hz in ambient temperatures of 25o C and 40o C.

11.2.5.1.4 - Bearings with

grease nipples

The bearings are factory lubricated

For LS motors > 200 LT (or on request for types 160,180,200 LT)
and for FLS (C) and FLSB motors 160, the bearings are fitted with
Tecalemit Hydraulic grease nipples type M8 x 125.

Note

Attention
11.2.5.1.5 Motor bearings
maintenance
11.2.5.1.6 Checking bearings

When you detect on the motor:

- A noise or abnormal vibration.
- Abnormal temperature rise in the bearing when it is correctly
greased.
The state of the bearings must be checked.
Damaged bearings must be replaced as soon as possible to
prevent worse damage to the motor and the driven equipment. When
one bearing needs to be replaced, the other bearing must also be
replaced.
The seals should be changed as a matter of course when the
bearings are changed.
The free bearing allows the rotor shaft to expand (make sure it is
identified during dismantling).

Bearings without grease nipple

11.2.5.2 Servicing motor bearings Dismantle the motor; remove the old grease and clean the bearings

and accessories with a degreasing agent. Fill with new grease: the
new grease should fill 50% of the capacity of the bearing.
- 32 -

Bearings with grease nipple

Always begin by cleaning the waste grease channel
When using the type of grease shown on the name plate, remove the
covers and clean the grease nipple heads. When using a different type
of grease, dismantle the motor and clean the bearing and accessories
with a degreasing agent (carefully clean the grease feeder and outlet
channels) in order to remove the old grease before re-greasing.
To ensure bearings are correctly greased, fill the retainers, end shields
and grease channels to capacity and fill the bearings to 30% of their
capacity. Then turn the motor to distribute the grease.

Warning

Note
11.2.6 Preventive maintenance

Too much grease causes the bearing to overheat dramatically

(statistics show that more bearings are damaged through too
much grease than too little grease).
The new grease must be recently manufactured, of equivalent
standard and must not contain any impurity (dust, water or
other).

The diagram and table below give the recommended equipment to use
and the ideal positions on the motor to take measurements of all
parameters which can affect operation of the machine, such as
eccentricity, vibration, winding, insulation, etc.
This system allows the user both to monitor the performance of the
equipment during use, and in the event of a fault to give
measurements which will allow LEROY-SOMER to analyze and
diagnose the causes quickly and efficiently, enduring the minimum
downtime.

- 33 -

Cross-section of the power supply cables

The higher the current, the greater the voltage drop will be (NFC
15.100 standards or end users national standard). The voltage drop
should therefore be calculated for the starting current to see if this is
suitable for the application. If the most important criterion is the
starting torque (or the starting time), the voltage drop should be
limited to 3% maximum (the equivalent of a loss of torque of around
6 to 8%).
The chart below can be use to select the conductors according to the
length of the supply cable and the starting current, in order to limit the
voltage drop to 3% maximum.

For motors with flying leads, the cable should not be used for handling.
Fan motor replacement
1. Shut off motor power.
2. Disconnect and tag power wires at motor terminals.
3. Loosen motor to mounting rail attaching bolts. Loosen belt
tensioning bolts as applicable.
4. Note belt position; remove and set aside belts.
5. Lift out motor with hoist suitable for the motor size and
weight. Slide motor out on suitable temporary skids to
avoid damage to cabinet or frame.
6. Reassemble by reversing above procedure. Be sure to reinstall
belts in their original position. Use new belts as required. Do
not stretch belts over sheaves. Review above for sheave
alignment and belt tensioning discussed previously.
7. Reconnect motor leads and restore power. Check fan for
proper speed and air flow.
- 34 -

12 - AIR INLET/CONTROL SECTION

Attention
Maintenance

Dampers
Never start fan when damper are closed.
Fan motor must be locked by controls, accordingly.
Damage of equipment!
Shaft of dampers are embed in plastic bearing sleeves. Normally
they dont require any maintenance. However it is recommended to
check periodically connecting rods, bearing seat as well as fulcrums
and if necessary to oil them.
In case of heavy contamination we recommend to purge by
compressed air and re-oil by use of resin-free oil.

13 - FILTER SECTION
13.1 - PRE-FILTER & BAG FILTER
Installation

Filter inserts are supply separately in cartons in order to avoid

damages/pollution during transport and installation of unit.
First remove maintenance panel or open door of filter section. Now
pull out (up to TW 26) the filter insert frame to fit-in the filter insert
and fix them by locking wires.
At walk-in unit TW 35 and bigger step into filter-section and fix as
described before.

Maintenance

If no differential pressure gauge is installed filter must be inspected

for contamination regularly (weekly) and change, if required.
Except Alu. filters, all other filter-media are of throw-away media.
Regeneration reduces in any case efficiency and is on risk of client.
Filter of following sizes and quantities per each unit type are used.
Model
No.
TW 2
TW 3
TW 4
TW 6
TW 8
TW 11
TW 14
TW 17
TW 22
TW 26
TW 35
TW 47
TW 60
TW 73
TW 90

24" x 12 "
610 mm x 305 mm
1
1
2
2
2
3

Quantity of Filters / Sizes

24" x 20 "
24" x 24 "
610 mm x 508 mm
610 mm x 610 mm
1
1
1
1
2
4
4
6
6
9
12
16
20
20
30

14 - COOLER SECTION
14.1 - COOLING COIL
Installation

In-/outlet connection should be connected in such way that coil is

working to counter flow principle. All piping connection work should
be tension free.
- 35 -

In order to facilitate repair, service and maintenance works, piping in

front of heat exchangers must be easily removable or should be able
to be swivelled off after loosening of cooling coil. Flow and return
flow have to be closed by valves.
Connect a drip-siphon to drain-connection of unit-drain pan.
Connection to main drainage system must be counter-pressure-free or
of open-type system. Design of siphon, refer to page 9.

Start-Up

Prior to start-up check all connection for correct and tight assembly.
For flanges check and re-tighten screws.
As far as no automatic air vents are built-in, open all pipe-ventilation
devices, prior filling of system. After finish of filling the system
pressure rise the same and check for tightness.
Prior start-up of fan the siphon to be filled up with water. After start
of fan height of siphon to be checked, as no air may be sucked
through or blown out.

Maintenance

Essentially maintenance works after start-up is restricted to check

tightness of system and components, as well as cleanness for coil
(tins). Dusty coil have a bad efficiency. At continuous operation,
cleaning of coil should be done at least once yearly or at seasonal
operation prior start of cooling period.
For cleaning remove coil and if applicable drip-eliminator, after all
connections are dismantled. Now unscrew drip eliminator, as well.
Cleaning can be now done by use of pressed air or by spraying of
water with detergent additives. After cleaning coil and dripeliminator, if applicable, to be re-assembled.

Attention
Winter shutdown

Correct direction of drip-eliminator fins (vertical position) to be

maintained.
Anti-freeze methods of coil protection
1. Close coil water supply and return valves.
2. Drain coil as follows:
a. Open vent.
b. Open coil drainage cock.
3. After coil is drained, connect line with a service valve
and union from either nozzle to an antifreeze reservoir.
Connect a centrifugal pump between the other header
connection and the reservoir.
4. Fill reservoir with any inhibited anti-freeze acceptable
to code and underwriter authority.
5. Open service valve and circulate solution for 15
minutes then check its strength.
6. If solution is too weak add more anti-freeze until
desired strength is reached then circulate solution thru
coil for 15 minutes or until concentration is satisfactory.
7. Stop pump drain coil to reservoir and close service valve.
8. Break union and remove reservoir and its lines.
9. Open coil and all needle valves (approximately 2 full
turns) until spring.
- 36 -

Air drying method of coil

protection

Coil replacement

Attention

(unit and coil must be level for this method)

1. Close coil water supply and return main valves.
2. Drain coil as described in procedures for anti-freeze
methods of coil protection.
3. Connect air supply or air blower to inlet header
connection and close its drain connection.
4. Circulate air and check for air dryness by holding mirror
in front of coil connection. Mirror sill fog up if water is
still present.
5. Allow coil to stand for few minutes repeat step 4 until coil
is dry.
1. Disconnect piping.
2. Remove coil connection cover panel.
3. On header end, remove screws holding air baffle to end
panels on-air entering side.
4. On blind end, remove screws holding baffle to end panels.
5. Slide coil and baffles out of unit
6. Lift coil using lift points. Do not lift by header or center of
coils.
7. Replace coil by reversion order of procedures listed.

PVC drip-eliminators are suitable up to air temperature of 80C,

only.
Material damage!
If necessary drain pan can be cleaned separately, as well.
After re-assembly of integral parts, they can be pushed into via
gliding guide mechanism.

Attention

Prior start of cooling period heat exchanger to be checked for

correct ventilation and system pressure, because otherwise if not
available, the full cooling capacity cannot be obtained. If cooling
media not mixed up with glycol, in winter freezing danger is given,
so far air temperature could be below zero. In this case either:
- Cooling not needed empty system coil purge it with
compressed air.
- Add glycol according maximum ambient air temperature.
Material damage!

14.2 - DX- DIRECT EXPANSION COILS SECTION

Installation

Installation of refrigerant connecting piping is to be in such way,

that service and maintenance works are not obstructed. We recommend to erect, fix the piping to top, on back side or if on maintenance side in space of webs/unit-profile, only. In this case maintenance panels can be removed without cutting the pipes.
Connect a drip-siphon to drain-connection of unit drain pan.
Connection to main drainage system must be counter-pressure-free
or of open-type system.
Design of siphon, refer to page 9.

- 37 -

Start-Up

Attention

Prior filling of system with freon has to be checked for tightness

(vacuumising).
Only trained personal are admissible (19L WHG or any other
country law, valid).
The user has to consider VBG 20, DIN 8975 or any other country
regulation, valid.
Damage of environment!
Prior start up of fan the siphon to be filled up with water. After
start of fan height of siphon to be checked as no air may be sucked
through or blown out.

Maintenance

Attention

Essentially maintenance works after start-up is restricted to check

tightness of system and components, as well as cleanness for coil
(tins). Dusty coil have a bad efficiency. At continuous operation,
cleaning of coil should be done once 1 year or at seasonal operation
prior start of cooling period.
For cleaning remove coil and if applicable drip-eliminator, after all
connections are dismantled. Cleaning can be now done by use of
pressed air or by spraying of water with detergent additives.

PVC drip-eliminators are suitable up to air temperature of 80C,

only.
Material damage!

15 - HEATER SECTION
15.1 - HEATING COIL
Installation

In-/outlet connection should be connected in such way that coil is

working to counter flow principle. Normally, if not required
special inlet of coil is on top, outlet in bottom. All piping
connection work should be tension, free.
In order to facilitate repair, service and maintenance works,
pipings in front of heat exchangers must be easily removable or
should be able to be swivelled off after loosening of heat
exchangers. Flow and return flow have to be closed by valves.

Start-Up

Prior to start-up check all connection for correct and tight

assembly. For flanges check and re-tighten screws.
As far as no automatic air vents are built-in, open all pipeventilation devices, prior filling of system. After finish of filling
the system pressure rise the same and check for tightness.

Maintenance

Same procedure as cooler, see cooler maintenance.

Attention

Bad vented coil and system interrupts circulation of water flow or

give insufficient quantity. Freezing changer occurs at ambient
temperature below zero!
- 38 -

15.2 - ELECTRIC HEATER

Installation

Power supply is to be made according to wiring diagram in

terminal box of the heater or as per attached wiring diagram.
To protect other unit components against to high temperature and to
away fire, the electric heat-exchanger is equipped with safety
thermostat. The safety thermostat cut-off the heater by excess temperature. Furthermore it is recommended to install suitable air flow
control device and to interlock fan-motor operation with function of
electric heater.
Means: - If fan motor stops by any reason electric heater
switched-off also.
- If electric heater switch-off by safety device, fan
motor shall continue controlled by time relays,
prior switching-off as well as.

Start-Up

Check all electric connection and function of safety devices.

Maintenance

Beside a periodically check of function no further maintenance

work is required.

Attention

Prior opening of panel/door of electric heater section, the plant/unit

to be switch-off.
Injury by burns (temperature) and voltage.

16 - HEAT RECOVERY SYSTEM

Please refer to attached manufacturer instructions.

17 - HUMIDIFIER SECTION
Air Washer:
Please refer to attached manufacturer instructions.
Steam Humidifier:
Please refer to attached manufacturer instructions.

18 - SOUND ATTENUATOR SECTION

Installation

Units are already equipped and splitter built-in. No further

installation needed.

Start-Up

Attenuator surface to be checked for damages and if needed to

repair by paste over with fibre-glass mat.

Maintenance

Besides check damage and inspection of dust to splitter surface

(once a year), no further special maintenance required. Dust can be
cleaned off by use of air jet (low pressure) or soft brush, manual.

- 39 -

19 DIFFERENTIAL PRESSURE SWITCH WITH ADJUSTABLE SETTING

Technical Data
Max operation pressure: 10 kpa for all pressure ranges.
Tolerance for upper and lower switching pressure: 15 %.
Temperature range: Medium and ambient temperature from -20 C
to +85 C. Storage temperature from - 40 C to + 85 C.
Pressure connections: P1 for connection to higher pressure
(designated +), P2 for connection to lower pressure (designated -).
Electrical rating: Standard version: Max 1.5a (.4a)/250 vac,
Low voltage version: Max .1a/24 CDC max. switching rate: 6
cycles/min.
Arrangement of contacts: Break contact NC operation contact NO
operating contact no power supply line COM.
19.1 REPLACING
DIFFERENTIAL PRESSURE
Check the pressure switch to ascertain whether any damage is
SWITCH
ascertain on the hosting. If the housing is leaky because of
damage the pressure switch must not be used!
A) Mounting Position
You should mount the pressure switch vertically with pressure
connections pointing downwards only then is it possible to drain
any condensation moisture which might occur.

B) Fixing with Screws

To secure the device on the rear side of the housing, only use the
sheet metal screws (3.5x8 mm) (usually supplied together with the
mounting brackets).

- 40 -

Under no circumstances must use longer screws! Otherwise, the base of

the housing could be punctured resulting in the pressure switch leaking!

Attention

19.2 - INSTALLING THE

HOSES

Do not tighten the screws so much that the base of the device is deformed.
Otherwise, the pressure switch can be shifted out of position or leak.

Important: under no circumstances must the hoses be kinked pay

particular attention to this point if you run the hoses over an edge.
It is better to form one (1) loop as shown in the illustration. If the
hoses are kinked the device cannot function accurately.
a) For the connection to the air handling unit
With the angled metal tube you can make a linear pressure connection
into the airflow or out of it if necessary. This allows very precise
control of the coupling.
With the straight plastic nipples you can make a linear pressure
connection to the air duct.
In each case, the lead throughs are supplied with their own installation
instructions. Install the lead through as described in their
instructions.

b) For the connection to the pressure switch

Two sockets are provided there for hoses with an internal diameter
of 6 mm connect the hose.
-With the higher pressure to socket P1 (white) which is located on
the lower section of the housing.
- 41 -

- With the lower pressure to socket P2 (grey) which is located on

the lower section of the housing.

P2

P1

Run the hoses so that nobody can trip over them. In particular,
make sure by leading them that you run the hoses so as to prevent
them from becoming loose when there are air movements, which
would result in leaks at the connection.
After you have installed the hoses it is absolutely essential to
check them for tightness of fit at the connection points and to
make sure that they run without any kinks.
Otherwise it may happen that faults which occurred when the
hoses were installed remain unnoticed leading to subsequent faults.
When you have done this, test the tightness of the hoses.
19.3 - ELECTRICAL CONNECTION

Warning

Caution

Work on electrical installations must only be carried out by

specialists who are specifically trained for this purpose. If you
are not a specialist yourself never undertake any work on
electrical installations!
First, make sure that there is no power on the connection cable
while you are working on the electrical connections!
Otherwise, a possibly fatal electric shock may result and the
conn- ected equipment may be damaged!
The connection cable can be run to the pressure switch from three
sides according to choice the screw cable connection has a plug in
design for this purpose.
The seal in the screw cable connection is designed for cables with
alternative sheath diameters of 7 or 10 mm. Only use these sizesotherwise the screw cable connection cannot seal adequately!
If you use a connecting cable ...
With a diameter of 7 mm you can line up the press nut the plain
washer and the sealing ring directly on the cable.
- 42 -

2 with a diameter of 10 mm you must first break the inner rubber

ring out of sealing ring.
Then line up the press nut the plain washer and the sealing ring on
the cable.

a) The switching device

In the pressure switch is designed as a change over contact as can
be seen from the wiring diagram. The rest position is shown in the
drawing (pressure below the upper switching point).
In this instance pole three (com) closes to
Pole 2 when the pressure is increasing (NO).
Pole 1 when the pressure is decreasing (NC).

Protect the feed line (to pole 3) by fuse either in the control system
of along the line and do so with .
3 max. 1.5 A/250 VAC if you are loading the contact with an
ohmic consumer;
Max 0.4 A/250 VAC if you are loading the contact with an
inductive consumer (such as a relay).
Max 0.1 A/24 VDC if you are using the pressure switch in the
weak current version with gold plated contacts.

- 43 -

b) The connection
Are intended for crimp type sockets 6.3 mm.
Make sure the crimp connection is perfect and that the cable lugs fit
properly on the connections!
If you do not have any crimp type sockets available you can also use
the cable lugs, which are supplied with mounted screw terminals
however, these are only intended for rigid copper wire!
On flex it is either necessary to crimp on strand end sleeves and then
you can also screw the strands on or to crimp cable lugs on directly
as previously described!

19.4 SETTING

Warning

Make sure that there is no power on the electrical connections before

you carry out by settings on the pressure switch! Otherwise, it could
be fatal if you accidentally touch the electrical connections or the
metal adjusting screw while you are performing the settings!

Setting the pressure range.

Use the setting button to set the pressure, which should trip the switch
when the pressure is increasing.
Setting button

When the pressure falls the switch returns into its resting position as
soon the pressure falls below the set switching differential.
19.5 - CLOSING THE SWITCH

Insert the screw cable connection into the place provided for this
purpose on the housing, then place the housing cover in position and
screw it down evenly on to the pressure switch.

Housing cover

- 44 -

19.6 - TESTING THE SETTING Do not operate the system until the housing is closed. Otherwise

there is the possibility of a fatal electric shock if you accidentally

touch the live parts!
Check the trip and reset pressures by slowly increasing the
pressure and then allowing it to fall again.
Important! Observe the maximum permissible operating pressure
of 50 mbar which is indicated in the data sheet otherwise the
pressure switch may be damaged!

20 BULK HEAD LIGHT

To replace a lamp
Make sure that the power supply to the lamp is OFF.
Warning
1- Unlock the holding wires.

2- Install the lamp into its proper place.

3- Cover the lamp by the glass cover and tighten it by locking the
holding wires.

- 45 -

21 - INCLINED TUBE MANOMETER

Installation:
Locate the manometer on a convenient vertical surface. Install gauge
horizontally with self-drilling screws provided.
Filling:
Back out zero adjust knob until it stops: then turn in approximately
two full turns so that there is room for adjustment in either direction.
Remove the FILL plug and fill it with gauge fluid until fluid is visible
in vicinity of zero on scale. Adjust for exact setting with zero knob
and replace FILL plug.
Fittings with air filter:
Run the tube from the fitting on the discharge side of the filter to the
left gauge connection (+). Remove paper from the red and green
stickers and install adjacent to the indicating tube to show clean and
dirty filter readings.
Maintenance:
Check oil level regularly to adjust zero knob as required. Be sure all
pressure is removed by disconnecting tubing at top of the gauge
before adjusting the zero knob.

22 - MAGNEHELIC DIFFERENTIAL PRESSURE GAUGE

Installation

1- Select a location free from excessive vibration and where the

ambient temperature will not exceed 140oF. Also, avoid direct
sunlight which accelerates discoloration of the clear plastic cover,
sensing lines may be run any necessary distance, long tubing
lengths will not affect accuracy but will increase response time
slightly. Do not restrict lines.
2- Magnehelic gauges are calibrated with the diaphragm vertical and
should be used in that position for maximum accuracy.
3- Surface Mounting.
Locate mounting holes, 120o apart on a 4 no. of 1/8 dia holes.

- 46 -

4- To zero the gauge after installation.

Set the indication pointer exactly on the zero mark, using the
external zero adjust screw on the cover at the bottom. Note that the
zero check or adjustment can only be made with the high and low
pressure taps both open to atmosphere.
Operation

Positive Pressure:
Connect tubing (1/4 OD) from source of pressure to either of the
two high pressure ports. Plug the port not used. Vent one or both
low pressure ports to atmosphere.
Negative pressure:
Connect tubing (1/4 OD) from source of vacuum or negative
pressure to either of the two low pressure ports. Plug the port not
used. Vent one or both high pressure ports to atmosphere.
Differential pressure:
Connect tubing from the greater of two pressure sources to either
high pressure port and the lower to either low pressure ports. Plug
both unused ports.
No lubrication or periodic servicing is required, keep the case
exterior clean. Occasionally disconnect pressure lines to vent both
sides of gauge to atmosphere and re-set to zero.

Maintenance

Calibration Check:
Select a second gauge or manometer of known accuracy and in an
appropriate range. Using short lengths of rubber or vinyl tubing,
connect the high pressure side of Magnehelic gauge and the test
gauge to two legs of a tee. Very slowly apply pressure through the
third leg. Allow a few seconds for pressure to equalize, fluid to
drain, etc., and compare readings. If accuracy unacceptable, filed
re-calibration needed as the following procedure:
1234-

567-

With gauge case, held firmly, loosen bezel, by turning

counter-clockwise. To avoid damage, a canvas strap wrench
or similar tool should be used.
Lift out plastic cover and O ring.
Remove scale screws and scale assembly. Be careful not to
damage pointer.
The calibration is changed by moving the clamp. Loosen the
clamp screw(s) and move slightly toward the helix if gauge is
reading high and away if reading low. Tighten clamp screw
and install scale assembly.
Place cover and O-ring in position. Make sure the hex shaft
on inside of cover is properly engaged in zero adjust screw.
Secure cover in place by screwing bezel down. Note that the
area under the cover is pressurized in operation and therefore
gauge will leak if not properly tightened.
Zero gauge and compare to test instrument. Make further
adjustment as necessary.

- 47 -

Warning

Re-calibration or repair by the user is not recommended, consult

factory for assistance.
Trouble shooting Tips:
Gauge wont indicate or is sluggish
1. Duplicate pressure port not plugged.
2. Diaphragm ruptured due to overpressure.
3. Fittings or sensing lines blocked, pinched or leaking.
4. Cover loose or O ring damaged, missing.
5. Ambient temperature too low ( below 20 oF).
Pointer stuck-gauge cant be zeroed.
1. Scale touching pointer.
2. Spring/magnet assembly shifter and touching helix.
3. Metallic particles clinging to magnet and interfering with
helix movement.
4. Cover zero adjust shaft broken or not properly engaged in
adjusting screw.

- 48 -

23 - ADDITIONAL MAINTENANCE INSTRUCTIONS FOR HYGIENIC UNITS

Besides of cleaning of all components and devices, special attention
must be given to the maintenance of filters. A permanent control of
filters is imperative as well as replacement at maximum recommended final filter pressure drop. Appearance and indication of defects
shall be solved in due time.

Cleanness of plant

Further they shall be in consideration of experience of maintenance

staff and ambient condition/influence of area, where unit is installed.

Air handling/conditioner unit

Each filter stage should/must have their own filter gauge, for
indication of filter-differential pressure drop.
For clear and correct check of filter condition, each filter section shall
be equipped with separate name plate, with indication of following:
filter class, type of filter-media, size/numbers of filter-inserts,
nominal air volume (m3/h), initial pressure drop, recommended final
pressure drop, date of last maintenance.
Plant room and size of unit shall be designed in such way the
reliability and demands of hygienic conditions of whole instalment
are assured on high standard of government rules.
For quick and easy dismantling/remove of unit components (purpose
of maintenance) any piping system for unit should be dismantled
easy, as well.

Air conditioning plant for OT-area

Switch-off is allowed for urgent maintenance or repair-works, only.
However the time should be limited to short period and must be
announced to hospital-management. General maintenance periods and
works should be in accordance to hospital organisation rules for OTarea and agreed by technical management of hospital.

Fan Breakdown

Notice

Power Failure

In case supply fan of overpressure system (+) breakdown, the exhaust

fan shall be switched-off automatically, as well. In case exhaust fan of
under pressure system (-) breakdown, supply fan shall be switch-off
automatically, as well. In both cases electric interlock in control
switch board is recommended.

Operation of plant, besides cooling system, must be secured by

power failure. Use of emergency power diesel generator, recommended.

Notice

Hygienic Inspection

All air conditioning plants/units to be inspected in view of hygienic

after start-up periodically. Suggestion by hospital management.

Notice

- 49 -

24 - TROUBLE SHOOTING
Problem
Noise

Probable Cause
Impeller hitting inlet ring

Impeller hitting cut-off

Drive

Bearing

Shaft Seal Squeal

Impeller

Housing
Electrical

High Air Velocity

Pulsation or Surge

Rattles and/or Rumbles

Solution
a. Impeller not centered 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. Cut-off not secure in housing.
b. Cut-off damaged.
c. Cut-off improperly positioned.
a. Sheave not tight on shaft (motor and /or fan).
b. Belts too loose. Adjust for belt stretching after 48
hours of operation.
c. Belts too tight.
d. Variable pitch sheaves not adjusted so each groove has
same pitch dia. (multi-belt drivers).
e. Misaligned sheaves.
f. Belt worn.
g. Isolation base shipping restraints not removed.
h. Belts oily or dirty.
a. Defective bearing.
b. Need lubrication.
c. Loose on bearing supports.
d. Loose on shaft.
e. Seals misaligned.
f. Foreign material inside bearing.
g. Worn bearing.
h. Fretting corrosion between inner race and shaft.
a. Need lubrication.
b. Misaligned.
a. Loose on shaft.
b. Defective Impeller. Do not run fan - Contact Zamil.
c. Unbalanced.
d. Worn as result of abrasive or corrosive material
moving through flow passage.
a. Foreign material in housing.
b. Cut-off or other part loose (rattling during operation).
a. AC hum in motor or relay.
b. Starting relay chatter.
c. Noisy motor bearings.
d. Single phasing a 3 phase motor.
a. Duct work too small for application.
b. Fan selection too small for application.
c. Registers or grilles too small for application.
d. Heating or cooling coil with insufficient face area for
application.
a. Restricted system causes fan to operate at poor point
of rating.
b. Fan too large for application.
c. Ducts vibrate at same frequency as fan pulsations.
a. Vibrating duct work.
b. Vibrating cabinet parts.
c. Vibrating parts not isolated from building.

- 50 -

Insufficient Air Flow

Fan

a. Mechanical volume control device is improperly set.

b. Fan running backwards.
c. Cut-off missing or improperly installed.
d. Dirty fan blades.
e. Loose or slipping belts.
f. Fan speed too slow.

Duct System

a. Actual system is more restrictive (more resistant to flow).

Filters
Coils
Obstructed Fan Inlets
No Straight Duct at Fan Outlet

Obstructions in High Velocity

Air Stream

Cam High -Too

Much Air Flow

System

Fan
Incorrect Static
Pressure

Static Pressure Low,

CFM High

b. Dampers closed.
c. Registers closed.
d. Leaks in supply ducts.
e. Insulating duct liner loose.
a. Dirty or clogged.
a. Dirty or clogged.
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).

a. Fans which are normally used in duct system are tested

with a length of straight duct at 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.
a. Obstruction near fan outlet.
b. Sharp elbows near fan outlet.
c. Improperly designed turning vanes.
d. Projections, dampers or other obstructions in part of
system where air velocity is high.
a. Oversized duct work.
b. Access door open.
c. Registers or grilles not installed.
d. Damper set to by-pass coils.
e. Filter (s) none in place.
f. System resistance much lower than anticipated.
a. Fan speed too fast.

System, Fan or Interpretation of General Notes:

measurements
a. The velocity pressure at any point of measurement is
function of the velocity of the air and its density.
b. 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 air flow rate.
c. In most systems, pressure measurements are indicators
of how the installation is operating. These measurements
are the result of air flow and as such are useful indicators
in defining system characteristics.

System
Fan

Static Pressure Low, System

CFM Low
Static Pressure High, System
CFM Low

d. 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 the inlet and outlet conditions in the laboratory.
a. System has less resistance to flow than expected. This is a
common occurrence. Fan speed may be reduce to obtain
desired flow rate. This will reduce HP (operating cost).

a. Backward inclined impeller installed backwards. HP

will be high.
b. Fan speed too high.
a. Fan inlet and/or outlet conditions not same as tested.
a. Obstruction in system.
b. Dirty filters.
c. Dirty coils.
d. System too restricted.
- 51 -

HP high

Fan

System

Fan Selection
Fan Does Not Operate

Electrical or Mechanical

a. Backward inclined impeller installed backwards.

b. Fan speed too high.
c. Too low system resistance for forward curved fan.
a. Oversized duct work.
b. Face and by-pass dampers oriented so coil dampers
are open at same time by-pass dampers are open.
c. Filter(s)-left out.
d. Access door open.
a. Fan not operating at efficient point of rating. Fan size
or type may not be best for application.
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.

h. Optional thermostats, fire stats, freeze stats may

lockout fan operation if set incorrectly.
Electric Heater Not
Operating

Electrical or Mechanical

a. Disconnect switch or main circuit breaker may be in the "OFF"

position. If heater has built - in disconnect switch, door must be
close and switch turned "ON" before heater will operate.

b. If the fan and heater are interlocked with a fan relay, the fan
must be on before the heater will operate. If an air flow switch
is used, air pressure in the duct must be sufficient (at least 0.7
W.C.) to close the switch before the heater will operate.
c. Automatic (or manual) reset thermal cut-out may have
opened when overheating resulted form insufficient air flow or
poor air distribution. Allow heater temperature to return to
normal reset thermal cut-out may be reset. Correct cause of
overheating before proceeding.
d. Heat limiter(s) may have opened if local "hot spot
developed or if automatic rest thermal cut-out failed to open
first, when overheating occurred. Correct cause of overheating
and replace heat limiter.

e. Check main fuses, if open, correct cause of failure

before replacing fuses.
Electric Heater Cycles Electrical or Mechanical
(will not stay on)

a. Check air inlet and discharge openings for obstructions.

See that filters are not clogged, fire dampers are open and
air system is balanced.
b. Check to see that the heater terminal box is tight against duct
and heater safety devices are receiving sufficient air flow. Air
flow must be distributed evenly over entire face area.
c. Look at heater coils in operation (through observation port in
duct): any red area is not receiving enough air. (A small
amount of redness is permissible inside the coil insulation
bushings). Make sure that air flow through every part of the
heater is sufficient. Coils must not glow.

d. If air flow switch is used, contactors may "chatter" if

air flow is not sufficient to keep switch fully on.
e. If duct has internal insulation, the insulation may be
blocking the safety devices.
Improper Temperature Electrical or Mechanical
regulation

a. Make sure associated control equipment, such as

Thermostats, are in the correct location and that all controls are
adjusted according to manufacturers specifications for existing
field conditions.

b. Check air system balance to see that correct amount of

air flow is supplied for proper zone control.
c. Automatic thermal cut-out may be opening (cycling)
before room thermostat is satisfied. (See "electric heater
cycles"). Insufficient heat may be caused by:
1- Open heat limiter(s) or thermal cut-out.
2- Incorrect supply voltage.
3- Heater too small (in wattage) for application.
- 52 -

Coil Does Not

Operate

Steam valve failure (Steam Coil)

a. Check steam valve. If air operated, check proper air pressure.

If electrically operated check for no power or loose connection.
If manual valve, check to see if valve is open. If necessary
repair or replace valve.

b. Defective thermostat or wrong setting.

Steam trap failure (Steam coil)

a. Check steam valve. If air operated, check proper air pressure.

If electrically operated check for no power or loose connection.
If manual valve, check to see if valve is open. Necessary repair
or replace valve.

b. Defective thermostat or wrong setting.

Steam trap failure (Steam Coil)
Diverter valve (hot water coil)
Coil Does Not Deliver No steam or hot water
Adequate Heat

Thermostat

Coil Leaks
Coils Does Not
Deliver Adequate
Cooling
Coil Leaks
Moisture on Walls
Downstream of
Cooling Coil

Coil undersized
Insufficient steam pressure
lack of hot water
Dirty finned tubes
Crack in brazed connection
Internal corrosion
Lack of chilled water
Dirty finned tubes
Coil undersized
Crack in brazed connection
Internal corrosion

a. Condensate backs up into coil. Check steam trap. Repair or replace.

a. Check power to valve as above.

b. Diverter valve piped wrong.
a. Check boiler for proper steam pressure or hot water
temperature setting.
a. Thermostat improperly located, relocate.
b. Thermostat defective, replace.
c. Improper set point, reset.
d. Defective controls see above.
Replace with larger coil.
Replace with larger coil.
Hot water pump undersized or malfunctioning.
Vacuum or use air hose to gently clean dirt from finned tubes.

Repair brazed joint.

Repair coil.
Chilled water pump undersized or malfunctioning.
Vacuum or use air hose to gently clean dirt from finned tubes.

Replace with larger coil.

Repair brazed joint.
Replace coil.
Excess capacity through cooling coil Check air flow through coil.
Standing water in drain pan
See "Condensate Drain Pan" Section.
V.A.V. Unit (Low Volume Air Verify that the air flow and water flow are synchronized.
Flow-High Volume Water Flow)

Standing Water in
Drain Pan

Motor Fails to Start

Unit is not level

Drain connection is clogged
Condensate drain line to drain is
not correctly pitched.
Trap is sized incorrectly

Check level of unit, shim if required.

Remove dirt or debris from drain pan.
Check pitch in line towards floor drain.
All condensate drain connections and floor drains must be
trapped. Failure to properly trap a drain will result in flooding
of the drain pan and potential water damage to the air-handling
unit and other building facilities.

Blown fuse or open circuit breaker

Replace fuse or reset circuit breaker.

Check and reset overload.
Check connections with diagram supplied with motor.
Open circuit in winding or starting Check inside motor to determine if switch is closed.
switch. Evidence by humming sound Check for loose connections.
Overload trips
Improper line connections

from motor when switch is closed

Improper current supplied

Check to determine that power supply agrees with motor

nameplate lubrication.

Mechanical Failure

Determine that motor and drive turn freely. Check bearings

and lubrication.

Short circuited stator

Defective rotor
Motor overloaded

Indicated by blown fuses. Motors must be rewound.

Look for broken bars or end rings. Replace rotor.
Reduce load or replace unit with larger motor.
Check line for open phase.

With a 3 phase power source one

phase may be open

Motor Stalls

Defective capacitor
Wrong application
Overloaded motor
Low line voltage

Replace capacitor.
Replace with a larger motor, consult factory.
Reduce load or replace unit with a larger motor.
Check across AC line and correct if possible.
- 53 -

Motor Runs and Then Partial loss of line voltage

Dies Down
Stator shorts when motor warms up

Motor Does Not

Come Up to Speed

Motor Takes too

Long to Accelerate
Wrong Rotation (3
Phase)
Motor Overheats
(Temperature Rise
Above Ambient
Greater Than
Nameplate
Specifications)
Motor Overheats
(Temperature Rise
Above Ambient
Greater Than
Nameplate
Specifications)
Motor Vibrates When
Connected to Driven
Equipment

Rapid Motor Bearing

Wear

Motor under designed for

application
Voltage too low at motor
terminals
Line wiring to motor connected
to 50 cycle line supply
Excessive load
loose connection(s)
Improperly wired to AC line
(Wrong sequence of phases)
Motor overloaded
Motor fan may be clogged with
dirt preventing proper ventilation
Motor (3 phase) may have one
phase open
Partially shorted stator coil
Line voltage too high
Line voltage too low

Check for loose connections. Determine adequacy of

main power supply.
Replace stator.
Replace with a larger motor.
Check across AC line and correct if possible.
Replace unit with a 50 cycle motor.
Replace with larger motor.
Check connection and tighten where necessary.
Check wiring diagram on motor nameplate and correct.
Reverse any two motor leads at line connection.
Replace with larger motor.
Remove fan cover and clean, replace fan cover.
Check to insure that all connections are tight.
Must be rewound.
Check across AC line and correct. Step-down transformer may
be required.

Rotor rubs stator bore

Worn bearings

Check across AC line. Consult power company. Step-up

transformer may be required.
Check motor bearings and replace.
Replace bearings and seals.

Motor mounting bolts loose

Tighten mounting bolts.

Rigid type coupling used to connect Replace coupling with a proper coupling.
motor to driven equipment

Driven equipment unbalanced

Worn motor bearings

Balance driven equipment.

Replace bearings and seals.
Motor (3 phase) running on single phase
Check for open circuit and correct.
Bent motor shaft
Replace shaft or rotor.
Excessive overhung load due to Check overhung load, re-tension drive.
over tensioned drive
Excessive overhung load due to a small Check "NEMA Sheave Selection Guide" in the Browning
diameter sheave than recommended catalog. Replace sheave with one of size equal to or grater than
minimum used on motor shaft
listing.

Short Belt life

Belts Turn Over in

Grooves

Spin burns from belt slipping on Tension belts.

drive under stalled load
conditions or when starting
Grooves or extreme cover wear Eliminate obstruction or realign drive to provide clearance.
caused by belts on drive guard or
other objects
High ambient temperature
a. Use grip notch Belts.
b. Provide ventilation.
c. Shield belts.
Grease or oil on belts
a. Check for leaky bearings.
b. Clean belts and sheaves.
Worn sheaves
Replace sheaves.
Center distance shorter than
Increase center distance by using longer belts. Replace
recommended minimum when
standard driven sheave with a companion sheave.
using standard sheave as a
companion sheave
Belt misalignment
Realign drive with sheave set at mean pitch diameter.
Damaged cord section in belts. Replace belts.
Frayed or gouged belts.
Excessive vibration
Tension belts, replace belts if damaged.
Flat idler pulley misaligned
Realign idler.
Worn sheaves
Realign drive.
- 54 -

Belt Squeal
Belt Breakage

Belt Stretch Beyond

Take-up

Excessive Vibration

Belts Too Long at

Installation
Belts Too Short at
Installation
Belts Mismatched at
Installation
Belts Mismatched at
Installation

Belts Mismatched
After Service

Excessive overload. High starting Tension drive or redesign and replace drive.
load. Belts not tensioned properly

Insufficient arc of contact

Foreign material in drive
Belts damaged during installation
Shock or extreme overload
Worn sheaves
Under designed drive
Take-up slippage
Drive excessively tensioned
Damage cord section during
installation
Damaged belt cord section
Loose belts
Belts improperly tensioned

Increase center distance or use Gripnotch belts.

Provide drive guard.
Replace belts.
Eliminate overload cause or redesign drive.
Replace sheaves.
Redesign and replace drive.
Reposition take-up.
Properly tension drive.
Properly belts and properly install.

Replace belts.
Tension drive.
Tension drive with slack of each belt on the same side of
the drive.
Insufficient take-up
Use shorter belts.
Drive improperly set up
Recheck drive and driven machine set up.
Wrong size belts
Use correct size belts.
Insufficient take-up
Use longer belts.
Drive improperly set up
Recheck drive and driven machine set up.
Wrong size belts
Use correct size belts.
Belts matched by code number Replace belts with Machine Matched Belts.
only
Old belts and new belts used Replace with new belts.
together on the same drive
Different brand name belts used Replace with a set of Machine Matched Belts.
on same drive
Drive and driven shaft shifted
Realign drive.
Worn sheaves
Replace sheaves.
Belts improperly tensioned, Replace belts and tension drive with slack of each belt on
causing more stretch of some the same side of the drive.
belts than others
Old belts and new belts used Replace with new belts.
together on the same drive
Different brand name belts used Replace with a set of Machine Matched Belts.
on same drive
Drive and driven shafts shifted Realign drive.
from parallel
Belt cord section damaged during Replace belts and install properly.
installation

Drive Fails to Adjust

Fretting corrosion (drive allowed Sheave must be disassembled, cleaned and lubricated,
to operate at one speed over a then reassembled.
period of time)

- 55 -