Air Treatment Division

DATA & FACTS

GEA CAIR

Air handling and low profile units GEA CAIRplus / GEA CAIRpicco

Table of contents

GEA CAIR

Table of contentsQuick design ................................................................................................. 4 Areas of application Equipment structure and function ....................................................... 5 Range of application of GEA CAIR standard units ............................. 6 Housing ......................................................................................................... 7 Profile variants .................................................................................... 8 Profile grades ...................................................................................... 8 Panels - Series S ................................................................................ 9 Panels: SX series .............................................................................. 10 Series SX C (standard) ................................................................. 10 Series SX T (thermally isolated) ................................................... 10 Air intake/discharge plenum .............................................................. 10 Housing properties according to DIN EN 1886 ................................. 11 Insertion loss in dB ............................................................................ 11 Material combinations ....................................................................... 12 Short description of components Fans .................................................................................................. Fan with housing ........................................................................... Overview ....................................................................................... Fan: plug fan ................................................................................. Overview ....................................................................................... Air filter .............................................................................................. Bag filter ........................................................................................ Bag filter can be incinerated completely ....................................... Fine dust filter ............................................................................... HEPA filter .................................................................................... Activated carbon filter ................................................................... Grease filter .................................................................................. Carbon combined filter .................................................................. Plastic cell filter ............................................................................. Cardboard cell filter ....................................................................... Heat exchangers ............................................................................... Copper/aluminium - copper/copper heat exchangers ................... Copper/aluminium - copper/copper heat exchangers with DX evaporator ............................................................................... Copper SD000 and stainless steel FE000 smooth pipe heat exchanger ..................................................................................... Galvanised steel heat exchangers (LPWW and LPHW mode). .... Galvanised steel heat exchanger (steam mode) .......................... Droplet eliminator .......................................................................... 13 13 13 14 14 15 15 15 15 15 16 16 16 16 16 18 18 18 18 19 19 19

Filter frames ...................................................................................... 17

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Table of contents

Electric heating battery (Engels make) ......................................... Electric heating battery (VEAB make) .......................................... Frost protection heating ................................................................ Gas-fired heater ............................................................................ Heat recovery .................................................................................... Heat pipe (ECOSTAT) .................................................................. Liquid-coupled heat exchanger (ECOFLOW) ............................... Plate-type heat exchanger (ECOPLAT) ........................................ Rotation heat exchanger (ECOROT) ............................................

20 20 20 20 21 21 21 22 22

Sound attenuator .............................................................................. 23 Sizes and air capacities CAIRplus ........................................................................................... 24 CAIRpicco ......................................................................................... 25 Unit dimensions ......................................................................................... 26 Configuration: straight through and side by side................................ 26 Configuration: double deck ................................................................ 26 Templates (standard unit combinations)................................................... 27 Template series 100 - inside installation - belt drive - straight through Dimensions ....................................................................................... 28 Weights ............................................................................................. 30 Template series 200 - inside installation - direct drive - straight through Dimensions and weights ................................................................... 32 Template series 300 - inside installation - direct drive - double deck Dimensions and weights ................................................................... 34 Template series 400 - inside installation - direct drive - side by side Dimensions and weights ................................................................... 36 Templates - inside installation - straight through Dimensions of the individual function units ....................................... 38 Maximum supply lengths .......................................................................... 40 Instructions for planning Transport ........................................................................................... 41 Installation ......................................................................................... 42 Information on guidelines and standards .......................................... 46

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Quick design

GEA CAIR

Quick designEnquiry from (company): Contact: Telephone: Fax: E-mail: Project: Please let me have: a unit drawing and brief technical details Full specification immediately Type of application Standard Standard according to RLT 01 Hygiene Explosion-protected Installation location Inside installation Outside installation Type of configuration Single unit Side by side Double deck One behind the other ................................................................................................ ................................................................................................ ................................................................................................ ................................................................................................ ................................................................................................ ................................................................................................

xxxx by e-mail Fans forwards backwards free-running Supply air volume .. [m/h] external compression of supply air .. Pa Exhaust air volume .. [m/h] external compression of supply air .. Pa Fan motors (speed r.p.m.) 1500 1500/1000 1500/750 1500/1000/750 1500/1000/500 Fans, accessories Repair switch Frequency converter Inlet and shaft protection Door protective grille V-belt protection V-belt monitoring Replacement V-belt Maintenance cover Condensate drain Interior lighting Sight window PG screw connector

xxxxx by fax Chiller Cu/Al galvanised steel DX evaporator Air inlet temperature .. C Air outlet temperature .. C Medium Medium inlet temperature .. C Medium outlet temperature .. C Humidifier Steam-humidified empty section Outside steam .. bar Spray humidifier Electrical steam humidifier Evaporation humidifier Circulating water Fresh water Sound attenuator 14 dB, length 600 mm 20 dB, length 920 mm 26 dB, length 1,200 mm 32 dB, length 1,520 mm 36 dB, length 1,720 mm 42 dB, length 1,920 mm 48 dB, length 2,240 mm Re-heater Cu/Al galvanised steel electrical .. C .. C .. C .. C

Filter Filter stage 1 grease filterG3 G4 F5 F7 Filter stage 2 F5 F7 F9 Activated carbon filter H13 Filter, accessories Inclined tube pressure gauge pointer presMotor forced draught sure gauge Pressure difference switch replacement filter Sight window lighting Free-hand sketch of unit Pre-heater Cu/Al galvanised steel electrical Air inlet temperature .. C Air outlet temperature .. C Medium Medium inlet temperature .. C Medium outlet temperature .. C Heat recovery ECOFLOW Cu/Al galvanised steel ECOSTAT ECOPLAT ECOROT Outside air temperature .. C Relative humidity of fresh air .. % Waste air temperature .. C Relative humidity of waste air .. % Efficiency required .. %4

Air inlet temperature Air outlet temperature Medium Medium inlet temperature Medium outlet temperature

Other accessories and special features

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GEA CAIR

Areas of applicationEquipment structure and function

GEA CAIR units are used for energy-saving room ventilation. Because of their modular design, the units can be configured individually for special air treatment requirements. Depending on the application, the transported air can be filtered, heated, cooled, humidified and/or de-humidified. The aim is to achieve the air volumes and air qualities demanded by the client. Primarily, GEA CAIR units are used at a central point in the comfort and commercial/industrial sectors for transporting and treating "normal" air. Special variants can also be used in the clean room and hygiene sectors, for example. GEA CAIR units with special explosion protection and compliant with ATEX Directive 94/9/EC are specifically identified as such. These units are supplied with additional operating instructions, which must be read and followed. Various components, such as rotary heat exchangers, plate-type heat exchangers, heat pipes and liquid-coupled heat exchangers are available for heat recovery and partial moisture recovery. The units are available in different sizes and different capacity classes: Depending on the type, GEA CAIR units can be installed with vertical or horizontal air flow and either as double deck, side by side or straight through arrangement. Units are available for indoor and outdoor installation. The modular design of the GEA CAIR units means that they can be divided into delivery units to suit the access openings. Because of the different unit sizes available and the possibility of ordering the units in small delivery quantities, GEA CAIR units are also suitable for the modernisation of existing buildings.

Equipment structure and functionBecause of the modular design of the units and the different applications, many unit configurations are possible. The basic unit structure and its functional description are described below based on examples. Fig. 1 shows a GEA CAIR unit that is used exclusively for transporting air. The unit consists of a housing with basic frame, fan unit, damper on the fresh air side, two flexible discharge connectors and a repair switch.Repair switch

R.A.

F.A.

Fig. 1:

Unit for transporting air

Supply air and exhaust air units can be combined. With these units, the exhaust air can be mixed with the supply air (completely, partly and/or occasionally), for example. This is mainly done to save heating and cooling energy. The unit illustrated inFig. 2 is a combination of an exhaust air unit and a supply air unit with additional filter and heater unit. The units are connected to each other via mixing air chambers.

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ApplicationsRange of application of GEA CAIR standard units

GEA CAIR

Repair switch

F.A.

E.A. S.A.

R.A.

Fig. 2:

Combined supply and exhaust air unit with mixing air chamber

Unlike the arrangement in Fig. 2, showing the units arranged straight through, Fig. 3 shows a combined supply air and exhaust air unit with heat recovery arranged as double deck. In addition to the air transporting, filtering, heating and mixing functions, with this unit, energy is also recovered via a plate-type heat exchanger.

S.A.

F.A.

R.A.

E.A.

Fig. 3:

Combined supply and exhaust air unit with heat recovery

Range of application of GEA CAIR standard units Note on extreme conditions Permitted storage conditions/ permitted air condition Mains voltage Notes Fresh air from -25 to +60 C Exhaust air from 0 to +80 C Atmospheric humidity as a function of temperature: 18 g/kg dry air Max. service pressure and temperature of heating/cooling battery 16 bar/90 C Min. service temperature of heating/cooling battery 6 C

In addition to air temperature/atmospheric humidity of the medium, the air temperature/ atmospheric humidity of the environment is also very important. Pay attention to the condensation limits! Air temperature: -10 C to +50 C atmospheric humidity: Store the units in a dry place The mains voltage needed is indicated in the order-related documentation, e.g. AC 230 V/50 Hz (monophase) or AC 400 V/50 Hz (3-phase). You must consider the information on the type plate and follow the operating instructions for accessories that are also supplied. You will find the range of application/limitations for the individual parts/components in the documentation on these parts and components and also in the information on the current version of the design software. For any application in corrosive or aggressive areas, the guarantee shall be valid only in case when assured materials are used. In the case of process air applications, particular attention must be paid to possible differences in the air parameters caused by tolerances. If there is a risk of frost, always use frost protection and anti-freeze for heating and cooling media. Range of application for GEA CAIR special units on request.

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GEA CAIR

Housing

Air handling is an important issue for architects, planners and plant engineers. Our new CAIR range of air handling units will help you to meet the needs of your clients in the best possible way. CAIR stands for Customized Air. This new generation not only offers an optimum modular grid size and range of variants, but it is also easy to install.

HousingGEA CAIR are air handling units of a particularly robust and thermally-optimised frame construction for "air treatment systems". The housing construction is a combination of aluminium profiles and panels. This type of structure means that the unit can even be assembled completely on site in special cases. All panels, doors and flaps can be fitted and removed from outside. The S series (panel thickness 30 mm) and SX series (panel thickness 50 mm) offer the best possible technical values for the requirements concerned. In the case of the SX series, a thermally isolated variant is also available. In addition to a completely isolated variant, the Lplus software makes it possible to isolate just those parts of the housing where there is a risk of condensation. The galvanised steel base frame available as an option (standard from unit size 160.160) gives the system additional strength and makes transport easier. The base frame also has feet - available in two heights with levelling device and rubber dampers, so that the CAIR units can be installed even without a supporting structure on site. Up to the unit size 128.128 inclusive, the feet can also be used without a base frame. The housing structure is strengthened and stabilised by a set of intermediate profiles. Each of these profiles can be removed without any problem. This considerably simplifies the installation and removal of large components. The completely smooth inner surface, without any projections, makes the unit easier to install and maintain. There are no door locks or internal panel bolts to hinder cleaning of the units. Large operating doors and service flaps make the components easy to access. Removable heat exchangers, droplet eliminator, etc. are also available. All maintenance and hygiene requirements according to VDI 6022 and VDI 3803 are met.

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HousingProfile variants

GEA CAIR

Profile variantsThe GEA CAIR housings are based on the principle of a frame construction: the resultant cuboids are completely enclosed by a profile. All the profiles are bolted together via stable diecast connectors. If required, intermediate profiles which accommodate panels, doors, flaps, etc. are located between these frame profiles. The profiles are made of aluminium. Basically, two series are available: The SX series with a profile thickness of 60 mm, which can also be thermally isolated by means of plastic webs. The S series with a profile thickness of 40 mm.GEA CAIR S GEA CAIR SX standard and thermally isolated (see diagram)

Universal frame profile

End wall frame profile

Division frame profile

Intermediate profile

Profile gradesNatural aluminium AlMgSi 0.5 Anodised aluminium AlMgSi 0.5; clear anodising 20m RAL 6032 RAL 9002 AlMgSi 0.5; signal green, powder coated min. 50 m; gloss 50 % AlMgSi 0.5; grey-white, powder coated min. 50 m; gloss 50 %

In the case of internal skin grade stainless steel V2A (or stainless steel V4A), the intermediate and dividing profiles are covered by stainless steel so that the entire inside surface is made of stainless steel.

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HousingPanels - Series S

Panels - Series SBasic variant with good thermal insulation and adequate acoustic damping.

Panel thickness: Insulating material Outside skin material:

30 mm Rockwool, non-combustible, fire class A 1 according to DIN 4102, FCHC-free, no adhesives used Aluzinc 185 - galvalume sheet steel with anti-fingerprint coating (FeP02G AZ 185), corrosion protection class III according to DIN 55928 part 8 RAL 9002 coated - galvanised sheet steel, SP polyester coated, film thickness min. 20 m, corrosion protection class III according to DIN 55928 part 8. NOTE! Materials in corrosion protection class III according to DIN 55928 part 8 are suitable according to guideline RLT 01 and VDI 3803 for the external skin of weatherproof units.

Material for internal skin:

Aluzinc 185 - Aluzinc sheet steel with anti-fingerprint coating (FeP02G AZ 185), corrosion protection class III according to DIN 55928 part 8 RAL 9002 coated - galvanised sheet steel, SP polyester coated, film thickness min. 20 m, corrosion protection class III according to DIN 55928 part 8.

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HousingPanels: SX series

GEA CAIR

Panels: SX seriesBasic variant with excellent thermal insulation and very good acoustic damping. Panel thickness: Insulating material Outside skin material: 50 mm Rockwool, non-combustible, fire class A 1 according to DIN 4102, FCHC-free, no adhesives used Aluzinc 185 - galvalume sheet steel with anti-fingerprint coating (FeP02G AZ 185), corrosion protection class III according to DIN 55928 part 8 RAL 9002 coated - galvanised sheet steel, SP polyester coated, film thickness min. 20 m, corrosion protection class III according to DIN 55928 part 8. NOTE! Materials in corrosion protection class III according to DIN 55928 part 8 are suitable according to guideline RLT 01 and VDI 3803 for the external skin of weatherproof units. Material for internal skin: Aluzinc 185 - galvalume sheet steel with anti-fingerprint coating (FeP02G AZ 185), corrosion protection class III according to DIN 55928 part 8 RAL 9002 coated - galvanised sheet steel, SP polyester coated, film thickness min. 20 m, corrosion protection class III according to DIN 55928 part 8. Stainless steel, V2A, mat. no. 1.4301, X5 CrNi 189, AISI 304, BS 304S15, AFNOR Z6 CN 18.09 Stainless steel, V4A, mat. no. 1.4571, X10 CrNi MoTi 1810, AISI 316TI, BS 320S17, AFNOR Z8 CNDT 17.12 Series SX C (standard)

Series SX T (thermally isolated) In the thermally isolated variant, additional plastic profiles prevent cold bridges - see corresponding tableHousing properties according to DIN EN 1886 on page 11.

Air intake/discharge plenumBoth series have frames for air openings that allow a 30 mm flange for connecting and sealing to the site duct network. The flanged frame allows a 4 hole bolt connection at the corners.

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HousingHousing properties according to DIN EN 1886

Housing properties according to DIN EN 1886CAIRplus S Test criterion Mechanical stability Housing leakage Filter bypass leakage Thermal insulation Heat bridge factorCAIRplus SX C = standard CAIRplus SX T = thermally isolated

CAIRplus SX C Class D2 L2 F9 T3 TB3 Limit 10 0.44 0.63 0.5 1