operation and assembly instructions production …...general maintenance guidelines in the operation...

central ventilation and air handling units (ahu)

gB

oPeration and asseMBlY instructions

Production series at4/at6

Translation from the original operating instruction2

AL-KO Production series AT4/AT6

table of contents

1. information on this manual ...............................................................................41.1 Signs & Symbols ........................................................................................................................................41.2 Regulations and norms ..............................................................................................................................41.3 Legal notices ..............................................................................................................................................5

2. safety instructions .........................................................................................62.1 Intended use ...............................................................................................................................................62.2 Possible misuse .........................................................................................................................................62.3 Rest went ...................................................................................................................................................72.4 Delivery ......................................................................................................................................................72.5 Storage, transport ......................................................................................................................................72.6 Operator's obligations ................................................................................................................................82.7 Disposal......................................................................................................................................................8

3. Product description ........................................................................................83.1 EC Statement of Conformity .......................................................................................................................93.2 EC Declaration of Incorporation ................................................................................................................10

4. transport .................................................................................................. 114.1 Transport with forklift ...............................................................................................................................114.2 Unit transport via transport tube ..............................................................................................................114.3 Unit transport via loop ..............................................................................................................................134.4 Unit transport via shackles .......................................................................................................................14

5. assembly .................................................................................................. 155.1 Unit assembly in Ex-proof models ............................................................................................................165.2 Internal unit connection at casing division ...............................................................................................165.3 AT4/AT6 unit connection with stacked units and with side-by-side units ..................................................175.3.1 Stacked unit arrangement .........................................................................................................................175.3.2 Side-by-side units.....................................................................................................................................185.3.3 Unit assembly via suspension ..................................................................................................................195.4 External installation ..................................................................................................................................205.4.1 Roof frame ...............................................................................................................................................205.4.2 Weatherproof units with height offset ......................................................................................................235.4.3 Weatherproof units with built-in rotating heat exchanger .........................................................................245.4.4 Weatherproof units with transport edges .................................................................................................245.5 Additional assembly instructions for hygiene units ..................................................................................24

6. commissioning and maintenance ..................................................................... 256.1 General guidelines ....................................................................................................................................256.2 Fans ..........................................................................................................................................................266.2.1 Fan (Belt Drive) .........................................................................................................................................266.2.2 Belt drive ..................................................................................................................................................276.2.3 Fan (free wheel with direct driven) ...........................................................................................................286.2.4 Torques of screw connections on the fan component ..............................................................................306.3 Heat Exchanger.........................................................................................................................................316.3.1 Finned heat exchanger ..............................................................................................................................316.3.2 Electric air heater ......................................................................................................................................366.4 Heat recovery ...........................................................................................................................................376.4.1 Plate heat exchanger ................................................................................................................................376.4.2 Rotary heat exchanger ..............................................................................................................................38

33062264 Subject to change, due to technical progress!

"Table of contents"

6.4.3 Recuperative energy recovery: Circulating coil system .............................................................................396.5 Filter .........................................................................................................................................................406.5.1 Bag filter ...................................................................................................................................................406.5.2 Activated carbon filter ...............................................................................................................................416.5.3 Grease trap filter .......................................................................................................................................416.5.4 Particulate air filter ...................................................................................................................................416.6 Louvre dampers .......................................................................................................................................426.7 Sound absorbers ......................................................................................................................................426.8 Droplet eliminator .....................................................................................................................................426.9 Air humidifier ............................................................................................................................................436.9.1 Spray humidifier (air washer) ...................................................................................................................436.9.2 Contact humidifier ....................................................................................................................................446.9.2.1 Fresh-water system ..................................................................................................................................446.9.2.2 Circulation water system ..........................................................................................................................446.9.3 High-pressure humidifier ..........................................................................................................................456.9.4 Steam humidifier ......................................................................................................................................466.10 Drive elements ..........................................................................................................................................476.10.1 Electric motor ...........................................................................................................................................476.10.2 Connection of three-phase motors ...........................................................................................................486.10.3 Wiring with frequency converter ...............................................................................................................506.11 Ex-protection ............................................................................................................................................516.11.1 General commissioning in the "Ex" zone ...................................................................................................516.11.2 The supply air- and/or exhaust air unit is located in the Ex-Zone ..............................................................516.11.3 Control (equipment cabinet) not in Ex-zone .............................................................................................516.11.4 Special installation and operational conditions for belt-driven, free-wheel fans in the Ex-Zone ................516.11.5 Gap and overlapping in RZR, VZR radial fans in the Ex-Zone ...................................................................526.11.6 Gap and overlapping in RLM Radial fans in the Ex-Zone ..........................................................................536.11.7 Additional guidelines for the Ex-Zone .......................................................................................................546.11.8 Specific details for the operation of equipment in Ex-Zones 21 and 22 ....................................................546.12 Refrigeration unit and heat pump .............................................................................................................54

7. Maintenance notes according to vdi 6022 and vdMa 24186 ..................................... 557.1 General .....................................................................................................................................................557.2 Initial and repeat inspection by category A-trained qualified personnel, in accordance with VDI 6022 part 2 ........................................................................................................................................557.3 Hygiene inspections carried out as part of maintenance by Category B-trained maintenance personnel in accordance with VDI 6022 part 2 .........................................................................................567.4 Hygiene requirements and maintenance, servicing of air conditioning equipment according to VDI 6022 and VDMA 24186 .................................................................................................................57

8. emergency ................................................................................................ 62

9. help in the event of malfunctions ..................................................................... 629.1 Contact persons .......................................................................................................................................62

10. shutdown .................................................................................................. 6310.1 Decommissioning .....................................................................................................................................6310.2 Dismantling ..............................................................................................................................................6310.3 Disposal....................................................................................................................................................63



1. information on this manual

� Read this documentation prior to assembly and commissioning. This is a requirement for safe work and trouble-free handling.

� Observe the safety guidelines and warnings in this documentation and on the product itself.

� This documentation is a permanent element of the described products – and should be handed over to the buyer upon sale!

1.1 signs & symbols

Warning!This symbol indicates safety activities which must absolutely be observed in order to avoid personal injury!

attention!This symbol indicates safety activities which must absolutely be observed in order to avoid property damage!

Specific guidelines for easier comprehensibility and handling.

1.2 regulations and norms

The following norms and guidelines were applied to the design of the units and apply to its installation, commissioning, operation and Maintenance:

DIN EN ISO 12100 Machine safety –General design rules – Risk assessment and risk reduction

DIN EN 60204-1 Machine safety – Electrical equipment of machines – Part 1: General requirements

DIN EN 349 Machine safety – Minimum safe distances to avoid crushing body parts

DIN EN ISO 13857 Machine safety – Safe distances to avoid reaching hazardous areas with the upper and lower extremities

DIN EN 12599 Ventilation of buildings – Testing and metric processes for the handover of ambient-air treatment installations

DIN EN 378-1 Chillers and heat pumps – Safety engineering and eco-relevant requirements – Part 1: Basic requirements, terms, classifications and selection criteria

DIN EN 378-2 Chillers and heat pumps – Safety engineering and eco-relevant requirements – Part 2: Design, manufacturing, testing, labelling and documentation

DIN EN 378-3 Chillers and heat pumps – Safety engineering and eco-relevant requirements – Part 3: Place of setup and protection of persons

DIN EN 378-4 Chillers and heat pumps – Safety engineering and eco-relevant requirements – Part 4: Operation, preventive maintenance, corrective maintenance and recycling

DIN EN 1127-1 Explosive atmospheres – Explosion prevention – Part 1: Basic premises and methods

DIN EN 13463-1 Non-electrical devices for use in explosion-prone areas – Part 1: Basic premises and requirements

DIN EN 60079-0 Explosive Atmosphere – Part 0: Devices – General requirements

DIN VDE 0100-100 Establishment of LV installations – Part 1: General basic premises, determinations of general features, terms


DIN VDE 0100-530 Establishment of LV installations – Part 530: Selection and setup of electrical resources – Toggle and control devices

VDMA 24167 Fans – Safety requirements

VDMA 24168 Pneumatic devices and installations; Ventilation apertures, determination of air flow with the pressure compensation method ("zero" method)

VDI 3801 Operation of spatial-pneumatic installations

VDI 3803-1 Spatial pneumatic engineering – Central spatial-pneumatic installations – structural and technical requirements

VDI 6022 Hygiene requirements for spatial-pneumatic installations and devices

BGV A1 Basic premises of prevention

BGV D4 Chillers, heat pumps and cooling devices

BGV D6 Cranes

BGR 500 Chapter 2.8 Operation of load-acceptance equipment in hoisting-equipment operation

BGR 132/CENELEC Avoidance of ignition risks due to electro-static charges

Report R 044-000Operational Safety Directive2006/42/EC Machine Guideline

97/23/EC Pressure Devices Guideline

(EC) 842/2006 Directive on certain fluorinated greenhouse gases ("F Gas" Directive)

1.3 legal notices

All specifications and datas apply only to the product description. No statement concerning a certain form/constitution or suitability for a certain purpose of use can be derived from these specifications. These specifications do not release the user from the obligation to make own assessments and own tests.

"Information on this manual"



2. safety guidelines

Observe these items in order to avoid injury, fire, and other hazards which may arise due to the incorrect use and ope-ration of the air handling unit (AHU):

Warning!Assembly, electrical connection, supply connection, maintenance, commissioning, repairs etc. may only be performed by trained specialist personnel.

Warning!Due to zone carry-over, the field accessories and other electrical devices or attachment parts within min. 1 m of the same zone as in the interior of the air handling units (if this value is higher than outside the unit).

The AHU may only be operated with its revision doors and panels (casing) completely closed!

Prior to all work on the AHU – or opening the revision doors – ensure that the power supply is shut off (power off all poles) and safeguarded from unauthorised powering on!

The AHU are to be properly assembled and used under precise observation of our instructions.

If the assembly is performed contrary to our regulations, and the defect/damage which has occurred is causally as-sociated with inappropriate modification, processing or any other treatment, all claims to damages compensation or warranty are thereby excluded. The ordering party must prove that incorrect assembly did not cause the defect which has occurred.

General maintenance guidelines in the operation and assembly instructions for air handling units from Series AT4/AT6 made by AL-KO THERM must absolutely be observed.

The design and method of construction of the AHU conforms to the norms indicated in the declaration of conformity or installation in order to minimise any potential hazard posed by the AHU. The furthest possible avoidance of potential hazards can only be warranted upon compliance with the additionally valid norms for the total installation in its ready-to-install form is maintained by the equipment manufacturer/system builder.

Ensure that all persons assigned to perform any work with or on the AHU during the individual phases of its useful life have read and understood the operation guide in its entirety and observe the guidelines therein!

In order to avoid hazards within the operation, all plant, operational and work procedures/instructions of the company/user shall apply in addition to this operation guide.

Work performed on the AHU requires personal protective equipment (PPE)!

2.1 intended use

AHU serve exclusively to handling air for rooms or to maintain the necessary air conditions. The range of use for the AHU’s is documented in the design data sheet as well as on the name plates. Any different areas of use are to be coordinated with the manufacturer's plant in order to avoid impairments in the function of the installation.

2.2 Possible misuse

The AHU may only be operated within the technical data specified by AL-KO. Another use or further use which exceeds the parameters in the item "2.1 Intended use" is considered improper. The manufacturer is not liable for damages resul-ting from such use.

Possible misuse is e.g.:

The transport of media with excessively high or low temperatures as well as aggressive media or media containing a large amount of dust.


2.3 rest went

Hazards may be posed by the AHU when it is not operated by trained persons and/or not used for the suitable purpose.

Residual hazards are potential non-obvious hazards such as e.g.:

� Injury due to any failure to observe the safety guidelines, norms, guidelines or regulations,

� Injury due to non-coordinated work,

� hazards due to anywork on the electrical system and/or cables/connectors,

� etc.

2.4 delivery

The AHU is delivered (depending on its size) either in completely-assembled form or as pre-assembled unit components!

2.5 storage, transport

Warning! attention!

� Store the individual functional parts in their original packaging and in a dry, weather-protected place.

� Cover open pallets with foil, and protect the functional parts from the effects of dirt (e.g. dust, stones etc.).

� During transport under difficult conditions (e.g. on open vehicles, unusually stressing in case of vibrations, during transport by sea or to sub-tropical countries), additional packaging must be used which prevents these particular influences.

� During storage, prevent permanent (and primarily abrupt) changes in temperature. This is particularly harmful whenever moisture can condense.

� During storage periods exceeding three months, check the ease of movement of rotating parts (bearings, fans etc.) before assembly.

� For this purpose, also observe the guidelines in the individual chapters.

� The unit transport can take place (as described in Item 4, "Transport“) with a forklift or a crane.

� The transport of individual components must be done in upright position and must be safed against fall over.

� During transport, ensure sufficient visibility.

(as necessary, possibly with a accompanying person etc.)

� No persons may be present in the transport area.

� During transport, observe the relevant regulations on work safety and environmental protection.

� The transport of the AHU’s may only be performed by trained, qualified and briefed personnel under the aspect of "Safety".

� When using transport devices which require an operator's licence, it must be ensured that the personnel holds such a valid licence.

� Ensure the use of suitable hoisting equipment.

"Safety guidelines"



2.6 operator's obligations

The operator of AL-KO THERM Products must train its personnel regularly on the following topics:

� Observance and use of the operation and assembly instructions as well as legal regulations.

� Proper operation of the AHU.

� As necessary, observe any instructions given by plant security and indicated in the operator's operating procedure.

� What to do in an emergency.

2.7 disposal

At the disposal of the packaging is in accordance with the implementation date valid, relevant, local environmental and recycling regulations of their country and their community to take action.

3. Product description

The air handling units (AHU´s) from Series AT4/AT6 are compact and highly-efficient ventilation units.

The model series AT4/AT6 is used is numerous areas of human climatisation as well as in industrial applications, che-mistry/pharmaceuticals, marine industry, ATEX, hygiene, swimming pool, leisure facilities and in numerous other sec-tors – as well as in the refurbishment of existing installations with highly-efficient heat recovery and energy savings according to the latest state of technic and applicable regulations.

The sound emissions from Series AT4/AT6 are minimised by way of a structurally well-planned housing design and op-timised arrangement of the device components, adapted to the respective purpose of use as well as by the use of highly efficient vibration-insulated fan and actuator units.

The housing structure (with its smooth interior) warrants quick and easy cleaning of the units as well as compliance with hygienic requirements.

In the model series AT4/AT6 (based on the given requirements), all known air-treatment units for filtering, heating, cooling, sound insulations, humdification and dehumidification, heat recovery (rotating heat exchanger, plate heat ex-changer, heat recovery circulation system or layer-storage modules etc.) are used.

Upon request, the air handling units are also available with integrated controls and/or cooling technology – incl. wiring and attachment of the field device and sensors).

Dimensions and technical data: see documentation supplies separately!

Our products are subject to constant quality control and conform to the valid regulations.


3.1 ec statement of conformity

"Product description"



3.2 ec declaration of incorporation


4. transport

The ventilation and air-conditioning units of the AT4/AT6 production series are shipped screwed to square transport tim-bers and, depending on their size, come either completely assembled or in separate components divided in accordance with the delivery section split.

The delivery splitting is indicated in the unit drawing.

Fig. 1: Unit components ready for transport

All AT4 units come equipped standard with a base frame that has openings for a crane transport. When the units are delivered, the transport openings are sealed with covering caps.

AT4/AT6 units can be transported to the installation location with crane or forklift.

4.1 transport with forklift

attention!Use suitable fork lengths in order to avoid damaging unit base.Always watch out for possible projections (e.g. floor drains).Service doors must always be closed during transport.

4.2 unit transport via transport tube

danger:For crane transport, all applicable safety regulations must be observed according to UVV BGV D6 Crane and BGR 500 chapter 2.8.

attention!For AHU’s in weatherproof design, the overhanging drip edges must be safeguarded by additional measures during crane transport (e.g. traverses or wooden spacer beams).Service doors must always be closed during transport.

"Transport"



Crossbar

Tube clampTransport tube

Spacer timberprovided

by customer

Fig.: Crane transport

� Remove covering caps.

� Slide transport tubes (accessory: 1 1/2" pipe in accordance with DIN EN 10255) through the transport openings in the base frame and secure with tube-securing mechanism.

� Fasten separate lifting accessories (cable, chains, flat lifting sling) to the laterally overlapping transport tubes (projection of at least 200 mm on both sides).

unit width in raster unit width in mm length (transport tube)

08 688 mm 1100 mm

12 994 mm 1400 mm

16 1300 mm 1700 mm

20 1606 mm 2000 mm

24 1912 mm 2300 mm

28 2218 mm 2600 mm

32 2524 mm 2900 mm

41 3213 mm 3600 mm

49 3825 mm 4200 mm

Table: Length of transport tube

Fig.: Transport tube


4.3 unit transport via loop

danger:For crane transport, all applicable safety regulations must be observed according to UVV BGV D6 Crane and BGR 500 chapter 2.8.

attention!For AHU’s in weatherproof design, the overhanging drip edges must be safeguarded by additional measures during crane transport (e.g. traverses or wooden spacer beams). Operating doors of the units must always be closed during transport.

transport with loops:

� The supplied cable loops must be used when transporting all components.

For this purpose, there are threaded bore holes on the edges into which the loops must be completely screwed.

� After removing the loops, always close the holes so that they are airtight!

� All cable loops and other possible suspension points on the unit must be used and must be loaded evenly! It is recommended to use crane gear (crossbar and chain hoist) if the unit in question has 6 or more possible suspen-sion points.

� The angle between cable and unit top must be greater than 45°.

� The central eyes must be removed before the units are connected.

Cable loop completelyscrewed in

Angle betweenunit top and trans-port suspensiongear at least 45°

Central eye

Chain hoist

Fig.: Transport with loop Fig.: Middle loop

"Transport"



4.4 unit transport via shackles

The shackles are screwed into the opening (Ø 13) in the base frame of RLT devices.

Transport is only permitted with a lifting beam in order to protect the device.

A tension plate is mounted on the front end of weather-proof RLT devices to protect the drip edges. The shackles are then inserted into the appropriate holes (Ø 13). The protruding drip edges must be protected by additional measures (e.g. crossbeams or spacing timber) during transport by crane.

The tension plates must be detached after transport and the bores must be closed again using the removed screws with sealing washers.

note:Any paint damage which occurred due to transport can be repaired with a touch-up applicator.

Crossbeam, buyer-provided

Hoisting cable, buyer-provided

Detail weatherproofDrip edge

Shackle

Screw M12x30Hoisting plate

Drilling screw6,3x25

Fig.: Shackle transport


5. assembly

in spite of optimised production processes, there is still a residual risk of injury due to cut edges.

in order to further minimise the risk of injury, personnel installing the units must generally wear protective equip-ment (protective gloves, etc.).

in general:

A flat foundation is required for unit assembly. The foundation can be designed as a completely flat foundation or as a strip foundation. With strip foundations, when the width of the unit is greater than 2 m, additional lateral supports must be provided for support at the beginning and end of the unit and at the component divisions.

There must be sufficient space for operation and maintenance of the air handling unit.

note:Upon delivery, the accessory parts lie in the respectively marked unit components.

recommendation:

� Suitable damping strips (not supplied in package contents) can be placed under the AT4/AT6 units to damp vibrati-on; this must be done in accordance with the specifications of the damping strip manufacturer.

� AL-KO THERM generally recommends placing the damping strips under the unit sides, component divisions, and in the longitudinal direction with components approx. 1,200 mm or longer.

� To prevent transmission of structure-borne noise, AL-KO THERM recommends using flexible connectors for the connection between the unit and ductwork.

attention!The set-up sequence of the individual unit components is shown in the order related drawing and must absolutely adhered to.

� The assembly of AT4/AT6 units begins with the unit component that contains the air outlet (channel interface).

� Adhere the sealing bands (included in the scope of supply) to the front sides of the unit components, flush to the exterior edge of the unit profil.

� Then, pull the respective connecting unit components as closely together as possible and connect these via the unit connector (and/or – for larger and heavier unit components – with suitable aids such as belts).

� Connect the air handling unit and the potential equalisation mounted on the unit to the conduit system.

attention!Units must be levelled in order to assure proper function.Do not walk on top of unit without means for preventing damage (scaffolding or supports).Until commissioning, carefully cover the units before and after the assembly in order to avoid any damages and/or contamination.

"Assembly"



5.1 unit assembly in ex-proof models

On various components, the panels must be removed to connect the units.

For air handling units in the standard design (panels galvanised and/or coated), the necessary equipotential bonding between the panels and the frame is attained via a special-designed fastening screw (please observe the existing posi-tioning).

In special designs (e.g. panel made of stainless steel), these panels include additional bores. After assembly, the bores must be closed with the blind rivets included in the scope of supply.

After units are connected, rivetcover with blind rivets 4.8 x 16.

(cover predrilled)

Fig.: Example: Blind rivet

5.2 internal unit connection at casing division

� Stick the included sealing band to the unit, flush with its outer edge.

� Insert hexagenal screw into gusset plate, optionally with an assembly angle and attach with washer and hexagenal nut.

� For the unit version in accordance with VDI 6022, the unit connecting points on the inside of the base areas must also be sealed with a microbially-inert sealing material.

� The unit connections serve solely to fix the final unit position!

Fig.: Unit connections


5.3 at4/at6 unit connection with stacked units and with side-by-side units

5.3.1 stacked unit arrangement

� The rubber sealing band is to be assembled round prior to attaching the top unit components (adhesive on a single side)

� Place upper unit component onto lower unit part by crane.

� Screw unit base frame to lower housing with hexagenal screw.

in the area of the mixing chambers (airstream connection) between the top and bottom unit, the unit's base frame must also be sealed additional with a microbially-inert sealing material.

attention!If the upper unit component is longitudinally offset in relation to the lower unit component, then the base frame lateral profile must be screwed to the casing cover.For AT4/AT6 units in weatherproof design, the base frame profile must also be properly sealed with a microbi-ally-inert sealing material.

base frame

bottom(upper unit)

cover

cover

roof(lower unit)

Rubber sealing band

Fig.: Stacked unit arrangement

base frame lateral profile

upper unit

microbially-inert sealing material

roof (lower unit)

Fig.: Stacked units with longitudinal offset

"Assembly"



5.3.2 side-by-side units

� Loosen hex bolts on factory-mounted spacer bar.

� Place unit components next to it with forklift or crane.

� Fix spacer bar by means of hexagenal screw.

distance rail

Fig.: Side-by-side units

in addition to the spacer bar, a continuous 25 mm wide sealing strip must be glued in the region of the mixing cham-bers (fresh air connection). this must be checked for leaks upon completion of assembly.

attention!For the lengthwise offset of the left to the right unit component, the facing angle must also be screwed to the panel. For AT4/AT6 units in weatherproof design, the facing angle must also be sealed with a microbially-inert sealing material.For AT4/AT6 units in weatherproof design, the screws included in the scope of supply are also equipped with an EPDM sealing washer.

attention!If a humidifier is installed, then the buyer must furnish offset foundations to compensate for the height diffe-rence between the humidifier drain pan and the base frames of the adjoining components.

Assembly angle integrated into housing

Assembly angleintegrated into housing

Unit Humidifier

Foundation provided by customer

Humidifier drain pan

Attachment angle integrated into humidifier

base frame

Foundationprovided

by customer

Humidifier drain pan

Unit Humidifier

Fig.: Humidifier installation


5.3.3 unit assembly via suspension

The unit assembly of small air handling units (up to an air output of 5.000 m3/h) is possible via suspension below a building's ceiling with the aid of the design described below. The suspension is performed with screw thread rods and special-designed unit edges. The assembly of the screw thread rods (and their fixation to the individual housing components) should take place at the factory. Here, the design of the unit (with or without base frames (GR)) must be considered. Mounting via "C" profiles below the unit can also be performed by the customer. The operability of the ins-tallations for maintenance purposes must be warranted. The respective design and sectioning of the "C" profiles is the responsibility of the installer of the installation. As a rule, the max. vertical load limits must be observed and maintained.

Design with base frame (GR) Design without base frame (GR)

Screw thread on the transport edge drilled open in production

The screw thread rod is screwed through the edge and countered from below!

Base

fram

e

Screw thread on the transport edge drilled open in production

The screw thread rod must be safeguarded by the customer against twisting!

NOT USE WITHOUT INDIVIDUALLY TESTING OF THE STATICS!

DO NOT USE WITHOUT INDIVIDUALLY TESTING OF THE STATICS!

Max. vertical load per screw thread rod: 500 kg! Max. vertical load per screw thread: 375 kg!

Fig.: Suspension

tip for assembly:

To avoid a collision with the panel and hinge screws, the screw thread rods must be assembled before the screws are mounted to the frame profiles! To assemble the screw-thread rods on job side, the panel screws and hinge screws must be loosened once again and shortened!

5.4 external installation

5.4.1 roof frame

1. Roof frame pre-assembled by the customer (cf. Fig. for Item 1)

� Place roof frame on the foundation and attach them to each other with screws.

� Close transport openings in roof frame with covering caps.

� Apply sealing compound to roof frame.

� Transport units by crane onto roof frame and attach with screws (assembly angle for cover plate with screws).

� Close transport openings in roof frame with covering caps.

� Lift up customer-supplied roof skin to be sealed to roof frame and glue under drip edge.

� Mount the cover plate to the drip edge and rivet it to the fastening angle (optional accessories).

"Assembly"



2. Base frame or roof frame assembled in the factory (cf. Fig. for Item 2)

� Close transport openings in base frame/roof frame with covering caps.

� Hoist customer-supplied vapour barrier to be sealed to base frame/roof frame and glue under drip edge.

3. For unit separations, set the individual components as close to each other as possible, pull them together with suitable handling aids (e.g. belts) and attach these to each other. The unit connections serve exclusively to fix the final device position!

4. Seal the unit separation points (cf. Fig. for Item 4)

Drainage area

Cover plate

Clamp *)

Bond the moisture-proof roofingsheet to the screw angle prior to fitting the cover plates

Screw angle

Drilling screw with EPDM washer


base frame

Sealing compound

Roof frame

*) Number of clamps per component at least 2, but the max. distance between the clamps is 700 mm.

Roof skin form customer side

Insulation providedby customer

Insulation providedby customer

Fig. for Item 1: Roof frame pre-assembled by the customer

Drilling screwwith EPDM washer

Coupling piece (only at division points)Drainage area

Insulationprovided by customer

Base frames/roof frames


Drainage area

Rooffoil

Fig. for Item 2: Base or roof frame assembled Fig.: Base frame assembled at the factory Fig. for Item 2: at the factory Fig.: (for arrangement of the units on top of each other)


attention!When executing from beneath (breaking through roof), clear all details with the factory first.For weatherproof design, lightning protection must be warranted by the customer!In accordance with VDI 3803-1, units for weatherproof set-up may not take over the performance of structural-engineering functions or the function of the building's roof!

sealing unit division points:

1. Check unit divisions for correct leak tightness.

2. Clean unit top in the region of unit division.

3. Clip the coupling piece (on the unit separation point) below the drip edge.

4. Fold back overlapping roof foil.

5. Apply solvent welding agent with brush.

6. Fold foil barrier back over it.

7. Abutting points should be pressed firmly in place in order to avoid wrinkling.

Welding agent

Coupling pieceSeam sealer

Fig. for Item 4: Sealing of the units separator points

attention!The solvent welding agent can only be used at outside temperatures > 10 °C.At low outside temperatures, preheat the corresponding locations with a hot air blower.Carefully check the seal of the housing.

danger:The solvent welding agent is highly flammable – keep away from ignition sources! Follow the safety instructions on the package. For further information, you can request the current EC safety data sheets from us.

alternative sealing of unit division points

Manual hot air welding

All hand welding devices with an angled, approx. 40 mm-wide nozzle and that produce the required temperatures of hot air of approx. 450 °C are suitable for the welding. The hand welding device is guided at an angle of

� approx. 45° to the sheet edge and

� approx. 30° to the roof surface

in the seam overlap.

"Assembly"



Fig. "Manual hot-air welding"

The sheets are seal-welded travelling backwards and in a single pass, whereas narrow pieces (up to 33 cm) are first tacked and then seal-welded.

During seal-welding, the nozzle should only be inserted between the sheets far enough that the upper sheet edge is also struck and therefore plastified by the hot air.

The plastified overlap regions are joined using moderate pressure applied with a silicone or metal pressing roller guided parallel to the nozzle opening. By welding while travelling backwards, the nozzle always blows against seam regions that have already been seal-welded.

5.4.2 Weatherproof units with height offset

Design with AT4-panel

The angle is riveted to the horizontal sideand bonded to the roof foil, then (on the vertical side) stopped and screwed shut with a panel.


Design without AT4-panel

The angle is riveted on the horizontal side to the roof film and sealed on the vertical side with microbially-inert sealing material on the adjoining component!

5.4.3 Weatherproof units with built-in rotating heat exchanger

Weatherproof units with rotors, arranged on top of each other and offset at the sides:Here, the foil angle is inserted on the horizontal side of the bottom housing with the plate below the roof fort and bonded to the roof foil.The vertical sides and the top horizontal edge of the foil angle must be sealed with microbially-inert sealing material.

"Assembly"



5.4.4 Weatherproof units with transport edges

� In weatherproof unit with transport edges, the roof track is only welded at the factory up to the counter-bores.

� After removing the loops, the closure stoppers included in the scope of supply ("Pine-Tree Clips") are pressed into the openings which thereby close.

� Then, the foil must be welded (see Item 5.4.1, Fig. "Manual hot-air welding)!

1 2 3

Fig.: "Pine-Tree" Clips

5.5 additional assembly instructions for hygiene units

attention!After the set-up and interconnection of the individual units components, the units separation points (incl. the unit connector angles on the inside of the unit) must be sealed with microbially-inert sealing material.

If the buyer installs pipework or electrical cables, care must be taken that these do not impede the function and operation of laterally removable built-in components of the units.

It is not permissible to connect the condensate drain outlet of the "hygiene unit" directly to the waste water system.


6. commissioning and maintenance

6.1 general guidelines

Warning!Assembly, commissioning, maintenance and corrective maintenance work may only be performed by qualified trained and briefed specialised personnel!AL-KO THERM recommends performing maintenance on the AHU based on the norms VDMA 24186 and VDI 6022.General maintenance guidelines in the operation and assembly instructions for air handling untits from Series AT4/AT6 made by AL-KO THERM must absolutely be observed.

Warning!For any work on the AHU, the unit must generally be disconnected from the power supply, the main switch and/or repair switch must be powered off (on all poles) and safeguarded against unauthorised restart. Only open the revision doors when the fans are powered off and not in motion. After the unit is powered off, the running wheel continues running for approx. 1-3 minutes.The running wheel may never be slowed down manually or with objects.After performing any work on the AHU, the responsible person must ensure that no other persons are present in the installation and that all safety measures applied by the plant are functional prior to recommissioning.In the event of shutdown intervals which exceed one week, weekly rotation of the motor and/or fan shaft is generally necessary to avoid a punctiform load on the bearings which would damage the bearings (in this res-pect, also observe the instructions in the chapter "Belt drive").Prior to the commissioning of the AHU’s, the sealing seat of all built-in filters must be checked.

attention!AL-KO THERM generally recommends the replacement of all installed filters after operating the AHU’s for a short time in order to remove the dirt which has entered the filter in the construction phase and after commissioning.Due to the pollution of the exhaust air with harmful gases, there may be hygienic-toxicological concerns during 100% recirculating-air operation. Therefore, in recirculating-air operation, a minimal external-air volume flow must be ensured.

cleaning:

For cleaning purposes, the non-freeze frame can be pulled out on the sides and must be cleaned outside the device with a pressure washer.

The view glasses in the AT4/AT6 device model series are (as necessary for cleaning purposes) easily removable.

For cleaning, only use lukewarm water (possibly add a mild, unscented soap solution).

All components can be extended or removed for cleaning; or after dismounting of a panel freely accessible or removeable form the unit.

If panels caps are removed for maintenance purposes, then the inside of the housing in this area must be re-sealed with microbially-inert sealant.

"Commissioning and maintenance"



6.2 Fans

6.2.1 Fan (Belt drive)

commissioning:

1. Remove transport locking device on fan base.

2. Check conduit system and fan for foreign objects.

3. Turn impeller by hand to make sure it rotates freely.

4. Test fan rotation direction (see arrow on fan housing) by temporarily switching on the motor.

5. If needed, reverse connections on the motor and correct the rotation direction.

6. Measure the current consumption with the operation doors closed, and compare this value to the nominal current indicated on the motor type plate.

7. Check the orientation (alignment) of the V-belt drive.

8. Check the V-belt tension and re-tighten as necessary.

9. Test equipment earthing conductor.

attention!When the rotation direction is incorrect, there is a danger of motor overload.Power consumption must not exceed the nominal current indicated.It is not permissible to exceed the maximum motor speed.It is not permissible to exceed the maximum fan speed.At rated motor outputs of greater than 3 kW: star-delta starting.

commissioning and maintenance:

� Check fan impeller for contamination and imbalance.

� Check bearings and regrease as needed.

� Tighten all fastening screws.

� Test function of vibration dampers.

� Test function of drainage if necessary.

� Check fan for contamination, damage and corrosion.

� Clean fan unit regularly.

Fig.: fan (belt drive)


For maintenance work the fan unit can be removed at the side:

1. Loosen the fastening screws on the fan unit.

2. Detach flexible connection.

3. Pull fan unit out of the housing laterally.

attention!Pull the fan unit out carefully in order to avoid damaging the housing coating.

6.2.2 Belt drive

commissioning:

1. Check V-belt drive and set required belt tension.

2. Check V-belt pulley for frictional seating and precise alignment (parallel).

3. After approx. one hour of running time, check the screws on the pulleys plate, the motor and the fan: tighten as ne-cessary. Check the belt tension and re-tighten as necessary.

attention!Incorrectly tensioned V-belts can lead to bearing damage in the fan and electric motor. With shut-downs of the unit of longer than 3 months, the V-belts must be loosened or removed to prevent bearing damage, otherwise this voids the guarantee for them.If the belt drive is altered without using an AL-KO design, then the limit speeds of the fan and the limit value diagram for the belt tensions in the respective technical catalogue must be respected. For EX fan units, only electrostatically conductive belts can be used.

Maintenance:

� Check V-belt drive for contamination, damage and corrosion.

� Check the V-belt tension and re-tighten as necessary.

� Check alignment of V-belt pulleys.

� Clean V-belt drive regularly.

attention!When replacing V-belts in multi-grooved drive units, it is always necessary to change the whole set of V-belts.




tensioning regulation for the v-belt drive (1)

The correct belt tension is attained when (with the individual testing force Fp) a belt deflection b is attained in accordance with the technical data sheet. As an alternative, this parameter is also adjustable via the frequency-gauging process.

L = belt length

b = belt deflection at testing force Fp

Fp = testing force in N from AL-KO document

Tensioning regulation for a flat-belt drive (2)

The correct belt tension is reached when the measurement marker distance LMu has increased by the belt elongation E*. The adjustment should be carried out in two stages with a interval of a few hours between them in order not to overload the bearings.

E*

Measuringpoints

LMu = Measuring points spacing on the non-tensioned flat belt

LMg = Measurement marker distance with correctly tensioned flat belt

E* = Belt elongation in mm from accompanying document

6.2.3 Fan (free wheel with direct driven)

commissioning:

� Remove transport locking device on fan base

� The unit must be checked for transport damage before commissioning.

� The impeller must not touch the fan intake nozzle. This can be checked by turning the impeller.

� After that, the rotation direction of the motor must be checked. The correct rotation direction is marked with a direction arrow on the running wheel and/or the motor. The rotation direction of the motor can be determined by switching it on briefly (attention when the door is open). If the rotation direction is wrong, the motor must then be reconnected.

� Perform a protective earthing conductor test.


Maintenance:

� Maintenance at least once annually.

� Check the fan for dirt, vibrations, damage, loose screws and corrosion. Every six months, check the impeller (especially its welds) for the information of any cracks.

� Check the safety equipment (access door stopper, protection grid) for its correct function.

Operation-point setting

The operation point can be precisely approached by the adjustable fan RPM level.

In the course of regulating the RPM level, ensure that the maximum fan RPM levels and permissible motor currents are not exceeded. The nozzle gap may not be changed.

danger:Fans (particularly those fans without a spiral housing) are to be checked for non-permissible vibrations in the context of commissioning and at regular intervals, and this must be documented accordingly!In the course of operation with a frequency inverter, this is to generally be operated without excess modulation.Operation of the fan motor system in the range of the resonance RPM level (and its multiple) is to be avoided.In the course of commissioning, any resonance RPM levels are to be detected and eliminated (e.g. by fading out the frequencies on the frequency inverter).Fans may not be operated if any unusual vibration and noises (or impermissibly high vibration speeds) occur!Running with not permissible high vibrations can produce broken impellers, which can lead to serious material- and personal injury. AL-KO recommend a continous observation/control with assistance of vibrations sensor (optional accessories).

installation group of machine well usable not permitted

fixed up to 15 KW K 0,7 mm/s 1,8 mm/s 4,5 mm/s

fixed from 15 KW M 1,1 mm/s 2,8 mm/s 7,1 mm/s

vibrations-isolated T 2,8 mm/s 7,1 mm/s 18 mm/s

Determining airflow quantities::

The fans come optionally equipped with a volume flow measuring device. A pressure measuring point in the inlet nozzle is used to measure the pressure difference between the static pressure in the chamber on the intake side and the pres-sure in the inlet nozzle. This differential pressure (differential head) is at a fixed ratio to the air volume flow. A detailed description is available on request.


Determining airflow quantity by measuring differential pressure



6.2.4 torques of screw connections on the fan component

After approx. one hour of running time, check the screw connections on the fan's base frame and tighten consistently as necessary, via the torque wrench, in keeping with the initial screw tightening torques indicated in the table below.

thread size screw torque (nm)

M 6 10

M 8 25

M 10 49

M 12 85

Table: Torques

Maintenance and testing of taper-lock clamping bushes:

1. Clean and degrease all bare surfaces such as the bore and conical surface of the taper clamping bush as well as the conical bore of the pulley. Insert taper clamping bush into the hub and bring all connecting bores into alignment (half threaded bores must each be aligned with a half smooth bore).

2. Provide headless screw (size 1008 – 3030) and cylindrical screws (size 3535 – 5050) with a small amount of screw locking compound and screw in – do not tighten screws yet!

3. Clean and degrease shaft. Slide pulley with taper clamping bush onto the shaft.

4. When using a feather key, this should first be inserted into the groove on the shaft. There must be back clearance between the feather key and the bore groove.

5. Using the torque wrench, tighten headless screws and cylindrical screws evenly with the torques indicated in following table.

Bush screw torque (nm)screw

Number Size

1008/1108 6 2 1/4“ BSW

1310/1315 20 2 3/8“ BSW

1210/1215 20 2 3/8“ BSW

1610/1615 20 2 3/8“ BSW

2012 31 2 7/16“ BSW

2517 48 2 1/2“ BSW

3020/3030 90 2 5/8“ BSW

3535 112 3 1/2“ BSW

4040 170 3 5/8“ BSW

4545 192 3 3/4“ BSW

5050 271 3 7/8“ BSW

Table: Torques Taper-lock bushings


changing belt pulleys:

loosen belt pulleys (i):

1. Unscrew screws.

2. Screw hexagonal bolt into threaded hole (4).

3. Push clamping bush out from conical bore.

4. Belt pulley can only be slid slightly on the shaft.

attach belt pulley (ii):

Tighten belt pulley and clamping bush to each other by means of hexagonal bolts (3). Make sure that the motor shaft and fan drive pulley are precisely aligned. install and tension belts according to regulations.

6.3 heat exchanger

6.3.1 Finned heat exchanger

The heat exchangers are largely maintenance-free. Heat exchangers must be cleaned regularly in order to assure proper function. As long as the tubes of the fin unit are not damaged, dented fins of the heat exchanger have no influence on the functional capability of the overall system and therefore do not constitute grounds for complaint. The fins can be "combed out" by the buyer. If needed, an appropriate tool can be purchased from the manufacturer.

note:The buyer should provide venting valves and drain valves in the pipeline.

attention!In general, care must be taken that the unit remains accessible for maintenance purposes. During installation, particularly of connecting pipes, care must be taken not to impede the opening of testing doors. According to VDI 6022 the removability of the heat exchanger (and optional droplet eliminator) must remain assured up to a unit clearance height of 1.6 m.

Operation only with water which is free of corrosive properties (and particularly contains neither oxygen nor carbonic acid)!

assembly:

1. Connect heat exchanger in accordance with the counterflow principle (water flow direction counter to airflow direc-tion in unit).

2. The water supply should be connected to the bottom or the top, depending on the airflow direction.


(I) (II)



attention!When connecting the heat exchanger, hold it in place with suitable means (e.g. pipe wrench) in order to prevent damage. Attach lines and connections so that the heat exchangers are freely accessible for maintenance.

Maximum operating pressure: 16 bar

Maximum water supply temperature hot water: 120 °C

additional instructions for using direct evaporators:

Installations must be carried out by an approved refrigeration company.

Only safe refrigerants in accordance with DIN 8960 are approved for use.

the cooling unit and the direct expansion each require a siphon to be attached by the customer. each drain pan must be equipped with a separate siphon.

Direct evaporator

Air

Refrigerant

RefrigerantInjection valve

Suctiongas line

Fig.: Air direction in installation of a direct evaporator

attention!For refrigeration connecting pipes, the customer must make the necessary opening at the panel.

Maintenance:

� Check heat exchanger for contamination, damage and corrosion.

� Clean heat exchanger (see below for appropriate method)

� Check attachments and screw connections.

� Check function of supply and return fuel lines.

� Test venting valve and filling of heat exchanger.

� Test function of frost protection thermostat.

� Check antifreeze concentration as needed.

� Check siphon and refill as needed.

� Check function of drain and trap.

� Check droplet eliminator and clean as needed.


cleaning heat exchanger:

Heat exchanger registers should only be cleaned with methods that do not cause any damage to the fins. These are listed below:

cleaning method Applicable types of finned heat exchanger

1 Compressed air all heat exchanger registers

2 Steam jet units only galvanised steel heat exchanger registers

3 High-pressure water jets only withthe THD multijet method

all heat exchanger registers

notes on 1 - 3:Deposits in heat exchangers cannot be completely removed with compressed air. When cleaning with com-pressed air and with steam jet units, it is not possible to assure a thorough cleaning, especially with deeper registers. Consequently, instead of dirt deposits being removed, they become compressed at the deepest part of the heat exchanger. This leads to an increased loss of pressure, a lack of hygiene, odours, corrosion, etc.

The use of high pressure cleaners which operate with water (with conventional single-stream nozzles) is not allowed, because this could damage the sensitive fins and through cleaning effect is not always achieved (particularly in the deep heat-exchanger registers). The cleaning of the heat-exchanger registers using high pressure cleaners which operate with water should only be performed according to the THD multi-stream process. This ensures the deep cleaning of the heat-exchanger registers without damage. This applies to all heat-exchanger register types. In the context of the hygiene-compliance inspection for Series AT4/AT6 AL-KO air handling units, the Institute for Lufthygiene (air hygiene) in Berlin verified the cleaning effect of heat-exchanger registers made by AL-KO – with the aid of the THD multi-stream process (see Fig. THD multi-stream process).

The use of the THD multi-stream process includes the correction of any bent fins to restore the optimum flow rate and output of the heat exchangers.

Fig.: THD multi-stream process (front)




Fig.: THD multi-stream process (rear)

For more detailed information about the THD multijet method, contact:

Technischer Hygiene-Dienst Fachreferat Lüftungs- und Kältetechnik Einemstraße 12 10785 Berlin tel.: +49 / (0)30 / 66765775-0 fax.: +49 / (0)30 / 66765775-5 email: [email protected] web: www.thd.info

attention!At temperatures below freezing point, due to the danger of frost and corrosion, the heat exchanger must either be emptied and blown out with compressed air, or must be filled with a commercially available antifreeze that contains a corrosion prevention agent.

In heat exchangers of a run-around coil system, the tube interconnections cannot be emptied individually; for this reason, the run-around coil system should only be operated using a frost-resistant water / glycol mixture and should be tested for leaks after assembly. If it should be necessary to empty the system, the heat exchangers can be blown out using compressed air; even in this case, though, residual water will remain in the heat exchanger.

With extended shut-downs of the units, corrosion can occur in the heat exchangers due to sulphate-reducing bacteria. These sulphides primarily attack the soldered seams, but also attack the copper base material itself. In order to reduce this type of copper corrosion, we recommend the following measures:

� Using sulphate-free water in the entire PWW circuit

� Assuring that the PWW circuit is free of leaks

� Avoiding long shut-downs of the filled PWW circuit

� Avoiding frequent refilling with fresh water

� Using material-compatible inhibitors

� Using biocides


snake siphon (positive or negative pressure):

The snake siphon with a screw cover for filling and checking is a fillable siphon for drainage of air handling units in the area of the heat exchanger, humidifier or other wet regions at a different pressure to ambient pressure.

Bottom pan with bottom drain

Outlet pipe Ø 40, buyer-providedFloor drain Ø 40

H2

H3

H1

30

element height min. max.H1 0 190H2H3

55100

245270

Positive pressure up to 1900 PA Negative pressure up to 1300 PAH1 = 50 mm H1 = mm WS + 50 mmH2 = 1,5* mm WS + 25 mm H2 = mm WS/2 + 50 mmH3 = H2 + 40 mm H3 = H1 + H2 – 10 mm

Below 600 PA requires compliance with min. measures H1 – H3!!!

Fig.: Siphon dimensioning

Ball siphon (positive pressure):

The ball siphon is a self-filling siphon for drainage of heat exchangers, humidifiers and other wet regions at a pressure lower than ambient pressure. It contains a floating ball, which, when the unit is running dry, prevents the intake of air so that the first accumulating condensate produced can fill the siphon. The ball also acts as a check valve when there are pressure surges in the system and prevents the system from being sucked dry.


Check valvewith ball

Floor drain Ø 40

BendØ 40

Dra

in h

eigh

tH

2

Inle

t hei

ght

H3

Tail pieceØ 40

30

Fig.: See snake siphon for calculation




Ball siphon (negative pressure):


element height min. max.H1 350H2 0

30320

Negative pressure up to 3200 PAH1 = mm WS + 30 mmH2 = mm WS

Floor drain Ø 40

Bend Ø 40

Tail piece Ø 40

Check valvewith ball

Ø 40

appr

ox. 3

5H

1

H2

30

Fig.: Ball siphon dimensioning for negative pressure

attention!The drain outlet tube and the siphon must be kept frost-proof by the customer!

6.3.2 electric air heater

special instructions for electric air heater:

� For the electrical connection, it is absolutely necessary to consult the wiring diagram supplied with the unit.

� The operating and maintenance instructions for the electric air heater must be observed.

� The electric air heater must be used only in combination with a flow monitor (to be positioned and adjusted by the buyer).

� The temperature monitor and the safety temperature limiter are to be integrated into the control circuit of the elec-tric air heater.

� In the case of variable-speed fans, the power of the electric air heater must be reduced accordingly.

� The system must be inspected for damage after a power failure or if fault messages are displayed. Faulty parts must be replaced where necessary.

� Heat build-up in the area of the electric air heater must be avoided at all time.


Frequent causes of errors for heat building-up are:

cause corrective measuresNo airflow volume Heater units must only be enabled when a sufficient airflow

over the heater is determined.—> Use of a volume flow monitor AL-KO recommends integrating the electric air heater control into the circuit of the repair switch (auxiliary switch)

Insufficient airflow volume from regulated fans The heat output must be adapted to the reduced airflow volume—> Infinitely variable regulation of the heating energy or switching of heating groups in accordance with the preset airflow volume

Temperature monitor is not connected The function of the temperature-induced shut down must be tested during commissioning.

Safety temperature limiter is not connected The function of the shutoff must be tested during commissioning.

No fan after running It is absolutely necessary for the fans to have a minimum of 5 minutes of after running time after the electric heating is switched off. Alternatively, fan after running can also be con-trolled via a thermostat.

Incorrect commissioning – Testing of electrical heating Make sure that there is always a sufficient airflow volume at the heating coil during testing.

Air temperatures above 60 °C It must be ensured that the air temperatures do not exceed 60 °C at any time. During normal operation (continuous operation), the air tempe-rature should not exceed 40 °C.

When the buyer retrofits electric air heaters, the following distances from other components must be maintained:

� Up to size 16 (clearance height 1224 mm): 300 mm

� Larger than size 16: 450 mm.

damage as a result of excessive temperatures due to heat build-up invalidates the guarantee!

6.4 heat recovery

6.4.1 Plate heat exchanger

Maintenance:

� Regularly clean plates:

a) Remove dust, fibre residues and any similar materials.

b) Remove oil and grease deposits with hot water, steam, or grease-dissolving cleansers.

� Clean condensate drain.


� Check damper connection, drive and control functions.




6.4.2 rotary heat exchanger

Maintenance:

� Check drive elements and control elements.

� Clean rotor regularly with compressed air, water, steam or degreasing cleansers.

� The cleaning of the thermal mass is to be selected dependent upon the material used!

thermal mass:

Before commissioning (particularly with horizontal rotors), care must be taken that no objects or to strongly pressed sealing felts block free movement. The thermal mass of the rotary heat exchanger is consists of wound aluminium foil. Because of the counterflow principle, in the majority of cases its follow on the self-cleaning effect, which is sufficient to prevent contamination of the thermal mass.

Should this self-cleaning be insufficient, the thermal mass can be cleaned at appropriate intervals (depending on the degree of contamination) with compressed air or in the case of stubborn soiling, with high-pressure devices (medium: only water without chemical additives).

attention!The jet of air or water must meet the thermal mass at right angles!

rotation direction:

In this process, ensure that the thermal mass always rotates from the exhaust air via the purge chamber into the supply air. This rotation direction of the thermal mass is indicated by a marking.

attention!Check rotation direction during maintenance!

v-belt

The driving V-belts have the descriptions SPZ and SPA and are available on the market under the description "end-less V-belt". Hinge locks are used as a connecting element. Since the V-belt has a natural stretching and this expansion in length can exceed the dimensions of the tensioning device, it is advisable to check the tension of the V-belt at set intervals. Particular care must be taken to do so during the first 400 operating hours. If the V-belt tension drops so low that the driving of the thermal mass is no longer assured, then the V-belt must be shortened.

1 Thermal-mass

2 V-belt

3 V-belt pulley

4 Hingeconnector

5 Motor

6 Motor-drivenrocker switch

7 Spring


split design (buyer-assembled)

Starting at a wheel diameter of 1800 mm, the rotors are designed split. Starting at frame dimensions of 2500 mm, the frame is also split. The set-up is to be performed in accordance with the separate assembly instructions.

seals

With normal-temperature rotors, sealing felts of the quality: NF-PES-LE 0.32 grey are used. The felts must be slid as close as possible to the thermal mass, but direct abrasion must be avoided. The sealing felts are pressed on at the fac-tory, but their position can change as a result of transport. Warning: Before commissioning, check felts and seals and position the felts while the fans are running.

Ball bearings

The ball bearings used are low-maintenance and are designed for a service life of up to 100,000 hours. They can gene-rally be used up to +120 °C. Under normal conditions, they do not require maintenance.

cleaning

The rotors can be cleaned with compressed air. In doing so, the air jet must strike the thermal mass at a 90 degree angle. Filters must be used to reduce contamination from the start.

6.4.3 recuperative energy recovery: circulating coil system

Fig.: Run-around coil system




attention!the heat exchanger must receive regular maintenance.

� Buyer must provide piping.

� Circulation pump must be sized in accordance with the technical data sheet.

� Heat exchangers must be connected in accordance with the counterflow principle.

� Antifreeze concentration must correspond to the guidelines in the technical data sheet.

� Always connect heat exchanger in counterflow.

� We recommend the use of Antifrogen N (mixed at 25 – 35 %).

� After the pressure test, the entire system must be thoroughly tested.

� It should be flushed until no more residue particles or scale wash out.

� When high-performance circuit heat recovery systems are used, always observe the assembly and operation guide, which is delivered separately!

6.5 Filter

6.5.1 Bag filter

Maintenance:

� Check all filter classes at least every 3 months for contamination and damage and replace as needed.

� Replace 1st filter stage at least every 12 months.

� Replace 2nd filter stage at least every 24 months.

Bag filters can optionally be replace on the dust air side or clean air side.

Up to filter class G4 and up to a housing width of 1,300 mm, the filter frame can be pulled out of housing laterally.

The filters are supplied packaged in a carton.

Optional for unit heights up to 1836 mm and filter classes up to F9 is a filter quick change device available.

Replacement of filter bags:

� Loosen clamping device simply by pulling it out by means of the loose removal lever provided.

� Pull filter bags out of the housing individually.

� Clean filter seals, check and replace damaged seals as needed.

� Insert new filter bags.

� Close clamping device by put in.

attention!In general, the filter bags should be replaced when the permissible final pressure difference indicated on the name plate is reached.


6.5.2 Activated carbon filter

The activated carbon must be replaced after reaching saturation. Maintenance and assembly are generally carried out on the clean air side.

Generally, the activated carbon cartridges are delivered packed in cardboard, inside the indicated components.

Changing the filter cartridge:

1. Loosen bayonet fastener on base plate (optional accessories).

2. Fixing the new filter cartridges to the base plate by using the bayonette fastener.

3. Check filter insert for tightness.

6.5.3 Grease trap filter

The grease trap filter must be cleaned with hot water (> 80 °C) or steam when it has become contaminated by grease or dust or has reached the recommended final pressure difference (name plate). Maintenance and assembly are generally carried out on the dust air side.

Cleaning of filter elements::

1. Unit sizes up to 16 x 16:

� Pull filter element out of the unit along with the housing frame including drain pans.

� Loosen clamping bracket on filter frame and clean filter element including drain pans.

2. Unit sizes of 20 x 16 or greater:

� Loosen clamping bracket on filter frame.

� Remove filter element and clean.

� Clean drain pan

6.5.4 Particulate air filter (HEPA-filters)

The particulate air filter must be replaced after they recommended final pressure difference has been reached (name plate). Maintenance and assembly are generally carried out on the dust air side. Generally, the particulate air filter ele-ment is delivered packed in cardboard, inside the indicated components.

Replacement of filter elements:

1. Loosen screws on filter frame.

2. Replace filter element.

3. Insert new filter element and fasten the screws.

attention!AL-KO THERM assumes no warranty for damages resulting from inappropriate handling of the HEPA-filters during assembly and disassembly!




6.6 louvre dampers

Maintenance:

� Check louvre dampers for contamination, damage and corrosion.

� Check mechanical function of louvre dampers.

� Lubricate bearings.

� Clean louvre dampers regularly.

� Check final position of damper adjusting motors and readjust as needed.

6.7 sound absorbers

The sound absorber must regularly be checked for dirt and damage.

recommendation:

After lengthy operating intervals, clean sound attenuator slats with a vacuum cleaner.

6.8 droplet eliminator

Fig.: Droplet eliminator

The droplet eliminator is extendable from the housing (for maintenance and cleaning purposes).

Maintenance:

� Check droplet eliminator for contamination, damage and corrosion.

� Clean droplet eliminator and condensate drain pan regularly with compressed air, water, steam, or grease-dissolving cleansers.

� Check drain and trap.

if buyer installs pipework, care must be taken that the droplet eliminator can still be removed.


6.9 Air humidifier

6.9.1 Spray humidifier (air washer)

attention! � If a spray humidifier (air washer) is installed, a siphon must be installed by the customer. (cf. Fig.: Siphon dimensioning)

recommendation:AL-KO THERM recommends installing an electric dry run prevention mechanism for the water circulation pump. Operate spray humidifiers only with demineralised water in order to prevent corrosion damage. Place the spray humidifier as the last component in the air handling unit, directly against the inlet of the ductwork system.

assembly and commissioning:

� Check spray humidifier for completeness and any transport damage that could have occurred.

� Remove any serious contamination from humidifier pan and check for proper seating of the pump intake screen.

� Check spray direction and proper seating of vaporising nozzles.

� Fill humidifier pan to approx. 10 mm under the upper edge of the inner siphon or overflow fitting and then place the floater of the floater valve at this water level.

� Check function of the drain and overflow and clean dirt trap and siphon.

� Check rotation direction of water circulating pump.

� Check screw and flange connections of pump pressure line for leaks.

� In a manual blow-down procedure, the blow-down rate must be adapted to the water quality used in accordance with manufacturer’s instructions.

� Check installation of water filter.

� Check droplet eliminator for function.

� The required water quality must be absolutely observed and regularly corrected.

� When reducing air volume flow (e.g. when using frequency converters), the pump output must also be reduced.

attention!Rotation direction of water circulating pump can only be checked when the water pan is filled. The water level in the humidifier pan must be high enough so as to preclude dry running of the water circulating pump.

The blow-down rate is reduced by 50 % when fully desalinated water is used. In droplet eliminators made of plastic profiles, in exceptional circumstances, a less amount of water can go through the plastic profils because the surface is not yet weathered due to the manufacturing method. Weathering sets in after approx. 24 operating hours.

Maintenance:

� Check spray humidifier for contamination, damage and corrosion.

� The spray humidifier unit including the nozzles and nozzle supports should be cleaned at least once a year.


� Check float valve.

� Check blow-down device and clean as needed.

� Check and clean droplet eliminator/rectifier.

attention!Follow maintenance, commissioning, and assembly instructions of the humidifier manufacturer! Do not clean spray humidifier with foaming cleansers.




6.9.2 Contact humidifier

6.9.2.1 Fresh-water system

attention! � In front of the supply magnet valve, the customer has to install a pressure reducer, a water filter (150 µm) and a shutoff valve. Constant water pressure between 1.5 and 6.0 bar.

� Upon connection to the drinking-water mains (in accordance with EN 1717, "Technical rules for drinking water installation“), a pipe separator (Installation Type 2) is required.

� The drain pan is to be connected to the waste water mains by the customer, via a siphon. In accordance with VDI 6022, after the siphon, an open drain is required to the customer's waste water line.

� The water quality for the contact humidifier is to be warranted in accordance with the manufacturer's speci-fications.


� Check the assembly of the contact humidifier. Are all water-distribution hoods connected and latched with the snap-shut safety latches?

� Check the installation of the contact humidifier and assembly accessories.

� Check the water and waste water installation.

� Check of the electrical connections.

� Fill the siphon with water.

� The water drain must be clean and free of any foreign objects. Primarily metal chips can lead to corrosion and damage.

� Set the water pressure on the pressure reducer.

� Open the shutoff valve and the magnetic valves, and check all connections for leakage.

� On the equalisation valves, adjust the water flow rates (l/min) for the individual sections.

Maintenance:

� Check the humidifier for its function as well as for damage and dirt.

� Check the water flow quantities.

� Only those products verified by the humidifier manufacturer are permitted for disinfection, cleaning and water treatment!

� The specified water quality must absolutely be maintained.

� The operator must document the preventive maintenance work in written report.

attention!Observe the project-based assembly and operation guide issued by the respective humidifier manufacturer!

6.9.2.2 circulation water system

attention! � In front of the supply magnet valve, the customer has to install a pressure reducer, a water filter (150 µm) and a shutoff valve. Water pressure between 1.5 and 5.0 bar.

� Upon connection to the drinking-water mains – in accordance with EN 1717, "Technical Rules for Drinking Water Installation“ – a pipe separator (Installation Type 2) is required.

� The drain pan is to be connected to the waste water mains by the customer, via a siphon. in accordance with VDI 6022, after the siphon, an open drain is required in the customer's waste water line.

� The water quality for the contact humidifier is to be warranted in accordance with the manufacturer's specifications.



� Check the assembly of the contact humidifier. Are all water distributor hoods linked and latched with the snap-shut safety latches?

� Check the installation of the contact humidifier and the assembly accessories.


� Check of the electrical connections.



� Verify the rotation direction of the circulating pump.

� Open the shutoff valve and the magnetic valves, and check to see that all connections are free of leaks.

� Set the water intake amount on the pressure reducer.

� Adjust the water flow amounts (l/min) to the individual sections on the equalisation valves.

� Set the amount of desalted.

� Perform the rinsing run for cleaning.

Maintenance:

� Check the humidifier for its function as well as for damage and dirt.

� Check the water flow quantities.

� Check the amount of desalted.

� Only those products verified by the humidifier manufacturer are permitted for disinfection, cleaning and water treatment!

� The specified water quality must absolutely be maintained.

� The operator must document the preventive maintenance work in a written report.

attention!Observe the project-based assembly and operation guide issued by the respective humidifier manufacturer!

6.9.3 High-pressure humidifier

attention! � Required maintenance interval: 2x annually � Prior to the start of maintenance work, the installation is to shut off. � Change the oil in the pump after the first 50 hours of operation. After that, every 500 hours of operation. � Gearbox oil in accordance with the manufacturer's specifications


� Check the assembly of the high-pressure humidifier.

� Check the insertion of the high-pressure humidifier and the assembly accessories.


� Check the electrical connections.



� Check the set-up of the pump unit and the connector for the high pressure connections. Check the pressure and set it as necessary.




Maintenance:

� Cleaning the interior with water. In the event of heavier contamination, an alkaline cleaning agent can be used.

� For rinsing, at least water of drinking- water quality should be used. Ensure sufficient rinsing with fresh water.

� Check of the high-pressure nozzles Visual check of the spray form.

� Clean or replace the nozzles as necessary. Rinsing with water.

� Rinsing the high pressure hose, the distributor and the nozzle stems with the beforementioned cleaning agent. Re-rinse sufficiently with fresh water (Permeat) and clean with compressed air.

� Rinsing the supply water filter with a sufficient amount of fresh water (Permeat). Replace the filter insert as necessary.

� Check the oil level and/or change the oil in the high-pressure pump.

� Check of transmission. Tooth belts, tooth discs.

� Functional check of safety equipment (magnetic valves, manometers, pressure switches).

� Check the controller's set values. Correct as necessary

6.9.4 Steam humidifier

attention!The water quality for the steam humidifier is to be warranted in accordance with the manufacturer's specifica-tions!

Maintenance:

� Check steam humidifier for contamination, damage and corrosion.

� Clean steam humidifier and dirt trap regularly.

� Check steam line and condensate line for leaks.

� Test function of steam distributor.

� Test function of solenoid valves.

� Test measuring units and control units.

Additional maintenance work in steam humidifiers with integrated steam generators:

� Test function of water supply and water level.

� Measure power consumption.

� Check steam cylinder for deposits and replace as needed.

Additional maintenance work in steam humidifiers without integrated steam generators:

� Test function of control valve.

� Readjust stuffing box of control valve.

note:The AL-KO THERM company guarantees neither steam humidifiers installed by the buyer nor housing openings produced by the buyer nor improper handling of bottom pan nor improperly connected outlet fittings. This also refers to improperly operated humidifiers or incorrect humidifier capacities.


6.10 drive elements

6.10.1 electric motor

Electric motors with a nominal output of 3 kW or greater must be operated with star-delta starting. Increased switching frequencies of motors ("cycling") leads to rapid functional failures. The electric motors are normally equipped with per-manently lubricated motor bearings.

In electric motors with re-greasable motor bearings, these components must be regularly inspected and re-greased as necessary. The maintenance intervals and the necessary amount of grease for re-greasing are specified on the motor.

commissioning:

1. Wire motor according to the accompanying wiring diagrams.

2. Measure the current acceptance in all three phases, and compare these values to those indicated on the motor type plate.

attention!Wiring work must be performed according to DIN VDE 0100, DIN EN 60204-1 (DIN VDE 0113) and DIN EN 50156-1 (DIN VDE 0116). Motor wiring must be designed so as to enable the motor to be moved for tensioning the V-belts. Due to the risk of overload, the motor's current acceptance may only be measured when the operation doors and panels are closed. The current consumption may not exceed the given value for nominal current.

attention!It is not permissible to operate multistep motors by means of a frequency converter.

attention!Motors with thermal contact and positive temperature coefficient resistors must be protected by a motor pro-tection device with a reclosing interlock. All other motors must be protected by an overload protection switch.

attention!In controllable motors, the maximum power consumption of the transformer and the motor must not be excee-ded. The motor protection device must be dimensioned accordingly for controllable motors.

Maintenance:

� Check motor for contamination, damage and corrosion.

� Check motor attachment and retighten all fastening screws/belts.

� Check bearings and regrease as needed.

� Clean motor and motor base regularly.

� Test function of protection devices.




6.10.2 connection of three-phase motors

Warning:

Do not connect top speed directly. In motors with positive temperature coefficient resistors or a thermal contact, the connection diagram in the motor terminal box must be strictly adhered to.

Wirings for one speed:

Wiring of winding strands

Circuit at terminal strip

Δ circuit Y circuit

YΔ switch

The ends of the threewinding strands lead tothe YΔ switch

Wiring for two speeds in the ratio 1 : 2 (winding in dahlander circuit)

Design example for 1,500/3,000 RPM and 4-/2-pole or 750/1,500 RPM and 8-/4-pole

In motors with Dahlander wiring, the six winding ends 1U, 1V, 1W and 2U, 2V, 2W are connected to the six terminals of the terminal strip of a normal motor terminal box.

low rotation speed high rotation speed

protection control pole-changing switch

Winding design for a power stage according to a moment curve for ventilator drive units..


Wiring for two speeds (two separate windings)

Design example for 1,000/1,500 RPM and 6-/4-pole or 750/1,000 RPM and 8-/6-pole

low rotation speed high rotation speed


Winding design

Wiring for three speeds

(two separate windings, one of them in a Dahlander circuit, nine terminals are required in this case). Design for ventilator drive units 750/1,000/1,500 RPM and 8-/6-/4-pole; 750/1,500 RPM in Dahlander circuit


Winding design

750 RPM 1500 RPM1000 RPM

or




6.10.3 Wiring with frequency converter

Wiring example:

Frequency inverter with pressure transmitter, repair switch and PTC-Thermistor.

Warning: Auxiliary contacts must be used to disconnect the control circuit!

Auxiliary contacts

DanfossFC 100

BROWN

YELLOW

GREEN

Pressure transmitter PTH

Fig.: Frequency-inverter wiring (FC 100) with pressure transmitter

Warning: Auxiliary contacts must be used to disconnect the control circuit!

Auxiliary contacts

DanfossFC 102

Pressure transmitter PTH

BROWN

YELLOW

GREEN

Applies to frequency converter with

integrated maint. switch

Fig.: Frequency-inverter wiring (FC 102) with pressure transmitter


When operating with a frequency converter, the following must be taken into account:

1. The fan motor must be suitable for operation by a frequency converter.

2. The motor must be protected from overload and overheating, e.g. by a positive temperature coefficient resistor. A motor protection switch with a bimetallic release is unsuitable.

3. Shielded lines must be used for the wiring of the motor positive temperature coefficient resistors to the frequency converter.

4. The maximal permissible speed of the fan and the motor must not be exceeded under any circumstances.

5. Alternatively, please refer to the installation and operation instructions of the respective frequency converter manuf-acturer.

6. The installation is to be warranted according to the EMC guideline!

6.11 ex-protection

6.11.1 general commissioning in the "ex" zone

Before commissioning, a qualified person or an expert from the local technical survey organisation must check compliance with the Ex specifications of the entire system. The results of the test must be verified on record.

6.11.2 the supply air- and/or exhaust air unit is located in the ex-Zone

� Supply air unit and exhaust air unit must correspond to the corresponding zone and the necessary temperature class.

� The supplied ATEX unit version must conform to the required Ex-Zone.

6.11.3 control (equipment cabinet) not in ex-zone

� As an option the electrical control (equipment cabinet) of the ventilation units can be delivered for operation outside the Ex-zones; the equipment cabinet must them be mounted outside the Ex-zone or be suitable for the Ex-zone.

6.11.4 special installation and operational conditions for belt-driven, free-wheel fans in the ex-Zone

1. Fans for use in explosion hazard areas are designated as such on the name plate; they are delivered with an EC Con-formity Declaration and with the operating and maintenance instructions.

it is mandatory to follow operating and maintenance instructions.

2. The temperature of the air flow must not fall below –20 °C or exceed +40 °C. In case of doubt, the temperature on the fan pressure size should be monitored.

If the air flow temperature exceeds +40 °C on the pressure side, then the fan must be switched off.

3. The name plate indicates the maximal speed of the fan.

the maximal permissible speed must not be exceeded.

4. The fans must be installed according to the manufacturer‘s instructions.

the fans must only be installed with a horizontal shaft.

5. Foreign substances must be prevented from being sucked in by the fan or from falling into the fan.

6. Before commissioning, the fans must be checked for proper condition and possible transport damage. When there is noticeable damage or a rubbing noise, then the gap between the impeller and the inlet nozzle must be measured and corrected so as to agree with the accompanying table.

if there is a discrepancy, then the inlet cone must be adjusted or replaced and the fan should be tested for other damage. if there is noticeable transport damage, then the balance must be checked.

7. When changing the V-belt (belt-driven design), only an electrically conductive belt may be used.




6.11.5 gap and overlapping in rZr, vZr radial fans in the ex-Zone

ImpellerMeasuring

PointsO

G

Inle

t Rin

g

Gap

OverlapCover Plate

dTe

stin

g Di

amet

er

rZrvZr

gap g overlap o

Min. 1.0 % Min. 0.5 %

test diameterd

check visually

0200 2.0 1.0

0225 2.0 1.0

0250 2.0 1.0

0280 2.0 1.0

0315 2.5 1.5

0355 3.0 1.5

0400 3.0 1.5

0450 3.5 1.5

0500 4.0 2.0

0560 4.5 2.0

0630 5.0 2.5

0710 5.5 2.5

0800 6.0 3.0

0900 6.5 3.5

1000 7.5 4.0

1120 8.5 4.5

1250 9.5 5.0

1400 10.5 5.5

1600 12.5 6.0

normal design

The gap check is carried out at four points offset from one another by 90°, visually and manually by feeling with the fingertips.The impeller must not touch and the gap should be as close as possible to the same dimension all the way around.In case of doubt, a check can be executed in the same way as in the Ex-design (see below).

The overlap is visually checked and normally, a "zero" test is carried out – i.e. there must be an overlap that is "greater than 0".The overlap must be visually checked from several directions and by turning the impeller: no gap should be visible.In case of doubt, a test can be carried out with a sheet of paper – the paper should not be able to slide between the inlet nozzle and the cover plate.

ateX design

The gap check is carried out at four points offset from one another by 90° using a test gauge with the prescribed testing diameter.The test gauge is hooked into place and the impeller is turned by hand once for a single rotation.The overlap test is carried out in the same way as in the normal design.


6.11.6 gap and overlapping in rlM radial fans in the ex-Zone

Measuring Points Measuring Points

O

GInle

t Rin

g

Gap

OverlapCover Plate

dTe

stin

g Di

amet

er

rlMrated size

gap g overlap o

Min. 1.0 % Min. 0.5 %

nominal diameter test diameterd

check visually

2528280 2.0 2-4

2831315 2.0 2-4

3135355 2.0 2-4

3540400 2.0 2-5

4045450 2.0 2-5

4550500 2.0 2-6

5056560 3.0 2-6

5663630 3.0 2-7

6371710 3.0 2-7

7180800 4.0 2-8

8090900 4.0 2-9

90101000 4.0 2-10

10111120 4.0 2-11

11121250 5.0 2-13

12141400 8.0 2-14

normal design

The gap check is carried out at four points offset from one another by 90°, visually and manually by feeling with the fingertips.The impeller must not touch and the gap should be as close as possible to the same dimension all the way around.In case of doubt, a check can be executed in the same way as in the Ex-design (see below).

The overlap is visually checked and normally, a "zero" test is carried out – i.e. there must be an overlap that is "greater than 0".The overlap must be visually checked from several directions and by turning the impeller: no gap should be visible.In case of doubt, a test can be carried out with a sheet of paper – the paper should not be able to slide between the inlet nozzle and the cover plate.




ateX design

The gap check is carried out at four points offset from one another by 90° using a test gauge with the prescribed testing diameter.The test gauge is hooked into place and the impeller is turned by hand once for a single rotation.The overlap test is carried out in the same way as in the normal design.

6.11.7 additional guidelines for the ex-Zone

� Before commissioning, a qualified person or an expert from the local technical survey organisation must check com-pliance with the Ex specifications of the entire system, especially the overload protection.

� When the buyer carries out wiring work, the requirements for the installation of electrical systems in explosion hazard areas according to DIN VDE 0165 and EEx-i-circuits (DIN EN 60079-14) must be respected.

� Compliance with Ex-protection measures for the ventilation units, which depend on "customer" control, must be tested by qualified personnel (expert/specialist) and must be tested before commissioning of the ventilation units.

� All externally mounted components must be taken into account in the potential comparison.

� When replacing parts, replacement parts from AL-KO must be used in accordance with the parts list.

� Add-ons to the unit that have not been supplied by AL-KO do not constitute part of the AL-KO-approved ATEX con-formity. The AL-KO ATEX conformity does not include components added by the buyer, e.g. actuating drives or sensors!

� All pipe insulation installed by the buyer must be either electrostatically conductive or electrostatically nonchargeable.

� In the course of the disassembly and/or assembly of unit components, the respective grounding points must be restored and checked.

� AL-KO supplies only one safety switch or maintenance switch for the fan drive unit.

6.11.8 Specific details for the operation of equipment in Ex-Zones 21 and 22

The built-in air filter cells fulfil a safety function. It is permissible for them to be operated up to the following final pres-sure loss levels:

Coarse particle filter media G1-G4 150 PaFine particle filter media F5-F7 200 Pa F8-F9 300 Pa

� The filter elements are to be monitored with regard to the above-mentioned final pressure levels and checked monthly for damage. Insofar as filter monitoring is performed via a standard pressure sensor, this components is to be integrated via an EEx-i currentcircuit.

� Only original components are permissible for use as replacement parts.

6.12 refrigeration unit and heat pump

The requirements in the separate delivered operation manual for chillers and heat pumps must be observed!


7. Maintenance details according to vdi 6022 and vdMa 24186

7.1 general

Long-term compliance with hygienic requirements and the execution of the necessary operational and maintenance mea-sures in air handling systems requires an appropriate qualification of the personnel. Demanding operational procedures in the context of maintenance and inspections as well as repairs should be carried out by trained, qualified personnel. Special training programs are offered for these procedures, for "simple hygiene procedures" (also known as category B), and "demanding hygiene procedures" (also known as category A). Only qualified personal that have successfully finished these training programs are authorised to carry out hygiene procedures.

attention!Clean inspection glass using only lukewarm water, possibly with a mild scent-free soap solution.

The tasks that comprise commissioning procedures are described in detail in the following table:

grouping of measures (according to vdMa)

InspectionAims of the measures (acc. to DIN 31 051)

MaintenanceAims of the measures (acc. to DIN 31 051)

RepairAims of the measures (acc. to DIN 31 051)

Determination andassessment of current state

Preservation of desired state Re-establishing desired state

Individual measures Individual measures Individual measures

Testing, measurement, evaluation Testing, readjusting,replacement, replenishing,

lubrication, preservation, cleaning

Repair, replacement

Carried out by Carried out by Carried out by

Technician, engineer, foreman Personnel familiar with the unit(for limited use),

specialised assemblers, technicians

Specialized assembler, technician

Required training for hygieneaccording to VDI 6022 page 2



Category A Category B Category C

7.2 Initial and repeated inspection by category A-trained qualified personnel, in accordance with vdi 6022 page 2

Inspections require a particular professional training or technician qualification in the field of building services enginee-ring and training in category A. In order to comply with these requirements, regular hygiene inspections must be carried out.

These must be carried out:

� every 2 years for air handling systems with humidifiers

� every 3 years for air handling systems without humidifiers.

Consulting qualified personnel is recommended.

"Maintenance details according to VDI 6022 and VDMA 24186"



The hygiene inspections include at least the following actions:

� Walkthrough inspection of the air handling control room, including all components and the rooms which are supplied by them.

� When hygiene deficiencies are discovered: Measurement of physical air-conditioning parameters (temperature, humidity, air speed) at representative points in the air handling system.

� Determination of the total germ count and the concentration of Legionnaire‘s bacteria in the circulation water of humidifier systems.

� In the event of visually perceptible hygiene deficiencies, their causes must be determined and eliminated. If neces-sary additional microbiological tests must be carried out in order to make the determination, e.g. colony count in the supply air, semiquantitative surface tests, or differentiation based on germ types.

A documented record of the results of the hygiene inspection must be made of the inspected air handling system and a copy of the written report on the inspection results must be provided to the operator, including a list of the steps required to eliminate the problem. The deadline for a required follow-up inspection should be set as a function of the urgency of the steps to be carried out.

Critical findings result from the following cases:

� Repeated exceeding of total germ counts in the humidifier water (standard value 1,000 CFU/ml).

� Repeated mould fungus contamination of the humidifier water

� Legionnaire‘s infection in humidifier water

� Occurrence of higher germ counts after air handling systems than before

� Visible mould fungus or other microbiological films

In the event of a critical finding, a hygiene specialist or other qualified personnel must be consulted and the company doctor must be notified.

7.3 hygiene inspections carried out as part of maintenance by category B-trained maintenance personnel in accordance with vdi 6022 page 2

The aim of the hygiene checks to be carried out regularly by the maintenance personnel is to use frequent visual inspections and random sample-based microbiological self-testing to provide early detection of hygiene deficiencies in air handling systems and to correct them.

The regular hygiene inspections include, among other things, the following steps:

� Visual inspection for hygienic deficiencies of the involved air handling region, e.g. germ growth or contamination, rust formation, lime scales, and damage.

� Testing of the total colony quantity in the circulation water of air humidifier systems.

In Table 2 on page 2, VDI 6022 declares the type and extent of inspection procedures to be carried out, the required steps for correcting hygiene deficiencies found and time intervals at which the respective hygiene inspections are to be carried out.


7.4 hygiene requirements and maintenance, servicing of air conditioning equipment according to vdi 6022 and vdMa 24186

task

unit components

actions 1month

3 months

6months

12months

24months

Inspection and recommended maintenance intervals

1. hygiene inspectionMust be carried out by trained, qualified personnel in accordance with VDI 6022 page 2

2. outside air and exhaust air openings2.1 Check for contamination, damage and

corrosionComplete cleaning and repair X

3. unit housing3.1 Check for contamination, damage and

corrosionClean and repair X

3.2 Check for water formation (condensa-te, leaks)

Clean and determination of cause X

3.3 Check function of drains Clean as needed X3.4 Check flexible connections for leaks X4. Air filters4.1.1 Check for impermissible contamina-

tion, damage (leaks) and odoursAir filters must have a collection efficiency appropriate to the filter class for the entire length of their use. The filter must be replaced in the event of conspicuous contamination or leaks. Replace the affected air filter if the filter stage was last replaced less than six months ago, otherwise replace the entire filter stage.

X

4.1.2 Check pressure difference Replace the filter stage when the maximal pressure differential is exceeded.

X

4.1.3 Checking of most recent filter change with non-regeneratable air filters, otherwise thorough cleaning

X

1. Filter stage X2. Filter stage X

4.1.4 Inspection of hygiene state X5. Air humidifier

It is necessary to assure that water cannot be deposited after the humidifier unit at any point during operation.

5.1 vaporising and recirculating spray humidifiers

The supplied water must at least meet drinking water standards and must not exceed a total hardness of 7° dH.

5.1.1 Check for contamination, damage and corrosion

Clean and repair X

5.1.2 Germ count measurement of humidi-fier water (dip slides)

With a colony count> 1,000 CFU/ml: Wash with cleanser, rinse, and dry out, disinfect if needed.

14 - day

5.1.3 Check vaporiser nozzles for deposits Clean nozzles, replace if needed X5.1.4 Check state and function of dirt trap Clean and repair X




task

unit components

Measures 1month

3 months

6months

12months

24months


5.1.5 Check for flake formation in bottom region of air humidifier pan

Clean pan X

5.1.6 Check recirculating pump for dirt and film build-up in the intake line

Clean pump circuit X

5.1.7 Check function of blow-down device Readjust blow-down device X5.1.8 Check function of conductivity cell Repair X5.1.9 Check function of disinfection system Repair X5.1.10 Check function of water supply and

distributionX

5.1.11 Check water level X5.1.12 Readjust water level in regulating unit X5.1.13 Check function of drain and overflow X5.2 Steam humidifiers with and without

integrated steam generatorsMust be operated so that no conden-sate can enter the air duct system. The vapour cannot contain any harmful substances.


Clean and repair, if necessary disinfect

X

5.2.2 Check for condensate precipitation in humidifier chamber

Determine causes and correct, clean steam humidifier

X (during operation)

5.2.3 Wash with cleanser, rinse, and dry humidifier chamber, disinfect if needed

X

5.2.4 Check state and function of dirt trap Clean and repair X5.2.5 Check steam distributing pipe for

depositsClean X

5.2.6 Check condensate drain Cleaning and repair X5.2.7 Check function of control valve Repair X5.2.8 Inspect hygiene state Wall surface, trays X5.2.9 Check steam cylinder for deposits Restore as needed or replace X5.2.10 Check steam lines and condensate

line for leaks and damageX

droplet eliminator5.2.11 Check for contamination, damage and

film build-upFunction maintenance cleaning, all surfaces including trays, may require disassembly of droplet eliminator

X

5.2.12 Check droplet eliminator for film build-up

Function maintenance cleaning when there is visible encrustation, may require disassembly of droplet eliminator

X

5.2.13 Check function of drain and odour trap

X

5.3 ultrasonic, spray, and hybrid humidifiers

5.3.1 Check for contamination, incrustation, damage, and corrosion

Clean and repair, if necessary disinfect

X

5.3.2 Clean water receptacle X5.3.3 Check function of electrical system X


tasks

unit components

actions 1month

3 months

6months

12months

24months


5.3.4 Check function of energy converters (only in ultrasonic humidifiers) and replace as needed

X

5.3.5 Check function of water supply and distribution

X

5.3.6 Check pump (only in spray and hybrid humidifiers)

X

5.3.7 Inspection of hygiene state Wall surfaces and trays Xdroplet eliminator

5.3.8 Check for contamination, damage and film build-up

Function maintenance cleaning, all surfaces including trays, may require disassembly of droplet eliminator

X


Function maintenance cleaning when there is visible encrustation

X


X

6. heat exchanger, generalIf the cleaning in the installed position is insufficient, then the heat exchanger must be removed and suitably cleaned


Clean and repair X

6.1.2 Check evaporative cooling unit, con-densate pan and droplet eliminator for contamination, corrosion and function

Repair X

6.1.3 Check function of siphon Repair X6.1.4 Inspection of hygiene state X6.2 air heater6.2.1 Check for contamination, damage and

corrosion on the clean air sideX

6.2.2 Clean function maintenance (clean air side)

X

6.2.3 Check function of water supply and return

X

6.2.4 Ventilate X6.3 electric air heater6.3.1 Check for scale encrustation and

corrosionX

6.3.2 Function maintenance cleaning (clean air side)

X

6.3.3 Check function X6.3.4 Check function of control unit and

safety deviceX

6.4 Air cooling unit (air/fluid) dehumidifier vaporiser (air/coolant)

The siphon with the reverse flow prevention mechanism must be sized and positioned in accordance with the pressure conditions so as to permit unhindered flow of condensa-te water


Clean and repair X

6.4.2 Check evaporative cooling unit, con-densate pan and droplet eliminator for contamination, corrosion and functionCheck siphon for function

Repair X

6.4.3 Clean evaporative cooling unit, droplet eliminator, and pans

X




tasks

unit components

actions 1month

3 months

6months

12months

24months


6.4.4 Check function of water supply and return

X

6.4.5 Ventilate (only with fluid) X6.4.6 Check for icing (only with vaporiser) only possible

during operationX

6.4.7 Check hygiene state Xdroplet eliminator

6.4.8 Check for contamination, damage and film build-up

Function maintenance cleaning, all surfaces including trays, may require disassembly of droplet eliminator

X


Function maintenance cleaning when there is visible encrustation

X


X

7. heat recovery, generalHeat exchanger and its accessories must be periodically checked on the clean air side for contamination, corrosion and damage


Clean and repair X

7.1.2 Check for leaks between exhaust and outside air

Repair X

7.1.3 Check condensate pan and droplet eli-minator for contamination, corrosion and function

Repair X

7.1.4 Check function of siphon Repair X7.1.5 Clean evaporative cooling unit, droplet

eliminator and condensate panX

7.1.6 Inspection of hygiene state X7.2 rotary heat exchanger (also see item 4.3.2)7.2.1 Check for contamination and

corrosion on clean air sideClean as needed X

7.2.2 Function maintenance cleaning The rotors can be cleaned with compressed air. In doing so, the air jet must strike the thermal mass at a 90° angle.

X

7.3.3 Check rotor for imbalance X7.3.4 Check bearings for noise The ball bearings used are low-

maintenance and are designed for a service life of up to 100,000 hours. They can generally be used at tempe-ratures up to 120 °C

X

7.3.5 Grease bearings with regreasing device

Only in bearings with a relubrication device

X

7.3.6 Check function of sealing element The brush seals on the thermal mass are positioned at the factory

X

7.3.7 Seals With normal-temperature rotors, sealing felts of the quality NF-PES-LE 0.32 grey are used. The felts must be slid as close as possible to the thermal mass, but prevented from producing direct abrasion.

X

7.3.8 Check hygiene state X7.3.9 Check drive elements X7.4 Cross flow heat exchanger7.4.1 Check for contamination, damage and

corrosion on clean air sideClean as needed X


tasks

unit components

actions 1month

3 months

6months

12months

24months


7.4.2 Function maintenance cleaning (clean air side)

X

7.4.3 Check function of cleaning unit If present X7.4.4 Check function of drain and odour

trapX

7.4.5 Check hygiene state X8. sound absorbers

Sound attenuators must be periodi-cally checked externally for contami-nation, damage and corrosion. If they are not visible, then they must be dismantled.

8.1 Check sound absorbers for contami-nation, damage and corrosion

Repair X

8.2 Check inner air-conducting surface for contamination and corrosion at two to three representative points

Determine causes, clean correspon-ding air duct sections

X

9. louvre dampers9.1 Check for contamination, damage and

corrosionClean as needed X

9.2 Check mechanical function X9.3 Actuating drive units Check function X10. Fire prevention dampers

if they are installed in the unit In addition, the inspection report must be noticed, also see VDMA 24186 part 7

10.1 Check locking device for contamination and function

Clean as needed X

10.2 Check tripping mechanism for conta-mination and function

X

10.3 Check seals for contamination and damage

X

10.4 Actuating drive units Check function X11. Fans

The fan unit and drive units must be periodically checked for contaminati-on, damage and corrosion

11.1 Check for contamination, damage and corrosionCheck the impeller (particularly the weld seams) for the formation of any cracks.

Clean and repair X

11.2 Clean function maintenance of air-exposed parts of fan and drain

X

11.3 Vibration test every six months! X11.4 Check bearings for noise X11.5 Grease bearings with regreasing

deviceX

11.6 Check flexible connections for leaks

X

11.7 Check function of vibration damper X11.8 Drive elements See pos. 1211.9 Control equipment Check function of pressure/volume

flow controllerX




tasks

unit components

actions 1month

3 months

6months

12months

24months


12. drive elements12.1 electric motors12.1.1 Check attachment and externally

check for contamination, incrustation, damage and corrosion

Clean as needed X

12.1.2 Check rotation direction (initial start-up)

12.1.3 Retighten connecting terminals X12.1.4 Measure voltage Measurement data must be recorded

in the test certificateX

12.1.5 Measure power consumption Measurement data must be recorded in the test certificate

X

12.1.6 Measure phase symmetry Measurement data must be recorded in the test certificate

X

12.1.7 Check bearings for noise X12.1.8 Grease bearings with regreasing

deviceX

12.2 Belt drive12.2.1 Check for contamination, damage and

wearReplace as needed X

12.2.2 Clean function maintenance Capacity range must be defined and agreed upon

X

12.2.3 Check tension and alignment readjust as needed X12.2.4 Change belts X

8. emergency

In case of fire, the dampers must be closed and power to the unit must be disconnected by means of the master switch. Rooms should be closed in order to minimise the air supply. Alert the fire brigade.

Warning:

In order to protect from the possible release of toxic substances, the rooms must only be entered when wearing respi-rator masks.

9. help in the event of malfunctions

Warning!Diagnosis, troubleshooting and re-commissioning may only be performed by authorised persons. That applies particularly to work on electrical equipment within the control cabinet (e.g. testing work, replacement etc.)!

9.1 contact persons

Whenever you have questions concerning our products, please contact the constructor of your air conditioning installa-tion, one of our branch offices or our main office directly:

AL-KO THERM GMBH Tel.: (+49) 8225/ 39-0

Hauptstraße 248-250 Fax: (+49) 8225/ 39-2113

89343 Jettingen-Scheppach E-mail: [email protected]

Germany Web: www.al-ko.com


10. shutdown

10.1 decommissioning

Prior to starting work, disconnect the power supply to the installation (switch off all poles), and safeguard the unit from powering on without authorisation.

attention!Several parts of the installation are under pressure.

If the installation is to be decommissioned for an extended period, always observe the guidelines for the individual components.

In addition, always observe the information provided by component manufacturers (request these as necessary).

attention!In the winter, the risk of freezing exists for several components.

As necessary, take suitable activities (such as filling these parts with antifreezing medium).

Prior to the next start-up, observe the items in the chapter "Commissioning and Maintenance".

10.2 dismantling

Prior to starting work, disconnect the power supply to the installation (switch off all poles), and safeguard the unit from powering on without authorisation.

attention!Several parts of the installation are under pressure.

The disassembly may only be performed by trained specialist personnel.

The dismantling process must be performed according to the work/accident prevention regulations valid at the time such work is performed.

10.3 disposal

Do not dispose of any disused devices, batteries or accumulators in household rubbish!For disposal of the AHU, the operation materials and accessories should executed according the relevant local environmental and recycling regulations in your state/country and muncipality as valid at the time of disposal.

"Shutdown"

al-Ko therM gMBh l Head Quarter l Hauptstraße 248 - 250 l 89343 Jettingen-Scheppach l GermanyFon +49 8225 39-0 l Fax +49 8225 39-2113 l [email protected] l www.al-ko.com

© Copyright 2015AL-KO THERM GMBH l Jettingen-Scheppach l GermanyAll rights held by AL-KO THERM GMBH, also in the event of applications for industrial property protection. Neither this documentation nor extracts thereof may be copied or hand over to any third parties without the express permission of the company AL-KO THERM GMBH. Technical modifications without impairing function are reserved.

3062264/August 2015

operation and assembly instructions production …...general maintenance guidelines in the operation...

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