AL-KO easyair flat. Flat air handling unit

Transcription

1 GB Operating and Assembly ManuAL AL-KO easyair flat Flat air handling unit I 12/2013

2 AL-KO EASYAIR flat Contents 1. About this manual Legend Regulations and standards Legal information Safety guidelines Proper use Possible incorrect use Residual hazards Delivery Storage, transport Duties of operator Disposal of packaging Product description EC declaration of conformity / EC declaration of incorporation Product description Technical data Transport / preparation Transport Preparation Space requirement Ceiling construction Assembly Opening / removing the maintenance panel Assembling the modules Procedure Removing components Duct connection Siphon connection Electrical connection Cable list Installation / connection of remote control (optional) Installation / connection of temperature sensors for supply, outdoor and extract air Electrical air heater connection (optional ELE) Hot water heater connection (optional WWE) Cooler module connection (option KWK) Installation of bus cards (optional) Connection control (optional) Original operating instructions

3 " Contents" 6. Commissioning Basics Before starting the system Turning the system on and off After starting the system Addressing damper actuator motors Addressing valve actuator motors Set-up menus Control unit (optional remote control) Main display Turning the fans on and off Setting the temperature from the main display Menu levels Setting the system parameters User level "Settings" menu "Displays" menu "Time functions" menu Service level "Unoccupied mode" menu "Night ventilation" menu "Supply air limitation" menu "Compensation" menu "AUTO operation" menu "Sensor offset" menu "Operating hours counter" menu "Alarm recording" menu "Presence detection" menu "Miscellaneous" menu Maintenance Safety Consumables and replacement parts Fuses and terminals Maintenance schedule Checking components WWE / KWK Plate heat exchanger Dampers Drip separator

4 AL-KO EASYAIR flat Fans Replacing components Replacing filter bags Trouble shooting Contact General faults "AL" display fault "AL" fault table Shutdown Decommissioning Dismantling Disposal Annexe data point list EASYAIR flat (PF-01 PF-03; GF-01 GF-03) EASYAIR flat (PF-01 PF-03; GF-01 GF-03) with electric heater EASYAIR flat (EF-01 EF-03) EASYAIR flat (EF-01 EF-03) with electric heater Annexe data point list LON-Bus Mod-Bus BACnet Ethernet Sample commissioning protocol Original operating instructions

5 "About this manual" 1. About this manual Read this document thoroughly before installation and start-up. This is a prerequisite for safe work and fault-free use. Observe the safety instructions and warnings in this document and on the product. This document is an essential component of the described product and should be passed on to the buyer upon sale. 1.1 Legend 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 standards The following standards and regulations were applied during construction and are valid during installation, start-up, operation and maintenance: DIN EN ISO Safety of machinery General principles for design - Risk assessment and risk reduction DIN EN ISO Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs DIN EN Electromagnetic compatibility (EMC) - Part 6: Generic standards Immunity for residential, commercial and light-industrial environments Immunity for industrial environments Emission standard for residential, commercial and light-industrial environments Emission standard for industrial environments DIN EN Safety of machinery - Electrical equipment of machines - (DIN VDE 0113) Part 1: General requirements DIN EN Ventilation for buildings - Air handling units - Rating and performance for units, components and sections DIN EN 1886 Ventilation for buildings - Air handling units Mechanical performance DIN EN 349 Safety of machinery - Minimum gaps to avoid crushing of parts of the human body VDMA Fans Safety requirements VDMA Ventilation devices and systems; Air outlets, determination of the air flow with the pressure compensation method (null method) VDI 3801 Operating of air-conditioning systems VDI Air-conditioning - Central air-conditioning systems - Structural and technical principles VDI 6022 Ventilation and indoor-air quality Hygiene requirements for ventilation and airconditioning systems and units

6 AL-KO EASYAIR flat BGV A1 BGV D6 BGR 500 Chapter /42/EC 97/23/EC 2004/108/EC Principles of Prevention Crane Operation of load-acceptance equipment in hoisting-equipment operation Machinery Directive Pressure Equipment Directive Electromagnetic Compatibility Directive (EMC) 1.3 Legal information All given data applies only to the product description. A statement cannot be inferred from this information about a specific condition or suitability for a particular purpose. The information does not remove the responsibility of the user to employ his/her own judgments and checks. 2. Safety guidelines Observe these points in order to avoid injury, fire and other hazards caused by improper use and operation of this equipment: Attention! Assembly, electrical connection, supply connection, maintenance, commissioning, repairs etc. may only be performed by trained specialist personnel! Prior to all work on the EASYAIR flat ensure that the power supply is shut off (power off all poles) and safeguarded from unauthorized powering on. Only operate EASYAIR flat when it is completely installed. If the assembly is performed contrary to our regulations, and the defect/damage which has occurred is causally associated 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 manual for EASYAIR flat made by AL-KO THERM must absolutely be observed. The design and method of construction of the EASYAIR flat conforms to the norms indicated in the declaration of conformity or declaration of incorporation in order to minimize any potential hazard posed by the EASYAIR flat. 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 authorized persons the operation and assembly manual have read and understood in its entirety and observe these! 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 EASYAIR flat requires personal protective equipment (PPE)! 2.1 Proper use This equipment is to be exclusively used for the ventilation of rooms and buildings, the maintenance of necessary room climates, and the reduction of the amount of dust and other contaminants in the air. It may only be operated within the temperature range of - 25 C to + 40 C. Furthermore EASYAIR flat units are exclusively designed for horizontal ceiling installation. Other scope of applications must be agreed by the manufacturer. 6 Original operating instructions

7 "Safety guidelines" 2.2 Possible incorrect use AL-KO EASYAIR flat may only be operated within the scope of the technical data defined by AL-KO. Any other use deviating from that described under "2.1 Proper Use" is regarded as improper. The manufacturer is not liable for any damages resulting from improper 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. Use in explosive atmospheres 2.3 Residual hazards The system may pose hazards if not used by trained personnel and/or is used improperly and not for its intended use. Residual hazards are potential, non-obvious hazards, such as: Injury due to any failure to observe the safety guidelines, norms, guidelines or regulations, Injuries caused during inadequately coordinated work Endangerment from working on electrical systems, cables and connections 2.4 Delivery EASYAIR flat units are delivered in modules. Please consider "5.2 Assembling the modules". 2.5 Storage, transport Store the individual functional parts in their original packaging in a dry place and protected from the weather. Cover open pallets with tarps and protect the functional parts from contamination (i.e. from shavings, stones, wire, etc.). For transport in harsh conditions (i.e. on open vehicles, unusual shaking, and sea transport or in subtropical countries) additional packaging must be used to protect the product from these particular influences. Prevent constant and especially abrupt temperature changes during storage. It can be particularly harmful if humidity is able to condense. During transport, ensure sufficient visibility. (as necessary, possibly with a accompanying person etc.) No persons may be present in the transport area. The transport of the modules of the EASYAIR flat may only be performed by trained, qualified and briefed personnel under the aspect of "Safety". When using transport devices which require an operator's license, it must be ensured that the personnel hold such a valid license. Ensure the use of suitable hoisting equipment. During transport, observe the relevant regulations on work safety and environmental protection. In order to avoid damage during storage, the fan must be turned once a month. For storage times of over one year, check the fans for ease of movement before assembly (turn them by hand). Avoid warping the housing or any other damage The initiator is at fault for any damage resulting from improper packaging, storage and transport

8 AL-KO EASYAIR flat 2.6 Duties of operator Operators of AL-KO THERM GMBH products are responsible for regularly training their personnel on the following topics: Compliance with and use of the operating- and assembly manual and the legal regulations. Proper operation of the ventilation unit. If applicable, compliance with the plant security directives and the operation instructions. Emergency procedures. 2.7 Disposal of packaging Disposal of packaging must be performed according to the currently valid, local environmental and recycling regulations of your country and your municipality. 8 Original operating instructions

9 "Product description" 3 Product description 3.1 EC declaration of conformity / EC declaration of incorporation

10 AL-KO EASYAIR flat 10 Original operating instructions

11 "Product description" 3.2 Product description Because of their low construction height, EASYAIR flat air handling units are intended for ceiling installation. The unit design consists of functional modules (filter, fan, silencer, heater, cooler, heat recovery). The devices can be ordered optionally as combined supply and exhaust air systems including heat recovery or simply as air supply and exhaust air systems. The units with heat recovery achieve a high degree of heat recovery. Thus the units make a considerable contribution to energy savings and a reduction of operation costs. All units can be ordered with the appropriate control devices. This ensures trouble-free unit operation. All field devices come ready assembled with the unit. The switch cabinet comes as a separate unit and can thus be installed wherever best suits the client. The wiring installation between the unit and switch cabinet must be supplied by the client. Optional extras allow the units to be extended. Optional components to extend use consist of: acoustically isolated unit connections, dampers, electrical or waterheated heater module, cooler module, silencer module, pressure sensors for pressure or constant volume regulation, air quality sensor, room temperature sensor, etc. When using the associated control system, filter replacements which become necessary are displayed by the pressuredifference filter monitoring device. All control functions are included in the control software and their parameters can be set. By means of pre-configured bus systems, the control system can easily be integrated into higher-level systems: the user can choose between Modbus, LON, BacNet/Ethernet. Our products are subject to constant quality control and comply with the applicable regulations. AUL Outdoor air (OA) ZUL Supply air (SA) ABL Return air (RA) FOL Exhaust air (EA) 1 Cross flow-plate heat exchanger-module 7 Cooling-module* 2 Fan-module supply air 8 Connecting piece* 3 Fan-module exhaust air 9 Damper* 4 Filter-module 10 Installation plates 5 Silencer-module* 11 Counter flow-plate heat exchanger-module 6 Heating-module* (Warmwater or E-Heater) * available as an option height width length (5) 2 mm per module connection distance for housing gasket note Fig. EASYAIR flat EF unit

12 AL-KO EASYAIR flat height width length (5) 2 mm per module connection distance for housing gasket note Fig. EASYAIR flat PF unit height width length (5) 2 mm per module connection distance for housing gasket note Fig. EASYAIR flat GF unit 12 Original operating instructions

13 "Product description" 3.3 Technical data Supply air / exhaust air unit EF Type Air volume (1) (m³/h)/ Sound power level (3) (db(a)) SFP (4) SA/RA Max. connection power (6) min nominal max W/m³s kva A V EF / / / ,81 3,5 1x230 EF / / / ,12 2,8 3x400 EF / / / ,28 3,2 3x400 Type Basic unit (mm) Duct connection Basic unit Length (5) Width Height Width Height Weight kg EF EF ,5 EF Options Type WWE KWK ELE SD kw (9) kg kw (8) kg kw (11) A kg kg EF 01 11,4 22,5 5,0 29,5 8,1 11, EF 02 20,5 26 8,9 34,5 14,6 21,1 35,5 55 EF 03 30, ,8 45,5 21,9 31,6 44,5 74 Supply and exhaust air unit PF with Cross flow-plate heat exchanger Type Air volume (1) (m³/h)/ Efficiency (2) / Sound power level (3) (db(a)) SFP (4) SA-/RA Max. connection power (6) min nominal max W/m³s kva A V PF / 55 / / 52 / / 52 / / 877 1,38 6,0 1x230 PF / 59 / / 57 / / 57 / / 814 1,84 4,6 3x400 PF / 58 / / 57 / / 57 / / 845 2,16 5,4 3x400 Type Basic unit (mm) A Duct connection (mm) Basic unit Length (5) Width Height mm Width Height Weight kg PF PF PF Options Type WWE KWK ELE SD kw (7) kg kw (8) kg kw (10) A kg kg PF 01 4,7 20 5,0 29,5 5,5 7, PF 02 8,4 22,5 8,9 34,5 9,5 13,7 31,5 55 PF 03 12, ,8 45,5 14,0 20,

14 AL-KO EASYAIR flat Supply and exhaust air unit PF with Counter flow-plate heat exchanger Type Air volume (1) (m³/h)/ Efficiency (2) / Sound power level (3) (db(a)) SFP (4) SA-/RA Max. connection power (6) min nominal max W/m³s kva A V GF / 84 / / 82 / / 80 / / 599 1,38 6,0 1x230 GF / 84 / / 80 / / 80 / / 862 1,84 4,6 3x400 GF / 84 / / 80 / / 80 / / 731 2,16 5,4 3x400 Type Basic unit (mm) A Duct connection (mm) Basic unit Length (5) Width Height mm Width Height Weight kg GF GF GF Options Type WWE KWK ELE SD kw (7) kg kw (8) kg kw (10) A kg kg GF 01 4,7 20 5,0 29,5 5,5 7, GF 02 8,4 22,5 8,9 34,5 9,5 13,7 31,5 55 GF 03 12, ,8 45,5 14,0 20, (1) External pressure loss supply air 200 Pa, exhaust air 200 Pa (2) Efficiency of heat recovery according to DIN EN 308 (without condensation) (3) Sound power level in the supply air duct (4) Specific Fan Power (SFP) in accordance with EnEV 2009 at nominal air volume and external duct pressure losses supply air 200 Pa, exhaust air 200 Pa, incl. filters (F7 / F5) (5) Basic unit length including 2 mm housing gasket per module connection (6) Without power for optional electric air heater (7) Heating capacity for temperature difference 14 K, medium 50 / 35 C (8) Cooling capacity for temperature difference 10 K, medium 6 / 12 C (9) Heating capacity for temperature difference 34 K, medium 50 / 35 C (10) Heating capacity for temperature difference 14 K, 400 V / 50 Hz (11) Heating capacity for temperature difference 22 K, 400 V / 50 Hz *Values based on nominal airflow 14 Original operating instructions

15 "Transport / preparation" 4. Transport / preparation 4.1 Transport The system s individual components may only be conveyed with the means of transport intended for this purpose. Only transport the system in modules; do not transport devices which have been connected together Do not leave or operate with suspended loads. Only approved hoisting equipment with sufficient load capacity may be used. The hoisting equipment must be in perfect condition. Lifting gear (slings, chains, etc) must be checked for load capacity and damage before use. Before lifting the devices, lock all maintenance doors! 4.2 Preparation Check the characteristics of the ceiling. Check the individual components for damage in transport. For the installation site, choose a place which allows easy access for servicing and maintenance. Care should be taken that the components and the connecting cable at the installation site can neither be damaged mechanically nor affected by oil or other aggressive substances. Check that security devices, contactors and circuit boards in the control cabinet are tightly secured. Push any loose assemblies in firmly. The fresh air intake is to be designed in line with the applicable standards and should be placed well away from exhaust air or extractor outlets (kitchens, laundries, etc.) If possible, the expelled air should be exhausted via a roof outlet well away from fresh air intakes, windows, balconies, etc. Attention! Components that become loose during transport can cause malfunctions or damage Space requirement Care should be taken to allow free access to the operating side (from underneath). The important thing is to allow sufficient distance so that the maintenance panel can be opened and the main components removed. The height of the siphon for condensate outflow tubes (optional) must be taken into account when suspending the unit from a ceiling; use a condensate pump if necessary Ceiling construction The devices may only be installed under horizontal, vibration-resistant ceilings. The design of the ceiling and the suspension construction must comply with the client's requirements on acoustics (sound insulation) and the correct drainage of the condensate. The ceiling construction must be able to bear the units structural load

16 AL-KO EASYAIR flat Example of ceiling construction: EF devices require a suspension option at the distance B1, while GF and PF devices require it at the distance B1 or B2 respectively. for max. M12 Fig.: Dimensions ceiling construction in mm EF 01 EF 02 EF 03 GF 01 GF 02 GF 03 PF 01 PF 02 PF 03 B B Original operating instructions

17 "Assembly" 5. Assembly AL-KO EASYAIR flat will be delivered in modules. The manufacturer s documents must be read before assembly or disassembly. The installation drawing supplied with the system must be adhered to during assembly of the modules, in particular the filter and fan modules! Assembly and disassembly are only to be undertaken by appropriately trained personnel with the requisite knowledge and experience. Work on electrical and mechanical equipment or components may only to be conducted by personnel with appropriate training and authorization. 5.1 Opening / removing the maintenance panel EASYAIR flat units are fitted with sufficiently large maintenance panels to make servicing and inspection easy. Operating and servicing is always performed from underneath. Specially designed hinges allow the maintenance panel to be opened but also completely unhooked and removed. Closed state Partially opened state (between 15 and 26 ) Operating lid can be detached Opened state Operating lid cannot be detached Fig.: Door positions To open the maintenance panel, open both locks completely using the key included and while supporting the panel with one hand, let the panel open slowly downwards. To unhook the maintenance panel, open both locks completely using the key included and open the panel about 3 cm. Then by hand, lift the panel slightly along the hinge side and unhook the hinges. Warning! Always keep the panel supported in your hand. When you unhook the panel, hold it firmly with both hands. Caution! The panel is not secured from falling in any way. 5.2 Assembling the modules Procedure Unpack the modules. Attach the click connector supplied with delivery in the intended aperture on the front side of the module; see Fig.: Click connector / door lock. The sealing strip provided must always be glued flush with the inside edge of the device and past the click-in connector onto the front part of the module, see Fig.: Attaching the sealing strip Care must be taken that the sealing strip is not attached under tension (particularly at the corners)!

18 AL-KO EASYAIR flat Fit the cover cap included on the interior of the housing. This way the inspection openings for the click connector are closed; see Fig.: click connector / door lock. Hook in the mounting straps at the top of the housing and attach them to the housing with the screws provided, see Fig.: Mounting straps Screw a Duo-Taptite M8X25 screw into the hole of the inner mounting bracket of the "left housing", see Figure: Connect modules The assembly of the GF and PF devices starts with the heat recovery module. Attach the modules to the ceilings in the appropriate assembling sequence (left housing before right housing!) using the mounting brackets and suitable mounting material (noise insulation to be provided by the customer). Take note of the device structures, see Fig.: Connect modules Once the modules have been installed on the ceilings, connect the modules with the click-in connectors by pressing them against each other. Care must be taken that the Duo-Tapite screw threads into the bracket of the "right housing". In order to reduce the weight of the individual modules, the components can be removed from the housings. After loosening the covers, using the special tool included, the click connectors can be opened at any time and removed from the housing; see Fig.: click connector / door lock. Establish potential equalisation of the modules by connecting them using a potential equalisation bolt; see Fig.: potential equalisation After that, fit cover; see Fig.: potential equalisation Connect the entire installation to the potential equalisation 1 1 Click connectors 2 Covering cap 3 Special tool 4 Door lock Fig.: Click connectors / door locks 18 Original operating instructions

19 "Assembly" Fig.: Installation links 1 Installation link 2 Fixing screws 3 Housing 1 Screw for potential equalization 2 Covering cap 1 2 Fig.: Potential equalization

20 AL-KO EASYAIR flat b a 1 Installation link 2 Sealing strip 3 Duo-Taptite M8X25 a PLT or GST Housing b Left Housing c Right Housing c 2 Fig.: Connecting modules 2 1 Sealing strip 2 Click connectors 1 Fig.: Sealing strip stick on Removing components Warning! The suspended parts have to be secured against falling down when they are extended. A second person may secure them as required. Falling down must be prevented by counter-action when the safeguards are removed. Generally speaking, the following components can be removed from inside the housings: Filter Open or unhook the operating panel; see "5.1 Opening / removing the operating panel". The filter can be removed from the housing by pulling at the frame of the filter bag. Silencer Open or unhook the operating panel; see "5.1 Opening / removing the operating panel". Turn the safety latches (red) by 90 to longitudinal orientation. Carefully remove the silencer from the housing. Fans Open or unhook the operating panel; see "5.1 Opening / removing the operating panel". Disconnect the electricity supply by loosening the snap coupling. Turn the safety plates (red) outwards. Carefully remove the fan from the housing. 20 Original operating instructions

21 "Assembly" Plate heat exchanger (Cross flow) Open or unhook the operating panel; see "5.1 Opening / removing the operating panel". Remove the safety screws from the air guidance panels, see Fig.: Safety screws Detach the cross link by removing the screws, see Fig.: Cross link plate heat exchanger Turn the safety plates (red) outwards. Carefully remove the plate heat exchanger from the housing Fig.: Safety screws Fig.: heat exchanger crosspiece 1 Safety screws 1 Fixing screws 2 Washer 2 Crosspiece 3 Plate heat exchanger (Cross flow) 4 Air guidance panel Plate heat exchanger (Counter flow) Open or unhook the operating panel; see "5.1 Opening / removing the operating panel". Support the door bar from the bottom Loosen the screws of the door bar, see Fig.: Door bar of the plate heat exchanger Carefully lower the door bar and modules of the plate heat exchanger (counter-current) out of the housing and remove separately. Warning! It is important that the door bar is lowered horizontally to prevent sliding of the blocks resting on it. 1 GF module 2 Door bar 3 Cover flap 4 Duo Taptite M5x Toothed disk 2 1 Fig.: Door bar for plate heat exchanger (counter-flow)

22 AL-KO EASYAIR flat Drip separator (cooler module) Open or unhook the operating panel; see "5.1 Opening / removing the operating panel". Carefully remove the drip separator from the housing by pushing it up and sidewards in the direction of the heat exchanger and then lowering it Duct connection For PF- and GF units the duct system channels the outdoor air into the air handling unit and into the building as supply air. The extract air is passed through the unit for heat recovery and channeled outside as exhaust air. For EF units the duct system channels the outdoor or room air (recirculation) to the ahu and into the building / room as supply air. Equipotential bonding between the device and the drain must be established with the grounding strip supplied. Duct connections (optional) Sound-isolated duct connections are available for all EASYAIR flat units, which use the entire available unit crosssection. These duct connections must be fixed with enclosed drilling screws to the casing. Connection of the ducts to the unit must be properly performed. Requirements for the duct system The ventilation system should be designed for slow air velocities and low pressure drop to boost efficiency, energy consumption and air output. Pulleys near the device should be avoided. All connections between ducts and air handling unit are to be executed accurately and securely. Condensation protection / thermal insulation For PF- and GF units the outside and exhaust air ducts must always be well insulated to prevent condensation. It is particularly important to carefully insulate all pipelines leading directly to the unit and to cold rooms/zones. For EF units that are used for cooling issues the supply air duct must be insualted. Generally speaking, all air ducts carrying cold air must be insulated Siphon connection EASYAIR flat heat recovery and cooler modules are provided with a condensate tray and a condensate pipe in the operating panel. This condensate pipe comes in the form of a snap-on coupling. This allows quick and easy connecting / disconnecting of the condensate drainage pipe to the device. It is possible to push-fit a 14 mm outside diameter drainage tube directly into this connector. As delivered, a short length of plastic 14 mm outside diameter drainage tube is inserted in the connector, so that it is possible to simply fit a commercial hose with 14 mm inside diameter onto this plastic hose using a hose clip. Condensate outflow pipes must be connected to the waste-water system using an s-bend (supplied by client). If this is not possible because of lack of space, a condensate pump (supplied by client) should be used. In order to prevent an intake or outtake of air from the closed drainage system, the height of each siphon must be designed for the negative or over pressure of the air handling unit. 22 Original operating instructions

23 "Assembly" Fig: Tray with siphon connection Height Over pressure Negative pressure H1 25 mm 105 mm H2 120 mm 65 mm H3 = H1 + H2 The installation height of the siphon must be kept in mind when installing the unit. 5.3 Electrical connection EASYAIR flat devices are delivered as standard without control devices and without field devices. As an option, the devices can be ordered with control and field devices ready installed. The switch cabinet is delivered as a separate unit and must be wired up by the client with the EASYAIR flat devices. This enables the switch cabinet to be installed in any easily accessible place as per the client's preferences. Warning! The electrical connection may only be performed by a licensed electrician in accordance with the regulations as well as the directives of the local power company. The connection is to be performed in exact accordance with the circuit diagram and assembly plan. If necessary, connect the switch cabinet to the field devices on the EASYAIR flat unit according to the wiring diagram which is included in the unit documentation (optionally with control system) Cable list No liability is assumed for the stated cable cross-sections. Type of installation and possible accumulations have not been taken into consideration! Unit type Cable PF-01; GF-01; EF-01 Supply line (230 VAC / 1 Ph), 3 x 1,5 mm 2 Unit type Cable PF-02; PF-03; GF-02; GF-03; EF-02; EF-03 Supply line (400 VAC / 3 Ph), 5 x 1,5 mm

24 AL-KO EASYAIR flat Cables from the switch board to the field devices: Field device Cable Actuator for dampers and bypass damper 3 x 0,75 mm 2 External control element 6-wire Telefone ribbon cable for RJ12 connector Temperature sensor 2 x 0,75 mm 2 Frost protection thermostat 2 x 0,75 mm 2 Valves (heating valve, cooling valve) 3 x 0,75 mm 2 Pumps (heating pump, cooling pump) 3 x 1,5 mm 2 Presence detector 2 x 0,75 mm 2 Electrical heater Cable from unit switch board to the electrical heater: Control 0-10 V DC 2 x 0,75 mm 2 Power supply (230 VAC / 1 PH) 3 x 1,5 mm 2 Unit Supply Capacity Current consumption Supply line PF VAC / 3 Ph 5,5 kw 7,9 A 4 x 1,5 mm 2 PF VAC / 3 Ph 9,5 kw 13,7 A 4 x 1,5 mm 2 PF VAC / 3 Ph 14,0 kw 20,2 A 4 x 2,5 mm 2 GF VAC / 3 Ph 5,5 kw 7,9 A 4 x 1,5 mm 2 GF VAC / 3 Ph 9,5 kw 13,7 A 4 x 1,5 mm 2 GF VAC / 3 Ph 14,0 kw 20,2 A 4 x 2,5 mm 2 EF VAC / 3 Ph 8,1 kw 11,7 A 4 x 2,5 mm 2 EF VAC / 3 Ph 14,6 kw 21,1 A 4 x 4 mm 2 EF VAC / 3 Ph 21,9 kw 31,6 A 4 x 4 mm 2 24 Original operating instructions

25 "Assembly" Installation / connection of remote control (optional) You can control all settings on your ventilation system using the central control unit on the switch board. If your system has the optional external control element, you can also control the settings from this control element that you can install away from the switch board. For connecting the remote control, use the supplied 6-wire ribbon cable (10 m) with a Western modular RJ12 plug. The maximum permissible cable length is 50 m. Connect the RJ12 plug with the J10 controller plug connection. 2 1 Fig.: Remote control connection 1 Control 2 Connection of remote control Installation / connection of temperature sensors for supply, outdoor and extract air Outdoor air temperature sensor In order to measure the exact outside temperature, the sensor must be placed in the weatherproof grid or outdoors. Temperature sensor extract air* In order to measure the exact extract air temperature, the extract air temperature sensor must be in the duct work in a way that a mixing temperature of all single zones can be detected. * An external room temperature sensor may be optionally installed inside the heated rooms. This replaces the factoryfitted sensor and is connected to the controller. Only a room or an extract air sensor may be connected! The connection of both sensors is not permitted

26 AL-KO EASYAIR flat Supply air temperature sensor In order to measure the exact supply air temperature, the supply air sensors must be mounted in the duct behind the air handling unit. Mounting directly onto the outlet of the supply air duct is ideal, taking into account any interference influences within the ductwork. Fig.: Temperature sensor location 1 Temperature sensor 3 Supply air* temperature sensor location 2 Extract air temperature sensor location 4 Outdoor air temperature sensor location * Mount the temperature sensor for supply air at least 3 m behind the unit! Electrical air heater connection (optional ELE) For heating up the supply air an optional electrical heater is available. Attention! Installation, electrical connection, maintenance and repair may only be conducted by trained personnel! The air heater is included in the controller for the room and supply air temperature and is continually regulated according to the temperature requirement. The air heater is equipped with an integrated safety-temperature limiter and airflow switch. Connect the air heater electrically according to the circuit diagram. Power consumption / cable list, see "5.3.1 cable list" The power supply must be realised on site. 26 Original operating instructions

27 "Assembly" 3 x 400V L1 1 L2 2 L3 PE X5 PE L1 L2 L3 Black V GND X5 L N PE X x 230V AC PE Red A1 A2 Black White Black 12 Black Orange White EFS Blue Black L1 L2 L3 PE 6 8 Fig.: Connection schematic for electric air heater 1 Ext. power supply 7 Power controller / pulser 2 Release control voltage AL-KO 8 Duct sensor (NTC) in the air heater 3 Miniature circuit breaker 9 Contactor 2 4 Contactor 1 10 Flow monitor (signaling contact) 5 Ext. control by AL-KO 11 Safety temperature limiter 6 Air heater 12 Flow monitor (power supply) Attention! A flow monitoring device and a fan overrun must be installed on-site for units without integrated control! Hot water heater connection (optional WWE) A pump hot water heater (PHW) may be used to heat the supply air. Supply and return lines are to be connected according to professional standards. Do not confuse the supply and return lines when connecting the pipes. The water intake is on the air outlet side (Fig.: counter-current principle). Warning! When connecting the heat exchanger with an appropriate tool (i.e. pipe wrench), hold it firmly in order to avoid damage. Attach cables and connections to the heat exchanger so that it is readily accessible for maintenance. Maximum operating pressure: 6 bar Maximum hot water flow temperature: 80 C Valves and actuators must be professionally installed. Actuators must be connected in the control cabinet and registered in the controller, see "6.5.2 Addressing Valve Actuator Motors" Carefully ventilate the heat exchanger

28 AL-KO EASYAIR flat Fig.: PHW air heater diagram 1 PHW heater 2 Frost protection 3 Valve 4 Valve actuator (bulk delivery) 5 Recirculation pump (on-site) Fig.: Counter-current principle 1 Air intake 2 Air outlet 3 Media intake 4 Media outlet The figure only shows the schematic hydraulic connection of the heater. The exact hydraulic connection must be done acc. to the requirements of the heating system. Access to the heat exchanger must be guaranteed on the duct side. Function The heater is included in the controller for the room and supply air temperature. Heat emission is metered through adjusting the appropriate control valve. Attention! For temperatures below freezing point, in order to prevent frost and corrosion the heat exchanger must either be emptied and exhausted with pressurized air or filled with commercial antifreeze with corrosion protection. Emptying can be performed via the discharge screw intended for this purpose on the underside of the collector Cooler module connection (option KWK) For an additional cooling of the supply air a chilled water cooling coil is available. A drip separator (DS) is mounted behind the cooler in order to prevent condensate carry-over into the duct. Supply and return lines from both heat exchangers are to be connected according to professional standards. Do not confuse the supply and return lines when connecting the pipes. The water intake is on the air outlet side (Fig.: counter-current principle). 28 Original operating instructions

29 "Assembly" Attention! When connecting the heat exchanger with an appropriate tool (i.e. pipe wrench), hold it firmly in order to avoid damage. Attach cables and connections to the heat exchanger so that it is readily accessible for maintenance. Valves and actuators must be professionally installed. Actuators must be connected in the control cabinet and registered in the controller, see "6.4.2 Addressing Valve Actuator Motors" Carefully ventilate the heat exchanger Fig.: PCW air cooler diagram 1 Cooler PCW 2 Valve 3 Valve actuator (bulk delivery) 4 Recirculation pump (on-site) Fig.: Counter current principle 1 Air intake 2 Air outlet 3 Media intake 4 Media outlet The figure only shows the schematic hydraulic connection of the cooler. The exact hydraulic connection must be done acc. to the requirements of the heating system. Access to the heat exchanger and drip separator must be ensured on the duct side. Function The cooler is included in the controller for the room and supply air temperature. The temperature is set by regulating the cold water control valves. Attention! For temperatures below freezing point, the heat exchangers must either be emptied and exhausted with pressurized air or filled with commercial antifreeze with corrosion protection in order to prevent frost and corrosion. Emptying can be performed via the discharge screw intended for this purpose on the underside of the collector

30 AL-KO EASYAIR flat Installation of bus cards (optional) The controller may be optionally integrated into a supra-ordinate network. In addition, the following bus cards may be inserted into the available control slot: LON Modbus BACnet Ethernet Fig.: Slot for optional bus cards The connection to the bus cable is directly performed with the optional plug-in card. Only one plug-in card is possible in each case. Data point lists, see "11 Appendix Data Point List" Connection control (optional) Connect the supply air sensor (included in delivery) at the switch cabinet. Connect the outdoor air sensor (included in delivery) at the switch cabinet. Connect the extract air sensor (included in delivery) at the switch cabinet. In case of the "room temperature regulation" option, connect the room sensor (included in delivery) at the switch cabinet. Connect the installed damper actuator at the switch cabinet. For WWE modules, connect the frost protection thermostat at the switch cabinet. For filter modules, connect the pressure sensor to the filter monitoring at the switch cabinet. Connect the associated valves and pumps at the switch cabinet. Connect the main power supply and the control circuits for fresh and exhaust air units at the switch cabinet and to the plugs (included in delivery) as per the wiring diagram. Then insert the plugs into the sockets built into the ventilator module. In case of the pressure or constant volume regulation option, connect the two pressure transmitters at the switch cabinet (at constant pressure regulation: previous on-site installation of the transmitters on channels). If, in additional, there is a remote control, it must be plugged into the adjustment control in position J10, using an RJ-12 plug. Connect the supply line according to the wiring diagram. 30 Original operating instructions

31 "Commissioning" 6. Commissioning 6.1 Basics For commissioning, AL-KO recommends proceeding according to the example commissioning protocol, see "12. Sample Commissioning Protocol." Before commissioning, make sure: that the device was installed as described in this manual, see "5. Assembly." that all filter elements are properly installed. that the duct system and the water and drainage system are properly connected to the unit. that the fresh air intake is an adequate distance from sources of dirt etc. (kitchen extractor hood, central dust vacuum, etc.). 6.2 Before starting the system Check the mechanical function of the blind flaps by manually unlocking them at the actuator motor. Check the seals of all built-in filters. AL-KO generally recommends replacing all of the filters after brief operation of the system in order to remove the contaminants from the construction and commissioning phases. Check the mechanical function of the by-pass flap (plate heat exchanger) by manually unlocking it at the actuator motor. Turn the fan impeller by hand several times and check for ease of movement. If necessary, remove foreign bodies from the fan enclosure. Check the heat exchanger for dirt and damage. Every condensate outflow pipe must be connected to the waste-water system using a separate s-bend. (see Siphon connection) Complete the installation and put into operation in accordance with the commissioning protocol. 6.3 Turning the system on and off All control systems and modules are made ready for operation when the power supply is detected at the switch cabinet

32 AL-KO EASYAIR flat 6.4 After starting the system The indicated menu settings are described in detail in chapter "7. Settings Menu." Check the damper actuator motors for the correct rotation the correct position If this is not the case, the direction of rotation must be changed with the rotation direction switch of the flap actuator motors. Address the damper actuator motors; see "6.5.1 Addressing Damper Actuator Motors." Check the correct direction of rotation of the fan motors by briefly switching on and off. The inlet valve is marked with a red arrow indicating the direction of rotation. With three-phase motors, the direction of rotation can be reversed by changing over 2 phases at the power supply input. Attention! Risk of injury from running fan! Block off the fan prior to inspecting the motor direction! After the machine is switched off, the rotor still runs for approx. 1 to 3 more minutes. Never bring the rotor to a stop by hand or other object! Check to make sure that the valves are set as shown in the "display" menu. If this is not the case, the rotational direction of the valve actuator drive must be changed as required. Set the operating hours counter to zero. Set the date, time, medium and low air flow, and program the weekly schedule. Enter the address of the service company. Operational commissioning of the electric heater (optional) Addressing damper actuator motors The actuator motors of the dampers are connected to the MP-bus of the EASYAIR flat air handling unit. They must be registered (addressed) using the controller during commissioning Rotation direction switch Switch over: Rotation direction changed 2 Press button and LED display green 3 Press button and LED display yellow 4 Button for gearbox disconnection Off: No voltage supply or fault Green illuminated: Operation Press button: Activate the rotation angle adjustment, thereafter normal operation Off: Normal operation without MP bus Yellow illuminated: Adaptation or synchronisation process active Yellow flashing: Request for access by MP master Press button: Confirm the access Yellow flickering: MP communication active Press button: Gearbox disconnected, motor stops, manual adjustment possible Release button: Gearbox connected, start synchronisation, thereafter normal operation 5 Service connector For connection of the parameterisation and service tools Fig.: Damper actuator motor MP Bus modules may only be addressed when the system is in the "OFF" operating mode! 32 Original operating instructions

33 "Commissioning" Steps 1. Press <ESC> in the main display. 2. Select the "Service" menu using the < > key. 3. Enter the "Service" menu by pressing <ENTER>. 4. Select "Password Entry" using the < > key. 5. Enter the password using the < + > and < > keys and confirm by pressing <ENTER>. The password "0005" is pre-set. 6. Select the "Other" menu using the < > key. 7. Enter the "Other" menu by pressing <ENTER>. 8. Select "MP Bus Components" using the < > key. 9. Select the MP Bus Module 1, "Supply Air Damper" using the < + > and < > keys. 10. Confirm by pressing <ENTER>. 11. Press the "Address" button on the damper actuator motor. The message "MP Bus module is addressed" appears. 12. Confirm by pressing <ENTER>. 13. Where present, address the second damper actuator motor in the same manner Addressing valve actuator motors The valve actuator motors for the WWE or WKE options are connected to the MP bus of the EASYAIR flat air handling unit. Heating and cooling valves must be addressed after installation. If the required Belimo module is not available, it must be configured at the manufacturer level. MP bus modules may only be addressed when the system is in the "OFF" operating mode! Steps 1. Press <ESC> in the main display. 2. Select the "Service" menu using the < > key. 3. Enter the "Service" menu by pressing <ENTER>. 4. Select "Password Entry" using the < > key. 5. Enter the password using the < + > and < > keys and confirm by pressing <ENTER>. The password "0005" is pre-set 6. Select the "Other" menu using the < > key. 7. Enter the "Other" menu by pressing <ENTER>. 8. Select "MP Bus components" using the < > key. 9. Select the MP bus module that you would like to configure using the < + > and < > keys. 10. Confirm by pressing <ENTER>. 11. Press the "address" button on the valve actuator motor. The message "MP Bus module is addressed" appears. 12. Confirm by pressing <ENTER>. 13. If available, address the cooling valve in the same manner

34 AL-KO EASYAIR flat 7. Set-up menus 7.1 Control unit (optional remote control) 1 2 Fig.: Remote control 1 Remote control 2 Main display Operating element General function Function in the basic image Showing a fault; Showing a fault ALARM Acknowledging a fault Acknowledging a fault Prg PRG Program display Shows the most common settings Esc ESC + Switches to the previous menu Navigation in the menu Switches to the main menu Raises the target value displayed - Navigation in the menu Lowers the target value displayed ENTER Confirming values Selecting menu items Adjusting the fan speed Turns the system OFF 34 Original operating instructions

35 "Set-up menus" 7.2 Main display After being switched on, the controller starts a self-test. The main display then appears. The display automatically switches to the main display if a button is not pressed in the sub-menu within 60 seconds Fig.: Main display 1 Date 4 Time 2 Alarm - error display 5 Temperature-target value * 3 Selected setting 6 Setting status * If the "ventilation" mode is selected, the actual temperature value will be displayed Turning the fans on and off The system is connected to the power network via the main switch. Thereby, all regulation and control components are ready. Attention! The main switch is NOT suitable for switching on and off during operation. Switch on by pressing <ENTER>. Fig.: Switching on and off Setting the temperature from the main display You can raise the target temperature value using the < + > key. You can lower the target temperature value using the < > key. If the time switch program is active, the programmed temperature can only be lowered or raised by 2 C by using these keys

36 AL-KO EASYAIR flat 7.3 Menu levels The controller is divided into 3 levels: User Level This level contains all important functions necessary for the system operator. Service Level This level contains all functions, which as a rule are only to be set during operational start-up and are necessary for the system start-up. Password: 0005 Manufacturer level This level is only needed by the manufacturer for system parameterization and is no longer required in this manual. Esc Main Menu Esc Set Point Temperature Esc Settings Esc see Set Point Fan Esc Esc Display Esc see User Level Time Functions Esc see Option Week Program Activ Esc Esc Service Esc see 7.5 Service Level Operation Mode Esc Example: Adjust Operation Mode Fig.: Menu Levels 36 Original operating instructions

37 "Set-up menus" Setting the system parameters General Select the menu item to be adjusted and confirm by pressing <ENTER>. Set the desired value using the < + > and < > keys. Setting the temperature Fig.: Setting the temperature 1. Press <ESC> in the main display. 2. Enter the settings menu by pressing <ENTER>. You can raise the target temperature value using the < + > key. You can lower the target temperature value using the < > key. When several adjustable parameters are within the display field, you can toggle between these by using the <ENTER> button. Setting the support function heating Fig.: Support function heating 1. Press <ESC> in the main display. 2. Enter the "Service" menu by pressing <ENTER>. Navigate to "Password Entry" using the < > key. Enter the password using the < > or < + > keys and confirm by pressing <ENTER>. Then navigate to the "Support Function" menu by pressing <ENTER>. Set the desired value using the < > and < + > keys

38 AL-KO EASYAIR flat 7.4 User level "Settings" menu Settings Temperature Fan Operation Mode Week Program (only available with season switch clock) Language Example: Set point adjustment Constant pressure control: Set Points Supply Air Fan Set Points Exhaust Air Fan Fig.: Menu tree settings 1. Press <ESC> in the main display. 2. Enter the "Settings" menu by pressing <ENTER>. Setting the values, see "7.3 Setting the System Parameters" Operating modes: Heating, cooling, ventilation, auto Heating: the system heats if the temperature target value is higher than the actual value. The system is otherwise in ventilation mode Cooling: The system cools if the temperature target value is lower than the actual value. The system is otherwise in ventilation mode Venting: The system ventilates. Auto: The system heats, cools or ventilates automatically, see "7.5.5 Auto Operation Menu." 38 Original operating instructions

39 "Set-up menus" "Displays" menu Settings Sensor Values 1 Components 2 Miscellaneous 3 Fig.: Menu tree display 1 Current temperature values from the connected sensors, where applicable, pressures, flow rates, and air quality. 2 Current operational status of the respective field devices and the system. 3 Supply air target temperature (automatically calculated by the controller with connected room and temperature sensors and sets the target temperature of the incoming air). 1. Press <ESC> in the main display. 2. Navigate to the "Display" menu using the < > key. There you can retrieve the actual states

40 AL-KO EASYAIR flat "Time functions" menu Activating the time program Time Functions Weekly Program Daily Program Date / Time Fig.: "Time functions" menu tree. 1. Press <ESC> in the main display. 2. Navigate to the "Time Functions" menu using the < > key. 3. Confirm by pressing <ENTER>. 4. Navigate as described below. The time program is designed in such a way that one of 4 individually adjustable daily schedules can be assigned every weekday in the weekly schedule (Mon Sun). Each daily schedule has 6 switching times with separately assigned temperature target values and fan speeds. 40 Original operating instructions

41 "Set-up menus" Setting the daily schedule 1. Navigate in the "Time Functions" menu to the "Daily Schedule" menu using the < > key. 2. Confirm by pressing <ENTER>. The respective switching times, temperature target values and fan speeds can be set by pressing the <ENTER> button several times. 3. Change the respective parameters by using the < + > and < > keys. After setting the first three time switching points, the cursor jumps back to the basic position. 4. Choose the time switching points 3 6 by using the < + > and < > keys. A maximum of 4 daily schedules are adjustable. Example: P1 P2 P3 P4 Switching point 1 Switching point 2 Switching point 3 Switching point 4 Switching point 5 Switching point 6 5:00 Off 8:30 St.1 18:00 Off 20:00 Off 21:30 Off 22:00 Off 21,0 C 21,0 C 21,0 C 21,0 C 21,0 C 21,0 C 5:00 Off 8:00 St.1 10:00 St.1 12:00 St.1 14:00 Off 17:00 Off 21,0 C 21,0 C 21,0 C 21,0 C 21,0 C 21,0 C 6:00 St.1 9:00 Off 17:00 St.1 19:00 St.1 22:00 St.1 23:00 St.1 21,0 C 21,0 C 21,0 C 23,0 C 19,0 C 19,0 C 8:00 St.1 8:00 St.1 10:00 St.1 12:00 St.1 18:00 St.1 20:00 St.1 21,0 C 21,0 C 21,0 C 21,0 C 21,0 C 19,0 C Fig.: Daily schedules Setting the weekly program P1 Fig.: Weekly program 1. Select the menu item "Weekly Program" in the "Time Functions" menu. 2. Confirm by pressing <ENTER>. 3. Select the respective days of the week by repeatedly pressing <ENTER>. A daily schedule (P1-P4) can be assigned to every weekday by using the < + > and < > keys

42 AL-KO EASYAIR flat Setting the time 1. Select the menu item "Date/Time" in the "Time Functions" menu. 2. Confirm by pressing <ENTER>. Fig.: Change the date / time 3. Pressing <ENTER> moves the cursor one position to the right. 4. The value can be changed using the < + > and < > keys. If the controller is connected to the power supply during the shift from summer to winter-time, or winter to summer-time, from 2:00 AM and 3:00 AM, the change takes place automatically. Maintaining temperature If no fan level is chosen for certain times on a day that is controlled by the time program, the system switches to maintaining the temperature. In this case the fan will only be switched on if the room temperature drops below the target value set in the daily schedule and it heats the room back up. The maintaining temperature function is only active with a connected room sensor and activated time switching program. 7.5 Service level "Unoccupied mode" menu (only available with room temperature sensor) 1. Press <ESC> in the main display. 2. Select the "Service" menu using the < > key. 3. Enter the "Service" menu by pressing <ENTER>. 4. Navigate to "Password Entry" using the < > key. 5. Enter your password (standard: 0005) using the < + > and < > keys and confirm by pressing <ENTER>. 6. Enter the "Unoccupied Mode" menu by pressing <ENTER>. Fig.: Unoccupied Mode display When the system is switched off, the temperature increases or decreases according to the prevailing outdoor weather conditions and the climate inside the room. The "Unoccupied Mode htg" and "Unoccupied Mode clg" are available to counteract this. 42 Original operating instructions

43 "Set-up menus" Unoccupied Mode Cooling Power up conditions If the temperature in the room increases beyond the unoccupied cooling limit, the "Unoccupied Mode Cooling" switches on. It remains on until the room temperature is 1 C less than the unoccupied cooling limit. Afterwards, the system is switched off. Unoccupied Mode Heating Power up conditions If the temperature in the room decreases to under the unoccupied heating limit, the "Unoccupied Mode Heating" switches on. It remains on until the room temperature is 1 C more than the unoccupied heating limit. Afterwards, the system is switched off. Boundary conditions System "OFF" No fault "Heating," "Cooling" or "Auto" mode Time switching program "off" or non-active Room temperature sensor connected Unoccupied Mode Heating and Cooling approved No night ventilation (in Unoccupied Mode Cooling)

44 AL-KO EASYAIR flat "Night ventilation" menu 1. Press <ESC> in the main display. 2. Select the "Service" menu using the < > key. 3. Enter the "service" menu by pressing <ENTER>. 4. Navigate to "Password Entry" using the < > key. 5. Enter your password (standard: 0005) using the < + > and < > keys and confirm by pressing <ENTER>. 6. Navigate to the "Night Ventilation" menu using the < > key. 7. Enter the "Night Ventilation" menu by pressing <ENTER> and set the parameters. Fig.: Night ventilation Power up conditions: Room temperature > room temperature power-on value Delta outdoor temperature/room temperature < room temperature - outdoor temperature Daily maximum value (previous day) > daily minimum Outdoor temperature > night minimum Power down conditions: Outdoor temperature < night minimum Room temperature < room temperature power-on value Boundary conditions: Room temperature sensor and outdoor temperature sensor connected Night ventilation approved Timer available Timer program non-active No fault System "OFF" Operating mode "Cooling" or "Auto" Night ventilation has the task of cooling the room in summer during operation-free times by using cool, outside air. This pushes the stored heat in the walls on hot summer days outside in the most energy efficient way possible. 44 Original operating instructions

45 "Set-up menus" "Supply air limitation" menu 1. Press <ESC> in the main display. 2. Select the "Service" menu using the < > key. 3. Enter the "Service" menu by pressing <ENTER>. 4. Navigate to "Password Entry" using the < > key. 5. Enter your password (standard: 0005) using the < + > and < > keys and confirm by pressing <ENTER>. 6. Navigate to the "Supply Air Limitation" menu using the < > key. 7. Go into the "Supply Air Limitation" menu by pressing <ENTER> and set the parameters. Fig.: Supply air limitation Maximum supply air temperature The supply air temperature calculated by the controller cannot rise above the set value. Minimum supply air temperature The supply air temperature calculated by the controller cannot fall below the set value. Supply air limitation Antifreeze limit / supply air temperature If the supply air temperature falls below the set value, the system goes into frost alarm. The supply air temperature is limited by a minimum and maximum value. If a high incidence of extraneous heat enters the room, the supply air temperature is prevented from falling too low. Drafts caused by the low supply air temperatures would occur in the room without this limit

46 AL-KO EASYAIR flat "Compensation" menu 1. Press <ESC> in the main display. 2. Select the "Service" menu using the < > key. 3. Enter the "Service" menu by pressing <ENTER>. 4. Navigate to "Password Entry" using the < > key. 5. Enter your password (standard: 0005) using the < + > and < > key and confirm by pressing <ENTER>. 6. Navigate to the "Compensation" menu using the < > key. 7. Enter the "Compensation" menu by pressing <ENTER> and set the parameters. Fig.: Compensation Summer and winter compensation are used to automatically switch the system between summer and winter operation. Due to the external temperature, the temperature target value is thus shifted. Summer Here you can program how many C higher or lower the temperature target value should shift. Winter Here you can program how many C higher or lower the temperature target value should shift. Start at Here you can program the external temperature at which summer or winter compensation begins. End at The fresh air rate can be limited here ("Settings" menu) Here you may program the external temperature at which summer or winter compensation ends and the temperature target value shift has reached its maximum value Fig.: Summer / winter compensation 1 End of winter compensation 3 Start of summer compensation 2 Start of winter compensation 4 End of summer compensation 46 Original operating instructions

47 "Set-up menus" "AUTO operation" menu 1. Press <ESC> in the main display. 2. Select the "Service" menu using the < > key. Fig.: AUTO operation Enter the "Service" menu by pressing <ENTER>. 4. Navigate to "Password Entry" using the < > key. 5. Enter your password (standard: 0005) using the < + > and < > keys and confirm by pressing <ENTER>. 6. Navigate to the "AUTO Operation" menu using the < > key. 7. Enter the "AUTO Operation" menu by pressing <ENTER> and set the parameters. If "AUTO" is switched on, the controller will constantly compare the calculated supply air target value with the outdoor temperature. If the outdoor temperature / supply air actual value is the same as the supply air target value, ventilation will be switched on. If the outdoor temperature / the supply air actual value falls below the value set in "differential heating," the controller automatically recognizes that the heat must be switched on. If the outdoor temperature / supply air actual value rises to the value set in "differential cooling," the system goes into cooling operation. The "differential heating" default value is set to 2K and the "differential cooling" value to 4K. It is normal that the actual temperature for the 2K heat demand and for the 4K cooling demand differ from the temperature target value. These values must be smaller if a more exact temperature control is desired. Example: Differential heating: 2K Differential cooling: 4K Adjusted basic target value: 20 C Outdoor temperature 19 C: Outdoor temperature 17 C: Outdoor temperature 25 C: System vents System heats because the outdoor temperature / supply air actual value has fallen below the "differential heating" value. System cools because the outdoor temperature / supply air actual value has risen above the "differential heating" value

48 AL-KO EASYAIR flat "Sensor offset" menu The "Sensor Offset" menu enables the sensor value to be compared if where the temperature is not being precisely displayed. It allows you to measure the actual temperature of the sensor with a calibrated thermometer and compare this with the temperature in the control display. The temperature value displayed can be corrected by up to ± 5K in this menu. 1. Press <ESC> in the main display. 2. Select the "Service" menu using the button < > key. 3. Enter the "Service" menu by pressing <ENTER>. 4. Navigate to "Password Entry" using the < > key. 5. Enter your password (standard: 0005) using the < + > and < > keys and confirm by pressing <ENTER>. 6. Navigate to the "Sensor Offset" menu using the < > key. 7. Enter the "Sensor Offset" menu by pressing <ENTER> and set the parameters. Fig.: Sensor Offset 48 Original operating instructions

49 "Set-up menus" "Operating hours counter" menu The operating hours counter counts the hours of operation during which the system is switched on. By doing this, the service intervals can be maintained. 1. Press <ESC> in the main display. 2. Select the "Service" menu using the < > key. 3. Enter the "Service" menu by pressing <ENTER>. Fig.: Operating hours counter 4. Navigate to "Password Entry" using the < > key. 5. Enter your password (standard: 0005) using the < + > and < > keys and confirm by pressing <ENTER>. 6. Navigate to the "Operating Hours Counter" menu using the < > key. 7. Enter the menu by pressing <ENTER>. 8. The operating hours counter can be reset by pressing <ENTER> "Alarm recording" menu The last 10 fault messages are saved here and can be displayed. 1. Press <ESC> in the main display. 2. Select the "Service" menu using the < > key. 3. Enter the "Service" menu by pressing <ENTER>. 4. Navigate to "Password Entry" using the < > key. 5. Enter your password (standard: 0005) using the < + > and < > keys and confirm by pressing <ENTER>. Shows the saved faults 6. Navigate to the "Alarm Recording" menu using the < > key. 7. Enter the menu by pressing <ENTER>. Fig.: Alarm Recording

50 AL-KO EASYAIR flat "Presence detection" menu Fig.: Presence detection 1 Fig.: Presence detection 2 Prerequisites: A presence detector must be connected and configured at the manufacturer level. The presence detector has the highest priority. Regardless of operating mode and current target value, the system will be driven at the set values during presence detection. The follow-up time indicates how long the system should run in the set operation mode after a presence detection defects "Miscellaneous" menu Miscellaneous siehe siehe siehe Fig.: Overview of "Miscellaneous" 1. Press <ESC> in the main display. 2. Select the "Service" menu using the < > key. 3. Enter the "Service" menu by pressing <ENTER>. 4. Navigate to "Password Entry" using the < > key. 5. Enter your password (standard: 0005) using the < + > and < > keys and confirm by pressing <ENTER>. 6. Navigate to the "Miscellaneous" menu using the < > key and perform one of the following steps. 50 Original operating instructions

51 "Set-up menus" New password The password for the service level may be changed here. 1. Enter the "Miscellaneous" menu by pressing <ENTER>. 2. Navigate to "Password Entry" using the < > key and confirm with <ENTER>. 3. Enter a new password using the < + > and < > keys. Fig.: New password 4. Confirm by pressing <ENTER>. Index: Service You can enter the service company's address and telephone number here. This display appears in the "service" menu. 1. Go into the "Miscellaneous" menu by pressing <ENTER>. 2. Navigate to "Index: Service" using the < > button and confirm by pressing <ENTER>. Fig.: Index Service Characters, letters and digits can be selected using the < + > and < > keys. Pressing <ENTER> moves the cursor one position over. 3. When everything is entered, press <ESC>. Addressing MP bus modules See "6.5.1 Addressing Damper Actuator Motors" and "6.5.2 Addressing Valve Actuator Motors"

52 AL-KO EASYAIR flat 8. Maintenance The air handling unit operator is obligated to ensure that the system undergoes routine maintenance by trained personnel. AL-KO recommends performing maintenance according to VDI 6022 and VDMA In addition, a hygiene inspection is required every 3 years according to VDI The AL-KO THERM GMBH assumes these tasks upon conclusion of a maintenance contract. 8.1 Safety Attention! Installation, start-up, maintenance and repairs may only to be carried out by trained personnel! Attention! As a general rule, when working on the device always disconnect the power supply (disconnect all phases). Only open the inspection doors when the machine is off and the fans are at a standstill. After the machine is switched off, the rotor still runs for approx. 1 to 3 more minutes. Never bring the rotor to a stop by hand or other object! After working on the unit, the person responsible is to ensure that no persons remain in the system and that all factory-fitted protection measures are working before powering the system back up. 8.2 Consumables and replacement parts Attention! Only use original consumables and replacement parts. Only in this way is safe operation guaranteed! The warranty is void in the case of non-compliance. You can find a replacement parts list in the unit documentation. 8.3 Fuses and terminals The fuses are time delay circuit breakers. Fuse and terminal assignments can be found in the wiring diagram included in delivery. 52 Original operating instructions

53 "Maintenance" 8.4 Maintenance schedule No. Component / activity Action / note Inspections to be carried out at monthly intervals Outdoor and exhaust air outlets Check for dirt, damage and corrosion Completely clean and repair X 2. Unit housing Check for dirt, damage and corrosion Clean and repair on the air side X Check for water formation Clean and identify the cause (condensate, leakages) X Check that drains are functioning Clean if needed properly X Flexible connections Check for leak tightness X 3. Air filter Check for unacceptable levels of dirt, damage (leakages) and odors. (The air filters must exhibit their designated filter class separating efficiency across their entire lifetime) "Filter change" warning message The appropriate filter is to be changed out with indication of contamination or leakages. If the entire filter change is overdue by more than 6 months, change out the entire filter Replace the filter if the maximum pressure difference is exceeded Most recent filter change Inspection of the hygiene state 4. Heat exchangers, general (optional) If cleaning in the installed state is insufficient, the heat exchanger must be removed and adequately cleaned. Check for contamination, damage Clean and repair and corrosion X Wet cooler, condensate pan and Repair drip separator are to be checked for contamination, corrosion and proper X functioning Check the siphon for functioning Repair X Inspection of the hygiene state Air heater Check for dirt, damage and Clean and repair corrosion on the air side Cleaning to maintain proper functioning (downstream) Ventilate Electrical air heater Check there is no formation of scaling or corrosion Check for dirt, damage and Clean and repair corrosion on the air side Check for proper functioning Check the controller and safety equipment for proper functioning X X X X X X X X X X X X

54 AL-KO EASYAIR flat No. Component / activity Action / note Inspections to be carried out at monthly intervals Cooler The siphon backflow is to be dimensioned and arranged according to the pressure conditions so that the condensation can flow unimpaired Check for dirt, damage and Clean and repair corrosion X Clean wet cooler, drip separator and pan X Check the supply and return for proper functioning X Ventilate X Check the hygiene state X Drip separator Check for dirt, damage and formation of deposits Check drip separator to ensure not formation of deposits Check the water drainage and siphon for proper functioning 5. Heat recovery, general Cleaning to maintain functionality - all surfaces including pan and drip separator, dismantling if necessary Carry out cleaning to maintain functionality, if encrustation is visible Heat exchangers and their accessories must be regularly inspected for dirt, corrosion and damage downstream. Check for dirt, damage and corrosion Check the exhaust and outdoor airflow for tightness Condensate pan is to be checked for dirt, corrosion and functioning Check the siphon for proper functioning Control of the hygiene state 6. Dampers Check for dirt, damage and corrosion Check for proper mechanical functioning The heat exchangers can be cleaned with a hot-water, high-pressure cleaner, (sec ) Repair Repair Repair Clean if necessary Damper actuator motors Check for proper functioning X 7. Fans Check fans for dirt, damage and Clean and repair X corrosion. Check rotor for dirt, imbalance and Switch on motor briefly X running noise. 8. Electrical control Visually inspect terminals and connectors. Clean if needed and check tightness of fitting. X X X X X X X X X X 54 Original operating instructions

55 "Maintenance" 8.5 Checking components All installed components are to either be easily accessible for inspection or extractable after removing the maintenance doors from the unit. The objective of regular hygiene checks is to detect and eliminate hygiene issues early on through frequent visual inspections or random microbiological checks. Regular hygiene control includes the following measures: Visual inspection of the unit for hygiene issues such as bacterial growth or contamination, rust build-up, calcium deposits and damage. Components identified as dirty during the hygiene inspections must immediately be cleaned WWE / KWK Attention! The use of high-pressure washers with conventional jet nozzles is not permitted due to risk of damage! Corrosion may occur in the heat exchangers after longer periods of downtime due to sulfate-reducing bacteria. These sulfides aggressively corrode welded joints and copper-based material. We recommend the following measures to reduce this type of copper corrosion: Using sulphate-free water in the entire circuit Ensuring there are no leaks in the system. Avoiding long periods of downtime for filled circuits. Avoiding frequent re-filling with fresh water. Using material-tolerant inhibitors or biocides Plate heat exchanger The heat exchanger can be cleaned with a hot-water, high-pressure cleaner. The following parameters must be met: Nozzle: Flat jet nozzle Pressure: max. 20 bar Amount of water: max. 450 l/h Water temperature: max. 70 C Distance from the heat exchanger: min. 30 cm Nozzle direction: 90 offset to the foil stamping or blades Fig.: Clean the plate heat exchanger 1 Plate heat exchanger 4 Supply air 2 High-pressure flat spray nozzle 5 Extract air 3 Outdoor air 6 Exhaust air