OPERATION MANUAL Modular Air Handling Units CAIRplus. Solutions with Maximum Flexibility

Transcription

1 OPERATION MANUAL Modular Air Handling Units CAIRplus Solutions with Maximum Flexibility

2 Table of Contents CAIRplus Table of Contents 1 Unit Type Code Safety and User Instructions Availability of the operation manual Scope of the operation manual Symbols used Labelling of safety instructions Used safety symbols Safety-conscious work procedures Proper use Safety devices Modifications and changes Spare parts Disposal Selection and qualification of personnel Technical Description Performance scope Technical Specifications Operating limits and range of application Shipping and Storage Delivery Transport Storage Assembly Unit placement Assembling the unit Installation Requirements Installing air-conveying components Installing air-handling components with coil connections Installing accessories Electrical Connection Requirements Connecting unit PR GB Subject to modifications R8-10/2015

3 CAIRplus Table of Contents 8 Commissioning and Maintenance Routine cleaning and maintenance Maintenance frequency checklist General considerations Fan assembly and drives Filter assembly Heater assembly Cooler assembly Cooling/heating coil Heat pipe Liquid-coupled energy recovery coil Plate heat exchanger Rotary heat exchanger Humidifier assembly Damper blades and shut-off dampers Sound attenuators Commissioning/maintenance of ECOTWINcool double-plate heat exchanger with adiabatic cooling commissioning/maintenance of integrated refrigerating systems Disassembly and disposal Dismantling Disposal Troubleshooting Appendix Maintenance Log Book CAIRplus Original operation manual Copyright note Disclosing, copying, distributing or taking any action in reliance on the contents of this document is strictly prohibited without express prior consent. Violations entail liability for any damages or other liability arising. All rights in relation to patents, utility patents or design patents are reserved. PR GB Subject to modifications R8-10/2015 3

4 Unit Type Code CAIRplus 1 Unit Type Code A V B V A Unit part 2 * Example: CAIR plus X 1 A # I H S E Z V B V A Prefix General Unit part 1 Product family Product group Series Unit design class führungsklasse Thermal separation Casing Type of application Installation site Air flow direction Arrangement Casing type Function Air flow Unit width Unit height Material Internal skin Material External skin Material Components Material of profiles CAIR plus (air handling unit) X SX Unit 1 Standard without accessories 2 Standard with accessories 3 Special design A Automatic T Complete K Without # Standard R Standard, in conformity with RLT 01 Directive H Hygiene variant E Explosion protected I Indoor installation A Outdoor installation D Ceiling mounting W Wall mounting U Underfloor installation H Horizontal V Vertical L L Form S Single N Side by Side Ü Double-deck H Straight-through E Single casing K Combined casing Z Supply air A Extract air Unit width (internal size in cm) Unit height (internal size in cm) V Aluzink AZ 185 B RAL 9002 coated 2 Stainless steel V2A (steel type ) or equivalent 4 Stainless steel V4A (steel type ) or equivalent B RAL 9002 coated S Coated in special colour V Galvanized L coated K Coated with enhanced corrosion protection A Natural Alu B RAL 9002 coated * Unit part 2 additional with arrangement types side-by-side, double-deck or straight-through 4 PR GB Subject to modifications R8-10/2015

5 CAIRplus Safety and User Instructions 2 Safety and User Instructions The CAIR units are constructed using the state-of-the-art technology and according to recognized safety regulations. Operation is only allowed if the unit is in perfect working order given that current operation manual and safety instructions are observed and potential hazards avoided! Otherwise failure to follow these instructions may result in death or injury to the user, third persons or damage to the unit, connected units or other equipment.have all faults repaired by an authorized specialist without delay! Consider the safety instructions provided by the manufacturers of individual components! 2.1 Availability of the operation manual This operation manual contains important instructions regarding safe and proper operation of the unit. This operation manual applies to installation companies, operators, building technicians, technical personnel or instructed persons as well as electricians. This manual as well as the safety information of the manufacturer of the individual components must always be available at the unit's installation site. When working on the equipment, observe all instructions and precautions in the current operation manual, in particular the chapter on safety. 2.2 Scope of the operation manual This operation manual as well as the instructions of the manufacturer of the individual components provide you the necessary information on the areas: Shipping and storage Mounting Installation and Electrical Connection Commissioning and Maintenance Disassembly and Disposal 2.3 Symbols used The following symbols are used to highlight particular text sections in this operation manual: This symbol is used to indicate normal lists. This symbol indicates instructions to follow. The result of an action is indicated with this symbol. Note! Additional details on using the unit are specified here. Danger symbols are specified in section "Labelling of safety instructions" on page 8. PR GB Subject to modifications R8-10/2015 5

6 Safety and User Instructions CAIRplus Special warning and danger symbols The following warning and instruction signs can be secured on the unit: To connect - counter hold with a pipe wrench. Attention: fire risk. Dust-laden filters are inflammable. Before opening, use the main isolator to disconnect power. Risk of injury. Wait until complete stop before opening. Type sheet and assembly instructions attached to unit inside. Remove these documents before the unit commissioning. Do not start up the fan against closed dampers. Designation of unit in explosion-risk areas (according to 94/9/EG regulation) Potential equalisation To equalize potentials the unit must be connected to an external protective conductor at the designated points on the base frame. 6 PR GB Subject to modifications R8-10/2015

7 CAIRplus Safety and User Instructions Function signs Fan or compressor indicating air flow direction Air heater/cooler with heat recovery function Air/water ECOFLOW Sound attenuator in unit Air heater/cooler with heat recovery function Air/steam ECOSTAT General air filter indicating air flow direction HEPA filter indicating air flow direction Air heater/cooler with heat recovery function Air/air ECOPLAT Air heater/cooler with heat recovery function Air/air ECOROT Opposed-blade dampers General air humidifier Air heater air/water General controller Air cooler air/water Droplet separator Air cooler Air/steam/refrigerant PR GB Subject to modifications R8-10/2015 7

8 Safety and User Instructions CAIRplus 2.4 Labelling of safety instructions To designate the safety instructions the following symbols and notices are provided in appropriate places throughout this document: DANGER - Death/serious irreversible injury Example: Indicates an extremely hazardous situation which will result in death or serious irreversible injury, if the safety instruction is not followed. Electrocution through hazardous voltage will lead to death or serious injury. Disconnect the unit from the power supply and ensure the power cannot be switched back on. Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components WARNING - Death/serious injury Example: Indicates a hazardous situation which can result in death or serious irreversible injury, if the safety instruction is not followed. High concentration of refrigerants in the air can result in death or serious injury! High concentration of refrigerants in the air may have an anaesthetic effect and cause unconsciousness. Prolonged exposure may cause irregular heartbeat and sudden death. Very high concentration of refrigerant may cause suffocation by reduced oxygen content in the surrounding air. You should therefore only work in an adequately ventilated environment, and exercise due care and attention when carrying out the work. Wear protective clothing and, if necessary, an autonomous breathing apparatus CAUTION - Minor or moderate injury Example: Indicates a hazardous situation which can result in minor or moderate injury, if the safety instruction is not followed. Sharp edges can cause injuries! Observe precaution when cleaning due to risk of cuts on thin and sharp edges. Wear protective gloves. 8 PR GB Subject to modifications R8-10/2015

9 CAIRplus Safety and User Instructions ATTENTION Environmental or material damage ATTENTION Examples: Indicates actions that can result in equipment or property-damage only accidents. ATTENTION Risk of environmental damage! Heavily contaminated filters can have a negative impact on production processes. Depending on the filtered-out materials, contaminated filters are therefore classified as hazardous waste and must be properly disposed of according to the prevailing guidelines and laws. ATTENTION Risk of damage to the unit! If dampers are abruptly shut during unit operation, the unit can be damaged beyond repair as a result of negative pressure or overpressure. 2.5 Used safety symbols Electrical hazard Explosive atmosphere PERSONAL injury Overhead loads Risk of tipping Rotating components! Rotating storage materials Toxic substances Crushing of limbs Sharp cutting edges Inflammable materials PR GB Subject to modifications R8-10/2015 9

10 Safety and User Instructions CAIRplus Scalding Hot surfaces Cooling Environmental damage Damage to the unit 2.6 Safety-conscious work procedures Observe the following instructions when carrying out installation, adjustment or repair jobs: Wear suitable protective clothing during work, such as protective footwear, gloves, safety goggles, etc.. Avoid flame sources, especially burning cigarettes. Open flame sources and smoking in the proximity to the unit are prohibited. Filters and especially used filters can easily catch fire. Leaking refrigerant can catch fire and emit noxious substances. When working within range of mains voltage: Electrocution through hazardous voltage will lead to death or serious injury. Disconnect the unit from the power supply and ensure the power cannot be switched back on. Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. When working in explosive atmosphere: Life-threatening danger of explosive atmosphere! The unit must only be operated under the conditions specified on the unit identification plate. Explosion-risk conditions may originate inside and/or outside the unit during its operation as well as during dowmtime period. For this reason, it is assumed that explosion-risk conditions are present, even if the unit is deactivated. Avoid using pro-inflammatory substances such as electrical tool and electronic devices. Smoking and open flames within direct proximity of the unit are prohibited. Before starting any jobs - ventilate the interior and/or exterior of the unit! 10 PR GB Subject to modifications R8-10/2015

11 CAIRplus Safety and User Instructions For all kinds of work: Risk of personal injury! No matter what kind of jobs are performed on the unit, there is always a risk of cuts by thin sheet metal and heat exchanger fins. In particular, this aspect applies when carrying out maintenance and cleaning work on the surfaces of heating and cooling coils. Wear suitable protective clothing. Before commissioning and after maintenance of the unit there is an increased risk of injury: Ensure that no persons are locked inside the unit. Walkable surfaces of the unit are equipped with emergency levers on the interior side of doors. Smaller units must provide a protection against inadvertent locking by using padlocks on the door stop. An operating unit poses a risk of injury: Danger of impacts by opening doors arranged on the discharge side Danger of crushing resulting from negative pressure applied to doors on the suction side Danger resulting from rotating parts such as fans etc. Danger of hot surfaces and/or media Units equipped with coolers with a refrigeration circuit pose additional risks. Observe all the safety notes contained in Chapter "commissioning/maintenance of integrated refrigerating systems" on page 80. ATTENTION Risk of damage to the unit! If dampers are abruptly shut during unit operation, the unit can be damaged beyond repair as a result of negative pressure or overpressure. Jobs on the unit can only be carried out if all poles for the power supply are disconnected the unit is secured to prevent inadvertent energising (also refer to "Electrical hazard") all moving components - in particular - fan impeller, motor, rotary heat exchanger, control and shut-off dampers have come to a standstill: wait at least 5 minutes after deactivating the unit the heat exchangers have cooled down to reach ambient temperature Upon completion of jobs on the unit ensure that all protective devices are operating properly for example, the fan safety devices (door protection grille, contact guard) are locked no persons are present in danger areas. PR GB Subject to modifications R8-10/

12 Safety and User Instructions CAIRplus Handling refrigerants (only for units with integrated refrigerating system) According to DIN EN 378 Part 1 the R-134a and R-410A refrigerants belong to A1 group. Refer to the unit identification plate for data and charge volume of a particular refrigerant. Observe the usage details in accordance with EC regulation 842/2006. First aid Inhalation Skin contact Eye contact Features of applicable refrigerant types: Non-combustible No direct toxic effect Colorless and odorless Heavier than air Contains fluorinated greenhouse gases as defined by the Kyoto protocol Ozone-depleting potential OPD: 0 Greenhouse potential GWP: R-134a: 1300, R-410A: 1980 Water hazard class WGK 1, with a slight risk to water Wear appropriate clothes when performing jobs with refrigerants and in the proximity to a refrigeration circuit, e.g. Sealing protective goggles PVA or leather gloves Protective clothes for entire body If necessary, an autonomous breathing apparatus First aid measures directly after or during contact with refrigerants: Ensure your own protection against leaking refrigerant. Under all circumstances - call a doctor or and/an ambulance. Remove clothes contaminated by the refrigerant. Additional measures after inhalation of refrigerants: Take the injured person to a well-ventilated location. Ensure that the injured person is in a stable lateral position. Consumption of food and beverages must be avoided. If the injured person collapses or loses consciousness perform mouth-to-mouth respiration. Additional measures after skin contact with refrigerants: Rinse the affected body parts using lukewarm water for at least 15 min. Additional measures after eye contact with refrigerants: Do not rub your eyes. Remove contact lenses if you have any. Rinse your eyes with lots of water. 2.7 Proper use The CAIRplus units are only intended for handling air and performing the following jobs: filtering normally polluted air filtering air in cleanroom applications (special cleanroom design) air heating and/or cooling humidifying and/or dehumidifying of air heat rejection or heat recovery filtering and treatment of air with a high moisture content and/or with high levels of contamination (special models, for example for swimming pool or kitchen exhaust applications) or combination of the above-mentioned functions. 12 PR GB Subject to modifications R8-10/2015

13 CAIRplus Safety and User Instructions Proper use also includes observance of the operation manual and instructions from the manufacturer of the individual components, as well as the inspection and maintenance intervals stipulated by DencoHappel. Improper use Any use other than that described above is considered improper. If necessary, check if your units are suitable for your intended purpose and application. The manufacturer/ supplier is not liable for any damages arising from improper use. The user alone bears the risk. Misuse particularly includes: Conveying any other gases except air Conveying steam or water Coarse filtering and/or filtering any other media except air Chopping up or reducing size of materials Drying out clothing The unit is not suitable for handling abrasive media. It is not allowed to operate CAIR units: in explosion-risk areas, unless units are certified for use in these relevant areas (air handling units meeting special explosion-protection requirements in accordance with ATEX Guideline 94/9/EG) in rooms with conductive dust in rooms with strong electromagnetic fields in rooms with aggressive atmosphere that may attack plastics or cause corrosion (especially in atmosphere where zinc is particularly susceptible to corrosion). CAIR units must not be accessible to the general public. 2.8 Safety devices Depending on the unit equipment, the following components are secured: Padlock in the door-stop device (TAS) on each door Locks of switch cabinet The panels and doors with lockable handles Fan chambers are secured by door protection grilles V-belt drives are secured by belt guards Ensure by others on site that the contact protection for intake and discharge fittings is provided. 2.9 Modifications and changes Changes, alterations or modifications of the unit are not allowed. Tampering with the unit or its misapplication will invalidate the CE conformity and void warranty. If delivered units are disassembled by others on-site, the factory warranty is rendered invalid. In this case professional services by DencoHappel should be arranged in advance Spare parts Only original DencoHappel spare parts are allowed, since DencoHappel is not liable if third-party spare parts are used Disposal Equipment, operating supply materials, components and filters must be disposed of according to the material type in a safe and environmentally friendly manner. PR GB Subject to modifications R8-10/

14 Safety and User Instructions CAIRplus 2.12 Selection and qualification of personnel Ensure that every person working on the unit has read and understood entire operation manual. Please read this document fully before commencing any work, and not while performing a task. All jobs must only be carried out by qualified licensed staff or other individuals with proper professional training and experience in the following areas: Occupational health and safety regulations Accident prevention regulations Directives and recognized codes of practice All jobs with the refrigeration circuit shall be performed only by certified and licensed staff in accordance with the valid EG Regulation 842/2006 Article 5, EG Regulation 303/2008 Article 4 and 5 as well as "Ordinance on climate protection against changes caused by release of certain fluorinated greenhouse gases" Article 5, passed by the German parliament. All skilled staff must be able to assess the entrusted work and must be able to recognize and avoid all associated dangers. 14 PR GB Subject to modifications R8-10/2015

15 CAIRplus Technical Description 3 Technical Description 3.1 Performance scope CAIRplus units are generally used for energy-saving supply-air and extract-air indoor ventilation. Due to their modular design, units can be configured individually to meet particular air-handling requirements and specifications. The transported air can be filtered, heated, cooled, humidified or dehumidified, depending on the application for each case. The aim is to meet the customer specifications concerning required air volume and conditions. CAIRplus units are used at a central point for comfort air conditioning on commercial and industrial premises for the transportation and treatment of normal air. The units can also be manufactured in a customized design and adapted for cleanroom and hygiene applications. CAIRplus units meeting explosion-protection standards and complying with the ATEX 94/9/EG Directive are clearly designated and marked. These units are supplied with an additional operation manual that must be read and considered. A range of unit components are available for energy-saving purposes: rotary heat exchangers, plate heat exchangers, heat pipes and liquid-coupled heat exchangers for the recovery of heat and the partial recovery of moisture as well. Units are performed in different sizes and have various capacities. Depending on the application for each case, CAIRplus units are designed for vertical or horizontal air flow and are arranged as double-deck, side-by-side and straight-through models. Units can be installed indoors and outdoors. Thanks to the modular design of the CAIRplus, units ship as complete assemblies or sub-assemblies that can pass through the available on-site openings in the course of installation. CAIRplus units are also suitable for the modernization and retrofitting of existing buildings due to the number of available unit sizes and a unit ordering option providing for delivery in small shipment units. 3.2 Technical Specifications Refer to the order-related documentation for the specific configuration of your CAIRplus unit (unit drawing with dimensions and technical data). 3.3 Operating limits and range of application Please carefully observe the unit type plate and the operation manuals for the supplied accessories. Please refer to the accompanying documentation or technical specifications provided in the unit-layout software for the operating limits or related restrictions of individual built-in parts and components. The unit warranty is only valid if the specified materials are adhered to when units are used in corrosive or aggressive environments! In process-air applications, consider the tolerance-related differences in aerodynamic values! In frost-risk cases, use antifreeze agents for heating and cooling media. Operating limits for CAIRplus special/customized units are available on request. PR GB Subject to modifications R8-10/

16 Technical Description CAIRplus Ambient conditions Outdoor air Note on extreme conditions! In addition to the air temperature/air humidity of the transported medium, the temperature/humidity of the ambient air is also critical. Observe the condensation limits. from -25 C to +60 C Extract air from 0 C to +80 C Air humidity Max. operating pressure and temperature Minimum operating temperature Notice on extreme conditions! depending on temperature max. 18 g/kg of dry air Heating/cooling coil 16 bar / 90 C Heating/cooling coil 6 C In addition to the air temperature/air humidity of the transported medium, the temperature/humidity of the ambient air is also critical. Environmental factors such as proximity to sea or ocean must be taken into account when selecting material quality. Different ambient conditions apply for integrated refrigerating unit Permitted storage conditions / permitted air condition for uninstalled units Air temperature -10 C to +50 C Air humidity Store units in a dry, non-condensing atmosphere Supply voltage The required supply voltage is specified in the order-related documentation, e.g. AC 230 V/50 Hz (1 phase) or AC 400 V/50 Hz (3 phases) Condensation limits Please pay due attention to condensation limits! The following diagrams illustrate condensation limits depending on temperature and relative humidity at the installation site - for series CAIRplus SX M and CAIRplus SX K. The diagrams are based on normal air values and are calculated using a model box. The given values are approximate figures and can not be used as a guarantee for avoiding condensation. Depending on different casing components, deviations are possible. 16 PR GB Subject to modifications R8-10/2015

17 CAIRplus Technical Description Read example: Relative humidity on unit external side in % Air temperature on unit internal side in C Air temperature on unit external side in C With ambient conditions of 27 C and 60 % relative humidity, air temperature in unit may amount to -1 C without formation of condensate. CAIRplus SX K = without thermal separation Condensation diagram for kb-value: 0.5 Relative humidity on unit external side in % Air temperature on unit internal side in C Air temperature on unit external side in C CAIRplus SX M = partial thermal separation Condensation diagram for kb-value: 0.62 PR GB Subject to modifications R8-10/

18 Technical Description CAIRplus Relative humidity on unit external side in % Air temperature on unit internal side in C Air temperature on unit external side in C 18 PR GB Subject to modifications R8-10/2015

19 CAIRplus Shipping and Storage 4 Shipping and Storage 4.1 Delivery CAIRplus unit can ship as a single piece or multiple individual shipment units. Delivery is done on transport pallets. When the unit is delivered, check that the shipment is correct according to the dispatch note, and also check for completeness. Notice! Consider instructions relating to the procedures in case of shipping damage provided on the unit packaging or in dispatch documents! What steps should you should take in the event of shipping damage? The exterior of the packaging is damaged 1 Unpack the equipment in the presence of the truck driver and have him confirm the damage on the shipping order. 2 Inform the DencoHappel Sales Company immediately. Exterior packaging is OK, contents are damaged. 1 Once you have established the extent of the damage, report the damage to the DencoHappel Sales Company in writing. 2 Take photographs of the damaged parts. 3 Possible shipping damage must be reported no later than 4 days after delivery. It will not be possible to process claims if the above-mentioned points are not fulfilled. In both cases, consult the DencoHappel Sales Company before installing the units. 4.2 Transport Danger due to overhead loads risk of grave injuries or death! Never stand beneath suspended loads, since there is always a risk that the lifting gear, tackle, ropes or slings are faulty or damaged. Use only the lifting lugs provided by DencoHappel! Make sure that equipment is firmly seated before lifting it. Risk of personal injury and equipment damage! Due to a high center of gravity, some equipment can tend to tip over and cause damage to persons and property. When transporting the unit, careafully observe its behavior and do not get near any possible hazardous areas. Notice! Transport the unit only in its original packing. Only remove the original packaging just before installation. Remove the pallet before lifting the unit modules at the lifting lugs / transport gear. PR GB Subject to modifications R8-10/

20 Shipping and Storage CAIRplus For safety reasons, wear protective clothing when lifting or transporting the unit. Before lifting or shipping the unit, make sure that all doors, dampers and panels are fixed and secured. Only use lifting gear with sufficient load-bearing capacity. Never use damaged lifting equipment. Ropes/chains must not be knotted and/or be exposed to sharp edges. Only use ropes/chains of the same length. Use only the lifting lugs provided by DencoHappel! Move the unit carefully without jerky movements. Do not set the unit down abruptly or bump it Lifting the unit lifting lugs on roof (provided with shipment units weighing up to 1500 kg) Angle range Lifting lugs may only be used for lifting. Do not use lifting lugs for lateral loads (pulling of unit on sides). The suspension angle must be between 70 and 110 (see fig. 4-1). Lifting lugs may only be used once. Do not use lifting lugs for permanent suspension of units. Do not lift any other loads together with the shipment unit. With units for outdoor installation, ensure that the roof sheets are not damaged by the lifting gear. The maximum lifted weight of the shipment unit may not exceed 1500 kg. Use all four eyeplates to lift the shipment unit. Fig. 4-1: Lifting lugs for shipment units weighing up to 1500 kg 20 PR GB Subject to modifications R8-10/2015

21 CAIRplus Shipping and Storage Lifting the unit - transport gear on the base frame (provided with shipment units weighing up to 4000 kg) Fig. 4-2: Lifting lugs for shipment units weighing up to 4000 kg Use only the transport gear attached to the base frame for lifting the units. Use the lifting gear (not part of the DencoHappel package) as shown in the figure. Use provided timber spacers to protect the unit at the edges. Suspension angle must not exceed 60. To effectively prevent the load from slipping or tilting, consider its center of gravity when lifting the unit. Use the transport gear only once. Do not use transport gear for permanent suspension of units. Do not lift any other loads together with the shipment unit. With units for outdoor installation, ensure that the roof sheets are not damaged by the lifting gear. Units with a slanting roof are delivered with a device that enables to fasten it in place during truck transport. This device must be removed before lifting the unit by crane! Shipping with a fork-lift truck ATTENTION Unit damage due to stacking the units! Never stack units on top of one another for shipping! Always place and rig the units one at a time! Stacking of units and other foreign field-provided components is not permitted. Exceptions apply for units delivered by the DencoHappel sites where the sufficient load-bearing capacity is considered beforehand. Always use the unit base frame or the supplied pallet as the supporting surface during transportation. Do not lift units without the base frame if the unit profiles are not sufficiently protected. When transporting the unit with a forklift both base-frame profiles must be resting on the forks. Verify proper center of gravity lift point and uniform distribution of weight. PR GB Subject to modifications R8-10/

22 Shipping and Storage CAIRplus 4.3 Storage Notice! Observe the permissible storage conditions when storing the unit. Remove the original packaging only before installation. If the unit is stored for a period of time before installation or commissioning, protect it from damage through elements, build-up of dust and dirt! Prior to commissioning, take appropriate measures to protect units without packaging against build-up of dust and dirt. If packing takes place on site by others, make sure that condensate cannot form below the packaging (consider relevant clearance between the packaging and casing). Always place units on an even surface for storage or intermediate storage. Protect units from bumps and knocks which may damage the casing and protruding components. If commissioning is not carried out within three months following the delivery, the belt drive must be slackened. Rotate the motor axis and fan through at least 2 revolutions every 3 months Permitted storage conditions / permitted air condition for non-installed units Air temperature -10 C to +50 C Air humidity Store units in a dry, non-condensing atmosphere 22 PR GB Subject to modifications R8-10/2015

23 CAIRplus Assembly 5 Assembly Notice! Here you will find information on how to mount and install the unit. Assemble and install exclusively by qualified staff. They must have proper professional training and experience in the relevant accident prevention regulations, as well as other generally recognized safety and occupational health codes, perform unit jobs. The unit must be installed in such a way that it is only accessible to trained and authorized technical personnel. The unit shall only be installed in accordance with the technical specifications provided in the supplied documentation. Stacking of units and other foreign field-provided components is not permitted. Exceptions apply for units delivered by the DencoHappel sites where the sufficient load-bearing capacity is considered beforehand. When connecting an air-duct to the unit, ensure that no foreign objects can enter the unit. If necessary, have a suitable protection grille installed by others on air discharge or intake openings of the unit. ATTENTION Risk of damage to the unit! When entering CAIR units, ensure that no loads are applied on the floor panels. For all installation jobs take appropriate measures to ensure that the load is evenly distributed across the bottom profiles. 5.1 Unit placement Danger due to overhead loads! Never stand beneath suspended loads, since there is always a risk that the lifting gear, tackle, ropes or slings are faulty or damaged. Failure to follow safety precautions could result in death or serious injury. Use only the lifting lugs provided by DencoHappel! Make sure that equipment is firmly seated before lifting it. Warning! Risk of personal injury and equipment damage! Due to a high center of gravity, some equipment can tend to tip over and cause severe injury to persons and damage to property. When transporting the unit, carefully observe its behavior and do not get near any possible hazardous areas Installation site For the unit installation the job site shall meet the following requirements: The site base must be level and stable. The maximum deflection of the site base must not exceed 4 mm per meter. PR GB Subject to modifications R8-10/

24 Assembly CAIRplus In units where a condensate drain is installed, ensure there is adequate height for condensate drain requirements - the height of the site base must at least correspond to the trap height (refer to "Condensate tray trapping"). In case of leaking liquids take measures to prevent damage to the installation site or the environment. Fig. 5-1: Installation site When installing a spray humidifier, use a plinth or unit feet corresponding to the tray height to ensure horizontal alignment with other unit sections. Fig. 5-2: Height compensation with spray humidifier Minimum clearances To remove fans, heat exchangers, droplet separators, etc. and enable adequate maintenance allow a minimum clearance of one unit width on the operating side. Allow a minimum clearance of 600 mm between the unit rear side and the wall if the unit configuration does not provide for an internal joint connection. Fig. 5-3: Minimum clearance 24 PR GB Subject to modifications R8-10/2015

25 CAIRplus Assembly Foundation requirements for indoor installation The foundation/bottom base may protrude a maximum of 20 mm beyond the outer edge of the unit to enable mounting of cover plates or accessories, such as condensate traps. The supporting points of the foundation must be located at every shipping split. Besides, ensure that the maximum distance between these points does not exceed 1600 mm in the unit length(see fig. 5-4). Units with side-by-side arrangement must be supported in the center (see fig. 5-5). L 1600 L 1600 Fig. 5-4: Foundation requirements with side-by-side units operator side Fig. 5-5: Foundation requirements with side-by-side cross-section PR GB Subject to modifications R8-10/

26 Assembly CAIRplus Foundation requirements for outdoor installation (weatherproof, roof frame) Notice! Units for outdoor installation are not roof substitutes! It is not allowed to use weatherproof units as supporting surfaces of a building or similar roof substitutes in accordance with pren and VDI Refer to valid instructions on "Foundation requirements for indoor installation" on page 25. Select an installation site with outdoor air intake not facing the main wind direction. If the unit is mounted on a roof, the latter must support the total weight of the unit, verify that the supporting structure is adequate for the unit. Consult a structural engineer, if necessary. The roof edge below the unit, as well as ducts and other roof openings must be sealed by others on site to prevent water and air leakage. Ensure that the field-provided roof frame is sealed to prevent condensation. For notes refer to "Preparing roof installation" on page 33. In areas with heavy snowfall, ensure that the unit is installed at a location where snow can not affect the unit operation. Provide for an adequate foundation with an appropriate height. Fig. 5-6: Foundation design with concrete base Fig. 5-7: Foundation design with field-provided steel beam Fig. 5-8: Foundation design with field-provided steel support Notice! Pay particular attention to ensure the exact size of the roof openings and level foundation. 26 PR GB Subject to modifications R8-10/2015

27 CAIRplus Assembly Structure-borne noise attenuation In order to reduce the transmission of vibration from the unit to the supporting structure, provide vibration and noise-dampening pads. We recommend to use rubber pads to isolate the foundation from the units installed on a level structure with no special requirements to structure-borne noise isolation. For a ceiling installation we recommend to use commercially available spring-based elements. For very special acoustics requirements please consult an acoustic engineer to select the most suitable method for neutralizing structure-borne noise Wind load High wind velocities can produce heavy loads that can cause the unit to move or tip over. Further on-site measures might be necessary to prevent this from happening Ceiling mounting unit There are various different fastening systems for installation under the ceiling. The dimensioning of the fixation in the ceiling must be performed on-site by others. 5.2 Assembling the unit Injuries due to crushing of limbs! During assembly there is the risk of unit parts crushing your limbs. Always wear protective clothing. Injuries caused by sharp edges! During assembly, there is always a risk of cuts inflicted by thin sheet metal and heat exchanger fins. Wear protective gloves. Notice! See unit submittal documentation for details. Data sheets, installation instructions, small parts and enclosed accessories are located in the unit section marked by this red adhesive label. ATTENTION Risk of damage to the unit! Do not mount or use field-supplied fittings and attachments on the unit panels or frames, as these components can cause an air or water leakage. Ensure easy access and service for the unit. PR GB Subject to modifications R8-10/

28 Assembly CAIRplus Required tools: Electric screwdriver, drill Bit holders/sockets Sockets of sizes 8, 10 Slotted head screw bits, sizes 2, 3 Open-ended spanners sizes 8, 13, 17 Screw drivers Hexagon socket size 6 Tensioning belts or suitable hoisting device Removing lifting lugs and safety devices Remove all lifting lugs, safety locks and devices mounted on and in the unit prior to assembly. Remove safety locks on the fan. Verify that that all lifting lugs on the roof are removed: Roof lifting lug Remove the lug, screw and bushing at the section joint, then secure the supplied M8 x 30 screw. Cylinder screw Plastic washer Support bushing Fig. 5-9: Lifting lug at roof Lifting lug at joints Remove the screws on the end walls and secure the supplied M8 x 70 screw. Cylinder screw Plastic washer Support bushing Fig. 5-10: Lifting lugs for roof and end wall Notice! Due to a risk of damage through lifting lugs - externally mounted dampers, flexible canvas connection partially ship separately. Mount these components on-site and seal them. 28 PR GB Subject to modifications R8-10/2015

29 CAIRplus Assembly Disassemble the lifting lug secured on the base frame. Fig. 5-11: Lifting lug secured on the base frame Notice! You may not use lifting lugsfor suspending the unit from the top on a permanent basis. It is allowed to use lifting lugs only once Installation of individual modules To join individual sections for final assembly (at joints) proceed as follows: Attach provided gaskets at the joint (separate assembly instructions are enclosed with the supplied sealing strip). Fig. 5-12: Installing individual modules PR GB Subject to modifications R8-10/

30 Assembly CAIRplus ATTENTION Risk of damage to the unit! Do not attach tensioning belts/hoisting devices to heat exchanger connections, condensate drains and door handles. Do not use the components to pull or push the equipment! Before joining the sections for final assembly position them as close to one another as possible. Use the unit base frame only to pull the sections together. If necessary, underlay round material to simplify pulling the sections together. Use the tensioning belts to pull together units without a base frame. Secure the belts on the unit profiles at the bottom or roof section. max. 100 mm Fig. 5-13: Unit with base frame Fig. 5-14: Unit without base frame Screw the outer joint connections together. Do not use partition joint connectors to pull the units together. Use screws M8x30. Fig. 5-15: Screw the base frame to the connectors Screw the outer joint connections together. Fig. 5-16: External view 30 PR GB Subject to modifications R8-10/2015

31 CAIRplus Assembly Install the seam cap. Fig. 5-17: External view If the rear side of the unit is not accessible, screw together the interior joint connection in the corner. Do not use partition joint connectors to pull the units together. Use screws M8x60. Fig. 5-18: Internal corners Starting from the internal unit width or height of 1280 mm or more an additional joint connection is provided in the middle of the profile (on the internal side), use the screws to secure this joint connection as well. Fig. 5-19: Internal partition join connector Note on joint connection! If screws can not be applied due to the unit components, unscrew the joint connections, place the screws and mount the joint connections together with screws. Seal pipe and cable ducts to prevent air leakage and condensation. For example use PU-foam to complete the sealing (not included in DencoHappel packaged content). Fig. 5-20: Pipe duct PR GB Subject to modifications R8-10/

32 Assembly CAIRplus Additional measure for double-deck and side-by-side units Connect both unit sections using supplied plates. Fig. 5-21: Connecting unit sections For offset double-deck units, use the screws as outlined. Fig. 5-22: Double-deck units For offset side-by-side units, use the screws as outlined. Fig. 5-23: Side-by-side units Additional measure for units in hygiene design Clean and seal internal joint seams at the bottom. The sealant is included in the packaged content for hygiene units. Fig. 5-24: Joint seams 32 PR GB Subject to modifications R8-10/2015

33 CAIRplus Assembly Additional measures for units for outdoor installation ATTENTION Risk of damage to the unit! Insufficient or improper sealing by others on site can cause water leakage and damage to the equipment and building materials! Carefully seal all unit components. When installing roof components ensure that no loads are applied on the roof panels. Do not walk on the floor panels. If necessary use a proper pad for the entire roof surface. During assembly and assembly pauses, take care that no rainwater gets into the units. After assembly is completed, you must remove the protective foil from the roof panels Preparing roof installation Remove all lifting lugs (1) Install sealing washers at all screws and tighten them (2). Fig. 5-25: Preparing roof installation PR GB Subject to modifications R8-10/

34 Assembly CAIRplus Installing inclined/bossed roof (CAIRplus SX) Secure the separately supplied joint strip. Fig. 5-26: Installing joint strip Single units 064.xxx to 160.xxx and side-by-side units 064.xxx to 096.xxx 1 Use the supplied sealant to caulk the roof panel seams (1). Slide the separately provided joint strips (2) over the seams. Manually crimp down the overhanging end (3) at Fig. 5-27: 2 Single units 064.xxx to 160.xxx and side-by-side units 064.xxx to 096.xxx 34 PR GB Subject to modifications R8-10/2015

35 CAIRplus Assembly Single unit 188.xxx to 252.xxx with inclined roof design 1 Secure the separately supplied joint strip as described above. Slide the separately provided joint strips (1) from both sides. Use a screwdriver to ensure that the connecting plate is placed below the opposite joint strip. 1 Use the supplied sealant to caulk the joint strips (2). 2 Secure in place with the fixing screw (3). 3 Fig. 5-28: Single unit 188.xxx to 252.xxx with inclined roof design PR GB Subject to modifications R8-10/

36 Assembly CAIRplus Single units 280.xxx to 312.xxx and side-by-side units 128.xxx to 160.xxx Secure the separately supplied joint strip as described on page 34. Use the supplied sealant to caulk the roof panel seams (1). Slide the separately provided joint strips (2) from both sides. Secure in place with the fixing screw (3) Fig. 5-29: Single units 280.xxx to 312.xxx and side-by-side units 128.xxx to 160.xxx 36 PR GB Subject to modifications R8-10/2015

37 CAIRplus Assembly Centrally-split roof panels 1 With centrally-split roof panels slide the separately provided roof joint strips (1) over the flanges. Secure in place a terminating angle plate (2) on each front wall. Apply sealant (3) as presented in the figure. Attach the separately provided weatherproof covers (4) and use supplied screws to secure them in place Fig. 5-30: Centrally-split roof panels Consider the following for side-by-side units with misalignment, sizes 128.xxx and 160.xxx Depending on the unit shipping splits, install a separately enclosed roof panel for side-by-side casing (1), if necessary, as presented in the drawing. 1 Fig. 5-31: Side-by-side units with offset, sizes 128.xxx and 160.xxx PR GB Subject to modifications R8-10/

38 Assembly CAIRplus Roof installation with double-deck units Roof installation for double-deck units is identical to the installation of single units refer to the specification from page Apply sealant evenly on the surface. Use the screws to attach the connecting panel to the end wall (1). Finally produce a concave groove in the sealant. Fig. 5-32: Roof installation with double-deck units 38 PR GB Subject to modifications R8-10/2015

39 CAIRplus Assembly Roof installation of side-by-side unit with ECOROT Roof installation side-by-side units equipped with ECOROT is identical to the installation of single units refer to the specification from page Apply sealant evenly on the surface. Use the screws to attach the connecting panel to the end wall (1). Finally produce a concave groove in the sealant. Fig. 5-33: Roof installation of side-by-side unit with ECOROT PR GB Subject to modifications R8-10/

40 Assembly CAIRplus Intermediate or base frame cover panels Mount the cover panels as outlined Fig Mount the cover panels as outlined Fig Mount the cover panels as outlined Fig PR GB Subject to modifications R8-10/2015

41 CAIRplus Installation 6 Installation Danger of injury due to toxic substances! Glycols and other antifreeze agents are harmful for humans and animals, if swallowed. Consult a doctor immediately if swallowed by mistake. Notice! Unit connections at coils and humidifiers shall only be performed by qualified licensed staff. Have qualified licensed staff or other individuals with proper professional training and experience in the relevant accident prevention regulations, as well as other generally recognized safety and occupational health codes, perform unit jobs. ATTENTION Risk of damage to the unit! When entering CAIR units, ensure that no loads are applied on the floor panels. For all installation work, take appropriate measures to ensure that the load is evenly distributed across the bottom profiles. 6.1 Requirements Check the unit for external damage and ensure proper instalation and anchorage. Check if vibration and noise-dampening pads are provided. The following applies: either rubber pads are used for level installation to insulate the unit from the foundation in a location where no special requirements for the neutralisation of structure-borne noise apply; or commercially available spring-based elements are used for ceiling installation; or very special acoustic requirements please consult an acoustic engineer to select the most suitable method for neutralising structure-borne noise. Check the following before performing coil connections of the unit: To allow maintenance and service, install drainage valves at all low points of the water circuit to ensure that the water circuit can be fully drained. Provide drainage with a shut-off valve for emptying the unit s water circuit. Ensure that air vents at all high points in the chilled water circuit are installed and can be easily accessed. Clean the field-provided piping and create the relevant report. 6.2 Installing air-conveying components In order to prevent transmission of structure-borne noise, enable a tension-free connection between ductwork and unit by using elastic connectors or sound attenuators to prevent structural noise transmission (also refer to "Structure-borne noise attenuation" on page 27). If using flexible canvas connections between unit and ductwork, installation length of the connectors must be smaller than their length in expanded condition. PR GB Subject to modifications R8-10/

42 Installation CAIRplus 6.3 Installing air-handling components with coil connections Recommendations on water quality for heat exchangers operating with pumped warm water and pumped chilled water: Water in proper quality, e.g. salt and lime-free drinking water, considerably increases the service life and efficiency of the heat exchanger. Check the limit values in the table once a year to prevent damage to the hydraulic system and installed components. If necessary, add inhibitors to water. Notice! These limit values are only intended to provide basic information on water quality and do not form any basis for a guarantee. Description Symbol Values Hydrogen ion concentration ph Effects in case of difference < 7 > 9 Corrosion Incrustation Calcium and magnesium content Hardness (Ca/Mg) Δ > 8.5 Incrustation Chlorine ions Cl < 50 ppm Corrosion Iron ions Fe³ + < 0.5 ppm Corrosion Magnesium ions Mg² + < 0.05 ppm Corrosion Carbon dioxide CO 2 < 10 ppm Corrosion Hydrogen sulphate H 2 S < 50 ppb Corrosion Oxygen O 2 < 0.1 ppm Corrosion Chlorine Cl 2 < 0.5 ppm Corrosion Ammonia NH 3 < 0.5 ppm Corrosion Ratio carbons/sulphates HCO 3 ² - /SO 4 ² - > 1 < 1 Corrosion 1/1.78 D = 1 Fr with 1 Fr = 10 g CaCO 3 /m³ ppm = parts per million (mg/l) ppb = parts per billion (μg/l) Installing air-handling components for cooling/heating applications ATTENTION Risk of damage to the unit! When connecting the heat exchanger, counter hold with a pipe wrench to prevent damage. The connections to coils made by others on side must generally be tension-free. Do not apply mechanical and static loads to the connection fittings. Consider the counter flow principle when connecting coils. (air and water moving in opposite directions in the coil) Protect the fins in the coils to prevent damage. Connect pipework by others to the chilled water inlet and outlet. The inlet and outlet coil connections are marked with labels. Insulate pipework on site. With air-handling components for cooling/heating applications, consider the following: Following installation insulate coil connections and pipework to prevent condensing water. Coil drip tray is made of stainless steel and collects forming condensate. The coil drip tray is fitted with a drain connection to empty condensate. Refer to the section on trap (see "Water drain trapping" on page 45). 42 PR GB Subject to modifications R8-10/2015

43 CAIRplus Installation For units with outside-air or mixed-air operation consider the following: ATTENTION Risk of damage to the unit! Protect the heat exchanger in unit from ice and freezing at ambient temperatures below the freezing point. Use proper antifreeze agents in the water circuit. Notice! Using glycol is allowed, but the glycol concentration shall not exceed 50% of the total charge. A higher quantity can cause operating faults Installing evaporator/condenser components ATTENTION Risk of environmental damage! Properly dispose of all liquids (refrigerants) in an environmentally-friendly way in accordance with the locally applicable laws and regulations. Use special tools and fittings for handling service connections. The units are charged with protective nitrogen that audibly discharges when caps are removed Installing coils with a liquid-coupled energy recovery system Refer to "Installing air-handling components for cooling/heating applications" on page 42. PR GB Subject to modifications R8-10/

44 Installation CAIRplus Installing humidifier Refer to the supplied documentation for instructions on assembly and installation. Also observe the German Drinking Water Act (Trinkwasserverordnung TWVo). The following recommendation applies Guide values for the quality of water circulating in the spray humidifier (air washer) (in accordance with: VDI 3803 HVAC systems. Constructional and technical requirements, February 2010, Appendix A, Table A1). Room-ventilation system equipment for: Quality Room-air quality IDA 2, IDA 3 or IDA 4 according to EN Room-air quality IDA 1 according to EN for IT rooms Room-air quality IDA 1 according to EN for sterile and cleanrooms indirect evaporative cooling (to be determined depending on the system) Appearance klar, farblos und ohne Bodensatz ph value 7 to 8.5 Total salt concentration TSC g/m³ < 800 < 250 < 100 Electrical conductivity (at reference temperature 20 C) Calcium ms/m < 100 < 30 < 12 μs/cm < 1000 < 300 < 120 Ca 2+ mol/m 3 > 0.5 g/m 3 > 20 Carbonate hardness KH dh < 4 Total hardness GH dh < 7 Chloride CL - mol/m 3 < 5 g/m 3 < 180 Sulphate SO 4 2- mol/m 3 < 1.5 < 1 g/m 3 < 150 < 100 Consumption KMnO 4 g/m 3 < 50 < 20 < 10 Microbial count CFU (colony forming units)/ ml < 1000 < 100 < 10 Legionella bacteria CFU/100 ml < 100 Notice! When installing a water-softening unit DencoHappel recommends to repeat the water analysis. The total salt concentration shall not exceed 250 g/m³! The electrical conductivity shall not exceed 300 µs! ATTENTION Risk of damage to the unit! Do not operate honeycomb humidifiers with fully demineralized water. 44 PR GB Subject to modifications R8-10/2015

45 CAIRplus Installation Water drain trapping Types of condensate drains Condensate drain by unit profile Fig. 6-1 Condensate drain by unit profile Fig. 6-2: Tray drainage adapter 22/40 mm Condensate drain through base frame Fig. 6-3 Notice! Direct connection to a sewage network is not allowed! Fill the condensate trap with water prior to commissioning and after extensive downtime periods. Hydraulic seal H of the trap must be greater than the maximum positive or negative pressure (mm water column) in unit (1 mm WC = 10 Pa). Use the following equation for the dimensioning: Unit overpressure/under pressure( Pa) H( mmwc) = The vertical difference between the water drain and hydraulic seal must also correspond to the dimension H (mm WC). Fig. 6-4: Trapping for section under positive pressure PR GB Subject to modifications R8-10/

46 0 Installation CAIRplus 1,5 H Connect the trap to the sewage water system as shown in the figure. Caution: freeze-up risk! In the event of freeze-up risk, the drain pipe must be insulated and kept warm using heating wire., Fig. 6-5: Trapping for section under negative pressure Fig. 6-6: A trap is required for each section with condensate drainage or overflow pipe. Connecting multiple drains to a common line with only one trap is not allowed (* can result in clogged drain). Notice! Negative pressure and positive pressure traps must be connected to separate common lines (refer to Fig. 6-6) Installation of integrated refrigerating systems Please observe the instructions contained in the separate operation manual on equipment systems with integrated refrigeration. In general, when working with refrigerants, be sure to pay attention to the following points: (see also "Handling refrigerants (only for units with integrated refrigerating system)" on page 12) Warning of high concentration of refrigerants in the air! High concentration of refrigerants in the air may have an anaesthetic effect and cause unconsciousness. Prolonged exposure may cause irregular heartbeat and sudden death. Very high concentrations of refrigerant may cause suffocation by reduced oxygen content in the surrounding air. You should therefore only work in an adequately ventilated environment, and exercise due care and attention when carrying out the work. Wear protective clothing and, if necessary, an autonomous breathing apparatus. 46 PR GB Subject to modifications R8-10/2015

47 CAIRplus Installation Injuries caused by smoking and open flames Smoking and open flames at the installation site of the unit or during work with refrigerants are prohibited. Open fire or flames can lead to the disintegration of a refrigerant and release of toxic gases. Do not keep any inflammable liquids in close proximity to the unit. Danger of injury from refrigeration! Contact with a liquid refrigerant can result in skin burns or injury to other organs. Exercise due caution and attention when carrying out jobs and avoid contact with a refrigerant. Wear suitable protective clothing. Danger of injury caused by high pressure! When working on hydraulic or refrigeration circuits or in case of damage to the components or piping, there is a risk of injury from fluids or gases escaping at high pressure. Exercise due caution and attention when carrying out this work. Wear appropriate protective clothing. ATTENTION Risk of environmental damage! Do not pollute the environment with liquid products, refrigerants or oils. Dispose of the latter in accordance with local laws and regulations by avoiding harm to the environment. Ethylene glycol and propylene glycol are categorized as water pollutants. This also applies to mixtures with water. Always make sure that the units are accessible only to authorized and trained technical personnel. If necessary, use appropriate equipment to keep unauthorized persons away from the unit. Have all leaks immediately eliminated by service personnel or a specialist refrigeration company (refer to section 4.10). The safety sheet stating the type of refrigerant charged on the given unit shall be firmly secured in the machine room of the unit in a well visible manner (refer to unit identification plate or operation manual for the unit). Ensure that proper trays or similar vessels are mounted below the unit in order to reliably capture oil and glycol liquids and prevent contact with the environment. Use only accredited components for ATEX units. Be sure to ground all electric components. Notice! Completion and commissioning of refrigerating systems may only be carried out by the manufacturer or another competent expert designated by the manufacturer. Assembly and installation is only allowed to be performed by qualified licensed staff. Comply with the prevailing standards and guidelines (e.g. DIN EN 378, BGR 500 and F-Gas Regulation) in performing all activities. PR GB Subject to modifications R8-10/

48 Installation CAIRplus Prerequisites for commissioning All structural building prerequisites such as accessibility, installation of self-contained units and ducts, and the sustained availability of all supply media must be satisfied. Furthermore, it must be possible to operate the equipment in the required operating points. Basis for warranty The basis for the warranty is the completion of a service contract with a qualified specialist company in refrigeration engineering and the proof of regular, competent maintenance recorded in the service booklet. SYSTEM OPERATION: The refrigeration unit can only be operated when the room-ventilation unit is in operation. Error messages from the refrigerating system are displayed at the switching cabinet. The equipment represents a system subject to monitoring in the sense of the German Law on Occupational Safety (BetrSichV), which poses specific requirements on the operator and where conditions according to Art.14 of this law must be satisfied before the system may be operated. Be sure to observe any further applicable laws of the respective installation site. Maintenance and inspection See the service booklet for refrigerating systems for requirements. 6.4 Installing accessories Refer to the supplied documentation of the accessories that specify assembly and installation instructions for accessories or field-provided accessory items. 48 PR GB Subject to modifications R8-10/2015

49 CAIRplus Electrical Connection 7 Electrical Connection Notice! The electrical connection may only be performed by a qualified licensed electrician. The electricial must have proper professional training and experience in the relevant accident prevention regulations, as well as other generally recognized safety and occupational health codes, perform unit jobs. Ensure and observe protective measures! When installing and connecting the unit, also observe protective measures for low-voltage systems according to the EU Directive as well as regulations and codes of the local utility providers. Ensure earthing and potential equalization of the individual sections and all connected components. Electrical connection must be assured and documented between all shipment units (potential equalisation usually to be provided via screw connections). Connect the entire unit to the same potential. Passive switch contacts in explosion-protected units may only be used in intrinsically safe electric circuits. Lightning protection! Especially roof units must be equipped with a proper lightning protection system. Electrocution through hazardous voltage will lead to death or serious injury. Disconnect the unit from the power supply and ensure the power cannot be switched back on. Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. NOTICE! Perform all wiring to the unit in accordance with enclosed unit-specific wiring diagrams and national electrical codes and regulations. You must use a separate mains power cable. Never connect other units to this mains power cable. Check all electric connections according to the supplied wiring diagrams and all terminal block screws for a tight seat. 7.1 Requirements Visual inspection of mechanical components Carry out a full visual inspection of the entire unit and installed components. Before you start setting up the unit electrical connections, check the following: The properties of the mains power supply must comply with EN regulations and the power requirements of the unit. Let a qualified licensed electrician determine the size of the pre-fuse based of the unit rated current. The motors must be able to operate at their rated capacity where the input voltage with rated frequency is between 95% and 105% of the nominal voltage. PR GB Subject to modifications R8-10/

50 Electrical Connection CAIRplus On-site routing of cables and cable penetrations by others Avoid cable penetrations and routing of cables near doors, dampers, panel connections and cover strips. Perform all screw connections and cable openings leak-free. The connecting cables in the fan chamber must be long enough to allow the motor to be moved easily (e.g. for belt tightening). 7.2 Connecting unit Separate grounding for each assembly group with an electrical connection is required. Consider the relevant instructions specified in the enclosed manuals for the accessory items Motor protection Motor protection with PTC thermistors Depending on the motor size and type, the AC motors are fitted from 2 to 6 PTC thermistors switched in series. The PTC thermistors are embedded in motor windings to enhance reading of the winding temperature. PTC thermistors are semiconductor resistors with variable temperature-dependent values. When the maximum allowed winding temperature of 135 C is reached, the resistance reading increases rapidly. This control method and the full motor-protection electronics deactivates motors. Notice! Unlike thermal contacts, PTC thermistors do not wear off. They provide a high degree of operational reliability due to shock-resistant, pressure-resistant and vacuum-proof features. ATTENTION Risk of damage to the unit! Do not apply voltage to separate lead-out sensor, since this would destroy it. The maximum allowable voltage reading must not exceed 5 V. Wire the sensor only to the motor full protection tripping unit (e.g. 912.MVS 1.0). Induction effects! To prevent induction effects for the PTC thermistor circuit DencoHappel recommends to use electrically screened lines, such as JY (st) Y, 2 x 2 x 0.5. Attach earth screen on one side to the potential equalisation terminal (PE). 50 PR GB Subject to modifications R8-10/2015

51 CAIRplus Electrical Connection Resistance R Operating point of tripping unit Temperature T +135 C Extended motor protection Disconnection in the event of an error Motor full protection electronics For motor full protection, we recommend to use 912.MVS 1.0 tripping units. These are specially designed for PTC thermistors of motors. Full motor protection is based on the closed-circuit principle and is intrinsically safe. Motor protection tripping units 12.MVS 1.0 generally enable isolated disconnection and a restart following a power outage. Electronic motor protection tripping units deactivate motors in the following situations: Overload Ambient temperatures exceed allowed limits Locked fan wheel Insufficient cooling Short circuit in winding Wire breakage and loose contacts in the measuring line With frequent start-ups, intermittent operation, high switching frequency and to ensure optimum protection against 2-phase run, DencoHappel recommends to protect motors using thermal overload relays/motor circuit breakers in addition to the PTC thermistor protection. In case of fault shutdown investigate the above-mentioned causes. Motor protection with thermal contact Thermal contacts are temperature-dependent operating elements for automatic monitoring of the motor winding temperature. Thermal contacts are integrated in motor windings and enable additional protection as compared to thermal cut-out devices and motor circuit breakers: Insufficient cooling High ambient temperature Extreme speed reduction in course of control and regulation operations Motor disconnection in case of control-voltage line failure Faulty contacts and cable breakages in the control circuit. A thermal contact opens if the allowed winding temperature is exceeded. As a result the mains circuit of the control unit is interrupted. The fan contactor drops out and disconnects the motor from the mains. Motor protection is intrinsically safe. PR GB Subject to modifications R8-10/

52 Electrical Connection CAIRplus Connecting electric motors For proper unit operation consider the clockwise rotating field for unit connection. If necessary, check the rotating field using an instrument specifically designed for this purpose. ATTENTION Risk of damage to the unit! Improper connection to the motor/fan could result in equipment damage. Check for the proper assignment of the phase sequence to the specified rotating direction before the motor is connected. Single-speed electric motors with direct start: Single-speed electric motors with Y/Δ-start: The terminals of AC motors are labelled in such a way that the alphabetical sequence of the terminal designation U1, V1, W1 corresponds with the temporal sequence of the phases L1, L2, L3 (with clockwise rotation). The rotation direction can be reversed by exchanging two connecting wires: Exchange the connecting cables, e.g. U1 and V1 Y-switch: exchange the connecting wires, e.g. U1 and V1 Δ-switch: exchange the connecting wires, e.g. U2 and V2 Voltage fluctuations Ensure that the supply voltage at mains frequency falls within the range from 95% to 105% of the rated voltage. If this condition is met, motors can deliver the rated capacity, otherwise non-compliance can result in equipment damage. To carry out the connection, proceed as follows: Connect the unit according to the wiring diagrams. Single-stage motor: 1500 min -1, with voltage change-over Notice! Please observe the name plate of the motor (Y/delta switch)! L3 W1 L1 U1 U2 W2 V2 V1 L2 W2 U2 V2 U1 V1 W1 L1 L2 L3 *1 Motor version: to 2.2 kw: 3 x 230 V with Δ-type switch, 3 x 400 V with Y-type switch from 3 kw: 3 x 400 V with Δ-type switch, 3 x 690 V with Y-type switch 2-3 PTC thermistors depending on the motor size Total resistance R K (20 C) approx Ω W2 L1 U1 W2 U2 V2 *1 PTC thermistor *2 Motor protection device K U1 V1 W1 W1 U2 *2 L3 L2 V2 V1 L1 L2 L3 K Fig PR GB Subject to modifications R8-10/2015

53 CAIRplus Electrical Connection Frequency inverter Make the parameter settings in the course of unit start-up. ATTENTION Risk of damage to the unit! Do not activate the parameter "overmodulation" as this can damage the impeller. Permanent magnet motors (PM motor) without integrated electronics may only be connected to suitable frequency inverters. It is not possible to operate several PM motors with one frequency inverter. Notice! In this case, DencoHappel neither accepts warranty claims nor assumes liability. Ensure that the maximum frequency does not exceed the allowable limit (refer to data sheet on fan). Consider the relevant instructions specified in the enclosed manual for the frequency inverter. Use a screened motor cable only EC Fans EC fans and motors provide air movement with the highest efficiency factor. Highly efficient electronically commuted motors with permanent magnets are used with variable speeds via integrated controller. Connect the fans according to the attached documentation/wiring diagram and observe the manufacturer's instructions. When using earth leakage circuit breakers, make sure that they are sensitive to universal current (type B). If the control cables are wired to a terminal box, observe the pin assignment shown in the following wiring diagram: Service switch Install a lockable service switch near the access door of the fan chamber. When there is a factory-mounted service switch, the wiring is run up to the motor. PR GB Subject to modifications R8-10/

54 Electrical Connection CAIRplus Fig Installing and connecting actuator motor Notice! Adjust the final position switch before commissioning! With a factory-mounted DencoHappel actuator, connect the latter in accordance with the specifications in the data sheet on actuators. If other actuators are used - refer to the relevant documentation. Ensure proper operation of this component. Be sure not to start up the fans with closed dampers Additional electrical components Connect additional electrical components in accordance with the relevant provided documentation and wiring diagrams. 54 PR GB Subject to modifications R8-10/2015

55 CAIRplus Commissioning and Maintenance 8 Commissioning and Maintenance Notice! Data sheet and assembly instructions are located inside the unit, refer to the labelled positions for the documentation! Remove these documents prior to the unit commissioning. Certain assembly groups and unit components require individual commissioning. The relevant instructions are listed in the following chapter. Electrocution through hazardous voltage will lead to death or serious injury! Disconnect the unit from the power supply and ensure the power cannot be switched back on. Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. Do not work on the PM motor when the fan wheel is freely rotating. You must mechanically prevent the fan from moving. Life-threatening danger of explosive atmosphere! Give special consideration to safety instructions, procedures on unit assembly and electrical installation instructions for units operating in explosion-risk areas. Failure to comply with these regulations may result in explosions causing severe personal injury or death! Risk of contusions from rotating components! Before opening unit doors, secure the fan from being inadvertently switched on. Wait at least five minutes following the complete fan stop before opening unit doors. Risk of burns due to hot surfaces! Temperatures above 85 C can occur on the motor surfaces, particularly on the controller casing! Severe burns can be the consequence. Risk of being inadvertently locked in! Ensure that no persons are locked inside the unit. Walkable surfaces of the unit are equipped with emergency levers on the interior side of doors. Smaller units must provide a protection against inadvertent locking by using padlocks on the door stop. Danger of crushing by rotating storage mass! Cutting injuries can be incurred from rotating sharp edges. PR GB Subject to modifications R8-10/

56 Commissioning and Maintenance CAIRplus ATTENTION Risk of damage to the unit! When entering CAIR units, ensure that no loads are applied on the floor panels. For all installation work, take appropriate measures to ensure that the load is evenly distributed across the bottom profiles. Maintenance intervals The specified maintenance intervals apply to air conditions with normal levels of contamination. The maintenance intervals must be reduced according to the level of air contamination. Notice! Carry out additional cleaning if treated air contains oil. Sealant material is oil-proof only for a limited time. When using disinfectants, only use those according to DGHM list, DVG or VAH certification. PERSONAL PROTECTION! For cleaning and certain maintenance jobs, use personal protective equipment including face shield and chemical resistant gloves. 8.1 Routine cleaning and maintenance HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 55. After the cleaning procedure ensure that the unit is dry and residue-free! Observe current legal regulations and standards! We recommend to perform maintenance steps and observe intervals specified in VDI 6022 Use a dry cloth or an industrial vacuum cleaner, if necessary, to remove dry coarse dirt. Remove remaining dirt following a subsequent installation of add-on accessory items. For other contaminants use a dry cloth to remove dirt, if applicable wash off using some water by adding alkaline cleaning agent. For disinfectioning unit surfaces use cleaning agents specified in the following sources: List of disinfection procedures (DGHM) issued by the German Association for Hygiene and Microbiology, certificates issued by DVG and VAH (German Association of Veterinary Medicine and the German Association for Hygiene and Microbiology/Association for Applied Hygiene). Refer to this list for details and consider the specified concentration and exposure time. Use the following cleaning agents: e.g. BODE Microbak or DESOMED Desotop. For correct concentration refer to the data sheet provided by the manufacturer and/or select a non-visible small surface to test the solution there beforehand. Using alcohol-containig agents is not allowed due to risk of explosion and fire. Do not use abrasive sponges or tools that may scratch or scrape the protective surface during cleaning (surface can be damaged). Treat galvanized parts with a preservative spray. Apply a lubricant spray to all moving parts, such as door latches and hinges, with the exception of dampers and louvres! Clean gaskets on the inspection doors and check for leaks, microbial growth and mould. It is recommended to treat gaskets with a waterproof preservative. Check electrical connections. Check earthing. Ensure that the unit is dry and residue-free! 56 PR GB Subject to modifications R8-10/2015

57 CAIRplus Commissioning and Maintenance Basic information about cleaning heat exchangers Injuries caused by sharp edges! Observe precaution when cleaning due to risk of cuts on thin and sharp edges. Wear chemical resistant gloves. ATTENTION Risk of damage to the unit! During commissioning, avoid one-sided pressure loads outside the design parameters otherwise the fins might be damaged. In this case, DencoHappel neither accepts warranty claims nor assumes liability. Fins require cleaning to ensure that the heat exchanger continues to operate at full capacity. Use a brush (not wire brush) or an industrial vacuum cleaner for this purpose. Do not use hard or sharp cleaning tools! Use compressed air stream against airflow direction or water spray at low pressure to clean copper or aluminum fins. Use steam-jet appliances to clean steel galvanized heat exchangers or heat exchangers with reinforced fins. PR GB Subject to modifications R8-10/

58 Commissioning and Maintenance CAIRplus 8.2 Maintenance frequency checklist Observe maintenance frequency specified in the European guidelines and standards (e.g. VDI 6022). ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITH SHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Unit part Frequency (months) Action Units for indoor installation (see page 62) Monthly Every 3 months Clean and refill available traps. Check casing for damage and proper fit. Check/replace gaskets of all service openings. Check panels for damage and corrosion, renew corrosion protection and check proper operation of door stop device (on the pressure side). Hygiene inspection (DencoHappel recommends to carry out maintenance jobs at intervals specified in VDI 6022!): check built-in parts for dirt and clean, if necessary; disinfect by wiping; check gaskets and seals for mould and microbial growth, clean/replace if necessary. Units for outdoor installation (weatherproof units for roof installation) refer to page 62) Every 12 months Complete the same steps specified for units for indoor installation. Verify that unit roof is leak-free. Check side panels and cover strips, reseal as necessary. Check base frame and base frame cover panels. Clean external weather grille on the the fresh and exhaust-air sides. Belt-driven fan assembly (see page 63 et seq.) Every 3 months Check fans and motors for secure mounting position, debris, damage and corrosion. Check anti-vibration isolators for proper operation Check belt protection grille for proper operation, clean if necessary. Check impeller for unbalanced condition. Check tension of V-belt and inspect for wear; re-tension or replace as necessary for specification see page 64 et seq. Check fan/motor for noise in bearing, replace bearing if necessary. Lubricate non-sealed fan bearing according to the motor manufacturer s recommendations (refer to Tab. 8-2 on page 66). Direct-driven fan assembly (See page 67) Every 3 months Check fan motors for debris, damage and corrosion. Check motors for noise in bearing, replace bearing if necessary. Check impeller (especially welded seams) for cracks; replace bearing if necessary. 58 PR GB Subject to modifications R8-10/2015

59 CAIRplus Commissioning and Maintenance Unit part Routines for all filters (see page 69et seq.) Bag/platetype/fine-particle filter (refer to page 69) Activated Carbon Filter (cartridges) (see page 70) Grease filter (see page 70) Other filters Heating unit (low pressure hot water) (p. page 71) Heater unit with steam (see page 72) Direct-fired (gas) heater assembly (see page 72) Frequency (months) Every 3 months Every 6 months at least every 6 to 9 months continuous measurem ent replace every 3 months Every 6 months Every 3-6 months Check filters for debris, damage and odour. Clean filter chamber. Check if the maximum allowed pressure difference (refer to RLT 01 guideline - German Association of HVAC Manufacturers) or pressure difference specified by manufacturer is exceeded, and replace the filter if necessary. Hygiene inspection (DencoHappel recommends maintenance routines and intervals specified in VDI 6022!): Even if the filter shows no visible signs of dirt, microbial growth and mould may propagate through the filter as result of its longterm use (in air with low dust content). Replace the filter if the maximum pressure difference is reached. Replace filter if activated carbon is saturated. Check if filter racks with activated-carbon cartridges are fitting correctly. To prevent the reduction of service life of the expensive activated-carbon filter, ensure that the pre-filtering and fine-filtering stages are in proper condition. Use a cleaning bath to wash filters cells. Refer to the relevant maintenance instructions specified in the supplied documentation. Every 12 months Every 12 months Action Check for leak-free condition and possible dirt on the air side. To ensure frost protection, periodically check the safety devices and take proper precautions such as draining the equipment or adding antifreeze agents. Ensure that pipework connections and mountings are securely fixed. Clean on air side, if necessary (blow through heat exchanger using compressed air or low pressure water). Air vent. Complete the same steps specified in "Heater assembly (pumped warm water)" Check steam inlet and condensate drain for proper operation. If necessary, check control functions. Refer to the relevant maintenance instructions specified in the supplied documentation. PR GB Subject to modifications R8-10/

60 Commissioning and Maintenance CAIRplus Unit part Frequency (months) Action Cooler without or with droplet separator (see page 73) Every 12 months Check for leak-free condition and possible dirt on the air side. To ensure frost protection, periodically check the safety devices and take proper precautions such as draining the equipment or adding antifreeze agents. Ensure that pipework connections and mountings are securely fixed. Clean on air side, if necessary (blow through heat exchanger using compressed air or low pressure water). Air vent. Clean coil drip tray and condensate line. Check trap for proper operation, top up as necessary. Clean droplet separator with a descaling spray. Before winterizati on Drain water from the cooling coil before winter. Evaporator/ condenser (see page 75) Every 12 months Clean and check evaporator/condenser. Ensure that all refrigeration components (refrigerating machine, direct evaporator, distribution manifold, refrigerant lines, etc.) are functioning properly. Heat pipe (see page 76) Every 12 months Clean coil fins. Clean coil drip tray and condensate line. Check trap for proper operation, top up as necessary. If a heat pipe is fitted with a bypass, check air-regulating and shut-off dampers for proper operation. Liquid-coupled energy recovery assembly (see page 76) Every 12 months Complete the same steps specified in "Cooler with/without droplet separator" (every 12 months). Plate heat exchanger (see page 77) Every 12 months Carry out cleaning depending on contamination degree of the plate assembly. Check bypass damper for proper operation, if required. Complete wet cleaning only if a tray is installed and available! Remove oil and fat deposits. Rotation heat exchanger (refer to page 78) Every 3 months Every 12 months Check tension of drive belt, tighten as necessary. Clean coil fins carry out wet cleaning only if a tray is installed! Never use highpressure water or steam for cleaning coil fins. Remove dirt from the section. Check dampers with energy-recovery system and bypass arrangement for proper operation. Check run-around gaskets, adjust as necessary. Check motor alignment. 60 PR GB Subject to modifications R8-10/2015

61 CAIRplus Commissioning and Maintenance Unit part Frequency (months) Action Damper blades and shut-off dampers (see to page 80) Sound attenuator (see to page 80) Every 6 months Every 6 months Use a vacuum cleaner to blow off damper blades, never add grease! Detach the actuator from dampers, check if dampers are moving freely. Check that the damper actuator moves to its final positions. Check the sound attenuator section and sound insulating splitters for dirt, clean as necessary. 8.3 General considerations ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITH SHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Commissioning of units for indoor installation DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Complete the following commissioning steps: Carefully check the entire casing and components for damage and correct fit: Doors and service openings Seals and gaskets Handles and levers Connections with foam rubber gaskets Sight windows Panels Remove protective film, if applicable. Remove all transportation/safety locks. Ensure that there are no loose items inside the unit. Check that the unit is air tight. Clean the unit as specified in Routine cleaning and maintenance on page 56. PR GB Subject to modifications R8-10/

62 Commissioning and Maintenance CAIRplus Maintenance of units for indoor installation DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Notice! Carry out additional cleaning in case of aggressive or oil-containing air. Sealant material is oil-proof only for a limited time. Doors and service openings Panels Trap Carry out the following maintenance steps: Carefully check the entire casing and components for damage and correct fit: Doors and service openings Seals and gaskets Handles and levers Connections with foam rubber gaskets Sight windows Panels Check seals and gaskets, replace if necessary. Check door stop device (on the pressure side) for proper operation. Check for damage and corrosion. If applicable, renew or apply new corrosion-protection (paint), impregnate, etc. Clean and refill available traps Commissioning of units for outdoor installation (weatherproof roof units) DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Complete the following commissioning steps: Complete all steps specified in Commissioning of units for indoor installation on page 61 first. Check condition of weatherproof gasketing (refer to Foundation requirements for outdoor installation (weatherproof, roof frame) on page 26) Maintenance of units for outdoor installation (weatherproof roof units) DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Carry out the following maintenance steps: Complete all steps specified in Maintenance of units for indoor installation on page 62 first. Verify that unit roof is leak-free. Check condition of side panels and cover strips, renew sealant if required. Clean weather protection grille on the fresh and exhaust-air side once a year. 62 PR GB Subject to modifications R8-10/2015

63 CAIRplus Commissioning and Maintenance 8.4 Fan assembly and drives ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITH SHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Commissioning of belt-driven fan assembly DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! ATTENTION Risk of damage to the unit! Do not activate the fan if damper blades are closed. Complete the following commissioning steps: Check general condition of the entire casing and all components for damage and correct fit. Remove transportation and safety locks. Check belt for proper tension and alignment. Check fan rotation direction at all speed stages. Measure the motor current consumption. The rated motor current should fall within the range given on the motor identification plate, this reading must not exceed the specified limit. Check motor protection device for proper operation. For motors with separated air supply inspect the air inlet grille and air ductwork for clean condition. The entire cross-section of the ductwork must be unobstructed. Check all system components (air-regulating and shut-off dampers, fire protection dampers, flow rate controller) for proper operation, open to ensure free movement Maintenance of belt-driven fan assembly DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! ATTENTION Risk of damage to the unit! With a completely stopped fan and open control valve of the heater assembly (pumped water, steam or refrigerant), temperatures inside the unit are roughly equivalent to the supply temperature of the heating medium (normally around 90 C). This can result in deformation damage to plastic parts (especially to plastic droplet separators, surfaces of humidifier honeycombs etc.). Besides, fans and motors with sealed bearings (re-lubrication is not required) may sustain damage at temperatures above 80 C. Consider a maximum operating temperature of 40 C for a number of electrical built-in components (frequency inverters etc.) see and observe relevant manufacturer's instructions! PR GB Subject to modifications R8-10/

64 Commissioning and Maintenance CAIRplus Carry out the following maintenance and inspection steps: Check fan for secure mounting. Check fans for dirt, damage and corrosion. Check anti-vibration isolators for proper operation Check belt protection grille for proper operation, clean if necessary. Check impeller for unbalanced condition. Initial check: Regular checks: Re-tensioning or replacing V-belt Perform the initial check following 50 hours of operation Subsequent checks depend on the operating load and experience. Check every three months, if the unit operates on a regular daily basis (approx. 8 hrs a day). With higher operating hours perform more frequent inspections. Belt profiles Smallest pulley diameter (mm) F force (N/belt) SPZ SPA SPB Fig. 8-1: High-performance narrow V-belt as per DIN 7753 Deflection x [mm] Distance between axes [mm] ATTENTION Equipment damage and notice Always reduce the distance between the axes to the point where the V-belt can be placed in grooves without applying force. It is not allowed to use crow bars, screwdrivers or similar tools for belt mounting. If the V-belt pulleys are fitted with several grooves, replace all V-belts. Do not use a belt set consisting of belts from different manufacturers. Belts do not require any special maintenance. Avoid using belt wax and belt spray. Inspect the belt for tension and wear, re-tension or replace if required. To re-tension the belt using the motor mounting plate or replace: Slacken the counter nuts of the set bolts. Replace the belt, if required. Check the pulley alignment and adjust, if required (fig. 8-2). Tension the fan belt (measure using a belt tensiometer or frequency calculation method, fig. 8-2). Tighten counter nuts. An acceptable belt deflection at a load of P = N is from 5 to 20 mm, depending on the axis distance (see fig. 8-2). 64 PR GB Subject to modifications R8-10/2015

65 CAIRplus Commissioning and Maintenance Center lines Fig. 8-2: Pulley alignment and fan belt tensioning Adjusting or removing fan belt pulley Slacken fan belt, see Re-tensioning or replacing V-belt on page 64, and: remove the belt. Loosen and remove both hexagon-socket screws (2). Screw a hexagon-socket screw into the empty threaded hole (1) and turn it until both pulley and bush are loose. Pull the pulley assembly off the motor shaft (fan shaft) and remove. Fig. 8-3 Shaft Bush Hexagon-socket screws for pulley fixation To mount the fan belt pulley, proceed as follows: Position the pulley and bush so that these engage with one another. Align both holes and insert screws without tightening. Slide the pulley and bush on the shaft as close to the motor or fan as possible (to keep leverage small) and align. (For alignment see Re-tensioning or replacing V-belt on page 64.) Evenly tighten the hexagon-socket screws. Tapped drill hole for pressing out pulley Fig. 8-4: Installing fan belt pulley V-belt pulley PR GB Subject to modifications R8-10/

66 Commissioning and Maintenance CAIRplus Consider the maximum tightening torque of hexagon-socket screws during the installation: Bush No Max. tightening torque (Nm) Tab. 8-1: Maximum tightening torque Check electric motors for dirt, damage, corrosion and secure mounting. Inspect motor and fan for bearing noise, replace bearing if necessary. Lubricate non-sealed fan bearing according to the motor manufacturer s recommendations (refer to Tab. 8-2)! Please refer to the manufacturer s documentation for correct lubrication details of non-sealed bearings. Fan TLZ THLZ VTZ TLZ-T THLZ-T VTZ-T Manufacturer Comefri Gebhardt Fläkt Woods NTHZ-B NTHZ- NTHZ T1 NTHZ VZR71 RZR11 RZR15 RZR19 GXLB GXLF GXHB R T2 NTHZ T2L RZR N 250 N 280 N 315 N N 355 N N 400 N N N 450 N N N 500 N N N 560 N N N N 630 N N N N 710 N N N N 800 N N N N N N N 900 N N N N N N N 1000 N N N N N N N 1120 N N N N N 1250 N N N N N N = Lubrication possible Tab. 8-2: Lubrication details for non-sealed fan bearings 66 PR GB Subject to modifications R8-10/2015

67 CAIRplus Commissioning and Maintenance Commissioning of direct-driven fan assembly DANGER! Please consider the safety instructions on page 5 and page 56 when performing all the described activities! Remove remaining installation debris and foreign matter from the impeller and air intake zone. Check motor protection for correct setup (also see separate project-related documentation and/or Motor protection on page 50). With Y/Δ starting, set up the motor protection device for 58% of the rated current if the phase current flows through the latter i.e. motor protection device must be installed between motor terminals U1, V1, W1 and not in mains supply line upstream of the control unit. It is not allowed to activate the parameter "overmodulation" as this can damage the impeller. Notice! In this case, DencoHappel neither accepts warranty claims nor assumes liability. Besides, ensure that the maximum frequency does not exceed the allowable limit (refer to data sheet on fan). Consider the relevant instructions specified in the enclosed manual for the frequency inverter. Use a screened motor cable only Maintenance of direct-driven fan assembly DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Carry out the following maintenance steps: Check electric motors for dirt, damage, corrosion and secure mounting. Check electric motors for noise in bearings, if required, engage qualified licensed staff to replace bearings. Check impeller, especially welded seams for possible cracks; if required, engage qualified licensed staff to replace bearings. PR GB Subject to modifications R8-10/

68 Commissioning and Maintenance CAIRplus Commissioning and Maintenance of EC fans Hazardous voltage can result in death! Waiting time at least 3 minutes! Due to the use of condensers, danger of death continues even after switching off the unit by directly touching live components which are still live owing to fault states. Therefore only remove or open the controller casing after a 3-minute waiting time after the unit has been disconnected to the mains supply line! Danger due to automatic restart! The fan/engine can be automatically switched on and off for functional reasons. After a power failure or power supply breakdown, the fans automatically restart when mains power returns again! Wait until the fans have come to a standstill before approaching them. With external rotor motors, the external rotor rotates during operation! Risk of burns due to hot surfaces! Temperatures above 85 C can occur on the motor surfaces, particularly on the controller casing! Severe burns can be the consequence. Please also observe the instructions of the component manufacturer! 8.5 Filter assembly ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITH SHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Commissioning of filter assembly DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Complete the following commissioning steps: Check filter assembly and installed filters for damage. Check that filter assembly is correctly fitting in the mounting frame. If required, clean installation dust before the filter assembly and unit parts in the direction of airflow. Repeat cleaning before installing filters from grade F9 into the air handling unit and ductwork. Put the fan into service and take readings of the initial pressure difference (if available). 68 PR GB Subject to modifications R8-10/2015

69 CAIRplus Commissioning and Maintenance Routine maintenance for all filters DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Danger of inflammable materials! There is a risk of inflammable filter material that could cause fire. Depending on the filtered substances, used filters pose a significantly higher fire hazard. Keep filters away from open fire! Notice! DencoHappel recommends to always operate the unit with an installed filter. Keep a set of spare filters on stock as well. Prevent the filter surface from damage, as this can destroy the filter during service, and no warranty can be assumed for the filter grade. ATTENTION Risk of environmental damage! Heavily contaminated filters pose a health risk and may adversely affect production processes. Depending on the filtered substances, dirty filters should be treated as special waste and must be disposed of in an environmentally-friendly manner and in accordance with current codes and regulations. As a general requirement and depending on the operating conditions, all filters must be checked at regular intervals and replaced if necessary. Carry out the following maintenance steps: Check filters for debris, damage and odour. Clean filter chamber. Check if the maximum allowed pressure difference (refer to RLT 01 guideline - German Association of HVAC Manufacturers) or pressure difference specified by manufacturer is exceeded, and replace the filter if necessary. Observe current legal regulations and standards! DencoHappel recommends maintenance steps and intervals specified in VDI 6022 Hygiene inspection Even if the filter shows no visible signs of dirt, microbial growth and mould may propagate through the filter as a result of its long-term use (in air with low dust content). The filters must be replaced regularly (at least every 6-9 months), even if dirt is barely visible Maintenance of bag filters/panel filters/fine-particle filters DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Carry out the following maintenance steps: Check filter and filter frame for dirt, corrosion and damage, replace if necessary. The end pressure difference of bag filters varies, refer to the relevant technical data for details (see filter identification plate). Replace the filter if the maximum pressure difference is reached. PR GB Subject to modifications R8-10/

70 Commissioning and Maintenance CAIRplus Replacing filter medium Ensure that unit is deactivated. Open the access door/maintenance panel. Release the top and bottom spring clips on the filter rack or open the quick-release filter frame. Pull out the filter frame. Replace a damaged or dirty filter. Slide the filter frame into the unit. Ensure an airtight seal and proper fit! Close the top and bottom spring clips on the filter rack or close the quick-release filter frame. Install filter bags only in the upright position! Close the service access door or maintenance panel Maintenance of activated-carbon filter DANGER! Replacing activatedcarbon filter (cartridges) Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Carry out the following maintenance steps: Replace the filter if activated carbon is saturated (designed number of operating hours elapsed). For monitoring the filter saturation level the cartridge weight can be checked and marked for subsequent reference to determine the weight increase. Check if filter racks with activated-carbon cartridges are fitting correctly. To prevent the reduction of service life of the expensive activated-carbon filter, ensure that the pre-filtering and fine-filtering stages are in proper condition. Disconnect power to the unit. Cartridges are secured in place with special bolts (bayonet lock)! Turn the filter cartridges as indicated by the rotation arrow and remove from the frame. Replace the pre-filter together with the activated-carbon filter. Dispose of the filters in accordance with the applicable regional regulations. Fig Maintenance of grease filter DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Follow the specified maintenance steps: Filter cells are made of aluminium wire mesh with each air-filter cell fitted with an integrated grease-collecting tray. Rinse filter cells in clean water and clean grease-collecting tray every 3-6 months Maintenance of HEPA filter DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Refer to the relevant maintenance instructions specified in the supplied documentation. 70 PR GB Subject to modifications R8-10/2015

71 CAIRplus Commissioning and Maintenance Maintenance of other filters DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Refer to the relevant maintenance instructions specified in the supplied documentation. 8.6 Heater assembly Electrical hazard and danger of rotating unit parts with sharp edges! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Commissioning of heater assembly (pumped warm water) DANGER! Requirement: Commissioning: Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Complete the following commissioning steps: Check supply and return lines for proper connection. Counterflow mechanism and water inlet on air-discharge side. Check shut-off devices and other fixtures for proper installation. Open provided air vent, if automatic air-venting is not installed. Charge the coil at the lowest point to prevent air cushions and water hammer. Slowly open air vent and wait until the coil is flushed with water. Open air vent completely. Close air vent; if the levels are different - close air vent gradually until water displaces air and starts to run out. Activate primary and secondary pump, check rotation direction and put the coil into service for ample time. Set the control valves in reverse position (three-way valves). Perform a subsequent check by repeated opening of air vent. Check for leak-free condition. Operate frost protection in a regulated mode to prevent over-conditioning Maintenance of heater assembly (pumped warm water) DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Carry out the following maintenance steps: Check for leak-free condition and possible dirt on the air side. To ensure frost protection, periodically check the safety devices and take proper precautions such as draining the equipment or adding antifreeze agents. Ensure that pipework connections and mountings are securely fixed. If necessary clean the coil on the air side (blow out with compressed air or lowpressure water). Air vent. PR GB Subject to modifications R8-10/

72 Commissioning and Maintenance CAIRplus Commissioning of steam heater assembly DANGER! Please consider the safety instructions on page 5 and page 56ff when performing all the described activities! Danger of injury from scalding! Hot steam escapes if an air vent is open! Consider scalding hazard. Open air vent carefully. For all jobs wear the appropriate personal protective equipment. Complete the following commissioning steps: Open drain and air vent. Slowly open steam valves and wait until steam starts to escape. Close drain and air vent Maintenance of steam heater assembly DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Danger of injury from scalding! Hot steam escapes if an air vent is open! Consider scalding hazard. Slowly open air vents. For all jobs wear the appropriate personal protective equipment. Carry out the following maintenance steps: Check for leak-free condition and possible dirt on the air side. To ensure frost protection, periodically check the safety devices and take proper precautions such as draining the equipment or adding antifreeze agents. Ensure that pipework connections and mountings are securely fixed. If necessary clean the coil on the air side (blow out with compressed air or lowpressure water). Check steam inlet and condensate drain for proper operation. Air vent. Check control functions if available Commissioning/maintenance of direct-fired (gas) heater assembly DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Refer to the relevant commissioning instructions specified in the supplied documentation Commissioning and maintenance of electric heater DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Refer to the relevant commissioning instructions specified in the supplied documentation. 72 PR GB Subject to modifications R8-10/2015

73 CAIRplus Commissioning and Maintenance 8.7 Cooler assembly ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITH SHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Notice! Have qualified and licensed refrigeration engineers from certified and authorized appointed contractors perform the following procedures and possible service jobs! Observe the relevant standards and legal regulations regarding refrigerants Commissioning of cooler assembly with/without droplet separator DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Complete the following commissioning steps: For droplet separator Clean coil drip tray and drain piping. Fill trap with water, refer to Water drain trapping on page 45; as a minimum requirement, the hydraulic seal of the trap must always correspond to the positive or negative pressure of the unit. Droplet separator (DS) reaches its full capacity following a start-up phase of 4 weeks once the separating agent volatizes. If necessary, rinse the droplet separator with water. Dust with lime if necessary. In case of insufficient performance of droplet separator: Inspect droplet separator for correct installation position. Check airflow velocity in droplet separator. DS standard w max =3.8 m/s DS 100 high performance w max =5.8 m/s Maintenance of cooler assembly with/without droplet separator DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Carry out the following maintenance steps: Check for leak-free condition and possible dirt on the air side. To ensure frost protection, periodically check the safety devices and take proper precautions such as draining the equipment or adding antifreeze agents. Ensure that pipework connections and mountings are securely fixed. If necessary clean the coil on the air side (blow out with compressed air or lowpressure water). Air vent. Clean coil drip tray and drain piping. Check trap for proper operation, top up as necessary. Clean droplet separator with a descaling spray. PR GB Subject to modifications R8-10/

74 Commissioning and Maintenance CAIRplus Procedures before winterization Drain water from the cooling coil before winter. As the coil piping diameter is small, residual water can remain in the unit following normal evacuation. For safety reasons, use compressed air to blow through the system in order to remove all remaining water. 8.8 Cooling/heating coil ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITH SHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Notice! Have qualified and licensed refrigeration engineers from certified and authorized appointed contractors perform the following procedures and possible service jobs! Observe the relevant standards and legal regulations regarding refrigerants. Always make sure that the units are accessible only to authorized and trained technical personnel. If necessary, use appropriate equipment to keep unauthorized persons away from the unit. Have all leaks immediately eliminated by service personnel or a specialist refrigeration company (refer to section 4.10). The safety sheet stating the type of refrigerant charged on the given unit shall be firmly secured in the machine room of the unit in a well visible manner (refer to unit identification plate or operation manual for the unit). Ensure that proper trays or similar vessels are mounted below the unit in order to reliably capture oil and glycol liquids and prevent contact with the environment Commissioning of evaporator/condenser DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! ATTENTION Risk of damage to the unit! Ensure not to expose the evaporator or condenser to the ambient temperatures exceeding 60 C (e.g. caused by fan dowmtime and/or water temperatures (heater bank) > 60 C). 74 PR GB Subject to modifications R8-10/2015

75 CAIRplus Commissioning and Maintenance Complete the following commissioning steps: For connection jobs ensure that nitrogen charge is present in coils. Check supply and return lines for proper connection. Check shut-off devices and other fixtures for proper installation, counterflow mechanism for medium inlet on the air-discharge side. Ensure that pipework connections and mountings are securely fixed. Charge the refrigeration circuit with a medium specifically designed for the system. Check if the system is air-tight. Check proper operation of safety valves. Check the maximum temperature and pressure of unit in operation (especially for R410A refrigerant) Saturation temperature = 60 C/bursting strength: 38 bar Maintenance of evaporator/condenser DANGER! Direct expansion coil Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Carry out the following maintenance steps: Clean and check the evaporator/condenser as specified in Maintenance of heater assembly (pumped warm water) on page 71. Ensure that all refrigeration components (refrigerating machine, direct evaporator, distribution manifold, refrigerant lines, etc.) are functioning properly. Performance of leakage tests according to EU Directive 517/2014 on the entire refrigeration circuit depending on the CO 2 equivalent of the refrigerant contained in the refrigerating system with at least the following frequency: 1 x annually from 5 t CO 2 equivalent 2 x annually from 50 t CO 2 equivalent 4 x annually from 500 t CO 2 equivalent A log book must be maintained to document the leak tests and all inspection, maintenance, and repair work. The performing certified person and certified company must be named in the log book. The refrigerant consumption data, type of refrigerant and quantity as well as the reasons for recharging must be documented. 8.9 Heat pipe Electrical hazard and danger of rotating unit parts with sharp edges! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Commissioning of heat pipe DANGER! Upright heat pipe Heat pipe with horizontal installation with a fixed slope Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Observe the following checkpoints for commissioning: The coil with warm airflow (return air) must be positioned on the bottom and the cold airflow (fresh air) - on the top. The coil with warm airflow (return air) must be positioned on the bottom and the cold airflow (fresh air) - on the top. PR GB Subject to modifications R8-10/

76 Commissioning and Maintenance CAIRplus Upright or horizontal with bypass damper control For commissioning see Commissioning of dampers and shut-off dampers on page Maintenance of heat pipe DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Carry out the following maintenance steps: Regular cleaning of coil fins: by blowing out the fins using compressed air against the airflow direction or by spraying fins with low-pressure water only! Clean coil drip tray and drain piping. Check trap for proper operation, top up as necessary. If a heat pipe with bypass is used, check air-regulating and shut-off dampers for proper operation as specified in the maintenance manual (see Maintenance of dampers blades and shut-off dampers on page 80) Liquid-coupled energy recovery coil ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITH SHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Commissioning/maintenance of liquid-coupled energy recovery coil DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Refer to Commissioning of heater assembly (pumped warm water) on page Plate heat exchanger ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITH SHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Commissioning of plate-type heat exchanger DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! 76 PR GB Subject to modifications R8-10/2015

77 CAIRplus Commissioning and Maintenance ATTENTION Risk of damage to the unit! Avoid inadmissible high differential pressures between supply air and extract air. This could cause damage to the fins. In this case, DencoHappel neither accepts warranty claims nor assumes liability. If energy recovery is done with a bypass arrangement, check dampers for correct operation (refer to Maintenance of dampers blades and shut-off dampers on page 80). Check bypass damper for proper operation, if required Maintenance of plate-type heat exchanger DANGER! Oil and grease (kitchen exhaust) Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! A plate-type heat exchanger operates without any external, mechanical or electrical actuators, is not equiped with any moving components and its service life can be negatively influenced only by corrosion. Carry out the following maintenance steps: Clean as needed according to degree of plate assembly contamination.use a hair broom to remove dry dust and fibers at the coil inlet, blow out. Check bypass damper for proper operation, if required. Complete wet cleaning only if a tray is installed and available! Remove oil and grease deposits with hot water and grease-dissolving cleaning agents Airflow routing in plate-type heat exchangers cold corner Condensate 1 = heat-dissipating 2 = heat-absorbing Condensate is attracted to the cold zone by gravity and airflow. If a lot of condensate precipitates, the risk of freezing decreases. If little condensate precipitates, the risk of freezing increases. Condensate is attracted to the Condensate is attracted to the cold zone by gravity and airflow. If a lot of condensate preflow. The risk of freezing warm zone by gravity and aircipitates, the risk of freezing decreases. decreases. If little condensate precipitates, the risk of freezing increases. Condensate is attracted to the warm zone by gravity and airflow. The risk of freezing decreases. Tab. 8-3: Airflow routing in plate-type heat exchangers PR GB Subject to modifications R8-10/

78 Commissioning and Maintenance CAIRplus 8.12 Rotary heat exchanger Electrical hazard and danger of rotating unit parts with sharp edges and rotating storage mass! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Commissioning of rotary heat exchanger DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Notice! Refer to the relevant commissioning and maintenance instructions specified in the supplied documentation (MicroMax/KR4R). Document the commissioning of the rotation heat exchanger according to the commissioning report! Complete the following commissioning steps: Check tension of drive belt, tighten if necessary. Check rotating direction. Check position of flush sections. Check gasketing and sealing for correct fit. Check run-around gasketing, adjust as necessary. Check motor alignment. If energy recovery is done with a bypass arrangement, check dampers for correct operation (refer to Maintenance of dampers blades and shut-off dampers on page 80) Maintenance of rotation heat exchanger DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Carry out the following maintenance steps: Use a vacuum cleaner to clean coil fins regularly. Carry out wet cleaning only if a tray is installed! Never use high-pressure water or steam for cleaning coil fins. Remove dirt from the section. If energy recovery is done with a bypass arrangement, check dampers for correct operation (refer to Maintenance of dampers blades and shut-off dampers on page 80). Check run-around gasketing, adjust as necessary. Check tension of drive belt, tighten if necessary. Check motor alignment. 78 PR GB Subject to modifications R8-10/2015

79 CAIRplus Commissioning and Maintenance 8.13 Humidifier assembly For steam humidifiers: Electrical hazard and danger of rotating unit parts with sharp edges! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Danger of injury from scalding! Hot steam escapes if an air vent is open! Consider scalding hazard. Slowly open air vents. For all jobs wear the appropriate personal protective equipment. Depending on the type of humidifier and installation location, you have to check different criteria, such as: Quality of Water Microbial count Drain cycles Deposit build-up, etc. Refer to the corresponding instructions specified in the supplied documentation Damper blades and shut-off dampers HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Commissioning of dampers and shut-off dampers DANGER! For actuators Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Complete the following commissioning steps: If several dampers are linked together, ensure that the connecting linkage is installed properly and is moving freely. Check all screw connections for proper fit. Adjust the connecting linkage to ensure a turning angle of 90 with damper blades reaching their final position when closed (consider tightening torques). Check if the damper actuator moves to its final positions. Ensure proper operation of this component. Do not start up the fans with closed dampers. PR GB Subject to modifications R8-10/

80 Commissioning and Maintenance CAIRplus Maintenance of dampers blades and shut-off dampers DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Carry out the following maintenance steps: Vacuum clean dampers (blow out), never apply grease! Detach the actuator from dampers, check if dampers are moving freely. Check that the damper actuator moves to its final positions Sound attenuators ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITH SHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Maintenance of sound attenuator DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Carry out the following maintenance steps: Check the sound attenuator section and sound insulating splitters for contamination, vacuum clean, if necessary Commissioning/maintenance of ECOTWINcool double-plate heat exchanger with adiabatic cooling ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITH SHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! Refer to the relevant commissioning instructions specified in the supplied documentation commissioning/maintenance of integrated refrigerating systems In general, when working with refrigerants, be sure to pay attention to the following points: (see also Handling refrigerants (only for units with integrated refrigerating system) on page 12) 80 PR GB Subject to modifications R8-10/2015

81 CAIRplus Commissioning and Maintenance Warning of high concentration of refrigerants in the air! High concentration of refrigerants in the air may have an anaesthetic effect and cause unconsciousness. Prolonged exposure may cause irregular heartbeat and sudden death. Very high concentration of refrigerant may cause suffocation by reduced oxygen content in the surrounding air. You should therefore only work in an adequately ventilated environment, and exercise due care and attention when carrying out the work. Wear protective clothing and, if necessary, an autonomous breathing apparatus. Smoking and open flames are prohibited Smoking and open flames at the installation site of the unit or during work with refrigerants are prohibited. Open fire or flames can lead to the disintegration of a refrigerant and release of toxic gases. Do not keep any inflammable liquids in close proximity to the unit. Danger of injury from refrigeration! Contact with a liquid refrigerant can result in skin burns or injury to other organs. Exercise due caution and attention when carrying out jobs and avoid contact with a refrigerant. Wear suitable protective clothing. Danger of injury caused by high pressure! When working on hydraulic or refrigeration circuits or in case of damage to the components or piping, there is a risk of injury from fluids or gases escaping at high pressure. Exercise due caution and attention when carrying out this work. Wear appropriate protective clothing. ATTENTION Risk of environmental damage! Do not pollute the environment with liquid products, refrigerants or oils. Dispose of the latter in accordance with local laws and regulations by avoiding harm to the environment. Ethylene glycol and propylene glycol are categorized as water pollutants. This also applies to mixtures with water. Always make sure that the units are accessible only to authorized and trained technical personnel. If necessary, use appropriate equipment to keep unauthorized persons away from the unit. Have all leaks immediately eliminated by service personnel or a specialist refrigeration company (refer to section 4.10). The safety sheet stating the type of refrigerant charged on the given unit shall be firmly secured in the machine room of the unit in a well visible manner (refer to unit identification plate or operation manual for the unit). Ensure that proper trays or similar vessels are mounted below the unit in order to reliably capture oil and glycol liquids and prevent contact with the environment. PR GB Subject to modifications R8-10/

82 Commissioning and Maintenance CAIRplus Recurrent tests DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! The system and its system components are subject to partially recurring tests conducted by a qualified person or an approved inspection agency according to Art.15 of the German Law on Occupational Safety (BetrSichV). Observe any further applicable laws of the respective installation site. ATTENTION Risk of damage to the unit! Only use types of oil approved by the compressor manufacturer (see specifications on the compressor), since otherwise the equipment could be damaged Taking out of service DANGER! Please consider the safety instructions on page 5 and page 55ff when performing all the described activities! See the service booklet for refrigerating systems for requirements. ATTENTION Risk of environmental damage! When disposing of refrigerant or compressor oil, observe the respective environmental protection provisions! 82 PR GB Subject to modifications R8-10/2015

83 CAIRplus Disassembly and disposal 9 Disassembly and disposal ATTENTION Risk of environmental damage! Have qualified licensed staff dismantle and dispose of the unit! 9.1 Dismantling To dismantle the unit proceed as follows: Electrocution through hazardous voltage will lead to death or serious injury. When carrying out any decommissioning and dismantling work on the units, disconnect all power supply connections and ensure the power cannot be inadvertently switched back on. Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover or shield off neighboring live components. Ensure that the hydraulic circuit is switched off. Close all hydraulic shut-off valves. Isolate all connections and ensure leak-free condition regarding oil, refrigerant or water-glycol mixture.as the coil piping diameter is small, residual water can remain in the unit following normal evacuation. For safety reasons, use compressed air to blow through the system in order to remove all remaining water. Warning! Risk of personal injury and equipment damage! Due to a high center of gravity, some equipment can tend to tip over and cause damage to persons and property. When transporting the unit, carefully observe its behavior and do not get near any possible hazardous areas. Release the fixing to the base or wall. The unit is ready for transport. Consider all instructions specified in chapter Transport on page Disposal ATTENTION Risk of environmental damage! Dispose of all components and filters (activated-carbon filter, filter cartridges, etc.) and disused operating materials (e.g. oil, refrigerants and water-glycol mixture) in an environmentally-friendly manner in accordance with the local codes, practices and environmental regulations. An authorized appointed contractor specializing in waste processing must dispose of the unit or its individual components. This appointed contractor must ensure that: the components are separated according to material types the used operating materials are sorted and separated according to their respective properties. PR GB Subject to modifications R8-10/

84 Troubleshooting CAIRplus 10 Troubleshooting Notice! Have qualified licensed staff perform troubleshooting and repair procedures. Qualified licensed staff or other individuals with proper professional training must be experienced in the relevant accident prevention regulations, as well as other generally recognized safety and occupational health codes. A simple diagnostic section specifying troubleshooting actions can not be presented in this chapter due a wide variety of built-in components and special configurations. For detailed maintenance and repair procedures contact your local supplier. 84 PR GB Subject to modifications R8-10/2015

85 CAIRplus Appendix 11 Appendix 11.1 Maintenance Log Book CAIRplus Notice! Observe maintenance procedures for air handling units as these are critical for unit service life. Due to use of various chemical substances and cleaning agents for sanitizing and cleaning, unit surfaces may be affected. Report all corrosion on unit surfaces to your installer without delay! Commissioning date: Commissioned by: Maintenance frequency Unit part Checked O.K. not O.K. Comment Date Signature Heat Exchanger Fan assembly Refrigeration plant Control Month 1 following Panels commissioning Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: Heat Exchanger Fan assembly Refrigeration plant Month 2 following Control commissioning Panels Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: Heat Exchanger Fan assembly Refrigeration plant Control Month 3 following Panels commissioning Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: on (date): on: on (date): on: on (date): on: PR GB Subject to modifications R8-10/

86 Appendix CAIRplus Maintenance frequency Unit part Checked O.K. not O.K. Comment Date Signature: Heat Exchanger Fan assembly Refrigeration plant Control Month 6 following commissioning Panels Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: Heat Exchanger Fan assembly Refrigeration plant Control Month 9 following commissioning Panels Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: Heat Exchanger Fan assembly Refrigeration plant Control Month 12 following Panels commissioning Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: Heat Exchanger Fan assembly Refrigeration plant Control Month 15 following Panels commissioning Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: on (date): on: on (date): on: on (date): on: on (date): on: 86 PR GB Subject to modifications R8-10/2015

87 CAIRplus Appendix Maintenance frequency Unit part Checked O.K. not O.K. Comment Date Signature: Heat Exchanger Fan assembly Refrigeration plant Control Month 18 following Panels commissioning Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: Heat Exchanger Fan assembly Refrigeration plant Control Month 21 following Panels commissioning Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: Heat Exchanger Fan assembly Refrigeration plant Control Month 24 following Panels commissioning Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: on (date): on: on (date): on: on (date): on: We recommend to keep account of all maintenance procedures in the log book even after the first two years of operation have elapsed. It is under circumstances necessary to perform specified maintenance and cleaning procedures in regular intervals anyway. PR GB Subject to modifications R8-10/

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