GEA Modular Air Handling Units. Solutions with maximum flexibility GEA CAIRéäìë. Operation Manual

Transcription

1 GEA Modular Air Handling Units Solutions with maximum flexibility GEA CAIRéäìë Operation Manual ÉåÖáåÉÉêáåÖ=Ñçê=~=ÄÉííÉê=ïçêäÇ db^=eé~í=bñåü~åöéêë

2 Table of Contents GEA CAIRplus Table of Contents 1 Unit Type Code Safety and User Instructions Availability of the operation manual Scope of the operation manual Symbols used Identification of safety instructions Safety-conscious work procedures Proper use Safety devices Modifications and changes Spare parts Disposal Selection and qualification of personnel Technical Description Performance scope Unit configuration and operation Technical Specifications Operating limits and range of application Shipping and Storage Delivery Transport Storage Mounting 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 K6-07/2013

3 GEA 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 Evaporator / condenser Heat pipe Liquid-coupled energy recovery coil Plate-type heat exchanger Rotary heat exchanger Humidifier assembly Damper blades and shut-off dampers Sound attenuator Disassembly and Disposal Dismantling Disposal Troubleshooting Appendix Maintenace 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 K6-07/2013 3

4 Unit Type Code GEA 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 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 Return 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 K6-07/2013

5 GEA CAIRplus Safety and User Instructions 2 Safety and User Instructions 2.1 Availability of the operation manual The GEA 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, 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 GEA 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! This operation manual contains important instructions regarding safe and proper operation of the GEA unit. This operation manual applies to installation companies, operators, building technicians, technical personnel or instructed persons as well as electricians. This operation manual must be available at the location of the unit at all times. 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 2.3 Symbols used This operation manual provides information about the following: Shipping and Storage Mounting Installation and Electrical Connection Commissioning and Maintenance Disassembly and Disposal 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 handling instructions. This symbol indicates the result of an action. NOTICE! Additional details on using the GEA unit are specified here. Danger symbols are specified in section "Identification of safety instructions" on page 8. PR GB Subject to modifications K6-07/2013 5

6 Safety and User Instructions GEA 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) Warning - risk of explosive atmosphere! 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 K6-07/2013

7 GEA 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 K6-07/2013 7

8 Safety and User Instructions GEA CAIRplus 2.4 Identification of safety instructions The following symbols and notices are provided in appropriate places throughout the user document to designate the safety instructions. HAZARDOUS VOLTAGE! This symbol indicates a risk of electrical shock when working on the equipment. PERSONAL INJURY! This section specifies procedures and precautions for preventing personal injury. WARNING: RISK OF ROTATING COMPONENTS! This section specifies procedures and precautions for preventing personal injury as a result of rotating unit parts. DANGER OF OVERHEAD LOADS! This section specifies procedures and precautions for the prevention of personal injury and damage to units through falling components. DANGER OF HOT SURFACES! This section specifies procedures and precautions for preventing personal injury resulting from hot surfaces. DANGER OF SCALDING! This section specifies procedures and precautions for the prevention of personal injury resulting from scalding by steam. DANGER OF EXPLOSIVE ATMOSPHERE! This section specifies procedures and precautions for the prevention of personal injury and damage to units resulting from explosive atmosphere. DANGER OF INFLAMMABLE MATERIALS! This section specifies procedures and precautions for the prevention of personal injury resulting from fire risk. DANGER SHARP CUTTING EDGES! This section specifies procedures and precautions for preventing personal injury due to cutting on thin metal fins. ENVIRONMENTAL DAMAGE! This section specifies procedures and precautions for preventing environmental damage with reference to the valid national regulations on environmental protection. EQUIPMENT DAMAGE! This section specifies procedures and precautions regarding the prevention of damage to the unit. 8 PR GB Subject to modifications K6-07/2013

9 GEA CAIRplus Safety and User Instructions 2.5 Safety-conscious work procedures Observe the following instructions when carrying out installation, adjustment or repair jobs: When working within range of mains voltage: HAZARDOUS VOLTAGE! Disconnect all electric power to the unit and ensure the power cannot be inadvertently energised, earth, short-circuit and block off all neighbouring live parts. Non-compliance can lead to death or serious injury. When working in explosive atmosphere 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 exist, even if the unit is deactivated. For all kinds of work: PERSONAL INJURY! 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. EQUIPMENT DAMAGE! If dampers are abruptly shut during unit operation, the unit can be damaged beyond repair as a result of negative pressure or overpressure. DANGER SHARP CUTTING EDGES! 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. 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 K6-07/2013 9

10 Safety and User Instructions GEA CAIRplus 2.6 Proper use The GEA CAIRplus units are only intended for handling of 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. Proper use also includes observance of the operation manual and the inspection and maintenance conditions stipulated by GEA. Improper use Any use other than that described above is considered improper. If necessary, check if your GEA CAIR unit is 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. GEA CAIR unit is not suitable for the handling abrasive media. PERSONAL INJURY! It is not allowed to operate GEA 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). GEA CAIR unit must not be accessible to general public. 2.7 Safety devices Depending on the unit design dampers and doors are secured by control cabinet locks/lockable handles fan sections are secured by door protection grilles V-belt drives are secured by belt guards 2.8 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 GEA Happel Service GmbH should be arranged in advance. 10 PR GB Subject to modifications K6-07/2013

11 GEA CAIRplus Safety and User Instructions 2.9 Spare parts Only original GEA Air Treatment spare parts are allowed, since GEA Air Treatment is not liable, if third-party spare parts are used Disposal 2.11 Selection and qualification of personnel Operating and auxiliary materials, components and filters must be disposed of properly and in environmentally-friendly manner. 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 skilled staff must be able to assess the entrusted work and must be able to recognize and avoid all associated dangers. PR GB Subject to modifications K6-07/

12 Technical Description GEA CAIRplus 3 Technical Description 3.1 Performance scope GEA CAIRplus units are generally used for energy-saving supply-air and extractair 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. GEA 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. GEA CAIRplus units meeting explosionprotection 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, GEA CAIRplus units are designed for vertical or horizontal air flow and are arranged as double-deck, side-by-side and straightthrough models. Units can be installed indoors and outdoors. Thanks to the modular design of the GEA CAIRplus, units ship as complete assemblies or sub-assemblies that can pass through the available on-site openings in the course of installation. GEA CAIRplus units are also suitable for the modernisation 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 Unit configuration and operation Thanks to the modular design of the units and various applications for each case, a customer can select a wide range of unit configurations. Refer to the following examples demonstrating the basic unit design and its operating principles. Fig. 3-1 shows a GEA CAIRplus unit that is used only for transporting air. The unit consists of a casing incorporating a base frame, fan assembly, dampers with blades on the fresh-air side, two flexible canvas connections and a service switch. 12 PR GB Subject to modifications K6-07/2013

13 GEA CAIRplus Technical Description Service switch SUPPLY AIR OUTSIDE AIR Fig. 3-1: Unit for transporting air Supply and extract-air units can be combined. These units are used to mix return air with supply air (completely, partially and/or intermittently). The main reason for such operating mode is to save heating or cooling energy. Fig. 3-2 presents a combined extract-air and supply-air application with additionally installed filter and heater sections. The units are connected via mixing-air sections. Service switch SUPPLY AIR OUTSIDE AIR EXHAUST EXTRACT AIR Fig. 3-2: Combined unit for supply-air and extract-air application with a mixed-air chamber Unlike the straight-through arrangement shown in Fig. 3-2, Fig. 3-3 presents a combined double-deck supply and return-air unit with a heat recovery facility. In addition to transporting, filtering, heating and mixing of air, this unit can also recover energy through a plate heat exchanger. EXTRACT AIR OUTSIDE AIR SUPPLY AIR EXHAUST AIR Fig. 3-3: Combined unit for supply-air and extract-air application with heat recovery module PR GB Subject to modifications K6-07/

14 Technical Description GEA CAIRplus 3.3 Technical Specifications Refer to the order-related documentation for the specific configuration of your GEA CAIRplus unit (unit drawing with dimensions and technical data). 3.4 Operating limits and range of application NOTICE! 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 GEA CAIRplus special/customised units are available on request Ambient conditions 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. Outside air from -25 C to +60 C Return 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 Allowable storage conditions / allowable air condition for non-installed units Air temperature -10 C to +50 C Air humidity Store units in a dry, non-condensing atmosphere 14 PR GB Subject to modifications K6-07/2013

15 GEA CAIRplus Technical Description 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 T and CAIRplus SX K. Read example: 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. Air temperature on unit internal side in C 9 Air temperature on unit external side in C PR GB Subject to modifications K6-07/

16 Technical Description GEA CAIRplus CAIRplus SX K = without thermal separation Condensation diagram for kb-value: 0.5 Air temperature on unit external side in C CAIRplus SX M = partial thermal separation Condensation diagram for kb-value: 0.62 Air temperature on unit internal side in C Air temperature on unit internal side in C Air temperature on unit external side in C 16 PR GB Subject to modifications K6-07/2013

17 GEA CAIRplus Shipping and Storage 4 Shipping and Storage 4.1 Delivery GEA 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 despatch note, and also check for completeness. NOTICE! Consider instructions relating to the procedures in case of shipping damage on the unit packaging or in despatch documents! What steps should I take in case of shipping damage? External side of the packaging is damaged 1 Unpack the equipment in the presence of the lorry driver and document the damage in the shipping order. 2 Inform the GEA office immediately. External side of the packaging is O.K., the contents is damaged. 1 Once you have established the extent of the damage, report the damage to the GEA office in writing. 2 Take photographs of the damaged parts. 3 Possible shipping damage must be reported no later than 4 days following the delivery. Processing of claims will not be possible, if the above-mentioned steps are not fulfilled. In both cases, before installing the units - consult the GEA office. PR GB Subject to modifications K6-07/

18 Shipping and Storage GEA CAIRplus 4.2 Transport NOTICE! For unit shipment use the original packing only. Remove the original packaging only before installation. Remove the pallet before lifting the unit modules at the lifting lugs / transport gear. For shipping and rigging the GEA unit use the lifting lugs or lifting points provided by the manufacturer. For safety reasons wear gloves and safety footwear when lifting or shipping the unit. DANGER OF OVERHEAD LOADS! Never stand beneath suspended loads, there is always a risk that the lifting gear, tackle, ropes or slings could be damaged. Failure to follow safety precautions could result in death or serious injury. 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. Move the unit carefully without jerky movements. Do not set the unit down abruptly or bump it. 18 PR GB Subject to modifications K6-07/2013

19 GEA CAIRplus Shipping and Storage Lifting the unit lifting lugs on roof (provided with shipment units weighing up to 1500 kg) PERSONAL INJURY! Use only the lifting lugs provided by GEA! Make sure that equipment is firmly seated before lifting the equipment. Lifting lugs are designed for vertical loads only. Do not use lifting lugs for lateral loads (pulling of unit on sides). Suspension angle must not exceed 60. 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. Fig. 4-1: Lifting lugs for shipment units weighing up to 1500 kg PR GB Subject to modifications K6-07/

20 Shipping and Storage GEA CAIRplus Lifting the unit - transport gear on the base frame (provided with shipment units weighing up to 4000 kg) PERSONAL INJURY! Use only the transport gear provided by GEA! Make sure that equipment is firmly seated before lifting the equipment. 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 GEA package) as shown in the figure. When using shackles, do not insert ropes/slings through the opening. 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 centre 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 Shipping with a (folk) lift truck 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 centre of gravity lift point and even distribution of weight. EQUIPMENT DAMAGE! Never stack units on top of one another for shipping! Always place and rig unit sections one at a time! Stacking of units and other foreign field-provided components is not permitted. Exceptions apply for units delivered by the GEA factory where the sufficient load-bearing capacity is considered beforehand. 20 PR GB Subject to modifications K6-07/2013

21 GEA CAIRplus Shipping and Storage 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. Ensure conditions when condensate can not form below packaging supplied by others (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 leadout 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. Air temperature -10 C to +50 C Permitted storage conditions / permitted air condition for non-installed units Air humidity Store units in a dry, non-condensing atmosphere PR GB Subject to modifications K6-07/

22 Mounting GEA CAIRplus 5 Mounting Here you will find information on how to assemble and install the unit. Mounting and installation shall only be completed by a qualified staff. 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. The unit shall be installed in such a way that it is only accessible to trained and authorized technical staff. 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 GEA factory 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, a suitable protection grille shall be installed by others on air discharge or intake openings of the unit. EQUIPMENT DAMAGE! When entering GEA CAIRplus units ensure that no loads are applied on the floor panels. For all installation jobs take appropriate measures to ensure that all load is evenly distributed across the bottom profiles (e.g. using grid walkways). 5.1 Unit placement 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. In units where a condensate drain is installed, ensure there is adequate height for condensate drain requirements - the height of the site base corresponds 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 22 PR GB Subject to modifications K6-07/2013

23 GEA CAIRplus Mounting 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 the unit configuration does not provide for an internal joint connection. Fig. 5-3: Minimum clearance 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. Units with side-by-side arrangement must be supported in the centre (see figure). Fig. 5-4: Foundation requirements with side-byside units PR GB Subject to modifications K6-07/

24 Mounting GEA CAIRplus Foundation requirements for outdoor installation (weatherproof, roof frame) NOTICE!Do not use GEA units for outside installation as a roof substitute! 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 23. 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 30. In areas with heavy snowfalls, 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. 5-5: Foundation design with concrete base Fig. 5-6: Foundation design with field-provided steel beam Fig. 5-7: Foundation design with field-provided steel support NOTICE! Pay particular attention to ensure the exact size of the roof openings and level foundation. 24 PR GB Subject to modifications K6-07/2013

25 GEA CAIRplus Mounting Structure-borne sound 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 springbased elements. For very special acoustic requirements please consult an acoustic engineer to select the most suitable method for neutralising structure-borne noise. 5.2 Assembling the unit NOTICE! See unit submittal documentation for details. Data sheets, installation instructions, small parts and enclosed accessories are located in the unit section specified in the parts list. EQUIPMENT DAMAGE! 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. 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: PR GB Subject to modifications K6-07/

26 Mounting GEA CAIRplus 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. 5-8: Lifting lug at joints Roof lifting lug Remove the screws on the end walls and secure the supplied M8 x 70 screw. Cylinder screw Plastic washer Support bushing Fig. 5-9: 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. These components shall be mounted and sealed by others on site. Disassemble the lifting lug secured on the base frame. Fig. 5-10: Lifting lug secured on the base frame 26 PR GB Subject to modifications K6-07/2013

27 GEA CAIRplus Mounting NOTICE! Lifting lugs are not designed for 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. 5-11: Installing individual modules EQUIPMENT DAMAGE! Do not attach tensioning belts/hoisting devices to heat exchanger connections, condensate drains and door handles. Do not use thee 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. 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. PR GB Subject to modifications K6-07/

28 Mounting GEA CAIRplus max. 100 mm Fig. 5-12: Unit with base frame Fig. 5-13: Unit without base frame Screw the outer joint connections together. Fig. 5-14: External view Install the seam cap. Fig. 5-15: External view If the rear side of the unit is not accessible, screw together the interior joint connection in the corner. Fig. 5-16: Internal corners 28 PR GB Subject to modifications K6-07/2013

29 GEA CAIRplus Mounting 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. 5-17: Internal joint connection 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 GEA packaged content). Fig. 5-18: Pipe duct Additional measure for double-deck and side-by-side units Connect both unit sections using supplied plates. Fig. 5-19: Connecting unit sections PR GB Subject to modifications K6-07/

30 Mounting GEA CAIRplus 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. 5-20: Joint seams Additional measures for units for outdoor installation EQUIPMENT DAMAGE! 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 Preparing roof installation 1 Remove all lifting lugs (1) Install sealing washers at all screws and tighten them (2). Fig. 5-21: Preparing roof installation 30 PR GB Subject to modifications K6-07/2013

31 GEA CAIRplus Mounting Installing inclined/bossed roof (CAIRplus SX) Secure the separately supplied joint strip. Fig. 5-22: 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. 5-23: Single units 064.xxx to 160.xxx and side-by-side units 064.xxx to 096.xxx PR GB Subject to modifications K6-07/

32 Mounting GEA CAIRplus 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. 5-24: Single unit 188.xxx to 252.xxx with inclined roof design 32 PR GB Subject to modifications K6-07/2013

33 GEA CAIRplus Mounting 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 31. 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. 5-25: Single units 280.xxx to 312.xxx and side-by-side units 128.xxx to 160.xxx PR GB Subject to modifications K6-07/

34 Mounting GEA CAIRplus 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. 5-26: 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. 5-27: Side-by-side units with misalignment, sizes 128.xxx and 160.xxx 34 PR GB Subject to modifications K6-07/2013

35 GEA CAIRplus Mounting 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. 5-28: Roof installation with double-deck units PR GB Subject to modifications K6-07/

36 Mounting GEA CAIRplus Roof installation of side-by-side unit with ECOROT Roof installation side-by-side units equipped with EC- OROT 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. 5-29: Roof installation of side-by-side unit with ECOROT 36 PR GB Subject to modifications K6-07/2013

37 GEA CAIRplus Installation 6 Installation 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. EQUIPMENT DAMAGE! When entering GEA CAIRplus units ensure that no loads are applied on the floor panels. For all installation and maintenance jobs take appropriate measures to ensure that all load is evenly distributed across the bottom profiles (e.g. using grid walkways). 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 "Structureborne sound attenuation" on page 25). 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 K6-07/

38 Installation GEA 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: Notice! These limit values are only intended to provide basic information on water quality and do not form any basis for a guarantee. 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. Description Icon Values Hydrogen ion concentration ph < 7 > 9 Calcium and magnesium content Hardness (Ca/Mg) Effects in case of difference Corrosion Incrustation 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 EQUIPMENT DAMAGE! Use a pipe wrench when attaching piping to coils 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. 38 PR GB Subject to modifications K6-07/2013

39 GEA CAIRplus Installation For 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 40). For units with outside-air or mixed-air operation consider the following: EQUIPMENT DAMAGE! 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 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 38. PR GB Subject to modifications K6-07/

40 Installation GEA 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, October 2002, Appendix A, Table A1). Constructional and technical requirements, October 2002, Appendix A, Table A1). Normal climate requirements Data processing rooms ph value Sterile rooms and cleanrooms Total salt concentration g/m³ < 800 < 250 < 100 Electrical conductivity (at reference temperature 20 C) Calcium (Ca 2+ ) (total hardness) ms/m μs/cm < 100 < 1000 mol/m 3 g/m 3 > 0.5 > 20 < 30 < 300 Carbonate hardness dh < 4 Carbonate hardness dh < 20 with hardness stabilisation Chloride (Cl - ) mol/m 3 < 5 g/m 3 < 180 Sulphate (SO 2-4 ) mol/m 3 < 3 g/m 3 < 290 < 12 < 120 Consumption KMnO 4 g/m 3 < 50 < 20 < 10 Germ quantity (KEB/ml) KEB/ml < 1000 < 100 < 10 Legionella bacteria KEB/ml < 1 NOTICE! When installing a water-softening unit GEA recommends to repeat the water analysis. The total salt concentration shall not exceed 250 g/m³! The electrical conductivity shall not exceed 300 µs! EQUIPMENT DAMAGE! Do not operate Honeycomb humidifiers with fully demineralized water Water drain trapping NOTICE! Direct connection to a sewage network is not allowed!fill the condensate trap with water prior to commissioning and after extensive downtime periods. 40 PR GB Subject to modifications K6-07/2013

41 0 GEA CAIRplus Installation 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: H( mmwc) = Únit positive/negative pressure( Pa) Fig. 6-1: Trapping for section under positive The vertical difference between the water drain and hydraulic seal must also correspond to the dimension H (mm WC). Connect the trap to the sewage water system as shown in the figure. 1,5 H, CAUTION: FREEZE-UP RISK! In the event of freeze-up risk the drain pipe must be insulated and kept warm using trace heating. Fig. 6-2: Trapping for section under negative pressure Fig. 6-3: 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 condensate retention). NOTICE! Negative pressure and positive pressure traps must be connected to separate common lines (refer to Fig. 6-3). 6.4 Installing accessories Refer to the supplied documentation specifying assembly and installation instructions for accessories or field-provided accessory items. PR GB Subject to modifications K6-07/

42 Electrical Connection GEA CAIRplus 7 Electrical Connection The electrical connection may only be completed by a qualified licensed electrician. 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. 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 unit, all connected components and shipment units! 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. HAZARDOUS VOLTAGE! Disconnect all electric power and ensure the power cannot be inadvertently energised, earth, short-circuit and block off all neighboring live parts. Non-compliance can lead to death or serious injury. NOTICE! Wiring to the unit must be completed in accordance with enclosed unit-specific wiring diagrams and national electrical codes and regulations. Only separate mains power cable shall be used. 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 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's 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 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). 42 PR GB Subject to modifications K6-07/2013

43 GEA CAIRplus Electrical Connection 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. EQUIPMENT DAMAGE! A separate lead-out sensor must not be energized due to risk of complete destruction. The maximum allowable voltage reading must not exceed 5 V. Wire the sensor only to the motor full protection tripping unit (e.g. GEA 912.MVS 1.0). INDUCTION EFFECTS! To prevent induction effects for the PTC thermistor circuit GEA 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). Motor full protection electronics Operating point of tripping unit For motor full protection GEA recommends to use GEA 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 GEA 912.MVS 1.0 generally enable isolated disconnection and a restart following a power outage. Resistance R Temperature T +135 C 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 PR GB Subject to modifications K6-07/

44 Electrical Connection GEA CAIRplus Extended motor protection Disconnection in the event of an error With frequent start-ups, intermittent operation, activation rate and to ensure optimum protection against 2-phase run, GEA 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 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. EQUIPMENT DAMAGE! Check for the proper assignment of the phase sequence to the specified rotating direction before the motor is connected. Improper connection to the motor/ fan could result in equipment damage. 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). Single-speed electric motors with direct start: Single-speed electric motors with Y/Δ-start: 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 Multi-stage electric motors: Stage 1: exchange the connecting wires, e.g. U1 and V1 Stage 2: exchange the connecting wires, e.g. U2 and V2 Stage 3: exchange the connecting wires, e.g. U3 and V3 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. 44 PR GB Subject to modifications K6-07/2013

45 GEA CAIRplus Electrical Connection 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 L1 W2 U2 V2 U1 U2 U1 V1 W1 V2 W2 L3 W1 V1 L2 L1 L2 L3 L1 W2 U2 V2 W2 U1 K K U1 V1 W1 W1 *2 U2 L3 L2 V2 V1 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 *1 PTC thermistor *2 Motor protection device Two-stage motor: 750/1500 min -1 Dahlander connection Y/YY 1W L3 L1 1U 2W 2U L1 2U Stage 1: 750 min -1 2V 1V L2 Stage 2: 1500 min -1 2U 2V 2W 1U 1V 1W L1 L2 L3 L1 L2 L3 *1 Motor version: 8/4 pole With pole-changing capability one winding with Y/YY Dahlander connection 2-3 PTC thermistors depending on the motor size Total resistance R K (20 C) approx Ω *1 PTC thermistor *2 Motor protection device L3 2W 1W 1U 1V 2V L2 2U 2V 2W 1U 1V 1W K *2 K Two-stage motor: 1000/1500 min -1 separated winding Y/Y L3 1W L1 1U L1 2U Stage 1: 1000 min -1 1V L2 Stage 2: 1500 min -1 2U 2V 2W 1U 1V 1W L1 L2 L3 L1 L2 L3 *1 Motor version: 6/4 pole With pole-changing capability two separated windings Y/Y 4-6 PTC thermistors depending on the motor size Total resistance R K (20 C) approx Ω *1 PTC thermistor *2 Motor protection device L3 2W 2V L2 2U 2V 2W 1U 1V 1W K *2 K PR GB Subject to modifications K6-07/

46 Electrical Connection GEA CAIRplus Three-stage motor: 750/1000/1500 min -1 Dahlander and separated winding Y/Y/YY L1 1U 3W 3U 1W L3 L1 2U 2W L3 Stage 1: 750 min -1 3V 1V L2 Stage 2: 1000 min -1 2V L2 L1 L2 L3 L1 L2 L3 1U 2U 3U 1V 2V 3V 1W 2W 3W 1U 2U 3U 1V 2V 3V 1W 2W 3W *1 Motor version: 8/6/4 pole With pole-changing capability Stage 1 and 3 in Y/YY Dahlander connection Stage 2 with Y-type switch, separated winding 4-6 PTC thermistors depending on the motor size Total resistance R K (20 C) approx Ω *1 PTC thermistor *2 Motor protection device L1 Stage 3: 3W 3U 1W 1U 1V 1500 min -1 1U 1V 1W 2U 2V 2W 3U 3V 3W L1 L2 L3 K *2 K L3 3V L2 Three-stage motor: 500/1000/1500 min -1 Dahlander and separated winding Y/Y/YY L1 Stage 1: 1U 1U 2U 3U 500 min -1 L1 2W 1V 2V 3V L2 1W 2W 3W 2U 2V L3 1W 1V L3 L1 Stage 2: 2U 1U 1000 min -1 2U 3U 1W 1V 1U 1V 1W 2V 3V 2W 2W 3W L3 2V L2 L1 3U Stage 3: 1U 2U 3U 1500 min -1 1V 2V 3V 1W 2W 3W 3W 3V L1 L2 L3 L1 L2 L3 K *1 *2 K Only for motors up to model size 225, 33 kw Motor version: 12/6/4 pole With pole-changing capability Stage 1 and 2 in Y/YY Dahlander connection Stage 3 with Y-type switch, separated winding 4-6 PTC thermistors depending on the motor size Total resistance R K (20 C) approx Ω *1 PTC thermistor *2 Motor protection device L3 L2 46 PR GB Subject to modifications K6-07/2013

47 GEA CAIRplus Electrical Connection Three-stage motor: 500/1000/1500 min -1 Dahlander and separated winding Y/YY/ D L1 Stage 1: 1U 1U 2U 3U 500 min -1 L1 2W 1V 2V 3V L2 1W 2W 3W 2U 2V L3 1W 1V L3 L1 Stage 2: 2U 1U 1000 min -1 2U 3U 1W 1V 1U 1V 1W 2V 3V 2W 2W 3W L3 2V L2 L1 3W2 3W Stage 3: 1500 min -1 3V 1U 2U 3U1 3W2 1V 2V 3V 1W 2W 3W L1 L2 L3 L1 L2 L3 *1 K K *2 Only for motors from model size 250, 45 kw Motor version: 12/6/4 pole With pole-changing capability Stage 1 and 2 in Y/YY Dahlander connection Stage 3 with Δ-type switch with Z-terminal 4-6 PTC thermistors depending on the motor size Total resistance R K (20 C) approx Ω *1 PTC thermistor *2 Motor protection device L3 L2 AC motor 230 V~ Anti-clockwise rotation M 1~ Clockwise rotation M 1~ Motor version: One-stage motor 1450 min -1 Supply voltage: 1 x 230 V~/50 Hz Max. output: 1.75 kw Motor connection: with operating capacitor Motor protection: thermal contact Z2 Z1 U2 U1 T T Z2 Z1 U2 U1 T PE T PE Check the motor voltage and amperage on all stages and compare with the specifications on the motor nameplate or enclosed documentation. Measure all electrical lines at every stage to verify symmetrical motor load. If the specified values are exceeded or in case current consumption varies in the individual phases, have a specialist determine the cause Frequency inverter In the course of unit start-up perform parameter settings. EQUIPMENT DAMAGE It is not allowed to activate the parameter "overmodulation" as this can damage the impeller. PR GB Subject to modifications K6-07/

48 Electrical Connection GEA CAIRplus NOTICE! GEA neither accepts warranty claims nor assumes liability if the above-mentioned condition is not adhered to. 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 Service switch Install a lockable service switch near the access door of the fan chamber. With a factory-mounted service switch the wiring is run up to the motor Installing and connecting actuator motor With a factory-mounted GEA 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. Do not start up the fans with closed dampers Additional electrical components Connect additional electrical components in accordance with the relevant provided documentation and wiring diagrams. 48 PR GB Subject to modifications K6-07/2013

49 GEA 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 specified throughout the current chapter. HAZARDOUS VOLTAGE! The following instructions apply for all maintenance and cleaning steps: open the doors only after complete deactivation of the unit, ensure that the power cannot be inadvertently energised beforehand. 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 material damage! WARNING: RISK OF ROTATING COMPONENTS! Before opening unit doors, use the main isolator to deactivate the fan and secure the latter against inadvertent energizing.wait at least five minutes following the complete fan stop before opening unit doors. EQUIPMENT DAMAGE! When entering GEA CAIRplus units ensure that no loads are applied on the floor panels. During all installation and maintenance jobs take proper measures to ensure that all load is evenly spread across the bottom profiles (e.g. using grid walkways). 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 oilproof only for a limited time. Use only alcohol-based disinfectants and cleaning agents. PERSONAL PROTECTION! For cleaning and certain maintenance jobs use personal protective equipment to include face shield and chemical resistant gloves. PR GB Subject to modifications K6-07/

50 Commissioning and Maintenance GEA CAIRplus 8.1 Routine cleaning and maintenance HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! OB- SERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on Page 49. After the cleaning procedure ensure that the unit is dry and residue-free! Observe current legal regulations and standards! GEA recommends to perform maintenance steps and 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). Handle 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! Routine cleaning of fins HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! OB- SERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on Page 49. DANGER SHARP CUTTING EDGES! Observe precaution when cleaning due to risk of cuts on thin and sharp edges. Fins require cleaning to ensure that the heat exchanger continues operating 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 aluminium fins. Use steam-jet appliances to clean steel galvanized heat exchangers or heat exchangers with reinforced fins. 50 PR GB Subject to modifications K6-07/2013

51 GEA CAIRplus Commissioning and Maintenance 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 safety instructions for all specified maintenance routines on Page 49 and Page 50! Unit part Units for indoor installation (see Page 54) Frequency (months) Action Monthly Clean and refill available traps. Every 3 Check casing for damage and proper fit. months 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 (GEA 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 55) Belt-driven fan assembly (see Page 56 et seq.) Every 12 months Every 3 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. 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 57 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. 8-3 on Page 59). PR GB Subject to modifications K6-07/

52 Commissioning and Maintenance GEA CAIRplus Unit part Direct-driven fan assembly (See Page 60) Routines for all filters (see Page 61et seq.) Bag/panel/ fine-particle filter (refer to Page 62) Activated Carbon Filter (cartridges) (see Page 62) Grease filter (see Page 63) Other filters Heater assembly (pumped warm water) (refer to Page 64) Steam heater assembly (see Page 64) Frequency (months) Every 3 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 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. 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 - if so - replace the filter. Hygiene inspection (GEA 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 long-term 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. 52 PR GB Subject to modifications K6-07/2013

53 GEA CAIRplus Commissioning and Maintenance Unit part Direct-fired (gas) heater assembly (see Page 65) Cooler assembly with/ without droplet separator (refer to Page 66) Evaporator/ condenser (see Page 67) Heat pipe (see Page 68) Liquid-coupled energy recovery assembly (see Page 68) Plate heat exchanger (see Page 68) Frequency (months) Refer to the relevant maintenance instructions specified in the supplied documentation. Every 12 months Before winterizati on Every 12 months Every 12 months 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. Clean coil drip tray and condensate line. Check trap for proper operation, top up as necessary. Clean droplet separator with a descaling spray. Drain water from the cooling coil before winter. Clean and check evaporator/condenser. Ensure that all refrigeration components (refrigerating machine, direct evaporator, distribution manifold, refrigerant lines, etc.) are functioning properly. 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. Complete the same steps specified in "Cooler assembly with/without droplet separator" (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. PR GB Subject to modifications K6-07/

54 Commissioning and Maintenance GEA CAIRplus Unit part Frequency (months) Action Rotation heat exchanger (refer to Page 70) 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 high-pressure 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. Damper blades and shut-off dampers (see to Page 71) Every 6 months 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 attenuator (see to Page 71) Every 6 months Check the sound attenuator section and sound insulating splitters for dirt, clean as necessary. 8.3 General considerations Commissioning of units for indoor installation 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 Maintenance of units for indoor installation HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! OB- SERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on Page PR GB Subject to modifications K6-07/2013

55 GEA CAIRplus Commissioning and Maintenance NOTICE! Carry out additional cleaning in case of aggressive or oil-containing air. Sealant material is oil-proof only for a limited time. 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 Doors and service openings Check seals and gaskets, replace if necessary. Check door stop device (on the pressure side) for proper operation. Panels Check for damage and corrosion. If applicable, renew or apply new corrosion-protection (paint), impregnate, etc. Trap Clean and refill available traps Commissioning of units for outdoor installation (weatherproof roof units) Complete the following commissioning steps: Complete all steps specified in "Commissioning of units for indoor installation" on page 54 first. Checks condition of weatherproof gasketing (refer to "Foundation requirements for outdoor installation (weatherproof, roof frame)" on page 24) Maintenance of units for outdoor installation (weatherproof roof units) Carry out the following maintenance steps: Complete all steps specified in "Maintenance of units for indoor installation" on page 54 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. PR GB Subject to modifications K6-07/

56 Commissioning and Maintenance GEA CAIRplus 8.4 Fan assembly and drives Commissioning of belt-driven fan assembly HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! OB- SERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on Page 49. EQUIPMENT DAMAGE 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 shall 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 HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! OB- SERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on Page 49. EQUIPMENT DAMAGE 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! 56 PR GB Subject to modifications K6-07/2013

57 GEA CAIRplus Commissioning and Maintenance 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. Re-tensioning or replacing V-belt Initial check: Regular checks: 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 Tab. 8-1: High-performance narrow V-belt as per DIN 7753 Deflection x [mm] Distance between axes [mm] 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. PR GB Subject to modifications K6-07/

58 Commissioning and Maintenance GEA CAIRplus 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. 8-1). Tension the fan belt (measure using a belt tensiometer or frequency calculation method, Fig. 8-1). 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. 8-1). Centre lines Fig. 8-1: Pulley alignment and fan belt tensioning Adjusting or removing fan belt pulley Slacken fan belt, see Re-tensioning or replacing V-belt on page 57, 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. 8-2: 58 PR GB Subject to modifications K6-07/2013

59 GEA CAIRplus Commissioning and Maintenance 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 57.) Evenly tighten the hexagon-socket screws. Tapped drill hole for pressing out pulley V-belt pulley Fig. 8-3: Installing fan belt pulley Consider the maximum tightening torque of hexagon-socket screws during the installation: Bush Nr Max. tightening torque (Nm) Tab. 8-2: 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. 8-3)! 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 200 N 250 N 280 N 315 N N 355 N N Manufacturer Comefri Gebhardt Fläkt Woods NTHZ-B NTHZ T1 NTHZ VZR71 RZR11 RZR15 RZR19 GXLB GXLF GXHB NTHZ-R T2 NTHZ T2L RZR 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. 8-3: Lubrication details for non-sealed fan bearings PR GB Subject to modifications K6-07/

60 Commissioning and Maintenance GEA CAIRplus Commissioning of direct-driven fan assembly HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! Please consider the safety instructions on Page 49. 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 43). With Y/? 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! GEA neither accepts warranty claims nor assumes liability if the above-mentioned condition is not adhered to. 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 HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! Please consider the safety instructions on Page 49. 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. 8.5 Filter assembly Commissioning of filter assembly HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! OB- SERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on Page PR GB Subject to modifications K6-07/2013

61 GEA CAIRplus Commissioning and Maintenance Complete the following commissioning steps: Check filter section and installed filters for damage. Check that filter section 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) Routine maintenance for all filters HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! OB- SERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on Page 49. 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! GEA recommends to always operate the unit with an installed filter. Keep a set of spare filters on stock as well. Ensure that the filter surface is not damaged as this can destroy the filter during service. In this case GEA can not assume any warranty for the filter grade. 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 - if so - replace the filter. Hygiene inspection Observe current legal regulations and standards! GEA recommends maintenance steps 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 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. PR GB Subject to modifications K6-07/

62 Commissioning and Maintenance GEA CAIRplus Maintenance of bag filters/panel filters/fine-particle filters Maintenance of activated-carbon filter HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! OB- SERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on Page 49. 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. 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 quickrelease 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 quickrelease filter frame. Install filter bags only in the upright position! Close the service access door or maintenance panel. HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! Please consider the safety instructions on Page 49. 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. Replacing activated-carbon filter (cartridges) 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. 62 PR GB Subject to modifications K6-07/2013