CAIRpool OPERATION MANUAL

Transcription

1 CAIRpool OPERATION MANUAL

2 Table of Contents CAIR pool 1 Unit type code Safety and User Instructions Availability of the operation manual Scope of the operation manual Symbols used Identification of safety information 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 Modular unit configuration and operation of CAIRpool Technical specifications Requirements of ErP Directive 2016/ 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 FläktGroup DC GB /R2 Subject to modifications

3 CAIR pool 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 ECOSTAT heat pipe Liquid-coupled energy recovery coil ECOFLOW ECOPLAT plate heat exchanger Damper blades and shut-off dampers Sound attenuators Commissioning/maintenance of integrated refrigerating systems Disassembly and Disposal Dismantling Disposal Troubleshooting Annex Maintenance Log Book CAIRpool 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. FläktGroup DC GB /R2 Subject to modifications 3

4 Unit type code CAIR pool 1 Unit type code A B B K B Unit part 2 * Example: CAIR pool X 1 M # I H Ü K Z B B K B 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 type Casing type Function Air flow Unit width Unit height Material Internal skin Material External skin Material Components Material of profiles CAIR pool (air handling unit) X SX Unit 1 Standard without accessories 2 Standard with accessories 3 Special design M Partial K Without # Standard R Standard, in conformity with RLT 01 Directive H Hygiene ver. E Explosion protected I Indoor installation A Outdoor installation D Ceiling mounting W Wall installation U Underfloor installation H Horizontal V Vertical L L Form S Single N Side by Side Ü Double deck H Straighthrough 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 Z275MA-C 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 B RAL 9002 coated * Unit part 2 additional with arrangement types side-by-side, double-deck or straight-through 4 FläktGroup DC GB /R2 Subject to modifications

5 CAIR pool Safety and User Instructions 2 Safety and User Instructions The CAIRpool 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. Notice! Additional details on using the unit are specified here. Danger symbols are specified in section "Identification of safety information" on page 7. FläktGroup DC GB /R2 Subject to modifications 5

6 Safety and User Instructions CAIR pool 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 FläktGroup DC GB /R2 Subject to modifications

7 CAIR pool Safety and User Instructions 2.4 Identification of safety information 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 chemical resistant gloves. FläktGroup DC GB /R2 Subject to modifications 7

8 Safety and User Instructions CAIR pool 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 8 FläktGroup DC GB /R2 Subject to modifications

9 CAIR pool Safety and User Instructions 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! FläktGroup DC GB /R2 Subject to modifications 9

10 Safety and User Instructions CAIR pool 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 81. 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. 10 FläktGroup DC GB /R2 Subject to modifications

11 CAIR pool Safety and User Instructions 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 CAIRpool units are only intended for handling air and performing the following jobs: filtering normally polluted air 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 (special models, swimming pool or damp rooms for example showers and changing rooms) or combination of the above-mentioned functions. 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 FläktGroup. FläktGroup DC GB /R2 Subject to modifications 11

12 Safety and User Instructions CAIR pool 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 The unit is not suitable for handling abrasive media. It is not allowed to operate CAIRpool 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). CAIRpool 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 FläktGroup should be arranged in advance. 12 FläktGroup DC GB /R2 Subject to modifications

13 CAIR pool Safety and User Instructions 2.10 Spare parts Only original FläktGroup spare parts are allowed, since FläktGroup is not liable if thirdparty 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 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. FläktGroup DC GB /R2 Subject to modifications 13

14 Technical Description CAIR pool 3 Technical Description 3.1 Performance scope CAIRpool units are used for energy-efficient air dehumidification in swimming pools and humid rooms. 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 and dehumidified, depending on the application for each case. The aim is to meet the customer specifications concerning required air volume and conditions. CAIRpool units are used at a central point for comfort air conditioning on commercial and industrial premises for the transportation and treatment of normal air (according to VDI 2089). A range of unit components is available for energy-saving purposes: plate-type heat exchangers, liquid-coupled heat exchangers and heat pumps with a heat recuperation function. Units are performed in different sizes and have various capacities. Depending on the application for each case, CAIRpool units are designed for horizontal air flow and are arranged as double-deck and side-by-side models. Units are only designed for indoor installation. Units for outdoor installation need have special design. Thanks to the modular design of the CAIRpool, units ship as complete assemblies or sub-assemblies that can pass through the available on-site openings in the course of installation. CAIRpool 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 Modular unit configuration and operation of CAIRpool 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 PPI/PPR Units with double-recuperator and heat pump The CAIRpool PPI/PPR is designed for various kinds of High Performance private and public swimming pools. The series can be supplied with air volume capacity between 750 up to m³/h. The unit's function is to dehumidify and heat air in swimming pools in mixed air mode. Together with a heat pump this unit type is additionally equipped with an efficient heat recovery system using a two stage recuperator. The unit is delivered with a DDC controls which regulates all functions of the system on a fully automated basis. SUP ODA ETA EHA Fig. 3-1: CAIRpool PPI/PPR 14 FläktGroup DC GB /R2 Subject to modifications

15 CAIR pool Technical Description The units dehumidify through a 24 h fresh air regulation. The accumulation of odors or toxic gasous pollutants in form of trihalogenmethanes, chloramines or other corrosionpromoting substances is reduced continuously. According to the required dehumidification demand, larger or smaller quantities of outdoor air are used. The regulation is performed continuously within range of 0-100%. To ensure this, a highly sensitive humidity sensor controls the extract-air humidity of the swimming pool in the extractair fan chamber. Furthermore, the fully automated DDC control sets the required outdoor-air rate for the dehumidification. The outdoor air is pre-warmed via the recuperator. The compressor unit operates as a heat pump and ensures the residual heat at the default setpoint temperature. The downstream heater bank is regulated at low outdoorair temperatures or in case of heating up. In the pool mode outside air and extract air dampers are open to ensure a pre-set minimum rate of outside air for hygienic reasons according to VDI 2089 to at least 30%. Depending on the swimming pool humidity requirement the outside/extract air rate is regulated automatically. Using an optimal pool or fresh-water condenser a certain amount of excess energy produced by the heat pump can be fed back into the pool water or a tank. In the event of overheated swimming pool the heat pump is reduced and the supply air bypass damper ensures cool air in the swimming pool. The bypass damper is continuously opened to divert the heat recovery facility depending on requirements. The PPR units are equipped with a reversible refrigeration circuit. Therefore, the swimming pool temperature can be kept constant during the summer time and high external loads according to the setting. For both versions, the function of the heat pump depends on the outdoor-air rate. The technical characteristics determine the running time and function of the compressor. The compressor is regulated via frequency inverter and is operated via DDC in the possible working area on a fully automatic basis PPX units with double-recuperator The CAIRpool PPX is designed for various kinds of High Performance private and public swimming pools. The series can be supplied with air volume capacity between 750 up to m³/h. The unit's function is to dehumidify and heat air in swimming pools in mixed air mode. The heat recovery is performed via a highly-efficient two stage recuperator. It can be delivered with/without DDC controls. When using DDC the controller regulates all functions of the system on a fully automatic basis. SUP ODA ETA EHA Fig. 3-2: CAIRpool PPX The units dehumidify through a 24 h fresh air regulation. The accumulation of odors or toxic gasous pollutants in form of trihalogenmethanes, chloramines or other corrosionpromoting substances is reduced continuously. According to the required dehumidification demand, larger or smaller quantities of outdoor air are used. The regulation is performed continuously within range of 0-100%. To ensure this, a highly sensitive humidity sensor controls the extract-air humidity of the swimming pool in the extract- FläktGroup DC GB /R2 Subject to modifications 15

16 Technical Description CAIR pool air fan chamber. Furthermore, the fully automated DDC control sets the required outdoor-air rate for the dehumidification. The outdoor air is pre-warmed via the recuperator. The downstream heater bank is regulated for the remaining temperature control. In the pool mode outside air and extract air dampers are open to ensure a pre-set minimum rate of outside air for hygienic reasons according to VDI2089 to at least 30%. Depending on the swimming pool humidity requirement the outside/extract air rate is regulated automatically. In the event of overheated swimming pool the recuperator block is diverted and fresh outdoor air is conveyed into the swimming pool via the supply air bypass damper. The bypass damper is continuously opened to divert the heat recovery facility depending on requirements. 3.3 Technical specifications Refer to the order-related documentation for the specific configuration of your CAIRpool unit (unit drawing with dimensions and technical data) 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 enclosed documentation for the operating limits of special built-in components. In frost-risk cases, use antifreeze agents for heating and cooling media. Operating limits for CAIRpool special/customized 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. Outdoor air from -25 C to +40 C Air humidity depending on temperature max. 18 g/kg of dry air Max. operating pressure Heating/cooling coil 16 bar / 90 C and temperature Minimum operating Heating/cooling coil 6 C temperature Notice on extreme conditions! ATTENTION Damage to the unit! The switch box with control display, frequency inverter with control display and other temperature-sensitive instruments are designed for indoor installation in frost-free conditions. 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. 16 FläktGroup DC GB /R2 Subject to modifications

17 CAIR pool Technical Description Permitted storage conditions / permitted air condition for uninstalled units Air temperature 5 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. 3 phases 400 V (50 Hz) + N + PE 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 CAIR pool SX M. 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. 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. FläktGroup DC GB /R2 Subject to modifications 17

18 Technical Description CAIR pool CAIRpool SX M = partial thermally separated Condensation diagram for kb-value: 0.62 Relative humidity on unit external side in % Air temperature on unit internal side in C Air temperature on unit external side in C 18 FläktGroup DC GB /R2 Subject to modifications

19 CAIR pool Technical Description 3.4 Requirements of ErP Directive 2016/2281 The values presented in the tables 2-17 and 2-18 are provided to ensure the implementation of the EU Directive 2009/125/EG. This Directive sets the framework for the requirements to the environmentally-friendly design of energy-related products such as air heaters, air coolers, units for air cooling in industrial processes with high operating temperature and fan coil units. Heat pump for roof installation Roof top heat pump with double plate heat exchanger Roof top heat pump with double plate heat exchanger Roof top heat pump with double plate heat exchanger Model: PPI 15/25 PPI 35 PPI 43 Outdoor side heat exchanger: Air Air Air Indoor side heat exchanger: Air Air Air Supplementary heater As an option As an option As an option Type: Compressor driven vapour compression Compressor driven vapour compression Compressor driven vapour compression Driver of compressor: Electric motor Electric motor Electric motor Rated heating capacity, total (P rated,h,tot ) in kw 8,9 12,6 15,9 Rated heating capacity, compressor, (P rated,h,compr ) in kw Seasonal space heating energy efficiency, total (η s,h.tot ) in % Annual space heating energy efficiency, total (η s,h.compr ) in % Outdoor temperature (T j ) Heating capacity (kw) 1,9 2,6 3, COP Heating capacity (kw) COP Heating capacity (kw) COP Total Compressor Total Compressor Total Compressor Total Compressor Total Compressor Total Compressor -7 C C C C C Bivalent temperature Reduction factor (C dc ) NA (variable speed compressor) NA (variable speed compressor) NA (variable speed compressor) Energy consumption Off mode (P OFF ), Thermostat off mode (P TO ) and Standby mode (P SB ) 0,0725 0,0725 0,0725 Capacity contol Variable speed Variable speed Variable speed Air flow rate outdoor in m³/h 450/ Sound power level From Lplus Selection Tool From Lplus Selection Tool From Lplus Selection Tool Refrigerant R410A R410A R410A GWP value Contact details CAIRpool units are designed for the dehumidification of swimming halls by using outside air. At outdoor temperatures [Tj] shown above, the amount of outdoor air is 30% of the supply air flow Units operate under operating conditions of return air temperature of 30 C, therefore a defrost mode is not necessary FläktGroup DC GB /R2 Subject to modifications 19

20 Technical Description CAIR pool Heat pump for roof installation Roof top heat pump with double plate heat exchanger Roof top heat pump with double plate heat exchanger Roof top heat pump with double plate heat exchanger Model: PPI 53 PPI 65 PPI 90 Outdoor side heat exchanger: Air Air Air Indoor side heat exchanger: Air Air Air Supplementary heater As an option As an option As an option Type: Compressor driven vapour compression Compressor driven vapour compression Compressor driven vapour compression Driver of compressor: Electric motor Electric motor Electric motor Rated heating capacity, total (P rated,h,tot ) in kw 18,9 23,1 32,3 Rated heating capacity, compressor, (P rated,h,compr ) in kw Seasonal space heating energy efficiency, total (η s,h.tot ) in % Annual space heating energy efficiency, total (η s,h.compr ) in % Outdoor temperature (T j ) Heating capacity (kw) 3,9 4,5 7, COP Heating capacity (kw) COP Heating capacity (kw) COP Total Compressor Total Compressor Total Compressor Total Compressor Total Compressor Total Compressor -7 C C C C C Bivalent temperature Reduction factor (C dc ) NA (variable speed compressor) NA (variable speed compressor) NA (variable speed compressor) Energy consumption Off mode (P OFF ), Thermostat off mode (P TO ) and standby mode (P SB ) 0,0725 0,0725 0,0725 Capacity contol Variable speed Variable speed Variable speed Air flow rate outdoor in m³/h Sound power level From Lplus Selection Tool From Lplus Selection Tool From Lplus Selection Tool Refrigerant R410A R410A R410A GWP value Contact details CAIRpool units are designed for the dehumidification of swimming halls by using outside air. At outdoor temperatures [Tj] shown above, the amount of outdoor air is 30% of the supply air flow Units operate under operating conditions of return air temperature of 30 C, therefore a defrost mode is not necessary 20 FläktGroup DC GB /R2 Subject to modifications

21 CAIR pool Technical Description Heat pump for roof installation Roof top heat pump with double plate heat exchanger Roof top heat pump with double plate heat exchanger Roof top heat pump with double plate heat exchanger Model: PPI 120 PPI 150 PPI 190 Outdoor side heat exchanger: Air Air Air Indoor side heat exchanger: Air Air Air Supplementary heater As an option As an option As an option Type: Compressor driven vapour compression Compressor driven vapour compression Compressor driven vapour compression Driver of compressor: Electric motor Electric motor Electric motor Rated heating capacity, total (P rated,h,tot ) in kw 42,9 53,2 67,2 Rated heating capacity, compressor, (P rated,h,compr ) in kw Seasonal space heating energy efficiency, total (η s,h.tot ) in % Annual space heating energy efficiency, total (η s,h.compr ) in % Outdoor temperature (T j ) Heating capacity (kw) 9,4 11,7 11, COP Heating capacity (kw) COP Heating capacity (kw) COP Total Compressor Total Compressor Total Compressor Total Compressor Total Compressor Total Compressor -7 C C C C C Bivalent temperature Reduction factor (C dc ) NA (variable speed compressor) NA (variable speed compressor) NA (variable speed compressor) Energy consumption Off mode (P OFF ), Thermostat off mode (P TO ) and Standby mode (P SB ) 0,0725 0,0725 0,0725 Capacity contol Variable speed Variable speed Variable speed Air flow rate outdoor in m³/h Sound power level From Lplus Selection Tool From Lplus Selection Tool From Lplus Selection Tool Refrigerant R410A R410A R410A GWP value Contact details CAIRpool units are designed for the dehumidification of swimming halls by using outside air. At outdoor temperatures [Tj] shown above, the amount of outdoor air is 30% of the supply air flow Units operate under operating conditions of return air temperature of 30 C, therefore a defrost mode is not necessary FläktGroup DC GB /R2 Subject to modifications 21

22 Technical Description CAIR pool Heat pump for roof installation Roof top heat pump with double plate heat exchanger Roof top heat pump with double plate heat exchanger Roof top heat pump with double plate heat exchanger Model: PPI 250 PPI 320 PPI 360 Outdoor side heat exchanger: Air Air Air Indoor side heat exchanger: Air Air Air Supplementary heater As an option As an option As an option Type: Compressor driven vapour compression Compressor driven vapour compression Compressor driven vapour compression Driver of compressor: Electric motor Electric motor Electric motor Rated heating capacity, total (P rated,h,tot ) in kw 88,3 113,0 127,2 Rated heating capacity, compressor, (P rated,h,compr ) in kw Seasonal space heating energy efficiency, total (η s,h.tot ) in % Annual space heating energy efficiency, total (η s,h.compr ) in % Outdoor temperature (T j ) Heating capacity (kw) 15,3 19,0 22, COP Heating capacity (kw) COP Heating capacity (kw) COP Total Compressor Total Compressor Total Compressor Total Compressor Total Compressor Total Compressor -7 C C C C C Bivalent temperature Reduction factor (C dc ) NA (variable speed compressor) NA (variable speed compressor) NA (variable speed compressor) Energy consumption Off mode (P OFF ), Thermostat off mode (P TO ) and Standby mode (P SB ) 0,0725 0,0725 0,0725 Capacity contol Variable speed Variable speed Variable speed Air flow rate outdoor in m³/h Sound power level From Lplus Selection Tool From Lplus Selection Tool From Lplus Selection Tool Refrigerant R410A R410A R410A GWP value Contact details CAIRpool units are designed for the dehumidification of swimming halls by using outside air. At outdoor temperatures [Tj] shown above, the amount of outdoor air is 30% of the supply air flow Units operate under operating conditions of return air temperature of 30 C, therefore a defrost mode is not necessary 22 FläktGroup DC GB /R2 Subject to modifications

23 CAIR pool Shipping and Storage 4 Shipping and Storage 4.1 Delivery CAIRpool 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 lorry driver and have him confirm the damage on the shipping order. 2 Inform FläktGroup immediately. Exterior packaging is O.K., contents are damaged. 1 Once you have established the extent of the damage, report the damage to FläktGroup 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 FläktGroup 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 FläktGroup! 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 damage to persons and property. When transporting the unit, carefully 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. FläktGroup DC GB /R2 Subject to modifications 23

24 Shipping and Storage CAIR pool 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 FläktGroup! Move the unit carefully without fast irregular movements. Do not set the unit down abruptly or bump it. Do not tilt or place on side units or modules with an integrated refrigeration system (compressor) 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. Lifting lugs are designed for vertical loads only. 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 24 FläktGroup DC GB /R2 Subject to modifications

25 CAIR pool 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 FläktGroup 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 FläktGroup 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. FläktGroup DC GB /R2 Subject to modifications 25

26 Shipping and Storage CAIR pool 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 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 5 C to 50 C Air humidity Store units in a dry, non-condensing atmosphere 26 FläktGroup DC GB /R2 Subject to modifications

27 CAIR pool Assembly 5 Assembly Notice! Here you will find information on how to mount and install the unit. Assemble and install exclusively by qualified staff. 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. 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 FläktGroup 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 Damage to the unit! When entering CAIRpool 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 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 FläktGroup! 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. FläktGroup DC GB /R2 Subject to modifications 27

28 Assembly CAIR pool 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 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 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. 5-2: 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(see fig. 5-3). Units with side-by-side arrangement must be supported in the center (see fig. 5-4). L 1600 L 1600 Fig. 5-3: Foundation requirements with side-by-side units operator side 28 FläktGroup DC GB /R2 Subject to modifications

29 CAIR pool Assembly Fig. 5-4: Foundation requirements with side-by-side cross-section 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 28. 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 38. 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. 5-5: Foundation design with concrete base Fig. 5-6: Foundation design with field-provided steel beam FläktGroup DC GB /R2 Subject to modifications 29

30 Assembly CAIR pool 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 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 chemical resistant gloves. 30 FläktGroup DC GB /R2 Subject to modifications

31 CAIR pool Assembly 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. 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. 5-8: Roof lifting lug 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. 5-9: Lifting lugs for roof and end wall FläktGroup DC GB /R2 Subject to modifications 31

32 Assembly CAIR pool 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. Disassemble the lifting lug secured on the base frame. Fig. 5-10: 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. 5-11: Installing individual modules 32 FläktGroup DC GB /R2 Subject to modifications

33 CAIR pool Assembly To join individual sections for final assembly (at joints of the double-plate heat exchangers of type PP_ or Micro CxT proceed as follows: Attach sealing strip on the joint profile of the unit frame. (Separate assembly instructions are enclosed with the supplied sealing strip). For units of type PP_ consider the following: ATTENTION Damage to the unit! Sealing is mandatory due to the possible condensate flow on this spot. Access is possible via the service opening after the assembly. For sealing, proceed as follows: clean joint seam seal smoothly and clean with sealing material Seal plate exchanger Due to the increased condensate formation during dehumidification mode provide adequate sealing of this zone to ensure a leak-free condition. ATTENTION Damage to the unit! To prevent humidity in gaps and seams, the sealing material must be applied flushly with the internal frame edge. The bottom or side area of the seal must be designed seamlessly for sealing. After sealing a separation is not possible anymore. Degrease the sealing face in advance. Keep the sealing face dust-free. FläktGroup DC GB /R2 Subject to modifications 33

34 Assembly CAIR pool Apply enough sealing material on the sealing face of the plate exchanger: At least 10 mm cord Appropriate sealing material for the use in central air handling units ATTENTION Damage to the unit! To prevent humidity in gaps and seams, the sealing strip must be applied flushly with the internal frame edge. The bottom or side area of the seal must be designed seamlessly for sealing. Degrease the sealing face in advance. Keep the sealing face dust-free. Attach sealing strip on the sealing face of the plate exchanger. Approx. 15 mm wide Sealing strip closed porous, gap filling, soft and suitable for the use in central air handing units. 34 FläktGroup DC GB /R2 Subject to modifications

35 CAIR pool Assembly Compile modules 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. 5-12: Unit with base frame Fig. 5-13: 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. 5-14: Screw the base frame to the connectors Screw the outer joint connections together. Fig. 5-15: External view FläktGroup DC GB /R2 Subject to modifications 35

36 Assembly CAIR pool Install the seam cap. Fig. 5-16: 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. 5-17: 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. 5-18: 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 packaged content). Fig. 5-19: Pipe duct 36 FläktGroup DC GB /R2 Subject to modifications

37 CAIR pool Assembly Additional measure for double-deck and side-by-side units Connect both unit sections using supplied plates. Fig. 5-20: Connecting unit sections For offset double-deck units, use the screws as outlined. Fig. 5-21: Double-deck units For offset side-by-side units, use the screws as outlined. Fig. 5-22: Side-by-side units 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. FläktGroup DC GB /R2 Subject to modifications 37

38 Assembly CAIR pool Preparing roof installation Remove all lifting lugs (1) Install sealing washers at all screws and tighten them (2). Fig. 5-23: Preparing roof installation Installing inclined/bossed roof (CAIRpool SX) Secure the separately supplied joint strip. Fig. 5-24: Installing joint strip 38 FläktGroup DC GB /R2 Subject to modifications

39 CAIR pool Assembly 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. 5-25: 1 Single units 064.xxx to 160.xxx and side-by-side units 064.xxx to 096.xxx 2 Single unit 188.xxx to 252.xxx with inclined roof design 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. 5-26: Single unit 188.xxx to 252.xxx with inclined roof design FläktGroup DC GB /R2 Subject to modifications 39

40 Assembly CAIR pool 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 38. 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. 5-27: Single units 280.xxx to 312.xxx and side-by-side units 128.xxx to 160.xxx 40 FläktGroup DC GB /R2 Subject to modifications

41 CAIR pool 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. 5-28: 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. 5-29: Side-by-side units with offset, sizes 128.xxx and 160.xxx FläktGroup DC GB /R2 Subject to modifications 41

42 Assembly CAIR pool 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. 5-30: Roof installation with double-deck units 42 FläktGroup DC GB /R2 Subject to modifications

43 CAIR pool Assembly Installation of inclined roof design for double-deck units 188.xxx to 312.xxx General: For installation of inclined roof of double-deck unit size 188.xxx to 312.xxx follow instructions specified for Single roof version, unit size 188.xxx to 252.xxx with singlepiece sheet and for unit size from 280.xxx and 312.xxx with centrally divided sheet. For 188.xxx to 252.xxx Installation transition/division (WFD-UT) and transition division (WFD-US) WFD-UT or WFD-US see figure Apply adhesive on installation contact surface, then bolt the parts together. WFD-UT or WFD-US Fig. 5-31: 188.xxx to 252.xxx After that use the adhesive to seal the cover sheet and connect by bolting together. Cover sheer Fig For 280.xxx to 312.xxx Apply adhesive on installation contact surface, then bolt the parts together. WFD-UT or WFD-US Fig FläktGroup DC GB /R2 Subject to modifications 43

44 Assembly CAIR pool Apply adhesive on installation contact surface of the UE-angle bar. Fig Slide the UE-angle bar on the cover sheets and press against the casing. Fig Apply the adhesive on the slide bar, clip the supplied the WFD-SL intermediate elements and bolt together. Applies for protrusion/end wall >200 Fig Special case 1 (protrusion of end wall = 40 or 80 mm) UE-slide angle bar 0040 or 0080 The slide bar and intermediate element are not necessary. Sealing procedure as previously specified. 44 FläktGroup DC GB /R2 Subject to modifications

45 CAIR pool Assembly Special case 2 (protrusion of end wall = 120 or 160 mm) UE-slide angle bar For this design a slide bar between the slide bar angle and terminating angle is not required. Only clip on the intermediate element. Sealing procedure as previously specified. Terminating angle Fig Terminating in-between frame All double-deck roof sheets contain a cover for the in-between frame. In such a way no intermediate frame cover has to be mounted on the protrusion side, only the outer angles have to be screwed to the intermediate frame cover (on both sides). Intermediate frame cover Outer angle Double-deck roof sheet/cover FläktGroup DC GB /R2 Subject to modifications 45

46 Assembly CAIR pool 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 FläktGroup DC GB /R2 Subject to modifications

47 CAIR pool 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. 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. Damage to the unit! ATTENTION Damage to the unit! When entering CAIRpool 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). Ensure that unit surfaces are not damaged or scratched! 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 30). If using flexible canvas connections between unit and ductwork, installation length of the connectors must be smaller than their length in expanded condition. FläktGroup DC GB /R2 Subject to modifications 47

48 Installation CAIR pool 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 sulphide 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) Notice! Corrosion protection of installed unit components on the air side is ensured if the chemical limit values for pool water as specified in VDI 2089 Sheet 2 "Water treatment in swimming baths" and VDI are not exceeded. Recommendation! Chlorine mg/l with a ph value of ; Redox 760 mv 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. 48 FläktGroup DC GB /R2 Subject to modifications

49 CAIR pool 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 55). 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. Installation of 3-way valve in heater assemblies Heat distribution There are two methods to use the 3-way valve: A) Design sample: three-way mixing control: Application in plants with air heaters with mixed air operation or with air heaters with very large dimensions. Advantage: good water circulation in plant circuit, low inlet temperature during off peak period. Heater Distributor systems, etc. M ~ VL RL AB A B Fig. 6-1: Three-way mixing control B) Possible alternative: three-way distribution control: Application in plants with air heaters in recirculating air mode. Heat distribution A B ~ M AB Heater Distributor systems, etc. VL RL Fig. 6-2: Three-way distribution control FläktGroup DC GB /R2 Subject to modifications 49

50 Installation CAIR pool 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 pool and fresh-water condenser (optional accessory) ATTENTION Damage to the unit! Avoid excessive levels of mass flow in the pool water condenser on the water side. Consider the technical specifications during the design stage. High water flow rate may permanently damage the pool water condenser and thus invalidate the warranty! Ensure that the pool water condenser pipework is resistant to heat (minimum +80 C) and deformation. Use the adequate materials. The drain connection of the pool water condenser is located directly at the condenser fitting. Air vent at the pool water outlet to be installed by others. Run the pipework as to provide free access to sections and components installed on panels. Examples for hydraulic connection of pool water condenser Example Fig. 6-3: Pool water condenser as a separate circuit 1: Pump 2: Filters 3: Pool-water condenser 4: Temperature sensor 50 FläktGroup DC GB /R2 Subject to modifications

51 CAIR pool Installation Example Fig. 6-4: Separate pool water condenser via splash water tank 1: Pump 2: Filters 3: Pool-water condenser 4: Temperature sensor Example Fig. 6-5: Circuit with pool water condenser and parallel filter circuit with only one pool water inlet and outlet. 1: Pump 2: Filters 3: Pool-water condenser 4: Temperature sensor 5: Filter circuit pump 6: Non-return damper Follow the procedure specified in example 3: Electrical interlock of the filter pump with the pool water condenser pump to be completed by others on site. In addition non-return dampers or non-return valves must be installed. FläktGroup DC GB /R2 Subject to modifications 51

52 Installation CAIR pool Example Fig. 6-6: Circuit with pool water condenser integrated in filter circuit bypass 1: Solenoid valve 2: pre-filter 3: Pool-water condenser 4: Temperature sensor 5: Filter circuit pump 6: Throttle valve 7: Flow meter Follow the procedure specified in example 4: Both the filter unit and the CAIRpool unit must regulate the pump. A parallel solenoid valve must be installed and regulated (instead of control output for PWC pump). If required, additional contacts to be provided by others on site. Install a throttle valve for regulating the water volume. Notice! Consider the maximum possible water flow rate in the circuit for pool water condenser. Refer to order-related unit documentation for technical data and specifications Installing coils with a liquid-coupled energy recovery system Piping set for ECOFLOW energy recovery system Refer to "Installing air-handling components for cooling/heating applications" on page 48. Standard: Circulating pump, safety valve, pressure gauge, expansion tank, two stop cocks, one charge and drain tap, connecting pipes, connecting sockets. Supplied as a separate assembly, connection pipes between the piping set and heat exchanger to be completed by others on-site. Consider that in the design and planning stage a maximum pipework length of max. 20 m to be completed by others on site. Weather-proof: For double mixing assembly ECOFLOW The same configuration as with standard, but fully integrated and piped in the assembly. ATTENTION Damage to the unit! When performing on-site pipework connections, consider the counter flow principle of air to heating medium (water/water-glycol mix). 52 FläktGroup DC GB /R2 Subject to modifications

53 CAIR pool Installation Heating element Cooling element Supply air Exhaust air Frost protection Provide a drain pan Fig. 6-7: Pipework example: counter flow of air to heating medium 1: Charge and drain valve 2: Sluice valve 3: Circulating pump 4: Pressure relief vessel 5: Membrane expansion vessel 6: Pressure gauge 7: Filling vent 8: Air-vent valve FläktGroup DC GB /R2 Subject to modifications 53

54 Installation CAIR pool Installing humidifier Also observe the German Drinking Water Act (Trinkwasserverordnung TWVo). Quality 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-air quality IDA 2, IDA 3 or IDA 4 according to EN HVAC systems for Room-air quality IDA 1 according to EN for IT rooms indirect evaporative cooling (to be determined depending on the system) Room-air quality IDA 1 according to EN for sterile and clean rooms Appearance clear, colourless without sediment ph value 7 to 8.5 Total salt concentration TSC g/m³ < 800 < 250 < 100 Electrical conductivity ms/m < 100 < 30 < 12 (at reference temperature 20 C) μs/cm < 1000 < 300 < 120 Calcium 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)/ < 1000 < 100 < 10 ml Legionella bacteria CFU/100 ml < 100 Notice! When installing a water-softening unit FläktGroup 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. 54 FläktGroup DC GB /R2 Subject to modifications

55 CAIR pool Installation Water drain trapping Types of condensate drains Condensate drain by unit profile Fig. 6-8 Condensate drain by unit profile Fig. 6-9: Tray drainage adapter 22/40 mm Condensate drain through base frame Fig 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, WC) in unit (1 mm WC = 10 Pa). Use the following equation for the dimensioning: positive pressure/negative pressure( Pa H( mmwc) = The vertical difference between the water drain and hydraulic seal must also correspond to the dimension H (mm WC). Fig. 6-11: Trapping for section under positive pressure FläktGroup DC GB /R2 Subject to modifications 55

56 0 Installation CAIR pool 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. 6-12: Trapping for section under negative pressure Fig. 6-13: 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. 6-13) 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 11) 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. 56 FläktGroup DC GB /R2 Subject to modifications

57 CAIR pool 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. FläktGroup DC GB /R2 Subject to modifications 57

58 Installation CAIR pool 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 all 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. 58 FläktGroup DC GB /R2 Subject to modifications

59 CAIR pool 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. FläktGroup DC GB /R2 Subject to modifications 59

60 Electrical Connection CAIR pool 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). Use the pre-installed cable conduits for running cables. First install and run all cables, then connect the cable conduits at the unit exit point or entry point of the switch cabinet. Thus entering of process air into the switch cabinet is avoided. Remove the sealing plug when running a new cable or replacing an existing one. To seal the cable conduit again, use a soft material, e.g. Armaflex. 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 FläktGroup 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). 60 FläktGroup DC GB /R2 Subject to modifications

61 CAIR pool Electrical Connection Resistance R Operating point of tripping unit Temperature T +135 C Motor full protection electronics 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 Extended motor protection Disconnection in the event of an error With frequent start-ups, intermittent operation, high switching frequency and to ensure optimum protection against 2-phase run, FläktGroup 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. 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. 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: The rotation direction can be reversed by exchanging two connecting wires: Exchange the connecting cables, e.g. U1 and V1 Single-stage EC motors with 0-10 V or MODbus regulation FläktGroup DC GB /R2 Subject to modifications 61

62 Electrical Connection CAIR pool Voltage fluctuations Ensure that the supply voltage at mains frequency remains 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. Single-stage motor Service switch Installing and connecting actuator motor To carry out the connection, proceed as follows: Connect the unit according to the wiring diagrams. Single-stage 3 phase motors with frequency inverters for plug fans. Single-stage 3 phase EC motors with 0-10 V or MODbus regulation If the switch box is assembled separately from the unit, 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 or terminal box/ switch box. 2 1 The FläktGroup actuators for regulating exhaust and outside air rate are mounted on the mixing-air section but are not wired. Carry out the wiring for power supply only after all unit components (multi-section units) have been installed. Install unit components. If the FläktGroup actuators were mounted at the factory (1) run the prepared and coiled connecting lines (2) for actuators through available cable openings, ensure firm fixation and connection. If other actuators are used, refer to relevant documentation. ATTENTION Damage to the unit! The actuators or sensors are wired through MODbus data line. Therefore, it is essential to observe the wiring diagram or cabling and the shielding! Incorrect connections lead to a malfunction! Fig Electric air heater Connect electric heater bank as specified in the enclosed documentation and wiring diagram. Connect safety temperature limiter and monitoring device. A high temperature cut out is enclosed with the unit. Check high temperature cut out for proper operation. Activate the heater bank only if the minimum air flow required is provided for its operation. Ensure that the control system activates the fan for a minimum of 3 minutes following the deactivation of the heater bank Additional electrical components Connect additional electrical components in accordance with the relevant provided documentation and wiring diagrams. NOTICE! Sensors and actuators are designed for units with regulation system as MODbus components, bus standards MODbus RTU. When replacing the components, the faulty elements must be strictly exchanged with the same structural elements (manufacturer and type). When using alternative components the bus system does not work. 62 FläktGroup DC GB /R2 Subject to modifications

63 CAIR pool Electrical Connection Overview of cable connections of the CAIRpool mixed-air units NOTICE! Only the unit wiring diagram provides exact information about the unit delivery condition. The switch box is supplied loose! (Special configuration includes intermediate terminal box) Use the enclosed documentation for detailed information about the installation of the switch box. Unit size with swing switch box on the unit Unit size with upright switch box near the unit Fig. 7-2: Swing switch box Fig. 7-2: Swing unit External connections: Valve heater NV24 A-MOD Modbus cable LI2YCY 2x2x0.5 mm² Actuator NE PWW pump CIM MODbus module Modbus cable LI2YCY 2x2x0.5 mm² supply 230 V~/50 Hz Pool water condenser CIM MODbus module Modbus cable LI2YCY & pump 2x2x0.5 mm² supply 230 V~/50 Hz 1 x temperature sensor Outdoor temperature/humidity sensor CIM MODbus module Modbus cable LI2YCY 2x2x0.5 mm² Actuator NE PWW pump CIM MODbus module Modbus cable LI2YCY 2x2x0.5 mm² Fresh-water condenser Power supply BMS connection by others 2 x temperature sensor 1 x solenoid valve 1 x water meter External safety shut-down 2 x 0.75 mm² 3 x 400 V~ V+N+PE / 50 Hz, see wiring diagram Fig. 7-2: Upright switch box FläktGroup DC GB /R2 Subject to modifications 63

64 Electrical Connection CAIR pool Optional connections: Status messages: Operation message Alarm signal Maintenance message Pool and idle mode Operating signal active Standards: Setpoint extract temp. Setpoint extract-air humidity External blocking Construction site mode Fire alarm contact Operating signal supply air Operating signal extract air Pool mode Idle mode Short pool mode volt free contact volt free contact volt free contact volt free contact NO switch contact input 2core shielded control cable 2core shielded control cable NC switch contact input NO switch contact input NO switch contact input NO switch contact input NO switch contact input NO switch contact input NO switch contact input NO switch contact input 64 FläktGroup DC GB /R2 Subject to modifications

65 CAIR pool 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. 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. FläktGroup DC GB /R2 Subject to modifications 65

66 Commissioning and Maintenance CAIR pool ATTENTION Damage to the unit! When entering CAIRpool 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 65. 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! 66 FläktGroup DC GB /R2 Subject to modifications

67 CAIR pool 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, FläktGroup 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. 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 65ff when performing all the described activities! Unit part Frequency (months) Action Units for indoor installation (see page 70) 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 (FläktGroup 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. FläktGroup DC GB /R2 Subject to modifications 67

68 Commissioning and Maintenance CAIR pool Unit part Units for outdoor installation (weatherproof units for roof installation) refer to page 71) Direct-driven fan assembly (See page 72) Routines for all filters (see page 73et seq.) Bag/platetype/fine-particle filter (refer to page 74) Other filters Heating unit (low pressure hot water) (p. page 75) Frequency (months) Every 12 months Every 3 months Every 3 months Every 6 months at least every 6 to 9 months continuous measurem ent replace 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 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, and replace the filter if necessary. Hygiene inspection (FläktGroup 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. Refer to the relevant maintenance instructions specified in the supplied documentation. 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. 68 FläktGroup DC GB /R2 Subject to modifications

69 CAIR pool Commissioning and Maintenance Unit part Frequency (months) Action Cooler without or with droplet separator (see page 76) 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 77) 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 78) 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 79) Every 12 months Complete the same steps specified in "Cooler with/without droplet separator" (every 12 months). Plate heat exchanger (see page 79) 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. Damper blades and shut-off dampers (see to page 80) 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. Sound attenuator (see to page 81) Every 6 months Check the sound attenuator section and sound insulating splitters for dirt, clean as necessary. FläktGroup DC GB /R2 Subject to modifications 69

70 Commissioning and Maintenance CAIR pool 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 65ff when performing all the described activities! Commissioning of units for indoor installation DANGER! Please consider the safety instructions on page 5 and page 65ff 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 Maintenance of units for indoor installation DANGER! Please consider the safety instructions on page 5 and page 65ff 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. 70 FläktGroup DC GB /R2 Subject to modifications

71 CAIR pool Commissioning and Maintenance Commissioning of units for outdoor installation (weatherproof roof units) DANGER! Please consider the safety instructions on page 5 and page 65ff when performing all the described activities! Complete the following commissioning steps: Complete all steps specified in "Commissioning of units for indoor installation" on page 70 first. Check condition of weatherproof gasketing (refer to "Foundation requirements for outdoor installation (weatherproof, roof frame)" on page 29) Maintenance of units for outdoor installation (weatherproof roof units) DANGER! Please consider the safety instructions on page 5 and page 65ff 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 70 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. 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 65ff when performing all the described activities! Commissioning of direct-driven fan assembly DANGER! Please consider the safety instructions on page 5 and page 66ff 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 60). 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! In this case, FläktGroup 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. FläktGroup DC GB /R2 Subject to modifications 71

72 Commissioning and Maintenance CAIR pool Maintenance of direct-driven fan assembly DANGER! Please consider the safety instructions on page 5 and page 65ff 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 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 65ff when performing all the described activities! 72 FläktGroup DC GB /R2 Subject to modifications

73 CAIR pool Commissioning and Maintenance Commissioning of filter assembly DANGER! Please consider the safety instructions on page 5 and page 65ff 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) Routine maintenance for all filters DANGER! Please consider the safety instructions on page 5 and page 65ff 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! FläktGroup 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! FläktGroup 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. FläktGroup DC GB /R2 Subject to modifications 73

74 Commissioning and Maintenance CAIR pool Maintenance of bag filters/panel filters/fine-particle filters DANGER! Replacing filter medium Please consider the safety instructions on page 5 and page 65ff 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. 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 other filters DANGER! Please consider the safety instructions on page 5 and page 65ff 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 65ff when performing all the described activities! Commissioning of heater assembly (pumped warm water) DANGER! Requirement: Please consider the safety instructions on page 5 and page 65ff 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. 74 FläktGroup DC GB /R2 Subject to modifications

75 CAIR pool Commissioning and Maintenance Commissioning: 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 65ff 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 Commissioning and maintenance of electric heater DANGER! Please consider the safety instructions on page 5 and page 65ff when performing all the described activities! Refer to the relevant commissioning instructions specified in the supplied documentation. 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 65ff 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 65ff when performing all the described activities! FläktGroup DC GB /R2 Subject to modifications 75

76 Commissioning and Maintenance CAIR pool 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 55; 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 65ff 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. 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 65ff when performing all the described activities! 76 FläktGroup DC GB /R2 Subject to modifications

77 CAIR pool Commissioning and Maintenance 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 65ff 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). 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 evaporator Please consider the safety instructions on page 5 and page 65ff 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 75. 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: FläktGroup DC GB /R2 Subject to modifications 77

78 Commissioning and Maintenance CAIR pool 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 ECOSTAT 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 65ff when performing all the described activities! Commissioning of heat pipe DANGER! Please consider the safety instructions on page 5 and page 65ff when performing all the described activities! Observe the following checkpoints for commissioning: Upright heat pipe The coil with warm airflow (return air) must be positioned on the bottom and the cold airflow (fresh air) - on the top Maintenance ECOSTAT heat pipe DANGER! Please consider the safety instructions on page 5 and page 65ff 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 ECOFLOW 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 65ff when performing all the described activities! 78 FläktGroup DC GB /R2 Subject to modifications

79 CAIR pool Commissioning and Maintenance Commissioning/maintenance of liquid-coupled energy recovery coil ECOFLOW DANGER! Please consider the safety instructions on page 5 and page 65ff when performing all the described activities! Refer to "Commissioning of heater assembly (pumped warm water)" on page ECOPLAT 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 65ff when performing all the described activities! Commissioning of ECOPLAT plate-type heat exchanger DANGER! Please consider the safety instructions on page 5 and page 65ff when performing all the described activities! 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, FläktGroup 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 ECOPLAT plate heat exchanger DANGER! Oil and grease (kitchen exhaust) Please consider the safety instructions on page 5 and page 65ff 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. FläktGroup DC GB /R2 Subject to modifications 79

80 Commissioning and Maintenance CAIR pool Airflow routing in ECOPLAT 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. 8-1: Airflow routing in plate-type heat exchangers 8.12 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 65ff 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 65ff 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 Maintenance of dampers blades and shut-off dampers DANGER! Please consider the safety instructions on page 5 and page 65ff when performing all the described activities! 80 FläktGroup DC GB /R2 Subject to modifications

81 CAIR pool Commissioning and Maintenance 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 65ff when performing all the described activities! Maintenance of sound attenuator DANGER! Please consider the safety instructions on page 5 and page 65ff 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 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 11) 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. FläktGroup DC GB /R2 Subject to modifications 81

82 Commissioning and Maintenance CAIR pool 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. 82 FläktGroup DC GB /R2 Subject to modifications

83 CAIR pool Commissioning and Maintenance Regular tests DANGER! Please consider the safety instructions on page 5 and page 65ff when performing all the described activities! The system and its system components are subject to partially regular 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 65ff 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! FläktGroup DC GB /R2 Subject to modifications 83

84 Disassembly and Disposal CAIR pool 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. 84 FläktGroup DC GB /R2 Subject to modifications

85 CAIR pool Troubleshooting 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. FläktGroup DC GB /R2 Subject to modifications 85

86 Annex CAIR pool 11 Annex 11.1 Maintenance Log Book CAIRpool 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 Month 1 following commissioning Heat Exchanger Fan assembly Refrigeration plant Control Panels Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: Month 2 following commissioning Heat Exchanger Fan assembly Refrigeration plant Control Panels Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: Month 3 following commissioning Heat Exchanger Fan assembly Refrigeration plant Control Panels 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: 86 FläktGroup DC GB /R2 Subject to modifications

87 CAIR pool Annex Maintenance frequency Unit part Checked O.K. not O.K. Comment Date Signature: Month 6 following commissioning Heat Exchanger Fan assembly Refrigeration plant Control Panels Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: Month 9 following commissioning Heat Exchanger Fan assembly Refrigeration plant Control Panels Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: Month 12 following commissioning Heat Exchanger Fan assembly Refrigeration plant Control Panels Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: Month 15 following commissioning Heat Exchanger Fan assembly Refrigeration plant Control Panels 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: FläktGroup DC GB /R2 Subject to modifications 87

88 Annex CAIR pool Maintenance frequency Unit part Checked O.K. not O.K. Comment Date Signature: Month 18 following commissioning Heat Exchanger Fan assembly Refrigeration plant Control Panels Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: Month 21 following commissioning Heat Exchanger Fan assembly Refrigeration plant Control Panels Filters Condensate pan Damper blades Other components Defects/damage was directly communicated to company: Defect/damage was repaired by: Month 24 following commissioning Heat Exchanger Fan assembly Refrigeration plant Control Panels 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. 88 FläktGroup DC GB /R2 Subject to modifications

89 CAIR pool Notes FläktGroup DC GB /R2 Subject to modifications 89

90 Notes CAIR pool 90 FläktGroup DC GB /R2 Subject to modifications

91 CAIR pool Notes FläktGroup DC GB /R2 Subject to modifications 91

92 FG_DC GB_CAIRpool_OM_2018_05_R2 CAIRpool FläktGroup is the European market leader for smart and energy efficient Indoor Air and Critical Air solutions to support every application area. We offer our customers innovative technologies, high quality and outstanding performance supported by more than a century of accumulated industry experience. The widest product range in the market, and strong market presence in 65 countries worldwide, guarantee that we are always by your side, ready to deliver Excellence in Solutions. PRODUCT FUNCTIONS BY FLÄKTGROUP Air Treatment Air Movement Air Diffusion Air Distribution Air Filtration Air Management Air Conditioning & Heating Controls Service» Learn more on or contact one of our office