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Assembly

CAIR

plus

26

PR-2009-0096-GB • Subject to modifications • R8-10/2015

5.1.4 Foundation requirements for outdoor installation (weatherproof, roof frame)

•

Refer to valid instructions on "Foundation requirements for indoor installation" on
page 25.

•

Select an installation site with outdoor air intake not facing the main wind direction.

•

If the unit is mounted on a roof, the latter must support the total weight of the unit,
verify that the supporting structure is adequate for the unit. Consult a structural
engineer, if necessary.

•

The roof edge below the unit, as well as ducts and other roof openings must be
sealed by others on site to prevent water and air leakage.

•

Ensure that the field-provided roof frame is sealed to prevent condensation. For
notes refer to "Preparing roof installation" on page 33.

•

In areas with heavy snowfall, ensure that the unit is installed at a location where
snow can not affect the unit operation. Provide for an adequate foundation with an
appropriate height.

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 13053 and VDI 3803.

Fig. 5-6:

Foundation design with concrete
base

Fig. 5-7:

Foundation design with field-pro-
vided steel beam

Fig. 5-8:

Foundation design with field-provided steel support

Notice!

•

Pay particular attention to ensure the exact size of the roof openings and level
foundation.

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Summary of Contents for CAIRplus

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

Page 2: ...nd changes 13 2 10 Spare parts 13 2 11 Disposal 13 2 12 Selection and qualification of personnel 14 3 Technical Description 15 3 1 Performance scope 15 3 2 Technical Specifications 15 3 3 Operating limits and range of application 15 4 Shipping and Storage 19 4 1 Delivery 19 4 2 Transport 19 4 3 Storage 22 5 Assembly 23 5 1 Unit placement 23 5 2 Assembling the unit 27 6 Installation 41 6 1 Requirem...

Page 3: ...r blades and shut off dampers 79 8 15 Sound attenuators 80 8 16 Commissioning maintenance of ECOTWINcool double plate heat exchanger with adiabatic cooling 80 8 17 commissioning maintenance of integrated refrigerating systems 80 9 Disassembly and disposal 83 9 1 Dismantling 83 9 2 Disposal 83 10 Troubleshooting 84 11 Appendix 85 11 1 Maintenance Log Book CAIRplus 85 Original operation manual Copyr...

Page 4: ...n A Automatic T Complete K Without Standard R Standard in conformity with RLT 01 Directive H Hygiene variant E Explosion protected I Indoor installation A Outdoor installation D Ceiling mounting W Wall mounting U Underfloor installation H Horizontal V Vertical L L Form S Single N Side by Side Ü Double deck H Straight through E Single casing K Combined casing Z Supply air A Extract air Unit width i...

Page 5: ...ion companies operators building techni cians technical personnel or instructed persons as well as electricians This manual as well as the safety information of the manufacturer of the individual com ponents 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 saf...

Page 6: ... 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 doc uments 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...

Page 7: ...in unit Air heater cooler with heat recov ery function Air steam ECOSTAT General air filter indicating air flow direction Air heater cooler with heat recov ery function Air air ECOPLAT HEPA filter indicating air flow direction Air heater cooler with heat recov ery function Air air ECOROT Opposed blade dampers General air humidifier Air heater air water General controller Air cooler air water Dropl...

Page 8: ...e 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 High concentration of refrigerants in the air can result in death or serious in jury High concentration o...

Page 9: ...cesses Depending on the filtered out materials contaminated filters are therefore classi fied as hazardous waste and must be properly disposed of according to the pre vailing 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 Electrical hazard Explosive at...

Page 10: ...e unit 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 The unit must only be operated under the conditions ...

Page 11: ... 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 ...

Page 12: ...rotection against leaking refrigerant Under all circumstances call a doctor or and an ambulance Remove clothes contaminated by the refrigerant Inhalation 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 coll...

Page 13: ...with strong electromagnetic fields in rooms with aggressive atmosphere that may attack plastics or cause corrosion especially in atmosphere where zinc is particularly susceptible to corrosion CAIR units must not be accessible to the general public 2 8 Safety devices Depending on the unit equipment the following components are secured Padlock in the door stop device TAS on each door Locks of switch...

Page 14: ...ng 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 ...

Page 15: ...d have various capacities Depending on the application for each case CAIRplus units are designed for vertical or horizontal air flow and are arranged as double deck side by side and straight through models Units can be installed indoors and outdoors Thanks to the modular design of the CAIRplus units ship as complete assemblies or sub assemblies that can pass through the available on site openings ...

Page 16: ... condition for uninstalled units Air temperature 10 C to 50 C Air humidity Store units in a dry non condensing atmosphere 3 3 3 Supply voltage The required supply voltage is specified in the order related documentation e g AC 230 V 50 Hz 1 phase or AC 400 V 50 Hz 3 phases 3 3 4 Condensation limits Please pay due attention to condensation limits The following diagrams illustrate condensation limits...

Page 17: ...densate CAIRplus SX K without thermal separation Condensation diagram for kb value 0 5 CAIRplus SX M partial thermal separation Condensation diagram for kb value 0 62 Air temperature on unit external side in C Air temperature on unit internal side in C Relative humidity on unit external side in Air temperature on unit external side in C Air temperature on unit internal side in C Relative humidity ...

Page 18: ...cal Description CAIRplus 18 PR 2009 0096 GB Subject to modifications R8 10 2015 Air temperature on unit external side in C Air temperature on unit internal side in C Relative humidity on unit external side in ...

Page 19: ...fter delivery It will not be possible to process claims if the above mentioned points are not fulfilled In both cases consult the DencoHappel Sales Company before installing the units 4 2 Transport Notice Consider instructions relating to the procedures in case of shipping damage pro vided on the unit packaging or in dispatch documents Danger due to overhead loads risk of grave injuries or death N...

Page 20: ...nts Do not set the unit down abruptly or bump it 4 2 1 Lifting the unit lifting lugs on roof provided with shipment units weighing up to 1500 kg Lifting lugs may only be used for lifting Do not use lifting lugs for lateral loads pulling of unit on sides The suspension angle must be between 70 and 110 see fig 4 1 Lifting lugs may only be used once Do not use lifting lugs for permanent suspension of...

Page 21: ... gear Units with a slanting roof are delivered with a device that en ables to fasten it in place during truck transport This device must be removed before lifting the unit by crane 4 2 3 Shipping with a fork lift truck Always use the unit base frame or the supplied pallet as the supporting surface during transportation Do not lift units without the base frame if the unit profiles are not sufficien...

Page 22: ...ermitted air condition for non installed units Air temperature 10 C to 50 C Air humidity Store units in a dry non condensing atmosphere 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 ...

Page 23: ...be installed in accordance with the technical specifications provided in the supplied documentation Stacking of units and other foreign field provided components is not permitted Exceptions apply for units delivered by the DencoHappel sites where the suffi cient load bearing capacity is considered beforehand ATTENTION Risk of damage to the unit When entering CAIR units ensure that no loads are app...

Page 24: ...onment Fig 5 1 Installation site When installing a spray humidifier use a plinth or unit feet corresponding to the tray height to ensure horizontal align ment with other unit sections Fig 5 2 Height compensation with spray humidifier 5 1 2 Minimum clearances To remove fans heat exchangers droplet separators etc and enable adequate maintenance allow a minimum clear ance of one unit width on the ope...

Page 25: ...ccessories such as condensate traps The supporting points of the foundation must be located at every shipping split Besides ensure that the maximum dis tance between these points does not exceed 1600 mm in the unit length see fig 5 4 Units with side by side arrangement must be supported in the center see fig 5 5 Fig 5 4 Foundation requirements with side by side units operator side Fig 5 5 Foundati...

Page 26: ...o prevent water and air leakage Ensure that the field provided roof frame is sealed to prevent condensation For notes refer to Preparing roof installation on page 33 In areas with heavy snowfall ensure that the unit is installed at a location where snow can not affect the unit operation Provide for an adequate foundation with an appropriate height Notice Units for outdoor installation are not roof...

Page 27: ...measures might be necessary to prevent this from happening 5 1 7 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...

Page 28: ...o assembly Remove safety locks on the fan Verify that that all lifting lugs on the roof are removed Remove the lug screw and bushing at the section joint then secure the supplied M8 x 30 screw Fig 5 9 Lifting lug at joints Remove the screws on the end walls and secure the sup plied M8 x 70 screw Fig 5 10 Lifting lugs for roof and end wall Roof lifting lug Plastic washer Support bushing Cylinder sc...

Page 29: ...ion of individual modules To join individual sections for final assembly at joints proceed as follows Attach provided gaskets at the joint separate assembly in structions are enclosed with the supplied sealing strip Fig 5 12 Installing individual modules 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 ...

Page 30: ...re the belts on the unit profiles at the bottom or roof section Screw the outer joint connections together Do not use partition joint connectors to pull the units together Use screws M8x30 Fig 5 15 Screw the base frame to the connectors Screw the outer joint connections together Fig 5 16 External view ATTENTION Risk of damage to the unit Do not attach tensioning belts hoisting devices to heat exch...

Page 31: ...eight of 1280 mm or more an additional joint connection is provided in the middle of the profile on the internal side use the screws to secure this joint connection as well Fig 5 19 Internal partition join connector Seal pipe and cable ducts to prevent air leakage and condensation For example use PU foam to complete the sealing not included in DencoHappel packaged content Fig 5 20 Pipe duct Note o...

Page 32: ...g 5 21 Connecting unit sections For offset double deck units use the screws as outlined Fig 5 22 Double deck units For offset side by side units use the screws as outlined Fig 5 23 Side by side units Additional measure for units in hygiene design Clean and seal internal joint seams at the bottom The sealant is included in the packaged content for hygiene units Fig 5 24 Joint seams ...

Page 33: ...nd tighten them 2 Fig 5 25 Preparing roof installation ATTENTION Risk of damage to the unit 9 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...

Page 34: ...rip Fig 5 26 Installing joint strip Single units 064 xxx to 160 xxx and side by side units 064 xxx to 096 xxx 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 90 Fig 5 27 Single units 064 xxx to 160 xxx and side by side units 064 xxx to 096 xxx 1 3 2 ...

Page 35: ...lied 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 Use the supplied sealant to caulk the joint strips 2 Secure in place with the fixing screw 3 Fig 5 28 Single unit 188 xxx to 252 xxx with inclined roof design 1 1 3 2 ...

Page 36: ...28 xxx to 160 xxx Secure the separately supplied joint strip as described on page 34 Use the supplied sealant to caulk the roof panel seams 1 Slide the separately provided joint strips 2 from both sides Secure in place with the fixing screw 3 Fig 5 29 Single units 280 xxx to 312 xxx and side by side units 128 xxx to 160 xxx 3 1 2 ...

Page 37: ...3 as presented in the figure Attach the separately provided weatherproof covers 4 and use supplied screws to secure them in place Fig 5 30 Centrally split roof panels Consider the following for side by side units with misalignment sizes 128 xxx and 160 xxx Depending on the unit shipping splits install a separately en closed roof panel for side by side casing 1 if necessary as presented in the draw...

Page 38: ... installation for double deck units is identical to the in stallation of single units refer to the specification from page 33 Apply sealant evenly on the surface Use the screws to attach the connecting panel to the end wall 1 Finally produce a concave groove in the sealant Fig 5 32 Roof installation with double deck units 1 ...

Page 39: ...ation side by side units equipped with ECOROT is identical to the installation of single units refer to the specification from page 33 Apply sealant evenly on the surface Use the screws to attach the connecting panel to the end wall 1 Finally produce a concave groove in the sealant Fig 5 33 Roof installation of side by side unit with ECOROT 1 ...

Page 40: ...2009 0096 GB Subject to modifications R8 10 2015 5 2 8 Intermediate or base frame cover panels Mount the cover panels as outlined Fig 5 34 Mount the cover panels as outlined Fig 5 35 Mount the cover panels as outlined Fig 5 36 ...

Page 41: ...ed 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 con nection between ductwork and unit by using elastic connectors or sound attenuators to prevent structural noise transmission also refer to Structure borne noise attenuation on page 27 If using flexible canvas co...

Page 42: ... site With air handling components for cooling heating applications consider the following Following installation insulate coil connections and pipework to prevent condensing water 9 Coil drip tray is made of stainless steel and collects forming condensate The coil drip tray is fitted with a drain connection to empty condensate Refer to the section on trap see Water drain trapping on page 45 Descr...

Page 43: ...ry system Refer to Installing air handling components for cooling heating applications on page 42 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 ...

Page 44: ...ing to EN 13779 for sterile and cleanrooms indirect evaporative cooling to be determined depending on the system Appearance klar farblos und ohne Bodensatz pH value 7 to 8 5 Total salt concentration TSC g m 800 250 100 Electrical conductivity at reference temperature 20 C mS m 100 30 12 μS cm 1000 300 120 Calcium Ca2 mol m3 0 5 g m3 20 Carbonate hardness KH dH 4 Total hardness GH dH 7 Chloride CL ...

Page 45: ... must be greater than the maximum positive or negative pressure mm water column in unit 1 mm WC 10 Pa Use the following equation for the dimensioning The vertical difference between the water drain and hydraulic seal must also correspond to the dimension H mm WC Notice Direct connection to a sewage network is not allowed Fill the condensate trap with water prior to commissioning and after extensiv...

Page 46: ...refrigerating sys tem on page 12 Fig 6 5 Trapping for section under negative pressure 1 5 H 0 Caution freeze up risk In the event of freeze up risk the drain pipe must be insulated and kept warm using heating wire Notice Negative pressure and positive pressure traps must be connected to separate common lines refer to Fig 6 6 Warning of high concentration of refrigerants in the air High concentrati...

Page 47: ...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 ...

Page 48: ...RATION The refrigeration unit can only be operated when the room ventilation unit is in opera tion Error messages from the refrigerating system are displayed at the switching cab inet 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 th...

Page 49: ...ve 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 con nected components Electrical connection must be assured and documented between all shipment units potential equalisation usually to be provided via screw connections Connect the...

Page 50: ...re 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 ...

Page 51: ... recommends to protect motors using thermal overload relays motor circuit breakers in addition to the PTC thermistor protection Disconnection in the event of an error In case of fault shutdown investigate the above mentioned causes Motor protection with thermal contact Thermal contacts are temperature dependent operating elements for automatic moni toring of the motor winding temperature Thermal c...

Page 52: ...supply voltage at mains frequency falls within the range from 95 to 105 of the rated voltage If this condition is met motors can deliver the rated capacity otherwise non compliance can result in equipment damage To carry out the connection proceed as follows Connect the unit according to the wiring diagrams Single stage motor 1500 min 1 with voltage change over Motor version to 2 2 kW 3 x 230 V wi...

Page 53: ...observe the pin assignment shown in the following wiring diagram 7 2 5 Service switch Install a lockable service switch near the access door of the fan chamber When there is a factory mounted service switch the wiring is run up to the motor ATTENTION Risk of damage to the unit Do not activate the parameter overmodulation as this can damage the impeller Permanent magnet motors PM motor without inte...

Page 54: ...the specifications in the data sheet on actuators If other actuators are used refer to the relevant documentation Ensure proper operation of this component Be sure not to start up the fans with closed dampers 7 2 7 Additional electrical components Connect additional electrical components in accordance with the relevant provided documentation and wiring diagrams Notice Adjust the final position swi...

Page 55: ...tening 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 bei...

Page 56: ...heet 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 ...

Page 57: ...r 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 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 commissioni...

Page 58: ...ce if necessary Units for out door installa tion weather proof units for roof installa tion refer to page 62 Complete the same steps specified for units for indoor installation Every 12 months 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 Bel...

Page 59: ...with activated carbon cartridges are fitting correctly To prevent the reduction of service life of the expensive activated carbon filter ensure that the pre filtering and fine filtering stages are in proper condition Grease filter see page 70 Every 3 6 months Use a cleaning bath to wash filters cells Other filters Refer to the relevant maintenance instructions specified in the supplied documentati...

Page 60: ... etc are functioning properly Heat pipe see page 76 Every 12 months Clean coil fins Clean coil drip tray and condensate line Check trap for proper operation top up as necessary If a heat pipe is fitted with a bypass check air regulating and shut off dampers for proper operation Liquid cou pled energy recovery as sembly see page 76 Every 12 months Complete the same steps specified in Cooler with wi...

Page 61: ...Ensure that there are no loose items inside the unit Check that the unit is air tight Clean the unit as specified in Routine cleaning and maintenance on page 56 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 it...

Page 62: ...oof roof units DANGER Please consider the safety instructions on page 5 and page 55ff when performing all the described activities Complete the following commissioning steps Complete all steps specified in Commissioning of units for indoor installation on page 61 first Check condition of weatherproof gasketing refer to Foundation requirements for outdoor installation weatherproof roof frame on pag...

Page 63: ...s flow rate controller for proper operation open to ensure free movement 8 4 2 Maintenance of belt driven fan assembly DANGER Please consider the safety instructions on page 5 and page 55ff when performing all the described activities 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 ...

Page 64: ...f the set bolts Replace the belt if required Check the pulley alignment and adjust if required fig 8 2 Tension the fan belt measure using a belt tensiometer or frequency calculation method fig 8 2 Tighten counter nuts An acceptable belt deflection at a load of P 20 30 N is from 5 to 20 mm depending on the axis distance see fig 8 2 Belt profiles Smallest pulley diameter mm F force N belt SPZ 70 85 ...

Page 65: ...ose Pull the pulley assembly off the motor shaft fan shaft and remove Fig 8 3 To mount the fan belt pulley proceed as follows Position the pulley and bush so that these engage with one another Align both holes and insert screws without tighten ing Slide the pulley and bush on the shaft as close to the motor or fan as possible to keep leverage small and align For alignment see Re tensioning or repl...

Page 66: ...ocumentation for correct lubrication details of non sealed bearings Bush No 1008 1108 1210 1610 1615 2012 2517 3020 3030 3525 3535 Max tightening torque Nm 5 6 5 6 20 20 20 32 50 90 90 115 115 Tab 8 1 Maximum tightening torque Fan Manufacturer Comefri Gebhardt Fläkt Woods TLZ THLZ VTZ TLZ T THLZ T VTZ T NTHZ B NTHZ R NTHZ T1 NTHZ T2 NTHZ T2L VZR71 RZR11 RZR15 RZR19 RZR13 GXLB GXLF GXHB 160 180 200...

Page 67: ... control unit It is not allowed to activate the parameter overmodulation as this can damage the impeller 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 8 4 4 Maintenance of direct driven fan assembly DANGER Please c...

Page 68: ... time at least 3 minutes 9 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 9 The fan engine can be auto...

Page 69: ...e 8 5 3 Maintenance of bag filters panel filters fine particle filters DANGER Please consider the safety instructions on page 5 and page 55ff when performing all the described activities Carry out the following maintenance steps Check filter and filter frame for dirt corrosion and damage replace if necessary The end pressure difference of bag filters varies refer to the relevant technical data for...

Page 70: ... increase Check if filter racks with activated carbon cartridges are fitting correctly To prevent the reduction of service life of the expensive activated carbon filter ensure that the pre filtering and fine filtering stages are in proper condition Replacing activated carbon filter cartridges Disconnect power to the unit Cartridges are secured in place with special bolts bayonet lock Turn the filt...

Page 71: ...els 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 preven...

Page 72: ...ecessary clean the coil on the air side blow out with compressed air or low pressure water Check steam inlet and condensate drain for proper operation Air vent Check control functions if available 8 6 5 Commissioning maintenance of direct fired gas heater assembly DANGER Please consider the safety instructions on page 5 and page 55ff when performing all the described activities Refer to the releva...

Page 73: ... m s 8 7 2 Maintenance of cooler assembly with without droplet separator DANGER Please consider the safety instructions on page 5 and page 55ff when performing all the described activities Carry out the following maintenance steps Check for leak free condition and possible dirt on the air side To ensure frost protection periodically check the safety devices and take proper precautions such as drai...

Page 74: ... 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 8 8 1 Commissioning of evaporator condenser DANGER Please consider the safety instructions on page 5 and page 55ff when performing all the described activities ...

Page 75: ...ines etc are functioning properly Performance of leakage tests according to EU Directive 517 2014 on the entire refrigeration circuit depending on the CO2 equivalent of the refrigerant contained in the refrigerating system with at least the following frequency 1 x annually from 5 t CO2 equivalent 2 x annually from 50 t CO2 equivalent 4 x annually from 500 t CO2 equivalent A log book must be mainta...

Page 76: ...al see Maintenance of dampers blades and shut off dampers on page 80 8 10 Liquid coupled energy recovery coil 8 10 1 Commissioning maintenance of liquid coupled energy recovery coil DANGER Please consider the safety instructions on page 5 and page 55ff when performing all the described activities Refer to Commissioning of heater assembly pumped warm water on page 71 8 11 Plate heat exchanger 8 11 ...

Page 77: ...f a tray is installed and available Oil and grease kitchen ex haust Remove oil and grease deposits with hot water and grease dissolving cleaning agents 8 11 3 Airflow routing in plate type heat exchangers ATTENTION Risk of damage to the unit Avoid inadmissible high differential pressures between supply air and extract air This could cause damage to the fins In this case DencoHappel neither accepts...

Page 78: ...f when performing all the described activities Carry out the following maintenance steps Use a vacuum cleaner to clean coil fins regularly Carry out wet cleaning only if a tray is installed Never use high pressure water or steam for cleaning coil fins Remove dirt from the section If energy recovery is done with a bypass arrangement check dampers for correct operation refer to Maintenance of damper...

Page 79: ...ng freely Check all screw connections for proper fit For actuators 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 Electrical hazard and danger of rotat...

Page 80: ...and sound insulating splitters for contamination vacuum clean if necessary 8 16 Commissioning maintenance of ECOTWINcool double plate heat exchanger with adiabatic cooling Refer to the relevant commissioning instructions specified in the supplied documenta tion 8 17 commissioning maintenance of integrated refrigerating systems In general when working with refrigerants be sure to pay attention to t...

Page 81: ...ly 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 toxi...

Page 82: ...l Safety BetrSichV Observe any further applicable laws of the respective installation site 8 17 2 Taking out of service DANGER Please consider the safety instructions on page 5 and page 55ff when performing all the described activities See the service booklet for refrigerating systems for requirements ATTENTION Risk of damage to the unit Only use types of oil approved by the compressor manufacture...

Page 83: ...used operating materials are sorted and separated according to their respective properties ATTENTION Risk of environmental damage Have qualified licensed staff dismantle and dispose of the unit 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 po...

Page 84: ...ilt in components and special configurations For detailed maintenance and repair procedures contact your local supplier 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 ...

Page 85: ... 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 on date Defect damage was repaired by on Month 2 following commissioning Heat Exchanger Fan assembly Refrigeration plant Control Panels Filters Condensate pan Damper blades Other components Defects ...

Page 86: ...ration plant Control Panels Filters Condensate pan Damper blades Other components Defects damage was directly communicated to company on date Defect damage was repaired by on 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 on date Defect damage w...

Page 87: ...efrigeration plant Control Panels Filters Condensate pan Damper blades Other components Defects damage was directly communicated to company on date Defect damage was repaired by on 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 on date Defect da...

Page 88: ... DencoHappel is a global company with expertise in air treatment air conditioning and air filtration Our nearest sales and service teams will be glad to discuss ideas and develop creative and effective solutions with you ...

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