AL-KO AIRCABINET Installation And Operating Manual Download

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COMPACT AIR HANDLING UNIT

INSTALLATION AND OPERATING MANUAL

AL-KO

AIR

CABINET

Summary of Contents for AIRCABINET

Page 1: ...COMPACT AIR HANDLING UNIT EN INSTALLATION AND OPERATING MANUAL AL KO AIRCABINET ...

Page 2: ...2 AL KO AIRCABINET Legal AL KO THERM GMBH Hauptstraße 248 250 D 89343 Jettingen Scheppach Germany Phone 49 8225 39 0 Fax 49 8225 39 2113 E mail klima technik al ko com Revision history Version Description Date 1 0 3420877 February 2021 26 02 2021 ...

Page 3: ... switch 15 3 1 6 Control unit 16 3 1 7 Remote access portal 17 3 1 8 HMI for web 17 3 1 9 Network connection 17 3 1 10 Connection for building management system 17 3 1 11 Air flows 18 3 1 12 Cooling 19 3 1 13 Combination exterior wall diffuser 19 3 1 14 Piping 20 3 1 15 Technical data 20 3 2 Type plat of the AL KO AIRCABINET compact air handling unit 21 4 Delivery transport storage 22 4 1 Delivery...

Page 4: ... 6 2 1 Safety 34 6 2 2 Overview 34 6 2 3 Switching on the unit 34 6 2 4 Switching off the unit 35 7 Servicing and maintenance 36 7 1 Safety 36 7 2 Maintenance schedule 37 7 3 Carry out filter change 39 7 3 1 Safety 39 7 3 2 Overview 40 7 3 3 Filter change indicator 40 7 3 3 1 Carry out filter change 41 7 4 Resetting the safety temperature limiter 42 7 4 1 Safety 42 7 4 2 Overview 42 7 4 3 Resettin...

Page 5: ...n this documentation and on the product This documentation is a permanent part of the described product and must be handed over to the buyer if the prod uct is sold 1 1 Explanation of symbols 1 1 1 Safety instructions DANGER This signal word is used to indicate an immediate dangerous situation which if not avoided will result in death or severe injury WARNING This signal word is used to indicate a...

Page 6: ...ed this can lead to severe injury or even death due to hazardous electric shock Warning of crushing hazard If the necessary safety instructions are not observed this can lead to severe injury or even death due to crushing Warning of hand injury risk If the necessary safety instructions are not observed this can lead to severe injury or even death Warning of substances hazardous to health If the ne...

Page 7: ...ion If foot protection is not worn injuries may be caused to the feet Wear hand protection If hand protection is not worn injuries may be caused to the hands Wear breathing masks If respiratory protection is not worn poisoning and chemical burns to the lungs may occur Isolate before maintenance or repair Failure to disconnect the unit from all energy sources before starting maintenance or repair w...

Page 8: ...enance work Avoid naked flames and sparks in the intake area of the unit Observe the working instructions and this Installation and Operating Manual Work carefully at all times Wear your PPE during all work on the unit WARNING Risk of injury from unauthorised opening Keep the maintenance panel and the maintenance doors closed during operation Never open the unit during operation The unit may only ...

Page 9: ...before starting work on the unit and must observe them at all times In order avoid hazards during operation all company operating and working instructions of the user apply in addition to this Installation and Operating Manual 2 1 4 Safety instructions for operation The unit may only be operated in the performance range specified in the AL KO THERM GmbH technical documents The AL KO AIRCABINET com...

Page 10: ...it operating location 2 1 7 Residual dangers The unit may pose hazards if it is not operated by trained personnel and or is operated improperly or not according to its intended use Residual dangers are potential hazards that are not immediately apparent such as Injuries due to failure to observe the safety instructions standards directives or regulations Injuries caused by uncoordinated work Injur...

Page 11: ...e safety data sheet and the hazardous substances regulations for the cleaning agents used 2 2 2 Training The owner operator of the AL KO AIRCABINET compact air handling unit must brief his personnel on the following subjects at regular intervals Compliance with the Installation and Operating Manual and the statutory regulations Intended used of the unit Observance of all company operating and work...

Page 12: ...AIRCABINET compact air handling unit may only be operated within the scope of the technical data specified by AL KO THERM GmbH Any other use or use beyond that described in section 2 2 3 Intended use on page 11 is regarded as being not in accordance with the intended use The manufacturer cannot be held liable for damage resulting from this Possible misuse includes Horizontal setup of the unit not ...

Page 13: ...the ability to concentrate of persons present The filtration meets the highest hygiene standards The exact type designation can be found on the type plate attached to the housing When ordering replacement parts or in case of other queries please specify the type designation of the AL KO AIRCABINET unit the year of man ufacture and the serial number see chapter 3 2 Type plat of the AL KO AIRCABINET...

Page 14: ...air handling unit consists of three modules which are assembled at the installation site of the unit Basic unit Silencer module Air distributor module 3 1 3 1 Basic unit The basic unit C contains the components for filtering the air flows the heat recovery 18 with thermal bypass 11 an electric air heater 20 for air heating the low noise EC fans 22 23 for conducting the two air flows the CO2 sensor...

Page 15: ...The permanently installed three metre long connection cable with 230 V safety plug is led out via the cable bushing 15 on the right hand outside of the compact air handling unit The power supply to the compact air handling unit is provided by a 16 A domestic power supply Alternatively a permanent connection provided on site can provide the power supply On the right side of the basic module there i...

Page 16: ...ol unit the control unit can be opened and the spiral cable can be replaced with a longer network cable Alternatively a wall mounting bracket with three screw connections is possible for this purpose the unit must be opened in the unplugged state on its rear side Pressing the INFO button 2 calls up the start page on the display The integrated LED signals the status of the compact air handling unit...

Page 17: ...ess portal offers functions such as historical recording of alarms and data points a plant diagram and automatic notification by e mail for alarms 3 1 8 HMI for web With the HMI for web the entire installation can be fully set and commissioned according to the logged in password level HMI for web is the standard equipment of the control The function can be accessed via the network connection of th...

Page 18: ... the space reaches the exhaust air filter 13 via the sound absorber 6 due to the suction effect of the fan 16 through the exhaust air opening 4 of the air distributor module 5 It is cleaned there before heat is removed from it in the heat recovery unit 12 and the exhaust air is passed on as outgoing exhaust air B The fan conveys the cooled exhaust air via the sound absorber 8 through the exhaust a...

Page 19: ...m AL KO THERM GmbH for installation in a window replacement element The unit is intended for connecting the outdoor air and the exhaust air piping to the compact air handling unit 2 4 3 5 6 5 A B 7 5 8 1 A Inner side interior 4 Combination exterior wall diffuser B Outer side 5 6 mm bores for screw connection 1 Outdoor air intake 6 Outdoor air fitting 2 Exhaust air outlet 7 Exhaust air fitting 3 Se...

Page 20: ...r 3 can be optionally piped however piping is not mandatory This can be carried out either using a textile air hose fitted on site and available as an option from AL KO THERM GmbH or using an air line with air passages The supply air can also exit directly from the fitting into the interior space The exhaust air 4 is extracted directly on the unit no piping is provided 3 1 15 Technical data Data A...

Page 21: ...Product description 3 2 Type plat of the AL KO AIRCABINET compact air handling unit The article no serial number year of manufacture name of the manufacturer and the design data can be found on the type plate This type plate is attached to the outside of the unit ...

Page 22: ...and delivered upright on two one way pallets Basic unit on one pallet Dimensions L x W x H 150 x 80 x 135 cm overall weight 235 kg Silencer module and air distributor module on one pallet Dimensions L x W x H 150 x 80 x 150 cm overall weight 215 kg The control unit is packed in a box behind the left maintenance door of the basic unit Additional optional accessories can be stored behind the mainten...

Page 23: ...ur PPE cut proof gloves safety shoes CAUTION Risk of injury due to the unit falling or tipping over Failure to observe the safety instructions standards directives and regulations leads to a Risk of injury due to the unit falling or tipping over Observe the applicable standards directives and regulations Observe the instructions in this Installation and Operating Manual Work only on surfaces on si...

Page 24: ... standard limitations of use 20 C to 40 C 4 2 3 Transport under aggravated conditions When transporting under aggravated conditions e g on open vehicles under unusual vibration stresses transport by sea or in subtropical countries additional packaging must be used that will protect the unit from these particu lar influences 4 2 4 Transport with pallet truck The compact air handling unit is pre ass...

Page 25: ...not store the compact air handling unit outdoors Frequent and above all abrupt temperature changes must be avoided during storage This entails a risk of moisture condensing Mould could develop as a result In order to avoid bearing damage the fans must be turned once a month during standstill times of more than one month To do this open the left maintenance door and turn the two fans by hand The co...

Page 26: ...help you Use the recessed handles and holding points provided when lifting the unit components Wear your PPE protective gloves safety shoes CAUTION Risk of injury due to tripping There is a risk of tripping due to objects on the floor when installing the unit Remove packaging materials and one way pallets that are no longer required from your working area immediately Do not climb over unit compone...

Page 27: ...person and place it on a level non slip surface 18 Remove the two one way pallets from your working area 5 3 Setting up and installing the unit ATTENTION Suitable screws and PVC universal shims for horizontal alignment of the compact air handling unit must be provided by the customer Proceed as follows to set up the compact air handling unit Step Action 1 Ensure that the appropriate domestic power...

Page 28: ...wn in unhindered through the exhaust air grille on the upper right side of the air distributor module Do not place anything on the air distributor module 5 4 Connecting the unit to the mains power supply ATTENTION The use of a all current sensitive residual current circuit breaker instead of an earth leakage circuit breaker is recommended for the electrical protection of the compact air handling u...

Page 29: ...s sufficient load bearing capacity for the combination exterior wall diffuser and does not become distorted after it has been in stalled Wear your PPE safety shoes protective helmet ATTENTION The combination exterior wall diffuser is not part of the scope of delivery of the compact air handling unit ATTENTION The sandwich window element and its installation must be provided by the customer ATTENTI...

Page 30: ...customer provision 4 Outdoor air intake 11 Sealing compound for window sandwich element 5 Inside cover 12 Sealing compound for combination exterior wall diffuser 6 Screw connection holes 13 Rear wall 7 Outdoor air fitting 5 5 3 Creating and inserting a sandwich window element A sandwich window element 10 is to be installed on site instead of a window pane in a window element by a glazier It must h...

Page 31: ...e holes of the inside cover 5 into the sandwich window element 10 Drill completely through the support material of the window sandwich element but not through the sheet metal of the rear wall 13 of the combination exterior wall diffuser 3 to ensure that the sheet metal screws can be securely fastened 8 Screw the six 5 5 x 45 mm self tapping screws for the screw connections 6 through the inside cov...

Page 32: ...ng is available in sufficient lengths 2 Ensure that the combination exterior wall diffuser 2 is properly mounted 3 Install the ceiling suspensions 3 for the outdoor air and exhaust air piping 4 If necessary install the optional ceiling rail 4 for the supply air piping 5 Install the piping for the outside air and exhaust air on the ceiling suspensions 3 Use permanent piping 7 8 or flexible piping 9...

Page 33: ...ribed in these installation instructions and the Operating Manual see 5 Instal lation on page 26 All the filter elements are correctly installed The unit is connected to the mains power supply WARNING Risk of damage to property There is a risk of property damage or total destruction of the unit if the components come into contact with solid or liquid media Install the unit only in interiors intend...

Page 34: ...terrupting the power supply must only be operated during maintenance work and when the unit is shut down NOTE The main switch connects the installation to the mains power supply This means that all control and regulating modules are ready for operation 6 2 2 Overview 3 1 2 1 O OFF switch position OFF 3 main switch 2 I ON switch position ON 6 2 3 Switching on the unit Step Action 1 Switch on the co...

Page 35: ...led down and the two fans have come to a standstill 3 Switch off the compact air handling unit at the main switch 3 The unit is off the LED status display above the main switch has gone out All displays on the control unit have gone out 4 Ensure that the main switch 3 is fully engaged in the O OFF 1 position 5 Secure the main switch 3 against unintentional restart of the unit with suitable locking...

Page 36: ... work carried out only by qual ified staff Make sure that all factory fitted safety units are functional before switching the unit on again WARNING Risk of injuries from the run on of the fan The unit may only by opened by qualified staff or by instructed persons The unit may only be opened when the fan has been switched off and has come to a standstill Observe the fan delay time Wait at least thr...

Page 37: ...ed out in accordance with German VDI 6022 and VDMA 24186 If a maintenance contract is concluded AL KO THERM GmbH will carry out this work in a professional manner Customer Service Phone 49 8225 39 2440 E mail aircabinet al ko com Web www al ko com ATTENTION Only use original consumable materials and spare parts This is the only way to ensure safe operation Use of other parts will void the warranty...

Page 38: ...t and outdoor air supply Repair X 4 5 Check the condensate drip pan for dirt corrosion and correct function Repair X 4 6 Checking the hygiene condition X 5 electric air heater 1 3 6 12 24 5 1 Check for scale deposits and corrosion Completely clean and repair X 5 2 Inspect on the air side for soiling and damage Completely clean and repair X 5 3 Check functionality Repair X 5 4 Check control and saf...

Page 39: ... supply Secure the mains lead so that it does not pose a tripping hazard WARNING Health hazards due to dust load and microbial contamination Lack of maintenance of the filters can cause these to collect dust and germs Skin contact with germs or inhalation of escaping dusts can lead to health hazards Observe the filter monitoring on the unit operating panel Observe the prescribed maintenance interv...

Page 40: ...iew 8 9 3 10 11 13 12 2 4 1 2 4 3 4 7 5 6 1 Supply air filter guide rail 8 LED status display 2 Basic unit 9 Main switch 3 Maintenance door right 10 Control unit 4 Turn lock 11 INFO button with integrated LED 5 Outdoor air filter 12 ALARM button with integrated LED 6 Exhaust air filter guide rail 13 Display 7 Exhaust air filter 7 3 3 Filter change indicator In the following cases it may be necessa...

Page 41: ...arry out filter change To replace both filters proceed as follows Step Action 1 Ensure that an alarm displayed on the control unit 10 indicates the required filter change 2 Switch off the compact air handling unit see chapter 6 2 4 Switching off the unit on page 35 3 Ensure that the main switch 9 is in the O OFF position 4 Disconnect the unit plug 5 Route the mains lead so that it does not pose a ...

Page 42: ...emperature limiter 7 4 1 Safety ATTENTION The following work may only be carried out after the unit has been disconnected from the power supply and has cooled down ATTENTION Before starting work the cause of the malfunction must be determined by a qualified electri cian The malfunction may only be corrected by a qualified electrician NOTE Further information on the control of the AL KO AIRCABINET ...

Page 43: ...s lead so that it does not pose a tripping hazard 6 Ensure that the unit has cooled down sufficiently and that the fans are completely stationary 7 Unlock the two turn locks 10 of the left hand maintenance door 9 of the basic unit 13 with the double bit key 8 Open the left maintenance door 9 9 Check that the electric air heater 5 is sufficiently cooled do not reach into the unit with unprotected h...

Page 44: ...manual 44 AL KO AIRCABINET 8 Integrated control NOTE Further information on the control of the AL KO AIRCABINET compact air handling unit can be found in the enclosed operating manual functional description for the ART TECH LEVEL II control ...

Page 45: ...e Main menu The topmost entry is the Password entry Press ENTER 2 A password consists of four numbers Each number is set separately with the rotary knob and confirmed by pressing the rotary knob Enter the user password 1 0 0 0 or the service password 2 0 0 0 After entering the password correctly two key symbols appear at the top right of the display Acknowledging alarms only when alarms are pendin...

Page 46: ...setpoint due to compensation The maximum setpoints is defined as follows Highest available step setpoint max compensation Example If I want a basic ventilation of 200 m h then I set step 1 to 25 This means I can enter a maximum of 75 for the max compensation In the case of poor air quality the fans are increased in power up to 1740 m h in this example The aim of the compensation is to convey more ...

Page 47: ...nosis troubleshooting and recommissioning to be carried out by author ised persons The unit may only be opened by qualified staff or trained persons Wear your PPE during all work on the unit Use further protective equipment according to the work to be carried out ATTENTION Ensure that the control unit is connected in the event of fault detection and troubleshooting Determine the alarm number and t...

Page 48: ... air piping Check and clean the exhaust air outlet on the combination exterior wall diffuser Outdoor air intake blocked Check the outdoor air intake of the com bination exterior wall diffuser Clean or remove any blockages with objects Exhaust air intake blocked Check the exhaust air fitting for con tamination clean if necessary Remove objects placed on the exhaust air grille Piping disconnected or...

Page 49: ...ing in conjunction with our products please contact one of our branches or contact us directly at AL KO THERM GmbH Phone 49 82 25 39 2440 Hauptstraße 248 250 Fax 49 82 25 39 2113 D 89343 Jettingen Scheppach E mail aircabinet al ko com Germany Web www al ko com Customer Service Phone 49 82 25 39 2574 E mail service center al ko com ...

Page 50: ...ng register 3407108 Turn lock 3407149 Connection hoses hose clips D250 3421281 Connection hose hose clip D280 3421282 Presence detector 3420858 Control unit 3327932 Cable temperature sensor 3093514 Sound attenuator splitter 3420601 Bypass damper 3420930 Pipe damper 3420809 Main switch 3420876 LED warning light 3420869 HMI extension 15 m 3420862 Unit foot 3420857 10 2 Proof of delivery AL KO THERM ...

Page 51: ...not dispose of worn out units spent batteries or rechargeable batteries in domestic waste When disposing of the device operating equipment and accessories proceed according to the relevant local environmental and recycling regulations in your country and community applicable at the time ...

Page 52: ...O 13854 2020 01 Sicherheit von Maschinen Mindestabstände zur Vermeidung des Quetschens von Körperteilen Safety of machinery Minimum gaps to avoid crushing of parts of the human body Sécurité des machines Distances minimales de prévention des contusions de parties du corps humain DIN EN ISO 13857 2020 04 Sicherheit von Maschinen Sicherheitsabstände gegen das Erreichen von Gefährdungsbereichen mit d...

Page 53: ...Subject to changes in line with technical progress 53 3420878 Notes ...

Page 54: ...Translation of the original operating manual 54 AL KO AIRCABINET Notes ...

Page 55: ......

Page 56: ...KO THERM GMBH l Jettingen Scheppach l Germany All rights reserved for AL KO THERM GMBH as well as in the event of applications for industrial property rights This documentation or excerpts thereof may not be copied or forwarded to third parties without the express consent of AL KO THERM GMBH We reserve the right to make technical changes that do not impair the function 3435687 February 2021 ...

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