Kampmann Ultra 73 Series Assembly, Installation And Operating Instructions
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- Page 1 Ultra ► Assembly, installation and operating instructions Keep these instructions in a safe place for future use! Issue05/20EN SAP No.1389221...
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Page 3: Table Of Contents
Table of contents 1 General ..........................6 1.1 About these instructions ......................... 1.2 Explanation of Symbols........................... 2 Safety............................ 7 2.1 Correct use.............................. 2.2 Limits of operation and use ........................2.3 Risk from electrocution!.......................... 2.4 Personnel requirements - Qualifications ....................11 2.5 Personal Protective Equipment ....................... - Page 4 6.5.6 Commissioning and functional checks ...................... 26 7 Electrical wiring ........................27 7.1 Maximum electrical rating values ......................27 7.2 Electromechanical control type ..58/56 ....................29 7.2.1 Connection (**00) ............................ 29 7.2.2 Cabling of Ultra (**00), actuation by speed controller type 30510............31 7.2.3 Cabling of Ultra (**00), actuation by speed controller type 30510 with industrial thermostat type 30058/ 30059............................
- Page 5 11.3 Fault table, KaControl, type ..58C1/ 56C1....................56 11.4 KaControl faults ............................56 11.5 Start-up after rectification of fault ......................57 12 List of KaControl parameters....................58 12.1 Ultra parameter list..........................58 12.2 KaController parameter list........................61 13 Certificates..........................63 13.1 153_EU-Konformitätserklärung_Lufterhitzer ..................
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Page 6: General
Ultra Assembly, installation and operating instructions General About these instructions These instructions ensure the safe and efficient handling of this equipment. These instructions form an integral part of the equipment and have to be kept in the direct vicinity of the equipment and available to personnel at all times. All personnel must have carefully read through these instructions prior to commencing all work on the equipment. -
Page 7: Safety
Ultra Assembly, installation and operating instructions Safety This section provides an overview of all important safety aspects to ensure optimum protection of personnel as well as safe and trouble-free operation. In addition to the safety instructions in these operating instructions, the valid safety, accident pre- vention and environmental protection regulations must be observed for the area of use of the unit. -
Page 8: Limits Of Operation And Use
Ultra Assembly, installation and operating instructions Limits of operation and use Limits of operation Min./max. water temperature °C 5-90 Min./max. air intake temperature °C -20 - (+40) Min./max. air humidity 15-75 Min. operating pressure bar/kPa Max. operating pressure bar/kPa siehe Typenschild Min./max. -
Page 9: Risk From Electrocution
Ultra Assembly, installation and operating instructions IMPORTANT NOTE! Danger of frost in cooling mode! There is a risk of the heat exchanger freezing when used in unheated rooms. Make sure that the unit is equipped with a frost protection sensor and/or thermostat in this case. IMPORTANT NOTE! Information and limits of operation for cooling mode Pay attention to specific settings and operating modes for cooling with dehumidification of the air:... - Page 10 Ultra Assembly, installation and operating instructions DANGER! Risk of fatal injury from electrocution! Where multiple EC fans are connected in parallel, an electrical charge (>50 C) is present between line conductor and protective earth conductor when the power is switched off. Before working on the elec- trical connection, short-circuit the network connections and PE! The terminals and connectors are still energised even when the unit is switched off.
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Page 11: Personnel Requirements - Qualifications
Ultra Assembly, installation and operating instructions Personnel requirements - Qualifications Specialist knowledge The installation of this product requires specialist knowledge of heating, cooling, ventilation, installation and electrical engin- eering. This knowledge, generally learned in vocational training in one of the fields mentioned above, is not described separ- ately. -
Page 12: Transport, Storage And Packaging
IMPORTANT NOTE! Warranty claims can only be made within the applicable period for complaints. (More information is avail- able in the T&Cs on the Kampmann website) IMPORTANT NOTE! 2 people are needed to transport the unit. Wear personal protective clothing when transporting the unit. -
Page 13: Storage
Ultra Assembly, installation and operating instructions Storage Store packaging under the following conditions: Do not store outdoors. Store in a dry and dust-free place. Store in a frost-free place. Do not expose to aggressive media. Protect from direct sunlight. Avoid mechanical vibrations and shocks. IMPORTANT NOTE! Under certain circumstances, packages can carry storage instructions that go beyond the requirements listed here. -
Page 14: Technical Data
Ultra Assembly, installation and operating instructions Technical data Unit Ultra Series Water content [l] 1.6 - 2.3 2.0 - 2.9 2.0 – 3.8 2.2 - 4.4 Weight [kg] 28 - 30 34 - 43 35 – 45 45 - 55 EC, 230 V standard 84_58 85_58... -
Page 15: Construction And Function
Ultra Assembly, installation and operating instructions Construction and function Overview Fig. 1: Ultra at a glance Base panel Plastic condensation tray Air baffle Cu/Al heat exchanger Whisper-quiet, sickle-blade fan, conforms to ErP 2015 Self-supporting plastic housing Condensation pump (concealed) 6-section intake crown Brief description The heating and/or cooling models of Ultra unit heaters are used as ceiling-mounted units for the decentralised heating and ventilation of halls, exhibition halls and sales rooms, as well as retail chains. -
Page 16: Wear Parts List
Ultra Assembly, installation and operating instructions Wear parts list Figure Article Properties Suitable for Art. no. Series 73 154000073051 Series 84 154000084051 ISO Coarse 45% (G3) spare For use with an open ceil- filter hood Series 85 154000085051 Series 96 154000096051... -
Page 17: Installation And Wiring
Ultra Assembly, installation and operating instructions Installation and wiring Requirements governing the installation site Only install and assemble the unit if the following conditions are met: Make sure that the ceiling is sufficiently load-bearing to take the weight of the unit (Technical data [} 14]). Make sure that the unit is securely suspended/standing. -
Page 18: Installation
Ultra Assembly, installation and operating instructions Type series Voltage [V] Speed [rpm] Max. installation height Throw W[m] H [m] 96_ _56 1000 96_ _58 Installation 2 people are needed to install the unit. CAUTION! Risk of injury from sharp metal housing! The inner metal of the casing can have sharp edges. -
Page 19: Ultra Suspension Points
Ultra Assembly, installation and operating instructions 6.3.1 Ultra suspension points... - Page 20 Ultra Assembly, installation and operating instructions...
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Page 21: Installation On A Solid Ceiling
Ultra Assembly, installation and operating instructions 6.3.2 Installation on a solid ceiling Fig. 3: Installation on a solid ceiling 6.3.3 Installation on a suspended ceiling Fig. 4: Installation on a suspended ceiling... -
Page 22: Assembly Of Air Intake Crown
Ultra Assembly, installation and operating instructions 6.3.4 Assembly of air intake crown IMPORTANT NOTE! Accessory components are no longer accessible once the air intake crown has been fit- ted! The air intake crown is fitted once all connection and installation work has been completed. The motor con- nection box, valves, motor guard, condensation pump etc. -
Page 23: Installation
Ultra Assembly, installation and operating instructions Screw the sections to each other. IMPORTANT NOTE! Air intake crown with the unit installed on a solid ceiling The air intake crown cannot be fitted as described when the unit is installed underneath a solid ceiling and the pipework is visible. -
Page 24: Connection To The Pipe Network
Ultra Assembly, installation and operating instructions 6.4.1 Connection to the pipe network The flow and return connections protrude out of the top of the housing. The heat exchanger connection dimension for cop- per/aluminium heat exchangers is: 1" Proceed as follows when connecting up the unit's hydraulic pipework: Disconnect the medium supply line. -
Page 25: Condensation Drain With Natural Gradient
Ultra Assembly, installation and operating instructions Supply voltage [V/Hz] 230 V/50 Hz (separate mains power line needed) Power consumption [W] 14 W Fuse [A] Max. 16 A Diameter of condensation pressurised line DN 6 mm (hose connection) Signal contact for condensation overflow Normally closed (NC) contact, potential-free, switching capacity 250 V/5 A Tab. 5: Technical data 6.5.2 Condensation drain with natural gradient... -
Page 26: Ultra Without Kacontrol Module Fitted, Recirculating Air
Ultra Assembly, installation and operating instructions 6.5.4 Ultra without KaControl module fitted, recirculating air Automatically stop cooling operation when the maximum condensation level is reached to prevent the condensation tray from overflowing. 6.5.5 Ultra with KaControl module fitted, recirculating air Voltage supply and alarm contact are factory-wired on the Ultra. -
Page 27: Electrical Wiring
Ultra Assembly, installation and operating instructions Electrical wiring IMPORTANT NOTE! Condensation formation in the cooling unit! In the event of on-site valve control, the cooling valve must be closed when the fans are switched off. IMPORTANT NOTE! Switch the unit on and off at the control input! Do not switch the unit on and off at the mains, since a fault message is generated for up to 10 seconds after the mains power is switched on! After this time, the EC fan's electronic circuit is ready for operation and a reliable status message is possible. -
Page 28: Maximum Electrical Rating Values
Ultra Assembly, installation and operating instructions Maximum electrical rating values Electromechanical model Type Nominal Mains fre- Active Nominal Leakage cur- Maximum IP protec- Protection voltage [V] quency [Hz] power [kW] current [A] rent [mA] preliminary tion rating class fuse [A] 73**58 50/60 0,14... -
Page 29: Electromechanical Control Type
Ultra Assembly, installation and operating instructions Electromechanical control type ..58/56 EMC-compliant installation of control cables To avoid interference, ensure there is sufficient clearance between the mains power and control cables. When using a shiel- ded cable, make sure that the shield is connected just on one side, i.e. only to the signal source with the protective earth (as short and low inductance as possible)! 7.2.1 Connection (**00) Voltage supply and actuation... - Page 30 Ultra Assembly, installation and operating instructions Control via 0 - 10 VDC The 0 - 10 VDC control signal is interpreted for speed according to the following values: Control signal Function 2 - 10 V - 100% (2 V) The speed can be limited to approx. 50% of the maximum speed via the potentiometer in the junction box. Refer to these points in the following installation diagrams with electromechanical control: Comply with the information on cable types and cabling with due consideration of VDE 0100.
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Page 31: Cabling Of Ultra (**00), Actuation By Speed Controller Type 30510
Ultra Assembly, installation and operating instructions 7.2.2 Cabling of Ultra (**00), actuation by speed controller type 30510... -
Page 32: Cabling Of Ultra (**00), Actuation By Speed Controller Type 30510 With Industrial Thermostat Type
Ultra Assembly, installation and operating instructions 7.2.3 Cabling of Ultra (**00), actuation by speed controller type 30510 with industrial thermostat type 30058/ 30059 Heating... -
Page 33: Cabling Of Ultra (**00), Actuation By Speed Controller Type 30510 With Room Thermostat Type 30055
Ultra Assembly, installation and operating instructions 7.2.4 Cabling of Ultra (**00), actuation by speed controller type 30510 with room thermostat type 30055 Heating... -
Page 34: Cabling Of Ultra(**00), Actuation By Speed Controller Type 30510 With Clock Thermostat Type 30056
Ultra Assembly, installation and operating instructions 7.2.5 Cabling of Ultra(**00), actuation by speed controller type 30510 with clock thermostat type 30056 Heating... -
Page 35: Cabling Of Ultra (**00), Actuation By Klimaregler Type 30155, 2-Pipe Valve Actuator 230 V Ac, Open
Ultra Assembly, installation and operating instructions 7.2.6 Cabling of Ultra (**00), actuation by Klimaregler type 30155, 2-pipe valve actuator 230 V AC, Open/Close... -
Page 36: Cabling Of Ultra (**00), Actuation By Klimaregler Type 30256, 2-Pipe Valve Actuator 230 V Ac, Open
Ultra Assembly, installation and operating instructions 7.2.7 Cabling of Ultra (**00), actuation by Klimaregler type 30256, 2-pipe valve actuator 230 V AC, Open/Close... -
Page 37: Cabling Of Ultra (**00), Actuation By Speed Controller Type 30515
Ultra Assembly, installation and operating instructions 7.2.8 Cabling of Ultra (**00), actuation by speed controller type 30515... -
Page 38: Cabling Of Ultra (**00), Actuation By Ddc/Bms, 2-Pipe Valve Actuator 230 V Ac, Open/Close
Ultra Assembly, installation and operating instructions 7.2.9 Cabling of Ultra (**00), actuation by DDC/BMS, 2-pipe valve actuator 230 V AC, Open/Close 2-pipe heating/cooling 2-pipe heating/cooling Unit 2 motor fault Contact open = fault Unit 2 speed (pay attention to the internal resistance of the unit!) Unit 1 motor fault Contact open = fault... -
Page 39: Kacontrol (*C1)
Ultra Assembly, installation and operating instructions KaControl (*C1) 7.3.1 KaController installation Fig. 7: Installation of flush-mounted back box Electrical wiring Connect the KaController to the nearest KaControl unit in line with the wiring diagram. The maximum bus length between the KaController and the KaControl master unit is 30 m. -
Page 40: Connection (*C1)
Ultra Assembly, installation and operating instructions 7.3.2 Connection (*C1) General information Route all low voltage cables along the shortest route. Ensure that low-voltage and power cables are separated, using metal partitions on cable harnesses. Wrong! Use only shielded cables as low-voltage and bus cables. Star-shaped wiring of the bus lines. - Page 41 Ultra Assembly, installation and operating instructions The type of activation is set by 6 DIP switches on the SmartBoard in accordance with the wiring diagram and system config- uration. Fig. 10: SmartBoard DIP switch and potentiometer Control via 0 - 10 VDC The 0-10 VDC control signal at input terminals AI2 and GND (Ri = 20 kOhm) on the SmartBoard is interpreted for speed and valve control according to the following values: Control signal...
- Page 42 Ultra Assembly, installation and operating instructions Observe these points in the following installation diagrams with KaControl: Comply with the information on cable types and cabling with due consideration of VDE 0100. None *: NYM-J. The requisite number of wires, including protective conductor, is stated on the cable. Cross-sections are not stated, as the cable length is involved in the calculation of the cross-section.
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Page 43: Cabling Of Ultra (*C1), Actuation By Kacontroller Type 321000X, 2-Pipe, 24 V Dc Valve, Open/Close
Ultra Assembly, installation and operating instructions 7.3.3 Cabling of Ultra (*C1), actuation by KaController type 321000x, 2-pipe, 24 V DC valve, Open/Close... -
Page 44: Cabling Of Ultra (*C1), Actuation By Kacontroller Type 321000X, 2-Pipe, 24 V Dc Valve, Open/Close
Ultra Assembly, installation and operating instructions 7.3.4 Cabling of Ultra (*C1), actuation by KaController type 321000x, 2-pipe, 24 V DC valve, Open/Close, with CANbus card... -
Page 45: Cabling Of Ultra (*C1), Actuation By 0-10 V Dc Signal By Others
Ultra Assembly, installation and operating instructions 7.3.5 Cabling of Ultra (*C1), actuation by 0-10 V DC signal by others 2-pipe heating/cooling respect unit’s internal resistance! -
Page 46: Pre-Commissioning Checks
Ultra Assembly, installation and operating instructions Pre-commissioning checks Check before initial commissioning whether all necessary conditions have been met so that the unit can function safely and properly. Structural tests Check that the unit is securely standing and fixed. Check that the unit is horizontal. Check the completeness and correct seating of all filters (dirt side). - Page 47 Ultra Assembly, installation and operating instructions Condensation water connection Check whether the condensation tray is free of building rubble. Check the condensation drain and operation of the alarm signal on the condensation pump. Check whether the cooling valve switches off in the event of an alarm signal. Check whether the unit is connected leak-free to the on-site condensation connection.
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Page 48: Operation
Ultra Assembly, installation and operating instructions Operation Operation of electromechanical control Speed controller type 30510 The speed controller is used to activate the fan and pre-set the fan speed. Actu- ation of a thermoelectric shut-off valve is not possible. Fig. 11: Speed controller type 30510 Electronic speed controller, type 30515 With integrated digital timer, protection rating IP 40 230 V, EC, with day, night, week programme, continuously variable fan op-... - Page 49 Ultra Assembly, installation and operating instructions Clock thermostat 230 V, type 30256 Electronic clock thermostat for 2- and 4-pipe applications, surface-mounted wall installation on a flush-mounted box in visually unobtrusive design Operation using 4 sensor keys Timer with automatic summer/winter changeover Option for external room sensor Control input for heating/cooling changeover with 2-pipe applications Digital input can be set to Comfort/ECO or ON/OFF switchover...
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Page 50: Operation Of The Kacontroller
Ultra Assembly, installation and operating instructions Operation of the KaController The following information is limited to the key content on the operation of the KaController and KaControl system. More in- formation is included separately in the KaControl SmartBoard user manual. 9.2.1 Function keys, display elements All menus can be selected and set using the navigator dial. - Page 51 Ultra Assembly, installation and operating instructions KaController, black without function keys (one-button opera- tion) type 3210006 1. Display with LED background lighting 2. Navigator dial Change settings Call up menus Fig. 17: KaController black, type 3210006 The symbols shown on the display depend on the application (2-pipe, 4-pipe etc.) and the parameters set. Fig. 18: Display Display of setpoint room temperature Current time...
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Page 52: Maintenance
Ultra Assembly, installation and operating instructions Maintenance 10.1 Securing against reconnection DANGER! Risk of death by unauthorised or uncontrolled restart! Unauthorised or uncontrolled restarting of the equipment can result in serious injury or death. Before restarting, ensure that all safety devices are fitted and working properly and that there is no haz- ard to humans. -
Page 53: Dismantling The Housing
Ultra Assembly, installation and operating instructions Interval Maintenance task Personnel Check the condensation tray, float switch and drain connection for dirt, damage and leak-tight- quarterly User ness. Remove any condensation deposits that have accumulated. 10.3 Dismantling the housing 10.4 Clean the inside of the unit Check all elements that come into contact with air (internal surfaces of the unit, outlet elements etc.) for dirt or deposits dur- ing maintenance and use a commercially available product to remove. -
Page 54: Faults
Ultra Assembly, installation and operating instructions Faults The following chapter describes possible causes of faults and the work needed to rectify them. Should faults occur frequently, shorten the maintenance intervals in line with the actual loading on the unit. Contact the manufacturer with any faults that cannot be rectified using the following information Behaviour in the event of faults The following applies: 1. -
Page 55: Fault Table
Ultra Assembly, installation and operating instructions LED code Relay in the fan* Cause Mains power too high Fault, peak current Temperature alarm MODBUS communication fault Tab. 10: Status via flash code * Relay in the fan with factory-programmed function (fault message not inverted) 0 relay de-energised 1 relay energised 11.1 Fault table... -
Page 56: Fault Table, Electromechanical Control Type
Ultra Assembly, installation and operating instructions Fault Possible cause Remedy Operating unit with integral sensor and/or ex- Place operating unit with integral sensor and/or ternal sensor is exposed to direct sunlight or po- external sensor in a suitable position. sitioned over a heat source. Air cannot blow out or in freely. -
Page 57: Start-Up After Rectification Of Fault
Ultra Assembly, installation and operating instructions Code Alarms Priority Motor fault. Room frost protection. Condensation alarm. General alarm. Sensor AI1, AI2 or AI3 faulty. Unit frost protection. EEPROM error. Offline slave in the CAN bus network. Tab. 11: KaControl unit alarms Code Alarms tAL1... -
Page 58: List Of Kacontrol Parameters
Ultra Assembly, installation and operating instructions List of KaControl parameters 12.1 Ultra parameter list Parameter Function Standard Min. Max. Unit Ultra P000 Software version P001 Base setpoint for setpoint input ± 3K °C P002 Switching on / off hysteresis for valves K/10 P003 Neutral zone in a 4-pipe system (only in automatic mode) - Page 59 Ultra Assembly, installation and operating instructions Parameter Function Standard Min. Max. Unit Ultra Fan run-on time after operating mode is switched to stage P035 P036 Type of setpoint P037 Display P038 Lock/disable function on control unit P039 Function of digital output V2 (in 2-pipe system) P040 Valve actuation via pulse width modulation Reset time of PI controller to activate the fan in automatic...
- Page 60 Ultra Assembly, installation and operating instructions Parameter Function Standard Min. Max. Unit Ultra P075 Serial address of Slave 5 P076 Serial address of Slave 6 P077 Serial address of Slave 7 P078 Serial address of Slave 8 P079 Serial address of Slave 9 P080 Serial address of Slave 10 P081...
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Page 61: Kacontroller Parameter List
Ultra Assembly, installation and operating instructions Parameter Function Standard Min. Max. Unit Ultra P118 On delay time P119 Off delay time P120 reserved P121 reserved P122 Relative fan speed increase via contact P123 Maximum valve running time P124 Minimum P + I output variation for valve motion (0 to 10) P125 reserved P126... - Page 62 Ultra Assembly, installation and operating instructions Para- Function Standard Min. Max. Unit Comment meter Interval of setpoint setting 0 = Automatic setting depending on t011 PCB (parameterisable, freely programmable) 1 = Increment of 1℃ (parametrisable PCBs) 2 = Increment of 0.5 ℃ (freely programmable PCBs) t012 Date/Time setting: Year t013...
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Page 63: Certificates
Ultra Assembly, installation and operating instructions Certificates... - Page 66 Ultra Assembly, installation and operating instructions Table Tab. 1 Limits of operation..............................8 Tab. 2 Operating voltage..............................8 Tab. 3 Water quality ................................8 Tab. 4 Technical data for the Ultra ............................ 14 Tab. 5 Technical data ................................ 24 Tab. 6 Technical data on the condensation pump ......................
- Page 68 https://l.kampmann.de/montage-ultra...
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