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FläktGroup CAIRfricostar Operation Manual

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CAIRfricostar
OPERATION MANUAL

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Summary of Contents for FläktGroup CAIRfricostar

  • Page 1 ® CAIRfricostar OPERATION MANUAL...

  • Page 2: Table Of Contents

    Technical Description ..............11 Performance scope ..................11 Modular unit configuration and operation of FläktGroup CAIRfricostar ..11 Unit configuration and operation of CAIRfricostar Micro compact units ..15 Technical specifications ................17 Shipping and Storage ..............20 Delivery ......................20 Transport .......................
  • Page 3 10.1 Dismantling ....................71 10.2 Disposal ......................71 Troubleshooting ................72 Appendix ..................73 12.1 Maintenance log book for your CAIRfricostar – Dehumidifier Units for indoor pools ....................73 – Original operation manual – Copyright note Disclosing, copying, distributing or taking any action in reliance on the contents of this document is strictly prohibited without express prior consent.

  • Page 4: Unit Type Code

    Unit Type Code ® CAIR fricostar Unit Type Code Unit part 2 * Example: CAIR fricostar Prefix General Unit part 1 Type identification CAIR fricostar (dehumidification of swimming pools) SX Unit Standard without accessories Standard with accessories Special design Complete Fixed High-Performance swimming pool Standard swimming pool...

  • Page 5: Safety And User Instructions

    CAIR fricostar Safety and User Instructions The FläktGroup CAIRfricostar units are constructed using the state-of-the-art technol- ogy and according to recognized safety regulations. Use the unit when it is in a technically sound condition for the intended purpose observ- ing current operation manual, taking safety aspects and potential hazards into account! Otherwise failure to follow these instructions may result in death or injury to the user, third persons or damage to the FläktGroup unit, connected units or other equipment!
  • Page 6 Safety and User Instructions ® CAIR fricostar Danger symbols are specified in section „Identification of safety instructions“ on page 8. 2.3.1 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.
  • Page 7 Safety and User Instructions ® CAIR fricostar 2.3.2 Function signs Air flow is generally indicated for fan or compressor Air cooler air/refrigerant Sound attenuator in unit Air heater/cooler with heat recovery function Air/water ECOFLOW General air filter Air heater/cooler with heat recov- indicating air flow direction ery function Air/ECOSTAT Opposed-blade dampers...

  • Page 8: Identification Of Safety Instructions

    Safety and User Instructions ® CAIR fricostar Identification of safety instructions To designate the safety instructions the following symbols and notices are provided in appropriate places throughout this document: HAZARDOUS VOLTAGE! This symbol indicates a risk of electric shock when working on the equipment. PERSONAL INJURY! This section specifies procedures and precautions for the prevention of personal injury.

  • Page 9: Safety-Conscious Work Procedures

    (door protection grille, contact guard) are locked – no persons are present in danger areas. Proper use The FläktGroup CAIRfricostar units are only designed for dehumidification, ventilat- ing, heating and filtration of air and are generally used in privately-owned and public swimming pools.

  • Page 10: Safety Devices

    Safety and User Instructions ® CAIR fricostar PERSONAL INJURY AND EQUIPMENT DAMAGE! It is not allowed to operate the unit: – In areas subject to explosion risk, – in environment with conductive dust, – in environment with strong electromagnetic fields, –...

  • Page 11: Technical Description

    The aim is to meet the customer specifications concerning required air volume and conditions. FläktGroup CAIRfricostar units are used at a central point for comfort air conditioning on commercial and industrial premises for the transportation and treatment of “normal”...
  • Page 12 3.2.3 CAM units The FläktGroup CAIRfricostar CAM is designed for various kinds of private and public swimming pools. This unit series can deliver air flow rate from 750 up to 45.000 m³/h.
  • Page 13 3.2.4 CWR units The FläktGroup CAIRfricostar CWR is designed for various kinds of private and public swimming pools. This unit series can deliver air flow rate from 750 up to 45.000 m³/h.
  • Page 14 3.2.6 CWP units The FläktGroup CAIRfricostar CWP is designed for various kinds of High Performance private and public swimming pools. This unit series can deliver air flow rate from 750 up to 37,500 m³/h. The unit's function is to dehumidify and heat air in swimming pools in mixed air mode.

  • Page 15: Unit Configuration And Operation Of Cairfricostar Micro Compact Units

    3.3.1 CAT units The FläktGroup CAIRfricostar CAT is a dehumidifier with compact configuration designed for private and hotel swimming pools as well as therapeutic baths. This unit series can deliver air flow rate from 750 up to 6,500 m³/h. The series is available in 5 model sizes.
  • Page 16 3.3.2 CWT units The FläktGroup CAIRfricostar CWT is a dehumidifier with compact configuration designed for private and hotel swimming pools as well as therapeutic baths. This unit series can deliver air flow rate from 750 up to 6,500 m³/h. The series is available in 5 model sizes.

  • Page 17: Technical Specifications

    Technical specifications Refer to the order-related documentation for the specific configuration of your Fläkt- Group CAIRfricostar Micro unit (unit drawing with dimensions and technical data). 3.4.1 Operating limits and range of application NOTICE! Please carefully observe the unit type plate and the operation manuals for the sup- plied accessories.
  • Page 18 Technical Description ® CAIR fricostar 3.4.5 Condensation limits Please pay due attention to condensation limits! The following diagrams illustrate condensation limits depending on the temperature and relative humidity at the installation site - for series CAIR and CAIRplus SX fricostar T and SX K.
  • Page 19 Technical Description ® CAIR fricostar CAIRplus SX K Condensation diagram for kb-value: 0.5 = without thermal separation Air temperature on unit external side in °C CAIRplus SX M Condensation diagram for kb-value: 0.62 = partial thermal separation Air temperature on unit external side in °C FläktGroup DC-2009-0019-GB 2018-01/R9 •...

  • Page 20: Shipping And Storage

    Shipping and Storage Delivery FläktGroup CAIRfricostar unit can ship as a single piece or multiple individual shipment units. Delivery is done on transport pallets. • When the unit is delivered, check that the shipment is correct according to the despatch note, and also check for completeness.
  • Page 21 Shipping and Storage ® CAIR fricostar • 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. •...
  • Page 22 Shipping and Storage ® CAIR fricostar 4.2.2 Lifting the unit - transport gear on the base frame (provided with shipment units weighing up to 4000 kg) PERSONAL INJURY! Use only the transport gear provided by FläktGroup! Make sure that equipment is firmly seated before lifting the equipment.

  • Page 23: Storage

    Shipping and Storage ® CAIR fricostar 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 packag- ing against build-up of dust and dirt.

  • Page 24: Mounting

    EQUIPMENT DAMAGE! When entering FläktGroup CAIRfricostar 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).
  • Page 25 Mounting ® CAIR fricostar 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 operating side. • Provide a minimum clearance of 600 mm between the unit rear panel and wall for service purposes.
  • Page 26 Mounting ® CAIR fricostar 5.1.4 Foundation requirements for outdoor installation (weatherproof, roof frame) NOTICE! Do not use FläktGroup units for outside installation as a roof substitute! It is not allowed to use weatherproof units as supporting surfaces of a building or similar roof substitutes in accordance with prEN 13053 and VDI 3803.

  • Page 27: Assembling The Unit

    Mounting ® CAIR fricostar 5.1.5 Structure-borne sound attenuation In order to reduce the transmission of vibration from the unit to the supporting structure, provide vibration and noise-dampening pads. – We recommend to use rubber pads to isolate the foundation from the units installed on a level structure with no special requirements to structure-borne noise isolation.
  • Page 28 Mounting ® CAIR fricostar 5.2.1 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: •...
  • Page 29 Attach provided gaskets at the joint (separate assembly in- structions are enclosed with the supplied sealing strip). • Attention: CAIRfricostar Micro units with a split configuration of model sizes 025 to 065 require adequate sealing of the joint in the double plate heat exchanger during assembly.
  • Page 30 Mounting ® CAIR fricostar • Before joining the sections for final assembly position them as close to one another as possible. Use the unit base frame only to pull the sections together. Use the tensioning belts to pull together units without a base frame. Secure the belts on the unit profiles at the bottom or roof section.
  • Page 31 Mounting ® CAIR fricostar • If the rear side of the unit is not accessible, screw together the interior joint connection in the corner. Fig. 5-11: 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.
  • Page 32 Clean and seal all internal joint seams. • Attention: CAIRfricostar Micro units with a split configuration of model sizes 025 to 065 require adequate sealing of the joint in the double plate heat exchanger during assembly. Due to the increased condensate formation during dehumidification mode provide adequate sealing of this zone to ensure a leak-free condition.
  • Page 33 Mounting ® CAIR fricostar 5.2.5 Installing inclined/bossed roof (CAIRplus SX) • Secure the separately supplied joint strip. Fig. 5-16: 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). •...
  • Page 34 Mounting ® CAIR fricostar 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.
  • Page 35 Mounting ® CAIR fricostar 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 33. • Use the supplied sealant to caulk the roof panel seams (1). • Slide the separately provided joint strips (2) from both sides.
  • Page 36 Mounting ® CAIR fricostar Centrally-split roof panels • 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. •...
  • Page 37 Mounting ® CAIR fricostar 5.2.6 Roof installation with double-deck units • Roof installation for double-deck units is identical to the in- stallation of single units – refer to the specification from page 32. • Apply sealant evenly on the surface. •...

  • Page 38: Installation

    EQUIPMENT DAMAGE! When entering FläktGroup CAIRfricostar units ensure that no loads are applied on the floor panels. For all installation and maintenance jobs take appropriate meas- ures to ensure that all load is evenly distributed across the bottom profiles (e.g.
  • Page 39 Installation ® CAIR fricostar Notice! Effects in case of dif- These limit values are Description Icon Values ference only intended to provide − < 7 Corrosion basic information Hydrogen ion concentration > 9 Incrustation on water quality − Δ Hardness Calcium and magnesium content 8.5 ×...
  • Page 40 Installation ® CAIR fricostar 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 There are two methods to use the 3-way valve: in heater assemblies A) Design sample: three-way mixing control: Application in plants with air heaters with mixed air operation or...
  • Page 41 Installation ® CAIR fricostar 6.3.3 Installing pool water condenser (optional accessory) EQUIPMENT DAMAGE! 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 war- ranty! EQUIPMENT DAMAGE!
  • Page 42 7: Flow meter Follow the procedure specified in example 4: • Both the filter unit and the CAIRfricostar 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.
  • Page 43 Installation ® CAIR fricostar 6.3.4 Installing coils with a liquid-coupled energy recovery system Refer to „Installing air-handling components for cooling/heating applications“ on page 39. Piping set for ECOFLOW Standard: energy recovery system – Circulating pump, safety valve, pressure gauge, expansion tank, two stop cocks, one charge and drain tap, connecting pipes, connecting sockets.

  • Page 44: Installing Accessories

    Installation ® CAIR fricostar 6.3.5 Water drain trapping NOTICE! Direct connection to a sewage network is not allowed!Fill the condensate trap with water prior to commissioning and after extensive downtime periods. Hydraulic seal H of the trap must be greater than the maximum positive or negative pressure (mm water column) in unit (1 mm WC = 10 Pa).

  • Page 45: Electrical Connection

    Electrical Connection ® CAIR fricostar Electrical Connection The electrical connection may only be completed by a qualified licensed electri- cian. Have qualified licensed staff or other individuals with proper professional training and experience in the relevant accident prevention regulations, as well as other generally recognized safety and occupational health codes, perform unit jobs.

  • Page 46: Connecting Unit

    Electrical Connection ® CAIR fricostar Connecting unit Separate grounding for each assembly group with an electrical connection is required. 7.2.1 Motor protection Motor protection with PTC thermistors Depending on the motor size and type, the AC motors are fitted from 2 to 6 PTC ther- mistors switched in series.
  • Page 47 Electrical Connection ® CAIR fricostar Motor protection with thermal contact Thermal contacts are temperature-dependent operating elements for automatic moni- toring 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: –...
  • Page 48 Electrical Connection ® CAIR fricostar 7.2.3 Service switch 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.
  • Page 49 Electrical Connection ® CAIR fricostar 7.2.7 Overview of cable connections for the FläktGroup CAIRfricostar mixed-air units NOTICE! Only the unit wiring diagram provides exact information about the unit delivery con- dition. The switch box is supplied loose! (Special configuration includes intermediate ter-...
  • Page 50 Electrical Connection ® CAIR fricostar 7.2.8 Overview of cable connections for the FläktGroup CAIRfricostar Micro CAT and CWT mixed-air units NOTICE! Only the unit wiring diagram provides exact information about the unit delivery con- dition. Unit size 015-065 fitted with an integrated switch box with lateral access (on return air...
  • Page 51 Electrical Connection ® CAIR fricostar 7.2.9 Overview of cable connections of the FläktGroup CAIRfricostar recirculating-air units NOTICE! Only the unit wiring diagram provides exact information about the unit delivery con- dition. The switch box is supplied loose! Fig. 7-7: Overview of cable connections of the FläktGroup CAIRfricostar recirculating-air units 1: Pool water thermostat (option);...

  • Page 52: Commissioning

    EQUIPMENT DAMAGE! When entering FläktGroup CAIRfricostar units ensure that no loads are applied on the floor panels. During all installation and maintenance jobs take proper meas- ures to ensure that all load is evenly spread across the bottom profiles (e.g. using grid walkways).

  • Page 53: General Considerations

    Commissioning ® CAIR fricostar General considerations Complete the following commissioning steps: • Check general condition of the entire casing and the following components – Doors and service openings – Gaskets and seals – Handles and latches – Connections with foam rubber gaskets –...

  • Page 54: Direct-Driven Fan Assembly

    Commissioning ® CAIR fricostar Direct-driven fan assembly Hazardous voltage and risk of rotating components! Please consider the safety instructions on page 52. Hazardous voltage with frequency inverter drives! Do not touch energised components - even following isolation from the mains due to the electrocution hazard.

  • Page 55: Heater Assembly

    Commissioning ® CAIR fricostar Heater assembly 8.6.1 Heater assembly (pumped warm water) ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITH SHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 52. Complete the following commissioning steps: •...

  • Page 56: Cooler Assembly

    Commissioning ® CAIR fricostar Cooler assembly ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITH SHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 52. Complete the following commissioning steps: • Clean coil drip tray and drain piping. •...

  • Page 57: Heat Pipe

    Commissioning ® CAIR fricostar Heat pipe ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITH SHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 52. Observe the following checkpoints for commissioning: Upright heat pipe Place the coil with warm airflow (return air) on the bottom and the cold airflow (fresh air) - on the top.

  • Page 58: Maintenance

    EQUIPMENT DAMAGE! When entering FläktGroup CAIRfricostar units ensure that no loads are applied on the floor panels. During all installation and maintenance jobs take proper meas- ures to ensure that all load is evenly spread across the bottom profiles (e.g. using grid walkways).

  • Page 59: Routine Cleaning And Maintenance

    – Subsequently, use much fresh water to rinse cleaned components and the conden- sate tray. If the corrosion-protection layer is damaged, repair the latter without delay. WARRANTY IN CASE CORROSION DAMAGE: The corrosion protection properties of FläktGroup CAIRfricostar units meet state- of-the-art standards and have been carefully configured by FläktGroup technical staff.

  • Page 60: Maintenance Frequency (Checklist)

    „Table 9-2“ . Within the first two years following commissioning consider „Maintenance log book for your CAIRfricostar – Dehumidifier Units for indoor pools“ on page 73 in the Appendix of the current operation manual.
  • Page 61 Maintenance ® CAIR fricostar Within first 3 months following commissioning ✓ Unit part Frequency Action • Entire unit monthly Carry out all steps as specified in section „Routine cleaning and maintenance“ on page 49. • Clean and refill available traps. (Reduce the frequency, if required) •...
  • Page 62 Maintenance ® CAIR fricostar Frequency ✓ Unit part Action (months) • Heater assem- Every 6 Check for leak-free condition and possible dirt on the air side. bly (pumped months • To ensure frost protection periodically check the safety devices and take proper warm water) precautions such as draining the equipment or adding antifreeze agents.

  • Page 63: General Considerations

    Maintenance ® CAIR fricostar General considerations HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! OB- SERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 58. NOTICE! Carry out intense cleaning in case of salt-containing and/or aggressive air. Carry out the following maintenance steps: •...
  • Page 64 Maintenance ® CAIR fricostar Re-tensioning or replacing V-belt Initial check: Perform the initial check following 50 hours of operation Regular checks: Subsequent checks depend on the operating load and experience. – Check every three months, if the unit operates on a regular daily basis (approx. 8 hrs a day).
  • Page 65 Maintenance ® CAIR fricostar ••• Centre lines Abb. 9-1: Pulley alignment and fan belt tensioning • Adjusting or removing fan belt pulley • Slacken fan belt, refer to „Re-tensioning or replacing V-belt“ on page 64, after that: • remove the belt. •...
  • Page 66 Maintenance ® CAIR fricostar Manufacturer Comefri Gebhardt Fläkt Woods TLZ-T NTHZ-B NTHZ T1 VZR71 RZR15 GXLB GXHB THLZ THLZ-T NTHZ-R NTHZ T2 RZR11 RZR19 GXLF VTZ-T NTHZ T2L RZR13 1000 1120 1250 N = Lubrication possible Tab. 9-5 Lubrication details for non-sealed fan bearings 9.4.2 Direct-driven fan assembly Hazardous voltage and risk of rotating components! Please consider the safety instructions on page 58.

  • Page 67: Filter Assembly

    Maintenance ® CAIR fricostar Filter assembly 9.5.1 Routine maintenance for all filters HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! OB- SERVE PERSONAL PROTECTION MEASURES Please consider the safety instructions on page 58. 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.

  • Page 68: Heater Assembly

    Maintenance ® CAIR fricostar Replacing filter medium • Ensure that unit is deactivated. Open the access door/maintenance panel. • Release the top and bottom springs clips on the filter rack or open the quick-release filter frame. • Pull out the filter frame. •...

  • Page 69: Evaporator / Condenser

    Maintenance ® CAIR fricostar 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. •...

  • Page 70: Liquid-Coupled Energy Recovery Coil

    Maintenance ® CAIR fricostar 9.10 Liquid-coupled energy recovery coil Refer to „Heater assembly (pumped warm water)“ on page 68. 9.11 Plate-type heat exchanger HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS! Please consider the safety instructions on page 58. 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 neg- atively influenced only by corrosion.

  • Page 71: Disassembly And Disposal

    Disassembly and Disposal ® CAIR fricostar 10 Disassembly and Disposal ENVIRONMENTAL DAMAGE! Have qualified licensed staff dismantle and dispose of the unit! 10.1 Dismantling To dismantle the unit proceed as follows: HAZARDOUS VOLTAGE! When carrying out decommissioning and dismantling work on the unit, disconnect all power supply connections, ensure the power cannot be inadvertently energized and verify that electric lines have been disconnected.

  • Page 72: Troubleshooting

    Troubleshooting ® CAIR fricostar 11 Troubleshooting NOTICE! Have qualified licensed staff perform troubleshooting and repair procedures. Qual- ified licensed staff or other individuals with proper professional training must be experienced in the relevant accident prevention regulations, as well as other gen- erally recognized safety and occupational health codes.

  • Page 73: Appendix

    Maintenance log bookAppendix ® CAIR fricostar 12 Appendix 12.1 Maintenance log book for your CAIRfricostar – Dehumidifier Units for indoor pools Commissioning date: Commissioned by: Date Signature Maintenance frequency Unit part Comment Heat exchangers Fan assembly Refrigeration unit Controls Month 1 following com-...
  • Page 74 Maintenance log bookAppendix ® CAIR fricostar Date Signature: Maintenance frequency Unit part Comment Heat exchangers Fan assembly Refrigeration unit Controls Month 6 following com- Panels missioning Filter Coil drip tray Damper blades Other components Defects/damage was directly communicated to company: on (date): Defects/damage was repaired by: Heat exchangers...
  • Page 75 Maintenance log bookAppendix ® CAIR fricostar Date Signature: Maintenance frequency Unit part Comment Heat exchangers Fan assembly Refrigeration unit Controls Month 18 following Panels commissioning Filter Coil drip tray Damper blades Other components Defects/damage was directly communicated to company: on (date): Defects/damage was repaired by: Heat exchangers Fan assembly...
  • Page 76 WWW.FLAKTGROUP.COM CAIRfricostar © 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.

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