Related Manuals for AL-KO EASYAIR flat GF-01
Summary of Contents for AL-KO EASYAIR flat GF-01
- Page 1 FLAT AIR HANDLING UNIT OPERATING AND ASSEMBLY INSTRUCTIONS AL-KO EASYAIR flat ®...
- Page 2 AL-KO EASYAIR flat ® Legal AL-KO THERM GmbH Hauptstraße 248 - 250 D-89343 Jettingen-Scheppach Germany Telephone: +49 8225 39 - 0 Fax: +49 8225 39 - 2113 E-mail: klima.technik@al-ko.com Revision history Version Description Date Initial release 01/12/2013 1.0a Revision 15/12/2016 1.0b...
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Page 3: Table Of Contents
Table of contents Table of contents About this manual ..................5 Explanation of symbols ..........................5 1.1.1 Safety instructions ............................5 Safety symbols ............................6 1.2.1 Abbreviations.............................. 7 Legal notices .............................. 7 Safety instructions ..................8 Intended use ............................... 8 Foreseeable misuse ............................ - Page 4 AL-KO EASYAIR flat ® 5.6.7 Connection of hot water heater (WWE option) ..................38 5.6.8 Connection of heater / cooler module (option) ..................40 5.6.9 Connection of cooler module (KWK option) ..................... 42 5.6.10 Control connection (option)........................45 Commissioning ................... 46 Principles..............................
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Page 5: About This Manual
About this manual About this manual The German version is the original operating instructions. All further language versions are translations of the orig- „ inal operating instructions. Read these operating and assembly instructions carefully before assembly, commissioning and maintenance. This „... -
Page 6: Safety Symbols
AL-KO EASYAIR flat ® Safety symbols Meaning Symbol GENERAL DANGER SYMBOL If the required safety instructions are not observed, this can lead to death, severe injuries and serious property damage. IMPORTANT NOTICE If you do not heed this notice, this can lead to problems with the unit. -
Page 7: Abbreviations
About this manual Meaning Warning sign Warning of hand injuries If the required safety instructions are not observed, this can lead to death or severe injuries. Warning of poisonous substances If the required safety instructions are not observed, this can lead to death or severe injuries due to poisonous substances. -
Page 8: Safety Instructions
Only operate the EASYAIR flat unit fully assembled. „ ® Protect the unit from moisture. „ Only use original spare parts from AL-KO THERM. „ Children and people who are not familiar with the unit may not use it. „ Observe the accident prevention regulations and fire protection regulations. „ Foreseeable misuse... - Page 9 Safety instructions WARNING Risk of severe injuries or death. Working on the EASYAIR®flat unit can result in serious injury or death. Only allow assembly, installation, commissioning, repair, maintenance and servicing „ work to be carried out by qualified staff. Before repair and maintenance work, disconnect the EASYAIR flat unit from the mains on ® „ all poles and secure to prevent restart. Integrate metal components to discharge static energy into the potential. „...
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Page 10: Safety Instructions For Operation
Damaged parts are only permitted to be replaced with original spare parts. „ For repair and maintenance work, disconnect the EASYAIR flat unit from the mains supply at all poles. ® „ General maintenance instructions in the operating and assembly instructions from AL-KO THERM must be observed „ under all circumstances. 2.3.3 Personal safety instructions The EASYAIR flat unit may only be operated by persons who are trained in operating it and expressly authorised to ®... -
Page 11: Training
Safety instructions Training The owner/operator of the EASYAIR flat unit must regularly train their personnel in the following subjects: ® Observance of the operating and assembly instructions as well as the legal regulations. „ Intended operation of the EASYAIR flat unit. „ ® Observance of all plant, operating and working instructions at the owner’s/operator's installation site. „ What to do in an emergency. „... -
Page 12: Product Description
AL-KO EASYAIR flat ® Product description The exact type designation can be found on the type plate. The type plate is usually affixed to the housing. When or- „ dering spare parts or in case of other queries, please specify the type designation of the EASYAIR flat unit, the year ® of manufacture and the order number. The EASYAIR flat unit may only be operated in the temperature range from -20 °C to +40 °C. „ ® The unit construction consists of functional modules (filter, fan, sound absorber, heater, cooler, heat recovery). The „... - Page 13 Product description EASYAIR flat EF unit: Supply and exhaust air unit ® Fig. 1 EASYAIR flat EF unit - Components and dimensions ® ODA Outdoor air SUP Supply air Supply air fan module Connection fitting Filter module Multi-leaf dampers Sound absorber module* Installation brackets Heater module* (hot water or electric heater) Pan drain Cooler module* *available as an option...
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Page 14: Technical And Electrical Data
AL-KO EASYAIR flat ® EASYAIR flat GF unit: Supply and exhaust air unit with heat recovery ® Length Fig. 2 EASYAIR flat GF unit - Components and dimensions ® ODA Outdoor air SUP Supply air Extract air EHA Exhaust air Supply air fan module Connection fitting Exhaust air fan module... -
Page 15: Ef Supply And Exhaust Unit
Product description 3.2.1 EF supply and exhaust unit Type Air volume /h)/sound level (dB(A)) Max. connected values Supply/ex- haust air normal value EF 01 650 / 68 1,000 / 68 1,700 / 73 1~ 230V 50Hz EF 02 900 / 69 1,800 / 79 2,750 / 87 1~ 230V 50Hz EF 03... -
Page 16: Vibration Values Of The Fan Impeller
Machine group Good Usable Still permissible Rigid up to 15 kW 0.7 mm/s 1.8 mm/s 4.5 mm/s Example type plate for EASYAIR flat ® AL-KO THERM GMBH Hauptstrasse 248-250 D-89343 Jettingen-Scheppach Germany Type: GF-01- Year of 2021 construction Order number: Position number The given data are nominal values. For device design data, see data sheet. -
Page 17: Transport
Transport Transport Delivery EASYAIR flat units are supplied in individual modules. ® „ Storage prior to assembly Store the individual functional parts in a dry and weatherproof location in their original packaging. „ Cover open pallets with tarpaulins, and protect the functional parts from dirt (e.g. chips, stones, wire, etc.). „... - Page 18 AL-KO EASYAIR flat ® WARNING Risk of injury from falling modules. During transport, modules may fall off onto persons and/or modules may fall down onto persons. Have the modules transported by qualified staff only. „ Observe the transport instructions in these operating and assembly instructions. „ Use only use suitable and approved fastening material.
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Page 19: Transport Under Difficult Conditions
Transport Transport under difficult conditions When transporting under difficult conditions (e.g. on open vehicles, under unusual vibrational stresses, transport „ by sea or in tropical/subtropical countries), additional packaging must be used that will protect against these par- ticular influences. Disposal of packaging When disposing of the packaging, comply with the relevant local environmental and recycling regulations in your country and community that are applicable at the time when the activity is undertaken. -
Page 20: Assembly
Work with care. „ Wear personal protective equipment (cut-proof gloves). „ ATTENTION Before installation and commissioning, it is essential to read and observe the operating and assembly instructions. The AL-KO THERM EASYAIR flat unit is supplied in modules. „ ® For constructing the modules, in particular in the layout of the filter and fan modules, the supplied unit drawing must „ be observed. Assembly or disassembly work may only be carried out by persons with appropriate training, knowledge and „... -
Page 21: Preparations
Assembly Preparations Check the condition of the ceiling. „ Check the individual components for transport damage. „ Select the installation site with regard to good accessibility for servicing and maintenance work. „ Ensure that the components and the connection cable at the installation site cannot be either damaged or contami- „... -
Page 22: Ceiling Construction
AL-KO EASYAIR flat ® Ceiling construction The units may only be installed under horizontal, vibration-resistant ceiling constructions. „ The version of the ceiling and suspended construction must meet the on-site requirements for the acoustics (struc- „ ture-borne sound insulation) and correct water drainage of the condensate. The ceiling construction must be able to bear the static load of the units. -
Page 23: Opening/Removing The Maintenance Panel
Assembly Opening/removing the maintenance panel WARNING Risk of injury from falling maintenance panels. The maintenance panels are no longer secured against falling after the clamp closures have been opened. Always support the maintenance panels by hand during opening/removal. „ EASYAIR flat units are equipped with sufficiently large maintenance panels for easy maintenance and inspection. -
Page 24: Disassembly Of The Maintenance Panel For Countercurrent Exchanger Module
AL-KO EASYAIR flat ® WARNING Risk of injury from falling maintenance panels. The maintenance panels are no longer secured against falling after the carabiners have been unhooked. Always support the maintenance panels by hand during opening/removal. „ Correctly re-suspend the safety ropes, including the carabiners, after closing the hous- „... -
Page 25: Assembly Of The Maintenance Panel For The Countercurrent Exchanger Module
Assembly Fig. 9 Remove the maintenance panel Maintenance panel Removal rail Step Action To fully remove the maintenance panel (1), lift it slightly. Move the maintenance panel (1) through the cut-out of the removal rail (2). Lower the maintenance panel (1) on the opposite side so that it can be moved below the removal rail (2) and take out the maintenance panel (1). - Page 26 AL-KO EASYAIR flat ® Fig. 11 Fit the maintenance panel Maintenance panel Removal rail Step Action Fit the maintenance panel (1) into the sealing position. Close the clamp closures. Translation of original operating instructions...
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Page 27: Assembly Of The Modules
Assembly Assembly of the modules 5.5.1 Work steps Fig. 12 Fit click connectors and covering caps Click connectors Special tool for disassembly Covering cap Fig. 13 Affix sealing tape Sealing tape Intermediate rib Click connectors Step Action Unpack modules. Fit the provided click connectors (2) into the intended opening on the front of the module. Always affix the enclosed sealing tape (1) flush to the unit inside edge past the click connector (2) to the end face of the modules and additionally to the intermediate rib (3) on the outer edge. It is important to ensure that the sealing tape (1) is not attached under tension (especially at the corners). - Page 28 AL-KO EASYAIR flat ® Fig. 14 Attach the installation brackets Installation bracket Housing Fastening screws Step Action Hang the installation brackets (1) on the upper side of the housing and screw them together with the supplied fastening screws (2) and the housing (3).
- Page 29 Assembly Step Action Screw the Duo-Taptite screw M8X25 (3) into the hole of the inner installation bracket (1) of the "left" housing (b). Assembly work on GF units should begin with the heat recovery module. Mount the modules in the corresponding assembly sequence (left housing in front of right housing!) on the ceilings using installation brackets (1) and suitable mounting material (on-site sound decoupling).
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Page 30: Removability Of The Components
AL-KO EASYAIR flat ® 5.5.2 Removability of the components WARNING Risk of injury from falling components. The components are no longer secured against falling after the component locks have been removed. For components in the suspended state, secure the parts that are to be pulled out against „... - Page 31 Assembly Fans Open or fit the maintenance panel, see “5.4 Opening/removing the maintenance panel” on page 23. „ Disconnect the electric cable by unfastening the plug-in connection. „ Position the component lock in the slot with a 90° rotation. „ Carefully remove the fan from the housing. „ Plate heat exchanger (counterflow) CAUTION Risk of injury due to slipping parts. The blocks on the door ribs are secured against falling. By moving the door ribs horizontally, prevent the blocks lying on them from slipping off.
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Page 32: Duct Connection
AL-KO EASYAIR flat ® Fig. 20 Remove door rib Tooth disc Covering cap DUO-Taptite M5x10 Droplet eliminator (cooling module) Open or fit the maintenance panel, see “5.4 Opening/removing the maintenance panel” on page 23. „ The droplet eliminator can be carefully removed from the housing by pushing it up and moving it to the side in the „... - Page 33 Assembly Fig. 21 Install the connection frame and equipotential bonding to the unit Drilling screw 4.8 x 38 Hexagon head bolt M6 x 30 Vibration absorber Drilling screw 4.8 x 19 Washer 6.4 Equipotential bonding Sealing washer 6.4 Rubber fitting Nut M6 Connection frame Fig.
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Page 34: Siphon Connection
AL-KO EASYAIR flat ® 5.5.4 Siphon connection Heat recovery modules and cooler modules of the EASYAIR flat units are fitted with base trays and a condensate con- ® nection in the maintenance panel. These can be fitted with a standard ½" diameter hose with a hose clip. Condensate drain lines must be connected to the drain system with a snake siphon. Direct connection of water drains to the drain system is not permitted. -
Page 35: Cable Lists
Assembly WARNING Risk of injury from falling from ladders, scaffolding or work platforms. Only use suitable and tested ladders, steps, scaffolding and work platforms. „ Only allow assembly, installation, commissioning, repair, maintenance and servicing „ work to be carried out by qualified staff. Work with care. „ If necessary, connect the switch cabinet to the field devices of the EASYAIR flat unit in accordance with the circuit dia- ®... -
Page 36: Cable From Unit Switch Cabinet To The Electric Fan Heater
AL-KO EASYAIR flat ® 5.6.3 Cable from unit switch cabinet to the electric fan heater 0-10 V DC control 2 x 1.0 mm Control voltage (230 VAC / 1 PH) 3 x 1.5 mm Equipment type Voltage (V) Output (kW) -
Page 37: Connection Of Electric Air Heater (Ele Option)
Assembly Supply air temperature sensor To measure the exact supply air temperature, the supply air sensor must be installed in the duct behind the air handling unit. Ideally, it should be mounted directly on the supply air duct outlet to take into account any interference in the duct network. -
Page 38: Connection Of Hot Water Heater (Wwe Option)
AL-KO EASYAIR flat ® NOTE The output-side power supply must be implemented on-site. 400V/50Hz 230V/50Hz 0-10V Fig. 25 Connection of electric air heater Connection of power supply line Connection of 0-100 % power request Connection of enabling voltage ATTENTION For units without integrated control, flow monitoring and fan delay must be implemented on-site. - Page 39 Assembly Valves and actuators must be installed professionally. Please note here whether a 2-way or 3-way valve version is „ to be set up. For the electrical connection of the actuator, see the circuit diagram. „ Requirements for water Maximum working pressure Maximum hot water flow temperature free of corroding properties 16 bar...
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Page 40: Connection Of Heater / Cooler Module (Option)
AL-KO EASYAIR flat ® ATTENTION If the device version control has been selected, neither the valve nor the valve actuator are supplied. In this case, these are on-site services. NOTE The figure shows schematics only of the hydraulic connection of the heater. The exact hydrau- lic connection must be carried out at the discretion of the heating specialist. - Page 41 Assembly 2-way valve, 3-way valve and combined 2-way and 3-way valve versions 2-way valves 3-way valves 2-way/3-way valves 3-way/2-way valves Fig. 28 2-way valve and 3-way valve connection versions PWW heater Valve actuator PCW cooler Valve Frost monitor Recirculation pump (on-site) Counterflow principle for heat exchanger connection Fig.
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Page 42: Connection Of Cooler Module (Kwk Option)
AL-KO EASYAIR flat ® Step Action Connect the heat exchanger using the counterflow principle (water flow direction opposite the air flow direction in the unit). Connect the pre flow up or down depending on the air direction. Carefully vent the heat exchanger. Check all of the piping for leaks. ATTENTION If the device version control has been selected, neither the valve nor the valve actuator are supplied. In this case, these are on-site services. - Page 43 Assembly ATTENTION Counter-hold using a suitable tool (e.g. pipe wrench) during connection of the heat exchang- ers in order to avoid damage. Install pipes and connections in such a way that the heat exchangers remain freely accessible for maintenance. Maximum working pressure: 16 bar „...
- Page 44 AL-KO EASYAIR flat ® Step Action Connect the heat exchanger using the counterflow principle (water flow direction opposite the air flow direction in the unit). Connect the pre flow up or down depending on the air direction. Carefully vent the heat exchanger. Check all of the piping for leaks. ATTENTION If the device version control has been selected, neither the valve nor the valve actuator are supplied. In this case, these are on-site services.
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Page 45: Control Connection (Option)
Assembly 5.6.10 Control connection (option) Connect the supplied supply air sensor to the switch cabinet. „ Connect the supplied outdoor air sensor to the switch cabinet. „ Connect the supplied external air sensor to the switch cabinet. „ With the "Room temperature control" option, connect the supplied room sensor to the switch cabinet. „... -
Page 46: Commissioning
AL-KO EASYAIR flat ® Commissioning Principles Before commissioning, always ensure the following: The unit has been installed as described in these operating and assembly instructions, see “5 Assembly” on „ page 20. All filter elements are properly installed. „ The duct system and the water and drain pipes are properly connected to the unit. -
Page 47: Switching The Installation On/Off
Commissioning Switching the installation on/off WARNING Risk of severe injuries or death! Working on the EASYAIR®flat unit can result in serious injury or death. After switching off via the main switch, no safety functions of the unit are then guaranteed „ (e.g. frost protection). Never use the main switch to switch it on and off during operation. „ Use the main switch only for repair purposes. „... -
Page 48: Integrated Control
AL-KO EASYAIR flat ® Integrated control NOTE Further information on the control of the EASYAIR flat unit can be found in the AL-KO THERM ® operating and assembly instructions/functional description for "ART TECH LEVEL II control". Translation of original operating instructions... -
Page 49: Hmi Basic Quick Start Guide
Integrated control HMI Basic quick start guide ART Tech Level II Quick Guide HMI Basic (Room Control Panel) Display on the start page If no button is pressed for a few minutes, the display jumps to the main menu. Press INFO to go to the start page with the most important plant information. UP arrow key 1. -
Page 50: Hmi Room Quick Start Guide
AL-KO EASYAIR flat ® HMI Room quick start guide ART Tech Level II Quick Guide to HMI Room (Room Control Panel) MODE button ON/OFF button PARTY button FAN button PROG button OK button MINUS button PLUS button Display range Temperature setpoint... -
Page 51: Servicing And Maintenance
In addition, a hygiene inspection in compliance with VDI 6022 is required every 3 years. The actual maintenance intervals are to be adjusted to the corresponding operating conditions. If a maintenance contract is concluded, AL-KO THERM will carry out this work. ATTENTION Only use original consumables and spare parts. This is the only way to ensure safe operation. -
Page 52: Maintenance Schedule
AL-KO EASYAIR flat ® Maintenance schedule Activity / unit component Measure / remark Inspections to be performed at monthly intervals Outdoor air intakes and exhaust air outlets Check for soiling, damage and corrosion Completely clean and repair Unit housing Inspect for soiling, damage and corrosion... - Page 53 Servicing and maintenance Activity / unit component Measure / remark Inspections to be performed at monthly intervals 4.8.4 Venting 4.8.5 Check the hygiene condition Droplet eliminator 4.9.1 Inspect for soiling damage and coating Function-preserving of all surfaces, formation including drip trays; dismantle the droplet eliminator, if necessary 4.9.2 Check function of water drain and odour...
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Page 54: Cleaning Components
AL-KO EASYAIR flat ® Cleaning components ATTENTION For maintenance and cleaning work, the unit is to be shut down on all poles and secured against restart. All installed components are either freely accessible for testing or can be pulled out of the unit after removing the main- tenance doors. - Page 55 Servicing and maintenance CAUTION Risk of burns as a result of contact with hot surfaces and media (plate heat exchanger, heat exchanger and electric heating register) Before and after cleaning and maintenance, wait until the hot surfaces have cooled down. „...
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Page 56: Multi-Leaf Dampers
AL-KO EASYAIR flat ® 8.4.3 Multi-leaf dampers WARNING Risk of crushing When closing the multi-leaf damper, there is a risk of crushing injuries to the hands. Do not reach into the damper when closing the multi-leaf damper. „ Wear personal protective equipment (gloves). -
Page 57: Replacing Components
Otherwise the warranty will be voided. A spare parts list can be found as part of the unit documentation. The filter bags must be disposed of in accordance with the currently valid and applicable local regulations. Customer Service Phone: +49 8225 39 - 2574 E-mail: service.center@al-ko.com Web: www.al-ko.com 3059570 Subject to changes in line with technical progress. -
Page 58: Help In The Event Of Malfunctions
Customer Service Telephone: (+49) 82 25 / 39 - 2574 E-mail: service.center@al-ko.com General malfunctions NOTE Further information on "general malfunctions" of the EASYAIR flat unit can be found in the ® AL-KO THERM Operating Manual for the "ART TECH LEVEL II Control". Translation of original operating instructions... -
Page 59: Shut-Down
Shut-down Shut-down 10.1 Decommissioning De-energise the installation before beginning work (all-pole shutdown) and secure it against unauthorised restart. WARNING Risk of injury due to pressurised parts! When decommissioning, note that certain unit parts are pressurised. „ Follow the applicable safety rules! „... -
Page 60: Disposal
AL-KO EASYAIR flat ® WARNING Risk of poisoning when draining the media. The unit may contain media that are hazardous to health, such as coolants. Work with care. „ Avoid skin and eye contact with the media, do not swallow media and observe the safety „ data sheets. Wear personal protective equipment. -
Page 61: Declaration Of Conformity
Declaration of Conformity EG-KONFORMITÄTSERKLÄRUNG EC DECLARATION OF CONFORMITY DÉCLARATION DE CONFORMITÉ CE AL-KO THERM GMBH I Hauptstraße 248-250 I 89343 Jettingen-Scheppach I Germany Hersteller / Manufacturer / Fabricant: Im Sinne der EG- Maschinenrichtlinie 2006/42/EG, Anhang II, Teil 1, Abschnitt A... - Page 62 AL-KO EASYAIR flat ® Notes Translation of original operating instructions...
- Page 64 AL-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.
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