Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for AL-KO EASYAIR RO-01
Summary of Contents for AL-KO EASYAIR RO-01
- Page 1 COMPACT AIR HANDLING UNIT INSTALLATION AND OPERATING MANUAL AL-KO EASYAIR ®...
- Page 2 AL-KO EASYAIR ® 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 Initial release 01/06/2011 Update 01/10/2015 Update 01/07/2016 3313736_BA-EASYAIR-4.0-02-2021...
-
Page 3: Table Of Contents
Table of contents Table of contents About this manual ..................6 Explanation of symbols ..........................6 1.1.1 Safety instructions ............................6 Safety symbols ............................7 1.2.1 Abbreviations.............................. 9 Legal notices .............................. 9 Safety instructions ..................10 Intended use ............................. 10 Foreseeable misuse .......................... - Page 4 AL-KO EASYAIR ® Electrical connection..........................30 5.6.1 Connection of room control panels (option) ..................... 30 5.6.2 Connection of the field devices to the control ................... 30 5.6.3 Assembly / connection of supply air, outdoor air, exhaust air temperature sensor ........30 5.6.4 Connection of electric air heater (option) ....................31 5.6.5...
- Page 5 Help in the event of malfunctions ..............58 Contacts ..............................58 General malfunctions ..........................58 Shut-down ....................59 10.1 Decommissioning ............................. 59 10.2 Dismantling .............................. 59 10.3 Disposal..............................60 Control schemes appendix................61 11.1 Control schemes legend ........................... 61 11.2 RO-units with PWW coil ...........................
-
Page 6: About This Manual
AL-KO EASYAIR ® About this manual The German version is the original installation and operating manual. All further language versions are translations „ of the original installation and operating manual. Read this installation and operating manual before installation, commissioning and maintenance. This is the prereq- „... -
Page 7: Safety Symbols
About this manual Safety symbols Meaning Symbol GENERAL DANGER SYMBOL If the required safety instructions are not observed, this can lead to death, severe injuries and severe property damage. IMPORTANT NOTICE If you do not heed this notice, this can lead to problems with the unit. OBSERVE THE INSTALLATION AND OPERATING MANUAL If you do not heed the notices in the installation and operating manual, this can lead to problems with the unit. - Page 8 AL-KO EASYAIR ® Meaning Warning sign Warning of sharp objects If the required safety instructions are not observed, this can result in death or serious injuries due to sharp objects. Warning of hand injuries If the required safety instructions are not observed, this can result in death or serious injuries.
-
Page 9: Abbreviations
About this manual 1.2.1 Abbreviations PPE: Personal protective equipment: such as cut-proof gloves, safety goggles, work gloves, ear protection, helmet, mask Legal notices All specified data serve solely to describe the product. No statement on a specific characteristic or suitability for a spe- cific purpose can be derived from these data. The data do not exempt the user from his own judgement and checks. 3313737 Subject to changes in line with technical progress. -
Page 10: Safety Instructions
Set up the unit horizontally, otherwise there is a risk that puddles may form, among other things. „ Protect the unit against moisture. „ Only original spare parts from AL-KO THERM are to be used. „ Children and people who are not familiar with the unit may not use it. „... -
Page 11: General Safety Instructions
Safety instructions General safety instructions WARNING Risk of serious injury or death due to working without personal protective equipment! Working on the EASYAIR ® without PPE can result in serious injury or death. Observe the safety instructions in this installation and operating manual. „... -
Page 12: Safety Instructions For Operation
„ to this installation and operating manual. 2.3.1 Safety instructions for operation The installation may only be operated in the performance range specified in the technical documents from AL-KO „ THERM. The EASYAIR must be installed properly and used subject to precise observation of our installation and operating ®... -
Page 13: Safety Instructions For Maintenance
® „ General maintenance instructions in the installation and operating manual of the AL-KO THERM must be observed „ under all circumstances. Observe the delay time of the fans. Observe a waiting time of at least 3 minutes, until the fan impellers are stationary, „... -
Page 14: Product Description
AL-KO EASYAIR ® Product description The exact type designation can be found on the type plates. The type plates are usually affixed to the housing. When „ ordering spare parts or in case of other queries, please specify the type designation of the EASYAIR unit, the year ® of manufacture and the order number (see chapter “3.3 Sample EASYAIR® type plates” on page 18). -
Page 15: Easyair ® With Rotary Heat Exchanger
Product description 3.2.1 EASYAIR with rotary heat exchanger ® ODA Outdoor air SUP Supply air Exhaust air EHA Outgoing exhaust air Base unit with ODA/EHA flaps, fans, filter, rotary heat Duct connectors (different versions possible) exchanger and integrated switch cabinet ODA/EHA silencer module Levelling foot (H = 98 - 136 mm) SUP/ETA silencer module Suction and outlet hoods with weatherproof housing design (ODA suction hood with integrated droplet elimi-... -
Page 16: Easyair ® With Countercurrent Plate Heat Exchanger
AL-KO EASYAIR ® 3.2.2 EASYAIR with countercurrent plate heat exchanger ® Outdoor air Supply air Exhaust air Exhaust air Base unit ODA/EHA flap, fans, filter, countercurrent plate Duct connectors (different versions possible) heat exchanger and integrated switch cabinet ODA/EHA silencer module Levelling foot (H = 98 - 136 mm) -
Page 17: Holes For On-Site Exchanger Connections
Product description 3.2.3 Holes for on-site exchanger connections External view IMPORTANT Holes for exchanger connections may only be inserted in the cross-hatched area. Non-com- pliance leads to constructional damage to the panel! 3313737 Subject to changes in line with technical progress. -
Page 18: Sample Easyair® Type Plates
AL-KO EASYAIR ® Sample EASYAIR® type plates Each functional unit is assigned a separate type plate. The type plates contain the order number, position details, „ year of manufacture, manufacturer's data as well as the design data. These type plates are externally attached to the unit. -
Page 19: Delivery, Transport, Storage
Delivery, transport, storage Delivery, transport, storage Delivery The EASYAIR air handling units are delivered in the basic unit version as a complete unit (see chapter “3.2.1 ® „ EASYAIR® with rotary heat exchanger” on page 15 and chapter”3.2.2 EASYAIR® with countercurrent plate heat exchanger”... -
Page 20: Transport Under Difficult Conditions
4.2.2 Fork lift truck / pallet truck The AL-KO EASYAIR is supplied on squared timbers. ® IMPORTANT Always place the lifting forks of the forklift on the squared timbers. -
Page 21: Crane Transport Using A Base Frame Bracket
Delivery, transport, storage 4.2.3 Crane transport using a base frame bracket The AL-KO EASYAIR is supplied with a base frame that is suitable for crane transport. Transporting the unit using the ® base frame bracket is permissible up to an overall weight of max. 1500 kg! -
Page 22: Storage Prior To Assembly
AL-KO EASYAIR ® Base frame bracket Shackle (on-site) Step Action Before lifting the units, close the inspection doors/inspection covers. Use only approved and tested transport harnesses to attach them to the intended mounting points. For subsequent crane transport, you must attach the base frame brackets to the base frame. Only use the fastening material supplied by us. -
Page 23: Assembly
„ IMPORTANT Before assembly and commissioning, it is essential to read and observe the Installation and Operating Manual. The AL-KO EASYAIR is delivered with its components pre-assembled. ® „ For the installation of the modules, in particular in the separated design of the indoor units, special attention must „... -
Page 24: Preparations
AL-KO EASYAIR ® Preparations IMPORTANT The installation site must be designed for the loads of the entire HVAC unit as well as for the components installed on site! A check by a structural engineer may be necessary! Observe the condition of the substrate. -
Page 25: Space Requirements
Assembly 5.2.1 Space requirements Sufficient space must be available to operate and maintain the unit (see VDI 2050 "Requirements on central techni- „ cal systems"). In general, it must be ensured during installation that the unit remains freely accessible for maintenance purposes. „ During setup and installation, in particular of the connecting pipework, it must be ensured that the inspection „... -
Page 26: Housing Separation Point Sealing For Outdoor Installation (Weather-Proof)
AL-KO EASYAIR ® 5.3.2 Housing separation point sealing for outdoor installation (weather-proof) In the case of outdoor installation, an additional sealing strip (3x15) must be applied to the left and right of the hous- „ ing frame, flush with the outer edge of the housing. Sealing tape 3 x 15 Outer housing edge 5.3.3... -
Page 27: Roof Assembly Of Optional Modules (Weather-Proof)
Assembly Roof assembly of optional modules (weather-proof) Level-height roof Joint material (Sikaflex 221 RLT) Blind rivet 4.2x8 Step Action Before assembling the housing parts, apply the supplied joint material (Sikaflex 221 RLT) to the sheet metal flange below and above the row of holes without gaps. Connect the roof ridges to the blind rivet via the corresponding holes. Remove excess joint material (Sikaflex 221 RLT) after assembly by gently tilting upwards. Vertically offset roof Joint material (Sikaflex 221 RLT) Blind rivet 4.2x8 Step... -
Page 28: Mechanical Connection
AL-KO EASYAIR ® Mechanical connection WARNING Risk of crushing When installing the duct connections as well as the intake and exhaust hoods, the multi-leaf damper must be closed. When closing the multi-leaf damper, there is a risk of crushing inju- ries to the hands. -
Page 29: Siphon Connection
Assembly 5.5.3 Siphon connection Condensate drain lines must be connected to the drain system with a snake siphon. A direct connection of water „ drains to the drain system is not permitted! NOTE The standing height of the respective siphon must be designed for the underpressure or over- pressure of the air handling unit to prevent suction or blowing out of air from the closed drain pipe. -
Page 30: Electrical Connection
AL-KO EASYAIR ® Electrical connection DANGER Hazard due to electric current. Incorrect connection to the energy supply or incorrect installation of electrical components can result in electric shock. Only have the electrical connection carried out by an approved electrician. „... -
Page 31: Connection Of Electric Air Heater (Option)
Assembly Supply air temperature sensor To measure the supply air temperature without interference, the supply air sensor must be installed in the duct be- „ hind the air handling unit. Assembly directly at outlet of the supply air duct is ideal. Position of outdoor air temperature sensor (ODA) Position of supply air temperature sensor* (SUP) Position of exhaust air temperature sensor (ETA) -
Page 32: Without Integrated Control (Option)
AL-KO EASYAIR ® The following figure shows the connection terminals of the electric air heaters. Behind the connec- tion terminals for the release voltage there is a safety chain of flow monitor and safety temperature limiter. These switch off the electric air heater if necessary. -
Page 33: Media Connection Of Optional Modules
Assembly Media connection of optional modules 5.7.1 Connection of hot water heater (option) For heating the supply air, a pump hot water air heater (PWW) can be used. Extraction and emptying of the heat exchang- er must be carried out on-site. The heat exchanger has an air-side frost protection thermostat. The additional unit must be flanged to the main unit (see chapter “5.3 Assembly of separated housing”... -
Page 34: Connection Of Heater / Cooler Module (Option)
AL-KO EASYAIR ® Counterflow principle for heat exchanger connection Air inlet Media inlet Air outlet Media outlet IMPORTANT If the unit version without the integrated switch cabinet has been selected, neither the valve nor the valve actuator are supplied. In this case, these are on-site services. - Page 35 Assembly IMPORTANT Counter-hold using a suitable tool (e.g. pipe wrench) during connection of the heat exchang- ers 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 36 AL-KO EASYAIR ® Counterflow principle for heat exchanger connection Air inlet Media inlet Air outlet Media outlet IMPORTANT If the unit version without the integrated switch cabinet has been selected, neither the valve nor the valve actuator are supplied. In this case, these are on-site services.
-
Page 37: Filling And Venting
Assembly 5.7.3 Filling and venting WARNING Danger of burns/scalds during filling. Danger due to contact with leaking media lines and hot surfaces. Perform a visual inspection of the pipelines and connections before filling. „ Wear personal protective equipment. „ WARNING Risk of poisoning when filling with glycol. Work with care. „ Avoid skin and eye contact with glycol, do not swallow glycol and observe the safety data „... -
Page 38: Commissioning
AL-KO EASYAIR ® Commissioning Principles During commissioning, all functions are checked, logged and signed by the operator. The signature also confirms the handover of the Installation and Operating Manual These documents must be attached to the unit documentation. WARNING Accident and injury risk due to human misconduct. Failure to observe the safety instructions, standards, directives and regulations leads to a risk of injury. -
Page 39: Switching The Installation On/Off
„ modules are ready for operation. After system start NOTE Further information on the control of the EASYAIR unit can be found in the AL-KO THERM ® Operating Manual/functional description for "Control ART TECH LEVEL II". WARNING Risk of injuries due to overrun of fans. Only open the inspection doors only when the fans are switched off and stationary. -
Page 40: Damper Adjustings Actuators
AL-KO EASYAIR ® Set the time, date, average and low air performance, and program the weekly schedule. „ Commissioning of the electric heating register (option): „ IMPORTANT Electric heating register (option) Check safety chain: Test the function of the flow monitor and temperature monitor and adjust these if necessary. This is the only way to ensure safe operation of the air handling unit! 6.4.1... -
Page 41: Integrated Control
Integrated control Integrated control NOTE Further information on the control of the EASYAIR units can be found in the AL-KO THERM ® Operating Manual/functional description for "Control ART TECH LEVEL II". 3313737 Subject to changes in line with technical progress. -
Page 42: Hmi Basic Quick Start Guide
AL-KO EASYAIR ® 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. -
Page 43: Hmi Room Quick Start Guide
Integrated control 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 Plant ON in economy mode (reduced temperature setpoint) Time (error code when an alarm is pending) Plant ON in comfort mode Fan steps:... -
Page 44: Servicing And Maintenance
The owner of an RLT installation is obliged to have the system maintained regularly by trained qualified staff. AL-KO recommends that maintenance is carried out in accordance with German VDI 6022 and VDMA 24186. In addition, a hygiene inspection in compliance with VDI 6022 is required every 3 years. -
Page 45: Fuses And Terminal Assignment
Otherwise the warranty will be voided! A spare parts list can be found in the scope of the unit documentation. Customer-Service Phone: +49 8225 39 - 2574 E-mail: service.center@al-ko.com Web: www.al-ko.com Fuses and terminal assignment The fuses implemented are slow-blow circuit breakers. - Page 46 AL-KO EASYAIR ® Electric air heater 4.7.1 Check for scale deposits and corrosion Clean and repair 4.7.2 Inspect on the air side for soiling and Clean and repair damage 4.7.3 Check functionality Repair 4.7.4 Check control and safety equipment for...
- Page 47 Servicing and maintenance Multi-leaf dampers Check for soiling, damage and corrosion Clean and repair Check the mechanical function Repair Check the function of the damper adjusting Repair actuators Fans Inspect the fan for soiling, damage and Clean and repair corrosion Check the impeller for soiling, unbalance Switch on motor briefly and running noises...
-
Page 48: Maintaining And Cleaning Components
AL-KO EASYAIR ® Maintaining and cleaning components All installed components are either freely accessible for maintenance and cleaning or can either be removed or pulled out from the unit after removing the inspection doors/inspection covers. Coarse dirt in the housing can be removed using an industrial vacuum cleaner. -
Page 49: Maintenance
Servicing and maintenance 8.4.1.1 Maintenance Inspect the heat exchangers on the air side for soiling, damage and corrosion. „ Check connections and screw fittings. „ Check the venting valve and filling of the heat exchangers. „ Check antifreeze concentration and top up if necessary. „ Inspect the siphon and top up, if necessary. „... - Page 50 ® The cleanability of the AL-KO THERM heat exchanger registers using the THD multi-jet method was demonstrated „ by the Institute for Air Hygiene Berlin during the hygiene conformity evaluation for the AL-KO air handling units (see figure THD multi-jet method). The use of the THD multi-jet method includes the correction of any bent fins to restore the optimum flow and per- „...
-
Page 51: Rotary Heat Exchanger
Servicing and maintenance 8.4.2 Rotary heat exchanger WARNING Risk of injuries. Before repair and maintenance work, disconnect the EASYAIR from the mains on all „ ® poles and secure to prevent restart. WARNING Risk of cuts During maintenance and cleaning of the heat exchanger there is a risk of cuts! Wear personal protective equipment (cut-proof gloves)! „... -
Page 52: Cleaning
AL-KO EASYAIR ® 8.4.2.2 Cleaning The thermal mass is made of wound aluminium foil. On the basis of the counterflow principle, self-cleaning takes place in most cases, which prevents contamination of the thermal mass. As access for cleaning the thermal mass of the rotary heat exchanger, you can use the inspection doors/inspection „ covers of the upstream and downstream functional units. -
Page 53: Countercurrent Plate Heat Exchanger
Servicing and maintenance 8.4.3 Countercurrent plate heat exchanger WARNING Risk of cuts During maintenance and cleaning of the countercurrent plate heat exchanger there is a risk of cuts! Wear personal protective equipment (cut-proof gloves)! „ 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. -
Page 54: Maintenance
AL-KO EASYAIR ® IMPORTANT The specified values must be adhered to, otherwise the plate heat exchanger may be damaged. NOTE To remove stubborn dirt, cleaning agents can also be used (e.g. all-purpose cleaner, biode- gradable). It must then be rinsed using plenty of fresh water! Do not use aluminium cleaners! These are acidic and attack the surface of the plate heat exchanger. -
Page 55: Maintenance
Servicing and maintenance 8.4.6 Fans WARNING Risk of injuries due to overrun of fans. Switch off the unit on all poles and secure it against being restarted. „ Only open the inspection doors only when the fans are switched off and stationary. „... -
Page 56: Replacing Components
AL-KO EASYAIR ® Replacing components 8.5.1 Replacing filter bags WARNING Risk to health when changing the filters due to dust load and microbial contamination. Switch off the unit on all poles and secure it against being restarted. „ Adhere to the maintenance plan. „ Wear the personal protective equipment (dust mask) when changing the filter. „ Use other protective equipment according to the work carried out. -
Page 57: Help In The Event Of Malfunctions
D-89343 Jettingen-Scheppach E-mail: klima.technik@al-ko.com Germany Web: www.al-ko.com Customer Service Phone: (+49) 82 25 / 39 - 2574 E-mail: service.center@al-ko.com General malfunctions NOTE Further information on "general malfunctions" of the EASYAIR unit can be found in the AL-KO ® THERM Operating Manual/functional description for the "ART TECH LEVEL II Control". 3313737 Subject to changes in line with technical progress. -
Page 58: Shut-Down
AL-KO EASYAIR ® Shut-down 10.1 Decommissioning De-energize 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 installation parts are pressurised. „ Comply with the safety rules! „... -
Page 59: Disposal
Shut-down WARNING Risk of injury when dismantling electrical and thermal components. Only have disassembly work carried out by trained qualified staff. „ Before starting work, disconnect the installation from the central supply line. „ When dismantling, note that certain parts of the installation are pressurised. „ Fix the impellers of the fans. „... -
Page 60: Control Schemes Appendix
AL-KO EASYAIR ® Control schemes appendix 11.1 Control schemes legend Presence detection Cooler valve actuator Fire/smoke alarm Cooler pump Collective fault message Electric fan heater Operating message Differential pressure 2nd filter stage Outdoor air temperature sensor Supply air temperature sensor Outdoor damper adjusting actuators... -
Page 61: Units With Pww Coil
Control schemes appendix 11.2 RO-units with PWW coil 3313737 Subject to changes in line with technical progress. -
Page 62: Units With Pww And Pcw Coils
AL-KO EASYAIR ® 11.3 RO-units with PWW and PCW coils Installation and Operating Manual (translation) -
Page 63: Units With Electric Heating Coil
Control schemes appendix 11.4 RO-units with electric heating coil 3313737 Subject to changes in line with technical progress. -
Page 64: Units With Pww Coil
AL-KO EASYAIR ® 11.5 PL-units with PWW coil Installation and Operating Manual (translation) -
Page 65: Units With Pww And Pcw Coils
Control schemes appendix 11.6 PL-units with PWW and PCW coils 3313737 Subject to changes in line with technical progress. -
Page 66: Units With Electric Heating Coil
AL-KO EASYAIR ® 11.7 PL-units with electric heating coil Installation and Operating Manual (translation) -
Page 67: Spare Parts
Spare parts Spare parts NOTE The valid spare parts list can be found in the corresponding customer documentation which is created on the basis of the order. AL-KO THERM GmbH Phone: (+49) 82 25 / 39 - 0 Hauptstraße 248-250 Fax:... -
Page 68: Certifications
AL-KO EASYAIR ® Certifications The following EC Declaration of Incorporation and EC Declaration of Conformity will be issued per order, according to their validity. If both the order number and the position of the unit are specified, the issued document must be assigned to the respec- tive unit. Installation and Operating Manual (translation) -
Page 69: Ec Declaration Of Incorporation Conforming To 2006/42/Ec
EC DECLARATION OF INCORPORATION DÉCLARATION DE MONTAGE CE Hersteller AL-KO THERM GMBH I Hauptstraße 248-250 I 89343 Jettingen-Scheppach I Germany / Manufacturer / Fabricant: Im Sinne der EG- Maschinenrichtlinie 2006/42/EG, Anhang II, Teil 1, Abschnitt B As defined in EC Machinery Directive 2006/42/EC, Annex II, Part 1, Section B Au sens de la directive Machines CE 2006/42/CE, annexe II, partie 1, section B Unvollständige Maschine... -
Page 70: Ec Declaration Of Conformity Conforming To 2006/42/Ec
EC DECLARATION OF CONFORMITY DÉCLARATION DE CONFORMITÉ CE Hersteller AL-KO THERM GMBH I Hauptstraße 248-250 I 89343 Jettingen-Scheppach I Germany / Manufacturer / Fabricant: Im Sinne der EG- Maschinenrichtlinie 2006/42/EG, Anhang II, Teil 1, Abschnitt A As defined in EC Machinery Directive 2006/42/EC, Annex II, Part 1, Section A... - Page 71 Notes 3313737 Subject to changes in line with technical progress.
- Page 72 AL-KO EASYAIR ® Notes Installation and Operating Manual (translation)
- Page 73 Notes 3313737 Subject to changes in line with technical progress.
- Page 76 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.
Need help?
Do you have a question about the EASYAIR RO-01 and is the answer not in the manual?
Questions and answers