AL-KO AT4F ATEX Series Operating And Assembly Instruction Manual
  1. Manuals
  2. Brands
  3. AL-KO Manuals
  4. Fan
  5. AT4F Series
  6. Operating and assembly instruction manual

AL-KO AT4F ATEX Series Operating And Assembly Instruction Manual

Central ventilation and air handling units
Hide thumbs Also See for AT4F ATEX Series:
Table of Contents

Advertisement

Quick Links

EN
CENTRAL VENTILATION AND AIR HANDLING UNITS
OPERATING AND ASSEMBLY INSTRUCTIONS
FOR CENTRAL VENTILATION UNITS
AT4F ATEX SERIES

Advertisement

Table of Contents
loading

Related Manuals for AL-KO AT4F ATEX Series

Summary of Contents for AL-KO AT4F ATEX Series

  • Page 1 CENTRAL VENTILATION AND AIR HANDLING UNITS OPERATING AND ASSEMBLY INSTRUCTIONS FOR CENTRAL VENTILATION UNITS AT4F ATEX SERIES...
  • Page 2 AL-KO AT4F ATEX Legal AL-KO THERM GMBH Hauptstraße 248 - 250 D-89343 Jettingen-Scheppach Germany Fon: +49 8225 39 - 0 Fax: +49 8225 39 - 2113 E-mail: klima.technik@al-ko.com Revision history Version Description Date 3082439/July 2015 July 2015 3082439/December 2021 December 2021...

  • Page 3: Table Of Contents

    Table of contents Table of contents About this manual ..................7 Explanation of symbols ..........................7 1.1.1 Safety instructions ............................7 Safety signs ..............................8 1.2.1 Abbreviations............................10 Legal notices ............................10 Safety instructions ..................11 Intended use ............................. 11 Foreseeable misuse ..........................
  • Page 4 AL-KO AT4F ATEX 5.4.2 Unit arrangement next to one another ...................... 44 5.4.2.1 Version of floor/roof assembly with unit frame profile ................44 5.4.2.2 Version of floor/roof assembly without unit frame profile ................ 45 Outdoor installation ..........................47 5.5.1 Roof frame - floor assembly version with unit frame profile ..............47 5.5.1.1 Roof frame preassembled on-site ......................47 5.5.1.2 Factory-mounted base frame ........................48 5.5.2...
  • Page 5 7.2 Maintenance instructions in accordance with VDI 6022 and VDMA 24186 ..........96 7.2.1 Initial and repeat inspections must only be performed by category A trained qualified staff accor- ding to VDI 6022 Sheet 1 ......................... 96 7.2.2 Performing of hygiene checks during maintenance by Category B trained maintenance personnel in accordance with VDI 6022 Sheet 1 ..................97 7.2.3 Maintenance schedule ..........................97 Maintaining and cleaning components ....................103 7.3.1 Finned heat exchanger ..........................104 7.3.1.1 Maintenance ............................105 7.3.1.2 Cleaning..............................106 7.3.1.3 Circulating coil system (heat exchanger with pipe circuits) ..............107 7.3.1.4 Steam register ............................
  • Page 6 AL-KO AT4F ATEX Shut-down ....................131 Decommissioning ........................... 131 Dismantling ............................131 Disposal..............................132 Spare parts ....................133 Certifications ..................... 134 11.1 EC Declaration of Incorporation conforming to 2006/42/EC ..............135 11.2 EU Declaration of Conformity in accordance with 2014/34/EC with gas ATEX marking ......136 11.3...

  • Page 7: 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 8: Safety Signs

    AL-KO AT4F ATEX Safety signs Meaning Symbol GENERAL DANGER SIGNS If the required safety instructions are not observed, this can lead to death, severe injuries and severe property damage. IMPORTANT NOTE If this notice is not observed, problems can arise with the unit.
  • Page 9 About this manual Meaning Warning sign Warning of sharp objects If the required safety instructions are not observed, this can lead to death or severe injuries due to sharp objects. Warning of hand injuries If the required safety instructions are not observed, this can lead to death or severe injuries.

  • Page 10: Abbreviations

    AL-KO AT4F ATEX 1.2.1 Abbreviations Abbreviation Meaning ATEX derived from the French abbreviation for ATmosphères EXplosibles. EC technology Electronically commutated DC drives technology (brushless DC motor) Exhaust air Extract air Explosion-protected version frequency converter Outdoor air Personal protective equipment, such as cut-proof gloves, safety goggles, work gloves, ear protection, safety...

  • Page 11: Safety Instructions

    Safety instructions Safety instructions Intended use The AT4F ATEX unit is intended only for processing and conveying respirable air, i.e. for ventilation and extraction of rooms and buildings or for maintaining the necessary room climate. The AT4F ATEX unit is suitable for operation in the temperature range from -20 °C to +40 °C.

  • Page 12: Foreseeable Misuse

    AL-KO AT4F ATEX Foreseeable misuse The AT4F ATEX unit may only be operated within the scope of the technical data specified by AL-KO THERM. Any other use or use beyond that described in section "2.1 Intended use" on page 11 is regarded as being not in accordance with the intended use. The manufacturer cannot be held liable for damage resulting from this. Possible misuse includes: Non-horizontal setup of the AT4F ATEX unit. „ Operation outside the design specifications, observe the data sheets of the unit design. „ Conveying media with impermissibly high or low temperatures. „ Conveying aggressive media or media with a high dust content.
  • Page 13 Safety instructions WARNING Risk of serious injuries or death! Working on/in the AT4FATEX unit can result in serious injury or death. The supplied unit version must be used according to the specified ATEX marking. Please „ refer to the data sheet, the ATEX unit nameplate and the EU Declaration of Conformity for the AT4F ATEX unit. Measures must be taken by the operator to ensure that a sufficient safety distance between „...
  • Page 14 AL-KO AT4F ATEX WARNING Risk of injury and explosion due to unauthorised opening. Ensure that work on/in the AT4F ATEX unit takes place during ATEX zone freedom. „ Keep the inspection doors/inspection covers closed during operation. „ Never open the AT4F ATEX unit during operation. „ Open the inspection doors/inspection covers using the relevant tool if necessary. „ The inspection covers are integrated into the unit potential; after each release of this con- „...

  • Page 15: Atex Warnings

    Safety instructions 2.3.1 ATEX warnings Warning of explosive atmosphere WARNUNG! WARNING! Explosionsgefahr! Danger of explosion! Die Anlage kann explosionsfähige Atmosphäre fördern. The installation can promote an explosive atmosphere. Das RLT-Gerät vor dem Öffnen mit Frischluft spülen um eine explosionsfähige Rinse the AC unit with fresh air before opening to remove an explosive atmos- Atmosphäre zu entfernen.

  • Page 16: Safety Instructions For Operation

    During repair and maintenance work, AT4F ATEX unit is to be disconnected from the mains on all poles and secured „ against restart. General maintenance instructions in the operating and assembly instructions from AL-KO THERM must be observed „ under all circumstances.

  • Page 17: Residual Dangers

    Safety instructions Residual dangers The AT4F ATEX unit may present a danger if it is not operated by trained personnel and/or is used improperly or not according to its intended use. Residual hazards are potential dangers that are not immediately obvious, e.g.: Injuries due to failure to observe the safety instructions, standards, directives or regulations. „...

  • Page 18: Product Description

    AL-KO AT4F ATEX 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 AT4F ATEX unit, the year of manufacture, order number, position and the ATEX marking according to the type plate, see chapter "3.3.1 ATEX type plate" on page 21.

  • Page 19: Functional Description

    The sound emissions from the AT4F ATEX Series are minimised by an ingenious housing design and an optimised „ component layout tailored to the respective, intended use, and through the use of fan and drive units with highly efficient vibration isolation.

  • Page 20: Area For On-Site Connections/Bushings

    AL-KO AT4F ATEX 3.2.1 Area for on-site connections/bushings Exterior view ATTENTION Holes for connections/bushings may only be inserted in the cross-hatched area. Non-compli- ance leads to constructional damage to the panel. Cable glands must be suitable for the required ATEX marking. Translation of original operating instructions...

  • Page 21: Sample At4F Atex Type Plates

    Product description Sample AT4F ATEX 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. Type plate Fig.

  • Page 22: Atex Type Plate Gas

    AL-KO AT4F ATEX Marking at special temperatures Unit Air/ambient temperature during operation Additional marking Maximum: +40 °C Normal None Minimum: -20 °C According to the manufacturer and specified in the Ta or Tamb together with the special area, e.g. Special operating instructions "0 °C ≤ Ta ≤ 60 °C" or the "X" symbol 3.3.1.1 ATEX type plate gas AL-KO THERM GMBH Hauptstraße 248-250...
  • Page 23 Product description Only the ATEX versions are explained, which are also designed as an air handling unit. Ex symbol Marking of explosion protection The unit may be used in potentially explosive atmosphere with the exception of mining. Equipment group (Mining I) The unit category indicates how often and for how long an explosive atmosphere is 2G;...

  • Page 24: Atex Type Plate Dust

    AL-KO AT4F ATEX 3.3.1.2 ATEX type plate dust AL-KO THERM GMBH Hauptstraße 248-250 D-89343 Jettingen-Scheppach Cert. Nr.: EPS 14 ATEX 2 748 X 24132xxxxx Order-Nr.: Pos: Supply Air X Exhaust Air 20xx Typ: AT4F Date: II 2D Ex h IIIA T150°C Db – inside II 3D Ex h IIIA T150°C Dc –...
  • Page 25 Product description Only the ATEX versions are explained, which are also designed as an air handling unit. Ex symbol Marking of explosion protection The unit may be used in potentially explosive atmosphere with the exception of mining. Equipment group (Mining I) The unit category indicates how often and for how long an explosive atmosphere is 2D;...

  • Page 26: Delivery, Transport, Storage

    With the disassembled, partially disassembled or disassemblable AT4F ATEX unit version, an AL-KO straightener is „...

  • Page 27: Transport Under Challenging Conditions

    Delivery, transport, storage ATTENTION Uniform lifting of the unit components must be ensured. „ Transport is only permitted using the attachment points given below. „ Only approved lifting equipment with a sufficient load capacity may be used. „ The lifting equipment must be in perfect condition. „ The lifting gear must be inspected for load-bearing capacity and damage before use. „...

  • Page 28: Crane Transport

    AL-KO AT4F ATEX 4.2.3 Crane transport All AT4F ATEX units have a crane transport option as standard. A distinction is drawn here between transport tube, shack- le, base frame bracket or crane eyelet. The transport openings are sealed with covering caps when the units are delivered.
  • Page 29 Delivery, transport, storage Unit width (overall) in grid Unit width (external) Length (transport tube) Projection of transport tube on each side 688.5 mm 1100 mm 994.5 mm 1400 mm 1300.5 mm 1700 mm 1606.5 mm 2000 mm 200 mm 1912.5 mm 2300 mm 2218.5 mm 2600 mm...

  • Page 30: Crane Transport Using Shackle

    AL-KO AT4F ATEX 4.2.3.2 Crane transport using shackle Max. permissible weight of the individual components Max. width f r unit transport with shackle 49 grid 2500 kg With AT4F ATEX units, the shackle is screwed into the borehole in the base frame.
  • Page 31 Delivery, transport, storage Fig. 12 Transport using a base frame bracket Base frame bracket Spreader beam, chains or slings (on-site) Spacer (on-site) Use lifting equipment that complies with the regulations. „ Secure attachment equipment (ropes, chains, lifting slings) to the base frame brackets protruding from the sides. „...

  • Page 32: Crane Transport Using Crane Eyelets

    AL-KO AT4F ATEX 4.2.3.4 Crane transport using crane eyelets Transporting the unit using crane eyelets is permissible up to a width of 49 grids! Suspension on crane eyelets Max. permissible weight of the individual components Suspension via 4 crane eyelets 1500 kg Suspension via 4 crane eyelets and additional 2 centre eyelets 2500 kg Transport with crane eyelets: The attached crane and centre eyelets must be used for the transport of all components.

  • Page 33: Disposal Of Packaging

    Delivery, transport, storage 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. 3468161 Subject to changes in line with technical progress!

  • Page 34: Assembly

    Integrate all components in the equipotential bonding of the unit. „ All on-site duct and pipe insulations in the ATEX zone are electrostatically conductive or „ electrostatically non-rechargeable. Mounting and installation parts that have not been supplied by AL-KO THERM are not part „ of the EU Declaration of Conformity issued by AL-KO THERM. Ensure that work on/in the AT4F ATEX unit takes place during ATEX zone freedom. „...

  • Page 35: Preparations

    Assembly CAUTION Risk of crushing the limbs and cutting injuries on sharp edges during assembly/installation of the modules. Have installation, commissioning, servicing and maintenance work carried out only by „ qualified staff. Use assembly aids when installing the modules and components. „...
  • Page 36 AL-KO AT4F ATEX Observe the condition of the substrate at the installation site. „ 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 cables at the installation site cannot be either damaged or contam- „...
  • Page 37 Assembly Maintenance panel Fig. 17 Connection of the maintenance panel for integration into the equipotential bonding of the unit When the unit is delivered, the maintenance panels are integrated into the housing potential. ATTENTION This equipotential bonding must be restored every time this connection is disconnected, oth- erwise the installation must not be operated.

  • Page 38: Space Requirements

    AL-KO AT4F ATEX Hand lever Fig. 19 Attach covering caps to hand lever axes The hand lever axes are fitted with corresponding covering caps. ATTENTION Ensure that these remain on the axes at all times. If the covering caps are lost, they must be replaced immediately, otherwise the installation must not be operated.

  • Page 39: Assembly Of Separated Housing

    ATTENTION On delivery, the accessories are in the correspondingly marked unit component. For vibration absorption, AL-KO THERM recommends that the AT4F ATEX units are underlaid with suitable insulation „ strips (not included). Observe the specifications from the insulation strip manufacturer.

  • Page 40: Housing Separation Point Seal For Indoor Installation

    AL-KO AT4F ATEX 5.3.1 Housing separation point seal for indoor installation Fig. 20 Sealing of separation points Sealing tape 8 x 15 mm Unit inside edge Step Action Stick the supplied sealing tapes (1) to the face ends of the unit components flush with the inner edge of the unit (2). 5.3.2 Housing separation point sealing for outdoor installation (weather-proof) Also observe the instructions in chapter "5.5 Outdoor installation" on page 47. With outdoor installation, an additional sealing strip (3 x 15) must be applied to the housing frame. „ Fig. 21 Separation point sealing with outdoor installation Additional sealing tape 3 x 15...

  • Page 41: Inside Unit Connections With Split Housing

    Assembly 5.3.3 Inside unit connections with split housing Fig. 22 Unit connections with split housing Unit connections, horizontal/vertical centre Washer Gusset plates Hexagon nut Hexagon head bolt ATTENTION The unit connections are used exclusively to fix the unit in its final position. They must not be used to draw the individual components together. In the case of units with several housings, the individual housings must be assembled on-site. To do this, proceed as follows: Step Action...

  • Page 42: Unit Connection With Unit Arrangement One Above The Other And Next To One Another

    AL-KO AT4F ATEX Unit connection with unit arrangement one above the other and next to one another 5.4.1 Unit arrangement one above the other ATTENTION The unit base frame must be additionally sealed all round with a microbially inert sealing ma- terial in the area of the mixing chambers (air-side connection) between upper and lower unit.
  • Page 43 Assembly Unit arrangement one above the other with length offset Fig. 24 Unit arrangement one above the other with length offset Base frame Floor (top unit) Microbially inert sealing material (with weatherproof units) Panel Roof (lower unit) Step Action With weatherproof units, install the microbially inert sealing material (2) around the circumference before installing the top unit (4).

  • Page 44: Unit Arrangement Next To One Another

    AL-KO AT4F ATEX 5.4.2 Unit arrangement next to one another 5.4.2.1 Version of floor/roof assembly with unit frame profile Unit arrangement next to one another without mixing chamber Fig. 25 Unit arrangement next to one another without mixing chamber Spacer rail Panel (side) Panel (roof) Countersunk drilling screw...

  • Page 45: Version Of Floor/Roof Assembly Without Unit Frame Profile

    Assembly Step Action Loosen the bolts on the factory-fitted/loose spacer rail (1). Fit sealing strips (3) to the upper and lower inner frame edges. Set down the unit components next to it using a forklift or crane. Pre-drill the spacer rail and lower it. Fix the spacer rail (1) using the countersunk drilling screws. This allows you to integrate these into the unit potential. After installing the components, check that they are integrated into the unit potential and document this.
  • Page 46 AL-KO AT4F ATEX Step Action Loosen the bolts on the factory-fitted/loose spacer rail (1). Fit sealing strips (3) to the upper and lower inner frame edges. Set down the unit components next to it using a forklift or crane. Pre-drill the spacer rail and lower it. Fix the spacer rail (1) using countersunk drilling screws. This allows you to integrate these into the unit potential.

  • Page 47: Outdoor Installation

    Assembly Outdoor installation 5.5.1 Roof frame - floor assembly version with unit frame profile 5.5.1.1 Roof frame preassembled on-site Drilling screw with EPDM washer Bohrschraube mit EPDM-Scheibe Drip edge Tropfkante Cover plate Abdeckblech bauseitige Dämmung On-site insulation Clamp*) Klemmstück *) Base frame Grundrahmen Dachbahn vor Montage der Adhere the roof membrane to the screw-on bracket Sealing compound Abdeckbleche an den Anschraub- Dichtmasse...

  • Page 48: Factory-Mounted Base Frame

    AL-KO AT4F ATEX 5.5.1.2 Factory-mounted base frame Drilling screw with Bohrschraube EPDM washer mit EPDM-Scheibe Coupling piece (only Kupplungsstück Drilling screw with at separation points) (nur an Trenn- Bohrschraube mit stellen) EPDM washer EPDM-Scheibe Base frame/ Grundrahmen/ Drip edge Tropfkante...

  • Page 49: Roof Frame - Floor Assembly Version Without Unit Frame Profile

    Assembly 5.5.2 Roof frame - floor assembly version without unit frame profile 5.5.2.1 Roof frame preassembled on-site Fig. 32 Roof frame preassembled on-site Foundation Sheet metal apron (on-site installation) Roof frame On-site insulation Sealing compound Z-bracket (on-site installation) Base frame Drilling screw with EPDM washer Step Action Place the roof frame (2) onto the foundation (1). Screw the roof frame (2) to the foundation (1) and tie it into the building potential.

  • Page 50: Factory-Mounted Base Frame

    AL-KO AT4F ATEX 5.5.2.2 Factory-mounted base frame Fig. 33 Factory-mounted base frame, right with units arrangement on top of one another Base frame Drilling screw with EPDM washer On-site insulation Drip edge Roof cladding Step Action With separated modules, position the unit modules as close to each other as possible.

  • Page 51: Sealing Of The Unit Separation Points With Solvent Welding Agent For Weatherproof Units

    Liquid and vapour of the solvent welding agent are highly flammable. Keep ignition sources and naked flame away from the solvent welding agent. „ Observe the safety instructions on the containers. For further information, you can re- „ quest the current EC safety data sheets from AL-KO THERM. Ensure that work on/in the AT4F ATEX unit takes place during ATEX zone freedom. „ Ensure that this sealing procedure may be implemented on-site. „ WARNING Danger to health from inhalation of toxic fumes of the solvent welding agent.
  • Page 52 Observe the safety instructions on the containers. For further information, you can re- „ quest the current EC safety data sheets from AL-KO THERM. ATTENTION Welding of the roof membrane must be started immediately after the unit installation to avoid damage.
  • Page 53 Observe the safety instructions on the containers. For further information, you can re- „ quest the current EC safety data sheets from AL-KO THERM. ATTENTION Welding of the foil strips must be started immediately after the unit installation to avoid damage.
  • Page 54 AL-KO AT4F ATEX NOTE For outside temperatures > 10 °C, the solvent welding agent or hot air dryer can be used. At lower outside temperatures, welding with the hot air dryer is to be used to seal the unit separation points. Check the housing seal carefully. Weatherproof units with height offset Fig. 37 Weatherproof units with height offset...
  • Page 55 Assembly Weatherproof unit with dual-function unit stacked on top This arrangement can also occur in units with heat recovery diagonally with plate heat exchanger (WRD). Fig. 39 Weatherproof units with dual-function units, stacked one above the other Component, upper unit Microbially inert sealing material Component, lower unit Foil bracket...
  • Page 56 AL-KO AT4F ATEX Sealing the drip edge corner In the case of weatherproof units, the roof membrane is factory-sealed only up to the countersunk holes at the drip „ edge corner. With the drip edge corner, the roof membrane is welded on-site (see chapter "5.5.2.3 Sealing of the unit separation „...

  • Page 57: Sealing Of The Unit Separation Points With Hot Air Welding For Weatherproof Units

    Assembly 5.5.2.4 Sealing of the unit separation points with hot air welding for weatherproof units WARNING Risk of burns and explosion from hot air and hot foil Due to the high air temperature, contact with hot air and hot, molten foil may result in an explosionr or cause burns to the limbs, especially the hands.

  • Page 58: Units With Split Plate Heat Exchanger (Option)

    The assembly instructions can be requested from customer services if necessary. Assembly may only be performed by trained qualified staff. „ With the explosion-protected unit version, an AL-KO supervisor is required for the con- „ struction of the divided, dismountable and dismounted plate heat exchanger. The latter checks the work and documents it. These documents are stored with us at the factory in the order documentation.

  • Page 59: Heat Exchanger Connection

    If inadmissible components are used for the ATEX version, the unit can be electrostatically charged. This can lead to an explosion. The heat exchanger used must be suitable for the required ATEX marking. „ The valves and actuators optionally supplied by AL-KO THERM may only be installed out- „ side the ATEX zone. Otherwise, valves and actuators approved for the ATEX zone must be used.
  • Page 60 AL-KO AT4F ATEX Valves and actuators must be installed professionally. Please note here whether a version with a 2-way or 3-way „ valve is to be set up. For electrical connection of the actuator, see the circuit diagram. „ Requirements for water...

  • Page 61: Connection Of Heater/Pumps-Cold Water Air Cooler (Option)

    If inadmissible components are used for the ATEX version, the unit can be electrostatically charged. This can lead to an explosion. The heat exchanger used must be suitable for the required ATEX marking. „ The valves and actuators optionally supplied by AL-KO THERM may only be installed out- „ side the ATEX zone. Otherwise, valves and actuators approved for the ATEX zone must be used.
  • Page 62 AL-KO AT4F ATEX 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.
  • Page 63 Assembly Counterflow principle for heat exchanger connection Fig. 47 Counterflow principle for heat exchanger connection Air inlet Media inlet Air outlet Media outlet 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. Ensure that the piping and the heat exchanger are integrated into the unit potential. ATTENTION If the unit version control has been selected, neither the valve nor the valve actuator are sup- plied.

  • Page 64: Connection Of Pumps/Cold Water/Air Cooler (Option)

    If inadmissible components are used for the ATEX version, the unit can be electrostatically charged. This can lead to an explosion. The heat exchanger used must be suitable for the required ATEX marking. „ The valves and actuators optionally supplied by AL-KO THERM may only be installed out- „ side the ATEX zone. Otherwise, valves and actuators approved for the ATEX zone must be used.
  • Page 65 Assembly 2-way valve and 3-way valve versions 2-way valve 3-way valve Fig. 48 2-way valve and 3-way valve connection versions PCW cooler Valve Valve actuator Recirculation pump (on-site) Counterflow principle for heat exchanger connection Fig. 49 Counterflow principle for heat exchanger connection Air inlet Media inlet Air outlet Media outlet Step Action Connect the heat exchanger using the counterflow principle (water flow direction opposite the air flow direction in the...

  • Page 66: Steam Register

    The heat exchanger used must be suitable for the required ATEX marking (note tempera- „ ture class, correction factor). The valves and actuators optionally supplied by AL-KO THERM may only be installed out- „ side the ATEX zone. Otherwise, valves and actuators approved for the ATEX zone must be used.
  • Page 67 Assembly WARNING Danger of burns/scalds during filling of the heat exchanger with steam. 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. „ Only use steam registers with pre-welding flanges for the corresponding pressure level. „ Comply with the Pressure Equipment Directive and the corresponding standards. „ The steam register is pressurised. „ WARNING Danger of bursts/explosions during filling of the heat exchanger with steam The steam register is pressurised.

  • Page 68: Circulating Coil System Ccs (Recuperative Energy Recovery)

    AL-KO AT4F ATEX 5.8.5 Circulating coil system CCS (recuperative energy recovery) Fig. 50 Schematic diagram of a circulating coil system With heat exchangers in a circulating coil system, the pipe circuits themselves cannot be emptied. For this reason, the circulating coil system is only to be operated with a frost-proof water/glycol mixture and tested for leak-tightness after assembly.

  • Page 69: Direct Evaporator/Condenser

    Assembly 5.8.6 Direct evaporator/condenser Additional information for the use of direct evaporators: ATTENTION The direct evaporator must be installed by an authorised refrigeration company. Only permitted with thermostatic expansion valve in the ATEX zone. Only safety refrigerants according to DIN 8960 are permitted to be used as refrigerants. Observe the operating instructions for cooling systems and heat pumps. WARNING Risk of explosion due to electrostatic discharge. The direct evaporator must be suitable for the required ATEX marking.

  • Page 70: Mechanical Connection

    AL-KO AT4F ATEX Mechanical connection WARNING Risk of crushing When installing the duct connections as well as fittings and other intake and exhaust options, the damper must be closed. 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.

  • Page 71: Intake And Exhaust Hood (Option)

    Assembly 5.9.2 Intake and exhaust hood (option) For a weatherproof version, an optional intake and exhaust hood can be ordered. „ Here, it must be ensured on-site that no ATEX zone or no higher ATEX zone can arise than the ATEX zone defined on „ the AT4F ATEX unit for outside use. For units without a factory-delivered intake hood, a drain tray must be provided on site at the unit inlet and in the duct. „...
  • Page 72 AL-KO AT4F ATEX Ball siphon (overpressure) The ball siphon is a self-filling siphon for draining coolers and other wet areas with vacuum relative to the environment. An inserted float ball prevents the suction of air in the dry operating condition, so that the first condensate produced can fill the siphon. The ball continues to act as a check valve in the event of pressure shocks in the system and prevents Bodenwanne mit Bodenablauf empty suction. Base tray with floor drain Check valve with Floor drain Bodenablauf Ø 40 Rückschlagventil ball mit Kugel Bogen Ø 40 Tauchrohr Immersion Ø 40 tube Fig. 53 Connection of the condensate drain with ball siphon with overpressure Dimensioning of snake siphon (overpressure or vacuum) and ball siphon (overpressure) Below 600 Pa observe min. dimensions H1 - H3.

  • Page 73: Filling And Venting

    Assembly NOTE The installation height of the siphon must be taken into account when installing the AT4F ATEX unit. Observe minimum dimensions H1-H3. 5.9.4 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.

  • Page 74: Electrical Connection

    AL-KO AT4F ATEX 5.10 Electrical connection DANGER Hazard due to electric current and explosion hazard due to electric current. Electric shocks or an explosion can occur in the event of incorrect connection to the power supply or incorrect installation of electrical components.

  • Page 75: Electric Motor

    Assembly 5.10.1 Electric motor WARNING Risk of explosion due to electric ignition sparks or electrostatic charging. If inadmissible components are used for the ATEX marking and ATEX zone, the unit may carry an electrostatic charge. Electrical ignition sparks can lead to an explosion. The motor used must be suitable for the required ATEX marking. „ Integrate the motor into the unit potential.

  • Page 76: Connection Of Three-Phase Motors

    AL-KO AT4F ATEX 5.10.1.1 Connection of three-phase motors ATTENTION Do not switch the upper speed directly. Observe the wiring diagram in the motor terminal box for motors with PTC thermistor or thermal contact. Circuit for one speed Schaltung der Wicklungsstränge...
  • Page 77 Assembly Circuits for two speeds in the ratio 1 : 2 (winding in the Dahlander pole changing) Version e.g. for 1500/3000 rpm or 4-/2-pole or 750/1500 rpm or 8-/4-pole In motors with Dahlander pole changing, the six winding ends 1U, 1V, 1W and 2U, 2V, 2W are connected to the six ter- minals of the clamping board of a normal motor terminal box.
  • Page 78 AL-KO AT4F ATEX Circuits for three speeds (two separate windings, one in Dahlander pole changing, nine terminals are required here). Version for ventilator drive units 750/1000/1500 rpm or 8-/6-/4-pole; 750/1500 rpm in Dahlander pole changing. 750 rpm 1000 rpm 1500 rpm 750 U/min 1000 U/min 1500 U/min Winding design Wicklungsausführung...

  • Page 79: Circuit With Frequency Converter - Wiring Examples

    Assembly 5.10.1.2 Circuit with frequency converter - wiring examples Wiring example: FC wiring (FC 102) with external repair switch FU - Verdrahtung / Ex mit Sinusfilter / FC wiring / ATEX version with sine filter / no ATEX marking outside ohne ATEX Kennzeichnung außen Frequenz-Umrichter Frequency converter SIL EX Remove the wire bridge Bei Verwendung des when using the PTC Kaltleiters Drahtbrücke entfernen. thermistor.

  • Page 80: Connection Of Ec Fans

    AL-KO AT4F ATEX The following must be noted when operating with frequency converter: The fan motor combination must be suitable for operation via frequency converters. Depending on the motor, frequency converter or fan manufacturer, a sine filter must be taken into account. The frequency converter and the sine filter must be mounted outside the ATEX zone. These components must not be mounted on the ATEX air handling unit.

  • Page 81: Connection Of Electric Air Heater

    Assembly 5.10.2 Connection of electric air heater WARNING Risk of injuries and explosion due to incorrect or faulty connection. Only have the electrical connection carried out by an approved electrician. „ Only have assembly, servicing and maintenance carried out by qualified staff. „ Wear personal protective equipment. „ The electric air heater used must be suitable for the required ATEX marking. „...

  • Page 82: Control (Switch Cabinet)

    AL-KO AT4F ATEX 5.10.3 Control (switch cabinet) The electrical control (switch cabinet) of the air handling units is available as an option for operation outside the „ ATEX zones. In this version, the switch cabinet must be installed outside the ATEX zone. For assembly in an ATEX zone, the switch cabinet must be suitable for the applicable ATEX zone. „ Translation of original operating instructions...

  • Page 83: Commissioning

    „ TRGS 727 is required for work on the AT4F ATEX unit. The maintenance instructions in the operating and assembly instructions for central AC „ units in the AT4F ATEX Series from AL-KO THERM must be observed under all circum- stances. Ensure that work on/in the AT4F ATEX unit takes place during ATEX zone freedom. „ Have installation, commissioning, servicing and maintenance work carried out only by „...

  • Page 84: Before System Start

    AL-KO AT4F ATEX Before commissioning, always ensure the following: that the AT4F ATEX unit has been installed as described in these operating and assembly instructions (see chapter „ "5 Assembly" on page 34). that all the filter elements are correctly installed. Check the tight fit of all installed filters, in particular the fine dust „ filters. that the duct system and the water and drain pipe are properly connected to the unit.
  • Page 85 Observe the table with the respective vibration values (see chapter "3.2 Technical data" on page  19). Contact our customer service if necessary. Phone: +49 8225 39 - 2574 E-mail: service.center@al-ko.com Web: www.al-ko.com Carry out a visual inspection for cracks in the impeller.
  • Page 86 Mechanical function of the multi-leaf dampers. „ Tight fit of all installed filters. „ NOTE AL-KO THERM generally recommends the replacement of all installed filters after a short period of operation of the AC unit to remove any dirt that may have entered the filters during the installation phase and after commissioning (see chapter "7.4 Replacing components" on page 126). Use only original spare parts.

  • Page 87: Commissioning Of The Electric Heating Coil

    Operation with impermissibly high vibration values can result in impeller breakage, which „ can lead to serious property damage and personal injuries. AL-KO THERM recommends continuous monitoring using a vibration sensor (available as an option). Only operate the fan when the fan is integrated into the unit potential.

  • Page 88: Commissioning Of Fans With Belt Drive

    AL-KO AT4F ATEX ATTENTION Danger of motor overloading with an incorrect direction of rotation. „ Power consumption must not exceed the specified nominal current. „ Maximum motor speed must not be exceeded. „ Maximum fan speed must not be exceeded. „ Above a rated motor output of 3 kW: Star-delta starting. „ Observe the operating instructions of the manufacturer.

  • Page 89: Commissioning Of Fan Free-Wheel With Direct Drive

    Commissioning 6.2.2.2 Commissioning of fan free-wheel with direct drive Remove transport locks from the fan base frame. „ The unit must be inspected for transport damage before commissioning. „ The impeller must not touch the fan inlet nozzle. Check the impeller moves freely by turning it by hand. „ Check the fan rotation direction (see arrow on fan housing) by briefly switching on the motor (caution with open door). „ If necessary, reverse the motor polarity and correct the rotation direction. „...

  • Page 90: Commissioning Of The Built-In Fan (Motor Outside The Air Flow)

    AL-KO AT4F ATEX ATTENTION Risk of ignition due to impermissible gap dimensions between stationary and rotating com- ponents. Ensure that the gap does not fall below the valid gap dimension at any point. „ ATTENTION Observe the manufacturer's documentation. 6.2.2.3 Commissioning of the built-in fan (motor outside the air flow) Remove transport locks from the fan base frame.
  • Page 91 Commissioning Fig. 62 Example for gap dimension (depending on the manufacturer) Impeller Inlet nozzle Gap dimension gauge Nominal width (nozzle) Inner diameter (cover disc nozzle of the impeller) Outer diameter (inlet nozzle) With test gauge for gap width to be ensured ü Coverage Step Action Check the gap dimension between the impeller and inlet nozzle according to the fan manufacturer documentation. En- sure that the gap dimension is not underrun during any phase of the rotary movement (turning by hand). For the valid measured values, see the documentation of the fan manufacturer.

  • Page 92: Heat Exchanger Commissioning

    AL-KO AT4F ATEX 6.2.3 Heat exchanger commissioning WARNING Risk of explosion due to impermissible components and electrostatic charging. If inadmissible components are used for the ATEX version, the unit can be electrostatically charged and result in an explosion. Check that the heat exchangers are integrated into the unit potential.

  • Page 93: Switching The Installation On/Off

    After system start NOTE Further information on the control of AT4F ATEX unit can be found in the AL-KO THERM op- erating manual for "Control ART TECH LEVEL II". WARNING Risk of injuries due to run-on of fans.

  • Page 94: Servicing And Maintenance

    AL-KO AT4F ATEX Servicing and maintenance Safety instructions for servicing and maintenance WARNING Risk of injury. Disconnect the AT4F ATEX unit from the mains power supply on all poles and secure it to „ prevent restart before starting any repair or maintenance work.
  • Page 95 NOTE The owner of an RLT installation is obliged to have the system maintained regularly by trained qualified staff. AL-KO THERM 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. Upon conclusion of a maintenance contract, AL-KO THERM undertakes these tasks.

  • Page 96: Qualifications Of Personnel

    AL-KO AT4F ATEX 7.1.1 Qualifications of personnel Constant adherence to the hygiene requirements and execution of the operation and maintenance measures required for this in AC installations necessitate corresponding personnel qualifications. Demanding operating activities as part of maintenance as well as inspections and repairs must only be performed by trained qualified staff. Due to the ATEX versions of the units, special expertise is required. Appropriate training is required for this purpose.

  • Page 97: Performing Of Hygiene Checks During Maintenance By Category B Trained Maintenance Personnel In Accordance With Vdi 6022 Sheet 1

    Servicing and maintenance As the result of the hygiene inspection, documentation of the hygiene status of the inspected AC installation and written notification of the inspection result to the owner, including a list of necessary measures, must be drawn up. The date of any necessary follow-up inspection must be defined depending on the urgency of the measures to be performed. Critical findings exist in the following cases: On occurrence of higher microbial counts downline of air conditioning installations than upline „ On visible mould infestation or other microbial coatings „...
  • Page 98 AL-KO AT4F ATEX Inspections to be performed at monthly intervals Activity/unit components Measure / remark Air filter Check for impermissible soiling, damage Air filters must have a filtration effi- (leaks) and odours ciency appropriate to the filter class over their entire period of use. If there is noticeable soiling or leakage, the filter must be replaced. Replace the air...
  • Page 99 Servicing and maintenance Inspections to be performed at monthly intervals Activity/unit components Measure / remark 6.1.2 Check wet cooler, condensate drip tray Repair. After installation, integrate into and droplet eliminator for soiling, corro- the unit potential, check the equipoten- sion and function tial bonding and document it.
  • Page 100 AL-KO AT4F ATEX Inspections to be performed at monthly intervals Activity/unit components Measure / remark Droplet eliminator 6.4.9 Inspect for soiling damage and coating Function-preserving cleaning of all formation surfaces, including trays; dismantle the droplet eliminator, if necessary. After installation, integrate into the unit po- tential, check the equipotential bonding and document it.
  • Page 101 Servicing and maintenance Inspections to be performed at monthly intervals Activity/unit components Measure / remark 7.2.7 Inspect the droplet eliminator for coating Function-preserving cleaning in the formation event of visible encrustation, dismantle droplet eliminator if necessary. After installation, integrate into the unit po- tential, check the equipotential bonding and document it.
  • Page 102 AL-KO AT4F ATEX Inspections to be performed at monthly intervals Activity/unit components Measure / remark 11.2 Function-preserving cleaning of the wa- ter drain and parts of the fan that come into contact with air 11.3 Vibration check! 11.4 Check bearings for noise 11.5...

  • Page 103: Maintaining And Cleaning Components

    Servicing and maintenance Maintaining and cleaning components All installed components are either freely accessible for cleaning or can be pulled out of the AT4F ATEX unit or removed after opening the inspection doors/removing the inspection cover. Coarse dirt in the housing can be removed using an industrial vacuum cleaner. „...

  • Page 104: Finned Heat Exchanger

    AL-KO AT4F ATEX Hygiene checks The aim of the hygiene checks to be performed regularly is to determine and eliminate hygiene deficiencies on the air conditioning systems at an early stage through frequent visual inspections or random microbiological self-checks. The regular hygiene checks include the following measures: Visual inspection of the relevant unit area for hygiene deficiencies such as e.g. microbial growth or soiling, rust for- „ mation, calcium deposits and damage. If soiled components are detected during the hygiene checks, these must be cleaned immediately.

  • Page 105: Maintenance

    Servicing and maintenance ATTENTION The use of high-pressure water cleaners with conventional single-jet nozzles is not permitted due to the risk of damage. Observe the manufacturer's documentation. The heat exchanger is essentially maintenance-free. Regular cleaning of the heat exchangers is necessary in order to ensure their proper function. Fins of the finned heat exchanger Dents in the fins of the heat exchanger have no influence on the function of the system as a whole – as long as the pipes of the fin unit are not damaged – and do not constitute grounds for complaints. The fins can be "combed out" on-site. If necessary, the corresponding tool can be obtained from the manufacturer. NOTE For the following heat exchanger designs, additional points are to be observed: Chapter "7.3.1.3 Circulating coil system (heat exchanger with pipe circuits)" on page 107.

  • Page 106: Cleaning

    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 107: Circulating Coil System (Heat Exchanger With Pipe Circuits)

    Servicing and maintenance 7.3.1.3 Circulating coil system (heat exchanger with pipe circuits) With heat exchangers in a circulating coil system, the pipe circuits themselves cannot be emptied. For this reason, the circulating coil system is only to be operated with a frost-proof water/glycol mixture and tested for leak-tightness after assembly.

  • Page 108: Evaporator/Condenser

    AL-KO AT4F ATEX WARNING Risk of slipping! Leaked condensate Immediately take up the spill quantity and dispose of it properly. „ CAUTION Risk of burns as a result of contact with hot surfaces and media (plate heat exchanger, heat exchanger and electric heating coil) Wait until the hot surfaces have cooled down.

  • Page 109: Plate Heat Exchanger

    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 coil) Wait until the hot surfaces have cooled down. „ Wear personal protective equipment. „ ATTENTION Observe the manufacturer's documentation.

  • Page 110: Maintenance

    AL-KO AT4F ATEX 7.3.2.1 Maintenance Check plates for soiling. „ Remove dust and fibrous materials or similar, clean condensate drain. „ Check water drain and siphon of the drain tray and top up if necessary. „ Check the damper connection, drive and control functions. „ The integration of the plate heat exchanger and the droplet eliminator into the equipotential bonding must be „...

  • Page 111: Grease Trap Filter

    Servicing and maintenance 7.3.3 Grease trap filter The grease trap filter must be cleaned with hot water (> 80 °C) or steam if soiled by grease or dust or after reaching the recommended end pressure difference (type plate). Servicing and assembly are generally carried out on the dusty air side. WARNING Risk of explosion Due to electrostatic charging of the grease trap filter, there is a risk of explosion. Integrate the grease trap filter back into the unit potential after each unfastening of the „ equipotential bonding. ATTENTION Observe the manufacturer's documentation. Cleaning the filter elements up to unit size 16 x 16 Step Action Pull the filter element with the mounting frame including the collecting troughs out of the AT4F ATEX unit.

  • Page 112: Maintenance

    AL-KO AT4F ATEX 7.3.4.1 Maintenance Check the damper for integration into the equipotential bonding. If necessary, the integration is to be renewed; al- „ ternatively the damper is to be replaced. Inspect the multi-leaf dampers for soiling, damage and corrosion.

  • Page 113: Maintenance

    Servicing and maintenance Fig. 66 Multiple silencer baffles with equipotential bonding Fig. 67 Equipotential bonding on the sound attenuator splitters 7.3.5.1 Maintenance Check the sound absorbers for soiling and damage at regular intervals. „ 7.3.5.2 Cleaning Sound attenuator splitters (optional) can be taken out/removed from the unit for cleaning. „...

  • Page 114: Droplet Eliminator

    AL-KO AT4F ATEX 7.3.6 Droplet eliminator WARNING Risk of cuts There is a risk of cutting injuries during cleaning and maintenance of the droplet eliminator. Wear personal protective equipment (cut-proof gloves). „ WARNING Risk of explosion Due to electrostatic charging of the droplet eliminator, there is a risk of explosion.

  • Page 115: Maintenance

    Servicing and maintenance Fig. 69 Loosen and reconnect the equipotential bonding connection on the droplet eliminator 7.3.6.1 Maintenance Inspect the droplet eliminator for soiling, damage and corrosion. „ Inspect the water drain and odour trap. „ Check water drain and siphon of the drain tray and top up if necessary. „...

  • Page 116: Electric Motor

    AL-KO AT4F ATEX 7.3.7 Electric motor DANGER Hazard due to electric current and explosion hazard due to electric current. Electric shocks can occur in the event of incorrect connection to the power supply or incor- rect installation of electrical components. Risk of explosion from electric ignition sparks and electric charge.

  • Page 117: Maintenance

    Servicing and maintenance 7.3.7.1 Maintenance The electric motors are usually equipped with permanently lubricated motor bearings. In the case of electric motors with relubricatable motor bearings, these must be regularly checked and, if necessary, relubricated. Use only lubricants specified by the motor manufacturer. Check motor for dirt, damage and corrosion. „...

  • Page 118: Maintenance

    AL-KO AT4F ATEX WARNING Risk of injury caused by impeller breakage Operation with impermissibly high vibration values, in particular with fans without spiral housing, can result in impeller breakage, which can lead to serious property damage and personal injuries. Perform a vibration measurement of the fan impeller regularly and document the checks.

  • Page 119: Removing The Fan For Maintenance Purposes

    Servicing and maintenance 7.3.8.3 Removing the fan for maintenance purposes Fig. 70 Removal opening for fan, in this case, fan with belt drive The fan unit can be removed laterally for maintenance purposes: Unfasten the fastening screws of the fan unit. „...

  • Page 120: Fan With Belt Drive

    AL-KO AT4F ATEX 7.3.8.4 Fan with belt drive Inspect V-belt drive for soiling, damage and wear. „ Check V-belt tension and retighten if necessary. „ Check alignment of the V-belt pulleys. „ Clean the V-belt drive at regular intervals. „...

  • Page 121: Built-In Fan (Motor Outside The Air Flow)

    Servicing and maintenance 7.3.8.6 Built-in fan (motor outside the air flow) Check gap dimension For built-in fans, the gap dimension between the inlet nozzle and impeller must be checked all the way around. Depending on the fan manufacturer and fan design, there are fixed values that must be observed. These must be checked before commissioning and documented accordingly. The diagrams of the gap dimensions to be measured differ depending on the fan manufacturer. The image below on the gap measurement is an example only. Depending on the fan manufacturer, the measured values are to be sent to the fan manufacturer for operational approval.

  • Page 122: Fan Free-Wheel With Direct Drive

    Do not operate fans in the range of the resonance speed (and its multiples) of the fan „ motor system. ATTENTION Observe the manufacturer's documentation. NOTE AL-KO recommends continuous monitoring using a vibration sensor (available as an option). Table of vibration values Installation Machine group Good Usable...
  • Page 123 Servicing and maintenance Operating point setting The operating point can be approached accurately with an adjustable fan speed. „ When controlling the speed, make sure that the maximum fan speed and the permissible motor currents are not „ exceeded. The nozzle gap must not be adjusted. „...

  • Page 124: Check Gap Dimension And Overlap For Fans

    AL-KO AT4F ATEX 7.3.8.8 Check gap dimension and overlap for fans Fig. 76 Example of gap dimensions and overlap (depending on manufacturer) Inlet nozzle Measuring nipple of the volumetric flow measuring device Gap dimension between impeller edge and measuring Impeller nipple of the volume flow measuring device Gap dimension between inlet nozzle and impeller Step Action Before commissioning, check the gap dimension between the impeller edge and the measuring nipple of the volumetric flow measuring device and between the impeller and inlet nozzle in accordance with the fan manufacturer's documenta- tion.

  • Page 125: Tightening Torques Of The Screw Connections On The Fan Part

    Servicing and maintenance 7.3.8.9 Tightening torques of the screw connections on the fan part ATTENTION After approx. 1 hour, check the screw connections on the fan base frame and, if necessary, tighten evenly with the screw tightening torques specified in the table below using a torque wrench. Thread dimension Screw thread tightening torque (Nm) 7.3.8.10 Maintenance or inspection of the taper-lock clamping bushes Clean and degrease all bare surfaces such as the hole and the conical surface of the taper-lock clamping bush as well „...

  • Page 126: Electric Air Heater

    AL-KO AT4F ATEX 7.3.10 Electric air heater WARNING Risk of explosion Due to electrostatic charging of the electric air heater, there is a risk of explosion. Integrate the electric air heater back into the unit potential after each unfastening of the „...

  • Page 127: Replacing Bag Filters

    Use of other parts will void the EU Declaration of Conformity and the warranty. A spare parts list can be found as part of the unit documentation. Customer Service Phone: +49 8225 39 - 2574 E-mail: service.center@al-ko.com Web: www.al-ko.com The filter elements must be approved according to ISO 16890.
  • Page 128 AL-KO AT4F ATEX Replacing the filter bags when fastening the clamps: NOTE When inserting the filter bags, make sure that they are installed centrally and firmly clamped to the seal by all four filter clamps. Step Action Disconnect the clamps in the filter frame by unhooking. Pull the filter bags out individually. Check the filter gaskets, inspect and replace any damaged gaskets. Check the new filter bags for damage, compare the ATEX marking of the filter with the ATEX marking on the unit. Insert the filter into the filter frame. Close the clamps in the filter frame by hooking and check that they are secure. Check that the installed filter is integrated in the unit potential. Fig. 77 Filter mounting frame, left filter clamp Fig. 78 Filter mounting frame, right filter clamp Fig. 79 Filter mounting frame with filter clamps Translation of original operating instructions...

  • Page 129: Replace The Particulate Air Filter

    Servicing and assembly are generally carried out on the dusty air side. Replacing the filter elements: Step Action Unfasten the screws on the filter frame and remove the filter element. Clean the sealing surfaces of the filter wall/filter frame. Check the new element for damage, compare the ATEX marking of the filter with the ATEX marking on the unit. Insert filter element and secure. Check that the installed filter is integrated in the unit potential. ATTENTION AL-KO THERM does not assume any warranty for damage due to improper handling of the particulate air filter during assembly and disassembly. 3468161 Subject to changes in line with technical progress!

  • Page 130: Emergencies And Malfunctions

    Use other protective equipment according to the work carried out. „ NOTE Further information on "General malfunctions" of AT4F ATEX unit can be found in the AL-KO THERM operating manual for "Control ART TECH LEVEL II". Contact for malfunctions For all questions that you have in connection with our products, please contact the manufacturer of your ventilation...

  • Page 131: Shut-Down

    Shut-down Shut-down ATEX zone freedom must be guaranteed on-site for safe decommissioning or disassembly. 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 installation parts are pressurised. „ Comply with the safety rules! „ ATTENTION In winter, there is a general freezing hazard for all components. If necessary, take suitable measures such as fully draining the liquid media. At temperatures below freezing, the heat exchanger must be either drained and blown out with compressed air, or filled with a com- mercially available antifreeze with corrosion inhibiting additive due to the risk of freezing and...

  • Page 132: Disposal

    AL-KO AT4F ATEX WARNING Risk of injury and risk of explosion 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. „ Perform all work only with ATEX zone freedom. „ Use suitable tools. „ When dismantling, note that certain parts of the installation are pressurised.

  • Page 133: Spare Parts

    If third-party spare parts are installed/attached or changes are made without consultation with the manufacturer, a new conformity assessment must be carried out. The ATEX Declaration of Conformity was issued exclusively in accordance with the scope of delivery of AL-KO THERM. In this context, the ATEX Declaration of Conformity issued by AL-KO THERM loses its validity due to modifications.

  • Page 134: Certifications

    AL-KO AT4F ATEX Certifications The following EC Declaration of Incorporation and EU Declaration of Conformity will be issued per order, according to their validity. The ATEX markings specified here are only by way of example. The documents always receive the valid ATEX marking for each order. If both the order number and the position of the unit are specified, the issued document must be assigned to the respective unit. Translation of original operating instructions...

  • Page 135: Ec Declaration Of Incorporation Conforming To 2006/42/Ec

    Certifications 11.1 EC Declaration of Incorporation conforming to 2006/42/EC 3468161 Subject to changes in line with technical progress!

  • Page 136: Eu Declaration Of Conformity In Accordance With 2014/34/Ec With Gas Atex Marking

    EU-KONFORMITÄTSERKLÄRUNG EU DECLARATION OF CONFORMITY DÉCLARATION DE CONFORMITÉ UE Hersteller AL-KO THERM GMBH I Hauptstraße 248-250 I 89343 Jettingen-Scheppach I Germany / Manufacturer Fabricant: Im Sinne der EU- Richtlinie 2014/34/EU, Anhang X, Abschnitt B vom 26. Februar 2014 As defined in EU Directive 2014/34/EU, Annex X, Section B of February 26, 2014 Au sens de la directive UE 2014/34/UE, annexe X, section B du 26 Février 2014...

  • Page 137: Eu Declaration Of Conformity In Accordance With 2014/34/Ec With Dust Atex Marking

    11.3 EU Declaration of Conformity in accordance with 2014/34/EC with dust ATEX marking 3468161 Subject to changes in line with technical progress!
  • Page 138 AL-KO AT4F ATEX Notes Translation of original operating instructions...
  • Page 140 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.

Table of Contents