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AL-KO AT4F Series Operation And Assembly Instructions
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AL-KO AT4F Series Operation And Assembly Instructions

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CENTRAL VENTILATION AND AIR HANDLING UNITS (AHU)
OPERATION AND ASSEMBLY INSTRUCTIONS OF CENTRAL
VENTILATION UNITS (TRANSLATION FROM THE ORIGINAL
OPERATING INSTRUCTION)
PRODUCTION SERIES AT4F

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Summary of Contents for AL-KO AT4F Series

  • Page 1 CENTRAL VENTILATION AND AIR HANDLING UNITS (AHU) OPERATION AND ASSEMBLY INSTRUCTIONS OF CENTRAL VENTILATION UNITS (TRANSLATION FROM THE ORIGINAL OPERATING INSTRUCTION) PRODUCTION SERIES AT4F...
  • Page 2 AL-KO Production series AT4F Table of contents Information regarding this manual ..............4 Description of symbols ..........................4 Regulations and norms ..........................4 Legal information ............................5 Safety instructions ..................6 Intended use ............................... 6 Possible misuse ............................6 Residual risks ............................. 7 Delivery ..............................
  • Page 3 "Table of contents" 6.2.4 Fan (free wheel with direct driven) ......................41 6.2.5 Torques of screw connections on the fan component ................43 Heat Exchanger............................44 6.3.1 Finned heat exchanger ..........................44 6.3.2 Electric air heater ............................47 Heat recovery ............................48 6.4.1 Plate heat exchanger ..........................
  • Page 4 AL-KO Production series AT4F Information regarding this manual Read this documentation prior to assembly and commissioning. This is a requirement for safe work and trouble- „ free handling. Observe the safety guidelines and warnings in this documentation and on the product itself.
  • Page 5 "Information on this manual" VDMA 24167 Fans – Safety requirements VDMA 24168 Ventilation devices and systems; air outlets, determination of the air flow with the pressure compensation method (null method) VDI 3810-1 Operation and maintenance of building installations – Fundamentals VDI 3810-4 Operating and maintenance of building services –...
  • Page 6 Possible misuse The AHU may only be operated within the technical data specified by AL-KO. Another use or further use which exceeds the parameters in the item "2.1 Intended use" is considered improper. The manufacturer is not liable for damages resul- ting from such use.
  • Page 7 "Safety guidelines" Residual risks Hazards may be posed by the AHU when it is not operated by trained persons and/or not used for the suitable purpose. Residual hazards are potential non-obvious hazards such as e.g.: Injury due to any failure to observe the safety instructions, norms, guidelines or regulations, „...
  • Page 8 AL-KO Production series AT4F Duties of the operating company The operator of AL-KO THERM Products must train its personnel regularly on the following topics: Observance and use of the operation and assembly instructions as well as legal regulations. „ Proper operation of the AHU.
  • Page 9 En cas de modification de la machine non convenue avec nous, la présente déclaration perd sa validité. Jettingen-Scheppach, den 09.11.2016 Dr. B. Müller Geschäftsführer / Managing Director / Directeur général AL-KO THERM GMBH I Hauptstraße 248-250 I 89343 Jettingen-Scheppach I Germany Hersteller / Manufacturer / Fabricant : 3086448 Subject to change, due to technical progress!
  • Page 10 AL-KO Production series AT4F EC Declaration of incorporation Translation from the original operating instruction...
  • Page 11 "Transport" Transport The ventilation and air-conditioning units of the AT4F production series are shipped screwed to square transport timbers and, depending on their size, come either completely assembled or in separate components divided in accordance with the delivery section split. The device dimensions are specified in grid units: 1 grid unit = 76.5 mm The delivery splitting is indicated in the unit drawing.
  • Page 12 AL-KO Production series AT4F Transport with forklift Attention! Use suitable fork lengths in order to avoid damaging unit base. Always watch out for possible projections (e.g. floor drains). Service doors must always be closed during transport. Unit transport via transport tube Device transport with a transport tube is permitted up to a width of 49 grid units and a maximum of 2000 kg! All AT4F units come equipped standard with a base frame that has openings for a crane transport.
  • Page 13 "Transport" Transport tube Lock washer Lock bolt Fig.: Transport tube Unit transport via crane eyelets Device transport with transport eyelets is permitted up to a width of 49 grid units! Max. permitted weight of the individual components: Attachment using 4 crane eyelets = 1500 kg „...
  • Page 14 AL-KO Production series AT4F Unit transport via shackles Transporting the device with shackles is permitted up to a width of 49 grid units and a maximum of 2 500 kg! The shackles are screwed into the opening (Ø 13) in the base frame of RLT devices.
  • Page 15 Upon delivery, the accessory parts lie in the respectively marked unit components. Recommendation: AL-KO THERM recommends supporting AT4F devices on suitable insulation strips (not part of the delivery scope) in „ order to reduce vibration. The instructions of the insulation strip manufacturer must be adhered to.
  • Page 16 AL-KO Production series AT4F Attention! The set-up sequence of the individual unit components is shown in the order related drawing and must absolutely adhered to. The assembly of AT4F units begins with the unit component that contains the air outlet (channel interface).
  • Page 17 "Assembly" Fig.: Unit connection horizontal Fig.: Unit connection vertikal Fig.: Unit connection gusset plate Fig.: Unit connection connecting profile 3086448 Subject to change, due to technical progress!
  • Page 18 AL-KO Production series AT4F Unit connection with stacked units and with side-by-side units 5.2.1 Stacked unit arrangement The basic frame compensation profile (adhesive on one side) must be circumferentially attached before the top „ device component is positioned on top (does not apply to weather-poof devices!).
  • Page 19 "Assembly" 5.2.2 Side-by-side units Loosen hex bolts on factory-mounted spacer bar. „ Place unit components next to it with forklift or crane. „ Fix spacer bar by means of hexagenal screw. „ Distance rail Cover (roof) Cover (side) Countersunk drilling screw Fig.: Side-by-side units In addition to the spacer bar, a continuous wide sealing strip (3) must be glued in the region of the mixing chambers (air-side connection).
  • Page 20 AL-KO Production series AT4F Attention! For the lengthwise offset of the left to the right unit component, the facing angle must also be screwed to the panel. For AT4F units in weatherproof design, the facing angle must also be sealed with a microbially-inert sealing material.
  • Page 21 "Assembly" External installation Attention! When executing from beneath (breaking through roof), clear all details with the factory first. „ For weatherproof design, lightning protection must be warranted by the customer! „ In accordance with VDI 3803-1, units for weatherproof set-up may not take over the performance of „...
  • Page 22 AL-KO Production series AT4F Drilling screw with EPDM washer Drainage area Insulation provided Cover plate by customer Clamp *) base frame Bond the moisture-proof roofing Sealing compound sheet to the screw angle prior to fitting the cover plates Roof frame...
  • Page 23 "Assembly" Sealing unit division points: Attention! The roof strip must be welded on immediately after the device has been installed to prevent damage. Check unit divisions for correct leak tightness. „ Clean unit top in the region of unit division. „...
  • Page 24 AL-KO Production series AT4F Alternative sealing of unit division points Manual hot air welding All hand welding devices with an angled, approx. 40 mm-wide nozzle and that produce the required temperatures of hot air of approx. 450 °C are suitable for the welding.
  • Page 25 "Assembly" 5.3.2 Weatherproof units with height offset Remove the cover (1) of the higher component (4) before placing two devices next to each other. „ Move the lower component (5) close and fasten the screws (see Chapter: Installation). „ Reattach the removed cover (1) and ensure that the foil bracket (2) is pressed down as well. „...
  • Page 26 AL-KO Production series AT4F 5.3.3 Weatherproof units with built-in rotating heat exchanger Place the lower device (2) component and the component with the rotation heat exchanger installed (3) next to each „ other and fasten the connection screws (see Chapter: Installation).
  • Page 27 "Assembly" 5.3.4 Weatherproof units with transport edges In weatherproof unit with transport edges, the roof track is only welded at the factory up to the counter-bores. „ The roof strip is welded together by the customer after removing the crane eyelets (see Chapter: Sealing the device „...
  • Page 28 AL-KO Production series AT4F Devices with split rotation heat exchanger Rotation heat exchangers are delivered in split form from a wheel diameter of 2500 mm onwards. These components are then assembled by the customer Special assembly instructions have been attached for this purpose.
  • Page 29 "Assembly" Operation only with water which is free of corrosive properties (and particularly contains neither oxygen nor „ carbonic acid)! Connect heat exchanger in accordance with the counterflow principle (water flow direction counter to airflow „ direction in unit). A droplet separator (TA) is installed as a standard feature downstream of the cooler to prevent condensate transfer „...
  • Page 30 AL-KO Production series AT4F Additional instructions for using direct evaporators: Installations must be carried out by an approved refrigeration company. Only safe refrigerants in accordance with DIN 8960 are approved for use. The cooling unit and the direct expansion each require a siphon to be attached by the customer. Each drain pan must be equipped with a separate siphon.
  • Page 31 "Assembly" Snake siphon (positive or negative pressure): The snake siphon is a siphon to be filled for drainage of air handling units in the area of the heat exchanger, humidifier or other wet regions at a different pressure to ambient pressure. Bottom pan with bottom drain Floor drain Ø...
  • Page 32 AL-KO Production series AT4F Ball siphon (negative pressure) Bottom pan with bottom drain Floor drain Ø 40 Bend Ø 40 Tail piece Ø 40 Check valve with ball Ø 40 element height min. max. Negative pressure up to 3200 PA...
  • Page 33 "Assembly" Attention! Wiring work must be performed according to DIN VDE 0100, DIN EN 60204-1 (DIN VDE 0113) and „ DIN EN 50156-1 (DIN VDE 0116). Motor wiring must be designed so as to enable the motor to be moved for tensioning the V-belts. „...
  • Page 34 AL-KO Production series AT4F Wiring for two speeds in the ratio 1 : 2 (winding in Dahlander circuit) Design example for 1,500/3,000 RPM and 4-/2-pole or 750/1,500 RPM and 8-/4-pole In motors with Dahlander wiring, the six winding ends 1U, 1V, 1W and 2U, 2V, 2W are connected to the six terminals of the terminal strip of a normal motor terminal box.
  • Page 35 "Assembly" Wiring for three speeds (two separate windings, one of them in a Dahlander circuit, nine terminals are required in this case). Design for ventilator drive units 750/1,000/1,500 RPM and 8-/6-/4-pole; 750/1,500 RPM in Dahlander circuit 750 RPM 1000 RPM 1500 RPM Winding design protection control...
  • Page 36 AL-KO Production series AT4F 5.9.3 Wiring with frequency converter Wiring example: Warning: Auxiliary contacts must be used to disconnect the control circuit! Auxiliary contacts BROWN YELLOW GREEN Danfoss FC 100 Pressure transmitter PTH Fig.: Frequency-inverter wiring (FC 100) with external repair switch and pressure transmitter...
  • Page 37 Prior to the commissioning of the AHU’s, the sealing seat of all built-in filters must be checked. „ Attention! AL-KO THERM generally recommends the replacement of all installed filters after operating the AHU’s for a „ short time in order to remove the dirt which has entered the filter in the construction phase and after com- missioning.
  • Page 38 AL-KO Production series AT4F 6.1.1 Cleaning Coarse dirt in the housing can be removed with an industrial vacuum cleaner. „ Other dirt can be removed with a wet cloth. „ Only clean with lukewarm water, possibly with moderate amounts of perfume-free soap.
  • Page 39 "Commissioning and maintenance" 6.2.2 Fan (Belt drive) Commissioning: Remove transport locking device on fan base. „ Check conduit system and fan for foreign objects. „ Turn impeller by hand to make sure it rotates freely. „ Test fan rotation direction (see arrow on fan housing) by temporarily switching on the motor. „...
  • Page 40 If the belt drive is altered without using an AL-KO design, then the limit speeds of the fan and the limit value diagram for the belt tensions in the respective technical catalogue must be respected.
  • Page 41 "Commissioning and maintenance" Tensioning regulation for a flat-belt drive The correct belt tension is reached when the measurement marker distance "L " has increased by the belt elongation "E*" The adjustment should be carried out in two stages with a interval of a few hours between them in order not to overload the bearings.
  • Page 42 Fans may not be operated if any unusual vibration and noises (or impermissibly high vibration speeds) occur! Running with not permissible high vibrations can produce broken impellers, which can lead to serious material- and personal injury. AL-KO recommend a continous observation/control with assistance of vibrations sensor (optional accessories).
  • Page 43 "Commissioning and maintenance" 6.2.5 Torques of screw connections on the fan component After approx. one hour of running time, check the screw connections on the fan's base frame and tighten consistently as necessary, via the torque wrench, in keeping with the initial screw tightening torques indicated in the table below. Thread size Screw torque (Nm) M 10...
  • Page 44 AL-KO Production series AT4F Changing belt pulleys: Loosen belt pulleys (I): Unscrew screws (3). „ Screw hexagonal bolt into threaded hole (4). „ Push clamping bush out from conical bore. „ Belt pulley can only be slid slightly on the shaft.
  • Page 45 This applies to all heat-exchanger register types. In the context of the hygiene-compliance inspection for AL-KO air handling units, the Institute for Lufthygiene (air hygiene) in Berlin verified the cleaning effect of heat-exchanger registers made by AL-KO – with the aid of the THD multi-stream process (see Fig. THD multi-stream process).
  • Page 46 AL-KO Production series AT4F Fig.: THD multi-stream process (rear) For more detailed information about the THD multijet method, contact: Technischer Hygiene-Dienst Fachreferat Lüftungs- und Kältetechnik Einemstraße 12 10785 Berlin tel.: +49 / (0)30 / 66765775-0 fax: +49 / (0)30 / 66765775-5 email: kontakt@thd.info...
  • Page 47 Heater units must only be enabled when a sufficient airflow over the heater is determined. —> Use of a volume flow monitor AL-KO recommends integrating the electric air heater control into the circuit of the repair switch (auxiliary switch) Insufficient airflow volume from regulated fans The heat output must be adapted to the reduced airflow volume —>...
  • Page 48 AL-KO Production series AT4F Heat recovery 6.4.1 Plate heat exchanger Maintenance: Regularly clean plates: „ a. Remove dust, fibre residues and any similar materials. b. Remove oil and grease deposits with hot water, steam, or grease-dissolving cleaners. Clean condensate drain.
  • Page 49 "Commissioning and maintenance" 6.4.2 Rotary heat exchanger Maintenance! The storage mass must be turned at regular intervals to prevent damage to the bearings when the system is not used for a prolonged period. Maintenance: Check drive elements and control elements. „...
  • Page 50 AL-KO Production series AT4F Seals With normal-temperature rotors, sealing felts of the quality: NF-PES-LE 0.32 grey are used. The felts must be slid as close as possible to the thermal mass, but direct abrasion must be avoided. The sealing felts are pressed on at the fac- tory, but their position can change as a result of transport.
  • Page 51 "Commissioning and maintenance" Filter 6.5.1 Bag filter Maintenance: Check all filter classes at least every 3 months for contamination and damage and replace as needed. „ Replace 1st filter stage at least every 12 months. „ Replace 2nd filter stage at least every 24 months. „...
  • Page 52 2. Replace filter element. 3. Insert new filter element and fasten the screws. Attention! AL-KO THERM assumes no warranty for damages resulting from inappropriate handling of the particulate air filters during assembly and disassembly! 6.5.5 Special instructions for the operation of the units The built-in air filter cells fulfil a safety function.
  • Page 53 "Commissioning and maintenance" Maintenance: Check louvre dampers for contamination, damage and corrosion. „ Check mechanical function of louvre dampers. „ Lubricate bearings. „ Clean louvre dampers regularly. „ Check final position of damper adjusting motors and readjust as needed. „ Sound absorbers The sound absorber must regularly be checked for dirt and damage.
  • Page 54 If a spray humidifier (air washer) is installed, a siphon must be installed by the customer. (cf. Fig.: Siphon dimensioning) Recommendation: AL-KO THERM recommends installing an electric dry run prevention mechanism for the water circulation pump. Place the spray humidifier as the last component in the air handling unit, directly against the inlet of the duct- work system.
  • Page 55 "Commissioning and maintenance" 6.9.2 Contact humidifier 6.9.2.1 Fresh-water system Attention! In front of the supply magnet valve, the customer has to install a pressure reducer, a water filter (150 µm) „ and a shutoff valve. Constant water pressure between 1.5 and 6.0 bar. Upon connection to the drinking-water mains (in accordance with EN 1717, "Technical rules for drinking „...
  • Page 56 AL-KO Production series AT4F 6.9.2.2 Circulation water system Attention! In front of the supply magnet valve, the customer has to install a pressure reducer, a water filter (150 µm) „ and a shutoff valve. Water pressure between 1.5 and 5.0 bar.
  • Page 57 "Commissioning and maintenance" 6.9.3 High-pressure humidifier Attention! Required maintenance interval: 2x annually „ Prior to the start of maintenance work, the installation is to shut off. „ Change the oil in the pump after the first 50 hours of operation. After that, every 500 hours of operation. „...
  • Page 58 „ Note: The AL-KO THERM company guarantees neither steam humidifiers installed by the buyer nor housing openings produced by the buyer nor improper handling of bottom pan nor improperly connected outlet fittings. This also refers to improperly operated humidifiers or incorrect humidifier capacities.
  • Page 59 "Maintenance details according to VDI 6022 and VDMA 24186" Maintenance details according to VDI 6022 and VDMA 24186 The air handling unit operator is obligated to ensure that the system undergoes routine maintenance by trained per- sonnel. The operating and installation instructions for the installation parts must always be adhered to (request as required)! General Long-term compliance with hygienic requirements and the execution of the necessary operational and maintenance mea- sures in air handling systems requires an appropriate qualification of the personnel.
  • Page 60 AL-KO Production series AT4F The hygiene inspections include at least the following actions: Walkthrough inspection of the air handling control room, including all components and the rooms which are „ supplied by them. When hygiene deficiencies are discovered: Measurement of physical air-conditioning parameters (temperature, „...
  • Page 61 "Maintenance details according to VDI 6022 and VDMA 24186" Hygiene requirements and maintenance, servicing of air conditioning equipment according to VDI 6022 and VDMA 24186 Task Actions month months months months months Unit components Inspection and recommended maintenance intervals Hygiene inspection Must be carried out by trained, Every 3 years for air handling systems qualified personnel in accordance...
  • Page 62 AL-KO Production series AT4F Task Actions month months months months months Unit components Inspection and recommended maintenance intervals 5.1.5 Check for flake formation in bottom Clean pan region of air humidifier pan 5.1.6 Check recirculating pump for dirt and Clean pump circuit film build-up in the intake line 5.1.7...
  • Page 63 "Maintenance details according to VDI 6022 and VDMA 24186" Task Actions month months months months months Unit components Inspection and recommended maintenance intervals 5.3.4 Check function of energy converters Replace (only in ultrasonic humidifiers) 5.3.5 Check function of water supply and Repair distribution 5.3.6...
  • Page 64 AL-KO Production series AT4F Tasks Actions month months months months months Unit components Inspection and recommended maintenance intervals 6.4.4 Check function of water supply and return 6.4.5 Ventilate (only with fluid) 6.4.6 Check for icing (only with vaporiser) only possible during operation 6.4.7...
  • Page 65 "Maintenance details according to VDI 6022 and VDMA 24186" Tasks Actions month months months months months Unit components Inspection and recommended maintenance intervals 7.3.4 Check function of drain and odour Clean and repair trap 7.3.5 Check hygiene state Sound absorbers Sound attenuators must be periodi- cally checked externally for contami- nation, damage and corrosion.
  • Page 66 AL-KO Production series AT4F Tasks Actions month months months months months Unit components Inspection and recommended maintenance intervals Drive elements 12.1 Electric motors 12.1.1 Check attachment and externally Clean and repair check for contamination, incrustation, damage and corrosion 12.1.2 Check rotation direction (initial start-up) 12.1.3 Retighten connecting terminals...
  • Page 67 (e.g. testing work, replacement etc.)! Contact persons Whenever you have questions concerning our products, please contact the constructor of your air conditioning installa- tion, one of our branch offices or our main office directly: AL-KO THERM GMBH Tel: (+49) 8225/ 39-0 Hauptstraße 248-250...
  • Page 68 All rights, including the registration of intellectual property rights, are held by AL-KO THERM GMBH. This documentation or excerpts thereof may not be copied or forwarded to third parties without the explicit permission of AL-KO THERM GMBH. The right to technical changes that do not alter the function is reserved.