AL-KO HYDRO-OPT M Operating And Assembly Instruction Manual
Central ventilation and air handling units
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Summary of Contents for AL-KO HYDRO-OPT M
- Page 1 CENTRAL VENTILATION AND AIR HANDLING UNITS OPERATING AND ASSEMBLY INSTRUCTIONS HYDRO-OPT M ®...
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Page 2: Revision History
AL-KO HYDRO-OPT ® Legal AL-KO THERM GmbH Hauptstraße 248 - 250 89343 Jettingen-Scheppach Germany Telephone: +49 8225 39 - 0 Fax: +49 8225 39 - 2113 E-mail: klima.technik@alko-air.com Revision history Version Description Date 3061955_BA-HydroOpt_M_de-V1.0_04-2020 27/04/2020 3061955_BA_DE_HydroOpt_M_V2.0 28/02/2024 Translation of the original operating instructions... -
Page 3: Table Of Contents
Table of contents About this manual ..................5 Explanation of symbols ..........................5 1.1.1 Safety instructions ............................5 Safety signs ..............................6 1.2.1 Abbreviations.............................. 8 Legal notices .............................. 8 Safety instructions ..................9 Intended use ............................... 9 Foreseeable misuse ............................ 9 General safety instructions ......................... - Page 4 AL-KO HYDRO-OPT ® Further operating options ......................... 35 6.6.1 HMI Web ..............................35 6.6.2 Plant diagram (optional) ........................... 38 Service and maintenance ................39 Safety instructions for servicing and maintenance ................... 39 7.1.1 Qualifications of personnel ........................40 Maintenance instructions as per VDMA 24186 ..................40 Maintenance schedule ..........................
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Page 5: About This Manual
About this manual About this manual The German version is the original operating instructions. All further language versions are translations of the orig- „ inal operating instructions. Read these operating and assembly instructions carefully before assembly, commissioning and maintenance. This „... -
Page 6: Safety Signs
AL-KO HYDRO-OPT ® Safety signs Meaning Sign GENERAL DANGER SIGNS If the required safety instructions are not observed, this can lead to death, severe injuries and serious property damage. IMPORTANT NOTICE If you do not heed this notice, this can lead to problems with the unit. - Page 7 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.
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Page 8: Abbreviations
AL-KO HYDRO-OPT ® 1.2.1 Abbreviations Abbreviation Meaning Personal protective equipment, such as cut-proof gloves, safety goggles, work gloves, ear protection, safety helmet, breathing mask Circulating coil system Pump warm water heater Exhaust air heat exchanger Hrec Heat recovery Legal notices All specified data serve solely to describe the product. -
Page 9: Safety Instructions
Foreseeable misuse HYDRO-OPT M only be operated within the scope of the technical data specified by AL-KO THERM. Any use other or ® more extensive than that described in the section “2.1 Intended use” on page 9 is regarded as not in accordance with the intended use. - Page 10 AL-KO HYDRO-OPT ® WARNING Risk of severe injuries or death! Working on the HYDRO-OPT M can result in serious injury or death. ® Only allow assembly, installation, commissioning, repair, maintenance and servicing „ work to be carried out by qualified staff.
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Page 11: Safety Instructions For Operation
M 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. 2.3.3 Personal safety instructions The HYDRO-OPT M may only be operated by persons who are trained in operating it and expressly authorised to... -
Page 12: Residual Dangers
AL-KO HYDRO-OPT ® Residual dangers The installation may present a danger if it is not operated by trained personnel and/or is used improperly or not used according to its designated use. Residual dangers are potential hazards that are not immediately apparent, such as: Injuries due to failure to observe the safety instructions, standards, directives or regulations. -
Page 13: Product Description
Product description Product description The hydraulic station is used for highly efficient heat and cold recovery in circulating coil systems (KVS). In winter, heat is extracted from the exhaust air flow from an exhaust air unit and transferred to a heat exchanger in the central supply air unit. -
Page 14: Station Structure (Example)
AL-KO HYDRO-OPT ® Station structure (example) From the supply air vom Zulufttauscher To the exhaust air exchanger zum Ablufttauscher exchanger To the supply air zum Zulufttauscher From the exhaust air exchanger vom Ablufttauscher exchanger Supporting frame Traggestell Return flow Temperatursensor temperature sensor Rücklauf... -
Page 15: Schematic With One Exhaust Air Device (Example)
A A L L - - K K O O - - H H Y Y D D R R O O - - O O P P T T Product description 3.1.1 Schematic with one exhaust air device (example) Mains supply 400 V / 50 Hz 20 A Input for external enable Hrec demand (0 –... - Page 16 A A L L - - K K O O - - H H Y Y D D R R O O - - O O P P T T AL-KO HYDRO-OPT ® Schematic with one exhaust air device and feed option (example) Mains supply 400 V / 50 Hz 20 A...
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Page 17: Technical Data
20 A slow The maximum on-site back-up fuse is specified on the enclosed circuit diagram. The exact dimensioning of the pump and the calculation of the necessary system pressure is carried out by AL-KO THERM after the order is placed. -
Page 18: Delivery, Transport, Storage
AL-KO HYDRO-OPT ® Delivery, transport, storage Delivery The HYDRO-OPT M is delivered on a one-way pallet. „ ® Transport WARNING Risk of injury due to impacts, cutting or piercing during loading, unloading and transport of the modules. Observe the working instructions and these operating and assembly instructions. -
Page 19: Transport Under Aggravated 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. „... -
Page 20: Crane Transport
AL-KO HYDRO-OPT ® 4.2.3 Crane transport All HYDRO-OPT M units have an option for crane transport. ® WARNING Danger of death – Suspended loads and crane transport! Observe the local and legal regulations and the rules of the professional associations. -
Page 21: Assembly
Assembly Assembly Safety instructions for assembly WARNING Risk of injury from falling from ladders, scaffolding or work platforms. Only use suitable and tested ladders, steps, scaffolding and work platforms. „ Work with care. „ WARNING Risk of slipping! Leaked medium/condensate. Immediately take up the spill quantity and dispose of it properly. -
Page 22: General Information
AL-KO HYDRO-OPT ® 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 23: Filling And Venting
Assembly Fig. 5 Counterflow principle Air inlet Brine inlet Air outlet Brine outlet Filling and venting WARNING Risk of poisoning when filling the installation. The unit may contain media that are hazardous to health, such as coolants. The media may only be filled and stored in approved containers. „... -
Page 24: Electrical Connection
AL-KO HYDRO-OPT ® 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 25: Bus Model Assembly (Option)
Assembly Outgoing to the on-site building management system: Heat recovery operating message potential-free contact Heat recovery warning message potential-free contact Heat recovery fault message potential-free contact * only optional for installations with heat input via plate heat exchanger ** mounted on the air handling unit or enclosed loose The cabling of the control lines is connected to the terminal rows in the station switch cabinet. -
Page 26: Commissioning
The maintenance instructions in the operating and assembly instructions for central air „ handling units of the HYDRO-OPT M series of the AL-KO THERM company must be ® observed under all circumstances. Have installation, commissioning, servicing and maintenance work carried out only by „... -
Page 27: Requirements
Commissioning Requirements ATTENTION Venting the rotary pump. It is essential that the rotary pump has been vented according to the manufacturer's informa- tion. To do so, the venting screw on the pump must remain open until brine comes out free of bubbles. -
Page 28: Operation
AL-KO HYDRO-OPT ® After the enable contact, an analogue request signal (0–10 V) is required on-site for operating the closed-cycle system. The heat recovery output can be controlled proportionally from 0–100 % via the signal. Thus the complete station behaves like a (albeit sluggish) heating valve with a continuous valve drive and can be easily integrated in the on-site control strategy. -
Page 29: Alarm Message/Warning Message
Commissioning Designation General function INFO button with integrated This button can be used to navigate from any menu item to the main menu. ALARM button with integrated This button can be used to navigate from any menu item to the alarms. The inte- grated LED also indicates the alarm and acknowledgement status (see chapter “8 Emergencies and malfunctions”... -
Page 30: Display Menu
AL-KO HYDRO-OPT ® Alarm text Class Description/Remedy Pump 2 The pump's frequency converter has tripped System test required Pump 1 + 2 If both pumps have a malfunction, the installation shuts down Frequency converter of the pump is faulty ... - Page 31 Commissioning The displayed language can be changed with the service password in the main menu. Fig. 11 System information, e.g. temperatures and brine/air volumes, can be viewed in the main menu under “Information”. These can vary depending on the expansion stage. Fig.
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Page 32: Main Menu (Info Button)
AL-KO HYDRO-OPT ® 6.5.4 Main menu (Info button) The selection of menu items changes depending on the access level: Enter password „ Information „ Settings „ Versions „ The display of the screens depends on the system configuration. Only the screens required for the system configuration are displayed. -
Page 33: Commissioning Menu
Commissioning Under “Settings”, the service technician can adjust the installation parameters in the service level. NOTE Always set a valid date or the correct time in order to obtain all functions. 6.5.5.1 Commissioning menu NOTE The safety functions of the software can be deactivated if incorrect settings are made. Commissioning can only be achieved by entering the service password. -
Page 34: System Information
AL-KO HYDRO-OPT ® “Out of service” must be set to “Active”. The actual value can then be entered manually. Fig. 20 The presence of a manual value entry can be indicated by orange/red flashing of the Info LED. NOTE Please reset this function for regular system operation again by setting “Out of service” back to “Passive”. -
Page 35: Further Operating Options
Commissioning If the Modbus connection is used via the IP network, network settings can be found under the following menu item: Main menu (press the INFO button) > System integrator > IP Config Name Range Explanation DHCP Setting the type of address reference: Active Obtain the address from the DHCP server. - Page 36 AL-KO HYDRO-OPT ® Step Description Enter the IP address of the controller in the address bar of the web browser. The IP address of the controller can be read from the local control unit. Enter username and password. Default username: WEB Default password: SBTAdmin! Username and password can be changed.
- Page 37 Commissioning Designation General function Show/Hide Trend Shows or hides the online trend window below the user interface. To record a value (e.g. supply air temperature), press a value directly. When the trend window is displayed, it is immediately displayed in the window.
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Page 38: Plant Diagram (Optional)
AL-KO HYDRO-OPT ® 6.6.2 Plant diagram (optional) Once this option has been enabled, the installation can be visualised on the PC using the plant graphic via a LAN con- nection. Fig. 22 Sign Description Display of the name and version of the controller software... -
Page 39: Service And Maintenance
Service and maintenance Service and maintenance Safety instructions for servicing and maintenance WARNING Risk of injuries. Before all repair and maintenance work, disconnect the HYDRO-OPT M from the mains ® „ on all poles and secure to prevent restart. Close the media supply (water, gas, etc.) before all repair and maintenance work. „... -
Page 40: Qualifications Of Personnel
The operator of an AC installation is obliged to have the installation maintained regularly by trained qualified staff. AL-KO THERM recommends that maintenance is carried out in accordance with German VDI 6022 and VDMA 24186. Upon conclusion of a maintenance contract, AL-KO THERM undertakes these tasks. - Page 41 Service and maintenance Implementation Item Activity Periodically As required Controller (according to VDMA 24186-4) Controller (CPU HEHR Connector) 3.1.1 Check integral power supply (e.g. buffer battery) 12 mon 12 mon 3.1.2 Check functional elements (e.g. operating and display equipment) 12 mon 3.1.3 Check input signals (e.g.
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Page 42: Maintaining And Cleaning Components
AL-KO HYDRO-OPT ® Implementation Item Activity Periodically As required 6.1.7 Measure power consumption 12 mon 12 mon 6.1.8 Measure phase symmetry 6.1.9 Check for smooth running and temperature increase 12 mon 3 mon 6.1.10 Check bearings for noise 6.1.11 Grease bearings using a relubrication device 6 mon 6.1.12... -
Page 43: Emergencies And Malfunctions
Contact for malfunctions For all questions that you have in connection with our products, please contact the manufacturer of your ventilation installation, one of our branches or directly to: AL-KO THERM GMBH Phone: (+49) 82 25 / 39 - 0 Hauptstraße 248-250... -
Page 44: Shut-Down
AL-KO HYDRO-OPT ® Shut-down Decommissioning The installation can remain permanently filled with the glycol/water mixture. WARNING Risk of injury due to pressurised parts. When decommissioning, note that certain installation parts are pressurised. „ Comply with the safety regulations! „ ATTENTION In winter, there is a general freezing hazard for all components. -
Page 45: 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. „... -
Page 46: Spare Parts
Machinery Directive. The Declaration of Conformity and Incorporation are invalidated in the event of a modification to the AC unit that is not coordinated with AL-KO THERM. The warranty may also be invalidated. -
Page 47: Appendix
Appendix Appendix 11.1 Commissioning protocol F.A.O.: Company: In order to ensure a smooth commissioning process, the following work is necessary in advance: Central ventilation unit: Central ventilation unit ready for operation Connection on air side available Air volume measurements carried out Hydraulic station: Hydraulic station installed and piped All heat exchangers connected in counterflow... - Page 48 AL-KO HYDRO-OPT ® Notes Translation of the original operating instructions...
- Page 49 Spare parts Notes 3522013 Subject to changes in line with technical progress.
- Page 50 AL-KO HYDRO-OPT ® Notes Translation of the original operating instructions...
- Page 51 Evidence of heat recovery Supply air volume Exhaust air volume Outside air temperature °C Temperature after Hrec SUP °C Exhaust air temperature °C Temperature after Hrec ETA °C BMS power demand in Outdoor air amount Pump frequency Displayed Hrec power in Place, date Name of commissioning person...
- Page 52 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.
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