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Summary of Contents for AL-KO HYDRO-OPT S
- Page 1 CENTRAL VENTILATION AND AIR HANDLING UNITS OPERATING AND ASSEMBLY INSTRUCTIONS HYDRO-OPT ®...
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Page 2: Revision History
AL-KO HYDRO-OPT ® Legal AL-KO THERM GMBH Hauptstraße 248 - 250 D-89343 Jettingen-Scheppach Germany Phone: +49 8225 39 - 0 Fax: +49 8225 39 - 2113 E-mail: klima.technik@alko-air.com Revision history Version Description Date Initial release 14/01/2016 Revision 26/10/2021 Revision 02/04/2024... -
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 ® Commissioning ................... 36 Principles..............................36 Requirements ............................37 Commissioning procedure (see also chapter “6.5.4 Settings for commissioning“ on page 42) ....37 Control-oriented integration of the HYDRO-OPT S in the higher-level control unit ......... 37 ® HYDRO-OPT® S operation ........................39 6.5.1...
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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 SIGN Failure to observe the required safety instructions may result in death, severe injury or serious damage to property. IMPORTANT NOTICE If this notice is not observed, problems can arise with the unit. - Page 7 About this manual Meaning Warning sign Warning of pointed object If the required safety instructions are not observed, this can lead to death or severe injuries due to pointed 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 Legal notices All specified data serve solely to describe the product. No statement on a specific characteristic or suitability for a spe- cific purpose can be derived from these data. The data do not exempt the user from his own judgement and checks. Translation of original operating instructions... -
Page 9: Safety Instructions
Permissible pressure range between 2.0 and 5.5 bar (g). Foreseeable misuse HYDRO-OPT S may 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. The manufacturer cannot be held liable for damage resulting from this. - Page 10 AL-KO HYDRO-OPT ® WARNING Risk of injury due to falling, and falling modules. When installing the modules or installing them on platforms or on the roof, persons may fall off and/or modules may fall down. Only allow assembly, installation, commissioning, repair, maintenance and servicing „...
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Page 11: Safety Instructions For Operation
During repair and maintenance work, the HYDRO-OPT S must be disconnected from the mains on all poles and „ ® locked out. 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... -
Page 12: Training
AL-KO HYDRO-OPT ® Training The owner/operator of the HYDRO-OPT S must regularly train their personnel in the following subjects: ® Observance of the operating and assembly instructions as well as the legal regulations. „ Intended operation of the HYDRO-OPT „... -
Page 13: Product Description
Product description Product description The HYDRO-OPT S hydraulic station is used for high-efficiency heat and cold recovery in circulating coil systems (CCS) ® and is prepared for connection on both the electrical and hydraulic sides. S transfers energy between an exhaust air device and a supply air handling unit. The ready integrated HYDRO-OPT ® The integrated control unit monitors the operating conditions and regulates the brine circulation amount. If there is a danger of frost on the exhaust air heat exchanger, a control-specific frost protection function is activated. -
Page 14: Function Monitoring
AL-KO HYDRO-OPT ® 3.1.2 Function monitoring The higher-level control unit is controlled by an enable signal (potential-free) as well as by the 0-10 V setpoint. A collec- tive fault is fed back potential-free to the higher-level control unit. With 0 V drive of the hydraulic unit, the enable must be rescinded so that the pump is switched off. The fault messages can appear: FC defective – installation is switched off... -
Page 15: Hydro-Opt ® S Set-Up
Product description HYDRO-OPT S set-up ® Fig. 1 HYDRO-OPT S set-up ® Carrier frame Drip pan Frequency converter/display/control unit/main switch Pre flow temperature sensor, exhaust air heat exchanger Pre-flow, supply air heat exchanger Pre-flow, exhaust air heat exchanger Return flow supply air heat exchanger Return flow exhaust air heat exchanger Level compensation foot Safety valve/pressure gauge/system pressure monitor Power control ball valve Pre flow temperature sensor, supply air heat exchanger Volume flow rate indicator Pressure expansion vessel with cap valve Circulating pump 3327038 Subject to changes in line with technical progress! -
Page 16: Hydro-Opt ® S Schematic With Supply Air/Exhaust Air Device
AL-KO HYDRO-OPT ® 3.4.1 HYDRO-OPT S schematic with supply air/exhaust air device ® exhaust air exhaust air supply air Fig. 2 HYDRO-OPT S schematic with supply air and exhaust air heat exchanger ® Exhaust air heat exchanger Pre flow temperature sensor, exhaust air heat exchanger Supply air heat exchanger... -
Page 17: Technical Data
Product description Technical data ATTENTION Read the documentation supplied with the unit. Information on the technical and electrical data can be found there. The HYDRO-OPT S is available in 5 sizes depending on the required quantity of brine being circulated: (see type over- ® view) Operating pressure: 2.0 to 5.5 bar (g) Supply voltage: 400 V/50 Hz (3 phases) Max. pre-fusing: 10 A slow The maximum on-site pre-fusing is oriented on the output of the frequency converter used as well as the length and cross-section of the supply line. -
Page 18: Type Plate
AL-KO HYDRO-OPT ® Maximum electrical connected load (depending on the pump output; see also switching document): Type Flow rate Max. connected load m3/h V / kW / A S0.5 0.35 - 0.55 3-400/0.37/1.0 S1.5 0.56 - 1.50 3-400/0.37/1.0 S3.5 1.51 - 3.50 3-400/1.1/2.5... - Page 19 Product description Calculating the upstream pressure p „ H[m] [bar] = + 0,2 bar Recommendation Evaporation pressure for hot water systems > 100 °C Differential pressure of the circulating pump; only take into account when installing the "reflex" on the pressure side of the circulating pump ≥...
- Page 20 AL-KO HYDRO-OPT ® Fig. 6 Setting the fill pressure Lock Water connection Step Action Open the shut-off (1) carefully. Carefully vent the expansion line and close the shut-off (1). Raise the fill pressure p by filling on the water side (2). End pressure Run the installation until it reaches the max. pre flow temperature (thermal degassing) „ Switch off the circulation pumps. Post-vent the installation „...
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Page 21: 3.6.1.2 Flowmeter
Product description 3.6.1.2 Flowmeter ATTENTION Index marker is the bottom edge of the baffle float. The factory settings must not be changed. Fig. 8 HYDRO-OPT S flowmeter ® General Operating temperature TB max: 100 ˚C Operating pressure PB max: 10 bar Measurement accuracy: Measurement range 20 - 80% ± 5% of the displayed value Measurement range < 20% / > 80% = ± 10% of the displayed value Material Housing: Brass Inner parts: Rust-free steel, brass and plastic Inspection glass: Heat-resistant, impact-proof plastic Seals: EPDM Flow media Water mixture with commonly used corrosion and antifreeze additives (see document “Glycol correction curves”). -
Page 22: 3.6.1.3 Control Ball Valve With Continuous Actuator
AL-KO HYDRO-OPT ® Korrekturkurve Durchflussmesser HYDRO-OPT® S Correction curve of HYDRO-OPT S flow meter ® device type 0.5 and 1.56 Gerätetype 0,5 und 1,5 (DN15/DN20) DN15/DN20) Angezeigter Durchfluss (l/min) Displayed flow rate (l/min) Fig. 9 Flowmeter diagram 3.6.1.3 Control ball valve with continuous actuator The control ball valve is adjusted by a rotary drive. The rotary drive is constantly controlled by the HYDRO-OPT S con- ®... - Page 23 Product description 3-way ball valve 3- Wege-Kugelhahn 100 % Energierückgewinnung 0 % Energierückgewinnung 0% energy recovery 100 % Energierückgewinnung (=100% Bypass) 100% energy recovery (=100% bypass) Fig. 11 HYDRO-OPT S 3-way ball valve (ball position) ® Control from the controller Direction of rotation R (standard) with switch setting, right Fig.
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Page 24: Hydro-Opt ® S Temperature Sensors
AL-KO HYDRO-OPT ® Control from the controller Measuring voltage for position feedback Direction of rotation Fig. 13 3.5 / 6.5 / 11 wiring diagram 3.6.1.4 HYDRO-OPT S temperature sensors ® Temperature sensors of type Ni1000 are always installed in the HYDRO-OPT ® Resistance values, temperature sensors Ni1000 Media temperature °C Fig. -
Page 25: Delivery, Transport, Storage
Delivery, transport, storage Delivery, transport, storage Delivery The HYDRO-OPT S is delivered on a euro 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 26: Transport Under Aggravated Conditions
AL-KO HYDRO-OPT ® 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 checked for load-bearing capacity and damage before use. -
Page 27: Crane Transport
Delivery, transport, storage 4.2.3 Crane transport HYDRO-OPT units have crane transport option. ® WARNING Danger of death - Suspended loads and crane transport! Observe the local and legal regulations and the rules of the professional associations. Do not walk under suspended loads. „... -
Page 28: Assembly
AL-KO HYDRO-OPT ® 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 29: General Information
Assembly CAUTION Risk of crushing the limbs and cutting injuries on sharp edges during assembly/installa- tion 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 30: Filling And Venting
AL-KO HYDRO-OPT ® Fig. 15 Counterflow principle in CCS installations 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. „ Work with care. „ Avoid skin and eye contact with the media, do not swallow media and observe the safety „... -
Page 31: Electrical Connection
Assembly 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. „ Perform the connection exactly according to the circuit diagram and the assignment plan. „... -
Page 32: Cabling To The On-Site Air Handling Control Unit
AL-KO HYDRO-OPT ® Cabling to the on-site air handling control unit The following cabling is required along with the 3-phase supply: Coming from the higher-level control unit: Release signal potential-free contact External setpoint 0-10 V analogue signal Going to the higher-level control unit:... -
Page 33: Bus Coupling
Assembly Bus coupling As an option, the control system can be integrated in a superordinate network. As standard, the integrated control unit contains a Modbus interface. A BAC-net MSTP interface can be provided via an additional board (option) The adjacent data points can be called up via the optional BAC-net board: Data type Instance Designation... -
Page 34: Circuit Diagrams
AL-KO HYDRO-OPT ® Circuit diagrams Fig. 17 Standard (without BAC-net) Translation of original operating instructions... - Page 35 Assembly Fig. 18 Optional with BAC-net-MCA 109 3327038 Subject to changes in line with technical progress!
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Page 36: Commissioning
The maintenance instructions in the operating and assembly instructions for central air „ handling units of the HYDRO-OPT S series of the AL-KO THERM company must be ob- ® served under all circumstances. Have installation, commissioning, servicing and maintenance work carried out only by „... -
Page 37: Requirements
Commissioning Requirements ATTENTION Venting the rotary pump It is essential that the rotary pump has been vented according to the manufacturer's information. To do so, the venting screw on the pump must remain open until brine comes out free of bubbles. The lack of (or improper) venting leads to damage to the pump and to system malfunctions. - Page 38 AL-KO HYDRO-OPT ® ATTENTION Components containing water in the air handling unit (heater, cooler, humidifier, etc.) can freeze at below-freezing temperatures. A sufficiently high temperature must be ensured. Especially when starting up the installation, the heat supply of the heater must be available immediately (by means of a pre-flow time). A heat recovery such as the circulating coil system (CCS) cannot make heating power available immediately because of its slowness (mass, exhaust temperature).
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Page 39: Hydro-Opt® S Operation
Commissioning HYDRO-OPT® S operation 6.5.1 Operating unit of the control system Fig. 20 Operating unit with display Plain text display Access to parameter main menu (all parameters) Menu selection Error buffer and alarm diagnostics Status LEDs Online help (for each parameter, menu item and alarm) operating mode Acknowledging an alarm Access to commissioning menus... - Page 40 Auto on, sets the installation in controlled operation Further details are given in the Danfoss manual supplied. NOTE All engine data of the circulating pump are parametrised in the control system by AL-KO THERM at the factory. Translation of original operating instructions...
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Page 41: Energy Recovery Display Menu
Commissioning 6.5.3 Energy recovery display menu Fig. 22 Basic menu display view Media temperature to supply air heat exchanger Freq Controls energy recovery in % Media temperature from supply air heat exchanger Fig. 23 Display view in the event of a malfunction A fault message is generated by malfunctions on the circulating pump or in the frequency converter or by triggering the system pressure monitoring system: 3327038 Subject to changes in line with technical progress! -
Page 42: Settings For Commissioning
1 bar). 2. Enable the installation with the – Reset – button on the operating unit of the control system. 6.5.4 Settings for commissioning The settings of the rated engine data and the maximum speed of the circulating pump are carried out by AL-KO THERM prior to delivery. The configured engine parameters can be seen in the "Quick menu" and can be compared with the type plate data of the pump. - Page 43 Commissioning Fig. 25 Example display for parameter 13-12 [2]: Activation of frost protection (-8 °C preset at the factory) NOTE Factory setting -000008.000 means frost protection deactivated. Setting -000002.000 means frost protection activated To activate the frost protection function, parameter 13-12 must be changed from factory setting – 8.0000 to – 2.0000 in the Quick menu/User menu. This frost protection function is only required for installations where there is a permanently high humidity load in the exhaust air.
- Page 44 AL-KO HYDRO-OPT ® Fig. 26 Example for parameter 4-14: Setting of the required flow rate (data in Hz) The operating flow rate for the HYDRO-OPT S must be set via parameter 4-14 (maximum setpoint) in the “Quick menu/ ® User menu”. The water/glycol volume flow for the circulating coil system stated in the equipment data sheet must be read on the flowmeter. The flow rate can be adjusted by changing the pump speed by adjusting parameter 4-14. The factory setting is 50 Hz and must be adjusted during commissioning. Process for setting the maximum operating circulation amount: Setting to manual mode (Hand on) or to automatic mode if it is certain that there is an external request with 10 V.
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Page 45: Handling Variable Air Volume Flows
Commissioning 6.5.5 Handling variable air volume flows If the air handling unit is operated with variable air volume flows, the circulating water/glycol amount must be adapted accordingly. This adjustment to limit the max. external setpoint (0-10 V) must be made with the higher-level control unit. Example: 100% air volume flow ➔ max. control of the energy recovery system with 10 V 50% air volume flow ➔ max. control of the energy recovery system analogue with 5 V An adequate adjustment of energy recovery to variable air volume flows can be realised using this mathematical depend- ency. -
Page 46: Servicing And Maintenance
AL-KO HYDRO-OPT ® Servicing and maintenance Safety instructions for servicing and maintenance WARNING Risk of injuries. Before any repair and maintenance work is performed, disconnect the HYDRO-OPT „ ® from the mains on all poles and lock it out. Close the media supply (water, gas, etc.) before all repair and maintenance work. -
Page 47: Qualifications Of Personnel
NOTE The owner/operator 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. Upon conclusion of a maintenance contract, AL-KO THERM undertakes these tasks. - Page 48 AL-KO HYDRO-OPT ® Item implementation Assembly/ Periodically As required Component/ Activity every Activity 3 mon 1.3.2 Check heat insulation for damage and completeness 3 mon 1.3.3 Check temperature and pressure measurement devices for damage and display accuracy (plausibility check) 1.3.4...
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Page 49: Maintaining And Cleaning Components
Servicing and maintenance Item implementation Assembly/ Periodically As required Component/ Activity every Activity Sub-stations (according to VDMA 24186-4) Sub-station 7.1.1 Check power failure and power recovery behaviour 12 mon Documentation (according to VDMA 24186-4) Maintenance-relevant documents 12 mon 8.1.1 Check for presence (circuit diagram, CHC operating instructions) Existing system markings (signage) 12 mon 8.2.1 Check for availability... -
Page 50: 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 51: Shutting Down The Unit
Shutting down the unit Shutting down the unit Decommissioning The installation can continue to remain filled with brine. 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 point, the installation must be either drained and blown out with compressed air, or filled with a commercially available antifreeze with corrosion inhibiting additive due to the risk of freezing and corrosion. -
Page 52: Disposal
AL-KO HYDRO-OPT ® 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 at all poles. „ When dismantling, note that certain parts of the installation are pressurised. -
Page 53: 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. NOTE The valid spare parts list can be found as part of the unit documentation created on the basis of the order. -
Page 54: Appendix
AL-KO HYDRO-OPT ® Appendix 11.1 HYDRO-OPT S commissioning protocol ® Project designation: Order number: Item: 1. HYDRO-OPT S system data ® Nominal brine quantity m³/h l/min Antifreeze (glycol) Glycol content (brine) Fill pressure bar (g) Pre-pressure of expansion vessel Pump output 2. HYDRO-OPT S visual inspection ®... -
Page 55: Certifications
Certifications Certifications The following EC Declaration of Incorporation and EC Declaration of Conformity will be issued per order, according to their validity. If both the order number and the position of the unit are specified, the issued document must be assigned to the respec- tive unit. 3327038 Subject to changes in line with technical progress! -
Page 56: Ec Declaration Of Incorporation Conforming To 2006/42/Ec
EG-EINBAUERKLÄRUNG EC DECLARATION OF INCORPORATION DÉCLARATION DE MONTAGE CE Hersteller AL-KO THERM GMBH I Hauptstraße 248-250 I 89343 Jettingen-Scheppach I Germany / Manufacturer Fabricant: Im Sinne der EG- Maschinenrichtlinie 2006/42/EG, Anhang II, Teil 1, Abschnitt B As defined in EC Machinery Directive 2006/42/EC, Annex II, Part 1, Section B... - Page 57 Certifications Notes 3327038 Subject to changes in line with technical progress!
- Page 58 AL-KO HYDRO-OPT ® Notes Translation of original operating instructions...
- Page 60 AL-KO THERM GMBH l Jettingen-Scheppach l Germany All rights reserved for AL-KO THERM GMBH, as well as in the event of applications for industrial property rights. This documentation or excerpts thereof may not be copied or forwarded to third parties without the express consent of AL-KO THERM GMBH. We reserve the right to make technical changes that do not impair the function.
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