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robatherm TI-50 Installation And Assembly Manual

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robatherm | Manuals
June 2023
English - translation of the original instructions
Air handling units | Type RM/RL/TI-50

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  • Page 1 | Manuals June 2023 English - translation of the original instructions Air handling units | Type RM/RL/TI-50...
  • Page 2 This leaflet is based on the generally accepted engineering standards at the time of drafting. Since the printed version is not subject to change control, the current version must be requested from robatherm or downloaded from the Internet at www.robatherm.com before application.

  • Page 3: Table Of Contents

    Contents General remarks   Information about these instructions   Security   General risk sources   Personnel qualification   What to do in case of danger   Installation site requirements   Installation site requirements for certain components   Footprint requirements   Foundation  ...
  • Page 4 Electro steam humidifier   Refrigeration technology (refrigeration plant, heat pump, and split air conditioner)   Personnel qualification   Connection of the refrigerant line   Hydraulic set   Inspection   Flushing   Filling   Exhaust ventilating   Pressure test   Hydraulic system  ...

  • Page 5: General Remarks

    The instructions describe all the available options. Whether and which options are available in the AHU depends on the options selected and the country for which the AHU is intended. The illustrations serve as an example and may differ. © robatherm...
  • Page 6 The instructions consist of several parts and have the following structure: Fig. 1: Parts of the instructions Main operating instructions Transport and unloading  Installation and assembly  Commissioning  Operation and incidents  Maintenance and cleaning  Disabling and disposal  © robatherm...

  • Page 7: Security

    After the work, mount the grates again according to the instructions. WARNING Danger to life from falling! When stepping on the protection roof, there is a risk to life from falling, as the protection roof is unsuitable for supporting loads. • Do not enter the protection roof. © robatherm...
  • Page 8 • Do not let several persons enter the AHU at the same time. • If this becomes necessary, take suitable measures to distribute the weight (e.g., grates, wooden boards, wood beams). © robatherm...

  • Page 9: Personnel Qualification

    ), extinguishing powder, or water spray. Fight larger fires with water spray or alcohol-resistant foam. • Do not allow extinguishing water contaminated with pollutants to enter waterways or waste water system. • Comply with the safety data sheet of the manufacturer. © robatherm...
  • Page 10 Disposal according to official regulations. Do not dispose of the product together with domestic waste. • In case of contamination of waterways, soil, or waste water system, inform relevant authorities. • Comply with the safety data sheet of the manufacturer. © robatherm...

  • Page 11: Installation Site Requirements

    The AHU must not be used as part of the external lightning protection system (see "Main operating instructions", chapter "Lightning protection for weatherproof devices"). • It must comply with the applicable regulations regarding protection against falls of people, tools, and materials, and suitable fall protection equipment must be in place. © robatherm...

  • Page 12: Installation Site Requirements For Certain Components

    Must not be installed in rooms with underpressure. Hydraulic set In the case of weatherproof AHUs with hydraulic sets, hydraulic components must be protected against frost by the customer (e.g., pipe trace heating, frost protection circuit, frost protection agents). © robatherm...

  • Page 13: Footprint Requirements

    (B) free as a revision area (A). • Leave ≥ 500 mm (D) free above the AHU as a revision area (A). Steam generator for electro steam humidifier For steam generators for electro steam humidifiers, observe the minimum wall clearance according to the manufacturer. © robatherm...
  • Page 14 Leave ≥ 350 mm (E) above the rack for the connections. • Leave ≥ 500 mm (F) free as a revision area (A) on the operating side and ≥ 650 mm (G) in front of the control cabinet. © robatherm...

  • Page 15: Foundation

    If the AHU is not secured, there is a danger to life if the AHU falls over. • AHUs must be secured to the foundation. • If the center of gravity is unfavorable (e.g., height/depth ratio ≥ 2.5), further security measures (e.g., steel structure) must be taken. © robatherm...
  • Page 16 (see chapter "Condensate, drain and overflow lines", page 33). The natural frequency of the support structure, especially in case of steel structures, must have sufficient distance to the excitation frequency of rotating components (e.g., fans, motors, pumps, compressors). © robatherm...
  • Page 17 Longitudinal support for units on DIN frames For units on DIN frame, two on-site longitudinal supports (A) are required over the entire length. The DIN frame (B) of the AHU rests on these. Fig. 9: Longitudinal support for units on DIN frames © robatherm...
  • Page 18 (E) (l1 - l1) and centrally between two transport loops (E) (l2 - l2). Fig. 11: Width support for units on DIN frames (identification) Fig. 12: Width support for units on DIN frames (dimensions) © robatherm...
  • Page 19 (E) (l – l ) and centrally between two transport loops (E) (l – l Fig. 14: Foundation spot for units on DIN frame (designations) Fig. 15: Foundation spot for units on DIN frame (dimensions) © robatherm...
  • Page 20 17). The on-site configuration must be carried out by a specialist, and must take into account all relevant factors (e.g., statics, load-bearing capacity, fastening, and vibrations). Fig. 17: Example 1 Fig. 18: Example 2 Fig. 19: Incorrect installation © robatherm...

  • Page 21: Unit Assembly

    Use the appropriate type depending on the load. The dimensioning of the vibration dampers is done by the customer. Use vibration dampers on all types of support points. Installation on longitudinal supports A base frame B Vibration damper C On-site longitudinal support Fig. 21: Longitudinal support © robatherm...
  • Page 22 Unit assembly Installation on width support A base frame B Vibration damper D On-site width support Fig. 22: Width support Installation on foundation spot A base frame B Vibration damper E On-site foundation spot Fig. 23: Foundation spots © robatherm...

  • Page 23: Casing Connection

    C Washer 8.4 D M8 hexagonal screw Fig. 24: Housing connection with through bolt and nut B Foam tape 20x3 C Washer 8.4 E M8 rivet nut F M8 hexagonal screw Fig. 25: Casing connection with rivet nut © robatherm...
  • Page 24 VDI 6022. Microbially inert joint sealant according to VDI 6022 The manufacturer of a microbially inert joint sealant proves that the requirements of VDI 6022 are met. The test procedures are described in ISO 846. © robatherm...

  • Page 25: Fastening To On-Site Beams

    B On-site support F FC beam clamp G Base frame/DIN frame H Close FC beam clamp completely Fig. 28: Fastening with beam clamp FC FC beam clamps (F) are recommended for fastening AHUs with on-site longitudinal beams (B). © robatherm...

  • Page 26: Connection Of Ahus With Roof Rack Frame

    For transport loops, the maximum permissible oblique pull is 10°. • Observe reduction of load-carrying capacity by spreading the lifting equipment according to the lifting equipment table. • Observe safety regulations of the conveying vehicles and means of transport. • Do not stand under suspended loads. © robatherm...
  • Page 27 Roof rack brackets (D) on the roof rack frame (C) serve to guide and center the base frame of the upper AHU (B). Fig. 31: Setting down the upper section Remove hexagonal screws from roof rack brackets (D). Fig. 32: Disassembling roof rack brackets © robatherm...
  • Page 28 Fig. 34: Roof rack bracket assembly The roof rack brackets (D) fix the base frame of the upper AHU (B) to the roof rack frame (C) of the lower AHU (A). Fig. 35: Connection of upper and lower © robatherm...

  • Page 29: Transport Lugs/Transport Loops

    B flexible connection C On-site duct L component length Fig. 36: Flexible connection The component length (L) of the flexible nozzle must in no case be the stretched length. The optimum component length (L) is 100 - 120 mm. © robatherm...
  • Page 30 Unit assembly Sound-insulated connection A Frame C On-site duct D Microlen tape E rubber buffer F Unit connection frame G gasket Fig. 37: Unit connection frame © robatherm...

  • Page 31: Air Openings Down

    (e.g., support point (C)) at both ends. Spacer tubes (D) prevent the grating element from slipping. Grating elements are available with the following dimensions: Supporting rod (A) length [Modules] L04,5 L07,5 [mm] Cross rod (B) length [Modules] T03 - 60 mm T06 - 60 mm [mm] © robatherm...

  • Page 32: Door

    Fig. 42: Hinge of the door After aligning the door leaf on the hinge side, align the external latch: • Align the locking cam bracket vertically. • Align the lock casing horizontally. Fig. 43: External lock with key size 10 / double-bit 3 © robatherm...

  • Page 33: Condensate, Drain And Overflow Lines

    Only a siphon filled with water can perform its function. A siphon may dry out after a long period of inactivity. • Fill the siphon manually before commissioning. • Use ball siphons for underpressure or overpressure (intake or discharge side). © robatherm...
  • Page 34 • pressure loss of individual components in the AHU (see technical data sheet), and • the external pressure on the intake side or • the external pressure on the discharge side. © robatherm...
  • Page 35 Unit assembly Fig. 45: Airflows in the combine unit Plate heat exchanger In combine units with plate heat exchangers, the airflows cross. Trace airflow jump when calculating the pressure. © robatherm...
  • Page 36 H [mm] = H1 + HS (Sample calculation for heating coil (A) p = -485 Pa) H [mm] = H = p [Pa] / 10 + p [Pa] x 0.075 H = 485/10 + 485x0.075 = 85 [mm] © robatherm...
  • Page 37 [Pa] Maximum internal pressure on the discharge side of the respective component H [mm] = 35 mm + H + 50 mm (Sample calculation for silencer (B) p = +465 Pa) H = 35 + H + 50= 35 + 465/10 + 50 = 131 [mm] © robatherm...
  • Page 38 (low pressure) Connect the drain line of the circulating water spray humidifier (low pressure) and the pan drain of the pre-assembled pan separately to the waste water system. Do not empty the humidifier pan into the pre-assembled pan. © robatherm...

  • Page 39: Weatherproof Unit

    Fig. 50: Separation point before Fig. 51: Separation point after A – panel; B – transport lug; C – separation point; D – drip edge; E – joint edge; F – drip edge overlapping part; G – roofing membrane stripes © robatherm...
  • Page 40 (suitable material: butyl rubber; thickness of the glove material: >= 0.7 mm) and protective clothing). • Do not allow the product to reach sewage system or waterways. • Comply with the safety data sheet of the manufacturer. Use up opened containers within 24 hours. © robatherm...
  • Page 41 Clean soiled roofing membranes and drip edges (D) using a damp cloth. Fig. 54: Cleaning Roofing membranes next to the separation point (C) must be dry. Dry wet roofing membranes and drip edges (D) using hot air. Fig. 55: Drying © robatherm...
  • Page 42 Installation temperature must be at least +10 °C. Fig. 58: Installation temperature At temperatures below +10 °C, roofing membranes next to the separation point (C) and roofing membrane stripes (G) must be preheated with hot air. Fig. 59: Preheating © robatherm...
  • Page 43 Approx. 5 to 10 cm wide at drip edges (D) and drip edge overlap pieces (F) over the complete Fig. 62: Apply solvent-welding agent in support point of the roofing sections membrane strip (G) Fig. 63: Applying solvent-welding agent © robatherm...
  • Page 44 Sealing paste of the roofing membrane dries quickly to a dense film. Fig. 66: Sealing paste Roofing is closed at the separation point (C). Fig. 67: Roof sealing at the separation point © robatherm...
  • Page 45 (white), depending on casing construction. Fig. 69: Close hole Roofing membranes must be clean. Clean soiled roofing membranes with a damp cloth. Fig. 70: Cleaning Roofing membranes must be dry. Dry wet roofing membranes with hot air. Fig. 71: Drying © robatherm...
  • Page 46 10 mm. Fig. 74: Cutting roofing membrane stripes to size Apply solvent-welding agent with a flat brush in the area of the hole the size of the cutting on the already laid roofing membrane. Fig. 75: Applying solvent-welding agent © robatherm...
  • Page 47 Fig. 78: Weighing down Press a thin strand of the sealing paste of the roofing membrane steadily into the joint edge. Sealing paste of the roofing membrane dries quickly to a dense film. Fig. 79: Sealing paste © robatherm...
  • Page 48 Unit assembly Roofing is closed at the corner. Fig. 80: Roof sealing at the corner © robatherm...
  • Page 49 D - hexagonal screw M8x8 DIN 931 galvanized steel; E - washer form A; d1=8,4; d2=16 DIN 125 galvanized steel; F - hexagon nut M8 DIN 934 galvanized steel Additional frames are delivered on a pallet or are clamped between the main frames. © robatherm...
  • Page 50 (D), washer (E) and hexagon nut (F). Fig. 85: Joining additional frame Fig. 86: Detail of the additional frame screw fitting Start/end (B) of the additional frame is mounted correctly. Fig. 87: Mounted additional frame © robatherm...
  • Page 51 Fig. 89: Joining additional frame Fig. 90: Detail of the additional frame screw fitting Additional frame in the center (C) is mounted correctly. Fig. 91: Mounted additional frame Mount upper AHU (see chapter "Connection of AHUs with roof rack frame", page 26). © robatherm...
  • Page 52 Cover protection roof sides and top with foam tape, 20x4 mm, PE foam, anthracite. Fig. 93: Taping Insert the supplied self drilling screw with lens head DIN 7504, 6.3x80 mm, Torx, galvanized steel. Fig. 94: Insert screws first © robatherm...
  • Page 53 Fig. 96: Screws have been removed Align the protection roof to the panel. Fig. 97: Alignment Use bit extension to mount protection roof with pre-inserted self drilling screw with lens head DIN 7504, 6.3x80 mm, Torx, galvanized steel. Fig. 98: Fit screws © robatherm...
  • Page 54 Fig. 99: Screws fitted Disassemble transport lugs. Fig. 100: Remove transport lugs Seal holes with plugs 13.0x11.0x5.0 PE RAL 9010/pure white. Fig. 101: Sealing holes The protection roof is mounted. Fig. 102: The protection roof is mounted © robatherm...

  • Page 55: Filter Component

    HEPA filter installation according to EN 1822 HEPA filter installation according to EN 1822 The preassembled filter component for HEPA filters according to EN 1822 consists of the following components: Fig. 103: F - rivet nut M8, hexagonal, V2A; G - filter wall © robatherm...
  • Page 56 Filter component If robatherm AHUs are equipped with HEPA filters according to EN 1822, the following install material is included in the delivery: Fig. 104: Install material A - filter; B - clamping profile; C - hexagon nut DIN 934 (EN-ISO 4032) M8 V2A; D - washer A2, DIN 9021 (EN-ISO 7093), d1=8.4mm, d2=24.0mm;...
  • Page 57 Fig. 108: Aligning the filter Slide 2 x clamping profiles (B) onto threaded rods (E). Fig. 109: Sliding clamping profiles on Align the clamping profiles (B) parallel to the filter wall (G). Fig. 110: Incorrect orientation of clamping profiles © robatherm...
  • Page 58 Fig. 112: Incorrect orientation of clamping profiles Fasten nuts (C) with a tightening torque of 2 Nm. Fig. 113: Tightening torque 2 Nm Align the clamping profiles (B) parallel to the filter wall (G). Fig. 114: Incorrect orientation of clamping profiles © robatherm...

  • Page 59: Filter Monitoring

    ISO class 50 Pa + initial pressure loss or 3x initial pressure loss ISO ePM1, 100 Pa + initial pressure loss or 3x initial pressure loss ISO ePM2.5, ISO ePM10 Table 5: Final pressure loss for ISO 16890 filters © robatherm...
  • Page 60 Recommended final pressure loss for EN 779 filters Filter class Recommended final pressure loss G1 - G4 150 Pa M5 - M6, F7 200 Pa F8 - F9 300 Pa E10 - E12, H13 500 Pa Table 6: Final pressure loss for EN 779 filters © robatherm...

  • Page 61: Fan

    Do not apply tension to the vibration dampers when removing the transport lock. • Perform the "Remove transport lock" steps (see chapter "Removing transport lock", page 62). Vibration dampers are secured for transport. A – transport lock Fig. 116: Transport lock © robatherm...
  • Page 62 Remove hexagonal screw. Fig. 117: Removing screws Fold up the two-piece transport lock. Fig. 118: Unfold transport lock Remove the two-piece transport lock. Fig. 119: Removing transport lock Transport locks have been removed. Fig. 120: Fan without transport lock © robatherm...

  • Page 63: Plug Fan

    (A). The gap overlap (R) must be approx. 1 % of the impeller diameter. In the case of plug fan installation with flexible connections, this test is not required. Fig. 121: Plug fan © robatherm...

  • Page 64: Heat Recovery Systems (Hrs)

    Open the inspection hatch at the marked rotary heat exchanger corner. Check whether V-belt is sufficiently tensioned by the tensioning device. If necessary, shorten the V-belt as follows: Open the joint lock. Shorten endless V-belts accordingly. Close the joint lock. Close the inspection hatch. © robatherm...

  • Page 65: Run Around Coil

    Connecting run around coils Fig. 122: The coils are to be connected according to the counterflow principle. Information on connecting coils see chapter "Coil connection", page 67. Information on the hydraulic set see chapter "Hydraulic set", page 80. © robatherm...

  • Page 66: Heating Coil, Cooling Coil, And Electric Heater

    For HE-RAC with dehumidification with run around coil: Preheating the air in the HE-RAC coil does not ensure sufficient frost protection. The cooling coil must be protected from freezing with a frost protection agent. © robatherm...

  • Page 67: Coil Connection

    When tightening the threaded connections provided by the customer on the connection pipe of the coil, hold them in place, e.g., with a pipe wrench, otherwise the internal pipes will be twisted off and damaged. Flange the on-site piping to allow easy removal of coils for scheduled maintenance or replacement. © robatherm...

  • Page 68: Electric Heater

    Place triple thermostat in the air direction immediately after the electric heater. Minimum distances to components For non-heat-resistant components, the minimum distance is 612 mm. A minimum distance of 300 mm applies to heat-resistant components. To avoid burns and damage, the connections to the duct system must be heat-resistant. © robatherm...

  • Page 69: Dampers

    (see chapter "Characteristic tripping or contact pressure", page 70). The presetting is made by means of the specified a dimension. Fig. 124: Pressure relief damper © robatherm...
  • Page 70 Dampers Characteristic tripping or contact pressure Fig. 125: A - activation pressure [Pa]; B - number of weight plates [pieces]; C - clearance a [mm]. © robatherm...

  • Page 71: Humidifier

    If bacterial counts are too high, clean the AHU immediately. Recurrent contamination In cases of doubt or in the event of rapidly recurring high levels of contamination, it is advisable to seek the advice of a qualified institute. © robatherm...

  • Page 72: Circulating Water Spray Humidifier (Low Pressure)

    CFU = Colony Forming Units Softening or partial desalination may be necessary; electrical conduction max. 800 µS/cm when humidifying to above 95 %r.H. Full desalination necessary ***) Lower value without additional disinfection measures; upper value with additional measures © robatherm...
  • Page 73 Contact a specialist water treatment company. These determined settings are approximate values and do not replace additional monitoring of the bacterial counts. robatherm recommends using test systems (dip slides). Observe the instructions for use. © robatherm...
  • Page 74 Humidifier Fresh water pressure The float valve is approved up to a max. operating pressure of 6 bar. robatherm recommends fresh water pressure of at least 3 bar; if necessary, install a pressure booster system. Cleaning before filling Clean the humidifier tray of foreign bodies, clean contaminants with water and a cleaning agent (non- foaming, pH value 7 - 9).

  • Page 75: Fresh Water Spray Humidifier (High Pressure)

    When connecting to the fresh water system, provide a pipe disconnector on site in accordance with EN 1717. High-pressure connection Check that the high-pressure hose is laid without tension or abrasion; correct if necessary. Treated water must be removed from galvanized parts immediately. There is a risk of white rust formation. © robatherm...

  • Page 76: Electro Steam Humidifier

    • Use condensate hose with a loop as a vapor barrier. Assembly of steam lances • All steam lances must be mounted horizontally. • Install close to the steam generator to minimize steam losses due to condensation. © robatherm...

  • Page 77: Refrigeration Technology (Refrigeration Plant, Heat Pump, And Split Air Conditioner)

    When opening the piping during preparation for the brazing process, there is a risk of suffocation due to the escape of refrigerant or compressor oil. • In case of a refrigerant leak, enter the machinery compartment only using heavy-duty respiratory protective equipment. © robatherm...

  • Page 78: Personnel Qualification

    (e.g., DIN EN 378, BGR 500, and F-Gas regulation) must be observed. Personnel qualification Refrigeration specialist Completion of refrigeration plants may only be carried out by the manufacturer or another specialist appointed by the manufacturer. © robatherm...

  • Page 79: Connection Of The Refrigerant Line

    In the case of direct expansion coils, after opening the coil connection lines, the nitrogen inert gas charge must escape with a hissing noise. Otherwise, there is a leakage. The piping outside the AHU must be insulated to be diffusion-tight. © robatherm...

  • Page 80: Hydraulic Set

    In closed system circuits (e.g., RAC/ HE-RAC circuits) use oil-resistant seals. The system must be flushed in accordance with VDI 2035 (removal of contamination). The oil residues must be dissolved during the flushing process, otherwise they will remain in the system. © robatherm...

  • Page 81: Filling

    For vertical multi-stage centrifugal pumps, also open a separate vent screw. Pressure test Optionally, proceed according to DIN 4753, part 1. Observe the approved pressure range. Hydraulic system Optionally, perform hydraulic commissioning by adjusting and balancing pressures (e.g., by means of a pressure regulating device). © robatherm...

  • Page 82: Direct Firing

    Observe requirements according to DIN 4794, DIN 4755, and DVGW worksheet G600. Connections In the case of on-site burners, approval must be requested from robatherm for the purpose of checking compatibility with the selected combustion chamber. Assembly of the oil or gas burner according to the manufacturer's instructions.

  • Page 83: Direct Gas-Fired Heater

    Guide drain valve into non-hazardous area. Assembly and wire all sensors (e.g., room thermostats). Each installation must be equipped with an emergency switch. Tightness Check the gas line, connections and gas control system for tightness using a test device. © robatherm...

  • Page 84: Control System

    This potential-free contact is provided on a terminal strip in the control cabinet of the AHU, but can also be used directly on the smoke detector. © robatherm...

  • Page 85: Uv-C Technology

    Keep broken pieces of UV-C illuminants in airtight packaging and dispose of properly. Removal of small amounts of mercury UV-C illuminants contain small amounts of mercury. Removal of the small amount leaked at breakage can be done with special sorbents for mercury. © robatherm...

  • Page 86: Final Cleaning

    Final cleaning Final cleaning After completing installation and assembly, check all components for contamination in accordance with VDI 6022 and clean if necessary before commissioning. In particular, metal chips must be removed carefully, as they can lead to corrosion. © robatherm...

  • Page 87: Directory

    Fig. 34: Roof rack bracket assembly   Fig. 35: Connection of upper and lower AHU   Fig. 36: Flexible connection   Fig. 37: Unit connection frame   Fig. 38: A - supporting rod; B - cross rod   © robatherm...
  • Page 88 Fig. 71: Drying   Fig. 72: Installation temperature   Fig. 73: Preheating   Fig. 74: Cutting roofing membrane stripes to size   Fig. 75: Applying solvent-welding agent   Fig. 76: Applying roofing membrane stripes   Fig. 77: Pressing   © robatherm...
  • Page 89 Fig. 111: Screw on washer and nut   Fig. 112: Incorrect orientation of clamping profiles   Fig. 113: Tightening torque 2 Nm   Fig. 114: Incorrect orientation of clamping profiles   Fig. 115: Mounted filter   Fig. 116: Transport lock   © robatherm...
  • Page 90 Fig. 122: The coils are to be connected according to the counterflow principle. 65   Fig. 123: Coil   Abb. 124: Pressure relief damper   Fig. 125: A - activation pressure [Pa]; B - number of weight plates [pieces]; C - clearance a [mm].   © robatherm...

  • Page 91: Keyword Index

    Operation and incidents ......6 Tetrahydrofuran ........9, 10 Transport and unloading ......6 Transport loops ......... 26 Transport lugs ........... 26 L  Lifting equipment ........26 U   List of figures ..........91 UV-C illuminants ........89 Load-carrying capacity ....... 26 © robatherm...
  • Page 92 John-F.-Kennedy-Str. 1 89343 Jettingen-Scheppach Tel. +49 8222 999 - 0 info@robatherm.com www.robatherm.com...

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