CENTRAL VENTILATION AND AIR CONDITIONING UNITS INSTALLATION AND OPERATING INSTRUCTIONS (ORIGINAL)

Transcription

1 CENTRAL VENTILATION AND AIR CONDITIONING UNITS INSTALLATION AND OPERATING INSTRUCTIONS (ORIGINAL) 1

2 "Product description" 2 Translation of the original installation and operating instructions 3 Contents 1. Product description Designated use Possible misuse Residual dangers Explanation of symbols Description of various application areas and versions Station setup (example) Technical data Diagram with exhaust air device (example) Diagram with exhaust air device and input options (example) Delivery Transport and storage Owner's obligations Disposal of the packaging Assembly General information Setup Filling and venting Electrical connections Cabling to the on-site control system Bus card installation (option) Start-up General information Requirements Start-up procedure Control-oriented integration of the HYDROOPT into the on-site MSR Operation Operating unit (optional remote control) Controller keypad Display menu Main menu (PRG button) Menu password Settings Start-up menu System time System information Alarm menu Warnings, malfunctions and emergencies Maintenance Maintenance schedule Decommissioning Taking out of service Dismantling Disposal Appendix Start-up log... 32

3 1. Product description The hydraulic station is used for highly efficient heat and cold recovery in closed-cycle systems (KVS). AL-KO HYDROOPT In winter, the heat is removed from the exhaust air flow coming from an exhaust device and forwarded to a heat exchanger in the central supply air device. The integrated control unit monitors the operating states and controls the optimum amount of brine circulation. Technical control measures are used to prevent the exhaust air heat exchanger from frosting up and prevent the optional heat input from freezing. The power control is managed via a frequency-controlled pump as well as a power control valve. The amount of brine circulation is continuously recorded and can be used together with the temperature measurement for heat quantity measurement. A superordinate central building control system must decide whether or not heat recovery is possible and how much heat should be recovered. Therefore, the station works together with the central building control system in a crucial relationship to save energy and reduce operating costs. Optional components for expanded application include: Plate heat exchanger for heat input Plate heat exchanger for cold input Warnings and malfunctions are displayed and forwarded via potential-free contacts. The control unit can be easily integrated into superordinate systems via pre-configured bus systems: Modbus, LON, Bacnet/TCP-IP are available for selection. Our products are subject to continuous quality control, and comply with the applicable regulations. "Product description" 1.1 Designated use This device may only be used for heat recovery from the exhaust air flow of a central ventilation unit. It may only be operated within a pressure range of 3 to 6 bar. Any deviating operating ranges must be coordinated with the manufacturing plant. 1.2 Possible misuse HYDROOPT may only be operated within the scope of the technical data specified by AL-KO. Any other use, or use beyond that described in the "Designated use" point is regarded as not in accordance with the designated use. The manufacturer cannot be held liable for damage resulting from this. 1.3 Residual dangers The system may represent a danger if it is not operated by trained personnel and/or is not used according to its designated use. Residual dangers are potential dangers that are not obviously apparent, such as: Injuries caused by non-observance of the safety instructions Injuries caused by uncoordinated work Danger caused by working on the electrical system, cables and connections 1.4 Key to symbols Warning! This symbol indicates safety measures that must be complied with in order to avoid injury to personnel! Important! This symbol indicates safety measures that must be complied with in order to avoid damage to property! Special instructions for ease of understanding and regarding handling. 4 Translation of the original installation and operating instructions 5

4 "Product description" 1.5 Description of various application areas and versions Dimensions: Station setup (example) From supply air exchanger To supply air exchanger Bearing frame Switch cabinet Flow rate measurement device Frequency converter Pressure gauge In-flow temperature sensor To exhaust air exchanger From exhaust air exchanger Return flow temperature sensor Dirt trap Frost protection valve (option) Power control valve Pressure gauge / Electrical system monitoring Pump Height Filling / Emptying Level compensation Tray Width Length Technical data The station is available in 5 sizes depending on the required quantity of brine being circulated: (see drawing) System pressure: Supply voltage: Max. fusing: 3 to 6 bar 3 Ph/400 V/50 Hz 20 A slow blow Compact control units Type Dimension Flow rate m 3 /h Length mm Width mm Height mm Weight kg 2 DN DN DN DN DN The weight will vary depending on the equipment and pump size. See the enclosed circuit diagram for the max. on-site fusing. The exact dimensions of the pump and the calculation of the required system pressure is performed in-house at AL-KO THERM once the order has been placed. 6 Translation of the original installation and operating instructions 7

5 "Product description" Diagram with exhaust air device (example) Diagram with exhaust air device and input options (example) K Exhaust air With additional energy feed-in K Exhaust air Pump station system limits M Switch cabinet FO T M * P P P T M I D * Frost protection control valve EB Safety valve and SV expansion tank blow-off pressure 6 bar AG with adapted system pressure. Installation on the pump suction side Switch cabinet FU P P P M Pump station system limits AG Safety valve and SV expansion tank blow-off pressure 6 bar AG with adapted system pressure. Installation on the pump suction side HVE Supply air * Frost protection control valve HVE T M * T M I D T T Plate heat exchanger Controller on-site E1 Supply air On-site cable Grid feed-in 400 V / 50 Hz 16 A Release Exhaust air systems 1 - n in operation (digital in) Request HRO % (0-10 V) Warning (digital out) Malfunction (digital out) Operational response (digital out) LiYCY 3x1,0 Pressure transmitter for volume flow determination 4-20 ma E1 On-site cable LiYCY 3x1,0 Grid feed-in 400 V / 50 Hz 16 A Feed-in additional energy cold and/or fast heating (digital in) Release Exhaust air systems 1 - n in operation (digital in) Request HRO % (0-10 V) Warning (digital out) Malfunction (digital out) Operational response (digital out) Pressure transmitter for volume flow determination 4-20 ma 8 Translation of the original installation and operating instructions 9

6 1.6 Delivery The station is delivered on a one-way pallet. 1.7 Transport and storage AL-KO HYDROOPT Transport within the building can be performed by a lift truck or a forklift. The forks can be inserted under the cross profiles of the supporting frame. The HYDROOPT station must be transported upright and secured against tipping over. Suitable fork lengths must be used to prevent damaging the device. Suitable layer pads must be used to prevent damage to the paint. The station must be stored in a dry location protected against the weather. The functional units must be protected against debris (e.g swarf, stones, wires, etc.) and strong UV exposure. The HYDROOPT station is delivered unfilled and is thus frost-proof. When transporting under difficult conditions (e.g. on open vehicles, under unusual vibration stresses, transport by sea or in subtropical countries), additional packaging must be used that will protect against these particular influences. Constant and, above all, abrupt temperature changes must be prevented during storage. It is especially damaging when moisture is able to form condensation. Damage that results from improper packaging, storage, and transport are at the expense of the person responsible. No personnel may be in the transport area. All relevant provisions related to occupational safety and environmental protection must be followed during transport. Sufficient visibility must be maintained during transport. If transport devices are used that require a driving licence, then it must be ensured that the personnel operating these devices have a valid driving licence. The HYDROOPT station may only be transported by properly trained and qualified personnel who are also familiar with the information in the "Safety" section. "Installation" 2. Installation 2.1 General information 2.2 Setup All hydraulic components are pre-mounted and piped on the supporting frame. All pipe parts and fittings that are at risk of condensation have been covered in cold- and vapour-proof insulation. Warning! The installation, electrical connection, power supply connection, maintenance, start-up, repair, etc. may only carried out by trained and authorised personnel. Important! Components that come loose during transport can lead to malfunctions or damage. The station must be checked for transport damage upon delivery. The condition of the ground must be taken into account. Level compensation can be carried out via the height-adjustable feet. The station must be bolted at the feet to the floor in a vibration-isolated manner. Connect piping to the heat exchangers. Make sure that no impurities get into the system. Take into account the reverse flow principle. Once the piping is complete, the system must be flushed out. 1.8 Owner's obligations The owner of AL-KO THERM products must regularly train its personnel in the following subjects: Compliance with and use of the installation and operating instructions as well as statutory regulations. Designated operation of HYDROOPT. If necessary, comply with the instructions for plant protection and the owner's company instructions. What to do in an emergency. 1.9 Disposal of the 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. Fig.: Reverse flow principle 1 Air inlet 2 Air outlet 3 Media inlet 4 Media outlet 10 Translation of the original installation and operating instructions 11

7 "Start-up" 2.3 Filling and venting The filling and venting equipment for the heat exchanger must be set up on-site. The pipe system must be resistant to ethylene glycol (N). The glycol content must match the manufacturer's information. Note: The glycol mixture must be replaced after a specified operating time according to the manufacturer's information. The glycol/water mixture must be mixed in advance before filling. Otherwise, the two may not blend properly when filled. Feed and return lines must be connected according to professional standards and properly insulated. The complete piping system must be checked for leak-tightness. When setting up the heat recovery system, the manufacturer's information regarding the heat carrier used (brine) must be taken into account! Bus card installation (option) As an option, the control system can be integrated into a superordinate network. For this purpose, the following bus cards can be inserted into the respective slots on the control unit: LON Modbus BACnet, TCP/IP 2.4 Electrical connection You must make sure that the components and the connection cable at the setup location cannot be either damaged or contaminated by oil or other materials. Fuses, clamping connections, contactors, and circuit boards must be checked to ensure that they are seated firmly. Any loose components must be re-secured. The pump motor must be protected against an overload. The electrical connection must be set up according to the available circuit diagram. Warning! The electrical connection may only be performed by a certified electrician according to statutory regulations as well as the guidelines of the local utility company. The connection must be performed according to the wiring diagram and according to the assignment plan Cabling to the on-site control system The following cabling is required along with the 3-phase supply: Coming from the on-site building control system: Release signal potential-free contact Power control signal 0-10 volt analogue signal Air quantity proportional signal 4-20 ma analogue signal mostly from supply air pressure transmitter** Heating operation requirement* potential-free contact Fig.: Slot for optional bus cards The bus cable connection is made directly to the optional plug-in card. Only one plug-in card at a time may be used. Data point lists, see point "Data point lists appendix". Going to the on-site building control system: Operation message heat recovery potential-free contact Warning message heat recovery potential-free contact Malfunction message heat recovery potential-free contact * only optional for system with heat input via a plate heat exchanger ** mounted on the ventilation unit or included unattached The cabling of the control lines must be laid to the terminals in the station switch cabinet. 12 Translation of the original installation and operating instructions 13

8 "Operation" 3. Start-up 3.1 General information 3.2 Requirements Warning! Installation, start-up, maintenance, and repair work may only be performed by trained and qualified technical personnel. The following must have already been completed on-site before HYDROOPT station start-up: The supply and exhaust air system must be operational. The air quantities must have already been measured. The system glycol content must have already been determined. The system pressure must meet the specified resting pressure. All isolation devices on the station and any on the heat exchangers must be open. The station electrical supply must have already been checked. The protective and neutral conductors must be in place. 3.4 Control-oriented integration of the HYDROOPT into the on-site MSR The closed-cycle system (KVS) covers most of the heating output during ongoing operation via heat recovery from the exhaust air flow. Due to the inertia of the system, any available pump warm water heater (PWW) should first be rinsed before starting up the central ventilation system. After the rinse time for warming up the on-site pipe system, the air shut-off dampers should be opened. Only then may the fans be put into operation and the KVS may be released for operation. After the release contact, an analogue request signal (0-10 volts) is required to operate the KVS. The heat recovery output can be controlled proportionally via the signal from 0-100%. Thus the complete station acts like a heating valve (also when inert) with constant valve actuation, and can easily be integrated into the on-site control system strategy. The decision whether or not to use heat recovery must be made by the on-site control unit via an air temperature comparison. y1 HRO 3.3 Start-up procedure Important! The rotary pump must have been vented according to the manufacturer's information. For this purpose, the corresponding plugs must be opened just long enough for the brine to come out bubble-free. Please have a suitable collection container available for this procedure. Improper venting can lead to damage to the rotary pump. y 100 % HRO y2 Heating After turning on the main switch, the pump can be manually operated on the frequency converter for a brief time. During this, the direction of rotation must be checked. The corresponding directional arrow is marked on the pump. The two-stage pressure monitor attached upstream from the pump protects the ppump from running dry through lost brine. The switching threshold is set at the factory to approx. 1.5 bar (warning) and at 0.5 bar media over-pressure (malfunction). Finally, re-set the frequency converter to AUTOmatic operation. The pressure transmitter attached to the air supply device must be connected at the inlet nozzle and the suction-side device ring line. The pressure transmitter must be set to 4-20 ma. The measurement range (factory-set 2500 Pa) must be adjusted accordingly if necessary. The pressure transmitter measures the effective pressure at the inlet nozzle and outputs this pressure linearly (not as a square root). The default setting of the measurement range end value of the flow rate sensor is approx. 1.4 times the nominal brine quantity because when there is a danger of frost, then the brine quantity is also briefly increased beyond the nominal brine quantity. Issue the on-site release signal and set the on-site power control signal to 10 volts. When demand reaches 95% and higher, "Optimisation active" appears on the control unit display so long as no other operational states are active (e.g. frost protection). The optimisation of the brine quantity is then carried out via the supply air quantity. 1 m 3 /h brine corresponds to approx m 3 /h of air. This optimisation process can take several minutes. When the power control signal is set below 90% (9 volts), this initially reduces the pump speed. When this reaches a lower limit of 12 Hz, then the power control valve diverts the brine to the exhaust air heat exchanger (bypass operation). Fig. Control strategy for actuating the KVS HYDROOPT Heating requirement Heating 14 Translation of the original installation and operating instructions 15

9 "Operation" 4. Operation 4.1 Operating unit (optional remote control) Fig. Remote control 4.2 Controller keypad Operation is menu-driven and is carried out via the buttons on the controller or an optional detached controller. Symbol Button Function PRG Displays the main menu 4.3 Display menu Screens that are not described here must be skipped when they appear using the Enter button! Escape Down UP Enter Alarm Switches to the previous menu Navigation key Goes to the next screen in the menu and/or to the next menu item Decreases the value being set Navigation key Goes to the previous screen in the menu and/or to the next menu item Increases the value being set Navigation key Confirms the set value Goes to the selected menu item Goes from an adjustable value to the next one within a screen In the Alarm menu, switches to display active alarms When pressed again, this confirms the alarms that are no longer active The Main menu displays the release and the request of the superordinate control unit. The display "Optim. active" only appears when optimisation is active. If there is no release from the superordinate control unit, then "Locked!" is displayed in the Main menu. 16 Translation of the original installation and operating instructions 17

10 "Operation" M02 screen Heat energy display. This can be reset by entering the customer password. Calculated heat energy display Calculated heat energy reset and date of the last reset Current heating output display The display is updated once every minute. M03 screen Cooling energy display. This can be reset by entering the customer password. 4.4 Main menu (PRG button) Selection of menu items: Password Settings Start-up System time Manual level System info Screens are displayed depending on the system configuration. Only the screens required for the particular system configuration are displayed. The display is updated once every minute. M04 screen Calculated cooling energy display Calculated cooling energy reset and date of the last reset Current cooling output display Menu password There are 3 password levels that are accessible via different passwords. Everyone No password Level 0 Customer level Password 0001, can be changed Level 1 Service level Password 0005, can be changed Level 2 The password can be entered in the Password menu. The password can be reset manually in the P02 screen using the PW Reset function. Temperatures display. The in-flow temperature after feed-in (T-IFaFI) is only displayed when a temperature sensor is activated in the settings after feed-in. P01 screen In-flow temperature display In-flow temperature display after feed-in Return flow temperature display Customer level Active/ Inactive Service level Active/ Inactive Manufacturer level Active/ Inactive M05 screen Brine/Air quantity displays P02 screen Manual reset of the active password. The air quantity is only displayed when a pressure difference sensor is available. Measured brine quantity display Measured air quantity display Customer level Active/ Inactive Service level Active/ Inactive Manufacturer level Active/ Inactive P03 screen The duration of password validity can be changed in this screen. Once the set time has expired without any buttons being pressed, the active password is reset automatically. Setting value 18 Translation of the original installation and operating instructions 19

11 "Operation" P04 screen The current password can be changed in this screen. The manufacturer password cannot be changed. What is visible: Manufacturer level Differential pressure sensor s measurement range end value Current customer password Current service password Number of values in the chronological averaging Settings The information in the windows displays the current default values. E04 screen What is visible: Service level E09 E11 screens What is visible: Service level Brine System type setting System type 1:1 = 1 Air supply heat exchanger: 1 Exhaust air heat exchanger Defines whether or not a feed-in with temperature sensor is available. Yes/No Brine flow measurement range end value at 20 ma at input B2 E05 screen Concentration of the filled brine What is visible: Service level Air quantity/brine quantity setting for the optimisation operation for systems with a constant air quantity. This menu is only visible when no differential pressure sensor was detected at analogue input 6. The optimal brine quantity is calculated for the specification of the air quantity. The brine factor from E08 is taken into account for this. As an alternative, the brine quantity can be entered directly without any correction factor. Min. flow rate, alarm after 30 s of undershooting Min. speed of the brine pump Display: "Air quantity" or "Brine quantity" E16 screen What is visible: Service level Temperatures The maximum value for air quantity is 320,000 m³/h, the setting is carried out in increments of 10 m³/h. E06 E08 screens What is visible: Service level This menu is only visible when no differential pressure sensor for air quantity measurement was detected at analogue input 6. Frost protection temperature for feed-in default +2.6 C Min. return flow temp./icing protection is active Factory setting -2.0 C A warning message is triggered when the frost warning is undershot. Factory setting -5.0 C Differential pressure sensor s measured effective pressure Differential pressure sensor s pressure offset Fan/pressure measurement s K-factor 20 Translation of the original installation and operating instructions 21

12 "Operation" Start-up menu What is visible: Service level The software s safety functions remain active. Start-up mode The start-up mode is turned off automatically after resetting the password flag, i.e. at the latest, after the time set in the P03 screen has elapsed without a button on the display being pressed. IB04 - IB05 screens Shut-off valves manual control. Depending on the system configuration, valves 1-3 are visible and can be controlled. OPEN/CLOSED OPEN/CLOSED IB01 screen Switches from normal operation to start-up mode. In start-up mode, the release signal and the power request are ignored. Normal operation/start-up OPEN/CLOSED OPEN/CLOSED OPEN/CLOSED System time T01 screen What is visible: Customer level Changing the system time. After changing the parameter from "N" to "J", the menu for changing the system time appears. IB02 screen Pump manual control and 3-way valve with brine flow measurement. The pump speed is increased when icing protection is required. The actuating value runs through the characteristic curve transformation. Therefore, the pump speed and the 3-way valve run in a non-linear manner. The optimisation is shut down. Important: Please always set the correct date and/or time because the system time is required for data logging. Date/Time entry Display: Day Light Savings Time/Standard Time (This changes automatically) ON/OFF Pump actuating value as a % (100.0 % = 10 V) at the FC IB03 screen Measurement value at the MID. Note: depends on the nominal value The pumps actuating value is required at the nominal value for specific operating modes. The currently saved actuating value for the nominal values is displayed. Set the actuating value so that the brine flow reaches the nominal value. Then set the copy flag from 0 to 1 to copy the actuating value. The flag resets automatically System information I01 screen What is visible: Always System info 1 Manufacturer information. Saved actuating value, no default Pump actuating value as a % (100.0 % = 10 V) at the FC/Copy flag (0 or 1) Measurement value at the MID. Note: depends on the nominal value "Copy flag" (confirmation of the set values) 22 Translation of the original installation and operating instructions 23

13 "Operation" I02 screen System info 2 Operating system version numbers and hardware configuration display. Bootloader version; BIOS Display configuration Controller variant A03 screen There is a danger of frost during feed-in, leads to a shut down I03 screen Description: the in-flow temperature after feed-in is in the frost range. Measure: check the feed-in function. System info 3 Software version display. Software type; version As of A04 screen The measured brine flow is below the limit value, leads to a shut down Alarm menu (alarm message/warning message) When a malfunction occurs, the alarm button s red LED lights up. Existing alarms and/or warnings can be displayed by pressing the Alarm button. The alarm or warning message remains active until the alarm or warning is acknowledged by re-pressing the Alarm button. The number of active alarms is displayed in the upper line of the alarm message. (Active alarms XX). Warnings are not numbered. You can scroll through the active alarms and/or warnings via the UP/DOWN button. Description: there is no circulated brine mass flow. Pump is not functioning or there is an interruption in the hydraulic circulation. Measure: check pump, shut-off elements or valves. Possible warning messages: Warnings do not lead to a shut down! Possible alarm messages: A01 screen Malfunction message from FC or pump, leads to a shut down A05 screen Shortage of brine Description: pump or FC malfunction Description: system pressure too low Measure: increase the system pressure by topping off the corresponding glycol/water mixture. A02 screen The brine pressure is too low, leads to a shut down A06 screen The sensor values are not plausible The temperature sensors are providing implausible values Description: if the brine pressure is less than the pressure required for the pump, the heat recovery system is shut down to protect the pump and an alarm message is triggered. Measure: increase the system pressure by topping off the corresponding glycol/water mixture. Description: temperatures from the temperature sensors indicate a sensor malfunction. Measure: check temperature sensors and contact points. 24 Translation of the original installation and operating instructions 25

14 "Maintenance" A07 screen Brine in-flow to the exhaust air heat exchanger is too low despite adding media Description: the brine return flow temperature could lead to the exhaust air heat exchanger icing up. Measure: check the exhaust air heat exchanger for icing. If there is icing, shut down the heat recovery system until icing is no longer detected on the exhaust air heat exchanger. A08 screen Detection of a broken cable during brine flow measurement 4-20 ma 5. Warnings, malfunctions and emergencies Warning! Diagnostics, malfunction correction and returning to service may only be performed by authorised personnel. This is especially true for work on electrical equipment within the switch cabinet (e.g. testing, replacement, etc.)! There is a difference between a warning messages (heat recovery operation is maintained) and a malfunction message. Both are transmitted by the building control system via a potential-free contact and via a bus. A malfunction message must be acknowledged on-site after the error is corrected. Error information is provided in clear text by the controller. In case of emergency and in case of questions, please contact the manufacturer of your ventilation technology system, one of our branch offices or us directly: AL-KO THERM GMBH Telephone: (+49) 8225/ 39-0 Hauptstrasse Fax: (+49) 8225/ Jettingen-Scheppach info.therm@al-ko.de Web: Description: measurement of brine circulation amount interrupted. Measure: check flow measurement device. A09 screen Heat recovery at exhaust air heat exchanger is not possible Description: the temperature difference between the in-flow and return flow temperature is too low for additional feed-in of heat and non-separated exhaust air heat exchanger. Heat recovery is no longer efficient or will even lead to losses via the exhaust air heat exchanger. A10 screen Cooling recovery at exhaust air heat exchanger is not possible Description: the temperature difference between the in-flow and return flow temperature is too low for additional feed-in of cold and non-separated exhaust air heat exchanger. Cooling recovery is no longer efficient or will even lead to losses via the exhaust air heat exchanger. 26 Translation of the original installation and operating instructions 27

15 "Maintenance" 6. Maintenance The owner of an air conditioning system is required to have maintenance performed on the system by specialised personnel on a regular basis. AL-KO THERM recommends performing maintenance of the complete RTL system based on VDMA and VDI AL-KO THERM GMBH will take over these functions upon signing a maintenance contract. Warning! Installation, start-up, maintenance, and repair work may only be performed by trained and qualified technical personnel! Warning! When working on the HYDROOPT, the device must normally be disconnected from the power supply beforehand, the main switch and/or repair switch turned off (all poles shut down), and secured against unauthorised reactivation. Once work is complete on the device, the responsible party must make sure that no personnel are in the vicinity of the system as well as that all factory installed protection measures are functional before putting the device back into operation. Only use original consumable materials and spare parts. This is the only way to ensure safe operation. In addition, if this is not followed, this can also void the warranty. 6.1 Maintenance schedule Excerpt from VDMA and -4 Item Implementation Assembly/ Component/ Periodically every As required Activity Activity 8 Pipe network (VDMA ) 8.1 Pumps Check exterior for dirt, damage, corrosion and a secure fit 3 Mon Function-maintaining cleaning (exterior) X Check functionality 6 Mon Check leak-tightness (visual check) 3 Mon Drive elements VDMA DDC technology VDMA Shut-off, adjustment, and control fittings Check exterior for damage and corrosion (visual check) 3 Mon Check functionality 6 Mon Check leak-tightness (visual check) 3 Mon Actuators VDMA Dirt trap Check for contamination X Clean sieve X Check sieve for damage X 8.4 Piping and expansion tanks Check the exterior of accessible piping for damage, leak-tightness and 3 Mon secure fitting Check heat insulation for damage and completeness 3 Mon Check temperature and pressure measurement devices for damage and display 3 Mon accuracy (plausibility check) Check functionality of safety equipment 6 Mon Check compensators for damage and secure fitting (visual check) 3 Mon Check fluid level 3 Mon Top off fluid X Check heat carrier of circulation-linked systems for frost resistance (1) 12 Mon Check functionality of piping trace heating 6 Mon Check functionality of venting valves 6 Mon Venting X (1) Requirements, see HVE overview sheet 10 Drive elements (according to VDMA ) 10.1 Electric motors Check the exterior for dirt, secure fitting, damage, and corrosion 3 Mon Function-maintaining cleaning (exterior) X Check direction of rotation X Re-tighten connection terminals X Measure tension 12 Mon Check connection terminals to ensure they are seated firmly 12 Mon Measure power consumption 12 Mon Measure phase symmetry 12 Mon Check for smooth running and temperature increase 12 Mon Check bearing for noise 3 Mon 28 Translation of the original installation and operating instructions 29

16 Item Implementation Assembly/ Component/ Periodically every As required Activity Activity Lubricate bearing using re-greasing device X Check functionality of protection equipment 6 Mon 11 Documentation and marking (according to VDMA ) 11.1 Maintenance-relevant documents Overview sheet available in HVE 3 Mon Inventory documents folder available 3 Mon 2 Switch cabinets (according to VDMA ) 2.1 Control part Check for proper and functional installation and check ambient conditions 12 Mon Check for dirt, damage, corrosion, and a secure fit 12 Mon Check protective covers 12 Mon Function-maintaining cleaning X Check connections 12 Mon Check functional elements (e.g. operating and display equipment) 12 Mon Check switching and control processes X 3 Field equipment (according to VDMA ) 3.1 Sensors (brine temperature sensor, magn. ind. flow rate transmitter) Check for proper and functional installation and check ambient conditions 12 Mon Check for dirt, damage, corrosion, and a secure fit 12 Mon Function-maintaining cleaning X Check measurement signals 12 Mon 4 Controller (according to VDMA ) 4.1 Controller (CPU HEHR connector) Check integral power supply (e.g. buffer battery) 12 Mon Check functional elements (e.g. operating and display equipment) 12 Mon Check input signals (e.g. sensors, remote dial, reference variable) 12 Mon Check control loop and control signal 12 Mon 5 Sub-stations (according to VDMA ) 5.1 Sub-station Check power failure and power recovery behaviour 12 Mon 10 Documentation (according to VDMA ) 10.1 Maintenance-relevant documents Check for availability (circuit diagram, operating instructions CHC) 12 Mon 10.2 Existing system markings (signage) Check for availability 12 Mon "Appendix" 7. Decommissioning 7.1 Taking out of service The system can continue to remain filled with the glycol/water mixture. Disconnect the system from the power supply before beginning work (all poles shut down) and secure it against unauthorised reactivation. 7.2 Dismantling Important! Certain system parts are under pressure. When the system is to be taken out of service for a long period of time, follow all notes related to the individual components. The information from the component manufacturers must also be followed (request this information if required). Important! In winter, there is a danger of individual components freezing. If necessary, take suitable measures such as adding frost protection/taking frost protection measures. Before recommissioning, follow the points in the Start-up and Maintenance chapters. Disconnect the system from the power supply before beginning work (all poles shut down) and secure it against unauthorised reactivation. 7.3 Disposal Important! Certain system parts are under pressure. Disassembly may only be performed by trained technical personnel. Dismantling must be carried out according to the currently valid and applicable occupational safety and accident prevention regulations. Do not dispose of worn-out machines or spent batteries (including rechargeable batteries) in domestic waste! When disposing of the HYDROOPT, operating material and accessories, 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. 30 Translation of the original installation and operating instructions 31

17 "Appendix" 8. Appendix 3. Controller setting (manufacturer password: 0109) 8.1 Start-up log Project designation: Order number: Item: 1. System data Number of exhaust air heat exchangers Feed-in plate heat exchanger Frost protection valve Nominal brine quantity m³/h l/min Glycol content % Fill pressure bar K-value of supply air fan Pump output kw 2. Visual check Wiring performed according to DIN VDE 0100/0113 Earthing OK and complete Operating material and line marking OK and complete Switch cabinet mounted Frequency converter mounted Flow rate sensor mounted (make): ABB FXE 4000 IFM SM8000 IFM SU9000 Temperature sensor mounted: In-flow after feed-in (optional) Return flow In-flow Control valve mounted Frost protection valve mounted (optional) System pressure switch mounted Date and time set Documentation of KVS controller s software status KVS Status Screen Designation Software version E01 E02 E03 E04 E05 E06 E07 E08 E09 E10 E18 Digital inputs Digital input 1 Digital input 2 Digital input 3 Digital inputs Digital input 4 Digital input 5 Digital input 6 Digital inputs Digital input 7 Digital input 8 NC System type System 1:1 Feed-in plate heat exchanger NO Quantity specifications (only when no pressure transmitter is connected) Airflow rate m 3 /h Pressure measurement 1 (only for pressure transmitter) Effective pressure 2500 Pa Offset NC NO NC NC NC NO NC 0000 Pa K-factor 0150 Pressure measurement 2 (only for pressure transmitter) Measurement range end value pressure 2500 Pa transmitter Pressure measurement 3 (only for pressure transmitter) Number of measurement values for averaging 05 Flow rate Measurement range end value flow measurement device l/min Brine Concentration: 025 % Frost protection Valve NO Setting at factory acceptance 32 Translation of the original installation and operating instructions 33

18 "Start-up and maintenance" 4. System function test Function and direction of rotation of pump tested (only start briefly!!!) Function and direction of rotation of control valve tested (position at rotary drive = square position!!!) A Exhaust air exchanger (AB) connection points to pump, A connection comes from exhaust air heat exchanger B A-AB open: heat recovery operation (control valve actuating value = 10 V) AB B-AB open: bypass operation without heat recovery (control valve actuating value = 0 V) Function and direction of rotation of frost protection valve tested (position at rotary drive = square position!!!) A AB A-AB open: frost protection operation (control valve actuating value = 10 V) Temperature sensor function tested Function and setting of system pressure switch tested (1 clockwise rotation = +0.5 bar) Setting S1 pressure malfunction Setting S2 pressure warning (switching point ambient pressure +0.5 bar) (switching point ambient pressure +1.0 bar) Input ID1 (external release) must be present to display both pressure malfunctions on the display!! Setting for end value for flow rate sensor carried out Set value (min. brine quantity * 1.4) 5. Documentation 2x electrical circuit diagrams KVS operating instructions Frequency converter pump parameter list 6. Comments Date Location Signature 34 Translation of the original installation and operating instructions 35

19 Copyright 2011 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. /December 2011 AL-KO THERM GmbH l Headquarters l Hauptstrasse l Jettingen-Scheppach l Germany Tel l Fax l info.therm@al-ko.de l