Transport, Assembly,

Commissioning and Maintenance

of Air Handling Units

Production Series AT4

M-AT 4
General Note
The units should be assembled properly and used in strict
accordance with our instructions. If the assembly is carried
out counter to our recommendations and if any defect /
damage is as a result of an improper alteration, operation, or
other action, this invalidates all claim for damages or guaran-
tee. The buyer must then furnish evidence that the improper
assembly was not the cause of the defect that occurred.
General maintenance indications in the assembly, commis-
sioning and maintenance instructions for AT4 air handling
units from the AL-KO THERM company must be absolutely
adhered to.
Assembly, commissioning and maintenance work must only
be carried out by trained personnel.
Air handling units are used exclusively for the ventilation of
spaces and buildings, for maintaining the required room air
conditioning as well as for removing dust and impurities
contained in the air.
The operational range of the air handling unit is documented
in the layout data page as well as on the rating plates. Other
operational ranges must be coordinated with the factory or
its field service employees in order not to impair operation
of the equipment.
The design and construction of the air handling unit
corresponds to the standards set forth in the manufacturer's
declaration in order to minimise a potential hazard possibly
arising from the air handling unit. It is only possible to assure
elimination of a potential hazard if the system installer
adheres to the continuing applicable standards for the
ready-to-install overall system.
 Table of contents

1. Transport 2 4.13 Control (equipment cabinet) not in Ex-zone 29

1.1 Transporting unit with forklift 3 4.14 Special installation and operating conditions
1.2 Transporting unit by crane 3 for belt-driven, freely turning fans 30
4.15 Gap and overlap in radial fans RZR,
VZR - manufacturer: Gebhardt 31
2. Assembly 4 4.16 Gap and overlap in radial fans RLM
2.1 Unit assembly in Ex-proof models 4 - manufacturer: Gebhardt 32
2.2 Internal unit connection at casing division 5 4.17 Gap and overlap adjustment for TLT-Turbo
2.3 AT4 unit connection with stacked units manufactured centrifugal fans 33
and with side-by-side units 5 4.18 Other notes 34
2.3.1 Stacked unit arrangement 5 4.19 Special instructions for the operation of
2.3.2 Side-by-side units 6 equipment in EX-zones 21 and 22 34
2.4 External installation 7, 8 4.20 Commissioning, general 34

3. Additional installation and maintenance instructions 5. Maintenance notes according to VDI 6022
for hygiene units 9 and VDMA 24186 35
3.1 Assembly 9 5.1 General 35
3.2 Commissioning and maintenance 9 5.2 Initial and repeat inspection by category A
-trained qualified personnel, in accordance
with VDI 6022 page 2 35, 36
4. Commissioning and maintenance 10 5.3 Hygiene inspections carried out as part of
4.1 Fan 10 maintenance by category B-trained mainten-
4.1.1 Air vent fan components 11 ance personnel, in accordance with VDI 6022
4.1.2 Torques of screw connections on fan component 12 page 2 36
4.2 Heat exchanger 13 5.4 Hygiene requirements and maintenance,
4.2.1 Louvre heat exchanger 13, 14 servicing of air conditioning equipment
4.2.2 Electric air heater 15 according to VDI 6022
4.3 Heat recovery 16 and VDMA 24186 37, 38, 39, 40, 41
4.3.1 Plate heat exchanger 16
4.3.2 Rotary heat exchanger 16, 17
4.3.3 Circulating coil system 17 6. Emergency 42
4.4 Filters 18
4.4.1 Bag filter 18
4.4.2 Active charcoal filter 19 7. Dismantling and disposal 42
4.4.3 Grease trap filter 19
4.4.4 Particulate air filter 19
4.5 Louvre dampers 20
4.6 Sound absorbers 20
4.7 Droplet eliminator 20
4.8 Air humidifier 21
4.8.1 Spray humidifier (air washer) 21
4.8.2 Steam humidifier 22
4.9 Drive elements 22
4.9.1 Electric motor 22
4.9.2 Belt drive 23
4.9.3 Connection of three-phase motors 24, 25, 26, 27
4.9.4 Wiring with frequency converter 28
4.10 Ex-protection 29
4.11 Intake air unit and exhaust air unit
inside the Ex-zone 29
4.12 Intake air unit and exhaust air unit
outside the Ex-zone 29

We reserve the right to make changes as a result of technical progress.

1
 Transport

The following regulations should be respected for unit set-up, VDI 3803 Ventilation and Air Handling Systems:
commissiong, and maintenance: Structural and Technical Requirements

DIN EN 292 Machine Safety VDI 6022 Hygiene Requirements for Ventilation and
Parts 1 and 2 Air Handling Systems, Offices and Meeting
Rooms
DIN EN 294 Machine Safety: Units and Systems
UVV VBG 1 Accident Prevention Regulations:
DIN EN 349 Machine Safety: Minimum Clearances General Regulations

DIN EN 60204-1 Machine Safety: Electrical Design of UVV VBG 7 Accident Prevention Regulations: Fans
Machines, General Requirements
UVV VBG 9 Accident Prevention Regulations: Cranes
DIN VDE 0100 Set-up of High-Voltage Systems of up to
1000 V UVV VBG 9a Accident Prevention Regulations:
Lift Operation
DIN VDE 0113 Electrical Equipment of Machines:
General Requirements 89/392/EWG Machine Guidelines

VDMA 24167 Fans, Safety Requirements EN 1127-1 Explosion Protection – Fundamentals

and Methodology
VDMA 24168 Ventilation and Air Handling Systems:
Execution Program for Maintenance EN 13463-1 Nonelectrical units for use in Ex-Areas

VDI 2079 Ventilation and Air Handling Systems: DIN EN 50 014 Electrical equipment for Ex-Areas
Specification Testing
BGR 132 / Avoiding Ignition Dangers
VDI 3801 Operation of Ventilation and Air Handling CENELEC due to electrostatic charges
Systems Report R 044-0001

1. Transport
The ventilation and air-conditioning units of the AT4 produc- components, depending on the delivery section split.
tion series are shipped screwed to square transport timbers, The delivery splitting is indicated in the unit number
depending on their size either completely assembled or in ( : = delivery section split).

Fig. 1: Unit components ready for transport

We reserve the right to make changes as a result of technical progress.

2
 Transport

All AT4 units come equipped standard with a base frame that AT4 units can be transported to the installation location with
has openings for crane transport. When the units are delive- crane or a forklift.
red, the transport openings are seated with covering caps.

1.1 Transporting unit with forklift

Warning:
Use suitable fork lengths in order to avoid damaging unit Service doors must always be closed during transport.
base. Always watch out for possible projections
(e.g. floor drains).

1.2 Transporting unit by crane

Danger: • Remove covering caps.

For crane transport, all applicable safety regula-
tions according to VBG 9 and VBG 9a must be
observed.
Warning:
During crane transport, the protruding drip edges in weather-
proof models of AT4 units must be protected by additional
measures (e.g. crossbeams or spacing timbers).
Service doors must always be closed during transport.
• Slide transport pipes (accessory: 1 1/2” pipe in accordance
with DIN 2440) through the transport openings in the base
frame and secure with pipe-securing mechanism.
• Fasten lifting tackle (cable, chains, flat lifting sling) to the
laterally protruding transport pipes (projection of at least
200 mm on both sides).

unit width unit width length

Spacer timber pro- in raster in mm (transport pipe)
vided by customer 08 688 mm 1,100 mm
12 994 mm 1,400 mm
Crossbar
16 1,300 mm 1,700 mm
20 1,606 mm 2,000 mm
24 1,912 mm 2,300 mm
28 2,218 mm 2,600 mm
32 2,524 mm 2,900 mm
Table 1

Transport
pipe
Pipe clamp

Fig. 2

We reserve the right to make changes as a result of technical progress.

3
 Assembly
2. Assembly
In General:
A flat foundation is required for unit assembly. The foundation
can be designed as a full foundation or as a strip foundation.
With strip foundations, when units are over 2 m wide,
additional lateral supports must be provided for support at the
beginning and end of the unit and at the component divisions.
There must be sufficient space for operation and maintenance
of the air handling unit.
Note:
The accessories are stored in the fan chamber during
delivery.
Recommendation:
• For vibration damping, the AT4 units can have suitable
damping strips placed under them (not supplied in package
contents), to the requirements of the damping strip
manufacturer.
• AL-KO THERM generally recommends placing the
damping strips under the unit sides, component divisions,
and in the longitudinal direction with components approx.
1,200 mm or longer.
• To prevent transmission of structure-borne noise,
AL-KO THERM recommends using flexible connectors
for the connection between the unit and ductwork.
2.1 Unit assembly in Ex-proof models
In various components, the cover must be removed in order
to connect the units. These covers are provided with drilled
openings. After the components have been connected to
each other, the drilled openings must be closed using the
blind rivets supplied with the accessories.
We reserve the right to make changes as a result of technical progress.
4
Warning:
The set-up sequence of the individual unit components is
shown in the set-up drawing and must absolutely be
observed.
• The assembly of AT4 units begins with the unit compo-
nent that contains the air outlet (ductwork connection).
• Stick the supplied sealing bands to the ends of the unit
components, flush with the inside and outside edges of
the unit.
• Place adjoining unit components as close to each other
as possible and connect by means of the automatically
centring unit connector or, with larger and heavier unit
components, pull them together and connect them using
suitable accessories (belts).
• Connect the air handling unit and the potential equalisation
mounted on the unit to the conduit system.
Warning:
Units must be levelled in order to assure proper function.
Do not walk on top of unit without damage protector
(scaffolding or supports).
Carefully cover units before and after assembly, until
commissioning in order avoid damage and contamination.
After units are connected, rivet
cover with blind rivets 4.8 x 16.
(cover predrilled)
Fig. 3
 Assembly

2.2 Internal unit connection at casing division

• Stick the included sealing band to the unit, flush with its
outer edge.
• Insert hex bolt into gusset plate, optionally with an
assembly angle and attach with washer and hex nut.

Fig. 4: Unit connection

2.3 AT4 unit connection with stacked units and with side-by-side units
2.3.1 Stacked unit arrangement

• Place upper unit component onto lower unit part by crane.
• Screw unit base frame to lower housing with hex bolts.
In the region of the mixing chambers (fresh air connec-
tion) between the upper and lower unit, the unit base
frame must additionally be sealed around the outside
with a fluid sealant (e.g. SIKA S221).
Warning:
If the upper unit component is longitudinally offset in relation
to the lower unit component, then the base frame lateral
profile must be screwed to the casing cover.
In weatherproof models of AT4 units, the base frame lateral
profile must also be properly sealed with a fluid sealant
(e.g. SIKA S221).

bottom upper unit

(upper unit) cover

base frame lateral profile

fluid sealant

base frame
roof (lower unit) roof (lower unit)

Fig. 6: Stacked units with longitudinal offset

cover

Fig. 5: Stacked unit arrangement

We reserve the right to make changes as a result of technical progress.

5
 Assembly

2.3.2 Side-by-side units

• Loosen hex bolts on factory-mounted spacer bar. Warning:

• Place unit components next to it with forklift or crane. If the left unit component is longitudinally offset in relation to
• Fix spacer bar by means of hex bolts. the right unit component, then the facing angle must be
screwed to the casing cover. In weatherproof AT4 units, the
facing angle must also be sealed with a liquid sealant.
Spacer bar
In weatherproof AT4 units, the hex bolts supplied are also
equipped with an EPDM sealing washer.

Warning:
If a humidifier is installed, then the buyer must furnish offset
foundations to compensate for the height difference between
Fig. 7: Side-by-side units the humidifier pan and the base frames of the adjoining
components.
In addition to the spacer bar, a continuous 25 mm wide
sealing strip must be glued in the region of the mixing
chambers (fresh air connection). This must be checked
for leaks upon completion of assembly.

Unit Humidifier

Assembly angle inte- Assembly angle inte-

grated into housing grated into housing

Unit Humidifier Humidifier pan Foundation provided

by customer

Attachment angle inte-

grated into humidifier

Base frame
Humidifier pan
Foundation
provided by
customer
Fig. 8: Humidifier installation

We reserve the right to make changes as a result of technical progress.

6
 Assembly

2.4 External installation

Roof frame

1. Roof frame preassembled by customer (see Fig. 9)
• Place roof frame on the foundation and attach with screws.
• Close transport openings in roof frame with covering caps.
• Apply sealing compound to roof frame.
• Transport units by crane onto roof frame and attach with
screws (assembly angle for cover plate with screws).
• Close transport openings in roof frame with covering caps.
• Hoist customer-supplied vapour barrier to be sealed to
roof frame and glue under drip edge.
• Hang covering plate in drip edge and rivet to assembly
angle.
2. Factory-mounted base frame or roof frame
(see Fig. 10)
• Close openings in base frame/roof frame with covering
caps.
• Raised customer-supplied vapour barrier to be sealed to
base frame/roof frame and glued under drip edge.
3. At housing divisions, place individual unit components as
close as possible next to one another, pull together via unit
connections (gusset plate and assembly angle) and screw
to each other. With large and heavy unit components, pull
them together using suitable accessories (e.g. belts).

4. Seal unit division points (see Fig.11).

Drilling screw with EPDM

washer

Drip edge

Base frame
Cover plate
Sealing compound

Clamp *) Cup rivet

Roof frame Screw angle

Insulation provided by customer

*) Number of clamps per component at least 2, but the max. distance between the clamps is 700 mm.

Fig. 9: Roof frame preassembled by customer

We reserve the right to make changes as a result of technical progress.

7
 Assembly

Drilling screw with

EPDM washer

Coupling piece
(only at division Drilling screw with
points) EPDM washer
Base
frames/roof Drip edge Vapour
frames barrier
Insulation
provided by
customer
Drip edge

Fig. 10: Factory assembled base or roof frame Fig. 10/1: Factory-assembled base frames

Warning: Warning:
When executing from beneath (breaking through roof), clear The solvent welding agent can only be used at outside
all details with the factory first. temperatures > 10 °C.
At low outside temperatures, preheat the corresponding
Sealing unit division points locations with a hot air blower.
1. Check unit divisions for correct leak tightness. Carefully check the seal of the housing.
2. Clean unit top in the region of unit division.
3. Slide the coupling piece at the unit division point over the Danger:
drip edge (top and bottom) and rivet in place.
4. Fold back overlapping vapour barrier. The solvent welding agent is highly flammable
5. Apply solvent welding agent with brush. - keep away from ignition sources!
6. Fold foil barrier back over it. Follow the safety instructions on the drum.
7. Abutting points should be pressed firmly in place in order For further information, you can request the
to avoid folding. current EC safety data pages from us.
Solvent
welding agent
(Alkorplus 81025)
Rivet

Coupling piece
Seam sealer
(Alkorflex 81036)

Fig. 11: Sealing unit division points

We reserve the right to make changes as a result of technical progress.

8
 Additional installation and maintenance instructions for hygiene units
3. Additional installation and maintenance instructions for hygiene units
3.1 Assembly
Warning:
After installation and connection of the individual unit compo-
nents to one another, the casing section split points including
unit assembly angles must be sealed on the inside of the
units with disinfectant-proof liquid sealing material.
3.2 Commissioning and maintenance
Before commissioning of the air handling system, the sealing
seat of all installed filters must be checked, especially that of
the fine dust filter.
Warning:
AL-KO THERM generally recommends changing all filters
after a short operation of the air handling system in order
to remove impurities that have got into the filter during the
installation phase and after initial start-up.
Because the exhaust can be contaminated with noxious
gases, hygienic and toxicological considerations must be
taken into account with 100 % recirculated air. Therefore
during recirculating operation, a minimal fresh air volume flow
of 1,200 m3/h must be assured.
Cleaning:
For cleaning purposes, the frost protection frame and droplet
eliminator can be removed laterally and must be cleaned out-
side the unit using a high-pressure jet. The droplet eliminator
can also be disassembled for cleaning.
We reserve the right to make changes as a result of technical progress.
If the buyer installs pipework or electrical cables, care must
be taken that these do not impede the function and operation
of laterally removable built-in components of the units.
It is not permissible to connect the condensate drain outlet of
the "hygiene unit" directly to the system.
If necessary for cleaning purposes, the inspection ports of the
AT4 hygiene unit series can be provided with a split casing
which can be taken apart easily.
For cleaning purposes, all installed components are either
freely accessible or can be pulled out or removed from the
unit after removal of the casing cover.
If casing covers are removed for maintenance purposes, then
after the maintenance has been carried out, the inside of the
housing in this region must be resealed with disinfectant-proof
liquid sealing material.
In General:
General maintenance indications in the Assembly,
Commissioning and Maintenance instructions for AT4
air handling units from the AL-KO THERM company must
be respected absolutely.
9
 Commissioning and maintenance / Fan

4. Commissioning and maintenance

Danger:
When working on the air handling unit, gene-
rally switch off power to the unit, switch off the
master switch and/or repair switch (switch off all
terminals) and prevent from being unintentio-
nally switched back on. Only open testing doors
when fans are switched off and stationary.
After switching off the unit, the impeller
continues to run for approx. 1 to 3 minutes.
The impeller must never be slowed down by
hand or by placing objects against it.
After the work on the air handling unit is
finished, the person in charge must assure that
no other persons are inside the system and that
all factory installed protective measures are
functional before the system is put back into
operation.
After downtimes of longer than 1 week, it is generally neces-
sary to turn the motor and fan shaft once a week in order to
avoid localised loading of the bearings and attendant bearing
damage (in this connection, also take into account page 23 -
belt drive).
AL-KO THERM recommends carrying out maintenance of
air handling systems in accordance with VDMA 24186 and
VDI 6022.
Assembly, commissioning, maintenance, and repairs
must be carried out exclusively by trained qualified
personnel.

4.1 Fan

Commissioning:
1. Remove transport locking device on fan base.
2. Check conduit system and fan for foreign objects.
3. Turn impeller by hand to make sure it is travelling freely.
4. Test fan rotation direction (see arrow on fan housing) by
temporarily switching on the motor.
5. If need be, reverse connections on the motor to correct.
6. Measure power consumption with closed service doors
and compare to the rated current indicated on the rating
plate.
7. Measure differential pressure pfa and if necessary,
adapt operating point by adjusting the nozzle gap
(AIR-vent).
8. Inspect alignment (flush) of V-belt pulleys.
9. Inspect V-belt tension and retighten as needed
(also see item 4.9.2).
10. Test equipment earthing conductor.
Warning:
When the rotation direction is incorrect, there is a danger
of motor overload.
Power consumption must not exceed the rated current
indicated.
Maximal motor speed must not be exceeded.
Maximal fan speed must not be exceeded.
From a rated motor output from 3 kW: Star-delta starting.
Commissioning and maintenance
• Check fan impeller for imbalance.
• Check bearings and regrease as needed.
• Tighten all fastening screws.

We reserve the right to make changes as a result of technical progress.

10

• Test function of vibration dampers.
• Test function of drainage if necessary.
• Check fan for contamination, damage and corrosion.
• Clean fan unit regularly.
Fig. 12
4.1.1 Air vent fan components
Commissioning:
• Remove transport locking devices on fan undercarriage.
• The unit must be checked for transport damage before
commissioning.
• The impeller must not touch the fan intake nozzle.
This can be checked by turning the impeller.
• Then the rotation direction of the motor must be checked.
The correct rotation direction is indicated by a direction
arrow on the impeller. The rotation direction can be deter-
mined by temporarily switching on the motor. If the rotation
direction is incorrect, the connections of the motor must be
reversed.
• Test equipment earthing conductor.
Inspection:
• In general, switch off master switch and/or repair switch
and prevent it from being unintentionally switched back on
(e.g. with a padlock).
• Inspection at least once a year.
• Check fan for contamination, damage, seized screws, and
corrosion (also see item 4.1.2)
• Test function of safety devices (belt, protective grid).
We reserve the right to make changes as a result of technical progress.
Fan
Fan unit can be removed laterally for maintenance purposes:
1. Loosen the four screws on the C-rails.
2. Detach flexible connection.
3. Pull fan unit out of the housing laterally.
Warning:
Pull the fan unit out carefully in order to avoid damaging the
housing coating.
Adjusting operating point:
1. In units with nozzle gap adjustment and without speed
regulation:
The operating point is adjusted by shifting the motor with
the fan impeller out from the intake nozzle in the axial
direction. As a result, part of the required air quantity can
flow through the gap (bypass) and the pressure and motor
power consumed can be reduced. The gap can be set in
the range from +8 to -15 mm. The correct nozzle gap is
given in the order documentation (tech. data page). If it is
necessary to alter the nozzle gap, then care must be taken
not to exceed the available motor power (measure power
consumption!).
11
 Fan

In order to adjust the gap, In order to adjust the gap,

loosen the four or six connect-
ing screws (VS) of the motor
block and C-rail slightly, move
the motor block into the desired
position, then tighten the
screws.
Torque, see item 4.1.2.
loosen the four screws on the
motor slightly, move the motor
and impeller into the desired
position, and then tighten the
screws.
Torque, see item 4.1.2.

+ Gap –

Unit size 08 x 08 to 20 x 16 Unit size 20 x 20 to 24 x 24 Determining airflow quantity by measuring differential head

Fig. 13

2. In units with speed regulation Determining airflow quantities:

(e.g. frequency convert er operation):
The operating point can be precisely approached by
means of the adjustable fan speed. In speed regulation,
care should be taken not to fall below the minimum fan
speed nor to exceed the maximum fan speed or the
permissible motor output. The nozzle gap cannot be
adjusted, it must always remain at the preset ideal value
of +8 mm.
The fans come optionally equipped with a volume flow meas-
uring device. A pressure measuring point in the inlet nozzle
is used to measure the pressure difference between the static
pressure in the chamber on the intake side and the pressure
in the inlet nozzle. This differential pressure (differential head)
is at a fixed ratio to the volume flow. A detailed description is
available on request.

4.1.2 Torques of screw connections on the fan component

After approx. 1 hour of fan running time, check screw Maintenance and testing of taper-lock clamping bushes:
connections on fan base and uniformly tighten as needed 1. Clean and degrease all bare surfaces such as the bore
with a torque wrench to the screw torques indicated in Table 2 and conical surface of the taper clamping bush as well as
below. the conical bore of the pulley. Insert taper clamping bush
into the hub and bring all connecting bores into alignment
(half threaded bores must each be aligned with a half
measurement screws- smooth bore).
thread torque 2. Provide headless screw (size 1008 - 3030) and cylindrical
(Nm) screws (size 3535 - 5050) with a small amount of screw
M6 10 locking compound and screw in - do not tighten screws!
M8 25 3. Clean and degrease shaft. Slide pulley with taper
M 10 49 clamping bush onto the shaft.
M12 85 4. When using a feather key, this should first be inserted
into the groove on the shaft. There must be back
Table 2
clearance between the feather key and the bore groove.
5. Using torque wrench, tighten DIN 911 headless screws
and cylindrical screws uniformly with the torques
indicated in Table 3.

We reserve the right to make changes as a result of technical progress.

12
 Fan / Heat Exchanger

Bush Screw Torque Screw

(Nm) Number Size
1008/1108 6 2 1/4" BSW
1310/1315 20 2 3/8" BSW
1210/1215 20 2 3/8" BSW
1610/1615 20 2 3/8" BSW
2012 31 2 7/16" BSW
2517 48 2 1/2" BSW
3020/3030 90 2 5/8" BSW
3535 112 3 1/2" BSW
4040 170 3 5/8" BSW
4545 192 3 3/4" BSW
5050 271 3 7/8" BSW
Table 3

Changing pulleys: Attach pulley (II):

Loosen pulleys (I):
1. Unscrew screws (3).
2. Screw Allen screw into threaded hole (4).
3. Push clamping bush out from conical bore.
4. Pulley can only be slid slightly on the shaft.
Tighten pulley and clamping bush to each other by means of
Allen screws (3). Make sure that the motor shaft and fan
drive pulley are precisely aligned. Installation and ten-
sioning of belts according to regulations. (see item 4.9.2)

4.2 Heat exchanger

4.2.1 Louvre heat exchanger
Assembly:
The heat exchangers are largely maintenance-free. Heat 1. Connect heat exchanger in accordance with the
exchangers must be cleaned regularly in order to assure counterflow principle (water flow direction counter to
proper function. As long as the tubes of the louvre unit are airflow direction in unit).
not damaged, dented louvres of the heat exchanger have 2. The water supply should be connected to the bottom or the
no influence on the operational capability of the overall sys- top, depending on the airflow direction.
tem and therefore do not constitute grounds for complaint.
The louvres can be "combed out" by the buyer. If needed, Warning:
an appropriate tool can be purchased from the manufacturer. When connecting the heat exchanger, hold it in place with
suitable means (e.g. pipe wrench) in order to prevent
Note: damage. Attach lines and connections so that the heat
The buyer should provide venting valves and drain valves exchangers are freely accessible for maintenance.
in the pipeline. Maximal operating pressure: 16 bar
Maximum water supply temperature hot water: 120 °C
Warning:
In general, care must be taken that the unit remains accessi-
ble for maintenance purposes. During installation, particularly
of connecting pipes, care must be taken not to impede the
opening of testing doors. According to VDI 6022 the remov-
ability of the heat exchanger (and optional droplet eliminator)
must remain assured up to a unit clearance height of 1.6 m.

We reserve the right to make changes as a result of technical progress.

13
 Heat Exchanger / Heat Recovery

Maintenance: Double siphon:

• Check heat exchanger for contamination, damage and
corrosion.
• Clean heat exchanger with compressed air; galvanised
steel heat exchangers can also be cleaned using
steam jet units.
• Check attachments and screw connections.
• Check function of water supply and return.
• Test venting valve and filling of heat exchanger.
• Test function of frost protection thermostat.
• Check antifreeze concentration as needed.
• Check siphon and refill as needed.
• Check function of drain and odour trap.
• Check droplet eliminator and clean as needed.
The double siphon with a screw cover for filling and checking
is a fillable siphon for drainage of air handling units in the
vicinity of the heat exchanger, humidifier, or other wet regions
at a pressure in excess of ambient pressure.
Overpressure in unit: H1 = 50 mm
H2 = p + 50 mm
Underpressure in unit: H1 = p + 50 mm
H2 = p/2 + 50 mm
p = unit pressure in mm WS
(100 Pa = 10 mm WS)

Warning:
At temperatures below freezing point, due to the danger of H1
frost and corrosion, the heat exchanger must either be emp-
tied and blown out with compressed air, or must be filled with
a commercially available antifreeze that contains a corrosion H2
prevention agent.

With extended downtimes, corrosion can occur in the heat

exchangers due to sulphate-reducing bacteria. These sul-
phides primarily attack the soldered seams, but also attack
the copper base material itself. In order to reduce this type
of copper corrosion, we recommend the following measures:
• Using sulphate-free water in the entire PWW circuit
• Assuring that the PWW circuit is free of leaks
• Avoiding long downtimes of the filled PWW circuit
• Avoiding frequent refilling with fresh water
• Using material-compatible inhibitors
• Using biocides
Fig. 14: Siphon size
Ball siphon:
The ball siphon is a self-filling siphon for drainage of heat
exchangers, humidifiers, and other wet regions at a pressure
lower than ambient pressure. It contains a floating ball, which,
when the unit is running dry, prevents the intake of air so that
the first condensate produced can fill the siphon. The ball also
acts as a check valve when there are pressure surges in the
system and prevents the system from being sucked dry.

Additional instructions for using direct evaporators: Direct evaporator

Installations must be carried out by an approved refrigeration
company.
Only safe refrigerants in accordance with DIN 8962 are Air
approved for use.

The buyer must also equip the heat exchanger and direct Coolant
evaporator with a siphon (as described below): Each pan Injection valve
drain must be provided with a separate siphon.
Suction gas
line

Coolant

Fig. 15: Air direction in installation of a direct evaporator

Warning:
The buyer must provide the opening for the suction gas line.

We reserve the right to make changes as a result of technical progress.

14

4.2.2 Electric air heater
Special instructions for electric air heater:
For the electrical connection, it is absolutely necessary to
consult the wiring diagram supplied with the unit:
Frequent causes for this malfunction include:
Cause
No airflow volume
Insufficient airflow volume from regulated fans
Temperature monitor is not connected
Safety temperature governor is not connected.
No fan coast-down
Incorrect commissioning - Testing of electrical heating
without sufficient airflow, e.g. due to closed dampers or
air entering through a leak
Air temperatures above 60 °C
When the buyer retrofits electric air heaters, the following
distances from other components must be maintained:
Surface temperature < 230 °C – distance 300 mm
Heating coil < 320 °C – distance 380 mm
We reserve the right to make changes as a result of technical progress.
Electric Air Heater
Heat build-up in the vicinity of the electric air heater must be
absolutely avoided.
Corrective measures
Heater units must only be enabled when a sufficient airflow
over the heater is determined.
—> Use of a volume flow monitor
The heat output must be adapted to the reduced airflow
volume
—> Stepless regulation of the heating energy or switching
of heating units in accordance with the preset airflow
volume
The function of the temperature-induced shutoff must be
tested during commissioning.
The function of the shutoff must be tested during
commissioning.
It is absolutely necessary for the fans to have a minimum
of 5 minutes of coast-down time after the electric heating
is switched off. Alternatively, the fan coast-down can also
be controlled by a thermostat.
Make sure that there is always a sufficient airflow volume
at the heating coil during testing.
The air temperatures must not at any time exceed 60 °C
(not even temporarily). During normal operation (continuous
operation), the air temperature should not exceed 40 °C.
Damage as a result of excessive temperatures due to
heat build-up invalidates the guarantee!
15
 Heat Recovery

4.3 Heat recovery

4.3.1 Plate heat exchanger

Maintenance:
• Clean plates regularly: • Clean condensate drain.
a) Remove dust and fibrous material or the like with • Check siphon and refill as needed.
a brush. • Check damper connection, drive and control functions.
b) Remove oil and grease deposits with hot water, steam,
or grease-dissdring cleansers.

4.3.2 Rotary heat exchanger

Maintenance: V-belt
• Check drive elements and control elements. The driving V-belts have the designations SPZ and SPA and
• Clean rotor regularly with compressed air, water, steam, are available on the market under the name "endless V-belt".
or grease-cutting cleansers. Hinge locks are used as a connecting element. Since the
V-belt experiences a natural stretching, and this expansion
Thermal mass: in length can go beyond the dimensions of the tensioning
Before commissioning (particularly with horizontal rotors), device, it is advisable to check the tension of the V-belt at
care must be taken that no objects or excessively thick set intervals. Particular care must be taken to do so during
pressed-on sealing felts, block free movement. The thermal the first 400 operating hours. If the V-belt tension drops so
mass of the rotary heat exchanger is comprised of wound low that the driving of the thermal mass is no longer assured,
aluminium foil. Because of the counterflow principle, in most then the V-belt must be shortened.
cases self-cleaning occurs, which is sufficient to prevent
contamination of the thermal mass.
1 Thermal mass
Should this self-cleaning be insufficient, the thermal mass can 2 V-belt
be cleaned at appropriate intervals (depending on the degree 3 V-belt pulley
of contamination) with compressed air or, in the case of stub-
born soiling, with high-pressure devices (medium: only water 4 Hinge
connector
without chemical additives).
5 Motor
Warning: 6 Motor-driven
The jet of air or water must strike the thermal mass at right rocker switch
angles!
7 Spring
Rotation direction:
It should be noted here that the thermal mass always rotates
from the exhaust, through the flushing chamber, and into the
fresh air.
This rotation direction of the thermal mass is indicated by
a yellow arrow at the corner of the motor.

Warning:
Check rotation direction during maintenance!

We reserve the right to make changes as a result of technical progress.

16

Split design
Starting from a wheel diameter of 1800 mm, the rotors are
provided with a split design. Starting from a wheel diameter
of 2,500 mm, the frame is also split. The upper housing part
is set in place after assembly of the thermal mass segments.
4.3.3 Recuperative energy recovery: Circulating coil system
Fig. 16: Combined coil system
The heat exchanger must receive regular maintenance.
Warning:
Buyer must provide piping.
Circulation pump must be sized in accordance with the
technical data page.
Heat exchangers must be connected in accordance with the
counterflow principle.
Antifreeze concentration must correspond to the guidelines
in the technical data page.
Always connect heat exchanger in counterflow.
We reserve the right to make changes as a result of technical progress.
Heat recovery / Run-around coil system RCS
Seals
With normal-temperature rotors, sealing felts of the quality:
NF-PES-LE 0.32 grey are used. The felts must be slid as
close as possible to the thermal mass, but prevented from
producing direct abrasion. The sealing felts are pressed-on
at the factory, but can change position again as a result of
transport. Warning: Before commissioning, check felts and
seals and position the felts while the fans are running.
Ball bearings
The ball bearings used are low-maintenance and are
designed for a service life of up to 100,000 hours.
They can generally be used up to +120 °C. Under normal
circumstances, they do not require maintenance.
Cleaning
The rotors can be cleaned with compressed air. In doing so,
the air jet must strike the thermal mass at a right angle. Wet
cleaning is not possible. The contamination must be reduced
from the start by filters. Wet cleaning will destroy the rotor.
The water supply is at the bottom or on the top, depending
on the airflow direction.
We recommend the use of Antifrogen N at a mixture ratio
of 25 – 35 %.
After the pressure test, the entire system must be thoroughly
tested. It should be flushed until no more residue particles or
scale wash out.
17
 Filter

4.4 Filter
4.4.1 Bag filter

Maintenance:
• Check all filter classes at least every 6 months for
contamination and damage and replace as needed.
• Replace 1st filter stage at least every 12 months.
• Replace 2nd filter stage at least every 24 months.
• Size 08 x 08: With permanently installed filters, the filter
clamp must be dismantled during filter changes.

Fig. 18

Optionally, a quick-acting clamp device is available for all filter

classes up to a unit clearance height of 1,836 mm.

Replacement of filter bags:

• Loosen clamping device simply by pulling it out by means
of the loose removal lever provided.
Fig. 17
• Pull filter bags out of the housing individually.
• Clean filter seals, check and replace damaged seals as
Bag filters can optionally be alternated on the dirty air side
needed.
or clean air side.
• Insert new filter bags.
• Close clamping device by inserting.
Up to filter class G4 and up to a housing width of 1300 mm,
the filter frame can be pulled out of housing laterally.
Warning:
In general, the filter bags should be replaced when the
For unit heights up to the 20 x 20 size, the filter bags are
permissible final pressure difference indicated on the rating
delivered installed. Starting from the 24 x 20 size, the filters
plate is reached.
are delivered packed in cardboard, inside the components
indicated.

We reserve the right to make changes as a result of technical progress.

18
 Filter

4.4.2 Active charcoal filter

The activated charcoal must be replaced after reaching Changing the filter cartridge:
saturation. Maintenance and assembly are generally carried 1. Loosen bayonet fastener on base plate
out on the clean air side. (accessories spanner).
Generally, the activated charcoal cartridges are delivered 2. Remove activated charcoal between the two perforated
packed in cardboard, inside the components indicated. page metal cylinders.
3. Refasten filter cartridges to the base plate with the bayonet
fastener.
4. Check filter insert seating for leaks.

4.4.3 Grease Trap Filter

The grease trap filter must be cleaned with hot water
(> 80 °C) or steam when it has become contaminated
by grease or dust or has reached the recommended final
pressure difference (rating plate). Maintenance and assembly
generally occur on the dirty air side.
Cleaning of Filter Elements:
1. Starting from a unit size of 16 x 16:
• Pull filter element out of the unit along with the housing
frame including drain pans.
• Loosen clamping bracket on filter frame and clean filter
element including drain pans.
2. Starting from a unit size of 20 x 16:
• Loosen clamping bracket on filter frame.
• Remove filter element and clean.
• Clean drain pan

4.4.4 Particulate air filter

The particulate air filter must be replaced after the recom- Replacement of filter elements:
mended final pressure difference has been reached (rating 1. Loosen screws on filter frame.
plate). Maintenance and assembly are generally carried out 2. Replace filter element.
on the dirty air side. Generally, the particulate air filter 3. Insert new filter element and tighten screws.
element is delivered packed in cardboard, inside the
components indicated.

We reserve the right to make changes as a result of technical progress.

19
 Louvre dampers / sound absorbers / droplet eliminators

4.5 Louvre dampers

Maintenance:
• Check louvre dampers for contamination, damage • Clean louvre dampers regularly.
and corrosion. • Check final position of damper adjusting motors and
• Check mechanical function of louvre dampers. readjust as needed.
• Lubricate bearings.

4.6 Sound absorbers

The sound absorbers are maintenance-free.

Recommendation:
After lengthy operating intervals, clean sound attenuators
slats with a vacuum cleaner.

4.7 Droplet eliminator

Maintenance:
• Check droplet eliminator for contamination, damage and
corrosion.
• Clean droplet eliminator and condensate drain pan
regularly with compressed air, water, steam, or grease-
dissolving cleansers.
• Check drain and odour trap.

If buyer installs pipework, care must be taken that the

droplet eliminator can still be removed.

Fig. 19

The droplet eliminator can be pulled out of the housing

laterally for maintenance purposes and can be disassembled
for cleaning.

We reserve the right to make changes as a result of technical progress.

20
 Humidifiers

4.8 Air humidifier

4.8.1 Spray humidifier (air washer)

Warning:
• Buyer must provide a siphon when installing a spray
humidifier (air washer).
(see Fig. 14: siphon size on page 14)
Recommendation:
AL-KO THERM recommends installing an electric dry run
prevention mechanism for the water circulation pump.
Operate spray humidifiers only with demineralised water in
order to prevent corrosion damage. Place the spray humidifier
as the last component in the ventilation unit, directly against
the inlet of the ductwork system.
Assembly and commissioning:
• Check spray humidifier for completeness and any transport
damage that could have occurred.
• Remove any serious contamination from humidifier pan
and check for proper seating of the pump intake screen.
• Check spray direction and proper seating of vaporising
nozzles.
• Fill humidifier pan to approx. 10 mm under the upper edge
of the inner siphon or overflow fitting and then place floater
of floater valve at this water level.
• Check function of the drain and overflow and clean dirt trap
and siphon.
• Check rotation direction of water circulating pump.
• Check screw and flange connections of pump pressure line
for leaks.
• Set blow-down (if provided) so that the blow-down rate is
twice as great as the vaporised water quantity.
• Check installation of water filter.
• Start operation of system on the air side and if need be,
adjust the operating point of the spray humidifier by
regulating the water quantity.
• Check droplet eliminator for punctures.
• The preset water quality must be absolutely maintained
and regularly corrected.
• When reducing volume flow (e.g. when using frequency
converters), the pump output must also be reduced.
Warning:
Rotation direction of water circulating pump can only be
checked when the water pan is filled. The water level in the
humidifier pan must be high enough so as to preclude dry
running of the water circulating pump.
The blow-down rate is reduced by 50 % when fully
desalinated water is used. In droplet eliminators made of
plastic profiles, in exceptional circumstances, temporary water
seepage can occur because the surface is not yet weathered
due to the manufacturing method. Weathering sets in after
approx. 24 operating hours.
Maintenance:
• Check spray humidifier for contamination, damage and
corrosion.
• The spray humidifier unit including the nozzles and nozzle
supports should be cleaned at least once a year.
• Check siphon and refill as needed.
• Check float valve.
• Check blow-down device and clean as needed.
• Check and clean droplet eliminator/rectifier.
Warning:
Respect maintenance, commissioning, and assembly
instructions of the humidifier manufacturer! Do not clean
spray humidifier with foaming cleansers.

We reserve the right to make changes as a result of technical progress.

21
 Air humidifier / Drive elements
4.8.2 Steam humidifier
Warning:
The steam humidifier must be supplied exclusively with water
of at least drinking water quality.
Maintenance:
• Check steam humidifier for contamination, damage and
corrosion.
• Clean steam humidifier and dirt trap regularly.
• Check steam line and condensate line for leaks.
• Test function of steam distributor.
• Test function of solenoid valves.
• Test measuring units and control units.
Additional maintenance work in steam humidifiers with
integrated steam generators:
• Test function of water supply and water level.
4.9 Drive elements
4.9.1 Electric motor
Electric motors with a rated output of 3 kW or greater must be
operated with star-delta starting. Increased switching frequen-
cies of motors ("cycling") leads to rapid functional failures.
The electric motors are as a rule equipped with permanently
lubricated motor bearings.
In electric motors with regreasable motor bearings, these
bearings must be checked regularly and regreased as
needed. The maintenance intervals and the required grease
quantity for regreasing are indicated on the motor rating plate.
Commissioning:
1. Wire motor according to the accompanying wiring
diagrams.
2. Measure power consumption in all three phases and
compare to the values given in the technical data page.
Warning:
Wiring must be executed in accordance with DIN VDE 0100,
DIN VDE 0113 and DIN VDE 0116. Motor wiring must be
designed so that the motor can be shifted for V-belt
tightening. Due to the overload risk to the motor, current
consumption must only be measured when service doors
and service covers are closed. Power consumption must not
exceed the rated current indicated.
We reserve the right to make changes as a result of technical progress.
22
• Measure power consumption.
• Check steam cylinder for deposits and replace as needed.
Additional maintenance work in steam humidifiers
without integrated steam generators:
• Test function of control valve.
• Readjust gland of control valve.
Note:
The AL-KO THERM company guarantees neither steam
humidifiers installed by the buyer nor housing openings
produced by the buyer nor improper handling of bottom pan
nor improperly connected outlet fittings. This is also true of
improperly operated humidifiers or incorrect humidifier
capacities.
Warning:
It is not permissible to operate multistep motors by means
of a frequency converter.
Warning:
Motors with thermal contact and positive temperature
coefficient resistors must be protected by a motor protection
device with a reclosing interlock.
All other motors must be protected by an overload switch.
Warning:
In controllable motors, the maximum power consumption
of the transformer and the motor must not be exceeded.
In controllable motors, the motor protection device must be
of appropriate size.
Maintenance:
• Check motor for contamination, damage and corrosion.
• Check motor attachment and retighten all fastening
screws/belts.
• Check bearings and regrease as needed.
• Clean motor and motor base regularly.
• Test function of protection devices.
4.9.2 Belt drive

Commissioning: Tensioning instructions for V-belt drive (1)

1. Check V-belt drive and set required belt tension. The correct belt tension is achieved when the individual
2. Check V-belt pulley for frictional seating and precise align- testing force Fp can produce a belt deflection b of 16 mm
ment (parallel). per 1,000 mm belt length.
3. After approx. 1 hour of running time, check screws/belts of
V-belt pulley, motor, and fan and tighten as needed. Check
belt tension and retighten as needed. (also see item 4.1.2)

Warning:
Incorrectly tensioned V-belts can lead to bearing damage
in the fan and electric motor. With downtimes of longer than
3 months, the V-belts must be loosened or removed to
prevent bearing damage, otherwise this voids the guarantee
for them. L = belt length
b = belt deflection at testing force Fp
If the belt drive is altered without using an AL-KO design, then Fp = testing force in N from AL-KO document
the limit speeds of the fan and the limit value diagram for the
belt tensions in the respective technical catalogue must be Tensioning instructions for flat belt drive (2)
respected. For EX fan units, only electrostatically conductive The correct belt tension is reached when the measurement
belts can be used. marker distance LMu has increased by the belt elongation e*.
The adjustment should be carried out in two stages with a
Maintenance: space of a few hours between them so as not to overload the
• Check V-belt drive for contamination, damage and bearings.
corrosion.
• Check V-belt tension and retighten as needed.
(also see item 4.1)
• Check alignment of V-belt pulleys.
• Clean V-belt drive regularly.

Warning:
When replacing V-belts in multi-grooved drive units, it is
always necessary to change the whole set of V-belts.
LMu = Measurement marker distance of untensioned
flat belt
LMg = Measurement marker distance with correctly
tensioned flat belt
E* = Belt elongation in mm from accompanying
document

We reserve the right to make changes as a result of technical progress.

23
 Drive elements

4.9.3 Connection of three-phase motors

Warning:
Do not connect top speed directly. In motors with positive
temperature coefficient resistors or a thermal contact, the
connection diagram in the terminal box must be adhered
to strictly.

Wirings for one speed:

Wiring of winding strands

The ends of the three

winding strands lead to
the Y switch

Circuit at terminal strip

Y switch
-circuit Y-circuit

Fig. 20

We reserve the right to make changes as a result of technical progress.

24
 Drive elements

Wiring for two speeds in the ratio 1 : 2 In motors with Dahlander wiring, the six winding ends 1U, 1V,
(winding in Dahlander circuit) 1W and 2U, 2V, 2W are connected to the six terminals of the
Design example for 1,500/3,000 RPM and 4-/2-pole terminal strip of a normal terminal box.
or 750/1,500 RPM and 8-/4-pole

low speed high speed

Winding design for a power stage according to a moment curve for ventilator drive units.

protection control pole-changing switch

Fig. 21

We reserve the right to make changes as a result of technical progress.

25
 Drive elements

Wiring for two speeds (two separate windings)

Design example for 1,000/1,500 RPM and 6-/4-pole
or 750/1,000 RPM and 8-/6-pole

low speed high speed

Winding design

protection control pole-change switch

Fig. 22

Fig. 22

We reserve the right to make changes as a result of technical progress.

26
 Drive elements

Wiring for three speeds

(two separate windings, one of them in a Dahlander circuit,
nine terminals are required in this case).
Design for ventilator drive units 750/1,000/1,500 RPM and
8-/6-/4-pole; 750/1,500 RPM in Dahlander circuit

750 RPM 1000 RPM 1500 RPM

Winding design

protection control pole-change switch

Fig. 23

We reserve the right to make changes as a result of technical progress.

27
 Drive elements

4.9.4 Wiring with frequency converter

Wiring example:
Frequency converter with pressure capsule, maintenance
switch, and positive temperature coefficient resistor.

Fig. 24
When operating with frequency converter, the following Example: EMC installation
must be taken into account:
1. The fan motor must be suitable for operation by frequency
converter.
2. The motor must be protected from overload and over- PLC etc. Housing Plate
heating, e.g. by a positive temperature coefficient resistor.
A motor protection switch with a bimetallic release is
unsuitable.
3. Shielded lines must be used for the wiring of the motor
positive temperature coefficient resistors to the frequency
converter. output relay

PLC
4. The maximal permissible speed of the fan and the motor Earthing
Strip
must not be exceeded under any circumstances.
Remove cable
5. Alternatively, please refer to the installation and operation insulation

instructions of the respective frequency converter manu-

Min. 16 mm 2 com-
facturer. pensation cable
Install all cables on
one plate side

Control Lines
Motor
Thermistor
Min. 200 mm Motor Cables
between control
lines, motor
Mains supply cables, and mains
cables

Motor
Min. 10 mm 2
PE: Min. 10 mm2

Fig. 25

We reserve the right to make changes as a result of technical progress.

28
 Unit installation in Ex-proof region

4.10 Ex-protection

4.11 Intake air unit and exhaust air unit inside the Ex-zone
• Intake air unit and exhaust air unit must correspond to the • The unit design supplied must correspond to the desired
corresponding zone and the necessary temperature class. Ex-zone.

4.12 Intake air unit and exhaust air unit outside the Ex-zone

• Ex-proof exhaust unit must correspond to the correspon- • Electrical components that are situated outside the
ding zone and the necessary temperature class. Ex-zone do not have to be Ex-proof (except pressure
• Intake air unit with louvre damper at air outlet to prevent sensors and frost protection thermostats).
reverse flows.
• Buyer must make sure that damper is set to "closed" when
the fan is switched off.

4.13 Control (equipment cabinet) not in Ex-zone

• As an option the electrical control (equipment cabinet) of the Ex-zones; the equipment cabinet must them be mounted
the ventilation units can be delivered for operation outside outside the Ex-zone or be suitable for the Ex-zone.

We reserve the right to make changes as a result of technical progress.

29
 Unit installation in Ex-proof region

4.14 Special installation and operating conditions for belt-driven, freely turning fans
1. Fans for use in explosion hazard areas are designated
as such on the rating plate; they are delivered with an
EC Conformity Declaration and operating and maintenance
instructions.
It is mandatory that the operating and maintenance
instructions be followed.
2. The temperature of the pumped fluid must not fall below
-20 °C or exceed +60 °C. In case of doubt, the tempera-
ture on the fan pressure size should be monitored.
If the pumped fluid temperature exceeds +60 °C on
the pressure side, the fan must be switched off.
5. Foreign bodies must be prevented from being sucked in
by the fan or from falling into the fan.
6. Before commissioning, the fans must be checked for
proper condition and possible transport damage.
When there is noticeable damage or a rubbing noise,
then the gap between the impeller and the inlet nozzle
must be measured and corrected so as to agree with the
accompanying table.
If there is a discrepancy, the inlet volute must be
adjusted or replaced and the fan should be tested for
other damage. If there is noticeable transport damage,
the balance must be checked.

3. The rating plate indicates the maximal speed of the fan. 7. When changing the V-belt (belt-driven design), only an
electrically conductive belt may be used.
The maximal permissible speed must not be exceeded.

4. The fans must be installed according to the manufacturer's

instructions.

The fans must only be installed with a horizontal shaft.

We reserve the right to make changes as a result of technical progress.

30
 Unit installation in Ex-proof region

4.15 Gap and overlap in radial fans RZR, VZR – manufacturer: Gebhardt

Measurement Overlap
Points Ü Cover Plate

Testing Diameter
Impeller

Inlet Ring

Gap
S

d
Normal design
Gap g Overlap o The gap check is carried out at four points offset from one
RZR Min. 1.0 % Min. 0.5 % another by 90°, visually and manually by feeling with the
VZR
test diameter Check visually fingertips.

The impeller must not touch and the gap should be as close
0200 2.0 1.0
as possible to the same dimension all the way around.
0225 2.0 1.0
0250 2.0 1.0
0280 2.0 1.0 In case of doubt, a check can be executed in the same way
0315 2.5 1.5 as in the Ex-design (see below).
0355 3.0 1.5
0400 3.0 1.5 The overlap is visually checked and in the normal circum-
0450 3.5 1.5 stance, a test is executed at "zero" - i.e. there must be an
0500 4.0 2.0 overlap that is "greater than 0".
0560 4.5 2.0
0630 5.0 2.5 The overlap must be visually checked from several directions
0710 5.5 2.5 and by turning the impeller: no gap should be visible.
0800 6.0 3.0
0900 6.5 3.5 In case of doubt, a test can be carried out with a sheet of
1000 7.5 4.0 paper - the paper should not be able to slide between the
1120 8.5 4.5 inlet nozzle and the cover plate.
1250 9.5 5.0
1400 10.5 5.5
ATEX design
1600 12.5 6.0
The gap check is carried out at four points offset from one
another by 90° using a test gauge with the prescribed testing
diameter.

The test gauge is hooked into place and the impeller is turned
by hand once for a single rotation.

The result is "good" or "bad":

good = the impeller does not touch or at most rubs
lightly against the test gauge
bad = the impeller rubs forcibly and comes to a stop.

The overlap test is carried out in the same way as in the

normal design.

We reserve the right to make changes as a result of technical progress.

31
 Unit installation in Ex-proof region

4.16 Gap and overlap in radial fans RLM – manufacturer: Gebhardt

Measurement Points Measurement Points Overlap

Testing Diameter
Ü Cover Plate

Inlet Ring

Gap
S

d
Normal design
RLM Gap g Overlap o
rated size Min. 1.0 % Min. 0.5 % The gap check is carried out at four points offset from one
rated test diameter Check visually another by 90°, visually and manually by feeling with the
diameter fingertips.
2,528
2.0 2-4 The impeller must not touch and the gap should be as close
280
as possible to the same dimension all the way around.
2,831
2.0 2-4
315
3,135 In case of doubt, a check can be executed in the same way
2.0 2-4 as in the Ex-design (see below).
355
3,540
2.0 2-5 The overlap is visually checked and in the normal circum-
400
4,045 stance, a test is executed at "zero" - i.e. there must be an
2.0 2-5
450 overlap that is "greater than 0".
4,550
2.0 2-6
500 The overlap must be visually checked from several directions
5,056 and by turning the impeller: no gap should be visible.
3.0 2-6
560
5,663 In case of doubt, a test can be carried out with a sheet of
3.0 2-7
630 paper - the paper should not be able to slide between the
6,371 inlet nozzle and the cover plate.
3.0 2-7
710
7,180
4.0 2-8 ATEX design
800
8,090
4.0 2-9 The gap check is carried out at four points offset from one
900
9,010 another by 90° using a test gauge with the prescribed testing
4.0 2-10 diameter.
1,000
1,011
4.0 2-11 The test gauge is hooked into place and the impeller is turned
1,120
1,112 by hand once for a single rotation.
5.0 2-13
1,250
1,214 The result is "good" or "bad":
8.0 2-14
1,400 good = the impeller does not touch or at most rubs
lightly against the test gauge
bad = the impeller rubs forcibly and comes to a stop.

The overlap test is carried out in the same way as in the

normal design.

We reserve the right to make changes as a result of technical progress.

32
 Unit installation in Ex-proof region

4.17 Gap and overlap adjustment for TLT-Turbo manufactured centrifugal fans

1. Adjusting „X“ gap

To check the gap between the fan runner and the inlet Four point checks should be made on the offset also and
nozzle, use a taperedmandrel inserted in the gap between this should be the same or greater than the "is" dimension
them and measure the gap. stated.

Check the offset dimensions with a quadrant device.

The measured values should be as indicated for the "is"
gap between the runner and inlet nozzle

Fan sizes 200 to 280 Fan sizes 315 to 1400

ER fan runner
ER fan runner
Inlet nozzle with
Inlet nozzle with
stainless steel ring
brass ring

Suction inlet dimension

Suction inlet dimension
E-nozzle externel

E-nozzle externel
øA

øA

øB
øB

Size Is X øA øB Gap size Size Is X øA øB Gap size

mm mm mm mm mm mm mm mm
200 4,0 136 144 1,4 315 3,0 222 228 2,2
225 4,0 153 161 1,6 355 3,0 249 255 2,5
250 5,0 171 181 1,8 400 3,3 279 286 2,8
280 2,5 198 203 2,0 450 3,5 314 321 3,2
500 4,2 352 360 3,6
560 4,3 396 404 4,0
630 4,8 444 453 4,5
710 5,2 498 508 5,0
800 5,0 560 570 5,7
900 5,8 628 640 6,4
1000 6,5 705 718 7,2
1120 7,5 792 807 8,0
1250 8,0 889 905 9,0
1400 9,0 997 1015 10,1

We reserve the right to make changes as a result of technical progress.

33
 Unit installation in Ex-proof region

4.17 Other notes

• The overload protection must occur directly by means
of the positive temperature coefficient resistor in the motor
in connection with an Ex-tested positive temperature
coefficient resistor evaluation unit
• When the buyer carries out wiring work, the requirements
for the installation of electrical systems in explosion hazard
areas according to DIN VDE 0165 and EEx-i-circuits
(DIN EN 60079-14) must be respected.
• Add-ons to the unit that have not been supplied by AL-KO
do not constitute part of the AL-KO-approved ATEX
conformity. The AL-KO ATEX conformity does not include
components added by the buyer, e.g. actuating drives or
sensors!
• All pipe insulation installed by the buyer must be either
electrostatically conductive or electrostatically
non-chargeable.

• The respecting of Ex-protection measures for the ventila-
tion units, which depend on "customer" control, must be
tested by qualified personnel (expert/specialist) and must
be tested before commissioning of the ventilation units.
• All externally mounted components must be taken into
account in the potential comparison.
• With assembly and reassembly of unit components,
the earthing points provided for them must be reconnected
and tested (see item 2.1).
• AL-KO supplies only one safety switch and maintenance
switch for the fan drive unit.

• When replacing parts, replacement parts from AL-KO

must be used in accordance with the parts list.

4.19 Special instructions for the operation of equipment in Ex-Zones 21 and 22

• The inbuilt air filter cells fulfil a safety function and because pressure drop be permanently monitored and the physical
of this a maximum pressure drop should be maintained condition checked monthly for possible damage. Any filter
with the specific filters as stated below: monitoring device must be to EEx-i power specifications

Coarse particle filter media G3 / G4 250 pa • Any additional sections must comply with the original unit
Fine particle filter media F5 / F9 450 pa specifications.

• It is further advised that a margin of 30% pressure drop on

the filters be allowed. It is advised that the filter maximum

4.18 Commissioning, general

Before commissioning, a qualified person or an expert from The results of the test must be verified with a protocol.
the local technical survey organisation must check compli-
ance with the Ex specifications of the entire system.

We reserve the right to make changes as a result of technical progress.

34
Notes

5. Maintenance notes according to VDI 6022 and VDMA 24186

5.1 General
Long-term compliance with hygienic requirements and the
execution of the necessary operational and commissioning
measures in air handling systems requires an appropriate
qualification of the personnel. Demanding operational proce-
dures in the context of maintenance and inspections as well
as commissioning should be carried out by trained, qualified
personnel. Special training programs are offered for these
procedures, for "simple hygiene procedures" (also known as
category B), and "demanding hygiene procedures" (also
known as category A). Only qualified personal that have
successfully finished these training programs are authorised
to carry out hygiene procedures.
The tasks that comprise commissioning procedures are
described in detail in the following table:

Grouping of measures (according to VDMA)

Inspection aims of the measures Maintenance aims of the measures Commissioning aims of the measures
(n. DIN 31 051) (n. DIN 31 051) (n. DIN 31 051)
Determination and assessment of Preservation of desired state Re-establishing desired state
current state
Individual measures Individual measures Individual measures
Testing, measurement, assessment Testing, readjusting, replacement, Repair, replacement
replenishing, lubrication, preservation,
cleaning
carried out by carried out by carried out by
Technician, engineer, foreman Personnel familiar with the unit Specialized assembler, technician
(for limited use), specialised assemblers,
technicians
Required training for hygiene Required training for hygiene Required training for hygiene
according to VDI 6022 page 2 according to VDI 6022 page 2 according to VDI 6022 page 2
Category A Category B Category C

5.2 Initial and repeat inspection by category A-trained qualified personnel, in accordance
with VDI 6022 page 2

Inspections require a particular professional training or
technician qualification in the field of supply engineering and
training in category A. In order to comply with these require-
ments, regular hygiene inspections must be carried out.
These must be carried out:
• every 2 years for air handling systems with humidifiers
• every 3 years for air handling systems without humidifiers.
Consulting qualified personnel is recommended.
The hygiene inspections include at least the following actions:
• Walkthrough inspection of the air handling control room,
including all components and the rooms supplied by them.
• When hygiene deficiencies are discovered: Measurement
of physical air-conditioning parameters (temperature,
humidity, air speed) at representative points in the
air handling system.
• Determination of the total germ count and the concentra-
tion of Legionnaire's bacteria in the circulation water of
humidifier systems.
• In the event of visually perceptible hygiene deficiencies,
their causes must be determined and rectified. If necessary
additional microbiological tests must be carried out in order
to make the determination, e.g. colony count in the intake
air, semiquantitative surface tests, or differentiation based
on germ types.

We reserve the right to make changes as a result of technical progress.

35
 Notes

Documentation record of the results of the hygiene inspection
must be made of the inspected air handling system and a
copy of the written report on the inspection results must be
provided to the operator, including a list of the steps required
to rectify the problem. The deadline for a required follow-up
inspection should be set as a function of the urgency of the
steps to be carried out.
Critical findings result from the following cases:
• Repeated exceeding of total germ counts in the humidifier
water (standard value 1,000 CFU/ml).
• Repeated mould contamination of the humidifier water
• Legionnaire's infection in humidifier water
• Occurrence of higher germ counts after air handling
systems than before
• Visible mould or other microbiological al films
In the event of a critical finding, a hygiene specialist or other
qualified personnel must be consulted and the company
doctor must be notified.

5.3 Hygiene inspections carried out as part of maintenance by Category B-trained

maintenance personnel in accordance with VDI 6022 page 2
The aim of the hygiene checks to be carried out regularly by
the maintenance personnel is to use frequent visual inspec-
tions and random sample-based microbiological self-testing to
provide early detection of hygiene deficiencies in air handling
systems and to correct them.
In Table 2 on page 2, VDI 6022 declares the type and extent
of inspection procedures to be carried out, the required steps
for correcting hygiene deficiencies found and time intervals
at which the respective hygiene inspections are to be
carried out.

The regular hygiene inspections include, among other things,

the following steps:
• Visual inspection for hygienic deficiencies of the involved
air handling region, e.g. germ growth or contamination,
rust formation, scale deposits, and damage.
• Testing of the total colony count in the circulation water
of air humidifier systems.

We reserve the right to make changes as a result of technical progress.

36
Notes
5.4 Hygiene requirements and maintenance, servicing of air conditioning equipment
according to VDI 6022 and VDMA 24186
Action Measures 1 3 6 12 24
month months months months months
Unit components Inspection and recommended maintenance intervals
1. Hygiene inspection
Must be carried out by trained, qualified per-
sonnel in accordance with VDI 6022 page 2
2. Outside air and exhaust air openings
2.1 Check for contamination, damage and Complete cleaning and commissioning X
corrosion
3. Unit housing
3.1 Check for contamination, damage and Cleaning and commissioning X
corrosion
3.2 Check for water formation Cleaning and determination of cause X
(condensate, leaks)
3.3 Check function of drains Clean as needed X
3.4 Check flexible connections for leaks X
4. Air filters
4.1.1 Check for impermissible contamination, Air filters must have a collection efficiency
damage (leaks) and odours appropriate to the filter class for the entire
length of their use. The filter must be replaced
in the event of conspicuous contamination or X
leaks. Replace the affected air filter if the filter
stage was last replaced less than six months
ago, otherwise replace the entire filter stage.
4.1.2 Check pressure difference Replace the filter stage when the maximal X
pressure differential is exceeded.
4.1.3 Checking of most recent filter change with
non-regeneratable air filters, otherwise X
thorough cleaning
1. Filter stage X
2. Filter stage X
4.1.4 Inspection of hygiene state X
5. Air humidifier
It is necessary to assure that water cannot be
deposited after the humidifier unit at any point
during operation.
5.1 Vaporising and recirculating spray The supplied water must at least meet drinking
humidifiers water standards and must not exceed a total
hardness of 7° dH.
5.1.1 Check for contamination, damage and Cleaning and commissioning X
corrosion
5.1.2 Germ count measurement of humidifier With a colony count > 1,000 CFU/ml: Wash 14 -
water (dip slides) with cleanser, rinse, and dry trough, disinfect if day
needed.
5.1.3 Check vaporiser nozzles for deposits Clean nozzles, replace if needed X
5.1.4 Check state and function of dirt trap Cleaning and commissioning X
5.1.5 Check for flake formation in bottom region Clean pan X
of air humidifier pan
5.1.6 Check recirculating pump for dirt and film Clean pump circuit X
build-up in the intake line
5.1.7 Check function of blow-down device Readjust blow-down device X
5.1.8 Check function of conductivity cell Commissioning X

We reserve the right to make changes as a result of technical progress.

37
 Notes

Action Measures 1 3 6 12 24
month months months months months
Unit components Inspection and recommended maintenance intervals
5 .1.9 Check function of disinfection system Commissioning X
5.1.10 Check function of water supply and X
distribution
5.1.11 Check water level X
5.1.12 Readjust water level in regulating unit X
5.1.13 Check function of drain and overflow X
5.2 Steam humidifiers with and without Must be operated so that no condensate can
integrated steam generators enter the air duct system. The vapour cannot
contain any harmful substances.
5.2.1 Check for contamination, damage and Cleaning and commissioning, possible X
corrosion disinfection
5.2.2 Check for condensate precipitation in Determine causes and correct, clean steam X (during
humidifier chamber humidifier operation)
5.2.3 Wash with cleanser, rinse, and dry humidi- Cleaning and commissioning X
fier chamber, disinfect if needed
5.2.4 Check state and function of dirt trap Cleaning X
5.2.5 Check steam distributing pipe for deposits Cleaning and commissioning X
5.2.6 Check condensate drain Commissioning X
5.2.7 Check function of control valve Wall surface, troughs X
5.2.8 Inspection of hygiene state Restore as needed or replace X
5.2.9 Check steam cylinder for deposits X
5.2.10 Check steam lines and condensate line for X
leaks and damage
Droplet eliminator
5.2.11 Check for contamination, damage and film Function maintenance cleaning, all surfaces X
build-up including troughs, may require disassembly of
droplet eliminator
5.2.12 Check droplet eliminator for film build-up Function maintenance cleaning when there is X
visible encrustation, may require disassembly of
droplet eliminator
5.2.13 Check function of drain and odour trap X
5.3 Ultrasonic, spray, and hybrid humidifiers
5.3.1 Check for contamination, incrustation, Cleaning and commissioning, possible X
damage, and corrosion disinfection
5.3.2 Clean water receptacle X
5.3.3 Check function of electrical system X
5.3.4 Check function of energy converters (only X
in ultrasonic humidifiers) and replace as
needed
5.3.5 Check function of water supply and X
distribution
5.3.6 Check pump (only in spray and hybrid X
humidifiers)
5.3.7 Inspection of hygiene state Wall surfaces and troughs X
Droplet eliminator
5.3.8 Check for contamination, damage and film Function maintenance cleaning, all surfaces X
build-up including troughs, may require disassembly of
droplet eliminator
5.3.9 Check droplet eliminator for film build-up Function maintenance cleaning when there is X
visible encrustation
5.3.10 Check function of drain and odour trap X

We reserve the right to make changes as a result of technical progress.

38
Notes

Action Measures 1 3 6 12 24
month months months months months
Unit components Inspection and recommended maintenance intervals
6. Heat exchanger, general
If cleaning in the installed position is insufficient,
then the heat exchanger must be removed and
suitably cleaned
6.1.1 Check for contamination, damage and corro- Cleaning and commissioning X
sion
6.1.2 Check evaporative cooling unit, condensate Commissioning X
pan and droplet eliminator for contamination,
corrosion, and function.
6.1.3 Check function of siphon Commissioning X
6.1.4 Inspection of hygiene state X
6.2 Air heater
6.2.1 Check for contamination, damage and X
corrosion on the clean air side
6.2.2 Function maintenance cleaning (clean air side) X
6.2.3 Check function of water supply and return. X
6.2.4 Ventilate X
6.3 Electric Air Heater
6.3.1 Check for scale encrustation and corrosion X
6.3.2 Function maintenance cleaning (clean air X
side)
6.3.3 Check function X
6.3.4 Check function of control unit and safety X
device
6.4 Air cooling unit (air/fluid) dehumidifier The siphon with the reverse flow prevention
vaporiser (air/coolant) mechanism must be sized and positioned in
accordance with the pressure conditions so as
to permit unhindered flow of condensate water.
6.4.1 Check for contamination, damage and Cleaning and commissioning X
corrosion
6.4.2 Check evaporative cooling unit, condensate Commissioning X
pan, and droplet eliminator for contamination,
corrosion and function. Test function of siphon.
6.4.3 Clean evaporative cooling unit, droplet X
eliminator, and pans
6.4.4 Check function of water supply and return X
6.4.5 Ventilate (only with fluid) X
6.4.6 Check for icing (only with vaporiser) only possible during X
operation
6.4.7 Check hygiene state X
Droplet eliminator
6.4.8 Check for contamination, damage and film Function maintenance cleaning, all surfaces X
build-up including troughs, may require disassembly of
droplet eliminator
6.4.9 Check droplet eliminator for film build-up Function maintenance cleaning when there is X
visible encrustation
6.4.10 Check function of drain and odour trap X
7. Heat Recovery, general
Heat exchanger and its accessories must be
periodically checked on the clean air side for
contamination, corrosion and damage.
7.1.1 Check for contamination, damage and Cleaning and commissioning X
corrosion
7.1.2 Check for leaks between exhaust and Commissioning X
outside air

We reserve the right to make changes as a result of technical progress.

39
 Notes

Action Measures 1 3 6 12 24
month months months months months
Unit components Inspection and recommended maintenance intervals
7.1.3 Check condensate pan and droplet Commissioning X
eliminator for contamination, corrosion,
and function.
7.1.4 Check function of siphon Commissioning X
7.1.5 Clean evaporative cooling unit, droplet X
eliminator, and condensate pan
7.1.6 Inspection of hygiene state X
7.2 Rotary heat exchanger (also see item 4.3.2)
7.2.1 Check for contamination and corrosion on Clean as needed X
clean air side
7.2.2 Function maintenance cleaning The rotors can be cleaned with compressed air.
In doing so, the air jet must strike the thermal X
mass at a right angle. Wet cleaning is not possi-
ble, it would destroy the rotor.
7.3.3 Check rotor for imbalance X
7.3.4 Check bearings for noise The ball bearings used are low-maintenance
and are designed for a service life of up to X
100,000 hours. They can generally be used at
temperatures up to 120 °C
7.3.5 Grease bearings with regreasing device Only in bearings with a relubrication device X
7.3.6 Check function of sealing element The brush seals on the thermal mass are posi- X
tioned at the factory
7.3.7 Seals With normal-temperature rotors, sealing felts of
the quality: NF-PES-LE 0.32 grey are used. The X
felts must be slid as close as possible to the ther-
mal mass, but without producing direct abrasion.
7.3.8 Check hygiene state X
7.3.9 Check drive elements X
7.4 Cross flow heat exchanger
7.4.1 Check for contamination, damage and Clean as needed X
corrosion on clean air side
7.4.2 Function maintenance cleaning (clean air X
side)
7.4.3 Check function of cleaning unit If present X
7.4.4 Check function of drain and odour trap X
7.4.5 Check hygiene state X
8. Sound absorbers
Sound attenuators must be periodically checked
externally for contamination, damage and corro-
sion. If they are not visible, then they must be
dismantled.
8.1 Check sound absorbers for contamination, Commissioning X
damage and corrosion
8.2 Check inner air-conducting surface for Determine causes, clean corresponding air duct
contamination and corrosion at two to three sections X
representative points
9 Louvre dampers
9.1 Check for contamination, damage and Clean as needed X
corrosion
9.2 Check mechanical function X
9.3 Actuating drive units Function check X

We reserve the right to make changes as a result of technical progress.

40
Notes

Action Measures 1 3 6 12 24
month months months months months
Unit components Inspection and recommended maintenance intervals
10 Fire prevention dampers
if they are installed in the unit In addition, the inspection report must be heed-
ed, also see VDMA 24186 part 7
10.1 Check locking device for contamination and Clean as needed X
function
10.2 Check tripping mechanism for contamination X
and function
10.3 Check seals for contamination and damage X
10.4 Actuating drive units Check function X
11 Fans
The fan unit and drive units must be periodically
checked for contamination, damage and
corrosion
11.1 Check for contamination, damage and Cleaning and commissioning X
corrosion
11.2 Function maintenance cleaning of X
air-exposed parts of fan and drain
11.3 Check impeller for imbalance X
11.4 Check bearings for noise X
11.5 Grease bearings with regreasing device X
11.7 Check flexible connections for leaks X
11.8 Check function of vibration damper X
11.9 Drive elements See pos. 12
11.10 Control equipment Check function of pressure/volume X
flow controller
12 Drive elements
12.1 Electric motors
12.1.1 Check attachment and externally check for Clean as needed X
contamination, incrustation, damage, and
corrosion
12.1.2 Check rotation direction (initial start-up)
12.1.3 Retighten connecting terminals X
12.1.4 Measure voltage Measurement data must be recorded in the test X
certificate
12.1.5 Measure power consumption Measurement data must be recorded in the test X
certificate
12.1.6 Measure phase symmetry Measurement data must be recorded in the test X
certificate
12.1.7 Check bearings for noise X
12.1.8 Grease bearings with regreasing device X
12.2 Belt drives
12.2.1 Check for contamination, damage and wear Replace as needed X
12.2.2 Function maintenance cleaning Capacity range must be defined and agreed X
upon
12.2.3 Check tension and alignment Replace as needed X
12.2.4 Change belts X

We reserve the right to make changes as a result of technical progress.

41
 6. Emergency

In case of fire, the dampers must be closed and power to the Warning:
unit must be disconnected by means of the master switch. In order to protect from the possible release of toxic
Rooms should be closed off in order to minimise the substances, the rooms must only be entered when wearing
air supply. Alert the fire brigade. respirator masks.

7. Dismantling and disposal

Dismantling and disposal of the air handling unit must be

carried out in accordance with legal guidelines in force at the
time of their execution.

We reserve the right to make changes as a result of technical progress.

42
We reserve the right to make changes as a result of technical progress.
43
 We reserve the right to make changes as a result of technical progress.
44
We reserve the right to make changes as a result of technical progress.
45
 We reserve the right to make changes as a result of technical progress.
46
We reserve the right to make changes as a result of technical progress.
47
AL-KO THERM GMBH
Bereich Klimatechnik
Hauptstraße 248-250
D-89343 Jettingen-Scheppach
Phone 0049 (0) 8225/39-0
Fax 0049 (0) 8225/39-113
e-mail info.therm@al-ko.de
Internet http://www.al-ko.de 11/2004