FG CAIRplus Operation Manual Technical-operationmaintenance-Installation-commissioning UN

CAIRplus®
OPERATION MANUAL
Table of Contents CAIRplus®
1 Unit Type Code .................................................................................. 4

2 Safety and User Instructions ........................................................... 5
2.1 Availability of the operation manual ................................................................ 5
2.2 Scope of the operation manual ....................................................................... 5
2.3 Symbols used .................................................................................................. 5
2.4 Labelling of safety instructions ........................................................................ 8
2.5 Used safety symbols ....................................................................................... 9
2.6 Safety-conscious work procedures ............................................................... 10
2.7 Proper use ..................................................................................................... 13
2.8 Safety devices ............................................................................................... 13
2.9 Modifications and changes ............................................................................ 14
2.10 Spare parts .................................................................................................... 14
2.11 Disposal ........................................................................................................ 14
2.12 Selection and qualification of personnel ........................................................ 14
3 Technical Description ..................................................................... 15

3.1 Performance scope ....................................................................................... 15
3.2 Technical Specifications ................................................................................ 15
3.3 Operating limits and range of application ...................................................... 15
4 Shipping and Storage ..................................................................... 19

4.1 Delivery ......................................................................................................... 19
4.2 Transport ....................................................................................................... 19
4.3 Storage .......................................................................................................... 22
5 Assembly ......................................................................................... 23
5.1 Unit placement .............................................................................................. 23
5.2 Assembling the unit ....................................................................................... 27
6 Installation ....................................................................................... 42
6.1 Requirements ................................................................................................ 42
6.2 Installing air-conveying components ............................................................. 43
6.3 Installing air-handling components with coil connections .............................. 43
6.4 Installing accessories .................................................................................... 50
7 Electrical Connection ..................................................................... 51

7.1 Requirements ................................................................................................ 51
7.2 Connecting unit ............................................................................................. 52
8 Commissioning and Maintenance ................................................. 57

8.1 Routine cleaning and maintenance ............................................................... 58
8.2 Maintenance frequency checklist .................................................................. 60
8.3 General considerations ................................................................................. 63
8.4 Fan assembly and drives .............................................................................. 65
8.5 Filter assembly .............................................................................................. 71
8.6 Heater assembly ........................................................................................... 75
8.7 Cooler assembly ........................................................................................... 77
8.8 Cooling/heating coil ....................................................................................... 78
8.9 Heat pipe ....................................................................................................... 79
8.10 Liquid-coupled energy recovery coil .............................................................. 81
8.11 Plate heat exchanger .................................................................................... 81
8.12 Rotary heat exchanger .................................................................................. 84
8.13 Humidifier assembly ...................................................................................... 85
8.14 Damper blades and shut-off dampers ........................................................... 85
2 FläktGroup DC-2009-0096-GB R10/12-2018 • Specifications are subject to alteration without notice

CAIRplus® Table of Contents
8.15 Sound attenuators ......................................................................................... 86

8.16 Commissioning/maintenance of ECOTWINcool double-plate
heat exchanger with adiabatic cooling ........................................................... 86
8.17 commissioning/maintenance of integrated refrigerating systems .................. 87
9 Disassembly and disposal ............................................................. 89

9.1 Dismantling .................................................................................................... 89
9.2 Disposal ......................................................................................................... 89
10 Troubleshooting .............................................................................. 90
11 Appendix .......................................................................................... 91
11.1 Maintenance Log Book CAIRplus .................................................................. 91
– Original operation manual –

Copyright note
Disclosing, copying, distributing or taking any action in reliance on the contents of this document
is strictly prohibited without express prior consent. Violations entail liability for any damages or
other liability arising. All rights in relation to patents, utility patents or design patents are reserved.
FläktGroup DC-2009-0096-GB R10/12-2018 • Specifications are subject to alteration without notice 3

Unit Type Code
CAIRplus®
1 Unit Type Code

A 1 2 8 0 6 4 V B V A
Unit part 2 *
Example: CAIR plus X 1 A # I H S E Z 1 2 8 0 6 4 V B V A
Prefix General Unit part 1
Thermal separation
Type of application
Material of profiles
Unit design class
Air flow direction

führungsklasse
Installation site
Product family
Product group
Arrangement
External skin
Components
Internal skin
Casing type
Unit height
Unit width
Function
Material
Material
Material
Air flow
Casing
Series
CAIR
plus (air handling unit)
X SX Unit
1 Standard without accessories
2 Standard with accessories
3 Special design
A Automatic
T Complete
K Without
# Standard
R Standard, in conformity with RLT 01 Directive
H
Hygiene
variant
E Explosion protected
I Indoor installation
A Outdoor installation
D Ceiling mounting
W Wall mounting
U Underfloor installation
H Horizontal
V Vertical
L L Form
S Single
N Side by Side
Ü Double-deck
H Straight-through
E Single casing
K Combined casing
Z Supply air
A Extract air
Unit width (internal size in cm)
Unit height (internal size in cm)
V Aluzink AZ 185
B RAL 9002 coated
2 Stainless steel V2A (steel type 1.4301) or equivalent
4 Stainless steel V4A (steel type 1.4571) or equivalent
B RAL 9002 coated
S Coated in special colour
V Galvanized
L coated
K Coated with enhanced corrosion protection
A Natural Alu
B RAL 9002 coated
* Unit part 2 – additional with arrangement types side-by-side, double-deck or straight-through

Safety and User Instructions
CAIRplus®
2 Safety and User Instructions

The CAIR units are constructed using the state-of-the-art technology and according to
recognized safety regulations. Operation is only allowed if the unit is in perfect working
order given that current operation manual and safety instructions are observed and
potential hazards avoided! Otherwise failure to follow these instructions may result in
death or injury to the user, third persons or damage to the unit, connected units or other
equipment.Have all faults repaired by an authorized specialist without delay!
Consider the safety instructions provided by the manufacturers of individual compo-
nents!
2.1 Availability of the operation manual

This operation manual contains important instructions regarding safe and proper ope-
ration of the unit.
This operation manual applies to installation companies, operators, building technici-
ans, technical personnel or instructed persons as well as electricians.
This manual as well as the safety information of the manufacturer of the individual com-
ponents must always be available at the unit's installation site. When working on the
equipment, observe all instructions and precautions in the current operation manual, in
particular the chapter on safety.
2.2 Scope of the operation manual

This operation manual as well as the instructions of the manufacturer of the individual
components provide you the necessary information on the areas:
– Shipping and storage
– Mounting
– Installation and Electrical Connection
– Commissioning and Maintenance
– Disassembly and Disposal
2.3 Symbols used

The following symbols are used to highlight particular text sections in this operation
manual:
– This symbol is used to indicate normal lists.
• This symbol indicates instructions to follow.
9 The result of an action is indicated with this symbol.
Note!
Additional details on using the unit are specified here.
Danger symbols are specified in section "Labelling of safety instructions" on page 8.

CAIRplus®
2.3.1 Special warning and danger symbols
The following warning and instruction signs can be secured on the unit:
To connect - counter hold with a pipe wrench.
Attention: fire risk. Dust-laden filters are inflammable.
Before opening, use the main isolator to disconnect power.
Risk of injury. Wait until complete stop before opening.
Type sheet and assembly instructions attached to unit inside. Remove these docu-
ments before the unit commissioning.
Do not start up the fan against closed dampers.
Designation of unit in explosion-risk areas (according to 94/9/EG regulation)
Potential equalisation To equalize potentials the unit must be connected to an exter-

nal protective conductor at the designated points on the base frame.

CAIRplus®
2.3.2 Function signs
Air heater/cooler with heat re-

Fan or compressor indicating covery function
air flow direction Air/water ECOFLOW
Air heater/cooler with heat re-

Sound attenuator in unit covery function
Air/steam ECOSTAT
General air filter Air heater/cooler with heat re-

indicating air flow direction covery function
Air/air ECOPLAT
HEPA filter Air heater/cooler with heat re-

indicating air flow direction covery function
Air/air ECOROT
General air humidifier

Opposed-blade dampers
Air heater air/water General controller
Air cooler air/water Droplet separator
Air cooler
Air/steam/refrigerant

CAIRplus®
2.4 Labelling of safety instructions

To designate the safety instructions the following symbols and notices are provided in
appropriate places throughout this document:
2.4.1 DANGER - Death/serious irreversible injury
Indicates an extremely hazardous situation which will result in death or serious irrever-
sible injury, if the safety instruction is not followed.
Example:
Electrocution through hazardous voltage will lead to death or serious injury.

• Disconnect the unit from the power supply and ensure the power cannot be
switched back on.
• Ensure the unit is voltage-free and isolated, earth and short circuit the unit, cover
or shield off neighboring live components.
2.4.2 WARNING - Death/serious injury
Indicates a hazardous situation which can result in death or serious irreversible injury,
if the safety instruction is not followed.
Example:
High concentration of refrigerants in the air can result in death or serious in-
jury!
High concentration of refrigerants in the air may have an anaesthetic effect and
cause unconsciousness. Prolonged exposure may cause irregular heartbeat and
sudden death. Very high concentration of refrigerant may cause suffocation by
reduced oxygen content in the surrounding air.
• You should therefore only work in an adequately ventilated environment, and
exercise due care and attention when carrying out the work.
• Wear protective clothing and, if necessary, an autonomous breathing apparatus.
2.4.3 CAUTION - Minor or moderate injury
Indicates a hazardous situation which can result in minor or moderate injury, if the
safety instruction is not followed.
Example:
Sharp edges can cause injuries!

Observe precaution when cleaning due to risk of cuts on thin and sharp edges.
• Wear protective gloves.

CAIRplus®
2.4.4 ATTENTION – Environmental or material damage

ATTENTION
Indicates actions that can result in equipment or property-damage only accidents.

Examples:
ATTENTION
Risk of environmental damage!
Heavily contaminated filters can have a negative impact on production processes.
Depending on the filtered-out materials, contaminated filters are therefore classi-
fied as hazardous waste and must be properly disposed of according to the pre-
vailing guidelines and laws.
ATTENTION
Risk of damage to the unit!
If dampers are abruptly shut during unit operation, the unit can be damaged
beyond repair as a result of negative pressure or overpressure.
2.5 Used safety symbols
Electrical hazard
Explosive atmosphere
PERSONAL injury
Overhead loads
Risk of tipping
Rotating components!
Rotating storage materials
Toxic substances
Crushing of limbs
Sharp cutting edges
Inflammable materials

CAIRplus®
Scalding
Hot surfaces
Cooling
Environmental damage
Damage to the unit
2.6 Safety-conscious work procedures

Observe the following instructions when carrying out installation, adjustment or repair
jobs:
• Wear suitable protective clothing during work, such as protective footwear, gloves,
safety goggles, etc..
• Avoid flame sources, especially burning cigarettes. Open flame sources and
smoking in the proximity to the unit are prohibited. Filters and especially used filters
can easily catch fire. Leaking refrigerant can catch fire and emit noxious substances.
When working within range of mains voltage:

switched back on.
When working in explosive atmosphere:
Life-threatening danger of explosive atmosphere!

The unit must only be operated under the conditions specified on the unit identifi-
cation plate.
Explosion-risk conditions may originate inside and/or outside the unit during its
operation as well as during dowmtime period. For this reason, it is assumed that
explosion-risk conditions are present, even if the unit is deactivated.
• Avoid using pro-inflammatory substances such as electrical tool and electronic
devices.
• Smoking and open flames within direct proximity of the unit are prohibited.
• Before starting any jobs - ventilate the interior and/or exterior of the unit!

CAIRplus®
For all kinds of work:
Risk of personal injury!

No matter what kind of jobs are performed on the unit, there is always a risk of
cuts by thin sheet metal and heat exchanger fins. In particular, this aspect applies
when carrying out maintenance and cleaning work on the surfaces of heating and
cooling coils.
• Wear suitable protective clothing.
Before commissioning and after maintenance of the unit there is an increased
risk of injury:
• Ensure that no persons are locked inside the unit. Walkable surfaces of the
unit are equipped with emergency levers on the interior side of doors. Smaller
units must provide a protection against inadvertent locking by using padlocks
on the door stop.
An operating unit poses a risk of injury:
– Danger of impacts by opening doors arranged on the discharge side
– Danger of crushing resulting from negative pressure applied to doors on the suc-
tion side
– Danger resulting from rotating parts such as fans etc.
– Danger of hot surfaces and/or media
Units equipped with coolers with a refrigeration circuit pose additional risks.
• Observe all the safety notes contained in Chapter "commissioning/maintenance
of integrated refrigerating systems" on page 87.
ATTENTION
If dampers are abruptly shut during unit operation, the unit can be damaged
beyond repair as a result of negative pressure or overpressure.
Jobs on the unit can only be carried out if

– all poles for the power supply are disconnected
– the unit is secured to prevent inadvertent energising (also refer to "Electrical
hazard")
– all moving components - in particular - fan impeller, motor, rotary heat exchanger,
control and shut-off dampers – have come to a standstill: wait at least 5 minutes after
deactivating the unit
– the heat exchangers have cooled down to reach ambient temperature
Upon completion of jobs on the unit ensure that
– all protective devices are operating properly – for example, the fan safety devices
(door protection grille, contact guard) are locked
– no persons are present in danger areas.

CAIRplus®
2.6.1 Handling refrigerants (only for units with integrated refrigerating system)
According to DIN EN 378 Part 1 the R-134a and R-410A refrigerants belong to A1
group. Refer to the unit identification plate for data and charge volume of a particular
refrigerant.
Observe the usage details in accordance with EC regulation 842/2006.
Features of applicable refrigerant types:
– Non-combustible
– No direct toxic effect
– Colorless and odorless
– Heavier than air
– Contains fluorinated greenhouse gases as defined by the Kyoto protocol
– Ozone-depleting potential OPD: 0
– Greenhouse potential GWP: R-134a: 1300, R-410A: 1980
– Water hazard class WGK 1, with a slight risk to water
• Wear appropriate clothes when performing jobs with refrigerants and in the proximity
to a refrigeration circuit, e.g.
– Sealing protective goggles
– PVA or leather gloves
– Protective clothes for entire body
– If necessary, an autonomous breathing apparatus
First aid First aid measures directly after or during contact with refrigerants:
– Ensure your own protection against leaking refrigerant.
– Under all circumstances - call a doctor or and/an ambulance.
– Remove clothes contaminated by the refrigerant.
Inhalation Additional measures after inhalation of refrigerants:
– Take the injured person to a well-ventilated location.
– Ensure that the injured person is in a stable lateral position.
– Consumption of food and beverages must be avoided.
– If the injured person collapses or loses consciousness – perform mouth-to-mouth re-
spiration.
Skin contact Additional measures after skin contact with refrigerants:
– Rinse the affected body parts using lukewarm water for at least 15 min.
Eye contact Additional measures after eye contact with refrigerants:
– Do not rub your eyes.
– Remove contact lenses if you have any.
– Rinse your eyes with lots of water.

CAIRplus®
2.7 Proper use

The CAIRplus units are only intended for handling air and performing the following
jobs:
– filtering normally polluted air
– filtering air in cleanroom applications (special cleanroom design)
– air heating and/or cooling
– humidifying and/or dehumidifying of air
– heat rejection or heat recovery
– filtering and treatment of air with a high moisture content and/or with high levels of
contamination (special models, for example for swimming pool or kitchen exhaust
applications)
– or combination of the above-mentioned functions.
Proper use also includes observance of the operation manual and instructions from the
manufacturer of the individual components, as well as the inspection and maintenance
intervals stipulated by FläktGroup.
Improper use Any use other than that described above is considered improper. If necessary, check
if your units are suitable for your intended purpose and application. The manufacturer/
supplier is not liable for any damages arising from improper use. The user alone bears
the risk.
Misuse particularly includes:
– Conveying any other gases except air
– Conveying steam or water
– Coarse filtering and/or filtering any other media except air
– Chopping up or reducing size of materials
– Drying out clothing
The unit is not suitable for handling abrasive media.
It is not allowed to operate CAIR units:
– in explosion-risk areas, unless units are certified for use in these relevant areas (air
handling units meeting special explosion-protection requirements in accordance
with ATEX Guideline 94/9/EG)
– in rooms with conductive dust
– in rooms with strong electromagnetic fields
– in rooms with aggressive atmosphere that may attack plastics or cause corrosion
(especially in atmosphere where zinc is particularly susceptible to corrosion).
– CAIR units must not be accessible to the general public.
2.8 Safety devices

Depending on the unit equipment, the following components are secured:
– Padlock in the door-stop device (TAS) on each door
– Locks of switch cabinet
– The panels and doors with lockable handles
– Fan chambers are secured by door protection grilles
– V-belt drives are secured by belt guards
Ensure by others on site that the contact protection for intake and discharge fittings is
provided.

CAIRplus®
2.9 Modifications and changes

Changes, alterations or modifications of the unit are not allowed. Tampering with the
unit or its misapplication will invalidate the CE conformity and void warranty.
If delivered units are disassembled by others on-site, the factory warranty is rendered
invalid. In this case professional services by FläktGroup should be arranged in
advance.
2.10 Spare parts

Only original FläktGroup spare parts are allowed, since FläktGroup is not liable if third-
party spare parts are used.
2.11 Disposal
Equipment, operating supply materials, components and filters must be disposed of
according to the material type in a safe and environmentally friendly manner.
2.12 Selection and qualification of personnel

Ensure that every person working on the unit has read and understood entire operation
manual. Please read this document fully before commencing any work, and not while
performing a task.
All jobs must only be carried out by qualified licensed staff or other individuals with pro-
per professional training and experience in the following areas:
– Occupational health and safety regulations
– Accident prevention regulations
– Directives and recognized codes of practice
All jobs with the refrigeration circuit shall be performed only by certified and licensed
staff in accordance with the valid EG Regulation 842/2006 Article 5, EG Regulation
303/2008 Article 4 and 5 as well as "Ordinance on climate protection against changes
caused by release of certain fluorinated greenhouse gases" Article 5, passed by the
German parliament.
All skilled staff must be able to assess the entrusted work and must be able to recog-
nize and avoid all associated dangers.

Technical Description
CAIRplus®
3 Technical Description
3.1 Performance scope

CAIRplus units are generally used for energy-saving supply-air and extract-air indoor
ventilation. Due to their modular design, units can be configured individually to meet
particular air-handling requirements and specifications. The transported air can be fil-
tered, heated, cooled, humidified or dehumidified, depending on the application for
each case. The aim is to meet the customer specifications concerning required air
volume and conditions.
CAIRplus units are used at a central point for comfort air conditioning on commercial
and industrial premises for the transportation and treatment of “normal” air. The units
can also be manufactured in a customized design and adapted for cleanroom and hygi-
ene applications. CAIRplus units meeting explosion-protection standards and com-
plying with the ATEX 94/9/EG Directive are clearly designated and marked. These
units are supplied with an additional operation manual that must be read and conside-
red.
A range of unit components are available for energy-saving purposes: rotary heat
exchangers, plate heat exchangers, heat pipes and liquid-coupled heat exchangers for
the recovery of heat and the partial recovery of moisture as well.
Units are performed in different sizes and have various capacities. Depending on the
application for each case, CAIRplus units are designed for vertical or horizontal air flow
and are arranged as double-deck, side-by-side and straight-through models. Units can
be installed indoors and outdoors.
Thanks to the modular design of the CAIRplus, units ship as complete assemblies or
sub-assemblies that can pass through the available on-site openings in the course of
installation. CAIRplus units are also suitable for the modernization and retrofitting of
existing buildings due to the number of available unit sizes and a unit ordering option
providing for delivery in small shipment units.
3.2 Technical Specifications

Refer to the order-related documentation for the specific configuration of your CAIR-
plus unit (unit drawing with dimensions and technical data).
3.3 Operating limits and range of application

– Please carefully observe the unit type plate and the operation manuals for the sup-
plied accessories.
– Please refer to the accompanying documentation or technical specifications provi-
ded in the unit-layout software for the operating limits or related restrictions of indi-
vidual built-in parts and components.
– The unit warranty is only valid if the specified materials are adhered to when units
are used in corrosive or aggressive environments!
– In process-air applications, consider the tolerance-related differences in aerodyna-
mic values!
– In frost-risk cases, use antifreeze agents for heating and cooling media.
– Operating limits for CAIRplus special/customized units are available on request.

CAIRplus®
3.3.1 Ambient conditions

Outdoor air
Note on extreme conditions!
In addition to the air temperature/air humidity of the transported medium, the tempe-
rature/humidity of the ambient air is also critical. Observe the condensation limits.
from -25 °C to +60 °C

Extract air from 0 °C to +80 °C
Air humidity depending on temperature max. 18 g/kg of dry air
Max. operating pressure Heating/cooling coil 16 bar / 90 °C
and temperature
Minimum operating tempera- Heating/cooling coil 6 °C
ture
Notice on extreme In addition to the air temperature/air humidity of the transported medium, the tempera-
conditions! ture/humidity of the ambient air is also critical. Environmental factors such as proximity
to sea or ocean must be taken into account when selecting material quality.
Different ambient conditions apply for integrated refrigerating unit.
3.3.2 Permitted storage conditions / permitted air condition for uninstalled units
Air temperature -10 °C to +50 °C

Air humidity Store units in a dry, non-condensing atmosphere
3.3.3 Supply voltage

The required supply voltage is specified in the order-related documentation, e.g. AC
230 V/50 Hz (1 phase) or AC 400 V/50 Hz (3 phases).
3.3.4 Condensation limits

Please pay due attention to condensation limits!
The following diagrams illustrate condensation limits depending on temperature and
relative humidity at the installation site - for series CAIRplus SX M and CAIRplus SX K.
The diagrams are based on normal air values and are calculated using a model box.
The given values are approximate figures and can not be used as a guarantee for avoi-
ding condensation. Depending on different casing components, deviations are pos-
sible.

CAIRplus®
Read example:
Relative humidity on unit external side in %
Air temperature on unit internal side in °C
Air temperature on unit external side in °C
With ambient conditions of 27 °C and 60 % relative humidity, air temperature in unit

may amount to -1 °C without formation of condensate.
CAIRplus SX K Condensation diagram for kb-value: 0.5

= without thermal separation

CAIRplus®
CAIRplus SX M Condensation diagram for kb-value: 0.62

= partial
thermal separation

Shipping and Storage
CAIRplus®
4 Shipping and Storage
4.1 Delivery
CAIRplus unit can ship as a single piece or multiple individual shipment units. Delivery
is done on transport pallets.
• When the unit is delivered, check that the shipment is correct according to the
dispatch note, and also check for completeness.
Notice!
Consider instructions relating to the procedures in case of shipping damage pro-
vided on the unit packaging or in dispatch documents!
What steps should you The exterior of the packaging is damaged

should take in the event of
1 Unpack the equipment in the presence of the truck driver and have him confirm the
shipping damage?
damage on the shipping order.
2 Inform the FläktGroup Sales Company immediately.
Exterior packaging is OK, contents are damaged.
1 Once you have established the extent of the damage, report the damage to the
FläktGroup Sales Company in writing.
2 Take photographs of the damaged parts.
3 Possible shipping damage must be reported no later than 4 days after delivery.
It will not be possible to process claims if the above-mentioned points are not fulfilled.
In both cases, consult the FläktGroup Sales Company before installing the units.
4.2 Transport
Danger due to overhead loads – risk of grave injuries or death!

• Never stand beneath suspended loads, since there is always a risk that the lifting
gear, tackle, ropes or slings are faulty or damaged.
• Use only the lifting lugs provided by FläktGroup!
• Make sure that equipment is firmly seated before lifting it.
Risk of personal injury and equipment damage!

Due to a high center of gravity, some equipment can tend to tip over and cause
damage to persons and property.
• When transporting the unit, careafully observe its behavior and do not get near
any possible hazardous areas.
Notice!
• Transport the unit only in its original packing. Only remove the original packaging
just before installation.
• Remove the pallet before lifting the unit modules at the lifting lugs / transport
gear.

CAIRplus®
• For safety reasons, wear protective clothing when lifting or transporting the unit.
• Before lifting or shipping the unit, make sure that all doors, dampers and panels are
fixed and secured.
• Only use lifting gear with sufficient load-bearing capacity.
• Never use damaged lifting equipment.
• Ropes/chains must not be knotted and/or be exposed to sharp edges.
• Only use ropes/chains of the same length.
• Move the unit carefully without jerky movements.
• Do not set the unit down abruptly or bump it.
4.2.1 Lifting the unit – lifting lugs on roof (provided with shipment units weighing up to 1500 kg)
• Lifting lugs may only be used for lifting.
• Do not use lifting lugs for lateral loads (pulling of unit on
Angle range
sides).
70 - 110° • The suspension angle must be between 70° and 110° (see
fig. 4-1).
• Lifting lugs may only be used once.
• Do not use lifting lugs for permanent suspension of units.
• Do not lift any other loads together with the shipment unit.
• With units for outdoor installation, ensure that the roof sheets
are not damaged by the lifting gear.
• The maximum lifted weight of the shipment unit
may not exceed 1500 kg.
• Use all four eyeplates to lift the shipment unit.
Fig. 4-1: Lifting lugs for shipment units weighing up to 1500 kg

CAIRplus®
4.2.2 Lifting the unit - transport gear on the base frame (provided with shipment units weighing up to 4000 kg)
• Use only the transport gear attached to the base frame for
lifting the units.
• Use the lifting gear (not part of the FläktGroup package) as
shown in the figure.
• Use provided timber spacers to protect the unit at the edges.
• Suspension angle must not exceed 60°.
• To effectively prevent the load from slipping or tilting, consid-
er its center of gravity when lifting the unit.
• Use the transport gear only once.
• Do not use transport gear for permanent suspension of units.
• Do not lift any other loads together with the shipment unit.
• With units for outdoor installation, ensure that the roof sheets
Fig. 4-2: Lifting lugs for shipment units weighing up to
are not damaged by the lifting gear.
4000 kg
• Units with a slanting roof are delivered with a device that en-
ables to fasten it in place during truck transport.
This device must be removed before lifting the unit by
crane!
4.2.3 Shipping with a fork-lift truck
ATTENTION
Unit damage due to stacking the units!
• Never stack units on top of one another for shipping!
• Always place and rig the units one at a time!
Stacking of units and other foreign field-provided components is not permitted.
Exceptions apply for units delivered by the FläktGroup sites where the sufficient
load-bearing capacity is considered beforehand.
• Always use the unit base frame or the supplied pallet as the supporting surface
during transportation.
• Do not lift units without the base frame if the unit profiles are not sufficiently
protected.
• When transporting the unit with a forklift both base-frame profiles must be resting on
the forks.
• Verify proper center of gravity lift point and uniform distribution of weight.

CAIRplus®
4.3 Storage
Notice!
• Observe the permissible storage conditions when storing the unit. Remove the
original packaging only before installation.
• If the unit is stored for a period of time before installation or commissioning,
protect it from damage through elements, build-up of dust and dirt!
• Prior to commissioning, take appropriate measures to protect units without
packaging against build-up of dust and dirt. If packing takes place on site by
others, make sure that condensate cannot form below the packaging (consider
relevant clearance between the packaging and casing).
• Always place units on an even surface for storage or intermediate storage.

• Protect units from bumps and knocks which may damage the casing and protruding
components.
• If commissioning is not carried out within three months following the delivery, the belt
drive must be slackened.
• Rotate the motor axis and fan through at least 2 revolutions every 3 months.
4.3.1 Permitted storage conditions / permitted air condition for non-installed units
Air temperature -10 °C to +50 °C

Air humidity Store units in a dry, non-condensing atmosphere

Assembly
CAIRplus®
5 Assembly
Notice!
Here you will find information on how to mount and install the unit.
– Assemble and install exclusively by qualified staff. They must have proper pro-
fessional training and experience in the relevant accident prevention regulations,
as well as other generally recognized safety and occupational health codes, per-
form unit jobs.
– The unit must be installed in such a way that it is only accessible to trained and
authorized technical personnel.
– The unit shall only be installed in accordance with the technical specifications
provided in the supplied documentation.
– Stacking of units and other foreign field-provided components is not permitted.
– Exceptions apply for units delivered by the FläktGroup sites where the sufficient
load-bearing capacity is considered beforehand.
• When connecting an air-duct to the unit, ensure that no foreign objects can enter the
unit.
• If necessary, have a suitable protection grille installed by others on air discharge or
intake openings of the unit.
ATTENTION
• When entering CAIR units, ensure that no loads are applied on the floor panels.
• For all installation jobs take appropriate measures to ensure that the load is
evenly distributed across the bottom profiles.
5.1 Unit placement
Danger due to overhead loads!

Never stand beneath suspended loads, since there is always a risk that the lifting
gear, tackle, ropes or slings are faulty or damaged. Failure to follow safety precau-
tions could result in death or serious injury.
• Make sure that equipment is firmly seated before lifting it.
Warning! Risk of personal injury and equipment damage!

severe injury to persons and damage to property.
• When transporting the unit, carefully observe its behavior and do not get near any
possible hazardous areas.

Assembly
CAIRplus®
5.1.1 Installation site

For the unit installation the job site shall meet the following requirements:
– The site base must be level and stable.
– The maximum deflection of the site base must not exceed 4 mm per meter.
– In units where a condensate drain is installed, ensure there is adequate height for
condensate drain requirements - the height of the site base must at least correspond
to the trap height (refer to "Condensate tray trapping").
• In case of leaking liquids take measures to prevent damage to the installation site or
the environment.
Abb. 5-1: Installation site
• When installing a spray humidifier, use a plinth or unit feet

corresponding to the tray height to ensure horizontal align-
ment with other unit sections.
Fig. 5-2: Height compensation with spray humidifier
5.1.2 Minimum clearances

• To remove fans, heat exchangers, droplet separators, etc.
and enable adequate maintenance allow a minimum clear-
ance of one unit width on the operating side.
• Allow a minimum clearance of 600 mm between the unit rear
side and the wall if the unit configuration does not provide for
an internal joint connection.
Fig. 5-3: Minimum clearance

Assembly
CAIRplus®
5.1.3 Foundation requirements for indoor installation
• The foundation/bottom base may protrude a maximum of 20

mm beyond the outer edge of the unit to enable mounting of
cover plates or accessories, such as condensate traps.
• The supporting points of the foundation must be located at
every shipping split. Besides, ensure that the maximum dis-
tance between these points does not exceed 1600 mm in the
unit length(see fig. 5-4).
• Units with side-by-side arrangement must be supported in
the center (see fig. 5-5).
L ≤ 1600 L ≤ 1600
Fig. 5-4: Foundation requirements with side-by-side units

operator side
Fig. 5-5: Foundation requirements with side-by-side

cross-section

Assembly
CAIRplus®
5.1.4 Foundation requirements for outdoor installation (weatherproof, roof frame)
Notice!
Units for outdoor installation are not roof substitutes!
It is not allowed to use weatherproof units as supporting surfaces of a building or
similar roof substitutes in accordance with prEN 13053 and VDI 3803.
• Refer to valid instructions on "Foundation requirements for indoor installation" on

page 25.
• Select an installation site with outdoor air intake not facing the main wind direction.
• If the unit is mounted on a roof, the latter must support the total weight of the unit,
verify that the supporting structure is adequate for the unit. Consult a structural
engineer, if necessary.
• The roof edge below the unit, as well as ducts and other roof openings must be
sealed by others on site to prevent water and air leakage.
• Ensure that the field-provided roof frame is sealed to prevent condensation. For
notes refer to "Preparing roof installation" on page 34.
• In areas with heavy snowfall, ensure that the unit is installed at a location where
snow can not affect the unit operation. Provide for an adequate foundation with an
appropriate height.
Fig. 5-6: Foundation design with concrete Fig. 5-7: Foundation design with field-pro-
base vided steel beam
Fig. 5-8: Foundation design with field-provided steel support
Notice!
• Pay particular attention to ensure the exact size of the roof openings and level
foundation.

Assembly
CAIRplus®
5.1.5 Structure-borne noise attenuation

In order to reduce the transmission of vibration from the unit to the supporting structure,
provide vibration and noise-dampening pads.
– We recommend to use rubber pads to isolate the foundation from the units installed
on a level structure with no special requirements to structure-borne noise isolation.
– For a ceiling installation we recommend to use commercially available spring-based
elements.
– For very special acoustics requirements please consult an acoustic engineer to
select the most suitable method for neutralizing structure-borne noise.
5.1.6 Wind load

High wind velocities can produce heavy loads that can cause the unit to move or tip
over. Further on-site measures might be necessary to prevent this from happening.
5.1.7 Ceiling mounting unit

There are various different fastening systems for installation under the ceiling. The
dimensioning of the fixation in the ceiling must be performed on-site by others.
5.2 Assembling the unit
Injuries due to crushing of limbs!

During assembly there is the risk of unit parts crushing your limbs.
• Always wear protective clothing.
Injuries caused by sharp edges!

During assembly, there is always a risk of cuts inflicted by thin sheet metal and heat
exchanger fins.
• Wear protective gloves.
Notice!
• See unit submittal documentation for details.
Data sheets, installation instructions, small parts and enclo-
sed accessories are located in the unit section marked by
this red adhesive label.
ATTENTION
• Do not mount or use field-supplied fittings and attachments on the unit panels or
frames, as these components can cause an air or water leakage.
• Ensure easy access and service for the unit.

Assembly
CAIRplus®
Required tools: – Electric screwdriver, drill

– Bit holders/sockets
– Sockets of sizes 8, 10
– Slotted head screw bits, sizes 2, 3
– Open-ended spanners sizes 8, 13, 17
– Screw drivers 4.5 - 6.5
– Hexagon socket size 6
– Tensioning belts or suitable hoisting device
5.2.1 Removing lifting lugs and safety devices

• Remove all lifting lugs, safety locks and devices mounted on and in the unit prior to
assembly.
• Remove safety locks on the fan.
Verify that that all lifting lugs on the roof are removed:
Roof lifting
• Remove the lug, screw and bushing at the section joint, then
lug secure the supplied M8 x 30 screw.
Cylinder
screw
Plastic
washer
Support bu-
shing
Fig. 5-9: Lifting lug at joints
Lifting lug
• Remove the screws on the end walls and secure the sup-
at roof plied M8 x 70 screw.
Cylinder
screw
Plastic
washer
Support bu-
shing
Fig. 5-10: Lifting lugs for roof and end wall
Notice!
Due to a risk of damage through lifting lugs - externally mounted dampers, flexible
canvas connection partially ship separately.
• Mount these components on-site and seal them.

Assembly
CAIRplus®
• Disassemble the lifting lug secured on the base frame.
Fig. 5-11: Lifting lug secured on the base frame
Notice!
• You may not use lifting lugsfor suspending the unit from the top on a permanent
basis.
• It is allowed to use lifting lugs only once.
5.2.2 Installation of individual modules

To join individual sections for final assembly (at joints) proceed as follows:
• Attach provided gaskets at the joint (separate assembly in-
structions are enclosed with the supplied sealing strip).
Fig. 5-12: Installing individual modules

Assembly
CAIRplus®
ATTENTION
• Do not attach tensioning belts/hoisting devices to heat exchanger connections,
condensate drains and door handles. Do not use the components to pull or push
the equipment!
• Before joining the sections for final assembly position them as close to one another
as possible.
• Use the unit base frame only to pull the sections together.
• If necessary, underlay round material to simplify pulling the sections together.
• Use the tensioning belts to pull together units without a base frame. Secure the belts
on the unit profiles at the bottom or roof section.
max. 100 mm
Fig. 5-13: Unit with base frame Fig. 5-14: Unit without base frame

Assembly
CAIRplus®
• Screw the outer joint connections together.

• Do not use partition joint connectors to pull the units together.
• Use screws M8x30.
Fig. 5-15: Screw the base frame to the

connectors
• Screw the outer joint connections together.
Fig. 5-16: External view

• Install the seam cap.
Fig. 5-17: External view

• If the rear side of the unit is not accessible, screw together the interior joint
connection in the corner.
• Do not use partition joint connectors to pull the units together.
• Use screws M8x60.
Fig. 5-18: Internal corners

Assembly
CAIRplus®
• Starting from the internal unit width or height of 1280 mm or more an additional joint
connection is provided in the middle of the profile (on the internal side), use the
screws to secure this joint connection as well.
Fig. 5-19: Internal partition join

connector
Note on joint connection!

• If screws can not be applied due to the unit components, unscrew the joint
connections, place the screws and mount the joint connections together with
screws.
• Seal pipe and cable ducts to prevent air leakage and condensation. For example
use PU-foam to complete the sealing (not included in FläktGroup packaged
content).
Fig. 5-20: Pipe duct

Additional measure for double-deck and side-by-side units
• Connect both unit sections using supplied plates.
Fig. 5-21: Connecting unit sections

Assembly
CAIRplus®
• For offset double-deck units, use the screws as outlined.
Fig. 5-22: Double-deck units
• For offset side-by-side units, use the screws as outlined.
Fig. 5-23: Side-by-side units
Additional measure for units in hygiene design

• Clean and seal internal joint seams at the bottom. The sealant is included in the
packaged content for hygiene units.
Fig. 5-24: Joint seams

Assembly
CAIRplus®
5.2.3 Additional measures for units for outdoor installation

ATTENTION
9 Insufficient or improper sealing by others on site can cause water leakage and
damage to the equipment and building materials!
• Carefully seal all unit components.
• When installing roof components ensure that no loads are applied on the roof
panels. Do not walk on the floor panels.
• If necessary use a proper pad for the entire roof surface.
• During assembly and assembly pauses, take care that no rainwater gets into the
units.
• After assembly is completed, you must remove the protective foil from the roof
panels.
5.2.4 Preparing roof installation

• Remove all lifting lugs (1).
1
1 2
• Install sealing washers at all screws and tighten them (2).
Fig. 5-25: Preparing roof installation

Assembly
CAIRplus®
5.2.5 Installing inclined/bossed roof (CAIRplus SX)

• Secure the separately supplied joint strip.
Fig. 5-26: Installing joint strip
Single units 064.xxx to 160.xxx and side-by-side units 064.xxx to 096.xxx

• Use the supplied sealant to caulk the roof panel seams (1).
1
• Slide the separately provided joint strips (2) over the seams.
• Manually crimp down the overhanging end (3) at 90°.
3
2
Fig. 5-27: Single units 064.xxx to 160.xxx

and side-by-side units 064.xxx to 096.xxx

Assembly
CAIRplus®
Single unit 188.xxx to 252.xxx with inclined roof design

• Secure the separately supplied joint strip as described abo-
ve.
• Slide the separately provided joint strips (1) from both sides.
1
• Use a screwdriver to ensure that the connecting plate is
placed below the opposite joint strip.
• Use the supplied sealant to caulk the joint strips (2).
• Secure in place with the fixing screw (3).
Fig. 5-28: Single unit 188.xxx to 252.xxx

with inclined roof design

Assembly
CAIRplus®
Single units 280.xxx to 312.xxx and side-by-side units 128.xxx to 160.xxx

• Secure the separately supplied joint strip as described on
page 35.
• Use the supplied sealant to caulk the roof panel seams (1).
• Slide the separately provided joint strips (2) from both sides.
• Secure in place with the fixing screw (3).
2
3
Fig. 5-29: Single units 280.xxx to 312.xxx

and side-by-side units 128.xxx to 160.xxx

Assembly
CAIRplus®
Centrally-split roof panels

1 • With centrally-split roof panels slide the separately provided
roof joint strips (1) over the flanges.
• Secure in place a terminating angle plate (2) on each front
wall.
• Apply sealant (3) as presented in the figure.
• Attach the separately provided weatherproof covers (4) and
use supplied screws to secure them in place.
Fig. 5-30: Centrally-split roof panels
Consider the following for side-by-side units with misalignment, sizes 128.xxx
and 160.xxx
• Depending on the unit shipping splits, install a separately en-
closed roof panel for „side-by-side casing“ (1), if necessary,
as presented in the drawing.
Fig. 5-31: Side-by-side units with offset,

sizes 128.xxx and 160.xxx

Assembly
CAIRplus®
5.2.6 Roof installation with double-deck units

• Roof installation for double-deck units is identical to the in-
stallation of single units – refer to the specification from
page 34.
• Apply sealant evenly on the surface.

• Use the screws to attach the connecting panel to the end
wall (1).
1
• Finally produce a concave groove in the sealant.
Fig. 5-32: Roof installation with double-deck units

Assembly
CAIRplus®
5.2.7 Roof installation of side-by-side unit with ECOROT

• Roof installation side-by-side units equipped with ECOROT
is identical to the installation of single units – refer to the
specification from page 34.
• Apply sealant evenly on the surface.

1
• Use the screws to attach the connecting panel to the end
wall (1).
• Finally produce a concave groove in the sealant.
Fig. 5-33: Roof installation of side-by-side unit with ECOROT

Assembly
CAIRplus®
5.2.8 Intermediate or base frame cover panels

• Mount the cover panels as outlined
Fig. 5-34
Fig. 5-35
Fig. 5-36

Installation
CAIRplus®
6 Installation
Danger of injury due to toxic substances!

Glycols and other antifreeze agents are harmful for humans and animals, if swallo-
wed.
• Consult a doctor immediately if swallowed by mistake.
Notice!
Unit connections at coils and humidifiers shall only be performed by qualified
licensed staff. Have qualified licensed staff or other individuals with proper profes-
sional training and experience in the relevant accident prevention regulations, as
well as other generally recognized safety and occupational health codes, perform
unit jobs.
ATTENTION
• For all installation work, take appropriate measures to ensure that the load is
6.1 Requirements
• Check the unit for external damage and ensure proper instalation and anchorage.
• Check if vibration and noise-dampening pads are provided. The following applies:
– either rubber pads are used for level installation to insulate the unit from the
foundation in a location where no special requirements for the neutralisation of
structure-borne noise apply;
– or commercially available spring-based elements are used for ceiling installati-
on;
– or very special acoustic requirements please consult an acoustic engineer to
select the most suitable method for neutralising structure-borne noise.
• Check the following before performing coil connections of the unit:
– To allow maintenance and service, install drainage valves at all low points of the
water circuit to ensure that the water circuit can be fully drained.
– Provide drainage with a shut-off valve for emptying the unit’s water circuit.
– Ensure that air vents at all high points in the chilled water circuit are installed and
can be easily accessed.
• Clean the field-provided piping and create the relevant report.

Installation
CAIRplus®
6.2 Installing air-conveying components

In order to prevent transmission of structure-borne noise, enable a tension-free
connection between ductwork and unit by using elastic connectors or sound attenua-
tors to prevent structural noise transmission (also refer to "Structure-borne noise atte-
nuation" on page 27). If using flexible canvas connections between unit and ductwork,
installation length of the connectors must be smaller than their length in expanded con-
dition.
6.3 Installing air-handling components with coil connections
Recommendations on water quality for heat exchangers operating with pumped

warm water and pumped chilled water:
Water in proper quality, e.g. salt and lime-free drinking water, considerably increases
the service life and efficiency of the heat exchanger.
• Check the limit values in the table once a year to prevent damage to the hydraulic
system and installed components. If necessary, add inhibitors to water.
Notice! Effects in case of

Description Symbol Values
These limit values are difference
only intended to provide
7.5 9
<7 Corrosion
Hydrogen ion concentration pH
basic information >9 Incrustation
on water quality Calcium and magnesium content Hardness (Ca/Mg) 4 8.5 ×' > 8.5 Incrustation
and do not form any Chlorine ions Cl– < 50 ppm Corrosion
+
basis for a guarantee. Iron ions Fe³ < 0.5 ppm Corrosion
Magnesium ions Mg²+ < 0.05 ppm Corrosion
Carbon dioxide CO2 < 10 ppm Corrosion
Hydrogen sulphate H 2S < 50 ppb Corrosion
Oxygen O2 < 0.1 ppm Corrosion
Chlorine Cl2 < 0.5 ppm Corrosion
Ammonia NH3 < 0.5 ppm Corrosion
Ratio carbons/sulphates HCO3²-/SO4²- >1 <1 Corrosion
1/1.78 °D = 1 °Fr with 1 °Fr = 10 g CaCO3/m³
ppm = parts per million (mg/l)
ppb = parts per billion (Pg/l)
6.3.1 Installing air-handling components for cooling/heating applications
ATTENTION
• When connecting the heat exchanger, counter hold with a pipe wrench to
prevent damage.
• The connections to coils made by others on side must generally be tension-free.
Do not apply mechanical and static loads to the connection fittings.
Consider the counter flow principle when connecting coils. (air and water moving in
opposite directions in the coil)
• Protect the fins in the coils to prevent damage.
• Connect pipework by others to the chilled water inlet and outlet. The inlet and outlet
coil connections are marked with labels.
• Insulate pipework on site.

Installation
CAIRplus®
With air-handling components for cooling/heating applications, consider the

following:
• Following installation insulate coil connections and pipework to prevent condensing
water.
9 Coil drip tray is made of stainless steel and collects forming condensate. The coil
drip tray is fitted with a drain connection to empty condensate.
• Refer to the section on trap (see "Water drain trapping" on page 47).
For units with outside-air or mixed-air operation consider the following:
ATTENTION
• Protect the heat exchanger in unit from ice and freezing at ambient
temperatures below the freezing point.
• Use proper antifreeze agents in the water circuit.
Notice!
Using glycol is allowed, but the glycol concentration shall not exceed 50% of
the total charge.
A higher quantity can cause operating faults.
6.3.2 Installing evaporator/condenser components
ATTENTION
• Properly dispose of all liquids (refrigerants) in an environmentally-friendly way
in accordance with the locally applicable laws and regulations.
• Use special tools and fittings for handling service connections.

9 The units are charged with protective nitrogen that audibly discharges when caps
are removed.
6.3.3 Installing coils with a liquid-coupled energy recovery system
Multiflow®
See separate operation manual
ECOFLOW / ECOFLOWplus
ECOFLOW Liquid-coupled energy recovery system with heat exchangers with 4 to 12 pipe rows,
adjustable with 3-way control valve
ECOFLOWplus Liquid-coupled energy recovery system with heat exchangers with 14 pipe rows, adju-
stable about 50% to 100% with 2-way bypass valve
See additional instructions under "Installation of air-handling components for cooling/
heating applications" on Page 43.
Only for units without factory- • Install the hydraulic system on-site according to schematic sketch, parallel piping for
made piping installation: divided heat exchangers; insulate pipework and fittings to be non-permeable.
Only for units with external • Install an automatic rapid exhaust ventilator suitable for glycol with incoming-side
heat-exchanger connec- shut-off valve on the outlets of both heat exchangers on-site.
tions:
Only for units without stan- • Observe the design and layout data of FläktGroup for the pump and 2/3-way valve;
dard-delivered piping set: choose proper dimensions for the safety valve and expansion tank, calculate the
nitrogen charging pressure and adjust as needed.
Only for on-site control • By controlling the 2/3-way valve ensure that the exhaust air temperature after the
system: liquid-coupled energy recovery system cooler is not below +2 °C to avoid air-side ice
formation.

Installation
CAIRplus®
Exhaust
Extract
Supply Outdoor
Fig. 6-1: Hydraulic scheme ECOFLOW, as an example for undivided heat exchangers
Extract
Exhaust
Outdoor
Supply
Fig. 6-2: Hydraulic scheme ECOFLOWPLUS, as an example for undivided heat exchangers

Installation
CAIRplus®
6.3.4 Installing humidifier

Refer to the supplied documentation for instructions on assembly and installation.
• Also observe the German Drinking Water Act (Trinkwasserverordnung – TWVo).
The following recommendation applies “Guide values for the quality of water circulating
in the spray humidifier (air washer)” (in accordance with: VDI 3803 “HVAC systems.
Constructional and technical requirements”, February 2010, Appendix A, Table A1).
Room-ventilation system equipment for:
Room-air quality Room-air quality Room-air quality

IDA 2, IDA 3 or IDA 1 according to EN IDA 1 according to EN
Quality IDA 4 according to EN 13779 13779 for sterile and cle-
13779 for IT rooms anrooms
indirect evaporative cooling
(to be determined depending on the system)
Appearance – klar, farblos und ohne Bodensatz
pH value – 7 to 8.5
Total salt concentration TSC g/m³ < 800 < 250 < 100
Electrical conductivity mS/m < 100 < 30 < 12

(at reference temperature 20 °C) PS/cm < 1000 < 300 < 120
2+
Ca mol/m3 > 0.5
Calcium
3
g/m > 20
Carbonate hardness KH °dH <4
Total hardness GH °dH <7
mol/m3 <5
Chloride CL-
g/m3 < 180
mol/m3 < 1.5 <1
Sulphate SO42-
3
g/m < 150 < 100
Consumption KMnO4 g/m3 < 50 < 20 < 10
CFU (colony for-
Microbial count < 1000 < 100 < 10
ming units)/mL
Legionella bacteria CFU/100 mL < 100
Notice!
When installing a water-softening unit FläktGroup recommends to repeat the
water analysis. The total salt concentration shall not exceed 250 g/m³! The electri-
cal conductivity shall not exceed 300 µS!
ATTENTION
• Do not operate honeycomb humidifiers with fully demineralized water.

Installation
CAIRplus®
6.3.5 Water drain trapping
Types of condensate drains

Condensate drain by unit profile
Fig. 6-3
Condensate drain by unit profile
Fig. 6-4: Tray drainage adapter 22/40 mm
Condensate drain through base frame
Fig. 6-5
Notice!
Direct connection to a sewage network is not allowed! Fill the condensate trap with
water prior to commissioning and after extensive downtime periods.
Hydraulic seal H of the trap must be greater than the maximum

positive or negative pressure (mm water column) in unit (1 mm
WC = 10 Pa).
Use the following equation for the dimensioning:
Unit overpressure/under pressure Pa

H mm WC = ------------------------------------------------------------------------------------------------------
10
The vertical difference between the water drain and hydraulic

seal must also correspond to the dimension H (mm WC).
Fig. 6-6: Trapping for section under positive
pressure

Installation
CAIRplus®
• Connect the trap to the sewage water system as shown in

the figure.
Caution: freeze-up risk!
In the event of freeze-up risk, the drain pipe
must be insulated and kept warm using heating
wire.
1,5 H
0,
Fig. 6-7: Trapping for section under negative
pressure
Fig. 6-8: A trap is required for each section with condensate drainage or overflow pipe. Connecting multiple drains to a common
line with only one trap is not allowed (* can result in clogged drain).
Notice!
• Negative pressure and positive pressure traps must be connected to separate
common lines (refer to Fig. 6-8).
6.3.6 Installation of integrated refrigerating systems

• Please observe the instructions contained in the separate operation manual on
equipment systems with integrated refrigeration.
In general, when working with refrigerants, be sure to pay attention to the follo-
wing points:
(see also "Handling refrigerants (only for units with integrated refrigerating
system)" on page 12)
Warning of high concentration of refrigerants in the air!

sudden death. Very high concentrations of refrigerant may cause suffocation by

Installation
CAIRplus®
Injuries caused by smoking and open flames

Smoking and open flames at the installation site of the unit or during work with refri-
gerants are prohibited. Open fire or flames can lead to the disintegration of a refri-
gerant and release of toxic gases.
• Do not keep any inflammable liquids in close proximity to the unit.
Danger of injury from refrigeration!

Contact with a liquid refrigerant can result in skin burns or injury to other organs.
• Exercise due caution and attention when carrying out jobs and avoid contact with
a refrigerant.
Danger of injury caused by high pressure!

When working on hydraulic or refrigeration circuits or in case of damage to the
components or piping, there is a risk of injury from fluids or gases escaping at high
pressure.
• Exercise due caution and attention when carrying out this work.
• Wear appropriate protective clothing.
ATTENTION
• Do not pollute the environment with liquid products, refrigerants or oils.
• Dispose of the latter in accordance with local laws and regulations by avoiding
harm to the environment.
Ethylene glycol and propylene glycol are categorized as water pollutants. This
also applies to mixtures with water.
• Always make sure that the units are accessible only to authorized and trained
technical personnel. If necessary, use appropriate equipment to keep unauthorized
persons away from the unit.
• Have all leaks immediately eliminated by service personnel or a specialist
refrigeration company (refer to section 4.10).
• The safety sheet stating the type of refrigerant charged on the given unit shall be
firmly secured in the machine room of the unit in a well visible manner (refer to unit
identification plate or operation manual for the unit).
• Ensure that proper trays or similar vessels are mounted below the unit in order to
reliably capture oil and glycol liquids and prevent contact with the environment.
• Use only accredited components for ATEX units.
• Be sure to ground all electric components.
Notice!
– Completion and commissioning of refrigerating systems may only be carried out
by the manufacturer or another competent expert designated by the manufactu-
rer.
– Assembly and installation is only allowed to be performed by qualified licensed
staff.
– Comply with the prevailing standards and guidelines (e.g. DIN EN 378, BGR 500
and F-Gas Regulation) in performing all activities.

Installation
CAIRplus®
Prerequisites for commissioning

All structural building prerequisites such as accessibility, installation of self-contained
units and ducts, and the sustained availability of all supply media must be satisfied.
Furthermore, it must be possible to operate the equipment in the required operating
points.
Basis for warranty

The basis for the warranty is the completion of a service contract with a qualified spe-
cialist company in refrigeration engineering and the proof of regular, competent main-
tenance recorded in the service booklet.
SYSTEM OPERATION:
The refrigeration unit can only be operated when the room-ventilation unit is in opera-
tion. Error messages from the refrigerating system are displayed at the switching cabi-
net. The equipment represents a system subject to monitoring in the sense of the
German Law on Occupational Safety (BetrSichV), which poses specific requirements
on the operator and where conditions according to Art.14 of this law must be satisfied
before the system may be operated. Be sure to observe any further applicable laws of
the respective installation site.
Maintenance and inspection

See the service booklet for refrigerating systems for requirements.
6.4 Installing accessories

Refer to the supplied documentation of the accessories that specify assembly and
installation instructions for accessories or field-provided accessory items.

Electrical Connection
CAIRplus®
7 Electrical Connection
Notice!
The electrical connection may only be performed by a qualified licensed electri-
cian. The electricial must have proper professional training and experience in the
relevant accident prevention regulations, as well as other generally recognized
safety and occupational health codes, perform unit jobs.
Ensure and observe protective measures!
When installing and connecting the unit, also observe protective measures for
low-voltage systems according to the EU Directive as well as regulations and
codes of the local utility providers.
Ensure earthing and potential equalization of the individual sections and all
connected components.
Electrical connection must be assured and documented between all shipment
units (potential equalisation usually to be provided via screw connections).
Connect the entire unit to the same potential.
Passive switch contacts in explosion-protected units may only be used in intrinsi-
cally safe electric circuits.
Lightning protection!
Especially roof units must be equipped with a proper lightning protection system.

switched back on.
NOTICE!
• Perform all wiring to the unit in accordance with enclosed unit-specific wiring
diagrams and national electrical codes and regulations.
• You must use a separate mains power cable.
• Never connect other units to this mains power cable.
• Check all electric connections according to the supplied wiring diagrams and all
terminal block screws for a tight seat.
7.1 Requirements
Visual inspection of mecha- • Carry out a full visual inspection of the entire unit and installed components.
nical components • Before you start setting up the unit electrical connections, check the following:
– The properties of the mains power supply must comply with EN 60204-1 regulations
and the power requirements of the unit.
– Let a qualified licensed electrician determine the size of the pre-fuse based of the
unit rated current.
– The motors must be able to operate at their rated capacity where the input voltage
with rated frequency is between 95% and 105% of the nominal voltage.

CAIRplus®
7.1.1 On-site routing of cables and cable penetrations by others

• Avoid cable penetrations and routing of cables near doors, dampers, panel
connections and cover strips.
• Perform all screw connections and cable openings leak-free.
• The connecting cables in the fan chamber must be long enough to allow the motor
to be moved easily (e.g. for belt tightening).
7.2 Connecting unit

Separate grounding for each assembly group with an electrical connection is required.
Consider the relevant instructions specified in the enclosed manuals for the accessory
items.
7.2.1 Motor protection
Motor protection with PTC thermistors

Depending on the motor size and type, the AC motors are fitted from 2 to 6 PTC ther-
mistors switched in series. The PTC thermistors are embedded in motor windings to
enhance reading of the winding temperature. PTC thermistors are semiconductor resi-
stors with variable temperature-dependent values.
When the maximum allowed winding temperature of 135 °C is reached, the resistance
reading increases rapidly. This control method and the full motor-protection electronics
deactivates motors.
Notice!
Unlike thermal contacts, PTC thermistors do not wear off. They provide a high
degree of operational reliability due to shock-resistant, pressure-resistant and
vacuum-proof features.
ATTENTION
• Do not apply voltage to separate lead-out sensor, since this would destroy it.
The maximum allowable voltage reading must not exceed 5 V.
• Wire the sensor only to the motor full protection tripping unit (e.g. 912.MVS 1.0).
Induction effects!
To prevent induction effects for the PTC thermistor circuit FläktGroup recom-
mends to use electrically screened lines, such as JY (st) Y, 2 x 2 x 0.5. Attach
earth screen on one side to the potential equalisation terminal (PE).

CAIRplus®
Motor full protection electronics

For motor full protection, we recommend to use 912.MVS 1.0 tripping units. These are
specially designed for PTC thermistors of motors. Full motor protection is based on the
closed-circuit principle and is intrinsically safe. Motor protection tripping units 12.MVS
Operating point of 1.0 generally enable isolated disconnection and a restart following a power outage.
tripping unit
Electronic motor protection tripping units deactivate motors in the following situations:
Resistance R
– Overload
– Ambient temperatures exceed allowed limits
– Locked fan wheel
Temperature T +135 C
– Insufficient cooling
– Short circuit in winding
– Wire breakage and loose contacts in the measuring line
Extended motor protection With frequent start-ups, intermittent operation, high switching frequency and to ensure
optimum protection against 2-phase run, FläktGroup recommends to protect motors
using thermal overload relays/motor circuit breakers in addition to the PTC thermistor
protection.
Disconnection in the event of In case of fault shutdown investigate the above-mentioned causes.
an error
Motor protection with thermal contact
Thermal contacts are temperature-dependent operating elements for automatic moni-
toring of the motor winding temperature. Thermal contacts are integrated in motor win-
dings and enable additional protection as compared to thermal cut-out devices and
motor circuit breakers:
– Insufficient cooling
– High ambient temperature
– Extreme speed reduction in course of control and regulation operations
– Motor disconnection in case of control-voltage line failure
– Faulty contacts and cable breakages in the control circuit.
A thermal contact opens if the allowed winding temperature is exceeded. As a result
the mains circuit of the control unit is interrupted. The fan contactor drops out and dis-
connects the motor from the mains. Motor protection is intrinsically safe.

CAIRplus®
7.2.2 Connecting electric motors

For proper unit operation consider the clockwise rotating field for unit connection.
• If necessary, check the rotating field using an instrument specifically designed for
this purpose.
ATTENTION
Improper connection to the motor/fan could result in equipment damage.
• Check for the proper assignment of the phase sequence to the specified rotating
direction before the motor is connected.
The terminals of AC motors are labelled in such a way that the alphabetical sequence
of the terminal designation U1, V1, W1 corresponds with the temporal sequence of the
phases L1, L2, L3 (with clockwise rotation).
The rotation direction can be reversed by exchanging two connecting wires:
Single-speed electric motors – Exchange the connecting cables, e.g. U1 and V1
with direct start:
Single-speed electric motors – Y-switch: exchange the connecting wires, e.g. U1 and V1
with Y/'-start: – '-switch: exchange the connecting wires, e.g. U2 and V2
Voltage fluctuations • Ensure that the supply voltage at mains frequency falls within the range from 95%
to 105% of the rated voltage. If this condition is met, motors can deliver the rated
capacity, otherwise non-compliance can result in equipment damage.
To carry out the connection, proceed as follows:
• Connect the unit according to the wiring diagrams.
Single-stage motor: 1500 min-1, with voltage change-over
Notice!
• Please observe the name plate of the motor (Y/delta switch)!
Motor version:
L1
U1
W2 U2 V2
*1 • to 2.2 kW: 3 x 230 V with '-type switch,
3 x 400 V with Y-type switch
U2
U1 V1 W1 • from 3 kW: 3 x 400 V with '-type switch,
V2
W2
3 x 690 V with Y-type switch
L3 W1 V1
L2 L1 L2 L3 2 - 3 PTC thermistors depending on the motor size
Total resistance RK (20 °C) approx. 200 - 300 :
*1 PTC thermistor
L1 W2 U2 V2
W2
*2 Motor protection device
U1
K K
U1 V1 W1
W1 U2 *2
L3 L2
V2 V1 L1 L2 L3
Fig. 7-1

CAIRplus®
7.2.3 Frequency inverter

Make the parameter settings in the course of unit start-up.
ATTENTION
• Do not activate the parameter "overmodulation" as this can damage the impeller.
• Permanent magnet motors (PM motor) without integrated electronics may only
be connected to suitable frequency inverters.
• It is not possible to operate several PM motors with one frequency inverter.
Notice!
In this case, FläktGroup neither accepts warranty claims nor assumes liability.
• Ensure that the maximum frequency does not exceed the allowable limit (refer
to data sheet on fan).
• Consider the relevant instructions specified in the enclosed manual for the
frequency inverter. Use a screened motor cable only.
7.2.4 EC Fans
EC fans and motors provide air movement with the highest efficiency factor. Highly effi-
cient electronically commuted motors with permanent magnets are used with variable
speeds via integrated controller.
• Connect the fans according to the attached documentation/wiring diagram and
observe the manufacturer's instructions.
• When using earth leakage circuit breakers, make sure that they are sensitive to
universal current (type B).
• If the control cables are wired to a terminal box, observe the pin assignment shown
in the following wiring diagram:

CAIRplus®
7.2.5 Service switch

Install a lockable service switch near the access door of the fan chamber.

When there is a factory-mounted service switch, the wiring is run up to the motor.







   




   








   
               
   
                   
                       
   













   
   




   
                   
                       
                   
                       



   
Fig. 7-2
7.2.6 Installing and connecting actuator motor
Notice!
• Adjust the final position switch before commissioning!
• With a factory-mounted FläktGroup actuator, connect the latter in accordance with

the specifications in the data sheet on actuators.
• If other actuators are used - refer to the relevant documentation.
• Ensure proper operation of this component.
• Be sure not to start up the fans with closed dampers.
7.2.7 Additional electrical components

• Connect additional electrical components in accordance with the relevant provided
documentation and wiring diagrams.

Commissioning and Maintenance
CAIRplus®
8 Commissioning and Maintenance

Notice!
Data sheet and assembly instructions are located inside the unit, refer to the label-
led positions for the documentation! Remove these documents prior to the unit
commissioning.
Certain assembly groups and unit components require individual commissioning. The
relevant instructions are listed in the following chapter.
Electrocution through hazardous voltage will lead to death or serious injury!

switched back on.
• Do not work on the PM motor when the fan wheel is freely rotating.
• You must mechanically prevent the fan from moving.
Life-threatening danger of explosive atmosphere!

• Give special consideration to safety instructions, procedures on unit assembly
and electrical installation instructions for units operating in explosion-risk areas.
Failure to comply with these regulations may result in explosions causing severe
personal injury or death!
Risk of contusions from rotating components!

• Before opening unit doors, secure the fan from being inadvertently switched on.
• Wait at least five minutes following the complete fan stop before opening unit
doors.
Risk of burns due to hot surfaces!

Temperatures above 85 °C can occur on the motor surfaces, particularly on the
controller casing! Severe burns can be the consequence.
Risk of being inadvertently locked in!

• Ensure that no persons are locked inside the unit.
– Walkable surfaces of the unit are equipped with emergency levers on the inte-
rior side of doors.
– Smaller units must provide a protection against inadvertent locking by using pad-
locks on the door stop.
Danger of crushing by rotating storage mass!

Cutting injuries can be incurred from rotating sharp edges.

CAIRplus®
ATTENTION
• For all installation work, take appropriate measures to ensure that the load is
Maintenance intervals The specified maintenance intervals apply to air conditions with normal levels of cont-
amination. The maintenance intervals must be reduced according to the level of air
contamination.
Notice!
Carry out additional cleaning if treated air contains oil. Sealant material is oil-proof
only for a limited time. When using disinfectants, only use those according to
DGHM list, DVG or VAH certification.
PERSONAL PROTECTION!
• For cleaning and certain maintenance jobs, use personal protective equipment
including face shield and chemical resistant gloves.
8.1 Routine cleaning and maintenance
HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS!

• OBSERVE PERSONAL PROTECTION MEASURES
• Please consider the safety instructions on page 57.
• After the cleaning procedure ensure that the unit is dry and residue-free!
Observe current legal regula- • Use a dry cloth or an industrial vacuum cleaner, if necessary, to remove dry coarse
tions and standards! We re- dirt.
commend to perform • Remove remaining dirt following a subsequent installation of add-on accessory
maintenance steps and ob- items.
serve intervals specified in • For other contaminants use a dry cloth to remove dirt, if applicable wash off using
VDI 6022 some water by adding alkaline cleaning agent.
• For disinfectioning unit surfaces use cleaning agents specified in the following
sources: “List of disinfection procedures (DGHM)” issued by the German
Association for Hygiene and Microbiology, certificates issued by DVG and VAH
(German Association of Veterinary Medicine and the German Association for
Hygiene and Microbiology/Association for Applied Hygiene). Refer to this list for
details and consider the specified concentration and exposure time. Use the
following cleaning agents: e.g. BODE Microbak or DESOMED Desotop. For correct
concentration refer to the data sheet provided by the manufacturer and/or select a
non-visible small surface to test the solution there beforehand.
• Using alcohol-containig agents is not allowed due to risk of explosion and fire.
• Do not use abrasive sponges or tools that may scratch or scrape the protective
surface during cleaning (surface can be damaged).
• Treat galvanized parts with a preservative spray.
• Apply a lubricant spray to all moving parts, such as door latches and hinges, with the
exception of dampers and louvres!
• Clean gaskets on the inspection doors and check for leaks, microbial growth and
mould. It is recommended to treat gaskets with a waterproof preservative.
• Check electrical connections.
• Check earthing.
• Ensure that the unit is dry and residue-free!

CAIRplus®
8.1.1 Basic information about cleaning heat exchangers
Injuries caused by sharp edges!

Observe precaution when cleaning due to risk of cuts on thin and sharp edges.
• Wear chemical resistant gloves.
ATTENTION
• During commissioning, avoid one-sided pressure loads outside the design
parameters – otherwise the fins might be damaged.
Fins require cleaning to ensure that the heat exchanger continues to operate at full
capacity.
• Use a brush (not wire brush) or an industrial vacuum cleaner for this purpose.
• Do not use hard or sharp cleaning tools!
• Use compressed air stream against airflow direction or water spray at low pressure
to clean copper or aluminum fins.
• Use steam-jet appliances to clean steel galvanized heat exchangers or heat
exchangers with reinforced fins.

CAIRplus®
8.2 Maintenance frequency checklist

Observe maintenance frequency specified in the European guidelines and standards
(e.g. VDI 6022).
ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITH

SHARP EDGES!
• Please consider the safety instructions on page 5 and page 57ff when performing
all the described activities!
Unit part Frequen- Action

cy ✓
(months)
Units Monthly • Clean and refill available traps.
for indoor
installation
Every 3 • Check casing for damage and proper fit.
months
(see page 64) • Check/replace gaskets of all service openings.
• Check panels for damage and corrosion, renew corrosion protection and check
proper operation of door stop device (on the pressure side).
• Hygiene inspection (FläktGroup recommends to carry out maintenance jobs at

intervals specified in VDI 6022!): check built-in parts for dirt and clean, if
necessary; disinfect by wiping; check gaskets and seals for mould and microbial
growth, clean/replace if necessary.
Units for out- • Complete the same steps specified for “units for indoor installation”.
door installa-
tion
Every 12 • Verify that unit roof is leak-free.
months
(weather- • Check side panels and cover strips, reseal as necessary.
proof units for
roof installa- • Check base frame and base frame cover panels.
tion) • Clean external weather grille on the the fresh and exhaust-air sides.
refer to
page 64)
Belt-driven Every 3 • Check fans and motors for secure mounting position, debris, damage and
fan assembly months corrosion.
(see page 65
et seq.)
• Check anti-vibration isolators for proper operation
• Check belt protection grille for proper operation, clean if necessary.
• Check impeller for unbalanced condition.
• Check tension of V-belt and inspect for wear; re-tension or replace as necessary
– for specification see page 66 et seq.
• Check fan/motor for noise in bearing, replace bearing if necessary.
• Lubricate non-sealed fan bearing according to the motor manufacturer’s
recommendations (refer to Tab. 8-2 on page 69).
Direct-driven Every 3 • Check fan motors for debris, damage and corrosion.
fan assembly months
(See page 70)
• Check motors for noise in bearing, replace bearing if necessary.
• Check impeller (especially welded seams) for cracks; replace bearing if
necessary.

CAIRplus®

cy ✓
(months)
Routines for Every 3 • Check filters for debris, damage and odour.
all filters months
(see page 72et
• Clean filter chamber.
seq.) Every 6 • Check if the maximum allowed pressure difference (refer to RLT 01 guideline -
months German Association of HVAC Manufacturers) or pressure difference specified
by manufacturer is exceeded, and replace the filter if necessary.
at least • Hygiene inspection (FläktGroup recommends maintenance routines and
every intervals specified in VDI 6022!): Even if the filter shows no visible signs of dirt,
6 to 9 microbial growth and mould may propagate through the filter as result of its long-
months term use (in air with low dust content).
Bag/plate- continuous • Replace the filter if the maximum pressure difference is reached.
type/fine-par- measurem
ticle filter (re- ent
fer to page 73)
replace
every 3
months
Activated Car- Every 6 • Replace filter if activated carbon is saturated.

bon Filter (car- months
tridges) (see
• Check if filter racks with activated-carbon cartridges are fitting correctly. To
prevent the reduction of service life of the expensive activated-carbon filter,
page 73)
ensure that the pre-filtering and fine-filtering stages are in proper condition.
Grease filter Every 3 - 6 • Use a cleaning bath to wash filters cells.

(see page 73) months
Other filters Refer to the relevant maintenance instructions specified in the supplied documentation.
Heating unit Every 12 • Check for leak-free condition and possible dirt on the air side.
(low pressure months
hot water)
• To ensure frost protection, periodically check the safety devices and take proper
precautions such as draining the equipment or adding antifreeze agents.
(p. page 75)
• Ensure that pipework connections and mountings are securely fixed.
• Clean on air side, if necessary (blow through heat exchanger using compressed
air or low pressure water).
• Air vent.
Heater unit Every 12 • Complete the same steps specified in "Heater assembly (pumped warm water)"
with steam months
• Check steam inlet and condensate drain for proper operation.
(see page 76)
• If necessary, check control functions.
Direct-fired Refer to the relevant maintenance instructions specified in the supplied documentation.
(gas) heater
assembly (see
page 76)

CAIRplus®

cy ✓
(months)
Cooler with- Every 12 • Check for leak-free condition and possible dirt on the air side.
out or with months
droplet sep-
arator
(see page 78) • Ensure that pipework connections and mountings are securely fixed.
• Clean on air side, if necessary (blow through heat exchanger using compressed
air or low pressure water).
• Air vent.
• Clean coil drip tray and condensate line.
• Check trap for proper operation, top up as necessary.
• Clean droplet separator with a descaling spray.
Before • Drain water from the cooling coil before winter.
winterizati
on
Evaporator/ Every 12 • Clean and check evaporator/condenser.

condenser months
(see page 79)
• Ensure that all refrigeration components (refrigerating machine, direct
evaporator, distribution manifold, refrigerant lines, etc.) are functioning properly.
Heat pipe Every 12 • Clean coil fins.

(see page 80) months
• Clean coil drip tray and condensate line.
• If a heat pipe is fitted with a bypass, check air-regulating and shut-off dampers
for proper operation.
Liquid-cou- Every 12 • Complete the same steps specified in "Cooler with/without droplet separator"
pled energy months (every 12 months).
recovery as-
sembly
(see page 81)
Plate heat Every 12 • Carry out cleaning depending on contamination degree of the plate assembly.
exchanger months
• Check bypass damper for proper operation, if required.
(see page 83)
Complete wet cleaning only if a tray is installed and available!
• Remove oil and fat deposits.
Rotation heat Every 3 • Check tension of drive belt, tighten as necessary.
exchanger months
(refer to
page 84) Every 12 • Clean coil fins – carry out wet cleaning only if a tray is installed! Never use high-
months pressure water or steam for cleaning coil fins.
• Remove dirt from the section.
• Check dampers with energy-recovery system and bypass arrangement for
proper operation.
• Check run-around gaskets, adjust as necessary.
• Check motor alignment.

CAIRplus®

cy ✓
(months)
Damper Every 6 • Use a vacuum cleaner to blow off damper blades, never add grease!
blades and months
shut-off • Detach the actuator from dampers, check if dampers are moving freely.
dampers (see • Check that the damper actuator moves to its final positions.
to page 86)
Sound Every 6 • Check the sound attenuator section and sound insulating splitters for dirt, clean
attenuator months as necessary.
(see to
page 86)
8.3 General considerations

SHARP EDGES!
8.3.1 Commissioning of units for indoor installation
DANGER! • Please consider the safety instructions on page 5 and page 57ff when performing
Complete the following commissioning steps:
• Carefully check the entire casing and components for damage and correct fit:
– Doors and service openings
– Seals and gaskets
– Handles and levers
– Connections with foam rubber gaskets
– Sight windows
– Panels
• Remove protective film, if applicable.
• Remove all transportation/safety locks.
• Ensure that there are no loose items inside the unit.
• Check that the unit is air tight.
• Clean the unit as specified in „Routine cleaning and maintenance“ on page 58.

CAIRplus®
8.3.2 Maintenance of units for indoor installation
Notice!
• Carry out additional cleaning in case of aggressive or oil-containing air.
Sealant material is oil-proof only for a limited time.
Carry out the following maintenance steps:

• Carefully check the entire casing and components for damage and correct fit:
– Doors and service openings
– Seals and gaskets
– Handles and levers
– Connections with foam rubber gaskets
– Sight windows
– Panels
Doors and service openings • Check seals and gaskets, replace if necessary.
• Check door stop device (on the pressure side) for proper operation.
Panels • Check for damage and corrosion.
• If applicable, renew or apply new corrosion-protection (paint), impregnate, etc.
Trap • Clean and refill available traps.
8.3.3 Commissioning of units for outdoor installation (weatherproof roof units)
• Complete all steps specified in „Commissioning of units for indoor installation“ on
page 63 first.
• Check condition of weatherproof gasketing (refer to „Foundation requirements for
outdoor installation (weatherproof, roof frame)“ on page 26).
8.3.4 Maintenance of units for outdoor installation (weatherproof roof units)
• Complete all steps specified in „Maintenance of units for indoor installation“ on
page 64 first.
• Verify that unit roof is leak-free.
• Check condition of side panels and cover strips, renew sealant if required.
• Clean weather protection grille on the fresh and exhaust-air side once a year.

CAIRplus®
8.4 Fan assembly and drives

SHARP EDGES!
8.4.1 Commissioning of belt-driven fan assembly
ATTENTION
• Do not activate the fan if damper blades are closed.

• Check general condition of the entire casing and all components for damage and
correct fit.
• Remove transportation and safety locks.
• Check belt for proper tension and alignment.
• Check fan rotation direction at all speed stages.
• Measure the motor current consumption. The rated motor current should fall within
the range given on the motor identification plate, this reading must not exceed the
specified limit.
• Check motor protection device for proper operation.
• For motors with separated air supply inspect the air inlet grille and air ductwork for
clean condition. The entire cross-section of the ductwork must be unobstructed.
• Check all system components (air-regulating and shut-off dampers, fire protection
dampers, flow rate controller) for proper operation, open to ensure free movement.
8.4.2 Maintenance of belt-driven fan assembly
ATTENTION
With a completely stopped fan and open control valve of the heater assembly
(pumped water, steam or refrigerant), temperatures inside the unit are roughly
equivalent to the supply temperature of the heating medium (normally around 90
°C). This can result in deformation damage to plastic parts (especially to plastic
droplet separators, surfaces of humidifier honeycombs etc.).
Besides, fans and motors with sealed bearings (re-lubrication is not required) may
sustain damage at temperatures above 80 °C. Consider a maximum operating
temperature of 40° C for a number of electrical built-in components (frequency
inverters etc.) – see and observe relevant manufacturer's instructions!

CAIRplus®
Carry out the following maintenance and inspection steps:

• Check fan for secure mounting.
• Check fans for dirt, damage and corrosion.
• Check anti-vibration isolators for proper operation
• Check belt protection grille for proper operation, clean if necessary.
• Check impeller for unbalanced condition.
Re-tensioning or replacing V-belt

Initial check: • Perform the initial check following 50 hours of operation
Regular checks: Subsequent checks depend on the operating load and experience.
• Check every three months, if the unit operates on a regular daily basis (approx. 8
hrs a day).
• With higher operating hours perform more frequent inspections.
Belt Smallest pulley F force

profiles diameter (mm) (N/belt) Deflection x [mm]
50
SPZ 70 – 85 13 – 19
86 – 155 15 – 23 40
116 – 150 19 – 27
151 – 200 25 – 24 30
201 – 250 29 – 38
SPA 112 – 150 25 – 34 20
151 – 200 29 – 38
201 – 250 35 – 44 10
251 – 300 40 – 50
0
SPB 180 – 224 40 – 52
0 500 1000 1500 2000 2500 3000
225 – 300 46 – 60
Distance between axes [mm]
301 – 400 55 – 76
401 – 500 67 – 90
Fig. 8-1: High-performance narrow V-belt as per DIN 7753
ATTENTION
Equipment damage and notice
• Always reduce the distance between the axes to the point where the V-belt can
be placed in grooves without applying force. It is not allowed to use crow bars,
screwdrivers or similar tools for belt mounting.
• If the V-belt pulleys are fitted with several grooves, replace all V-belts.
• Do not use a belt set consisting of belts from different manufacturers.
• Belts do not require any special maintenance. Avoid using belt wax and belt
spray.
• Inspect the belt for tension and wear, re-tension or replace if required.
To re-tension the belt using the motor mounting plate or replace:
• Slacken the counter nuts of the set bolts.
• Replace the belt , if required.
• Check the pulley alignment and adjust, if required (fig. 8-2).
• Tension the fan belt (measure using a belt tensiometer or frequency calculation
method, fig. 8-2).
• Tighten counter nuts.
An acceptable belt deflection at a load of P = 20-30 N is from 5 to 20 mm, depending
on the axis distance (see fig. 8-2).

CAIRplus®
Center lines
Fig. 8-2: Pulley alignment and fan belt tensioning
Adjusting or removing fan belt pulley
• Slacken fan belt, see “Re-tensioning or replacing V-belt” on page 66, and:
• remove the belt.
• Loosen and remove both hexagon-socket screws (2).
• Screw a hexagon-socket screw into the empty threaded hole (1) and turn it until both
pulley and bush are loose.
• Pull the pulley assembly off the motor shaft (fan shaft) and remove.
Fig. 8-3

CAIRplus®
Hexagon-socket screws To mount the fan belt pulley, proceed as follows:

for pulley fixation • Position the pulley and bush so that these engage with one
Shaft another. Align both holes and insert screws without tighten-
ing.
Bush • Slide the pulley and bush on the shaft as close to the motor
or fan as possible (to keep leverage small) and align. (For
alignment see “Re-tensioning or replacing V-belt” on page
66.)
• Evenly tighten the hexagon-socket screws.
V-belt pulley
Tapped drill hole
for pressing out pulley
Fig. 8-4: Installing fan belt pulley

CAIRplus®
• Consider the maximum tightening torque of hexagon-socket screws during the

installation:
Bush No. 1008 1108 1210 1610 1615 2012 2517 3020 3030 3525 3535
Max. tightening torque (Nm) 5.6 5.6 20 20 20 32 50 90 90 115 115
Tab. 8-1: Maximum tightening torque
• Check electric motors for dirt, damage, corrosion and secure mounting.
• Inspect motor and fan for bearing noise, replace bearing if necessary.
• Lubricate non-sealed fan bearing according to the motor manufacturer’s
recommendations (refer to Tab. 8-2)! Please refer to the manufacturer’s
documentation for correct lubrication details of non-sealed bearings.
Manufacturer
Comefri Gebhardt Fläkt Woods
Fan
TLZ THLZ TLZ-T THLZ-T NTHZ-B NTHZ- NTHZ T1 NTHZ VZR71 RZR11 RZR15 RZR19 GXLB GXLF GXHB
VTZ VTZ-T R T2 NTHZ T2L RZR13
160
180
200 N
250 N
280 N
315 N N
355 N N
400 N N N
450 N N N
500 N N N
560 N N N N
630 N N N N
710 N N N N
800 N N N N N N N
900 N N N N N N N
1000 N N N N N N N
1120 N N N N N
1250 N N N N N
N = Lubrication possible
Tab. 8-2: Lubrication details for non-sealed fan bearings

CAIRplus®
8.4.3 Commissioning of direct-driven fan assembly
DANGER! • Please consider the safety instructions on page 5 and page 58 when performing
• Remove remaining installation debris and foreign matter from the impeller and air
intake zone.
• Check motor protection for correct setup (also see separate project-related
documentation and/or „Motor protection“ on page 52).
• With Y/' starting, set up the motor protection device for 58% of the rated current if
the phase current flows through the latter – i.e. motor protection device must be
installed between motor terminals U1, V1, W1 and not in mains supply line upstream
of the control unit.
• It is not allowed to activate the parameter "overmodulation" as this can damage the
impeller.
Notice!
• Besides, ensure that the maximum frequency does not exceed the allowable limit
(refer to data sheet on fan).
• Consider the relevant instructions specified in the enclosed manual for the
frequency inverter. Use a screened motor cable only.
8.4.4 Maintenance of direct-driven fan assembly

• Check electric motors for dirt, damage, corrosion and secure mounting.
• Check electric motors for noise in bearings, if required, engage qualified licensed
staff to replace bearings.
• Check impeller, especially welded seams for possible cracks; if required, engage
qualified licensed staff to replace bearings.

CAIRplus®
8.4.5 Commissioning and Maintenance of EC fans
Hazardous voltage can result in death!

Waiting time at least 3 minutes!
9 Due to the use of condensers, danger of death continues even after switching off
the unit by directly touching live components which are still live owing to fault
states.
• Therefore only remove or open the controller casing after a 3-minute waiting time
after the unit has been disconnected to the mains supply line!
Danger due to automatic restart!

9 The fan/engine can be automatically switched on and off for functional reasons.
9 After a power failure or power supply breakdown, the fans automatically restart
when mains power returns again!
• Wait until the fans have come to a standstill before approaching them.
9 With external rotor motors, the external rotor rotates during operation!
Risk of burns due to hot surfaces!

9 Temperatures above 85 °C can occur on the motor surfaces, particularly on the
controller casing!
9 Severe burns can be the consequence.
• Please also observe the instructions of the component manufacturer!
8.5 Filter assembly

SHARP EDGES!

CAIRplus®
8.5.1 Commissioning of filter assembly

• Check filter assembly and installed filters for damage.
• Check that filter assembly is correctly fitting in the mounting frame.
• If required, clean installation dust before the filter assembly and unit parts in the
direction of airflow.
• Repeat cleaning before installing filters from grade F9 into the air handling unit and
ductwork.
• Put the fan into service and take readings of the initial pressure difference (if
available).
8.5.2 Routine maintenance for all filters
Danger of inflammable materials!

There is a risk of inflammable filter material that could cause fire.
Depending on the filtered substances, used filters pose a significantly higher fire
hazard.
• Keep filters away from open fire!
Notice!
FläktGroup recommends to always operate the unit with an installed filter. Keep a
set of spare filters on stock as well.
• Prevent the filter surface from damage, as this can destroy the filter during
service, and no warranty can be assumed for the filter grade.
ATTENTION
Heavily contaminated filters pose a health risk and may adversely affect produc-
tion processes.
• Depending on the filtered substances, dirty filters should be treated as special
waste and must be disposed of in an environmentally-friendly manner and in
accordance with current codes and regulations.
As a general requirement and depending on the operating conditions, all filters must
be checked at regular intervals and replaced if necessary. Carry out the following main-
tenance steps:
• Check filters for debris, damage and odour.
• Clean filter chamber.
• Check if the maximum allowed pressure difference (refer to RLT 01 guideline -
German Association of HVAC Manufacturers) or pressure difference specified by
manufacturer is exceeded, and replace the filter if necessary.
Hygiene inspection
Observe current legal regula- Even if the filter shows no visible signs of dirt, microbial growth and mould may propa-
tions and standards! gate through the filter as a result of its long-term use (in air with low dust content).
FläktGroup recommends
• The filters must be replaced regularly (at least every 6-9 months), even if dirt is
maintenance steps and inter-
barely visible.
vals specified in VDI 6022
CAIRplus®
8.5.3 Maintenance of bag filters/panel filters/fine-particle filters

• Check filter and filter frame for dirt, corrosion and damage, replace if necessary.
The end pressure difference of bag filters varies, refer to the relevant technical data for
details (see filter identification plate).
• Replace the filter if the maximum pressure difference is reached.
Replacing filter medium • Ensure that unit is deactivated. Open the access door/maintenance panel.
• Release the top and bottom spring clips on the filter rack or open the quick-release
filter frame.
• Pull out the filter frame.
• Replace a damaged or dirty filter.
• Slide the filter frame into the unit. Ensure an airtight seal and proper fit!
• Close the top and bottom spring clips on the filter rack or close the quick-release
filter frame.
• Install filter bags only in the upright position!
• Close the service access door or maintenance panel.
8.5.4 Maintenance of activated-carbon filter

• Replace the filter if activated carbon is saturated (designed number of operating
hours elapsed). For monitoring the filter saturation level the cartridge weight can be
checked and marked for subsequent reference to determine the weight increase.
• Check if filter racks with activated-carbon cartridges are fitting correctly. To prevent
the reduction of service life of the expensive activated-carbon filter, ensure that the
pre-filtering and fine-filtering stages are in proper condition.
Replacing activated- • Disconnect power to the unit.
carbon filter (cartridges)
Cartridges are secured in place with special bolts (bayonet lock)!

• Turn the filter cartridges as indicated by the rotation arrow and remove from the
frame.
• Replace the pre-filter together with the activated-carbon filter.
• Dispose of the filters in accordance with the applicable regional regulations.
Fig. 8-5
8.5.5 Maintenance of grease filter
Follow the specified maintenance steps:

Filter cells are made of aluminium wire mesh with each air-filter cell fitted with an inte-
grated grease-collecting tray.
• Rinse filter cells in clean water and clean grease-collecting tray every 3 - 6 months.

CAIRplus®
8.5.6 Maintenance of HEPA filter
Refer to the relevant maintenance instructions specified in the supplied documenta-
tion.
8.5.7 Maintenance of other filters
Refer to the relevant maintenance instructions specified in the supplied documenta-
tion.

CAIRplus®
8.6 Heater assembly
Electrical hazard and danger of rotating unit parts with sharp edges!
8.6.1 Commissioning of heater assembly (pumped warm water)

Requirement: • Check supply and return lines for proper connection.
• Counterflow mechanism and water inlet on air-discharge side.
• Check shut-off devices and other fixtures for proper installation.
Commissioning: • Open provided air vent, if automatic air-venting is not installed.
• Charge the coil at the lowest point to prevent air cushions and water hammer.
• Slowly open air vent and wait until the coil is flushed with water.
• Open air vent completely.
• Close air vent; if the levels are different - close air vent gradually until water
displaces air and starts to run out.
• Activate primary and secondary pump, check rotation direction and put the coil into
service for ample time.
• Set the control valves in reverse position (three-way valves).
• Perform a subsequent check by repeated opening of air vent.
• Check for leak-free condition.
• Operate frost protection in a regulated mode to prevent over-conditioning.
8.6.2 Maintenance of heater assembly (pumped warm water)

• Check for leak-free condition and possible dirt on the air side.
• If necessary clean the coil on the air side (blow out with compressed air or low-
pressure water).
• Air vent.

CAIRplus®
8.6.3 Commissioning of steam heater assembly
Danger of injury from scalding!

Hot steam escapes if an air vent is open! Consider scalding hazard.
• Open air vent carefully.
• For all jobs wear the appropriate personal protective equipment.

• Open drain and air vent.
• Slowly open steam valves and wait until steam starts to escape.
• Close drain and air vent.
8.6.4 Maintenance of steam heater assembly

Hot steam escapes if an air vent is open! Consider scalding hazard.
• Slowly open air vents.

pressure water).
• Check steam inlet and condensate drain for proper operation.
• Air vent.
• Check control functions if available.
8.6.5 Commissioning/maintenance of direct-fired (gas) heater assembly
Refer to the relevant commissioning instructions specified in the supplied documenta-
tion.

CAIRplus®
8.6.6 Commissioning and maintenance of electric heater
tion.
8.7 Cooler assembly

SHARP EDGES!
Notice!
Have qualified and licensed refrigeration engineers from certified and authorized
appointed contractors perform the following procedures and possible service jobs!
Observe the relevant standards and legal regulations regarding refrigerants.
8.7.1 Commissioning of cooler assembly with/without droplet separator

• Clean coil drip tray and drain piping.
• Fill trap with water, refer to „Water drain trapping“ on page 47; as a minimum
requirement, the hydraulic seal of the trap must always correspond to the positive or
negative pressure of the unit.
For droplet separator Droplet separator (DS) reaches its full capacity following a start-up phase of 4 weeks
once the separating agent volatizes.
• If necessary, rinse the droplet separator with water.
• Dust with lime if necessary.
In case of insufficient performance of droplet separator:
• Inspect droplet separator for correct installation position.
• Check airflow velocity in droplet separator.
DS standard wmax=3.8 m/s
DS 100 high performance wmax=5.8 m/s

CAIRplus®
8.7.2 Maintenance of cooler assembly with/without droplet separator

pressure water).
• Air vent.
• Clean droplet separator with a descaling spray.
Procedures before winterization

• Drain water from the cooling coil before winter. As the coil piping diameter is small,
residual water can remain in the unit following normal evacuation. For safety
reasons, use compressed air to blow through the system in order to remove all
remaining water.
8.8 Cooling/heating coil

SHARP EDGES!
Notice!
Have qualified and licensed refrigeration engineers from certified and authorized
appointed contractors perform the following procedures and possible service jobs!
• Observe the relevant standards and legal regulations regarding refrigerants.
8.8.1 Commissioning of evaporator/condenser

CAIRplus®
ATTENTION
• Ensure not to expose the evaporator or condenser to the ambient temperatures
exceeding 60 °C (e.g. caused by fan dowmtime and/or water temperatures
(heater bank) > 60 °C).

• For connection jobs ensure that nitrogen charge is present in coils.
• Check supply and return lines for proper connection.
• Check shut-off devices and other fixtures for proper installation, counterflow
mechanism for medium inlet on the air-discharge side.
• Charge the refrigeration circuit with a medium specifically designed for the system.
• Check if the system is air-tight.
• Check proper operation of safety valves.
• Check the maximum temperature and pressure of unit in operation (especially for
R410A refrigerant)
Saturation temperature = 60 °C/bursting strength: 38 bar.
8.8.2 Maintenance of evaporator/condenser

• Clean and check the evaporator/condenser as specified in „Maintenance of heater
assembly (pumped warm water)“ on page 75.
Direct expansion coil • Ensure that all refrigeration components (refrigerating machine, direct evaporator,
distribution manifold, refrigerant lines, etc.) are functioning properly.
• Performance of leakage tests according to EU Directive 517/2014 on the entire
refrigeration circuit depending on the CO2 equivalent of the refrigerant contained in
the refrigerating system with at least the following frequency:
1 x annually from 5 t CO2 equivalent
• A log book must be maintained to document the leak tests and all inspection,
maintenance, and repair work. The performing certified person and certified
company must be named in the log book.
• The refrigerant consumption data, type of refrigerant and quantity as well as the
reasons for recharging must be documented.
8.9 Heat pipe
8.9.1 Commissioning of heat pipe

CAIRplus®
Observe the following checkpoints for commissioning:

Upright heat pipe The coil with warm airflow (return air) must be positioned on the bottom and the cold
airflow (fresh air) - on the top.
Heat pipe with horizontal The coil with warm airflow (return air) must be positioned on the bottom and the cold
installation with a fixed slope airflow (fresh air) - on the top.
Upright or horizontal with For commissioning see „Commissioning of dampers and shut-off dampers“ on
bypass damper control page 85.
8.9.2 Maintenance of heat pipe

• Regular cleaning of coil fins:
– by blowing out the fins using compressed air against the airflow direction or
– by spraying fins with low-pressure water only!
• If a heat pipe with bypass is used, check air-regulating and shut-off dampers for
proper operation as specified in the maintenance manual (see „Maintenance of
dampers blades and shut-off dampers“ on page 86).

CAIRplus®
8.10 Liquid-coupled energy recovery coil

SHARP EDGES!
8.10.1 Commissioning/maintenance of liquid-coupled energy recovery coil
Multiflow®
See separate operation manual
ECOFLOW / ECOFLOWplus
ECOFLOW Liquid-coupled energy recovery system with heat exchangers with 4 to 12 pipe rows,
adjustable with 3-way control valve
ECOFLOWplus Liquid-coupled energy recovery system with heat exchangers with 14 pipe rows, adju-
stable about 50% to 100% with 2-way bypass valve
See instructions under "Commissioning heater assembly (pumped warm water)" on
page 75.
• Fill the plant with pre-mixed water-glycol mixture; prepare glycol percentage
according to the plant design.
• Charging pressure min. 1.5 bar, max. 2.5 bar.
Pump display • First switch pump to maximum rotational speed (actuator operation) in order to move
actuator operation remaining air bubbles to the highest point. Observe the Wilo Stratos operation
manual.
• Open and close the 2/3-way-valve so that enclosed air bubbles can escape.
• After complete venting, permanently close the valves "b".
Pump display • Set the pump to constant pressure control "'p-c", set pump delivery head. Observe
constant pressure the Wilo Stratos operation manual. Note: 10 kPa = 1.0 m delivery head.
For ECOFLOW (4-12 RR): Total water-side pressure loss of the extract air and supply-air heat exchanger plus
pressure loss of the control valve according to design and layout data (kPa).
For ECOFLOWplus (14 RR): Total water-side pressure loss of the extract air and supply-air heat exchanger accor-
ding to design and layout data (kPa) plus 5 kPa.
.
8.11 Plate heat exchanger

SHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES
Please consider the safety instructions on page 5 and page 57ff when performing

CAIRplus®
8.11.1 Commissioning of plate-type heat exchanger
ATTENTION
• Avoid inadmissible high differential pressures between supply air and extract air.
This could cause damage to the fins.
• If energy recovery is done with a bypass arrangement, check dampers for correct
operation (refer to „Maintenance of dampers blades and shut-off dampers“ on
page 86).

CAIRplus®
8.11.2 Maintenance of plate-type heat exchanger
A plate-type heat exchanger operates without any external, mechanical or electrical
actuators, is not equiped with any moving components and its service life can be nega-
tively influenced only by corrosion.
• Clean as needed according to degree of plate assembly contamination.Use a hair
broom to remove dry dust and fibers at the coil inlet, blow out.
• Complete wet cleaning only if a tray is installed and available!
Oil and grease (kitchen • Remove oil and grease deposits with hot water and grease-dissolving cleaning
exhaust) agents.
8.11.3 Airflow routing in plate-type heat exchangers

cold corner 1 = heat-dissipating
Condensate 2 = heat-absorbing
Condensate is attracted to the Condensate is attracted to the Condensate is attracted to the Condensate is attracted to the
cold zone by gravity and air- cold zone by gravity and air- warm zone by gravity and air- warm zone by gravity and air-
flow. If a lot of condensate pre- flow. If a lot of condensate pre- flow. The risk of freezing flow. The risk of freezing
cipitates, the risk of freezing cipitates, the risk of freezing decreases. decreases.
decreases. If little condensate decreases. If little condensate
precipitates, the risk of freez- precipitates, the risk of freez-
ing increases. ing increases.
Tab. 8-3: Airflow routing in plate-type heat exchangers

CAIRplus®
8.12 Rotary heat exchanger
Electrical hazard and danger of rotating unit parts with sharp edges and rota-
ting storage mass!
8.12.1 Commissioning of rotary heat exchanger
Notice!
Refer to the relevant commissioning and maintenance instructions specified in the
supplied documentation (MicroMax/KR4R).
Document the commissioning of the rotation heat exchanger according to the
commissioning report!

• Check tension of drive belt, tighten if necessary.
• Check rotating direction.
• Check position of flush sections.
• Check gasketing and sealing for correct fit.
• Check run-around gasketing, adjust as necessary.
page 86).
8.12.2 Maintenance of rotation heat exchanger

• Use a vacuum cleaner to clean coil fins regularly. Carry out wet cleaning only if a
tray is installed! Never use high-pressure water or steam for cleaning coil fins.
• Remove dirt from the section.
page 86).
• Check run-around gasketing, adjust as necessary.
• Check tension of drive belt, tighten if necessary.

CAIRplus®
8.13 Humidifier assembly

For steam humidifiers:

Hot steam escapes if an air vent is open!
Consider scalding hazard.
• Slowly open air vents.
Depending on the type of humidifier and installation location, you have to check diffe-
rent criteria, such as:
– Quality of Water
– Microbial count
– Drain cycles
– Deposit build-up, etc.
Refer to the corresponding instructions specified in the supplied documentation.
8.14 Damper blades and shut-off dampers
HAZARDOUS VOLTAGE AND RISK OF ROTATING COMPONENTS!

8.14.1 Commissioning of dampers and shut-off dampers

• If several dampers are linked together, ensure that the connecting linkage is
installed properly and is moving freely.
• Check all screw connections for proper fit.
For actuators • Adjust the connecting linkage to ensure a turning angle of 90° with damper blades
reaching their final position when closed (consider tightening torques).
• Check if the damper actuator moves to its final positions.
• Ensure proper operation of this component.
• Do not start up the fans with closed dampers.

CAIRplus®
8.14.2 Maintenance of dampers blades and shut-off dampers

• Vacuum clean dampers (blow out), never apply grease!
• Detach the actuator from dampers, check if dampers are moving freely.
• Check that the damper actuator moves to its final positions.
8.15 Sound attenuators

SHARP EDGES!
8.15.1 Maintenance of sound attenuator

• Check the sound attenuator section and sound insulating splitters for contamination,
vacuum clean, if necessary.
8.16 Commissioning/maintenance of ECOTWINcool double-plate heat exchanger with

adiabatic cooling

SHARP EDGES!

tion.

CAIRplus®
8.17 commissioning/maintenance of integrated refrigerating systems

• In general, when working with refrigerants, be sure to pay attention to the following
points:
(see also „Handling refrigerants (only for units with integrated refrigerating system)“
on page 12)
Warning of high concentration of refrigerants in the air!

sudden death. Very high concentration of refrigerant may cause suffocation by
Smoking and open flames are prohibited

Smoking and open flames at the installation site of the unit or during work with refri-
gerants are prohibited. Open fire or flames can lead to the disintegration of a refri-
gerant and release of toxic gases.
• Do not keep any inflammable liquids in close proximity to the unit.
Danger of injury from refrigeration!

Contact with a liquid refrigerant can result in skin burns or injury to other organs.
• Exercise due caution and attention when carrying out jobs and avoid contact with
a refrigerant.
Danger of injury caused by high pressure!

When working on hydraulic or refrigeration circuits or in case of damage to the
components or piping, there is a risk of injury from fluids or gases escaping at high
pressure.
• Exercise due caution and attention when carrying out this work.
• Wear appropriate protective clothing.

CAIRplus®
ATTENTION
• Do not pollute the environment with liquid products, refrigerants or oils.
• Dispose of the latter in accordance with local laws and regulations by avoiding
harm to the environment.
Ethylene glycol and propylene glycol are categorized as water pollutants. This
also applies to mixtures with water.
8.17.1 Recurrent tests
The system and its system components are subject to partially recurring tests con-
ducted by a qualified person or an approved inspection agency according to Art.15 of
the German Law on Occupational Safety (BetrSichV).
• Observe any further applicable laws of the respective installation site.
ATTENTION
• Only use types of oil approved by the compressor manufacturer (see
specifications on the compressor), since otherwise the equipment could be
damaged.
8.17.2 Taking out of service
See the service booklet for refrigerating systems for requirements.
ATTENTION
• When disposing of refrigerant or compressor oil, observe the respective
environmental protection provisions!

Disassembly and disposal
CAIRplus®
9 Disassembly and disposal

ATTENTION
Have qualified licensed staff dismantle and dispose of the unit!
9.1 Dismantling
To dismantle the unit proceed as follows:

• When carrying out any decommissioning and dismantling work on the units,
disconnect all power supply connections and ensure the power cannot be
inadvertently switched back on.
• Ensure that the hydraulic circuit is switched off.

• Close all hydraulic shut-off valves.
• Isolate all connections and ensure leak-free condition regarding oil, refrigerant or
water-glycol mixture.As the coil piping diameter is small, residual water can remain
in the unit following normal evacuation. For safety reasons, use compressed air to
blow through the system in order to remove all remaining water.
Warning! Risk of personal injury and equipment damage!

damage to persons and property.
• When transporting the unit, carefully observe its behavior and do not get near any
possible hazardous areas.
• Release the fixing to the base or wall.

9 The unit is ready for transport.
• Consider all instructions specified in chapter „Transport“ on page 19.
9.2 Disposal
ATTENTION
• Dispose of all components and filters (activated-carbon filter, filter cartridges, etc.)
and disused operating materials (e.g. oil, refrigerants and water-glycol mixture) in
an environmentally-friendly manner in accordance with the local codes, practices
and environmental regulations.
An authorized appointed contractor specializing in waste processing must dispose

of the unit or its individual components. This appointed contractor must ensure that:
– the components are separated according to material types
– the used operating materials are sorted and separated according to their respective
properties.

Troubleshooting
CAIRplus®
10 Troubleshooting
Notice!
Have qualified licensed staff perform troubleshooting and repair procedures. Qua-
lified licensed staff or other individuals with proper professional training must be
experienced in the relevant accident prevention regulations, as well as other
generally recognized safety and occupational health codes.
A simple diagnostic section specifying troubleshooting actions can not be presented in

this chapter due a wide variety of built-in components and special configurations.
• For detailed maintenance and repair procedures contact your local supplier.

Appendix
CAIRplus®
11 Appendix
11.1 Maintenance Log Book CAIRplus
Notice!
Observe maintenance procedures for air handling units as these are critical for unit service life.
Due to use of various chemical substances and cleaning agents for sanitizing and cleaning, unit surfaces
may be affected.
• Report all corrosion on unit surfaces to your installer without delay!
Commissioning date: Commissioned by:
Checked
not O.K.
Maintenance Date Signature

Unit part Comment
O.K.
frequency
Heat Exchanger
Fan assembly
Refrigeration plant
Control
Month 1 following
Panels
commissioning
Filters
Condensate pan
Damper blades
Other components
Defects/damage was directly communicated to company: on (date):
Defect/damage was repaired by: on:
Heat Exchanger
Fan assembly
Refrigeration plant
Month 2 following Control
commissioning Panels
Filters
Condensate pan
Damper blades
Other components
Heat Exchanger
Fan assembly
Refrigeration plant
Control
Month 3 following
Panels
commissioning
Filters
Condensate pan
Damper blades
Other components

Appendix
CAIRplus®
Checked
not O.K.
Date Signature:
Maintenance
Unit part Comment
O.K.
frequency
Heat Exchanger
Fan assembly
Refrigeration plant
Control
Month 6 following com-
Panels
missioning
Filters
Condensate pan
Damper blades
Other components
Heat Exchanger
Fan assembly
Refrigeration plant
Control
Month 9 following com-
Panels
missioning
Filters
Condensate pan
Damper blades
Other components
Heat Exchanger
Fan assembly
Refrigeration plant
Control
Month 12 following
Panels
commissioning
Filters
Condensate pan
Damper blades
Other components
Heat Exchanger
Fan assembly
Refrigeration plant
Control
Month 15 following
Panels
commissioning
Filters
Condensate pan
Damper blades
Other components

Appendix
CAIRplus®
Checked
not O.K.
Date Signature:
Maintenance
Unit part Comment
O.K.
frequency
Heat Exchanger
Fan assembly
Refrigeration plant
Control
Month 18 following
Panels
commissioning
Filters
Condensate pan
Damper blades
Other components
Heat Exchanger
Fan assembly
Refrigeration plant
Control
Month 21 following
Panels
commissioning
Filters
Condensate pan
Damper blades
Other components
Heat Exchanger
Fan assembly
Refrigeration plant
Control
Month 24 following
Panels
commissioning
Filters
Condensate pan
Damper blades
Other components
We recommend to keep account of all maintenance procedures in the log book even after the first two years of operation
have elapsed. It is under circumstances necessary to perform specified maintenance and cleaning procedures in regu-
lar intervals anyway.

Notes
CAIRplus®
94 FläktGroup DC-2009-0096-GB 2018-01/R9 • Specifications are subject to alteration without notice

Notes
CAIRplus®
FläktGroup DC-2009-0096-GB 2018-01/R9 • Specifications are subject to alteration without notice 95

A_FG_DC-2009-0096-GB_CAIRplus_OM_R10-12-2018_150dpi © Copyright 2018 FläktGroup
WWW.FLAKTGROUP.COM CAIRplus®
FläktGroup is the European market leader for smart and energy efficient Indoor Air
and Critical Air solutions to support every application area. We offer our customers
innovative technologies, high quality and outstanding performance supported by more
than a century of accumulated industry experience. The widest product range in the
market, and strong market presence in 65 countries worldwide, guarantee that we
are always by your side, ready to deliver Excellence in Solutions.
PRODUCT FUNCTIONS BY FLÄKTGROUP

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Air Management | Air Conditioning & Heating | Controls | Service
» Learn more on www.flaktgroup.com

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CAIRplus®

1 Unit Type Code .................................................................................. 4

3 Technical Description ..................................................................... 15

4 Shipping and Storage ..................................................................... 19

7 Electrical Connection ..................................................................... 51

8 Commissioning and Maintenance ................................................. 57

2 FläktGroup DC-2009-0096-GB R10/12-2018 • Specifications are subject to alteration without notice

8.15 Sound attenuators ......................................................................................... 86

9 Disassembly and disposal ............................................................. 89

– Original operation manual –

FläktGroup DC-2009-0096-GB R10/12-2018 • Specifications are subject to alteration without notice 3

1 Unit Type Code

Air flow direction

4 FläktGroup DC-2009-0096-GB R10/12-2018 • Specifications are subject to alteration without notice

2 Safety and User Instructions

2.1 Availability of the operation manual

2.2 Scope of the operation manual

2.3 Symbols used

Danger symbols are specified in section "Labelling of safety instructions" on page 8.

FläktGroup DC-2009-0096-GB R10/12-2018 • Specifications are subject to alteration without notice 5

2.3.1 Special warning and danger symbols

Attention: fire risk. Dust-laden filters are inflammable.

Before opening, use the main isolator to disconnect power.

Risk of injury. Wait until complete stop before opening.

Do not start up the fan against closed dampers.

Designation of unit in explosion-risk areas (according to 94/9/EG regulation)

Potential equalisation To equalize potentials the unit must be connected to an exter-

6 FläktGroup DC-2009-0096-GB R10/12-2018 • Specifications are subject to alteration without notice

2.3.2 Function signs

Air heater/cooler with heat re-

Air heater/cooler with heat re-

General air filter Air heater/cooler with heat re-

HEPA filter Air heater/cooler with heat re-

General air humidifier

Air heater air/water General controller

Air cooler air/water Droplet separator

FläktGroup DC-2009-0096-GB R10/12-2018 • Specifications are subject to alteration without notice 7

2.4 Labelling of safety instructions

2.4.1 DANGER - Death/serious irreversible injury

Electrocution through hazardous voltage will lead to death or serious injury.

2.4.2 WARNING - Death/serious injury

2.4.3 CAUTION - Minor or moderate injury

Sharp edges can cause injuries!

8 FläktGroup DC-2009-0096-GB R10/12-2018 • Specifications are subject to alteration without notice

2.4.4 ATTENTION – Environmental or material damage

Indicates actions that can result in equipment or property-damage only accidents.

2.5 Used safety symbols

Rotating storage materials

Sharp cutting edges

FläktGroup DC-2009-0096-GB R10/12-2018 • Specifications are subject to alteration without notice 9

Damage to the unit

2.6 Safety-conscious work procedures

When working within range of mains voltage:

Electrocution through hazardous voltage will lead to death or serious injury.

When working in explosive atmosphere:

Life-threatening danger of explosive atmosphere!

10 FläktGroup DC-2009-0096-GB R10/12-2018 • Specifications are subject to alteration without notice

For all kinds of work:

Risk of personal injury!

Jobs on the unit can only be carried out if

FläktGroup DC-2009-0096-GB R10/12-2018 • Specifications are subject to alteration without notice 11

12 FläktGroup DC-2009-0096-GB R10/12-2018 • Specifications are subject to alteration without notice

2.7 Proper use

2.8 Safety devices