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Air Conditioning Technology

Operating and
Maintenance Instructions

Air Handling Units


WK, WK.com: for indoor installation
WK-W, WK-W.com: for outdoor installation
WK-HY, WK-HY.com: Hygiene Units
AHUs WK-Series
Certificates

Inspected Security EG-Conformity-Declaration


EC-Conformity Declaration
in the sense of the EC-Guideline Machines 98/37/EG

Denomination Central Air Handling Unit


of the Machine: - AHU for Indoor Installation, Type WK, WK.com
- AHU for Outdoor Installation, Type WK-W, WK-W.com
- AHU-Hygiene Machine, Type WK-HY, WK-HY.com

Type Name: WK-, WK-W, WK-HY


-21, -31, -41, -61, -101, -161, -241, -351, -501, -701, -1001
WK.com, WK-W.com, WK-HY.com
- 42, 63, 85, 127, 170, 212, 255, 318, 382

Serial Number: 55750 and more


is developed, constructed and produced in accordance with
the EC-Guideline:
- Machines 98/37/EG
- Low Voltage 73/23/EWG

in sole responsibility WOLF GmbH & Co. KG


of Messrs.: Münchener Str. 54
D-85290 Geisenfeld

Applied EN 60204-1 Safety of Machines; Electric Equipment


Harmonized EN 292 Safety of Machines; Fundamentals
Regulations: EN 294 Safety of Machines; Safety Distances
EN 60335-1 Safety of Electric Appliances for Domestic Use
EN 1886 Central AHU – Mechanical Properties
EN 13053 Central AHU – Pformance Data

Applied VBG 4, VBG 7w


National VDMA 24167 Fans; Safety Requirements
Standards: VDI 6022/BI, 1,2 – Hygienic Requirements to AHUs
VDI 3803 Technical Plants for Room Air –
Constructional and Technical Requirements

There is a complete technical documentation.


Each plant is accompanied by operating instructions.

Geisenfeld, 01.04.2003 Vogl-Wolf - Managing Director

Quality Control Certification and Approval


AHU for indoor for indoor Hygiene Unit
installation installation

WK-HY.com
WK-W.com
WK.com

WK-HY
WK-W
WK

8 8

8 8 8 8 8

8 8 8

8 8 8 8 8 8

2
Air Handling Units (AHU) WK-Series
01 Table of Contents

Table of Contents
01 Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
02 Proper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
03 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
04 General Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
04.02 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
04.03 Protective Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
04.04 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
04.05 Material Resistance against Detergents and Disinfectants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
05 Storage, Transport and Assembly
05.01 Goods Acceptance, Transport Damages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
05.02 Indication to Packing ( non-returnable ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
05.03 Storage on Building Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
05.04 Building Site Transport of AHUs and Building Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
05.05 Foundations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
05.06 Impact Noise Decoupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
05.07 Required Space for Operation and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
05.08 Machine Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
05.09 Assembly of Machine Units for Indoor and Outdoor Machines. . . . . . . . . . . . . . . . . . . . . . . . . . 9
05.10 Transport Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
05.11 Potential Equalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
05.12 Air Connections, Louver Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
05.13 Connections on Medium Side ( Pump Warm Water, Pump Cold Water, Refrigerant, Steam ) . . . . 12
05.14 Connections on Waste Water Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
05.15 Frost Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
05.16 Air Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
05.17 Connections on Combustible Side ( Oil, Gas ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
05.18 Electric Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
05.19 Refrigeration Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
05.20 MSR-Technology ( Measuring, Controlling, Regulating ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
05.21 AHUs weatherproof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
06 Commissioning
06.01 First Trial Run. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
06.02 Fan Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
06.03 Air Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
06.04 Steam Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
06.05 Refrigeration Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
06.06 MSR-Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
07 Maintenance
07.01 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
07.02 Maintenance Intervals of Machine Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
07.03 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
07.04 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
07.05 Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
07.06 Motor – Pull-out Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
07.07 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
07.08 Drop Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
07.09 Sound Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
07.10 Heat Recovery - Aluminium Plate Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
07.11 Air Humidifier / Air Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
07.12 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
07.13 Louver Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
07.14 Hygiene Machines WK-HY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
07.15 Refrigeration Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
07.16 MSR-Technology ( Measuring, Controlling, Regulating ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
07.17 Additional Operating and Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
08 Stopping Procedure, Dismantling and Elimination
08.01 Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
08.02 Dismantling and Elimination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
09 Emergency
09.01 Fire-Fighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
09.02 Escape of Harmful Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10 Manufacturer‘s Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3
Air Handling Units (AHU) WK-Series
02 Proper Use

Proper Use
AHU-Central Unit for ventilation and air-conditioning of
• office rooms
• meeting rooms
• lounges
• commercial and production companies
• hospitals
• clean rooms

The AHU-Central Units are suitable for


providing air which is
• dust-free
• free from pollutants
• not aggressive
• not developing corrosion
• incombustible

preparing air for


• filtration
• heating
• cooling
• humidifying
• de-humidifying

as well as acc. to the operational parameters fixed in the quotation, the order and on the identification plates, like
• media temperatures ( air, water, refrigerant, steam etc. )
• air humidity
• explosive atmosphere
• max. capacity limits of propulsions

Deviations must be agreed and allowed by the manufacturer.

AHUs for providing combustible gases, vapours, fogs or dusts must be specially rated. Normal AHUs must not be
operated in this danger zone without respective indication in our technical ratings.

4
Air Handling Units (AHU) WK-Series
03 Safety

Safety
The qualified staff charged with
• assembly
• commissioning
• maintenance
must be informed of the observance of these operating instructions before starting work.

Non-observance of the operating instructions can cause danger to the persons in charge as well as functional
defects of the machine.

The AHU is only a part of the complete AHU-plant. Only when installed, after connection of the air ducts to be
provided by customer, the machine will fulfil its safety standard.

Attention !
Work on the AHU must only be started or effected, if following functions are fulfilled:
• Repair switches fixed on the machine are connected in the control circuit of the AHU-plant.
• Power supply is dead on all poles.
• Power-operated, turning parts are secured against reconnection ( repair switch lockable ).
• Standstill of turning parts.
• Machine components are cooled down to normal ambient temperature ( room temperature ).

After having finished the work, start plant acc. to >> commissioning – trial run << !

Attention !
Only qualified staff must be charged with work on electric components. The local EVU ( Power Supply
Company ) and VDE ( Association of German Electricians ) Regulations must be observed.

No constructional modifications or additions must be effected at the AHU, since otherwise the manufacturer‘s
conformity declaration will expire !

Symbols:
You will find the opposite symbol in the operating instructions wherever
• there is danger to life and limb of persons
• damages of the machine can occur
in case of non-observance.

You will find the opposite symbol in the operating instructions wherever there is danger by electric components.

You will find the opposite symbol in the operating instructions wherever there are indications which must not
be followed.

The opposite symbol in the operating instructions shows you guidelines or crossreferences which are important
for the operation of the AHU.

The opposite symbol in the operating instructions shows you information or application tips.

5
Air Handling Units (AHU) WK-Series
04 General Indications

General Indications
04.01 Application Field
The application field of the supplied AHU is shown in the order confirmation, especially the technical
machine rating.

04.02 Accessories
The manufacturer offers and supplies AHUs acc. to tenders of external planning companies of the whole AHU-plant.
This is usually only a partial range of the whole AHU-plant. Since delivery is effected only by special companies,
certain accessories like
• actuators
• differential pressure switches for filters, volume stream
• repair switches
• complete regulation, control system, power electricity
can be provided by customer. The technical rating indicates accessories to be provided by customer. The special
company must install safety-relevant accessories before the first trial run.

04.03 Protective Measures


Our AHUs are usually equipped with the technical safety measures.
• Access to be opened by inspection doors or inspection covers with tools.
The access to the fan extraction is possible at delivery; after connection of the ducts to be provided by customer, this
will not be possible any more.

04.04 Noise
Our AHUs are rated and produced acc. to delivery instructions of a planning company. The technical values indicated
in the technical rating and on the identification plates are reached
• with completely installed machine
• with customer‘s observance of the rating criteria, for example external delivery pressure

04.05 Material Resistance against Detergents and Disinfectants


For wiping disinfection of the inside surfaces of our AHUs in design
• hot-dip galvanized
• high-grade steel ( 1.4301 )
• aluminium ( AIMg )
all commercial disinfectants can be used.
We recommend disinfectants on formaldehyde base; the indications on the manufacturer‘s safety data sheets
regarding
• material compatibility
• finish
must be observed.

6
Air Handling Units (AHU) WK-Series
05 Storage, Transport and Assembly

Storage, Transport and Assembly


05.01 Goods Acceptance, Transport Damages
Unpack the goods in the driver‘s presence and check them acc. to our delivery note regarding completeness
and damage.
Transport damages must be receipted by the transport agent ( date and signature ) !
A subsequent complaint will be refused by the transport insurances.

05.02 Indications to Packing ( non-returnable )


The packing is a mere transport packing. Its quantity has been reduced to the indispensable minimum in order
to be able to transport and unload the high-grade parts without damage.
The material can be completely recycled and thus can be given to reutilization.
The elimination costs now as before have to be borne by the customer.
As an alternative, it is possible to return the packing material to us. The transport costs have to be borne by the
consignee of the goods. Please note that the packing material must not be contaminated and must be brought
separated in groups.

05.3 Storage on Building Site


If parts are packed in foil, the foil has to be removed immediately on delivery. Foils cause deposit of moisture and
thus oxidation, especially on hot-dip galvanized material.
If parts cannot immediately be taken to the installation site, the following measures must be taken:
• Remove the foils.
• In the meantime, store the machines at a place which is protected from weather influences.
• Close machine openings, so that no dirt ( dust, vermin ) can get in.
Observe a / m points especially for hygiene machines WK-HY !

05.04 Building Site Transport of AHUs and Building Groups


Machines without Transport Device: In case of transport
by stacker truck or rolls, leave transport pallet under
air-conditioning equipment. In case of transport by
fork-lift truck, pay attention that the forks cover the
whole width of the housing. The frame must lie on the
forks on both sides.

The machine components must only be transported


in installation position. They must not be upset or
turned in longitudinal axis, since otherwise damages of
installation parts can occur ( for example: fan vibration
dampers can fall out ).

05.04.01 Fixing Points for Lifting Devices


The transport rope must be at least as long as the
eye distance.
The arrangement and size of the transport eyes refer
to a rope angle of 60 °. Larger rope angles cause an
overloading of the transport eyes and damages of the
machine.
During unloading, lifting and assembly, several machine
units must not be lifted together. Only lift as transport
unit when ready for delivery. Lift machines with more
than 4 transport eyes only by crane beam.

05.05 Foundations
For a proper assembly of the machine parts, a flat, horizontal floor ( possibly insulated against vibrations ) is
required. Strip foundations, especially made of steel supports, must be sufficiently stiff in order to avoid that the
machine is bending.
Moreover, strip foundations at the beginning and at the end of the machine as well as cross supports at the
separation points of the machine components are necessary.

7
Air Handling Units (AHU) WK-Series
05 Storage, Transport and Assembly

If these requirements are not fulfilled, problems at the machine - for example
jamming doors - may occur !
If a washer is installed, a substructure for the other machine parts has to be provided by customer.
In case of machines with siphon, pay attention to the foundation height !

In case of contact in points, also the WK 41 to WK 101 require a support frame. In case of complete contact surface,
no support frame is required for the WK 41 to WK 161.

Erection Surface: For a proper assembly of the Height Compenstion when Installing a Washer:
machine parts, a flat, horizontal floor When installing a washer, a substructure for the other
( possibly insulated against vibrations ) is required. machine parts is necessary.
Do not effect a contact in points of the machine. Order No.: 566-10 ( tub compensation for washer ) or
to be provided by customer.

05.06 Impact Noise Decoupling


For vibration insulation, we recommend to use suitable insulators. Install sylomer strips ( supplied by us ) all around
or acc. to our indications.

05.07 Required Space for Operation and Maintenance


Required space: Basically, one machine width should
be available on the operating side.

600 mm housing width


Minimum width in front
B
of the integral parts: ≥b
Fan part: 1000 mm
operating side Heater, radiator: machinewidth + 200 mm
Pocket filter: 700 mm
Pocket filter, installation
frame extractable: machine width
On the opposite side, the machine should also be
accessible. A distance of 600 mm would be sufficient
for the assembly.

For a better cleaning as well as for disinfection work, hygiene machines WK-HY must be accessible also on the back
side ( cf. drawing ) !
When laying connection pipes ( electricity, air, water etc. ), make sure that operating doors or inspection covers are
not obstructed.
Acc. to VDI 6022, the construction parts installed in the AHU shall be accessible on both sides !

05.08 Machine Arrangement


Machines on top of each other ( pick-a-back design ) are available up to WK 1001 incl.
At the WK 241 and WK 351, the upper machine parts are only available in separate cubes !

Machines must be installed only acc. to their


destination. If modifications become necessary - for
example machines planned on one level, modification
to pick-a-back design - you have to contact our factory
before.

WK 21 to WK 1001: WK 241 and WK 351 are


supplied with support frame at the lower
machine.

8
Air Handling Units (AHU) WK-Series
05 Storage, Transport and Assembly

05.09 Assembly of the Machine Units for Indoor and Outdoor Machines
When assembling and installing the machine units, pay attention that they are installed in the order shown in
our machine drawing. Parts belonging together have the same mark at the respective connection point on the
connection flanges - for example connect „flange 1“ with „flange 1“.

During production of the machine, the doors were adjusted in optimal conditions.
After installation on site, possibly readjust the doors:
–Loosen the screws of the hinge at the door wing – Adjust door wing to the same door gap – Tighten firmly the
screws at the hinge.

05.09.01 Assembly WK 21 to WK 351


Parts supplied by us: screws M 8 x 90 / M 8 x 80
nuts M8
discs 9 /35 mm
Tools required: open-end wrench SW 13
Inbus wrench size 6

Assembly steps:
1. The machine parts to be connected are glued at one piece, each,
with the sealing tape 12 x 6 mm ( supplied by us ) at the
connection flange, fair-faced at the inside and outside edge.
2. At the corners, use the screws M 8 x 90, nuts M 8 and
discs 9/ 35 mm ( supplied by us ), and connect the machine
parts firmly alternately ( above - below ) by tightening the nuts.
Important ! The screwing serves only for connecting the parts,
not for drawing together distant machine units.
3. Additionally insert screws M 8 x 80 with nuts M 8 through the
borings which are in the frame profile ( middle of machine ) and
screw them.

Machine connection of machines on top of each other ( pick-a-back design ) or machines beside
each other:
Screw the machine parts at the provided borings with screws M 8 x 80 and nuts M 8.

05.09.02 Assembly WK 501 to WK 1001


Parts supplied by us: gusset plates
thread bars M 12 x 163 / M 8 x 163
nuts M 12 / M 8
discs - / 8,5 / 15 mm
Tool required: open-end wrench 2 x SW 13 / 2 x SW 19

Assembly steps:
1. The machine parts to be connected are glued at one piece,
each, with the sealing tape 12 x 6 mm ( supplied by us ) at the
connection flange, fair-faced at the inside and outside edge.
2. At the corners, place the gusset plates ( supplied by us ) on
both sides ( borings fairfaced ), lead the thread bars M 12 x 163
through 2 gusset plates, each, and connect the machine parts
firmly alternately ( above - below ) by tightening the nuts.
Important ! The screwing serves only for connecting the parts,
not for drawing together distant machine units.
3. Additionally insert thread bars M 8 x 163 through the borings
which are in the frame profile ( middle of machine ) and screw
them with discs 8,5 / 15 mm and nuts M 8.
Machine connection of machines on top of each other ( pick-a-back design ) or machines
beside each other:
Screw the machine parts at the provided borings with thread bars M 8 x 163, discs 8,5 / 15 mm and nuts M 8.

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Air Handling Units (AHU) WK-Series
05 Storage, Transport and Assembly

05.09.03 Assembly of AHUs WK-HY


Parts supplied by us:
cylinder-head screws M 8 x 50
countersunk head screws M 8 x 70

Tool required:
Inbus wrench size 6/5

Assembly steps:
1. The machine parts to be connected are glued at one piece ( flange with nuts ) with the sealing tape 10 x 5 mm
( supplied by us ). This is effected 5 mm from the inside and outside edge of the machine flange. Fix sealing all
around with a central separation point.
2. Open the inspection covers or inspection doors.
3. Remove the plastic cover at the back, vertical, inside bar cladding. Screw the parts with cylinder screw
M 8 x 50. Place the plastic cover tightly onto the boring.
4. Screw the parts with the countersunk head screws M 8 x 70 ( supplied by us ) at the borings in the frame profile
( operating side ).
5. Finally, seal the machine connection inside and outside with the sealing material supplied by us. On the
machine inside, only the sealing material supplied by us must be used ( approval for hygiene
machines ) !

05.09.04 Assembly of AHUs WK.com


Parts supplied by us:
hexagonal nuts M8
hexagonal screws M 8 x 100
stressing segments ( depending on
machine size )
Inbus screws M 8 x 40

Tools required: open-end wrench 2 x SW 13


Inbus wrench size 6

Assembly steps:
1. The machine parts to be connected are glued at one piece with the sealing tape 10 x 5 mm ( supplied by us ).
This is effected 5 mm from the inside and outside edge of the machine flange. Fix sealing all around with a
central separation point.
2. At the corners, use the screws M 8 x 100 and nuts M 8 ( supplied by us ), and connect the machine parts firmly
alternately ( above - below ) by tightening the nuts.
Important ! The screwing serves only for connecting the parts, not for drawing together distant machine units.
3. Make additional machine connection on the machine outside with the stressing segments, the Inbus screws
M 8 x 40 and the nuts M 8 ( supplied by us ). Place the stressing segments with hexagonal opening towards
outside.
4. Finally, seal the machine connection inside and outside with the sealing material supplied by us. On the
machine inside, only the sealing material supplied by us must be used ( approval for AHUs ) !

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Air Handling Units (AHU) WK-Series
05 Storage, Transport and Assembly

05.09.05 Assembly of AHUs WK.com – Pick-a-back


Parts supplied by us:
Inbus screws M 8 x 40
nuts M8
stressing segments

Tools required: open-end wrench SW 13


Inbus wrench size 6

Assembly steps:
Connect the machine parts on the outside with the stressing
segments as well as screws M 8 x 40 and nuts M 8 ( supplied by
us ). Place the stressing elements with hexagonal opening
towards outside.

Important ! The screwing serves only for connecting the parts, not for drawing together distant machine units.

05.10 Transport Safeguards


Remove the transport safeguards fixed in the machine only after erection of the AHU on the assembly site. Usually,
there are transport safeguards in the fan part, at the vibration dampers.
Transport safeguards are marked in red and must be removed before commissioning of the machine !

05.11 Potential Equalization


Installed potential equalizations must not be removed. The potential equalizations installed on the suction and on
the pressure side must be connected with the connection duct ( to be provided by customer ).
For machines to be used in explosive atmosphere, elastic connections with increased conductivity are used.
Nevertheless, these are additionally provided with a potential equalization.

05.12 Air Connections, Louver Flaps


Between machine and air duct ( to be provided by customer ), elastic connections must be installed in order to
avoid the transfer of impact noise. Elastic ( canvas ) connections must be installed so that the elastic material is fully
movable. Do not turn flanges, since the elastic connection will get stressed.
Elastic connections must be insulated by customer in order to avoid deposit of moisture and noise transfer.
If the actuator is installed by customer, make sure that in the range of the louver flaps sidewalls are not bored or
screws turned in. The flaps would get jammed !

Driving Torques:
Louver flaps for outside, recirculating and exhaust air may be loaded with a max. torque of 40 Nm.
The max. torque for heat recovery bypass flaps is 20 Nm.

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Air Handling Units (AHU) WK-Series
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05.13 Connections on Medium Side ( PWW, PCW, Refrigerant, Steam )


The heat exchangers are joined by disconnectable connections.
Pay attention that the connecting pipes don‘t hinder the access to
other machine parts ( fan, filter, washer etc. ). When connecting the
heat exchangers, hold against with a pipe wrench.

The connections of the heat exchangers must not be


stressed with tensile forces of the customer‘s connecting
pipes.

Arising forces must be balanced by extension loops or


compensators.

The advance of the heating or cooling system is connected to the


exchanger on the air exit side ( counterflow principle ).
The customer has to provide a de-aeration and emptying possibility !
In case of steam heat exchangers, make sure that there is no
condensate accumulation in the heat exchanger and provide an
efficient de-aeration. Observe the assembly instructions of the condensate discharge manufacturer.

For screwed connections, only approved thread sealant must be used.


When filling the heat exchangers, pay attention to the following on the heating medium side ( pump warm water,
pump cold water, steam ):
• Open de-aeration valves
• Open feed valve slowly in order to avoid water hammers or thermal stress
• Close de-aeration and emptying valves
• Check if all connections are tight

Attention ! In order to avoid an overheating of the installed parts when the fan is switched off, the combustible
supply to air heaters with an advance temperature of over 90 °C and to heaters operated with saturated steam
must be interrupted by force. In these cases, the fan must be switched with an afterrunning period of 3 - 5 minutes.

Commissioning of Refrigerant-Direct Evaporator and Liquefier


Heat exchangers of this construction type get a nitrogen protective filling after completion.

When connecting the refrigerant pipes, pay attention to the following:


• When opening the connecting pipes of the heat exchanger, the nitrogen filling is getting out with a hissing
sound. In this case, the tightness is guaranteed.
• If no nitrogen is getting out, there is a leakage caused by transport or other influences. Please return the
heat exchanger to us.
• A respective number of stopping valves should be installed, so that the system can be controlled easily and
defective parts can be replaced quickly.
• For larger systems, a stopping valve, a sight-glass and a drier should be installed in front of each
evaporator; a stopping valve behind each evaporator.

05.14 Connections on Waste Water Side


( Condensate, Discharge, Overflow Pipes, Siphon )
All machine discharges ( condensate connecting piece of radiator, steam humidifier, surface humidifier,
heat recovery as well as overflow of washer ) must be connected with a siphon with non-return safeguard and
automatic filling. The siphon must be dimensioned so that the water ( condensate ) out of the collecting tub
can flow out without problems.

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Important ! The siphon must guarantee the separation between sewerage and air stream in the machine !

Before commissioning and after longer standstill, fill siphon with water ! The machine must not hang towards the
back side ( view from siphon ). Install the machine absolutely horizontally !

Siphon Calculation

Overpressure in the Machine Negative Pressure in the Machine


Pa Pa
HD = HS =
10 10
Pa = Overpressure in the Machine ( Pa ) Pa = Negative Pressure in the Machine ( Pa )
H1 = HD + 50 H2 = HS + 50

05.15 Frost Protection


Frost Protection for Heat Exchanger
Frost protection thermostat on the air exit side of the preheater. Operation with freezing preventives.
Electric heating device, controlled by thermostat. With heating system switched off: Empty all parts filled with water
( carefully blow out heat exchanger with compressed air ). Also protect siphon from freezing.

05.16 Air Filters


If no constructive measures were taken to limit the air humidity in the range of the filters to < 80 % relative
humidity ( outside air preheating ), biostatic filters must be used. In the first equipment, biostatic filters
are installed !
In the second equipment ( maintenance of the AHU-plant ), then also biostatic filters must be used !

Attention ! The use of air filters with anti-microbial effect is only admissible if these are harmless to health
and if their efficiency during the required filter lifetime has been proved in practical tests at high air humidities
( > 90 % relative humidity ). A certificate by an approved institute must be provided !

There are different installation possibilities:


Bag filters G3, pocket filters G4 and F5 are pushed in laterally. Pocket filters G4 – F5, 7 and 9 are installed on dust
air side. Roller tape filters cf. separate operating instructions.
Filters shall be provided with supervision devices and be replaced when the saturation pressure is indicated.

Filter Filter Class Final Pressure


TB G 4 kurz 150 Pa
TK G4 150 Pa
TL F5–F7 250 Pa
F8–F9 350 Pa

Recommendation acc. to pr. EN 13053

When installing the new filters, always pay attention to possibly standing filter pockets !

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Air Handling Units (AHU) WK-Series
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05.17 Connections on Combustible Side ( Oil, Gas )


For air heaters, type WLE; WLE-K in lying design.

For assembly and connection of the air heaters, type WLE; WLE-K, the following passages of the enclosed operating
instructions Stationary Air Heaters WLE / WLE-K must be observed:
* Safety Requirements for Assembly * Flame Shape
* Lying Machines * Combustion Air
* Exhaust Gas Plant * Safety Thermostat
* Burner Adjustment – Efficiency * Additional Indications for Air Heater WLE-K
* Burner Assembly - Condensating Operation
- Introduction Conditions for Condensates
* Operation with Oil Burner EN 267 - Condensate Elimination
* Operation with Gas Burner EN 676 - Connection, Siphon
Section:
Schnitt:Side View
Seitenansicht Schnitt:Top
Section: Draufsicht
View

Burner Tube Length of WK-Machines ( Wall thickness 30; 60 mm )


WK – Wall thickness 30 mm

Type WLE / WLE-K 30 45 80 140 260


Inside Ø 140 140 140 197 197
A 144 125 167 170 213
B 144 175 217 247 303
C 172 186 190 278 350

WK, WK.com - Wall thickness 60 mm

Type WLE / WLE-K 30 45 80 140 260 500 1000


Inside Ø 140 140 140 197 197 240 290
A 174 155 197 200 230 300 322
B 174 205 247 277 320 405 492
C 172 186 190 278 350 500 550

The burner tube length of the oil / gas burner must be adjusted to the burner tube of the air heater. The burner tube
must be determined so that the burner flame does not touch the burner tube of the air heater.

The heat exchanger WLE-K is installed inside the cladding with a fall of 2 ° towards the back side in order to
support the condensate discharge. For this reason, a sealing inclined on one side is fixed at the burner connection
flange.

Attention !
The burner axle must Richtig:
Right: Burner Tube
Länge Length
Brennerrohr Falsch:Burner
Wrong: Tube too
Brennerrohr short
zu kurz
point 2 ° inclined
downwards ( cf.above,
section: side view )
in order to burn
symmetrically into the
combustion chamber
hanging towards the
back side !

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Air Handling Units (AHU) WK-Series
05 Storage, Transport and Assembly

05.18 Electric Connection


05.18.01 Motor Connection
Safety Indications
Electric motors are operating plants with dangerous, live and rotating parts during operation. Thus, they could cause
damages to health or material damages in case of wrong handling, improper use or insufficient maintenance.
• Therefore, only qualified persons are allowed to work on the motors.
• Perform all work on electric motors only when they are switched off.
• Secure the motors against reconnection.

Pay attention to safety indications !


Before connection and commissioning of the motor, drain off the water penetrated into the motor ( condensate ) via
the condensate discharge opening ( at the deepest point of the end shield ) and close opening again. Protect motor
clamp box from water penetration. - Open clamp box cover only for wiring !

Requirements to be provided by customer:


a ) Electric supply line acc. to the valid VDE-regulations ( Association of German Electricians ) and the regulations
of the competent EVU ( Power Supply Company ).
• The connection of the network supply line must be carried out carefully by an expert.
• The cross-sections of the supply lines must be adjusted to the nominal current.
• Provide tension protection of the connection cables.
• In any case, connect protective conductor at the marked earthing screw acc. to VDE 0100.
• When closing the clamp box, use the original sealings.
• Close inlet openings which have not been needed dust- and water-proof.

b ) The voltage indicated at the fan motor must prevail at the switchboard. Voltage deviations of more than ± 6 %
will cause disturbances. Acc. to DIN / EC 38, the three-phase motors can be used in the
range 400 V + 6 % - 10 %, the single-phase alternatingcurrent motors in the range 230 V + 6 % - 10 %.

Starting by star-delta-relay with automatic switching from to is necessary from motors 3 kW on ( enquire
at the competent EVU ).
Before commissioning, the inspections in the sense of VDE 0100 Part 610, VDO 0105, VBG 4 and VDE 0113 resp.
VDE 0701 must be effected !
Observe especially the permeability of the protective conductor and the main potential equalization
to insulated construction parts like doors, vibration frames etc.

Commissioning of the fan motor:


1. Secure properly ( VDE 0100 ).
2. Measure motor power consumption ( ampere ).
a ) Measuring point between fuse and -switch, power consumption must be lower than the nominal
power indicated on the identification plate ( cf. electric wiring ).
b ) Measuring point between -switch and motor clips, power consumption must be lower than the
nominal power indicated on the identification plate x 0,58 ( cf. electric wiring ).
3. Motor Protection
Acc. to DIN VDE 0165, each motor must be protected against inadmissible heating due to overload by means of
a supervision device. If the motor shall be supervised by an overcurrent device with delayed reaction depending
on the power acc. to VDE 0660 ( for example protection switch ), a protection on all poles is necessary.

Adjustment of thermal overcurrent relay:


The thermal overcurrent relay must be adjusted to the measured value. In case of UD-switching adjustment acc. to
measuring point b. If the motor consumes too many amperes despite its proper connection, the existing channel
pressure is lower than indicated when placing the order. This can be solved by artificially increasing the channel
pressure ( additional installation of a deflector or a damper ), modifying the V-belt pulley or partly by adjusting the
variable V-belt pulleys ( cf. modification of rotational speed of drive ).

Overloaded motors must not be put into operation. There will be no warranty from the motor manufacturers.
The motors may be used only for permanent operation and only for normal, not frequently recurring startings, at
which there are no substantial starting heatings.
When the air inlet or air outlet fan is switched off or does not work, all regulation valves must automatically be
closed and the washer pump must be switched off.

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Air Handling Units (AHU) WK-Series
05 Storage, Transport and Assembly

Electric Wiring

Motor with 1 Rotational Speed:

voltage indicated mains voltage L1-L2 / L1-N


at the motor

230 / 133 V 400 / 230 V 960 / 400 V


133 / 230 V / /
230 / 400 V /
400 / 690 V, 400
= star-delta-starting

S1 S2
Motor with 2 Rotational Speeds:
L1 L1
synchronous speed 750 / 1500 min –1
1U
2W 1U
2U 2V
1W 1V
1W 1V three-phase motor pole-changeable, for square decreasing torque
L3 L2 L3 L2 switchings number synchronous speed number of windings switching number of
of poles clips
L1 L1
2U S1 4/2 1500 / 3000 1 : II 6
2U
1W 1V
2W 2V 8/4 750 / 1500 1 : II 6
2W 2V
1U
L3 L2 L3 L2 synchronous speed 1000 / 1500 min –1
three-phase motor pole-changeable, for square decreasing torque
switchings number synchronous speed number of windings switching number of
S3 S4 of poles clips
S2 6/4 1000 / 1500 2 6
L1 L1
1U 1U

3W 2W
3U 3V 2U 2V
Motor with 3 Rotational Speeds:
1W 1V 1W 1V

L3 L2 L3 L2
L1
synchronous speed 750 / 1000 / 1500 min-1 500 / 1000/ 1500 min-1
L1
3U 2U
three-phase motor pole-changeable, for square decreasing torque
1W 1W 1V
1V
3W
1U
3V 2W 1U 2V switchings number synchronous number of windings switching number of
L3 L2 L3 L2 of poles speed clips
L1 L1 S3 8/6/4 750 / 1000 / 1500 2 : II 9
2U 3U

2W 2V 3W 3V S4 12 / 6 / 4 500 / 1000 / 1500 2 : II 9


L3 L2 L3 L2

05.18.02 Electric Heat Exchanger


In order to avoid overheating, the machines must be operated with minimum air quantity which is indicated in the
technical documents and the order confirmation.
Attention: When the fan is switched off or doesn‘t work, the electric heat exchanger must automatically be
switched off. Connection of the performance stages and overheating monitor cf. separate operating instructions.
Switch off machine before opening it ! The switch-off device must assure that the plant can‘t be switched on
without the person in charge noticing it.
In order to avoid an overheating of the installed parts when switching off the machine, the fans
must be switched off after an afterrunning period of 3 - 5 minutes, only.
Moreover, observe the operating and maintenance instructions of the manufacturer !

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Air Handling Units (AHU) WK-Series
05 Storage, Transport and Assembly

05.18.03 Frequency Converter


Frequency converters supplied externally must be adjusted to the max. frequency „f max“ before the trial run. The
max. rotational speed of the fan indicated on the dentification plate must not be passed !
EMV-Guidelines and the degree of radio noise suppression must be taken into account.
For mains bypass switchings, the relevant regulations acc. to VDE ( Association of German Electricians ) and EVU
( Power Supply Company ) for star-delta-starting or direct starting must be observed.
When measuring the motor connection, the efficiency of the frequency converter must be taken into account !
Acc. to Guideline EWG 82 / 499 and the EMV-Specifications, all cables on the exit side of the frequency converter
including the control and regulation lines must be executed screened !
Observe the manufacturer‘s connection guidelines !
For freewheel fan wheels, check if a direct operation at the power mains with regard to minimum air quantities is
permissible.
Commissioning: Pay attention to the operating instructions of the frequency converter during commissioning. The
settings of the frequency converter must be recorded.
Attention: Touching electric components can be dangerous to life even after separation from the power mains.
Waiting time at least 15 minutes.

05.19 Refrigeration Technology


Will be effected by the manufacturing company.
If the assembly should not be effected by the manufacturer, this plant must be realized by an authorized special
company for refrigeration technology.

05.20 MSR-Technology ( Measuring, Controlling, Regulating )


1. Assemble switchboard ( only if the switchboard is not integrated in the ventilating machine ).
2. Assemble all field units ( sensors, valves, servo-motors etc. ).
3. Effect complete wiring and supply line to the switchboard.
4. Effect clamping work at the field units and at the switchboard.
Attention: The electric connections and the wiring must be effected by qualified electrician. The valid standards
must be observed.

05.21 AHUs weatherproof


05.21.01 Machine Arrangement
Our AHUs in weather-proof design are included in the VOB Part C / DIN 18379 as „Roof Central Machines“
and considered as part of the TGA. The machines are produced acc. to the rules of engine building and thus not
considered as part of the building ( cf. explanation in VDMA 24 175 ).
Our AHUs have been inspected by the TÜV-
Süddeutschland acc. to RAL GZ 652; the mechanical
stability of the housing has been inspected acc. to frame profile with insulation
EN 1886.
roof foil with
Machine arrangement: If possible, the machine water drip
should be placed so that the outside air is sucked
on the side which is turned away from the wind.
If this is not feasible, rain cowls and not weather
protection grids have to be used at the suction water drip
opening of outside air. (water shed)

Foundation Design: The machines can be roof foil


installed on foundations ( to be provided by
customer ) or on base frames. The serial machine crude concrete
vapour barrier
floor must not be used at the same time as roof of concrete slab
the building. cork / Sylone or Malfund pebbles

Stability: The stability of the machine > connection ground frame roof foil roof insulation
with the substructure ( to be provided by customer )
> must be checked for the respective site acc. to
the local wind loads. For the connection with the
substructure ( to be provided by customer ), fixture elements ( approved by the building supervisory board )
must be used.
You must not walk on the machine roof. For walking, planks should be laid.
Additional loads: Do not place or install any additional loads on the machine roof.
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Air Handling Units (AHU) WK-Series
05 Storage, Transport and Assembly

05.21.02 Foundations
A ) Foundations to be provided
80 80
A ) B ) by customer: Height of concrete base
300 mm or higher. Acc. to the local situation
( for example snow load ), insulation plates
for vibration and sound insulation can be
external dimension external dimension laid between air-conditioning unit and
of machine B/L of machine B/L concrete base.

B ) Ground Frame: The customer must


provide an even surface. The ground frame
also serves as connection for the roof

50
50

15 insulation to be provided by customer. If


15 roof foil
(provided by customer) ground frame necessary, insulation strips for vibration and
sound insulation have to be laid between
40 ground frame and installation surface to be
provided by customer. The serial machine floor
must not be used as roof of the building.

05.21.03 Connections on Medium Side

Heater and radiator connections Heater and radiator connections Heater and radiator connections
inside the air-conditioning unit: inside weather-proof projecting through side wall:
Ô connections squared off. structure: Ô insulation to be provided by
Ô piping to be provided by customer.
customer.

05.21.04 Assembly of Delivery Units


05.21.04.01 Roof Foil
Join the building units with groove and tongue of the cladding panels and screw them.
Attention: Do sealing work only at temperatures of over + 5 °C !
cover tape
1. Roof construction made of projecting hard polyurethane elements with
a cover of special weather-proof plastic foil. Sealing to the profile frame
also with an elastic sealing tape.

2. Sealing machine separation point to roof foil:


Clean cover foil approx. 60 mm on both sides of the separation point.
After removing the paper protection strip, fix cover tape ( 100 m wide )
stress-free systematically over the separation point; begin on one side.
Press cover strip firmly on the roof web ( use roller ).

3. Sealing of the transport eyes:


Remove transport eyes after machine assembly. Press closing plugs
( supplied by us ) into the thread boring ! Clean roof foil systematically
120 mm around the opening of the transport eyes.
Remove paper protection strip from the cover tape 100 x 100 mm and
lay it upon the cleaned surface. cover tape
Press firmly ( use roller ).

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Air Handling Units (AHU) WK-Series
05 Storage, Transport and Assembly

4. Sealing at the T- / Cross Seam ( Machine Separation


cover tape
Point )
• Cut Rhepanol - cover tape ( 10 cm wide ) so that
all seams are covered by 5 cm.
sealing seam
• Round corners. sealing seam
• Clean transverse seam range.
• Apply Rhepanol - paste about 4 mm thick at web
separation point
edges ( projecting by 1 cm, each ) in order to
avoid capillaries. outside corner
• After peeling off the paper protection strip, fix
Rhepanol - cover tape stress-free centrally and
press firmly ( use roller ).
• At the T-joint ( cross joint ) press firmly ( use
roller ) both to the web edge and parallel to it.

Cf. also 05.21.04.02

05.21.04.02 Closing of Transverse Seam

• Cut Rhepanol - cover tape • Apply Rhepanol - paste about • After peeling off the paper
( 10 cm wide ) so that all seams 4 mm thick at web edges protection strip, fix Rhepanol
are covered by 5 cm. ( projecting by 1 cm, each ) - cover tape stress-free centrally
• Round corners. in order to avoid capillaries. and press firmly ( use roller ).
• Clean transverse seam range.
• At the T-joint ( cross joint ) press
firmly ( use roller ) both to
the web edge and parallel to it;
do not squeeze out paste.

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Air Handling Units (AHU) WK-Series
06 Commissioning

Commissioning
06.01 First Trial Run
During commissioning, make sure that the AHUs are not operated over the limits fixed in the rating data.
Pay especially attention to:
• Max. rotational speed of fan
• Max. power input of driving motors
• Max. machine inside room temperature 60 °C.

Improper working conditions will cause damages to the machine for which we will grant no warranty !
During commissioning and the later operation of the AHU, observe the indicating signs which are fixed on the AHU !

Check before the first trial run:


• Was the AHU cleaned inside?
• Were the transport safeguards ( parts marked in red ) removed?
Can the vibration dampers move freely in all directions?
• Are the V-belt pulleys aligned?
Are the hub joint bolts and clamp screws of the bushings tightened firmly?
• Is the stress of the V-belts o.k.?
• Are the water tubs of the air humidifiers filled?
• Are all siphons filled with water?
• Are all air ducts connected to the AHU?
Are all components installed in the duct system, so that the required external pressure loss is reached?
• Are all motors connected correctly acc. to connection voltage?
• Check turning direction of the actuators !
Attention ! The actuators of the louver flaps are driving against a stop when they are closed.
• In addition to a / m points, all components must be checked acc. to the technical requirements of these as
well as enclosed presuppliers‘ operating instructions.
• Are all machine access openings closed by inspection covers or doors?

Important for hygiene machines WK-HY !


• Are hours counters installed by the customer, so that the „continuous operation“ of the machine
can be checked?

Hydraulics – Connection of Heating and Cooling Media


When filling and de-aerating the plant, you may get hurt by
• Pressure jet coming out
• Scald with hot heating media
• Cauterization by skin contact with anti-frost additives of cooling media.
The max. admissible pressures of the following components must be observed:
• Heater, radiator – 16 bar at 20 °C
• Piping of heat recovery WRG-KVS 1,5 bar, response pressure of the safety valve 2,5 bar.
Check the frost protection temperature of WRG-KVS system. The frost protection must be adjusted to the locally
lowest outside air temperature. Pay attention to manufacturer‘s information and safety data sheet.
Check before Filling the Machine
Before filling the hydraulic regulating group, check the following parameters:
• Correct installation of all parts
• De-aerating valve installed at the highest point of the piping
• Flow direction at valves, pumps etc.
• Installation position of valves etc.
• Connection of heater, radiator in counterflow principle – since otherwise there will be considerable
performance losses
• Tight position of all connections ( screwings, flanges etc. )
• Smooth working stroke of valves, sleeves, actuators.
Filling and De-aeration
Fill hydraulic regulating group slowly – de-aerate carefully. While filling, open the de-aerating valve. While filling,
check if all connection points are tight; if necessary, repair leakages. After reaching the machine pressure on the
medium side, close de-aerating valve.
Check after Filling
Switch on recirculating pump, check turning direction, if necessary reverse electric sense of rotation. Let recirculating
pump run in order to remove the remaining air cushions from the regulating group. Check machine pressure;
if necessary, refill and de-aerate once more.

20
Air Handling Units (AHU) WK-Series
06 Commissioning

Check for Heating Medium Steam


There must be no condensate accumulation in the heat exchanger for steam. In case of condensate impact in the
heat exchanger, provide a condensate discharge in the steam supply line, since otherwise the heat exchanger can
be destroyed. Pay attention to an impeccable condensate ischarge out of the heat exchanger; observe the assembly
instructions of the condensate discharge manufacturer.

First Trial Run


• Switch on main switch.
• Are all louver flaps opened? Closed louver flaps can cause damages to the machine housing !
• Is the frequency converter adjusted to the max. frequency „f max“? The max. rotational speed indicated
on the identification plate must not be passed ! Pass machine in the frequency range, fade out resonance
ranges !
• Switch on the motor for a short time, so that the direction of rotation of the fan ( acc. to rotation arrow at
the fan ) can be checked.
Check this with closed door through peep hole or after switching off the motor by subsequently opening
the inspection door. If necessary, change the direction of rotation.
Attention ! Do not touch the turning fan resp. drive !
• Measure power input of the driving motor. The power input must not be higher than indicated on the
identification plate !
• Check motor starting time ! The power input must return to nominal current within the switch-over time
from Y to . If necessary, use a heavy-starting relay.
• Measure the air stream and check external pressure loss. Too low external pressure losses increase the air
stream, which causes an overload of various installation components.
For example: - motors are overloaded
- drop separators strike through
which causes water damages to the subsequent machine part and building.

Important for hygiene machines WK-HY !


• AHUs must secure that there are air streams between rooms, from rooms with higher requirement to rooms
with lower requirement !
• In case of infinitely variable speed regulation, a minimum volume stream of 15 % of the nominal volume
stream must be secured !
• Beside the different dimensioning of the air inlet and outlet streams, it is indispensable to hold the air inlet
stream constant !

06.02 Fan Part


Before commissioning, remove fixed transport safeguards ( parts
marked in red ). The fan shaft must in all installation positions
lie horizontally. Only specially designed fan parts may be used vertically
for the air guidance. Vibration dampers must always be subjected to
compression.

After completely effected assembly of the AHU-plant ( with air


ducts to be provided by customer ) and closed inspection doors at the
machine
1. Check direction of rotation of the fan wheel.
2. Check power input of the fan motor - cf. motor connection.
3. Check capacity - air quantity
- total resistance
and correct by modification of rotational speed, if necessary.
4. Check motor starting time.
The motor power input must return to nominal current within the
switch-over time from Y to . If necessary, use a heavy-starting relay.

06.02.01 Drive / V-Belts – Stress - Alignment


In order to avoid unnecessary loads of V-belt pulleys, bearings and heating of V-belts, pay attention to a correct
alignment and stress of the V-belts !
The adjustment is effected by changing the position of the driving motor. It can be moved in longitudinal and
transverse axis after loosening the fastening screws of the motor stressing device.
At the WK 41, 61, 101, the V-belts are stressed by the adjustable motor slide. Loosen the lock nuts, stress the
V-belts and retighten the lock nuts.

21
Air Handling Units (AHU) WK-Series
06 Commissioning

Pay attention to the following!


V-belts must be checked and reclamped after the first run of 30 minutes.
Stress of V-belts: Stress V-belts only to a degree so that, when starting, a slip will be avoided. It must still be
possible to force through the V-belts.
Calculation for check with bearing reaction:
Indentation x = E * L; E = Indentation per 100 mm ( cf. table ), L = Axis Distance in m.

Values for Narrow V-Belts acc. to DIN 7753:


V-Belt Bearing Reaction of each Smallest Disc Indentation per
Profile V-Belt in N Diameter 100 mm Axis Distance
> 71 < 90 2,20
SPZ 25 > 90 < 125 2,05
> 125 1,90
> 100 < 140 2,75
SPA 50 > 140 <200 2,55
> 200 2,45
> 112 < 160 3,00
SPB 75 > 160 < 224 2,55
> 224 < 355 2,22

Test with Prestressing Measuring Device


V-Belt Smallest Side Force in N Side Force in N
Profile Disc Diameter First Installation Reclamping
SPZ > 71 < 90 250 200
> 90 < 125 350 250
SPA > 100 < 140 400 300
> 140 <200 500 400
SPB > 112 < 160 650 500
> 160 < 224 700 550
> 224 < 355 900 700

Length of V-belts – Exchange of V-belts:


In case of propulsion by several V-belts, only bunched V-belts from one manufacturer have
to be used. Never lay up old and new V-belts. If necessary, exchange complete set.

Attention ! Before commissioning, make sure that all screws are firmly tightened.

06.02.02 Modification of Rotational Speed of Drive


This can partly be effected by variable V-belt pulleys. After removing the V-belt, the pulley-
half opposite the motor ( fan ) on the thread hub can be turned and thus adjusted by
loosening the Inbus-screws. In case of a higher power input, the rotational speed has to be
reduced.
By turning the pulley-half counter-clockwise, it moves away from the other pulley-half,
which reduces the contact radius of the V-belt ( lower rotational speed ).
Pay attention that the Inbus-screws meet again with a flattening of the thread hub in order
to avoid a damage to the thread. After adjusting, tighten the Inbus-screw firmly again and
lay up the V-belt.

06.02.03 Repair Switch


Attention: A repair switch must be fixed at each fan part in order to be able to switch off the driving motor dead
on all poles for maintenance work.
Work on electric installations may be carried out by qualified electricians, only.

06.02.04 Motor Capsule


In order to guarantee the cooling of the motor, the necessary air stream must be adjusted. This depends on the
negative pressure in the fan part and can therefore be adjusted only on site when it is installed.
Fix a short measuring channel at the outer air suction opening and determine the air speed with an air speed
measuring device. This calculated air quantity must exceed the air quantity indicated in the technical rating.
Corrections can be made by moving the suction slot sleeve at the suction opening at the motor shaft.

22
Air Handling Units (AHU) WK-Series
06 Commissioning

06.03 Air Washer


Pay attention to the following before commissioning !
• Clean water tub from dirt in order to avoid consequential damages to the pump.
• Fill tub with water up to 10 mm below the installed siphon or overflow branch.
• Adjust float valve to this water level.
Attention: At first commissioning, the siphon must be filled with water; otherwise, the humidifier draws entrained
air. The overflow cannot work any more and the tub can flow over.
• Commission the plant downstream and adjust the air quantity to the kind of operation.
• Commission the water recirculating pump after having checked the turning direction. Even with wrong
turning direction, water is delivered.
The turning direction of the pump may only be checked with filled water tub !
Check power input of the pump !
• Check if there are any leakages at screw or flange connections in the pump pressure pipe.
• Dispense the elutriation device and adjust it so that the elutriation quantity is twice as high as the
evaporation quantity. In case of completely desalinated water, the elutriation quantity is reduced by 50 %.
• Put humidifier into operation for several hours. During the first days, water drops can strike through at the
drop separator, since the separation rate depends on the wetting state.
• Switch on recirculating pump at intervals of 2 days for at least 1 minute ( provide time control ! ).
• If the water limit values acc. to VDI 3803, Annex A4, Table 9 or special indications of the humidifier
manufacturer are reached, a maintenance has to be effected immediately ! ( cf. Maintenance )
In case of frost danger, empty water tub, pump and pipe system !
Recommended limit values for the quality of the air washer recirculating water acc. to VDI-Guideline 3803, Annex
A4, Table A1.
Put air washer into operation for several hours. During the first days, water drops can strike through at the drop
separator, since the separation rate depends on the wetting state. Remove regularly deposits from the drop
separator profiles. Switch on recirculating pump at intervals of 2 days for at least 1 minute ( provide time control ).
When looking for the mistake,
check the water striking through: and check the humidifier performance:
- Is the drop separator correctly fixed? - Is the pump pressure existing?
- Is the nominal air quantity existing? - Check turning direction of the pump.
- The nozzles must spray against the air stream. - Do all nozzles spray?
- Pump pressure < 3 bar.
Moreover, observe the operating and maintenance instructions of the air humidifier / air
washer manufacturer !

06.04 Steam Humidifier


In case of complete equipment of the AHU with a steam humidifier, the rating is effected acc. to the presupplier‘s
guidelines as well as the hygienic requirements like:
• no condensate formation after the humidification
• no drop formation after the humidification
• sufficient humidification line to following components
• for vapour generation, use water of drinking-water quality.
If the steam humidifier is provided by customer, he will be responsible for a / m points !

06.05 Refrigeration Technology


The commissioning is effected by the manufacturer.
All requirements of the building like accessibility, finished machine and duct assembly and uninterrupted availability
of all supply media must be fulfilled. It must be possible to operate the plant in the required operating points.
All required electric lines must be laid up at the refrigeration board.
• Supply • Release Contact • Performance Regulation ( if existing )
Attention: The electric connections and the wiring must be effected by a qualified electrician.
The valid standards must be observed.

06.06 MSR-Technology ( Measuring, Controlling, Regulating )


The commissioning must be effected by qualified staff ( MSR-technology ), only. The valid standards must
be observed.

23
Air Handling Units (AHU) WK-Series
07 Maintenance

Maintenance
07.01 Warranty
Our warranty will expire in case of damages by improper handling and maintenance. Moreover, experience has
shown that with increasing age of the products there are larger damages by lacking maintenance.
The legislator here definitely indicates annual maintenance intervals for safety equipment, for example:
Guideline of Places of Work - § 53, Paragraph 2
Safety equipment must only be checked by expert, competent staff !
VDI 6022 Hygienic Requirements to Technical Equipment for Room Air
VDI 3801 Operation of Technical Equipment for Room Air
VDMA 24186 Performance Program for the Maintenance of Air-conditioning and other Technical
Equipment in Buildings; Air-conditioning Equipment and Plants
AMEV Recommendation – Maintenance 85
DIN 1946 / 4 Technical Equipment for Room Air in Hospitals.
We refer to the check lists included in a / m regulations, where recommendations for maintenance intervals are
indicated. For maintenance and servicing work at AHUs, a training acc. to VDI 6022 acc. to category B ( hygiene
training ) is required.

07.02 Maintenance Intervals of the Machine Parts


The maintenance intervals for following points cannot be prescribed. The regular maintenance and cleaning
of the machine solely depend on the degree of contamination which is due to the dust content of the outside or
recirculating air.

Check List for hygienic Operation and Servicing of Technical Equipment for Room Air
Months
Activity Necessary Measure
1 3 6 12 24

2 Chamber Central Stations / Machine Housing

Check downstream contamination,


Clean and service x
damage and corrosion
2.2 Check water formation Clean, find out cause x

3 Air Filter

Replace respective air filters, if the last


Check inadmissible contamination and replacement of the filter stage was done later
3.1 x
damage ( leakages ), odours than six months ago, otherwise replace
the whole filter stage.
3.2. Check differential pressure Replace filter stage x
3.3 Latest filter replacement 1. stage x
3.4 Latest filter replacement 2. stage x

4 Air Humidifier

4.1 Evaporation and Circulation Spraying Humidifier


4.1.1 Check contamination, damage and corrosion Clean and service x
4.1.2 Check function of switch-off devices Re-adjust, if necessary x
twice a month

At number of colonies > 1.000 KBE/ml:


Measure number of colonies of the
4.1.3 Wash with detergent, rinse and dry the tub,
humidifier water ( dipslides )
if necessary disinfect
4.1.4 Check deposits on spray diffusers Clean nozzles, if necessary replace x
4.1.5 Check condition and function of mudguards Clean and service x
Check flake formation in the floor range
4.1.6 Clean tub x
of the air humidifier tub.

24
Air Handling Units (AHU) WK-Series
07 Maintenance

Months
Activity Necessary Measure
1 3 6 12 24

Check dirt and lining formation in the


4.1.7 Clean pump cycle x
suction pipe of the recirculating pump
4.1.8 Check function of elutriation device Re-adjust elutriation device x
4.1.9 Check function of conductivity detector Service x
4.1.10 Check function of sterilization plant Service x
Empty humidification plant completely

standstill
4.1.11

at
and dry it
4.2 Drop Separator
Check contamination, damage, lining formation
4.2.1 Function-maintaining cleaning x
and corrosion
4.3 Steam Humidifier
4.3.1 Check contamination, damage and corrosion Clean and service, if necessary disinfect x
Check condensate deposit in the Find out the cause ( s ) and repair, clean steam
4.3.2 x
humidification chamber humidifier
4.3.3 Check deposits on steam lance Clean x
4.3.4 Check condensate discharge Clean and service x
4.3.5 Check function of regulating valve Service x
4.3.6 Check moisture limiter Service x

5 Heat Exchanger

Heater: Check contamination, damage, corrosion and


5.1 Clean and service, if necessary replace x
possibly tightness ( directly fired )
Radiator: Check contamination, corrosion, damage
5.2 and tightness of heat exchanger ( register ), Service x
condensate tub and drop separator
5.3 Check function of siphon Service x

6 Fan

Check contamination, damage


6.1 Clean and service x
and corrosion
Function-maintaining cleaning of the
6.2 air-touched parts of the fan and the x
water discharge

7 Heat Recovery

7.1 Check contamination, damage and corrosion Clean and service x


7.2. Check tightness between exhaust and outside air Service x
Check contamination, corrosion and function of
7.3
condensate tub and drop separator
Service x

7.4 Check function of siphon Service x


7.5 Clean wet radiator, drop separator and condensate tub x

8 Air Ducts and Sound Mufflers

8.1 Check damage of accessible air duct sections Service x


Check contamination, corrosion and Find out the cause, measure the dust density
8.2 water deposit of inner air duct surface at acc. to annex A, clean respective air duct x
2 – 3 representative points sections acc. to annex A
Check contamination, damage and corrosion Find out the cause, service or replace; if
8.3
of sound muffler necessary, strike-off tests
x

25
Air Handling Units (AHU) WK-Series
07 Maintenance

07.03 Motor
The fan motor is maintenance-free. It should regularly be cleaned from dust ( dry cleaning ). At regular intervals
( depending on formation of dew ), the accumulated condensate must be drained off by the condensate water
discharge ( at the deepest point of the end shield ) and the opening must be closed again !

07.04 Fan
Fan – Wheel
The wheel should be cleaned at the same time from dust and other deposits in order to
avoid unbalance.

Fan – Bearings
The used grooved ball bearings ( installed in the bearing crosses ) as well as ball bearings without lubrication nipple
are maintenance-free. The self-aligning ball bearings ( installed in the bearing crosses ) as well as ball bearings
without lubrication nipple are maintenance-free.
The self-aligning ball bearings ( installed in ball bearing housings ) with lubrication nipple should be lubricated
every 6 months with lithium soap grease until a new grease ring forms. Old grease must be removed - pay attention
to unhindered escape of the old grease !
In case of central lubrication with hose, pay attention to airtight first lubrication !

07.05 Motor Replacement


Fan part with radial-flow fan and motor installed on vibration frame:
Relax the motor, so that the V-belts are lying slack in the V-belt pulleys.
Remove V-belts.
Loosen motor fixing screws and remove them.
Screw new motor slack axially symmetric to the fan on vibration frame ( stressing rails ).
Install motor disc with bushing on the motor shaft; make sure that it is sitting centrally on the hub.
Align motor and stress V-belts – cf. passage „V-belts – Stress – Alignment“.

Fan part with freewheel fan wheel:


Attention: Motor replacement and fan wheel assembly should be done by an expert, since after finished assembly,
a function test with possibly necessary rebalancing must be effected.
Dismantling and assembly steps: cf. operating instructions of the manufacturer ( enclosed to these operating
instructions ).

07.06 Motor Pull-out Rail


Before pulling out the crane rail, pay attention to the following:
• Loosen the screws at the holding devices.
• Loosen the stopper ( 2 ) on the door side and fix it at the door side of the crane
rail.Without stopper fixed on both sides of the crane rail, no motor transport
must be effected !
• Pull out the crane rail to approx. 700 mm outside the door.
• Tighten the screws firmly at the holding devices ( 1 ).
• After use, reduce the motor rail to its original state in reverse order.

Attention:
When lifting with an inclined pulley block, make sure that the motor will swing carefully.
If necessary, use additional lifting gear for securing the oscillation.

07.07 Heat Exchanger


Check lamellae package to downstream contaminations and clean with compressed air, if necessary. If the heat
exchanger is removable, it can also be cleaned with a steam cleaner. Pay attention to low pressure and a nozzle
distance of at least 300 mm ! Do not deform the lamellae !
Check tightness of collecting pipes as well as all connection points to the connection piping.
Check frost protection function as well as function of the anti-frost thermostat.

26
Air Handling Units (AHU) WK-Series
07 Maintenance

07.08 Drop Separator


The drop separator of hygiene machines can be taken out of the
machine and completely dismantled for optimal cleaning.
After cleaning, pay attention to correct installation !
The drop separator lamellae must be adjusted to the air direction Air direction
in the machine.

07.09 Sound Mufflers


For a better cleaning, the sound muffler links can be taken out of the machine.
Clean links in the range of the sealing material with the vacuum cleaner. Frame parts and resonance surfaces can be
cleaned by wiping. The sealing material must not be soaked.

07.10 Heat Recovery – Aluminium Plate Exchanger


Long years of experience have shown that in normal ventilation
and air-conditioning equipment, a contamination of the plate heat
exchangers is not expected because of the increased air velocity in
the plate heat exchanger.
If nevertheless the exchanger entry is contaminated in case of
special applications, for example welding extractions, spray booths,
exhaust air from kitchens etc., the exchanger package can be
cleaned as follows:
a ) Dust and fibres can easily be removed with a hair-broom. Be
careful when blowing through with compressed air in order to
avoid damages of the exchanger package.
b ) Oil, solvents etc. can be solved with hot water, fat-dissolving
detergents etc. by washing or immersing.

Attention:
The detergent must not attack the exchanger itself. When using a steam cleaner, pay attention that the exchanger
package is not damaged ( keep a distance of at least 300 mm ).

07.11 Air Humidifier – Air Washer


Upon reaching the water limit values acc. to VDI 3803, Annex A4, Table A1, and acc. to
the degree of contamination of the water, the water tub as well as the installation parts
must be cleaned !
When filling and emptying the tub, the machine must not be in operation !
• Empty water tub and clean it. Basically, do not use foam-producing detergents.
• Lime deposits can be removed with decalcifying detergents or strongly diluted acid.
• Clean humidifier nozzles in order to assure an optimal spraying and thus an optimal humidification
performance at any time.
Remove deposits from drop separator profiles, since they impair the separation performance.

Steam Humidifier
• Check tightness of screwings.
• Clean mudguards.
• Check function of regulating valve.
• Check state of humidification line and steam lance.
• Check if there is a condensate deposit.
• Check if the water for steam generation has drinking-water quality.
Moreover, observe the operating and maintenance instructions of the humidifier manufacturer !

27
Air Handling Units (AHU) WK-Series
07 Maintenance

07.12 Filters
In the first filter stage ( AUL-filter ), biostatic filters must be installed in order to fulfil the requirements of VDI 6022.
The filters must have an approval of their biostatic efficiency.

Attention ! When replacing the filters, wear a respirator with filter P 3 !


Contaminated filters cause an increased health risk !

Bag filters G3, pocket filters G4 and F5 are pushed in laterally. Pocket filters G4 – F5, 7 and 9 are installed on dust
air side. Roller tape filters cf. separate operating instructions.
Filters shall be provided with supervision devices and be replaced when the saturation pressure is indicated.

Filter Filter Class Final Pressure


TB G 4 kurz 150 Pa
TK G4 150 Pa
TL F5–F7 250 Pa
F8–F9 350 Pa

Recommendation acc. to pr. EN 13053

When installing the filters, always pay attention to possibly standing filter pockets !

07.13 Louver Flaps


Louver flaps can be installed both horizontally and vertically. Clean flap shafts and flap linkage once a year,
do not oil.

07.14 Hygiene Machines WK-HY


The complete operating side of the AHUs in hygiene design, type WK-HY, is accessible by removable inspection
covers ( operating doors ).

The installed parts can be pulled out of the machine by the following steps:
• Pocket filters removable Ô filter pressure rail, by loosening the locking screws and loosening the pressure
• Fan part - freewheel fan wheel - standard: stationary, optional: extractable by floor and ceiling rails Ô
loosen the Inbus screws under the plastic cover hoods at the lower and upper guide rail.
• Fan part with radial-flow fan or freewheel fan wheel, installed on floor rails Ô remove front star screws and
pull out the complete fan with vibration frame to the stop.
• Heat exchanger ( heater, radiator ) Ô possible by respective piping ( flange connection ), otherwise
accessible from both sides in the machine
• Drop separator.

Thus, the whole inside machine is optimally accessible for cleaning or wiping disinfection. All sealings are attached
and can easily be replaced, if necessary.
After cleaning, install the parts firmly again, so that the provided sealings will function.
At the freewheel fan wheel with floor and ceiling rail, tighten the Inbus screws firmly and put the cover hoods into
the respective borings.

07.15 Refrigeration Technology


During the warranty time, a maintenance must be effected every six months.
The maintenance can be done by the manufacturer of by an authorized special company for refrigeration
technology.

07.16 MSR-Technology ( Measuring, Controlling, Regulating )


The plant must regularly be maintained by an authorized special company for MSR-technology.

28
Air Handling Units (AHU) WK-Series
07 Maintenance

07.17 Additional Operating and Maintenance Instructions


There are additional operating and maintenance instructions for various installation parts resp. supplied parts.
For this order, the following operating and maintenance instructions marked with a cross have been enclosed in
addition to our operating and maintenance instructions:
Electric Heater
Heat Recovery WRG-R
Heat Recovery WRG-Rot
Air Washer
Surface Humidifier
Steam Generator
Freewheel Fan Wheel
Driving Motor / Electric Installation Parts
Air Heater Type WLE / WLE-K – Cleaning of Heat Exchanger
Compressor – Liquefier Unit
Radial-flow Fan
Volume Stream Measuring Device

Stopping Procedure, Dismantling and Elimination


08.01 Stopping Procedure
Seasonal Stopping Procedure
Operate WRG-rotor during the summer months periodically because of surface cleaning.

Short-term Stopping
Reduce the machine to minimum performance by regulation / control system.
• Run louver flaps in recirculating air operation – close outside air flap in order to avoid cooling
and frost danger.
• Close all regulating valves.
• Switch off recirculating pump.
• Close fresh water valves, close manual valves.
• Empty installation parts in frost danger. Blow through heat exchanger and connecting pipes with
compressed air, until they are completely empty.
Fan afterrunning until all surfaces are dry.
• Empty siphon.
• Switch off main switch and close down the machine.

Long-term Stopping for several months


Measures as described in „Short-term Stopping“, however additionally relax resp. remove fan part – V-belts in order
to avoid damages to the bearings.

Re-commissioning – cf. also 06 Commissioning


Make visual inspection, if any damages can be recognized. Then put AHU into
operation again as described in 06 „Commissioning“.
• Fan part
- Lay up and clamp V-belt
- For fans with bearing to be lubricated: remove old grease, lubricate with new
Lithum – soap grease
• Refill slowly emptied components – de-aerate carefully.
• Open all valves.
• Actuate main switch.
• Switch on regulation / control system.

29
Air Handling Units (AHU) WK-Series
08 Stopping Procedure, Dismantling and Elimination

08.02 Dismantling and Elimination


Dismantling
Before starting dismantling, the AHU and the integrated consumers must be switched off dead. A qualified
electrician must remove all alive connecting lines.

Moreover, all medium-bearing components must be emptied completely. This must be done by a specialized
company effecting a proper elimination of
• water with freezing preventive
• refrigerant in direct evaporator.

Then the AHU can be dismantled on site into the single machine units or into its component parts.
This should also be done by a specialized company familiar with an ecologically beneficial elimination of the
component parts.

When handling dusty components ( filters ) and mineral wool products, wear suitable respirators.

Elimination
The following materials are used in our AHUs:

Housing – Frame profiles, cladding panels and installation parts made of


• hot-dip galvanized sheet steel
• high-grade steel 1.4301
• aluminium AIMg.
All metals can be given to material cycle by separate waste disposal.

Sealing profiles made of


• caoutchouc mixed profile EPDM
• PVC.

Sealing compounds made of


• Polyurethane – waste key No. 55908, 080404.
All sealing materials can be given to separate waste disposal or to a controlled combustion.

Insulation material
• mineral wool – waste key No. 31416
• sound damping mats
All insulation materials can be eliminated by normal rubble dumping grounds.

Emergency
09.01 Fire Protection
There is no direct fire danger caused by the AHUs. By external influence, only the sealings which are installed in
small quantities can burn down.
In case of fire, wear a respirator which is independent of recirculating air.
The machine must be switched off dead.
Suitable fire-extinguishing media are:
• water spraying jet
• fire-extinguishing foam
• fire-extinguishing powder.

09.02 Escape of Harmful Substances


Since only small quantities of combustible sealings are installed, only small quantities of pollutants can be
produced in case of fire. Due to the used materials, these are – nitric oxides, carbon dioxide, carbon monoxide,
hydrogen chloride.

30
WOLF GmbH & Co. KG
3M4ND0

BU: Air Conditioning Technology


Münchener Str. 54
D-85290 Geisenfeld
Telefon +49 ( 0 ) 8452 99-0
Telefax +49 ( 0 ) 8452 99-250
E-Mail info @ wolf-geisenfeld.de
Internet www.wolf-geisenfeld.de

D Printed in Germany
ATB ANTRIEBSTECHNIK AG
ATB AUSTRIA ANTRIEBSTECHNIK AG

OPERATING INSTRUCTIONS
INDUSTRIAL MOTORS

• Standard three-phase
motors
• Single-phase motors
• Brake motors
• Explosion-proof motors
– Increased-safety enclo-
sure “e”
– Enclosure of type “n”

B-IND 01 EN
General, applicable standards, transport,
storage, installation

General

The live parts, rotating parts and potentially hot surfaces of low voltage
motors are a source of danger. Therefore, all transport, connecting, commis-
! sioning and maintenance work must be performed by duly qualified, respon-
sible specialists (see IEC 364; DIN VDE 0105 and DIN VDE 0100). Improper
use and handling may cause serious bodily injury and damages to property.

Applicable standards
These low voltage motors are designed for use in industrial facilities and comply with the
harmonised standards of the EN 60034 / IEC 34 / DIN VDE 0530 series. Use in a potentially
explosive atmosphere is prohibited unless the relevant type is specifically approved for
hazardous zones (note additional information). These motors are subject to the rules and regu-
lations of the DIN EN 50014 to DIN EN 50019 and prEN 50021 (DIN VDE 0170/0171) series.
Do not use enclosures ≤ IP 54 in the open. Air-cooled units are rated for an ambient temper-
ature range from -20 °C to +40 °C and for an installation altitude of ≤ 1000 m above sea level.
Always check for incompatibility with the information on the rating plate. The conditions at
the site of operation must be in full compliance with the data given on the rating plate.

Low voltage motors comply with the provisions of the low voltage directive 73/23
EEC and amendment 93/68 EEC; these components are for installation in machin-
ery within the provisions of machine directive 89/392/EEC. Commissioning is pro-
hibited until conformity of the final product with this directive has been established
(also refer to EN 60204-1). Motors operated in a potentially explosive atmosphere
also fall within the provisions of DIN EN 50014 to DIN EN 50019 and prEN 50021.
Furthermore, compliance with the explosion directive 94/9 EC is mandatory.

Transport, storage
Immediately notify the forwarding agent of any damages discovered after delivery; if neces-
sary, do not allow the unit to be operated. Check all lifting eyes are tightened properly. As
the lifting eyes are rated for the weight of the low voltage motor, do not attach additional
loads. If required, use suitable and sufficiently rated lifting gear (e.g. rope guides).
Before starting the motor, check all shipping braces and shaft blocks have been removed.
Keep safe for subsequent transportation. If storage is required, ensure your low voltage
motor is kept in a dry, dust-free low-vibration (veff ≤ 0.2 mm/s) environment (to prevent
damages to the idle unit). Before commissioning, measure insulation resistance. If the measured
value is ≤ 1.5MΩ, dry the winding. Observe storage instructions.

Installation
Position on an even support, check for satisfactory foot or flange mounting and align precisely
(direct coupling applications). Avoid coincidence of the natural frequency of the structure with
the rotation frequency and with the double mains frequency. Turn rotor by hand and listen
out for unusual grinding noises. Check sense of rotation before coupling (see section titled
“Electrical Connection”).
Mount and remove pulleys and couplings with suitable tools only (heating!). Fit a cover for
protection against accidental contact. Avoid excessive belt tension (see Technical Docu-
mentation).

2 General information about industrial motors


19
Contents

General information about


industrial motors

General, applicable standards,


transport, storage, installation Page 2
Installation, electrical
connection, operation Page 3
Operation, warranty, design,
mounting arrangements Page 4
Mounting arrangements Page 5
Transport, checking prior to
installation, bearing braces,
preventing defects, installation Page 6
Installation, assembly, connection,
insulation resistance Page 7
Installation Page 8
Sense of rotation, reversing,
pre-commissioning checks Page 9
Storage and lubrication,
regreasing, terminal housings,
terminals, cooling air ducts Page 10
Accessories, spare parts,
storage requirements Page 11

Information about explosion-proof


industrial motors

Increased-safety enclosure “e”,


enclosure of type “n”:
general, intended use Page 12
Installation, protective measures Page 13
Brake motors, maintenance
and repair Page 14
Maintenance and repair,
spare parts Page 15

Information about brake motors

Operating instructions for


brake motors with spring-loaded
single-disk brake Page 16

Troubleshooting Page 18
Troubleshooting

Fault Possible causes Remedy

Bearing is Bearing Motor runs


too hot noises*) irregularly

Too much grease in bearing Remove excessive grease

Dirty bearing Replace bearing

Excessive belt tension Reduce belt tension

Coupling forces pull or push Realign motor, correct coupling

Coolant temperature above 40 °C Adjust cooling air temperature

Not enough grease Lubricate according


in bearing to specifications

Bad mounting Check mounting arrangement

Dark colour Check for


of the bearing grease bearing current
Scoring at the inner bearing ring, Replace bearing,
for instance caused by starting avoid vibrations
the motor with locked bearings at standstill
Unbalance attributable
Balance precisely
to pulley or coupling

Unstable motor fastening Check fastening

Fault Possible causes Remedy


Motor will Motor Speed Protective
not start too hot decreases device
quickly triggered

Counter-torque too high Check motor and load torque

Mains voltage too low Check mains condition

Phase interruption Check mains supply

Wrong winding Observe wiring diagram and


connection rating plate

Compare with data


Overload
on rating plate

Switching frequency too high Observe rated duty type

Check cooling air ducts,


Insufficient ventilation
check sense of rotation

Ventilation ducts dirty Clean

Short circuit winding


Measure insulation resistance
and terminal

Starting time exceeded Check starting conditions

18 *) if the remedies described herein are not sufficient to restore proper operating conditions, it is recommended to replace the bearings.
Installation, electrical connection, operation

Low voltage motors are balanced with a key as provided for


in the standards. A corresponding mark is found on the shaft ≥ d/4
end face or on the rating plate (H = half key; F = full key). If
balancing with half key “H” is specified on the end face, the
counterpart – coupling, pulley, gearwheel etc. – must also be
balanced with a half key. As a result, the corresponding
components only need to be balanced with the cylindrical
bore. For the customer, the advantage of rotation symmetrical d = Air opening
components with neutral balancing dynamics is that the need
for additional subsequent balancing after the insertion of the parallel key is eliminated.

Make all required pipe connections, if applicable. If the shaft end of the motor points up (verti-
cal mounting arrangement), it is necessary to fit a cover on site to prevent parts from drop-
ping into the fan. The ventilation mechanism must be free of obstruction. Furthermore, it is
necessary to prevent the exhaust air – including the exhaust air from the neighbouring units –
from entering the intake of the next unit straight away.

Electrical connection
All work must be performed by qualified staff only. Before working on the low voltage motor,
ensure machine is at a standstill, isolated and appropriately secured to prevent accidental
restarting. This also applies to auxiliary circuits (e.g. space heater).
Ensure motor is fully de-energised!
If the tolerance limits according to EN 60034-1 / IEC 34-1 / DIN VDE 0530-1 are exceeded
– voltage ± 5%, frequency ± 2%, waveform, symmetry – surplus heat will be released and
the electromagnetic compatibility will be affected. Observe information on the rating plate
and on the connection diagram in the terminal box. Always note connection data and check
for incompatibility with information on the rating plate.

When making the connection, ensure that a permanently safe electrical connection is main-
tained (no loose wire ends); use appropriate cable boxes and glands. Connect PE conductor
and ensure it cannot come loose!
The minimum air gap between individual naked live parts and between naked parts and earth
must comply with the limit values specified in DIN VDE 0110: 8 mm for UN ≤ 550 V; 10 mm for
UN > 550 V ≤ 725 V; 14 mm for UN > 725 V ≤ 1000 V.
The terminal box must be free of foreign matter, dirt and humidity. Seal all unused cable entry
points and the box itself with plugs to create a dust and waterproof housing. For trial opera-
tion without driven machinery secure parallel key. Low voltage motors with brake: before
operating the motor, check whether brake works properly.

Operation
A vibration severity of v eff ≤ 1.8 mm/s for P2 ≤ 7.5 kW (up to and including FS 132)
v eff ≤ 2.8 mm/s for P2 > 7.5 kW ≤ 37 kW (up to and including FS 200)
v eff ≤ 3.5 mm/s for P2 > 37 kW (up to and including FS 400)

in coupled condition is safe. If there are any changes compared to normal operation (e.g.
increased temperatures, noises, vibrations), determine cause and, if necessary, consult
manufacturer. Do not override protective equipment either in normal operation or in trial
operation. In case of doubt, switch off low voltage motor. In a very dirty environment, it is
necessary to clean the air ducts regularly.

General information about industrial motors 3


Operation, warranty, design,
mounting arrangements

Regrease bearings with regreasing facility while low voltage motor is running. Observe
instructions concerning the type of lubricant, lubrication schedule, grease quantity (lubrication
plate). If lubricant drainholes are closed with plugs (IP 54), remove plugs before initial opera-
tion of the motor. Replace bearings lubricated for life (2Z or 2RS-Lager) after 10,000 hrs (2-pole
version) or 20,000 hrs (higher pole versions), respectively, or in any case at the latest after 3 to
4 years or according to manufacturer’s instructions.

Warranty
No warranty claim will be considered unless these safety and operation instructions and the
information concerning additional equipment, if applicable, is fully complied with. Further
information is found in subsequent sections of the operating instructions.

The operating instructions contain all the information a skilled worker will require to operate
the electrical motor in an industrial environment. Additional information and instructions
concerning the use of the machines in a non-industrial environment are not contained in
these operating instructions.

Design
The low voltage motors with squirrel cage are of the totally enclosed fan-cooled type with
grease lubricated anti-friction bearings.

Mounting arrangements
An illustration of the most common mounting arrangements is given in the table. Please refer
to the dimension drawings to find out the range of frame sizes for which each of the individual
mounting arrangements is available. Further mounting arrangements on request. The basic
mounting arrangement is indicated on the rating plate according to Code I, DIN EN 60 034-7.
Standard motors (i.e. frame sizes 56 – 315M) ordered with basic mounting arrangement (uni-
versal mounting arrangements) IM B3, IM B5 or IM B14 may also be operated in the following
alternative installation positions:
IM B3 in IM B6, IM B7, IM B8, IM V5 or IM V6,
IM B5 in IM V1 or IM V3,
IM B14 in IM V18 or IM V19.
This applies without limitation to motors up to frame size 315 (standard design without drain
hole for condensed water). Due to the possibility to rotate the terminal box through 90°, all
mounting arrangements are easily connected to the mains.

4 General information about industrial motors


Operating instructions for brake motors with
spring-loaded single-disk brake

Setting the brake torque


The brake is delivered with pre-set nominal brake torque. However, the brake torque can be
reduced to dimension hE (max.) by unscrewing the adjustment ring (11).

To set the brake torque, remove manual release lever, (7), the fan cowl (10) and the fan (9).

For Lenze brakes

Break size 06 08 10 12 14 16 18 20 25

Nominal brake torque [Nm] 4 8 16 32 60 80 150 260 400

sLü [mm] 0.2 0.2 0.2 0.3 0.3 0.3 0.4 0.4 0.5

sLü max. [mm] 0.5 0.5 0.5 0.75 0.75 0.75 1.0 1.0 1.25

s [mm] 1.0 1.0 1.0 1.5 1.5 1.5 2.0 2.0 2.5

For Lenze brakes

Break size 06 08 10 12 14 16 18 20 25

Nominal brake torque [Nm] 4 8 16 32 60 80 150 260 400


Reduce by turning in the
appropriate direction 0.2 0.35 0.8 1.3 1.7 1.6 3.6 5.6 6.2

hE [mm] 4.5 4.5 7.5 9.5 11 10 15 17 19.5

Information about brake motors 17


Transport, checking prior to installation, bearing bra-
ces, preventing defects, installation

Transport
All motors of frame size 100 and above have lifting eyes for easier handling.

Check whether screw-fastened lifting eyes are properly tightened. Attach lifting
gear to these lifting eyes only. Always use two lifting eyes to lift motor.

! The rating of the motor lifting eyes corresponds to the motor weight. Do not
use these eyebolts to lift additional loads attached to the motor.

Checking prior to installation


Check whether the motor has suffered damages in transit.

If external damages are discovered upon delivery of the motor, immediately advise the forward-
ing agent.

Bearing braces
(Only motors with cylindrical-roller bearing).
To prevent vibration at standstill from damaging the bearing, either of the
following methods is used to block the rotor:
! – locking screws (red marking) in the bearing cover, or
– transport brace on the shaft end.

Before mounting the motor, screw back locking bolts (10 mm out) and secure,
or remove the transport brace (see sign on motor).
Now it should be possible to turn the shaft by hand.

It is advisable not to loosen or remove the brace until the drive element is
firmly fitted.

The transport brace must be refitted if the motor is to be transported subse-


quently.

Preventing defects; avoiding bodily injury and damages to property.


The person in charge of the facility shall ensure
– that all safety and operating instructions are available and complied with at
all times.
! – that the accident prevention regulations of the professional associations are
complied with: “General Rules and Regulations” (VBG 1) and “Electrical
Equipment and Production Facilities (VBG 4)”.
– that the operating instructions and technical data as specified in the order
are observed.
– that safety devices are used, and
– that all required maintenance work is performed.

Installation
Compare the data on the rating plate with the available type of current, voltage, frequency
and required output, speed and duty type. Use motor only in compliance with the punched
enclosure according to EN 60034-5 / IEC 34-5 / DIN VDE 0530-5 and only with the mounting
arrangement intended by the manufacturer according to EN 60034-1 / IEC 34-7 / DIN VDE 0530-7.

6 General information about industrial motors


Maintenance and repair, spare parts

If work is not performed by the manufacturer, it has to be approved by an


officially authorised expert. This expert must issue a written confirmation or
! apply his test mark to the machine. Outside Germany, always observe the
applicable national legislation.

If repair work is carried out, always observe the required clearances and creep-
age distances.

Spare parts
With the exception of standardised, commercially available and equivalent
parts (e.g. anti-friction bearings), use original spare parts only (see spare parts
! list); this applies in particular to sealings and connecting parts.

Information about increased safety industrial motors 15


Installation

Installation
The terminal box of a single-speed motor usually houses a terminal board with 6 terminals.
Example: specified voltage 400/230 V.

Therefore:
for wye connection for delta connection
use higher voltage. use lower voltage.
Example: 400 V Example: 230 V

You will find a wiring diagram in the terminal box of every motor.

! The cross section of the supply line should be compatible with the rated current.

Use a strain relief device for the connection cables.

Always connect a protective earth conductor to DIN VDE 0100 to the specially
marked PE terminal.
Use the original seal when closing the terminal box.
Seal unused entry openings sufficiently to prevent ingress of dust and water.

If terminal boards with U shaped terminal washers are


used, first bend the conductor you wish to connect in a
U shape and then slip it under the terminal washer.
See drawing!

After long-term storage or an extended standstill period, it is necessary to measure the


phase-to-phase and phase-to-ground insulation resistance of the winding before operating
the motor. Moist windings may produce leakage current, flashover and disruptive discharge.
Measured at a winding temperature of 20 °C, the insulation resistance of the stator winding
of a motor for 220–1000 V must be at least 1.5 MΩ. If this is not the case, the winding must
be dried.

8 General information about industrial motors


Installation, protective measures

Installation and electrical connection


In Germany, the installation of electrical equipment in a potentially explosive atmosphere
requires compliance with the following regulations:

– DIN 57165/DIN VDE 0165 “Installation of Electrical Equipment in Hazardous and Potentially
Explosive Zones”
– ElexV “Decree on Electrical Apparatus in Potentially Explosive Closed Spaces”

Outside Germany, compliance with the applicable national rules and regulations is required.

If a system with pulleys is used, the belts must be of a type that prevents electrostatic
charging.

If a vertical mounting arrangement with the shaft end pointing down is used, it is necessary
to fit a protective roof above the fan cowl. Generally, but depending on the fixing conditions
on location, other mounting arrangements should also be protected against an ingress of for-
eign matter. However, it must be ensured that protective devices and components do not
impair the ventilation performance. The user is responsible for the proper installation of the
motor. This includes the need to protect the motor against falling parts and ensuring a satis-
factory ventilation performance.

The electrical connection must comply with the general safety and commissioning instruc-
tions. The cable entries must be approved for hazardous areas and secured to prevent
unwanted loosening. Unused openings must be sealed with approved plugs.

Protection against heating


Unless the certificate of conformity or the EC prototype test certificate or the rating plate con-
tains information to the contrary with respect to duty type and tolerances, electrical machines
are designed for continuous running duty and normal, non-frequent starting without major
release of starting heat. Use the motors exclusively for the duty type indicated on the rating
plate.

The voltage tolerance in zone A in DIN EN 60034-1 / IEC 34-1 / DIN VDE 0530-1 is ± 5 %
and the frequency tolerance ± 2%; compliance with the waveform and mains symmetry is
required to keep the release of heat within permissible limits. A major deviation from the rated
values may increase the production of heat beyond the acceptable limit and must be indicat-
ed on the rating plate.

Each machine must be protected against excessive heating. This can be


achieved by a current-dependent delayed circuit breaker with phase-failure
! protection according to DIN VDE 0660 or by an equivalent arrangement, such
as thermal machine protection with thermistors (PTC) in all phases. If a current-
dependant protection device is chosen, the device must be set to the rated
current.

In delta connected windings, the circuit breakers must be series connected with the phase
windings and set to 0.58 times the rated current. If the connection is not possible, additional
protective measures are required (e.g. thermal motor protection).

Information about increased safety industrial motors 13


Storage and lubrication, regreasing, ter-
minal housings, terminals, cooling air ducts

Storage and lubrication


Bearings of totally enclosed fan-cooled motors up to frame size 200 are lubricated for life.
The bearings are packed with grease in the factory. This grease is suitable for normal coolant
temperatures (see EN 60034-1 / IEC 34-1 / DIN VDE 0530-1 and page 2 of these instructions
(-20 °C to +40 °C) and, if the motor is operated under standard operating conditions, it will
provide sufficient lubrication for several years.

Bearings of totally enclosed fan-cooled motors from frame size 225 and above are equipped
with regreasing devices. In this type, a grease gun regreases the bearing through the grease
nipples integrated in the end shield.

Only regrease during operation.

Regreasing intervals, grease quantity and grease quality are shown on the
signs attached to the motor.
! Regrease at least once per year.

If the motor is equipped with a grease removal blade, the spent grease must
be removed after regreasing by repeatedly pulling the blade attached to the
bearing to the end stop while the motor is running.

If the motor is equipped with grease collection chambers, it is necessary


– at the intervals indicated on the sign – to stop the motor, unscrew the grease
collection chambers and remove the spent bearing grease. Failure to do so will
lead to an accumulation of grease and to overheating of the bearings.

An extension of the regreasing period may reduce the bearing life.


Furthermore, the sealing provided by the grease deteriorates and dust may
! enter the bearing. If the motors are not operated for some time, it is always
preferable to regrease the bearings before starting up the motor, even if the
motor is new. Always note the saponification type of the lubricant used for
regreasing. This is important to avoid decomposition of the grease, a loss of
the lubricating effect and ultimately a total failure of the bearing, which may
occur if two greases with different saponification properties mix. Hence, the
saponification type of the lubricant used for regreasing must be identical to
that of the original grease.

Terminal housings, terminals, cooling air ducts

Depending on the operating conditions, at certain intervals it is recommended


– to check the cleanliness of the terminal housings and terminals
! – to check whether electrical connections are tight
– to clean the cooling air ducts.
Protect intake openings and cooling surfaces against obstruction and conta-
mination.
Do not use sharp-edged tools for cleaning.

10 General information about industrial motors


Accessories, spare parts,
storage requirements

Accessories
Although temperature sensors, electronic speed controllers, space heaters and forced-air
ventilation are not part of our standard equipment, these accessories are available upon
request.
Connect accessories as indicated on the applicable wiring diagram. Please observe the
instructions and information in the section titled “connection”.

Spare parts
Always state the type, motor number and spare part description when placing your spare
parts order. The type and motor number are given on the rating plate.

Storage instructions
Observe the instructions concerning the storage of electrical equipment under various con-
ditions. If applicable, please request a copy of the instructions.

General information about industrial motors 11


Increased-safety enclosure “e”, enclosure of
type “n”: general, applicable standards

General
Due to the increased risk in a potentially explosive atmosphere, strict compliance with the
general safety and commissioning instructions that apply to increased safety motors is of
utmost importance.

Applicable standards
Electrical motors of the increased safety type comply with the standards of the
DIN EN 60034 / IEC 34 / DIN VDE 0530 series and with DIN EN 50014 to draft
! prEN 50021. Their use in a potentially explosive atmosphere is subject to the
conditions imposed by the competent supervision authority. It is also the
responsibility of the supervision authority to establish the explosion hazard
(classification of zones).

The protection type, temperature class and special conditions are stated on
the rating plate, in the certificate of conformity or in the EC prototype test certi-
ficate.

Equipment group II, category 2 (formerly zone 1)


Electrical machines with increased safety enclosure belong to this category.

– Increased safety “e”

– Flameproof enclosure “d”

– Pressurised enclosure “p”

With the exception of mining applications, these machines may be used in all zones with an
explosive atmosphere.

Equipment group II, category 3 (formerly zone 2)


Electrical machines with an enclosure of type “n” belong to this category.

If the certificate of conformity or EC prototype test certificate includes the let-

! ter X, the special conditions in this certificate of conformity or EC prototype


test certificate must be observed.

Operation at the converter requires express approval. Always strictly comply with the manu-
facturer’s instructions. If an enclosure is of the increased safety type “e”, the motor, convert-
er and protective device must be tested and labelled as a unit, and the admissible operation
data must be specified in the joint certificate of conformity or EC prototype test certificate
(DIN VDE 0165). The connection cable between the converter and electrical machine may
adversely influence the extent of the voltage peaks produced by the converter.

In the system consisting of the converter, cable and electrical machine, the
maximum of the voltage peaks at the machine terminals shall not exceed the
! value indicated in the special manufacturer’s instructions or in the IEC/VDE
and PTB recommendations.

12 Information about increased safety industrial motors


Sense of rotation, reversing,
pre-commissioning checks

Sense of rotation
Most motors can be used for either sense of rotation.
However, if a certain sense of rotation is required, the rotational direction is indicated by an
arrow on the motor (e.g. on the rating plate or on the wiring diagram).

If terminals U1, V1, W1 are connected to phases L1, L2, L3 (in alphabetical or numerical
order), the motor’s sense of rotation is always clockwise. This applies to all motors, even if
they are not suitable for clockwise operation. (IEC 34-8 / DIN VDE 0530-8).

Reversing the sense of rotation


If DOL (direct on-line) starting or pole-changing motors with separate windings are used, the
sense of rotation can be changed by reversing any two supply cables on the terminal board.

In motors with wye/delta starting and pole-changing motors with Dahlander winding, it is
necessary to change two supply cables at the input to the motor switch.

Machines with one shaft end only or with two shaft ends of unequal thickness: the sense of
rotation is the rotational direction of the rotor as seen from the front end of the only shaft or
thicker shaft end, respectively.

If forced-air cooling is used, the sense of direction is indicated by an arrow on the forced-air
ventilator.

Pre-commissioning checks
– Check whether the bearing brace is removed! (Applies to motors with
cylindrical-roller bearing only)

! – Verify compliance with the data on the rating plate!


– Check whether voltage and frequency of the motor coincide with the mains.
– Check whether the sense of rotation is correct and, in converter operation,
ensure the limit speed is not exceeded.
– Check whether the motor is protected as required by the regulations!
– Wye-delta starting: due to the risk of excessive loads in operation, it is impor-
tant to check and ensure that switching from wye to delta will not occur until
the starting current of the wye position is off.
– Check whether all electrical connections are tightened; check if the moni-
toring equipment is properly connected and set!
– Check coolant temperature!
– Check whether additional equipment – if any – works properly.
– Check whether air inlet and cooling surfaces are clean!
– Check whether equipment is earthed and duly protected!
– Check whether the motor is properly fastened!
– Belt drive: check tension of the belt!
– Check whether the terminal box cover is closed; check if the cable entry
points are properly sealed.

General information about industrial motors 9


Brake motors, maintenance and repair

Thermal motor protection by directly monitoring the winding temperature is acceptable if it is


approved and indicated on the rating plate. This type of protection consists of temperature
sensors according to DIN 44081/DIN 44082 which, in connection with tripping devices bear-
ing the mark of approval of an authorised test institute, provide a satisfactory level of safety.

For pole-changing motors, separate and interlocked protective devices are needed for each
speed step. It is recommended to use a device that has been approved by an authorised test
institute (test report).

Contrary to a type “n” enclosure, motors with an increased safety enclosure of type “e” include
a start-up monitoring function, too. Therefore, the protective device must trip within the tE
time specified for the corresponding temperature class if the rotor is locked. This demand is
satisfied if the tripping time – as indicated by the tripping characteristic (initial temperature
20°C) for the IA / IN ratio – does not exceed the specified tE time. Electrical machines for high
starting duty (acceleration time > 1.7 x tE time) must be protected with a starting-cycle
monitoring circuit in accordance with the information provided in the certificate of conformity or
in the EC prototype test certificate.

Brake motors
For motors with increased-safety enclosure “e”, the exclusive use of brakes
with flameproof enclosure is mandatory.

!
Maintenance and repair
In Germany, the execution of all maintenance or repair work and modifications of explosion-
proof machines must comply with ElexV, with the safety provisions and with the descriptions
in the general maintenance instructions. All work affecting explosion protection, which is
deemed to include work such as

– repair of stator and rotor windings and terminals


– repair of the ventilation system,

must be carried out by the manufacturer or by a specialised repair shop for

! electrical machines. An additional repair label containing the following informa-


tion must be attached to the machine:

– date
– executing company
– type of repair work, if applicable
– code of the expert, if applicable

14 Information about increased safety industrial motors


Installation, assembly, connection,
insulation resistance

Maximum coolant temperature (room temperature at the installation site max.


40 °C and permissible installation altitude up to 1000 m above sea level*) ac-
! cording to EN 60034-1 / IEC 34-1 / DIN VDE 0530-1.
*) other values see rating plate

Ensure that the flow of cooling air to and through the intake air and exhaust air
openings is unobstructed. Also ensure that exhaust air will not enter the intake
! of the next unit straight away. Prevent blockage of intake and exhaust openings
and protect from large dust particles.
If pulleys, gear wheels etc. are used, ensure that the permissible axial shaft
load is not exceeded (refer to technical documentation).

Installation
Fit pulleys or coupling with special mounting tool only.
Do not use a hammer to fit drive elements as this may cause damage to

! the bearings and additional components, e.g. sensors etc.


Always use suitable tools and the shaft centre holes if it is necessary to
replace a bearing.

As a standard, the rotor is dynamically balanced with a half-key. Therefore,


parts to be fitted must be balanced dynamically without keyway, e.g. on a plain
shaft. The motor balancing procedure is stated on the shaft end face or on the
rating plate (H = half key, F = full key, N = without parallel key, X = plain shaft).
Motors balanced with a half-key (H) require the coupling to be balanced with a
half-key, too (i.e. without keyway).

After installation, the drain holes for condensed water must be located at the
very lowest point of the motor. Open sealed drain holes from time to time to
drain the condensation water, then close the holes again.

Connection, insulation resistance


The connection must be made by skilled personnel and be in compliance with all applicable
safety regulations. Observe all relevant installation and operation regulations as well as all
customary, national and international regulations.

Observe information on the rating plate!


Observe connection requirements!
! Note rated current for the adjustment of the circuit breaker!
Connect motor according to the instructions given in the wiring diagram in the
terminal box! The motor must be protected against overheating, e.g. by fitting
a motor circuit breaker.

General information about industrial motors 7


Operating instructions for brake motors with
spring-loaded single-disk brake

Description
The maintenance-free brake is fail-safe. In released state, it can be operated for any period
of time in any installation position. It can be used for either sense of rotation. The asbestos-
free friction linings are highly wear resistant.

Please note! The frictional surfaces must be free of oil or grease at all times.

! If readjustment is required, the correct air gap can be set by turning the read-
justment socket screws.

If a manual release brake is used, ensure that dimension “s” between the self-locking nuts
and the armature disk is set evenly on both sides. Do not make changes to the manual
release if the air gap sLü is readjusted.

1 4 2 12 3 7 5 6 10

11

5 Armature disk
8

sLü
hE

1 End shield with brake friction surface 7 Manual release lever


2 Friction lining 8 Securing ring
3 Readjustment socket screws 9 Fan
4 Brake rotor 10 Fan cowl
5 Armature disk 11 Adjustment ring
6 Magnet 12 Sleeve

16 Information about brake motors


Mounting arrangements

Code I (Code II) Code I (Code II)

Foot mounted IM B3 (IM 1001) IM B8 (IM 1071)


motors – horizontal shaft – horizontal shaft
all frame sizes – feet on the floor – feet pointing up

IM B6 (IM 1051) IM V5 (IM 1011)


– horizontal shaft – vertical shaft
– feet against the wall pointing down
and left if facing – feet against the wall
shaft end

IM B7 (IM 1061) IM V6 (IM 1031)


– horizontal shaft – vertical shaft
– feet against the wall pointing up
and right if facing – feet against the wall
shaft end

Flange mounted IM B5 (IM 3001) IM B35 (IM 2001)


motors, – horizontal shaft – horizontal shaft
with A flange, – feet against the
through holes floor
all frame sizes
IM V1 (IM 3011) IM V15 (IM 2011)
– vertical shaft – vertical shaft
pointing down pointing down
– feet against the wall

IM V3 (IM 3031) IM V36 (IM 2031)


– vertical shaft – vertical shaft
pointing up pointing up
– feet against the wall

Flange mounted IM B14 (IM 3601) IM B34 (IM 2101)


motors, C flange – horizontal shaft – horizontal shaft
with threaded- – feet against
holes the floor
frame sizes
≤ 112 mm IM V18 (IM 3611) IM V58 (IM 2111)
– vertical shaft – vertical shaft
pointing down pointing down
– feet against the wall

IM V19 (IM 3631) IM V69 (IM 2131)


– vertical shaft – vertical shaft
pointing up pointing up
– feet against the wall

Motors without IM B9 (IM 9101) IM B15 (IM 1201)


end shield – Mounting rods – feet and mounting
and anti-friction with thread rods with thread
bearing on DE – horizontal shaft – horizontal shaft
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Veuillez le rabattre!
Concessionnaires Allemagne

Est
ATB ANTRIEBSTECHNIK AG Ouest Sud-Ouest
Neues Ufer 19-25 ATB ANTRIEBSTECHNIK AG ATB ANTRIEBSTECHNIK AG
D-10553 Berlin Kallenbergstraße 11 Industriestraße 60
Tél. +49 (30) 34 50 02 46 D-45141 Essen D-73642 Welzheim
Fax +49 (30) 34 50 04 23 Tél. +49 (2 01) 8 31 26 13 Tél. +49 (71 82) 14-1
Fax +49 (2 01) 8 31 26 10 Fax +49 (71 82) 14-590
Nord
ATB ANTRIEBSTECHNIK AG Sud
ATB ANTRIEBSTECHNIK AG GEISERT Engineering GmbH
Industriestraße 3
Zeppelinstraße 4 Industriestraße 3
D-30855 Langenhagen
D-82179 Puchheim D-66129 Saarbrücken
Tél. +49 (5 11) 97 32 98-3
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Fax +49 (5 11) 97 32 98-55
Fax +49 (0 89) 54 71 73-10 Fax +49 (68 05) 80 07

Concessionnaires Europe

Allemagne
ATB AUSTRIA ANTRIEBSTECHNIK
VERTRIEBSGES. MBH
Finlande
Industriestraße 60
FLENDER OY
73642 Welzheim
Korppaanmäentie 17 CL 6
Tél. +49 (71 82) 14-525 Suède
Fin-00300 Helsinki
Fax +49 (71 82) 14-574 ATB DRIVTECH A.B.
Tél. +3 58 (9) 4 36 13 66
Ringvägen 4
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Autriche P. O. Box 109
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A-8724 Spielberg ATB FRANCE Fax +46 (8) 56 03 46 93
Tél. +43 (35 77) 7 57-0 17 Parc de la Calarde
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CH-5600 Lenzburg
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Succursales et représentations dans les pays non européens: adresses sur demande

ATB ANTRIEBSTECHNIK AG
Industriestraße 60 • D-73642 Welzheim
Téléphone +49 (71 82) 14-1 • Téléfax +49 (71 82) 28 87
http://www.atb.de • E-Mail: info@atb.de

ATB AUSTRIA ANTRIEBSTECHNIK AG


G.-Bauknecht-Straße 1 • A-8724 Spielberg
Téléphone +43 (35 77) 7 57-0 • Téléfax +43 (35 77) 7 57-1 82
http://www.atb.de • E-Mail: gL@atb.co.at
OPERATING INSTRUCTIONS
1. Operating Instructions for Air Heating Batteries

a, Technical Prerequisites for Putting into Operation


Prior to connecting the heating batteries it must be checkes if the voltage indicated on the name plate
agrees with the existing supply voltage.The heating batteries are connected together into one or more
groups for switching purposes, and for three-phase supplies each switching group has three
terminals, and for DC or AC supplies each switching group has two terminals and a terminal for
earthing purposes for each switching group in addition. The parts of the housing or flange plates are
made of metal and must also be earthed.
It is a general requirement that the electrical connection may be made by certified personnel only. The
applicable regulations as per DIN 57100, part 420/VDE 0100, must also be complied with. The
temperature safety limiter, temperature monitor, flow monitor and so forth must be controlled
accordingly.

b, Putting into Operation


In the case of the embodiment with cold air inlet in line with types ERR/91 and ERRG/91 the heating
element cables and the connecting bars are provided inside the duct. The air flowing through the
heater cools the cable connections continuously thus reducing the heat in the IP 54 connection box.
Therefore standard cables may be used.
In the case of very high final air temperatures or very unfavourable conditions (e.g. reduced air
quantity or recirculated air operation depending on the method used) there may be temperatures
existing in the connection box which are no longer suited to use standard, rubber-insulated cables
(this decision can be taken by the customer only). In this case use high temperature resisting cables,
e.g. silicone, teflone or fiberglass insulated cables.
Depending on the distance between the control box and the air heating battery it is recommended to
mount separate connecting blocks in a short distance to the air heating battery with the aim to save
running metres of heat resisting cables.
The correct manufacture of the current supply connections and both earthings (electrical connection
and housing) must be checked prior to the test run.
On the occasion of a test run all parameters, e.g. air quantity, final air temperature and so forth
(Technical Data Sheet refers), must be completely complied with. In unfavourable cases partial
considerations of or deviations from the values prescribed by the manufacturer (Technical Data Sheet
refers) may cause damage to or destruction of the air heating battery.

c, Normal Shut-Down Procedure


The shut-down procedure for fan and air heating battery shall be as such that the fan is still in
operation for another five minutes to avoid overheating. For this reason the fan motor after-running is
ensured with the help of a time-limit relay.
Also, existing thermostats must be set on site in accordance with the requirements requested for. For
example, a temperature safety limiter is adjusted between 50°C and 60°C with a final air temperature
of 40°C; this applies also to other final air temperatures.

d, Safety Shut-Down in the Case of Power Failure


Depending on the operation conditions and in the case of voltage failure the surface of the heating
rods can be heated up by 50°C to 70°C. It can hardly be expected that the air heating battery will be
damaged. At worst, it may be necessary to replace a filter or a plastic cover.
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e, Regulations for the Use of Control and Adjustment Devices


On principle, there are 4 parameters to be observed for the control of a heat battery made by VOLTA:
- quantity of air;
- air intake or air exhaust temperature;
- operating voltage or current resulting thereof;
- use of operating groups (performence distribution).
If the air exhaust temperature is required to be changed or if the air intake temperature changes a
control can be achieved by switching on or switching off one or more operating groups without
changing the quantity of the air. If the quantity of air changes (to less than approx. 70-80 per cent of
the quantity of air defined for each heat battery embodiment) this may be balanced only by a voltage
control (less current required). For technical reasons the switching off of one or more operating groups
will not lead to success. If these instructions recommended by the manufacturer are not complied with
this may result in a partly or completely destruction of an air heating battery.

f, Operating Conditions
Air heating batteries are single piece productions which are produced for special customer operating
conditions and in accordance with the dimensions provided and requested for by our customer. On
delivery of the air heating batteries a complete documentation (Operating Instructions, Declaration of
Conformity, Technical Data Sheet, Table of Dimensions, Wiring or Circuit Diagram, Operating
Instructions for Thermostats used) is provided, the dates and operating instructions of which apply
exclusively to this individual air heating battery provided. The data included in the Technical Data
Sheet are to be considered as nominal operating values applying to the air heating battery specified
by the customer and manufactured in accordance with the requirements requested for by the
customer. They must be complied with to ensure an application of the air heating battery as directed.
It is also possible to manufacture air heating batteries in accordance with different operating
conditions which are considered on the occasion of its development and design and included in the
Technical Data Sheet. Any deviations from these recommended data provided must be compensated
by suitable control and adjustment actions to be carried out on-site. In unfavourable cases partial
considerations of or deviations from the values prescribed by the manufacturer (Technical Data Sheet
refers) may cause damage to or destruction of the air heating battery.

Unless otherwise specified in the Documentation of the Air Heating Battery normal
environmental and operating conditions, normal methods and modes of operation
in accordance with Standard DIN VDE 0100 are a prerequisite for the use and operation
of the Air Heating Battery.

g, Repair Activities:
VOLTA GmbH are able to supply replacement heating rods within a few days if the manufacturer's
identification number of the heating battery is advised by the customer. Then a qualified electrician will
be able to perform the required repair himself. Repair or maintenance activities may be performed
only if all electrical devices have been switched off, and the current supply system must be protected
against re-switching in. Furthermore it must be paid attention to the fact that the heating rods are
cooled off sufficiently prior to beginning with any repair and maintenance activities.
All repair activities may be performed by a corresponding expert only who installs and connects
replacement heating rods the same way he has removed the damaged heating rods prior to repair
activities involved. If larger heating batteries are subject to repair activities and to the extent that no
experts are available, it is advisable to have the repair work performed by the manufacturer. A heating
battery sent in for repair purposes will be returned in a few days as good as new and tested in
accordance with the regulations and/or specifications.
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h, Long-Term Control and Maintenance


As a matter of principle it is not required to maintain air heating batteries. It will be sufficient to
examine the connecting cables periodically to ensure that the screws at the terminals are still tight and
that both earthing systems (connection and housing) are still operating properly and that the insulation
of the cables has not been cracked. Cleaning activities are required to be part of the maintenance
activities only if the medium to be heated is extremenly dirty or dusty (e.g. wood dust produced in a
joiner's shop). It is recommended to clean the heating rods with the help of compressed air.
Air filters that may have been installed in front of or behind the air heating battery must be cleaned at
regular intervals.
If an occasional overheating of the heatig rods has produced some scale on the outer surface, it can
be assumend that said scale may have been produced on the inner surface as well, which scale might
become loose due to vibrations and thus may cause a short circuit. Therefore if scaled heating rods
are found it is advisable to return the air heating battery for repair purposes.

i, Use of Themostats
Thermostats which are marketed and installed by VOLTA GmbH are perhaps mechanically integrated
in the air heating batteries. Temperatures or flow speeds must be set and adjusted by the customer
on-site, because he himself knows the necessary and complete operating dates and conditions only
(flow, air quantity preservation and so forth). For these reasons it is not advisable to have the
thermostats preset by VOLTA GmbH.
When leaving our works the thermostats have been preset to the highest value possible, and it is
imperative to adjust them on-site (in accordance with the Operating Instructions of the thermostat
supplied).

j, EMVG Regulations and Advice


Based on the design and the physical features of air heating batteries and heating rods manufactured
and marketed by VOLTA GmbH no interference emission or operating trouble may be expected in
case of interference effects in accordance with EMVG requirements and regulations.
When wiring or connecting the air heating batteries or heating elements to the thermostats or control
devices supplied by VOLTA GmbH all remedial actions required in accordance with EMVG are to be
taken by the customer on-site in the event of possible interferences which might occur. All necessary
remedial actions and modifications are to be taken and made in accordance with EMVG requirements
and regulations. When wiring or connecting the air heating battery to other electrical components,
installations and products on-site it must be ensured that all EMVG requirements and regulations are
complied with. Any remedial actions necessary are to be taken by the customer in accordance with
the requirements existing on-site. All working activities and actions mentioned and referred to in this
paragraph may be carried out by the corresponding experts only.

k, Manufacturer Machine Standard 89/392/EWG Declaration


The complete machine equipped with air heating batteries or heating element components may be
operated only if the Protection Requirements and Standrads of the Machine Standard 98/392/EWG
required for the complete machine have been complied with.

2. Safety Regulations pertaining to Operating Instructions


a, Operating Directions
Air heating batteries are to be used for the heating of fresh, recirculated or processing air only (normal
operating method according to Standard DIN VDE 0100).
The contact safety device must be examined electrically and be provided and ensured thermically on-
site.
4

b, Electrical Air Heating Battery Installation Location


If no data provided by the customer are existing the electrical air heating batteries are manufactured
for vertikal or horizontal installation. In general, a horizontal installation with a lateral terminal box is
preferential.

c, Installation and Removal Directions


Upon electrical connection of the air heating batteries it is a fundamental requirement to comply with
the instructions of Standards EN 73/23/EWG and DIN VDE 0100, in particular with regard to the rating
of all electrical devices connected to the air heating batteries, intentional putting into operation, safe
switching off, and safe separation from sources of energy.
Upon installation of the air heating battery the electrical connection system may be installed only if
mechanical installation activities have been completed. This applies in reverse order when removing
the air heating battery: any mechanical removing activity may be started only as soon as the electrical
connection system has been cut completely. Furthermore it must be paid attention to the fact that the
heating rods are cooled off sufficiently prior to beginning with any repair and maintenance activities. It
is a fundamental requirement that experts may perform work on electrical connection systems only
who must comply with the instructions as per Standards DIN VDE 0100 or DIN VDE 0110. Special
care must be given to the connection of the protective conductor to the terminal provided in the switch
box and to the additional earthing of the housing. At both ends there are flanges provided for
mechanical installation purposes which are to be used according to their design. All mechanical
operations must also be performed by experts.

d, Contact Protection Directions


The normal installation situation is as such that an air heating battery supplied by VOLTA will be
installed between two channel elements and be rigidly connected to said channels mechanically (by
screws). If not and if one side of the air heating battery remains open or unprotected, the customer
himself has to take steps for contact protection purposes. It must be ensured that it will be impossible
for any person to come into contact with the heating rods of an air heating battery. For example, this
protection must be provided by assembling a grid to the open side of the air heating battery. In
principle, the air heating battery housing hardly represents a grave danger or risk, because to is
grounded by means of a protective conductor. However, if the housing warms up too much,
depending on the installation situation and the on-site technical datas, it must be insulated (against
heat) by the user/customer himself independently.

e, Repair or Maintenance Directions


Repair or maintenance activities may only be performed if all electrical devices have been switched
off, and the current supply system must be protected against re-switching in. Furthermore it must be
paid attention to the fact that the heating rods are cooled off sufficiently prior to beginning with any
repair and maintenance activities.

3. Manufacturer
The manufacturer is at your disposal for any questions you may have and for any repair and
maintenance activities to be performed (footnote refers). Always specifiy the purchase order or
machine identification number specified at the end of the Operating Instructions. All Operating
Instructions apply to the equipment only provided together with the purchase order or machine
identification number specified.

Please specify the following purchase order or machine identification number


when submitting any enquiries: