AL-KO DESIGN Series User manual

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3910831 Subject to changes in keeping with technical developments!
OPERATING AND INSTALLATION INSTRUCTIONS
AIR HEATER / AIR COOLER
DESIGN
VENTILATION AND CENTRAL AIRCONDITONING DEVICES
GB

Translation from the original operating instruction2
AL-KO air heater / air cooler DESIGN
Table of contents
1. Information concerning this handbook..................................................................4
1.1 Description of symbols...............................................................................................................................4
1.2 Regulations and standards .........................................................................................................................4
1.3 Legal information .......................................................................................................................................4
2. Safety information .........................................................................................5
2.1 Appropriate use ..........................................................................................................................................5
2.2 Possible inappropriate uses........................................................................................................................5
2.3 Residual risks.............................................................................................................................................6
2.4 Delivery .....................................................................................................................................................6
2.5 Storage, transport ......................................................................................................................................6
2.6 Duties of the operating company................................................................................................................7
2.7 Disposal of the packaging...........................................................................................................................7
3. Product description ........................................................................................ 8
3.1 Declaration of incorporation .....................................................................................................................10
3.2 Declaration of conformity .........................................................................................................................11
3.3 Technical data...........................................................................................................................................12
3.3.1 TYPE ED-…..............................................................................................................................................12
3.3.2 Noise in connection with rotation speed adjustment ................................................................................14
3.4 Accessory.................................................................................................................................................14
3.5 Condensate pump.....................................................................................................................................15
4. Transport .................................................................................................. 15
4.1 Fork lift / industrial truck transport...........................................................................................................15
5. Assembly .................................................................................................. 16
5.1 Ceiling installation of the devices..............................................................................................................16
5.2 Installation of accessory components ......................................................................................................17
5.3 Heat exchanger connection ......................................................................................................................17
5.4 Condensate pump.....................................................................................................................................18
5.5 Electrical connection.................................................................................................................................21
5.5.1 Fan............................................................................................................................................................21
5.5.2 Cable list...................................................................................................................................................22
6. Operation / general information ....................................................................... 24
7. Switch cabinet ............................................................................................ 24
8. Maintenance .............................................................................................. 24
8.1 Safety .......................................................................................................................................................24
8.2 Consumables and spare parts ..................................................................................................................24
8.3 Maintenance plan .....................................................................................................................................25
8.4 Checking the components ........................................................................................................................26
8.4.1 Checking the heat exchanger....................................................................................................................26
8.4.2 Checking the condensate pump................................................................................................................26
8.4.3 Check the air guidance ns.......................................................................................................................26
8.4.4 Check the fan............................................................................................................................................26
8.5 Cleaning the components .........................................................................................................................27
8.5.1 Clean the heat exchangers........................................................................................................................27
8.5.2 Cleaning the condensate pump.................................................................................................................27
8.5.3 Cleaning the air ns..................................................................................................................................27
8.5.4 Cleaning the fan........................................................................................................................................27

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3910831 Subject to changes in keeping with technical developments!
"Table of contents"
8.6 Exchanging components ..........................................................................................................................28
8.6.1 Exchanging the heat exchanger ................................................................................................................28
8.6.2 Exchanging the condensate pump............................................................................................................28
8.6.3 Exchanging the air guidance ns..............................................................................................................28
8.6.4 Exchanging the fan ...................................................................................................................................28
9. Help with faults........................................................................................... 29
9.1 Contact person .........................................................................................................................................29
9.2 General faults ...........................................................................................................................................29
10. Shut-down................................................................................................. 29
10.1 Decommissioning.....................................................................................................................................29
10.2 Dismantling ..............................................................................................................................................30
10.3 Disposal....................................................................................................................................................30

Translation from the original operating instruction4
AL-KO air heater / air cooler DESIGN
1. Information concerning this handbook
Read this documentation before installation and commissioning. This is a requirement for safe working and fault-
free operation.
Adhere to the safety and warning notes in this documentation and on the product.
This documentation is a permanent part of the product described and should be handed to the buyer in the event
of a sale!
1.1 Description of symbols
Warning!
This symbol refers to safety procedures that are required to prevent injuries!
Caution!
This symbol refers to safety procedures that are required to prevent damage to goods!
Special information to improve comprehension and handling.
1.2 Regulations and standards
The following standards and regulations were applied during the design phase and also apply to installation, commis-
sioning, operation and maintenance:
DIN EN ISO 12100 Safety of machinery – General principles for design – Risk assessment and risk reduction
DIN EN 60204-1 Safety of machinery – Electrical Equipment of machines – Part 1: General requirements
DIN EN 349 Safety of machinery – Minimum gaps to avoid crushing of parts of the human body
DIN EN ISO 13857 Safety of machinery – Safety distances to prevent hazard zones being reached by upper and
lower limbs
VDMA 24167 Fans - Safety requirements
2006/42/EC Machinery Directive
97/23/EC Pressure Equipment Directive
2004/108/EC Electromagnetic Compatibility
1.3 Legal information
All data provided are only intended to describe the product. They do not guarantee a certain composition of the system
or its suitability for a specic application. This information does not release the user from his obligation to perform
evaluations and tests.

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3910831 Subject to changes in keeping with technical developments!
2. Safety information
Please take note of these issues to prevent injuries, res and other hazards caused by inappropriate use and operation
of the air heater / air cooler:
Warning!
Installation, electrical connection, media supply connection, maintenance, commissioning, repair, etc. may only
be performed by trained staff.
Before any work on the air heater / air cooler is undertaken, it must be ensured that the power supply is switched off
(all-pole separation) and secured against unauthorised re-operation!
Only operate the air heaters / air coolers once they have been completely assembled and provided with appropriate
reach-in protection.
All claims for damages or warranties become void when the installation does not comply with our stipulations or when
the fault/damage is causally related to inappropriate alterations, processing or other treatment. The user must prove that
the fault is not due to inappropriate installation.
The general maintenance instructions in the operating and installation instructions for the AL-KO air heaters / air coolers
must always be adhered to.
The implementation and design of the air heater / air cooler corresponds to the standards listed in the declaration of
conformity and declaration of incorporation to minimise the risk potential posed by the air heater. The potential risk can
only be minimised when these additional, applicable standards for the installation-ready system are adhered to by the
system builder.
It must be ensured that all authorised persons have read and understood all of the operating and installation instructions
and adhere to them!
All plant, company and work instructions of the user apply in addition to these operating instructions to prevent hazards
within the company.
Personal protective equipment is required for work on the air heater / air cooler!
2.1 Appropriate use
The application range for AL-KO air heaters / air coolers is exclusively air heating or cooling of the air in rooms and build-
ings with normal climate and normal atmosphere.
The air heaters / air coolers may only be operated in an environmental temperature range between -20 °C and +40 °C and
a humidity range between 50% and 85% relative humidity without condensation.
Installation of the air heaters / air coolers at a location more than 800 m above sea level may lead to a drop in perfor-
mance and has to be investigated on a case-by-case basis.
Different areas of application should be discussed with the manufacturing plant.
2.2 Possible inappropriate uses
AL-KO air heaters / air coolers may only be operated within the range specied in the technical data provided by AL-KO.
Any other or further use that deviates from the description in Point "2.1" Appropriate use" is deemed inappropriate use.
The manufacturer is not liable for damage resulting from such use.
Possible inappropriate use includes, for example:
Transport of media with temperatures above or below the permitted range, aggressive media or media containing
a lot of dust.
Use in an explosive atmosphere.
Use in wet areas with a high humidity content (e.g. washing system)
"Safety information"

Translation from the original operating instruction6
AL-KO air heater / air cooler DESIGN
2.3 Residual risks
The air heater / air cooler may pose risks when it is used by untrained persons or in an incorrect or inappropriate way.
Residual risks are potential risks that are not obvious, e.g.:
Injuries due to not adhering to the safety instructions, standards, guidelines or regulations
Injuries due to uncoordinated work.
Risk due to working on the electrical system, the cables and the connections
2.4 Delivery
AL-KO air heaters / air coolers are delivered in cardboard boxes or on pallets incl. lm packaging!
2.5 Storage, transport
Warning! Caution!
Store the air heaters / air coolers in their original packaging in a dry place and protected against the weather.
Cover open pallets with tarpaulins and protect the air heaters / air coolers against dirt (e.g. chips, stones, wire, etc.)
Additional, protective packaging must be used for transport under harsh conditions, (e.g. on open vehicles, exposed
to unusual vibration, transport by sea or in subtropical countries).
Prevent repeated and, in particular, sudden temperature changes. They are particularly harmful when the humidity
can condense.
Check the ease of movement of the fan bearings (turn them by hand) after storage periods longer than 1 year.
The device can be transported with a fork lift or and industrial truck as described in Point 4.1 "Fork lift / industrial
truck transport".
Clear vision must be ensured during the transport
(use support staff as required)
No persons may remain in the transport area.
The relevant worker safety and environmental protection regulations must be adhered to during transport.
The air heater / air cooler may only be transported by educated, trained and instructed personnel and with appropri-
ate consideration of safety issues.
It must be ensured that drivers have appropriate driving licences when transporting devices requiring a driving li-
cence.
Avoid twisting of the housing or other forms of damage.
Damage caused by in appropriate packaging, storage or transport are to be borne by the party that caused them.
When the system stands still for more than one month, the fan must be turned once a month to prevent damage to
the bearings.

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3910831 Subject to changes in keeping with technical developments!
2.6 Duties of the operating company
The operator of the AL-KO products must regularly train his staff with regard to the following:
Adherence to and use of the operating and installation instructions as well as the legal regulations.
Appropriate operation of the air heater / air cooler.
Adhere to the instructions of the company security and the operating instructions of the operating company as re-
quired.
Conduct in emergencies
2.7 Disposal of the packaging
Disposal of the packaging must be performed according to the currently valid, local environmental and
recycling regulations of your country and your municipality.
"Safety information"

Translation from the original operating instruction8
AL-KO air heater / air cooler DESIGN
3. Product description
AL-KO air heaters / air coolers of the DESIGN series have a stable, tted and optically appealing plastic housing. The
materials of the plastic housing are self-extinguishing according to Fire Class V-0 in the event of a re. The inner,
load-bearing construction is made of galvanised steel sheeting. The plastic housing can be completely removed from
the supporting component by using quick fasteners. The integrated support belt prevents the hood from falling down.
Individually adjustable ns are integrated in the upper area and jointly adjustable nds are integrated in the bottom area
of the housing to ensure optimal air ow. A maintenance-free axial fan ensures low-noise operation. The drives of the
AL-KO air heaters / air coolers are external rotor motors. They have a permanently lubricated deep-groove ball bearing
and the fan forms a single unit with the rotor. A heat exchanger for air heating / cooling is installed in the housing next
to the fan. It is made of copper pipes with attached aluminium ns. The air heating/cooling devices can be extended by
various attachment and electronic accessories.
The DESIGN series has been developed for low as well as high rooms.
The device can be used for cooling as well as heating by changing the direction of rotation (change of polarity). This
allows universal application of the DESIGN series.
Fig. Heating of low rooms Fig. Cooling of low rooms
Fig. Heating of high rooms Fig. Cooling of high rooms

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3910831 Subject to changes in keeping with technical developments!
Type key DESIGN:
E D - H 1 - C 2 - 400 - L
Device type
E EuroLine
D DESIGN
Device size
H Heating
K Cooling
1 Design Size 1
2 Design Size 2
3 Design Size 3
Heat exchanger type
C Cu/Al
1 1 row of pipes, distance of ns 2.5 mm
2 2 rows of pipes, distance of ns 2.5 mm
3 3 rows of pipes, distance of ns 2.5 mm
Motor version
400 400 V
Supplementary text for additional options
O without control
L level 4 control
"Product description"

Translation from the original operating instruction10
AL-KO air heater / air cooler DESIGN
3.1 Declaration of incorporation