AL-KO AT4F Series Product guide

CENTRAL VENTILATION AND AIR HANDLING UNITS
OPERATING AND ASSEMBLY INSTRUCTIONS
FOR CENTRAL VENTILATION UNITS
AT4F ATEX SERIES
EN

Translation of original operating instructions
2
AL-KO AT4F ATEX
Legal
AL-KO THERM GMBH
Hauptstraße 248 - 250
D-89343 Jettingen-Scheppach
Germany
Fon: [phone] - 0
Fax: [phone] - 2113
E-mail: [email protected]
Revision history
Version Description Date
1.0 3082439/July 2015 July 2015
2.0 3082439/December 2021 December 2021

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Table of contents
1 About this manual..........................................................................................7
1.1 Explanation of symbols ..............................................................................................................................7
1.1.1 Safety instructions......................................................................................................................................7
1.2 Safety signs................................................................................................................................................8
1.2.1 Abbreviations............................................................................................................................................10
1.3 Legal notices ............................................................................................................................................10
2 Safety instructions ....................................................................................... 11
2.1 Intended use.............................................................................................................................................11
2.2 Foreseeable misuse ..................................................................................................................................12
2.3 General safety instructions .......................................................................................................................12
2.3.1 ATEX warnings .........................................................................................................................................15
2.3.2 Safety instruction for unit installation.......................................................................................................15
2.3.3 Safety instructions for operation ..............................................................................................................16
2.3.4 Safety instructions for maintenance .........................................................................................................16
2.3.5 Personal safety instructions .....................................................................................................................16
2.4 Residual dangers......................................................................................................................................17
2.5 Training ....................................................................................................................................................17
3 Product description ...................................................................................... 18
3.1 Functional description ..............................................................................................................................19
3.2 Technical data...........................................................................................................................................19
3.2.1 Area for on-site connections/bushings.....................................................................................................20
3.3 Sample AT4F ATEX type plates .................................................................................................................21
3.3.1 ATEX type plate.........................................................................................................................................21
3.3.1.1 ATEX type plate gas..................................................................................................................................22
3.3.1.2 ATEX type plate dust.................................................................................................................................24
4 Delivery, transport, storage ............................................................................ 26
4.1 Delivery ....................................................................................................................................................26
4.2 Transport ..................................................................................................................................................26
4.2.1 Transport under challenging conditions ...................................................................................................27
4.2.2 Fork-lift truck/pallet truck .........................................................................................................................27
4.2.3 Crane transport.........................................................................................................................................28
4.2.3.1 Crane transport using transport tube........................................................................................................28
4.2.3.2 Crane transport using shackle ..................................................................................................................30
4.2.3.3 Crane transport using a base frame bracket .............................................................................................30
4.2.3.4 Crane transport using crane eyelets .........................................................................................................32
4.3 Storage prior to assembly ........................................................................................................................32
4.4 Disposal of packaging ..............................................................................................................................33
5 Assembly .................................................................................................. 34
5.1 Safety instructions for assembly ..............................................................................................................34
5.2 Preparations .............................................................................................................................................35
5.2.1 Space requirements..................................................................................................................................38
5.2.2 Foundation................................................................................................................................................38
5.3 Assembly of separated housing................................................................................................................39
5.3.1 Housing separation point seal for indoor installation................................................................................40
5.3.2 Housing separation point sealing for outdoor installation (weather-proof)...............................................40
5.3.3 Inside unit connections with split housing ...............................................................................................41
5.4 Unit connection with unit arrangement one above the other and next to one another ..............................42
5.4.1 Unit arrangement one above the other ....................................................................................................42
Table of contents

Translation of original operating instructions
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AL-KO AT4F ATEX
5.4.2 Unit arrangement next to one another ......................................................................................................44
5.4.2.1 Versionofoor/roofassemblywithunitframeprole .............................................................................44
5.4.2.2 Versionofoor/roofassemblywithoutunitframeprole ........................................................................45
5.5 Outdoor installation ..................................................................................................................................47
5.5.1 Roofframe-oorassemblyversionwithunitframeprole.....................................................................47
5.5.1.1 Roof frame preassembled on-site.............................................................................................................47
5.5.1.2 Factory-mounted base frame....................................................................................................................48
5.5.2 Roofframe-oorassemblyversionwithoutunitframeprole ...............................................................49
5.5.2.1 Roof frame preassembled on-site.............................................................................................................49
5.5.2.2 Factory-mounted base frame....................................................................................................................50
5.5.2.3 Sealing of the unit separation points with solvent welding agent for weatherproof units .........................51
5.5.2.4 Sealing of the unit separation points with hot air welding for weatherproof units ....................................57
5.6 Units with split plate heat exchanger (option) ..........................................................................................58
5.7 Additional installation instructions for hygiene units ................................................................................58
5.8 Heat exchanger connection ......................................................................................................................59
5.8.1 Connection of hot water heater (option)...................................................................................................59
5.8.2 Connection of heater/pumps-cold water air cooler (option) .....................................................................61
5.8.3 Connection of pumps/cold water/air cooler (option) ................................................................................64
5.8.4 Steam register ..........................................................................................................................................66
5.8.5 Circulating coil system CCS (recuperative energy recovery) ....................................................................68
5.8.6 Direct evaporator/condenser ....................................................................................................................69
5.9 Mechanical connection.............................................................................................................................70
5.9.1 Duct connection .......................................................................................................................................70
5.9.2 Intake and exhaust hood (option).............................................................................................................71
5.9.3 Condensate drain connection via siphon ..................................................................................................71
5.9.4 Filling and venting ....................................................................................................................................73
5.10 Electrical connection.................................................................................................................................74
5.10.1 Electric motor...........................................................................................................................................75
5.10.1.1 Connection of three-phase motors ...........................................................................................................76
5.10.1.2 Circuit with frequency converter - wiring examples..................................................................................79
5.10.1.3 Connection of EC fans ..............................................................................................................................80
5.10.2 Connection of electric air heater ...............................................................................................................81
5.10.3 Control (switch cabinet) ...........................................................................................................................82
6 Commissioning........................................................................................... 83
6.1 Principles..................................................................................................................................................83
6.2 Before system start ..................................................................................................................................84
6.2.1 Commissioning of the electric heating coil...............................................................................................87
6.2.2 Commissioning of fans.............................................................................................................................87
6.2.2.1 Commissioning of fans with belt drive .....................................................................................................88
6.2.2.2 Commissioning of fan free-wheel with direct drive...................................................................................89
6.2.2.3 Commissioningofthebuilt-infan(motoroutsidetheairow) ................................................................90
6.2.3 Heat exchanger commissioning................................................................................................................92
6.2.3.1 Commissioning of circulating coil system CCS (recuperative energy recovery) .......................................92
6.3 Switching the installation on/off ...............................................................................................................93
6.4 After system start .....................................................................................................................................93
7 Servicing and maintenance ............................................................................ 94
7.1 Safety instructions for servicing and maintenance ...................................................................................94
7.1.1 Qualicationsofpersonnel .......................................................................................................................96

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7.2 MaintenanceinstructionsinaccordancewithVDI6022andVDMA24186 ..............................................96
7.2.1 InitialandrepeatinspectionsmustonlybeperformedbycategoryAtrainedqualiedstaffaccor-
dingtoVDI6022Sheet1 .........................................................................................................................96
7.2.2 PerformingofhygienechecksduringmaintenancebyCategoryBtrainedmaintenance
personnelinaccordancewithVDI6022Sheet1 ......................................................................................97
7.2.3 Maintenance schedule ..............................................................................................................................97
7.3 Maintaining and cleaning components ...................................................................................................103
7.3.1 Finned heat exchanger............................................................................................................................104
7.3.1.1 Maintenance ...........................................................................................................................................105
7.3.1.2 Cleaning..................................................................................................................................................106
7.3.1.3 Circulating coil system (heat exchanger with pipe circuits) ....................................................................107
7.3.1.4 Steam register ........................................................................................................................................107
7.3.1.5 Evaporator/condenser ............................................................................................................................108
7.3.2 Plate heat exchanger ..............................................................................................................................109
7.3.2.1 Maintenance ...........................................................................................................................................110
7.3.2.2 Cleaning..................................................................................................................................................110
7.3.3 Greasetraplter.....................................................................................................................................111
7.3.4 Dampers.................................................................................................................................................111
7.3.4.1 Maintenance ...........................................................................................................................................112
7.3.4.2 Cleaning..................................................................................................................................................112
7.3.5 Sound absorber......................................................................................................................................112
7.3.5.1 Maintenance ...........................................................................................................................................113
7.3.5.2 Cleaning..................................................................................................................................................113
7.3.6 Droplet eliminator...................................................................................................................................114
7.3.6.1 Maintenance ...........................................................................................................................................115
7.3.6.2 Cleaning..................................................................................................................................................115
7.3.7 Electric motor.........................................................................................................................................116
7.3.7.1 Maintenance ...........................................................................................................................................117
7.3.7.2 Cleaning..................................................................................................................................................117
7.3.8 Fans........................................................................................................................................................117
7.3.8.1 Maintenance ...........................................................................................................................................118
7.3.8.2 Cleaning..................................................................................................................................................118
7.3.8.3 Removing the fan for maintenance purposes .........................................................................................119
7.3.8.4 Fan with belt drive ..................................................................................................................................120
7.3.8.5 EC fan.....................................................................................................................................................120
7.3.8.6 Built-infan(motoroutsidetheairow)..................................................................................................121
7.3.8.7 Fan free-wheel with direct drive..............................................................................................................122
7.3.8.8 Check gap dimension and overlap for fans.............................................................................................124
7.3.8.9 Tightening torques of the screw connections on the fan part.................................................................125
7.3.8.10 Maintenance or inspection of the taper-lock clamping bushes ...............................................................125
7.3.9 Cooling system and heat pump ..............................................................................................................125
7.3.10 Electric air heater....................................................................................................................................126
7.4 Replacing components...........................................................................................................................126
7.4.1 Changingthelter ..................................................................................................................................126
7.4.1.1 Replacingbaglters...............................................................................................................................127
7.4.1.2 Replacetheparticulateairlter ..............................................................................................................129
8 Emergencies and malfunctions ......................................................................130
8.1 Emergency..............................................................................................................................................130
8.2 Help in the event of malfunctions ...........................................................................................................130
8.3 Contact for malfunctions ........................................................................................................................130

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AL-KO AT4F ATEX
9 Shut-down................................................................................................ 131
9.1 Decommissioning...................................................................................................................................131
9.2 Dismantling ............................................................................................................................................131
9.3 Disposal..................................................................................................................................................132
10 Spare parts...............................................................................................133
11 Certications............................................................................................. 134
11.1 EC Declaration of Incorporation conforming to 2006/42/EC...................................................................135
11.2 EU Declaration of Conformity in accordance with 2014/34/EC with gas ATEX marking..........................136
11.3 EU Declaration of Conformity in accordance with 2014/34/EC with dust ATEX marking.........................137

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About this manual
1 About this manual
The German version is the original operating instructions. All further language versions are translations of the orig-
inal operating instructions.
Read these operating and assembly instructions carefully before assembly, commissioning and maintenance. This
is the prerequisite for safe work and trouble-free handling.
Observe the safety instructions and warnings in this documentation and on the product.
This documentation is a permanent part of the described product, and must be handed over to the buyer if the product
is sold.
1.1 Explanation of symbols
1.1.1 Safety instructions
DANGER
This signal word is used to indicate an imminently dangerous situation which, if not avoided,
will result in death or severe injury.
WARNING
This signal word is used to indicate a potentially dangerous situation which, if not avoided,
could result in death or severe injury.
CAUTION
This signal word is used to indicate a potentially dangerous situation which, if not avoided,
could result in minor injury.
ATTENTION
This signal word is used to indicate a potential risk of property damage.
NOTE
Special instructions for ease of understanding and handling.

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AL-KO AT4F ATEX
1.2 Safety signs
Meaning Symbol
GENERAL DANGER SIGNS
If the required safety instructions are not observed, this can lead to death, severe
injuries and severe property damage.
IMPORTANT NOTE
If this notice is not observed, problems can arise with the unit.
OBSERVE THE OPERATING AND ASSEMBLY INSTRUCTIONS
If you do not heed the notices in the operating and assembly instructions, this can
lead to problems with the unit.
INFORMATION
Heeding this information makes working with the machine easier.
Warning sign
Thewarningsignsusedintheseoperatingandassemblyinstructionsdrawattentiontospecichazards.
Meaning Warning sign
Warning of danger of falling
If the required safety instructions are not observed, this can lead to death or
severe injuries due to falling.
Warning of danger of slipping
If the required safety instructions are not observed, this can lead to death or
severe injuries due to slipping.
Warning of electrical voltage
If the required safety instructions are not observed, this can lead to death or
severe injuries due to dangerous electrical voltage.
Warning against suspended loads
If the required safety instructions are not observed, this can lead to death or
severe injuries due to a suspended load.
Warning of falling objects
If the required safety instructions are not observed, this can lead to death or
severe injuries due to falling objects.
Warning of hot surfaces
If the required safety instructions are not observed, this can lead to death or
severe injuries due to hot surfaces.
Warning of danger of crushing
If the required safety instructions are not observed, this can lead to death or
severe injuries due to crushing.

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About this manual
Meaning Warning sign
Warning of sharp objects
If the required safety instructions are not observed, this can lead to death or
severe injuries due to sharp objects.
Warning of hand injuries
If the required safety instructions are not observed, this can lead to death or
severe injuries.
Warning of poisonous substances
If the required safety instructions are not observed, this can lead to death or
severe injuries due to poisonous substances.
Risk of explosion
If the required safety instructions are not observed, this can lead to death, severe
injuries and property damage due to explosive substances (particularly in poten-
tially explosive atmosphere according to the ATEX Directive).
Warning of an explosive atmosphere
If the required safety instructions are not observed, this can lead to death, severe
injuries and property damage due to an explosive atmosphere (particularly in
potentially explosive atmosphere according to the ATEX Directive).
Instruction symbol
The prohibition signs in these operating and assembly instructions draw attention to instructions to be observed.
Meaning Instruction symbol
Wear eye protection
If eye protection is not worn, injuries may be caused to the eyes.
Wear foot protection
If foot protection is not worn, injuries may be caused to the feet.
Wear hand protection
If hand protection is not worn, injuries may be caused to the hands.
Wear head protection
If you do not wear head protection, there is a risk of head injuries.
Wear a mask
If you do not wear respiratory protection, this can lead to poisoning and chemical
burns to the lungs.
Isolate before maintenance or repair
Failure to disconnect the unit from all energy sources before starting maintenance
or repair work can result in serious injuries.

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AL-KO AT4F ATEX
1.2.1 Abbreviations
Abbreviation Meaning
ATEX derived from the French abbreviation for ATmosphères EXplosibles.
EC technology Electronically commutated DC drives technology (brushless DC motor)
EHA Exhaust air
ETA Extract air
Ex Explosion-protected version
FU frequency converter
ODA Outdoor air
PSA Personal protective equipment, such as cut-proof gloves, safety goggles, work gloves, ear protection, safety
helmet, breathing mask
AC unit Air handling unit
SUP Supply air
TA Droplet eliminator
TRGS TechnicalRulesforHazardousSubstances
WRD Heat recovery, diagonal (plate heat exchanger)
WS Water column
1.3 Legal notices
Allspecieddataservesolelytodescribetheproduct.Nostatementonaspeciccharacteristicorsuitabilityforaspe-
cicpurposecanbederivedfromthesedata.Thedatadonotexempttheuserfromhisownjudgementandchecks.

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Safety instructions
2 Safety instructions
2.1 Intended use
The AT4F ATEX unit is intended only for processing and conveying respirable air, i.e. for ventilation and extraction of
rooms and buildings or for maintaining the necessary room climate. The AT4F ATEX unit is suitable for operation in the
temperaturerangefrom-20°Cto+40°C.
Depending on the ATEX marking, the AT4F ATEX units are suitable for use in either ATEX gas or ATEX dust. The range
of application of the AT4F ATEX unit is documented in the design data sheet, on the type plates, the ATEX type plates
and in the EU Declaration of Conformity. Deviating ranges of application must be coordinated with the manufacturer's
plant to avoid impacting the installation's function. Explosion-protected AC units bear an ATEX type plate. This is marked
accordingtotheATEXDirective2014/34/EU.TheseunitsmayonlybeusedinthedeclaredcategoryorintheATEXzone
denedbytheATEXmarking.
Theusualatmosphericconditionswithregardtotheexplosioncharacteristicsoftheatmosphereapply,thesearedened
in the ATEX standards as follows:
Temperaturerange-20°Cto+60°C
Pressure80kPa(0.8bar)to110kPa(1.1bar)
Airwithstandardoxygencontent,normally21%(v/v)
PleasenotetherethattheATEXstandardversionisforthetemperaturerangefrom-20°Cto+40°C.Aunitfortemper-
aturesupto+60°Cisaspecialversionandismarkedaccordingly.
Measures must be taken by the operator to ensure that there is a sufcient safety distance between the medium
temperature and the minimum ignition temperature of the potentially present explosive mixture in accordance with
DINEN1127-1.
For the intended use, the AT4F ATEX unit must be professionally installed and operated as intended. To do this, observe
the"5Assembly"onpage34chapterandotherrelevantinformation.Furthermore,theintendedusealsoincludescom-
pliance with the operating and maintenance conditions listed in these operating and assembly instructions (see chapters
"6Commissioning"onpage83and"7Servicingandmaintenance"onpage94).Theriskisbornesolelybytheuser.
The AT4F ATEX unit is an air handling unit for air conditioning.
Only operate the AT4F ATEX unit when fully assembled.
Setuptheunithorizontally.Otherwisethereisariskthatpuddlesmayform,amongotherthings.
Use only original spare parts.
Children and persons who are not familiar with the AT4F ATEX unit must not use it.
Observetheaccidentpreventionregulations,reprotectionregulations,explosionprotectiondirectiveandtherel-
evant standards.
PersonalprotectiveequipmentconformingtoTRGS727isrequiredforworkontheAT4FATEXunit.

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AL-KO AT4F ATEX
2.2 Foreseeable misuse
TheAT4FATEXunitmayonlybeoperatedwithinthescopeofthetechnicaldataspeciedbyAL-KOTHERM.Anyother
useorusebeyondthatdescribedinsection"2.1Intendeduse"onpage11isregardedasbeingnotinaccordancewith
the intended use. The manufacturer cannot be held liable for damage resulting from this.
Possible misuse includes:
Non-horizontalsetupoftheAT4FATEXunit.
Operationoutsidethedesignspecications,observethedatasheetsoftheunitdesign.
Conveying media with impermissibly high or low temperatures.
Conveying aggressive media or media with a high dust content.
Installation in an environment with aggressive media (e.g. sea air) or heavily dust-containing media (coast).
Installation of a non-permissible joint seal.
Non-compliancewiththestaticlimits(customersupplied).
Installing unsuitable components.
ATEX components with inadmissible ATEX marking.
Use of unit in an unapproved ATEX area.
Incaseofre,usetheunitasasmokeextractionsystem.
Use of the AT4F ATEX unit in conjunction with hybrid mixtures.
The included cover screws are intended exclusively for retention/statics of the cover. The installation of other mate-
rials or mounting clamps, etc. is not permitted.
2.3 General safety instructions
WARNING
Risk of serious injury or death due to working without
personal protective equipment!
Working on the AT4F ATEX unit without personal protective equipment can result in serious
injury or death.
Observe the safety instructions in this operating and assembly instructions.
Use the personal protective equipment when working on the installation.
Use further protective equipment according to the work to be carried out.
PersonalprotectiveequipmentconformingtoTRGS727isrequiredforworkontheAT4F
ATEX unit.
Ensurethatworkon/intheAT4FATEXunittakesplaceduringATEXzonefreedom.

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Safety instructions
WARNING
Risk of serious injuries or death!
Working on/in the AT4FATEX unit can result in serious injury or death.
ThesuppliedunitversionmustbeusedaccordingtothespeciedATEXmarking.Please
refer to the data sheet, the ATEX unit nameplate and the EU Declaration of Conformity for
the AT4F ATEX unit.
Measuresmustbetakenbytheoperatortoensurethatasufcientsafetydistancebetween
media temperature (e.g.: medium of the heat exchanger) and the minimum ignition tem-
peratureofthepotentiallypresentexplosivemixtureinaccordancewithDINEN1127-1.
Ensurethatworkon/intheAT4FATEXunittakesplaceduringATEXzonefreedom.
Only use approved tools and suitable tools.
Only allow assembly, installation, commissioning, repair, maintenance and servicing
worktobecarriedoutbyqualiedstaff.
Disconnect the AT4F ATEX unit from the mains power supply on all poles and secure it to
prevent restart before starting repair or maintenance work.
Integrate weatherproof units into the lightning protection concept when installed out-
doors.
Avoidnakedamesandyingsparks.
Observe the working instructions and these operating and assembly instructions.
Document your work and store the evidence in your documentation.
Work with care.
PersonalprotectiveequipmentconformingtoTRGS727isrequiredforworkontheAT4F
ATEX unit.
Use further protective equipment according to the work to be carried out.
WARNING
Risk of injury due to falling, and falling modules.
When installing the modules or installing them on platforms or on the roof, persons may fall
off and/or modules may fall down.
Only allow assembly, installation, commissioning, repair, maintenance and servicing
worktobecarriedoutbyqualiedstaff.
Observe the assembly instructions in these operating and assembly instructions.
Use only tested ladders, scaffolding or suitable platforms.
Only use suitable lifting equipment.
Only use approved fasteners when assembling the AT4F ATEX unit.
Use the personal protective equipment when working on the installation.

Translation of original operating instructions
14
AL-KO AT4F ATEX
WARNING
Risk of injury and explosion due to unauthorised opening.
Ensurethatworkon/intheAT4FATEXunittakesplaceduringATEXzonefreedom.
Keep the inspection doors/inspection covers closed during operation.
NeveropentheAT4FATEXunitduringoperation.
Open the inspection doors/inspection covers using the relevant tool if necessary.
The inspection covers are integrated into the unit potential; after each release of this con-
nection, it must be restored, checked and documented.
When opening the inspection covers, ensure that they are connected to the unit potential
with a potential equalisation cable. If necessary, disconnect the connection for work on/
in the air handling unit. The integration into the unit potential must be restored, checked
and documented after the work.
Observethehazardwarningsontheinspectiondoors/inspectioncovers.
WARNING
Risk of poisoning and explosion when working with sealants, adhesives and pre-treat-
ment agents.
Ensurethatworkon/intheAT4FATEXunittakesplaceduringATEXzonefreedom.
Do not touch the sealant, adhesive or pre-treatment agent.
Work with care.
Do not swallow the sealant, adhesive or pre-treatment agent.
Ensure that there is adequate ventilation at the workplace.
Observe the safety data sheets and operating procedures in accordance with the Ordi-
nanceonHazardousSubstances.
Use personal protective equipment during all work on the installation.
WARNING
Risk of injury from falling from ladders, scaffolding or work platforms.
Only use suitable and tested ladders, steps, scaffolding and work platforms.
Work with care.
Observethesafetyinstructionsintheseoperatingandassemblyinstructionstoavoidinjuries,res,explosionandother
hazardsduetoimproperuseandimproperoperation of the unit:
The version and construction of the AT4F ATEX unit complies with the standards listed in the EU Declaration of Con-
formityorECDeclarationofIncorporation.Apotentialhazardcanonlybeextensivelyruledoutiftheotherapplicable
standards for the overall system to be completed and installed by the plant manufacturer are adhered to.
If installation is performed contrary to our regulations, and the defect/damage which has occurred is attributable to
impropermodication,processingoranyothertreatment,alldamagecompensationorwarrantyclaimsareruled
out. The orderer must prove that improper installation did not cause the defect which has occurred.
Safety and monitoring equipment must not be removed, bridged or disabled in any other way.
All authorised persons must have read and understood the operating and assembly instructions in full before start-
ing work on the AT4F ATEX unit and must observe them at all times.
To avoid dangers during operation, all of the user's plant, operating and working instructions apply in addition to
these operating and assembly instructions.

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Safety instructions
2.3.1 ATEX warnings
Warning of explosive atmosphere
WARNUNG!
Explosionsgefahr!
Die Anlage kann explosionsfähige Atmosphäre fördern.
Das RLT-Gerät vor dem Öffnen mit Frischluft spülen um eine explosionsfähige
Atmosphäre zu entfernen.
• RLT-Gerät nur öffnen, wenn sichergestelltist, dass keine explosions-
fähige Atmosphäre vorhanden ist!
• Sicherheits- und Wartungshinweise der Betriebsanleitung beachten!
3457846
WARNING!
Danger of explosion!
The installation can promote an explosive atmosphere.
Rinse the AC unit with fresh air before opening to remove an explosive atmos-
phere.
• Only open the AC unit if it has been ensured that no explosive
atmosphere is present!
• Observe the safety and maintenance instructions!
Fig. 1 Warning of explosive atmosphere
The warning notice is located on the air handling unit.
Warning for cleaning work
WARNUNG!
Explosionsgefahr!
Gefahr durch elektrostatische Entladung.
Das Abwischen des RLT-Geräts mit trockenen Tüchern kann zu statischer
Aufladung führen, bei deren Entladung Explosionsgefahr besteht.
• RLT-Gerät nur mit feuchten Tüchern abwischen!
• Sicherheits- und Reinigungshinweise der Betriebsanleitung beachten!
3457845
WARNING!
Danger of explosion!
Danger due to electrostatic discharge.
Wiping the AC unit with dry cloths can lead to static charging, which can result
in an explosion hazard when discharged.
• Wipe the AC unit using damp cloths only!
• Observe the safety and cleaning instructions in the operating instructions!
Fig. 2 Warning of electrostatic discharge
The warning notice is located on the air handling unit. It indicates that the air handling unit must not be cleaned with dry
cloths.
Observe the cleaning instructions in the operating instructions.
2.3.2 Safety instruction for unit installation
The ATEX units must be used according to the ATEX marking on the ATEX type plate, the EU Declaration of Conform-
ity and the technical data sheet. The unit is labelled in accordance with the applicable ATEX directives and standards
andcanbeusedinthedenedpotentiallyexplosiveatmospheres.
Ensure that the ATEX marking is suitable for your ATEX requirements.
Observe the usage limitations.
Observe the applicable standards and directives, in particular the ATEX standards and the ATEX directives 2014/34/
EU and 1999/92/EC.

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16
AL-KO AT4F ATEX
2.3.3 Safety instructions for operation
AT4F ATEX unit must only be operated with completely closed inspection doors/inspection covers.
All components must be integrated into the unit potential.
NounauthorisedpersonsarepermittedtohaveaccesstoAT4FATEXunitduringoperation.
TheAT4FATEXunitmayonlybeoperatedintheperformancerangespeciedintheAL-KOTHERMtechnicaldoc-
uments.
AT4F ATEX unit must be installed properly and used subject to precise observation of our operating and assembly
instructions.
OnlyoperatetheAT4FATEXunitinanapprovedATEXzone.
Only operate the AT4F ATEX unit when it meets your required ATEX requirements.
Ensureasufcientsafetydistancebetweenmediatemperature(e.g.:mediumoftheheatexchanger)andthemini-
mumignitiontemperatureofthepotentiallypresentexplosivemixtureinaccordancewithDINEN1127-1.
Observe the applicable standards and directives, in particular the ATEX standards and the ATEX directives 2014/34/
EU and 1999/92/EC.
OnlyoperateAT4FATEXunitwhenitisfullyassembledandwithcorrectlyttedcontactprotection(optional).
TheAT4FATEXunitmayonlybeoperatedwheninatechnicallyawlesscondition.Malfunctionsanddamagethat
canaffectsafetymustbeimmediatelyandprofessionallyrectied.TheversionandconstructionofAT4FATEXunit
complies with the standards listed in the Declaration of Conformity or Declaration of Incorporation.
Wear personal protective equipment (e.g. ear protection) during operation of AT4F ATEX unit.
2.3.4 Safety instructions for maintenance
Ensurethatworkon/intheAT4FATEXunittakesplaceduringATEXzonefreedom.
Observe the applicable standards and directives, in particular the ATEX standards and the ATEX directives 2014/34/
EU and 1999/92/EC.
Damaged parts are only permitted to be replaced with original spare parts. The spare parts must correspond to the
required ATEX marking.
During repair and maintenance work, AT4F ATEX unit is to be disconnected from the mains on all poles and secured
against restart.
General maintenance instructions in the operating and assembly instructions from AL-KO THERM must be observed
under all circumstances.
Observe the delay time of the fans. Observe a waiting time of at least 3 minutes, until the fan impellers are stationary,
before opening the inspection doors.
Please note that all inspection covers/inspection doors, other housing parts and components are integrated and
components are integrated into the unit potential; after each release of these connections, they must be restored
again. Check the integration into the unit potential and document the function in the on-site documentation.
2.3.5 Personal safety instructions
The AT4F ATEX unit may only be operated by persons who are trained in operating it and expressly authorised to
use it.
PersonalprotectiveequipmentconformingtoTRGS727isrequiredforworkontheAT4FATEXunit.
To avoid dangers during operation, all of the operator's plant, operating and working instructions apply in addition
to these operating and assembly instructions.
The operating and assembly instructions must be kept at a suitable, known place in the workplace.
The operator of AT4F ATEX unit must draw up operating procedures in an understandable form and in the language
of the employees, taking the operating and assembly instructions and the operating conditions into consideration.

Subject to changes in line with technical progress! 17
3468161
Safety instructions
2.4 Residual dangers
The AT4F ATEX unit may present a danger if it is not operated by trained personnel and/or is used improperly or not
according to its intended use.
Residualhazardsarepotential dangers that are not immediately obvious, e.g.:
Injuries due to failure to observe the safety instructions, standards, directives or regulations.
Injuries caused by uncoordinated work.
Danger caused by working on the electrical installation, cables and connections.
Transporting, unpacking and setting up the AT4F ATEX unit; these may result in crushing, cutting, puncture or im-
pact injuries.
Tipping of the AT4F ATEX unit; uneven and loose surfaces promote the AT4F ATEX unit tipping over.
There is a risk of stumbling, slipping, falling and falling down when installing the AT4F ATEX unit and the accessory
parts.
There is a danger of electric shock due to damaged and defective electrical components.
Electrical connection cable: Danger due to stumbling, falling and slipping.
Noise(hearingdamage).
Humanmisconduct:Non-observanceofsafetyinstructions,standardsandregulations.
Operation or transport without suitable safety measures.
2.5 Training
The operator of AT4F ATEX unit must regularly train their personnel on the following topics:
Observance of the operating and assembly instructions as well as the legal regulations.
Intended operation of the AT4F ATEX unit.
Observance of all company, operating and working instructions at the owner’s/operator's installation site.
What to do in an emergency.
CompliancewithVDI6022.
Compliance with ATEX directives and ATEX standards.

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AL-KO AT4F ATEX
3 Product description
Theexacttypedesignationcanbefoundonthetypeplates.Thetypeplatesareusuallyafxedtothehousing.When
ordering spare parts or in case of other queries, please specify the type designation of the AT4F ATEX unit, the year
of manufacture, order number, position and the ATEX marking according to the type plate, see chapter "3.3.1 ATEX
typeplate"onpage21.
TheAT4FATEXunitissuitableforoperationinthetemperaturerangefrom-20°Cto+40°C.
Dependingontherequirements,allknownairhandlingunitsareusedintheAT4FATEXSeriesforltration,heating,
cooling, silencing, heat recovery, (plate heat exchangers or circulating coil systems), etc.
Thecustomer-specicunitversioncanbefoundintherespectivedatasheetsanddrawings.
AT4F ATEX units are available as a weatherproof version or for indoor installation.
ForAT4FATEXunitsofzone2inside/withoutrequirementsoutside,thefollowingpointmustbeobserved,among
others:IfnoATEXzonehasbeendenedintheoutdoorareaoftheAT4FATEXunit,theoperatormustensurethat
the installation room/installation site is adequately ventilated so that no explosive atmosphere can arise due to leaks
during normal operation.
Ingeneral,theinstallationroom/locationmustbesuitablefortheairhandlingunittobeinstalled.DINEN60079-10-1/
DINEN60079-10-2mustbetakenintoaccountintheplanningforthedeterminationofthenecessaryairexchange.
NOTE
Our products are subject to continuous quality control, and comply with the applicable regulations.
EHA
ODA
ETA
SUP
3
1
2
Fig. 3 ATEXzoneson/inanairhandlingunit
1ATEXzoneinsidetheairhandlingunitextractair
2ATEXzoneinsidetheairhandlingunitsupplyair
3ATEXzoneoutsidetheairhandlingunit/attheinstallationsite
Dependingontherequirementsoftheairhandlingunit,oneormoreATEXzonesmaybepresent.Thesecanoccurboth
inside and outside the air handling unit.
Abackowduringstandstilltimesisalwaystobeavoided.Thiscanbeachievedbyon-site,air-tightdampers(DIN1946T4)
in the air lines.

Subject to changes in line with technical progress! 19
3468161
Product description
Units with different ATEX zones:
Forairhandlingunits,theATEXzonesinsidetheunitaswellasoutsidetheunitmustalwaysbeconsidered:
ATEXzoneinside:insidetheunit(medium)
ATEXzonesoutside:outsidetheunit(installationinanATEXzone/zonecarryover)
ATTENTION
The ventilation and extraction of the installation room (technical room) must be considered
and planned on-site.
3.1 Functional description
CentralventilationandairhandlingunitsintheAT4FATEXSeriesarehighlyefcientairhandlingunits.
The AT4F ATEX Series is used in many areas of human air conditioning, industrial applications, chemicals/pharma-
ceuticals, marine, hygiene, swimming pools, recreational facilities and many other sectors, as well as in the mod-
ernisationofoldexistinginstallationsusinghighlyefcient,state-of-the-artheatrecoveryandenergysavingtech-
nologies.
The sound emissions from the AT4F ATEX Series are minimised by an ingenious housing design and an optimised
component layout tailored to the respective, intended use, and through the use of fan and drive units with highly
efcientvibrationisolation.
The internally smooth housing design guarantees easy and fast unit cleaning of the units and compliance with the
hygiene requirements.
On request, the air handling units can also be supplied with control and/or cooling technology, incl. wiring and in-
stallationoftheelddevicesandsensors.
3.2 Technical data
ATTENTION
Read the documentation provided. There information on the technical and electrical data can
be found.

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20
AL-KO AT4F ATEX
3.2.1 Area for on-site connections/bushings
1
1 Exterior view
ATTENTION
Holesforconnections/bushingsmayonlybeinsertedinthecross-hatchedarea.Non-compli-
ance leads to constructional damage to the panel.
Cable glands must be suitable for the required ATEX marking.