AL-KO HYDROOPT M User manual

TRANSLATION OF THE ORIGINAL INSTALLATION AND OPERATING INSTRUCTIONS
HYDROOPT M ®
CENTRAL VENTILATION AND AIR CONDITIONING UNITS
EN

Translation of the original installation and operating instructions
2
AL-KO HYDROOPT®
Legal
AL-KO THERM GmbH
Hauptstraße 248 - 250
89343 Jettingen-Scheppach
Germany
Telephone: [phone] - 0
Fax: [phone] - 2113
E-mail: [email protected]
Revision history
Version Description Date
1.0 Initial release 27/04/2020

Subject to changes in line with technical progress. 3
3061955
Table of contents
1 Product description ........................................................................................4
1.1 Intended use...............................................................................................................................................5
1.2 Possible misuse .........................................................................................................................................5
1.3 Residual dangers........................................................................................................................................5
1.4 Explanation of symbols ..............................................................................................................................5
1.5 Description of various application areas and versions................................................................................6
1.5.1 Station structure (example)........................................................................................................................6
1.5.2 Technical data............................................................................................................................................. 6
1.5.3 Schematic with one exhaust air device (example) ......................................................................................8
1.5.4 Schematic with one exhaust air device and feed option (example).............................................................9
1.6 Delivery ....................................................................................................................................................10
1.7 Transport and storage ..............................................................................................................................10
1.8 Owner's obligations..................................................................................................................................10
1.9 Disposal of the packaging.........................................................................................................................10
2 Installation ................................................................................................ 11
2.1 General information..................................................................................................................................11
2.2 Setup........................................................................................................................................................11
2.3 Filling and venting ....................................................................................................................................12
2.4 Electrical connection.................................................................................................................................12
2.4.1 Cabling to the customer's control technology ..........................................................................................12
2.4.2 Bus model assembly (option)...................................................................................................................13
3 Commissioning........................................................................................... 14
3.1 General information..................................................................................................................................14
3.2 Requirements ...........................................................................................................................................14
3.3 Procedure for commissioning ..................................................................................................................14
3.4 Control-oriented integration of the HYDROOPT M®in the customer's instrument and control facilities ..15
4 Operation.................................................................................................. 16
4.1 Operating unit...........................................................................................................................................16
4.2 Alarm message/Warning message ...........................................................................................................16
4.3 Display menu............................................................................................................................................17
4.4 Main menu (Info key) ...............................................................................................................................19
4.4.1 Password menu........................................................................................................................................19
4.4.2 Settings ....................................................................................................................................................20
4.4.3 Commissioning menu...............................................................................................................................20
4.4.4 System information ..................................................................................................................................21
4.4.5 System integrator.....................................................................................................................................21
4.5 Further operating options .........................................................................................................................26
4.5.1 HMI Web ..................................................................................................................................................26
4.5.2 System graphic (optional) ........................................................................................................................28
5 Warnings, faults and emergencies.................................................................... 29
6 Maintenance .............................................................................................. 30
6.1 Maintenance schedule ..............................................................................................................................31
7 Shut-down................................................................................................. 33
7.1 Decommissioning.....................................................................................................................................33
7.2 Dismantling ..............................................................................................................................................33
7.3 Disposal....................................................................................................................................................33
8 Appendix................................................................................................... 34
8.1 Commissioning list...................................................................................................................................34
Table of contents

Translation of the original installation and operating instructions
4
AL-KO HYDROOPT®
1 Product description
The hydraulic station is used for highly efcient heat and cold recovery in closed-cycle systems.
In winter, heat is extracted from the exhaust air ow from an exhaust air unit and transferred to a heat exchanger in the
central supply air unit.
The integrated controller monitors the operating conditions and regulates the optimum brine circulation amount. Frost
on the exhaust air heat exchanger and freezing of an optional heat feed are prevented by the control system.
Power control is achieved by a frequency-controlled pump and a power regulating valve.
The brine circulation amount is continuously recorded and can be used together with the temperature measurement for
heat quantity metering.
The decision whether heat recovery is possible and how much heat should be recovered must be made by a higher-level
building control technology.
Together with the building control technology, the station thus makes a signicant contribution to saving energy and
reducing operating costs.
Optional components for extended use are:
Plate heat exchanger for heat feed
Plate heat exchanger for cold feed
Redundancy pump for increased operational safety
Warnings and faults are displayed and forwarded via potential-free contacts.
The control system can be easily integrated into higher-level systems via permanently congured bus systems: Modbus,
Bacnet/TCP-IP are available.
Our products are subject to continuous quality control, and comply with the applicable regulations.

Subject to changes in line with technical progress. 5
3061955
Product description
1.1 Intended use
These devices are used exclusively for heat recovery from the exhaust air ow of a central ventilation unit. It may only be
operated within a pressure range of 4–6bar. Deviating operating areas must be agreed with the manufacturer.
1.2 Possible misuse
HYDROOPT M® may only be operated within the scope of the technical data specied by AL-KO. Any other use or use
beyond that described in the "intended use" point is regarded as not in accordance with the designated use. The manu-
facturer cannot be held liable for damage resulting from this.
1.3 Residual dangers
The system may present a danger if it is not operated by trained personnel and/or is not used according to its designated
use.
Residual dangers are potential dangers that are not obviously apparent, such as:
Injury caused by non-observance of the safety instructions
Injury caused by uncoordinated work
Danger caused by working on the electrical system, cables and connections
Please use suitable personal protective equipment such as gloves and safety shoes when working on the device.
1.4 Explanation of symbols
Warning!
This symbol indicates safety measures that must be complied with in order to avoid injury to personnel.
Important!
This symbol indicates safety measures that must be observed under all circumstances to avoid damage to
property.
Special instructions for ease of understanding and handling.

Translation of the original installation and operating instructions
6
AL-KO HYDROOPT®
1.5 Description of various application areas and versions
1.5.1 Station structure (example)
Traggestell
Schaltschrank
Durchflussmesser
Frequenzumrichter
Temperatursensor
Vorlauf
Manometer
Füllen / Entleeren
Wanne
Pum
p
e
Niveauaus
g
leich
Manometer / elektrische
Systemüberwachung
Schmutzfänger
Leistungsregelventil
Frostschutzventil
(Option)
Temperatursensor
Rücklauf
vom Ablufttauscher
zum Ablufttauscher
vom Zulufttauscher
zum Zulufttauscher
1.5.2 Technical data
The station is available in 5 sizes depending on the required quantity of brine being circulated:
(see drawing)
System pressure: 4 to 6bar
Supply voltage: 3Ph/400V/50Hz
Fuse, max.: 20A slow blow
The maximum customer-side back-up fuse is specied on the enclosed circuit diagram.
The exact dimensioning of the pump and the calculation of the necessary system pressure is carried out by AL-KO
THERM after the order is placed.
from the supply air exchanger
to the supply air exchanger
Supporting frame
Switch cabinet
Flowmeter
Frequency converter
(second frequency converter,
optional)
Pressure gauge
Flow temperature sensor
Fill/Empty
Tray
Level compensation
Pump
(second pump, optional)
Pressure gauge/electrical system
monitoring
Power control valve
Frost valve
Dirt trap
Return temperature
sensor
from the exhaust air exchanger
to the exhaust air exchanger

Subject to changes in line with technical progress. 7
3061955
Product description
Dimensions:
Breite Länge
Höhe
Compact control units
Type Dimension Flow ratem3/h Lengthmm Widthmm Heightmm Weightkg
2 DN 32 0.5–1.9 1330 695 1680 170
5 DN 40 2.0–4.9 1330 695 1680 178
10 DN 50 5.0–9.9 1330 695 1680 205
15 DN 65 10.0–14.9 1630 895 1880 307
25 DN 80 15.0–25.0 1630 895 1880 380
Weight varies depending on equipment and pump size.
Width Length
Height

Translation of the original installation and operating instructions
8
AL-KO HYDROOPT®
1.5.3 Schematic with one exhaust air device (example)
M
I
D
P
K
P
P
T
AL-KO -HYDRO-OPT
1
2
35
6
9
7
8
710
11
12
13
4
T11
Mains supply 400V/50Hz 20A
Input for ext. release
HRO demand (0–10V)
Heat-up mode demand (disconnect all exhaust air exchangers)
Operating feedback message (digital out)
Error alarm A
Error alarm B
OPTIONAL bus connection
1 Switch cabinet 9 Expansion tank installation on the intake side
2 Frequency converter 10 Flowmeter
3 Dirt trap 11 Temperature sensor
4 Power control valve 12 Frost valve
5Safety valve 6bar 13 Eff. pressure fan differential pressure sensor
6 Filling connection
7 Pressure gauge
8 Pressure monitor

Subject to changes in line with technical progress. 9
3061955
Product description
1.5.4 Schematic with one exhaust air device and feed option (example)
M
I
D
P
K
P
P
T
AL-KO -HYDRO-OPT
T
1
2
35
6
9
7
8
710
11
T11
11
12
14
15
13
4
Mains supply 400V/50Hz 20A
Input for ext. release
HRO demand (0–10V)
Heat-up mode demand (disconnect all exhaust air exchangers)
Operating feedback message (digital out)
Error alarm A
Error alarm B
OPTIONAL bus connection
1 Switch cabinet 9 Expansion tank installation on the intake side
2 Frequency converter 10 Flowmeter
3 Dirt trap 11 Temperature sensor
4 Power control valve 12 Frost valve
5Safety valve 6bar 13 Eff. pressure fan differential pressure sensor
6 Filling connection 14 Plate heat exchanger, heat feed
7 Pressure gauge 15 Plate heat exchanger, cold feed
8 Pressure monitor

Translation of the original installation and operating instructions
10
AL-KO HYDROOPT®
1.6 Delivery
The station is delivered on a one-way pallet.
1.7 Transport and storage
Transport within the building can be performed by a lift truck or a forklift. The forks can be inserted under the cross
proles of the supporting frame.
Note that the position of the centre of gravity is not exactly central.
The HYDROOPT M®station must be transported upright and secured against tipping over.
Suitable fork lengths must be used to prevent damaging the device.
Use suitable intermediate layer pads to avoid damage to the paint.
The station must be stored in a dry location, protected against the weather. The functional units must be protected
against debris (e.g swarf, stones, wires, etc.) and strong UV exposure. The HYDROOPT M®station is delivered un-
lled and thus frost-proof.
When transporting under difcult conditions (e.g. on open vehicles, under unusual vibrational stresses, transport
by sea or in tropical/subtropical countries), additional packaging must be used that will protect against these par-
ticular inuences.
Constant and, above all, abrupt temperature changes must be prevented during storage. This is especially harmful
if moisture is able to form condensation.
Damage that results from improper packaging, storage, and transport are at the expense of the person responsible.
No personnel may be in the transport area.
All relevant provisions related to occupational safety and environmental protection must be followed during trans-
port.
Sufcient visibility must be maintained during transport.
When using transport devices requiring a driving licence, ensure that the personnel has a valid driving licence.
The HYDROOPT M® station may only be transported by properly trained and qualied personnel who are also famil-
iar with the information in the "Safety" section.
1.8 Owner's obligations
The owner of AL-KO THERM products must regularly train its personnel in the following subjects:
Compliance with and use of the installation and operating instructions as well as statutory regulations.
Intended use of the HYDROOPT M®
If necessary, comply with the instructions for plant protection and the owner's company instructions.
What to do in an emergency.
1.9 Disposal of the packaging
When disposing of the packaging, comply with the relevant local environmental and recycling regulations in your country
and community that are applicable at the time when the activity is undertaken.