Kampmann KaCool D 1 User manual

KaCool D
Ceiling Cassette
Installation and Operating Instructions
Keep these instructions in a safe place for future use!
I 500/01/17 GB | SAP-Nr. 1216770

Kampmann.co.uk/KaCool-D
Kampmann GmbH
Friedrich-Ebert-Str. 128 - 130
49811 Lingen (Ems)
Germany
T+49 591 7108-660
F+49 591 7108-173
E[email protected]
WKampmann.eu

3KaCool D02.02.2017
Table of Contents
1 General ................................................................................ 5
1.1 About these Instructions ........................................ 5
1.2 Explanation of Symbols .......................................... 5
1.3 Copyright ................................................................. 6
1.4 Customer Service ..................................................... 6
2 Safety .................................................................................. 7
2.1 Intended Use ........................................................... 7
2.2 Fundamental Dangers ............................................ 8
2.2.1 Dangers due to Electrical Energy ........................... 9
2.3 Responsibility of the Operator ............................... 9
2.4 Training ................................................................. 10
2.5 Personnel Requirements ....................................... 10
2.5.1 Qualifications ........................................................ 10
2.6 Personal Protective Equipment .............................11
3 Technical Data ........................... ..... ...................................12
3.1 Main Dimensions .............................. .................... 12
3.2 Connection Dimensions ........................................ 13
3.3 Weights .............................. ................................... 14
3.4 Connected Loads ................................................... 14
3.5 Operating Data ..................................................... 15
3.6 Specification Plates ............................................... 16
3.6.1 Specification Plate for Basic Unit ..........................16
3.6.2 Specification Plate with Control Configuration
KaControl ...................................... ........................16
3.7 Spare Parts List ................................. .....................17
4 Design and Function ......................................................... 18
4.1 Overview ................................................................ 18
4.2 Short Description ................................................. . 20
4.3 Accessories ............................................................. 21
5 Transport, Packaging and Storage ................................... 23
5.1 Safety Instructions for Transport ................ ......... 23
5.2 Packages ................................................................ 24
5.3 Transport Inspection ..............................................25
5.4 Packaging .............................................................. 25
5.5 Storage ................................................................ .. 26
Inhaltsverzeichnis

KaCool D 02.02.20174
Table of Contents
6 Installation and Connection ............................................. 27
6.1 Requirements at the Installation Site .................. 27
6.2 Inspection Openings with a Sealed Ceiling ......... 27
6.3 Wiring .................................................................... 35
6.4 Control Overview .................................................. 36
7 Operation and Commissioning ........................................ 51
7.1 Pre-commissioning Checks ................................... 51
7.2 Venting the Heat Exchanger ................................ 52
7.3 Switching on the Unit .......................................... 52
8 Maintenance ..................................................................... 53
8.1 Preventing the Unit from being Switched on
Again ........................ ............................................. 53
8.2 Maintenance Schedule ......................................... 54
8.3 Maintenance Work ............................................... 55
8.3.1 Cleaning the Filter ................................................ 56
8.3.2 Cleaning the Unit ................................................. 57
9 Faults ................................................................................ 58
9.1 Fault Display ......................................................... 58
9.2 Fault Table ............................................................ 59
10 Dismantling and Disposal ................................................ 60
10.1 Safety Instructions for Dismantling and
Disposal ................................................................ 60
10.2 Dismantling............................................................ 60
10.3 Disposal .................................................................. 61
11 Declaration of Conformity ................................................. 62

5KaCool D02.02.2017
1 General
1.1 About these Instructions
These instructions allow the safe and efficient handling of the
unit. The instructions are part of the unit and must be stored in
its immediate vicinity and be accessible to the personnel at all
times.
The personnel must have carefully read and understood these
instructions before commencing any work. Compliance with
all the safety instructions and handling instructions in these
instructions is a fundamental requirement for working safely.
Furthermore, the local accident prevention regulations
and general safety conditions for the application are also
applicable.
Illustrations in these instructions are intended to facilitate basic
understanding and may deviate from the actual design.
1.2 Explanation of Symbols
Information
General
Explanation of symbols
DANGER!
This combination of symbol and signal word
indicates an imminently dangerous situation
that will lead to death or serious injuries
if not avoided.
This symbol highlights tips and recommendations
as well as information for the efficient and
trouble-free operation of the unit.
NOTE!
This combination of symbol and signal word
indicates a potentially dangerous situation
that may lead to property and environmental
damage if not avoided.

KaCool D 02.02.20176
General
Customer service
Additional markings The following markings are used in these instructions to
highlight handling instructions, results, lists, references and
other elements.
1.3 Copyright
The contents of these instructions are protected by copyright.
It is permitted to use them for operating the unit. Any other
use is not permitted without the written consent of the
manufacturer.
1.4 Customer Service
Our Customer Service team is on hand to provide technical
information:
We are also always interested in information and experiences
resulting from the use of the unit and that may be valuable for
the improvement of our products.
Marking Explanation
Step-by-step handling instructions
Results of action taken
References to sections of these instructions
and other applicable documents
Lists without a specified sequence
[Button] Operating controls (e.g. button, switch),
Display elements (e.g. indicator lights)
"Display" Screen elements (e.g. buttons,
assignment of function keys)
Address
Kampmann GmbH
Friedrich-Ebert-Str. 128–130
49811 Lingen (Ems)
Phone [phone]
Fax [phone]
Email [email protected]
Website www.kampmann.de

7KaCool D02.02.2017
Safety
Intended Use
2 Safety
This section gives an overview of all important safety
information for the protection of individuals as well as for the
safe and trouble-free operation of the unit. Other task-related
safety instructions are indicated in the sections about the
individual life cycles.
2.1 Intended Use
Correct and proper use is also deemed to include observing all
the information in these instructions.
Any use over and above the intended use or any other use is
deemed to be misuse.
The units are exclusively designed for the heating and
cooling of air in dry, frost-free rooms. The unit must be
connected to the on-site heating / cooling / ventilation
system in the room to be heated as well as the sewage
system and power supply on site.

KaCool D 02.02.20178
2.2 Fundamental Dangers
The following section lists the residual risks that may occur
even when the unit is used as intended.
Please observe the safety instructions shown here and in the
following sections of these instructions to reduce the risk of
personal injuries and property damage and to avoid dangerous
situations.
Safety
Fundamental dangers
WARNING!
Danger due to misuse!
Never operate the unit in humid areas, such as
swimming pools, in wet rooms, etc.
Never operate the unit in areas with a
potentially explosive atmosphere.
Never operate the unit in areas with a high dust
content.
Never operate the unit in areas containing high
temperature gases.
Never operate the unit in an aggressive or
corrosive atmosphere (such as sea air).
Never operate the unit above electrical
equipment (such as switch cabinets, computers
or other electrical equipment or contacts
that are not drip-proof).
Never operate the unit outdoors.
Keep windows closed whilst operating
the unit.
Only operate the unit in its entirety and when
connected to the supply networks (waste water,
heating/cooling, electricity).
Never operate the unit outside its technical
specifications ( Chapter 3 "Technical Data" on
page 12).
Install away from radiators or other heating
appliances.
The air flow must be able to circulate freely.
Do not place any objects on the unit.
Do not cover the unit.
Always observe the requirements at the
installation site ( Chapter 6.1 "Requirements at
the Installation site" on page 27).

9KaCool D02.02.2017
Safety
Responsibility of the operator
2.2.1 Dangers due to Electrical Energy
Electric current
2.3 Responsibility of the Operator
Obligations of the operator
Use the unit in the commercial sector. The operator of the
unit therefore subject to the legal obligations regarding
occupational health and safety.
The applicable safety, occupational safety and environmental
regulations for the application must also be observed in
addition to the safety guidelines in these instructions.
The following applies in particular:
The operator must know about the applicable occupational
safety regulations and use a risk assessment to determine
additional hazards that arise from the special working
conditions at the location in which the unit is used. He must
implement this in the form of operating instructions for the
operation of the unit. The operator must clearly regulate
and specify
the responsibilities for installation, operation,
troubleshooting, maintenance and cleaning. The operator
must ensure that
all people handling the unit have read and understood
these instructions. In addition, he must train the personnel
at regular intervals and inform them about the dangers. The
operator must provide
the necessary protective equipment to the personnel
carrying out maintenance and repair work and advise
them that it is mandatory to wear the necessary protective
equipment.
DANGER!
Mortal danger from electric current!
Contact with live parts
may result in immediate mortal danger by electric
shock. Damage to the insulation or individual
components may endanger life.
Work on electrical equipment may only be
carried out by qualified electricians.
In case of damage to the insulation, switch off
the power supply immediately and arrange for
repairs to be carried out.
Keep moisture away from live parts. This may
cause a short circuit.
Ground the unit properly.

KaCool D 02.02.201710
Safety
Personnel requirements
In addition, the operator is responsible for ensuring that the
unit is always in a perfect technical condition.
The following therefore applies:
The operator must ensure that the maintenance intervals
described in these instructions are observed.
Hygiene requirements The operator must observe the guidelines regarding hygiene
requirements in accordance with the standards and directives
applicable at the location in which the unit is used. These
include the following, amongst others:
Observing
the hygienic separation of fresh and waste water,
the appropriate maintenance and inspection intervals,
the guidelines for air ducts and air passages,
the specified filter grades.
2.4 Training
The manufacturer offers training to users. Please refer to
Chapter 1.4 "Customer Service" on page 6 for contact details.
2.5 Personnel Requirements
2.5.1 Qualifications
Only people who are expected to perform their work reliably
are allowed. People whose reactions are influenced, for
example, by drugs, alcohol or medication are not allowed.
Qualified electrician
A qualified electrician is specifically trained for the working
environment in which they operate and are familiar with the
relevant standards and regulations.
Installation personnel
The installation personnel have the technical skills and
experience as well as knowledge of the relevant provisions to
carry out the tasks assigned to them and to recognise possible
dangers themselves as a result of their training. The installation
personnel have all the necessary equipment and tools.
Caretaker/user
The caretaker/user have been trained by the manufacturer in
the tasks assigned to them and advised about possible dangers
in case of improper conduct. The caretaker/user may only carry
out tasks over and above operation of the unit in normal mode
if this is specified in these instructions.

11KaCool D02.02.2017
Safety
Personal protective equipment
2.6 Personal Protective Equipment
Personal protective equipment is used to protect individuals
from safety hazards and health risks at work. The accident
prevention regulations applicable at the location in which the
unit is operated always apply.
If necessary, the personnel must wear the personal protective
equipment referred to separately in the individual sections of
these instructions whilst carrying out maintenance and repair
work on and with the unit.

KaCool D 02.02.201712
Technical Data
Main dimensions
3 Technical Data
3.1 Main Dimensions
Front view
Top view
Side view
Details
13
4
2-pipe
3Water inlet
4Water outlet
4-pipe
1Hot water inlet
2Hot water outlet
3Cold water inlet
4Cold water outlet
2
Model 1–3 (dimensions in mm)
Unit size Model 1– 3
Condensation connection 1/2"
Connections without valve kit
Water inlet/outlet 2-pipe Inches 3/4"
Water inlet/outlet 4-pipe cooling Inches 3/4"
Water inlet/outlet 4-pipe heating Inches 1/2"
Connections with valve kit
Water inlet/outlet 2-pipe Inches 1"
Water inlet/outlet 4-pipe cooling Inches 1"
Water inlet/outlet 4-pipe heating Inches 3/4"

13KaCool D02.02.2017
Model 4-6 (dimensions in mm)
Unit size Model 4– 6
Condensation connection 1/2"
Connections without valve kit
Water inlet/outlet 2-pipe Inches 3/4"
Water inlet/outlet 4-pipe cooling Inches 3/4"
Water inlet/outlet 4-pipe heating Inches 1/2"
Connections with valve kit
Water inlet/outlet 2-pipe Inches 1"
Water inlet/outlet 4-pipe cooling Inches 1"
Water inlet/outlet 4-pipe heating Inches 3/4"
Front view Side view
Top view Details
2-pipe
3Water inlet
4Water outlet
4-pipe
1Hot water inlet
2Hot water outlet
3Cold water inlet
4Cold water outlet
1
2
3
4

KaCool D 02.02.201714
Technical Data
Operating data
3.2 Weights
3.3 Connected Loads
3.4 Limits of operation and use
Unit size: model 1 model 2– 3 model 4 model 5–6
Heat exchanger, 2-pipe model
Basic unit kg 22 24 36 39
Casing kg 3 3 6 6
Total kg 25 27 42 45
Heat exchanger, 4-pipe model
Basic unit kg 24 24 39 39
Casing kg 3 3 6 6
Total kg 27 27 45 45
Unit size: model 1 model 2 model 3 model 4 model 5 model 6
Mains voltage 230 V / 50 Hz
Protection IP 21
Protection class class 1
AC fan model
Max. power consumption W 56.5 80.5 102.5 89.5 132.5 182.5
Max. current consumption A 0.35 0.45 0.60 0.50 0.65 0.90
EC fan model
Max. power consumption W 28.5 44.0 81.0 43.5 126.0 –
Max. current consumption A 0.25 0.40 0.70 0.40 1.10 –
operating limits
water temperature min./max. °C 5-80
air inlet temperature min./max. °C 15-40
air humidity min./max. % 15-75
operating pressure max. bar 8
max. glycol concentration % 50
water properties
pH*1 8-9
Conductivity*1 μS/cm < 700
Oxygen content (O2) mg/l < 0.1
Hardness °dH 4-8.5
Sulphur ions (S) not detectable
Sodium ions (Na+) mg/l < 100
Iron ions (Fe2+, Fe3+ ) mg/l < 0.1
We would refer to VDI-2035 Sheet1&2, DIN EN 14336 and DIN EN 14868 with regard to the properties
of the medium used to protect the equipment. The following values provide further guidance.
The water used should also be free of suspended matter, dust etc. and any additional substances that
could cause reactions.
Manganese ions (Mn2+ ) mg/l <0,05
Ammonia ions (NH4+) mg/l < 0,1
Chlorine ions (CI) mg/l < 100
CO2ppm < 50
Sulphate ions (SO42-) mg/l < 50
Nitrite ions (NO2-) mg/l < 50
Nitrate ions (NO3-) mg/l < 50

15KaCool D02.02.2017
Technical Data
Operating data
Unit size: model 1 model 2 model 3 model 4 model 5 model 6
AC fans, 2-pipe model
Min./max. cooling output
*1
W 1840 - 2680 2250 - 4330 2940 - 5020 4210 - 6160 5310 - 9510 5310 - 11100
Min./max. heat output
*2
W 1350 - 2040 1570 - 3180 6340 - 11570 9510 - 14620 11300 - 21932 11300 - 26310
Min./max. air volume m³/h 310 - 520 320 - 710 430 - 550 630 - 1140 710 - 1500 710 - 1820
Min./max. sound pressure level
*3
dB(A) 24 - 36 24 - 44 32 - 50 24 - 39 25 - 44 25 - 49
Min./max. sound power level dB(A) 33 - 45 33 - 53 41 - 59 33 - 48 34 - 53 34 - 58
AC fans, 4-pipe model
Min./max. cooling output
*1
W 1850 - 2700 2090 - 3930 2720 - 4530 4140 - 6340 4490 - 8770 4990 - 10200
Min./max. heat output
*2
W 2630 - 3780 1490 - 2950 3310 - 5330 6710 - 10170 7310 - 12400 7310 - 14345
Min./max. air volume m³/h 310 - 520 320 - 710 430 - 880 630 - 1140 710 - 1500 710 - 1820
Min./max. sound pressure level
*3
dB(A) 24 - 36 24 - 44 32 - 50 24 - 39 25 - 44 25 - 49
Min./max. sound power level dB(A) 33 - 45 33 - 53 41 - 59 33 - 48 34 - 53 34 - 58
EC fans, 2-pipe model
Min./max. cooling output
*1
W 1840 - 2750 2240 - 4330 2560 - 5020 4210 - 6330 5290 - 10750 –
Min./max. heat output
*2
W 4150 - 6480 4730 - 9770 5475 - 11570 9510 - 15060 10915 - 23770 –
Min./max. air volume m³/h 310 - 535 310 - 710 360 - 880 630 - 1165 710 - 1770 –
Min./max. sound pressure level
*3
dB(A) 24 - 38 24 - 45 28 - 51 24 - 39 25 - 48 –
Min./max. sound power level dB(A) 33 - 47 33 - 54 37 - 60 33 - 48 34 - 57 –
EC fans, 4-pipe model
Min./max. cooling output
*1
W 1850 - 2770 2090 - 3930 2380 - 4530 4300 - 6510 4980 - 9870 –
Min./max. heat output
*2
W 2760 - 4070 2295 - 3765 2540 - 4220 6970 - 10450 6020 - 10645 –
Min./max. air volume m³/h 310 - 535 310 - 710 360 - 880 630 - 1165 710 - 1770 –
Min./max. sound pressure level
*3
dB(A) 24 - 38 24 - 45 28 - 51 24 - 39 25 - 48 –
Min./max. sound power level dB(A) 33 - 47 33 - 54 37 - 60 33 - 48 34 - 57 –
*1 at CHW 7/12 °C, tL= 27°C, 48% relative humidity
*2 at LPHW 75/65, tL= 20°C
*3 Sound pressure level data for a room size 100m3, reverberation time 0.5 seconds, sound absorption 9 dB(A).
3.5 Operating Data

KaCool D 02.02.201716
3.6.2 Specification Plate with KaControl Control Configuration
The specification plate is also located on the electrical housing
in addition to the unit rating plate.
Technical Data
Specification plate
3.6 Specification Plates
3.6.1 Specification Plate for Basic Unit
The specification plate is located on the electrical housing of
the basic unit and contains the following information:
Type
Nominal voltage
Nominal power
Article number
Serial number
Year and month of manufacture
Manufacturer
CE mark
Fig. 7: Sample specification plate

17KaCool D02.02.2017
Technical Data
Spare parts list
Unit size: model 1 model 2 model 3 model 4 model 5 model 6
Air intake filter 003251173061 003251173062
Plastic casing, only middle section 003251173063 003251173064
Air outlet louvre (1 no.) 003251173065 003251173066
Plastic lock for casing, left 003251181302
Plastic lock for casing, right 003251181305
Fan impeller 003251173010 003251173011
Polystyrene condensation tray 003251173034 003251173035
Condensation tray for valves 003251173036
Float switch for condensation pump 003251173037
Condensation pump 003251173036
Mounting bracket/fixing for cassette
4 no.
003251173059
AC fan model
Fan motor 003251172596 003251172598 003251172996
Condenser 003251173048 003251173049 003251173050
Transformer 003251173045 003251173046 003251173046
Electronics (not infra-red remote control) 003251173041
Electronics (infra-red remote control) 003251173042
EC fan model
Fan motor 003251172998 3003251172999 –
Speed PCB 003251173051 003251173052 003251173053 003251173054 3251173055 –
Electronics (not infra-red remote control) 003251173043
Electronics (infra-red remote control) 003251173044
3.7 Spare Parts List

KaCool D 02.02.201718
Design and Function
Overview
4 Design and Function
4.1 Overview
1
2
4
5
3
Punched opening
for optional
fresh air connection
Punched opening for
external air outlet
Compact basic housing
Stylish casing
Electrical control
box
3
9
5
10
Features
1
11
Specification plate and
serial number

19KaCool D02.02.2017
Design and Function
Overview
6Air outlet
8Air intake grille
7Air filter
1Punched opening for optional
fresh air connection:
For 20 % fresh air at medium
fan speed (Fig. including
fresh air spigot)
2Punched opening for external
air outlet:
Connection option for
on-site air outlets
3Electrical control box for
Control PCBs:
KaControl
Infra-red electronic receiver
Terminals only
4Compact basic housing:
Made of galvanised sheet steel
The outside has a fleece coating
for improved insulation from the
environment
The inside has high-grade
10 mm vapour diffusion-tight
polyethylene foam matting
5Stylish casing similar to RAL
9003 (signal white):
Dimensions coordinated to
acoustic ceiling grids (with
model 4–6, the casing and the
unit can be centred within four
fields)
6Air outlet:
Four manually adjustable
outlet air louvres
made of smooth plastic
Easy to clean
7Air filter:
Simple to remove
Easy to clean
8Air intake grille:
Large free cross-section
to minimise pressure losses
9Hydraulic connections:
For CHW, LPHW and drainage
of condensation Valve drip tray
drains
any condensation produced into
the condensation tray
Drip tray is supplied with the unit
10 Condensation pump and
float switch:
Easily accessible by removal of
the polystyrene condensation
tray Integrated condensation
pump
drains the condensation up to a
max. head of 650 mm
Pump activation by a two-stage
float switch
The pump is switched on when
the first stage is reached and the
second stage activates an
evaluable alarm contact
11 Fans:
3-stage AC fans
Infinitely adjustable EC fans
Vibration-damped mounting
Direct-driven, backward-curved
impeller
Efficient and low-noise
Protection class IP 44, insulation
class B
Integrated thermal contacts to
prevent the motor from
overheating
12 Heat exchanger:
Made of copper pipe with
aluminium fins
2 / 4 pipe configuration
Vent and drain valves on the
outside of the unit
Max. operating pressure: 8 bar

KaCool D 02.02.201720
Design and Function
Short Description
4.2 Short Description
The KaCool D is a decentralised unit for heating, cooling and
filtering air in hotels, offices and conference rooms, amongst
other places. Users can set a comfortable temperature for
themselves thanks to the effective and extremely quietly
operated fan.
Operating mode The secondary air is drawn in to the middle section of the
casing. The air initially passes through the air intake grille to
the filter. This removes dust, for example, from the secondary
air and therefore protects the following components from
contamination. The air is drawn out by the filter and forced
through the copper/aluminium heat exchanger. The air is
cooIed or heated in the exchanger depending on the
temperature at which the medium flows through the heat
exchanger.
The air passes through the outlet air slats into the room. The
outlet air slats can be manually adjusted depending on the
desired air direction.
Condensation may be produced on the heat exchanger when
cooling with low water temperatures. This drips onto the heat
exchanger and falls into the condensation tray underneath.
The condensation accumulates in one corner. A float switch
monitors the condensation level. The condensation pump is
activated when a a certain level is exceeded. A condensation
warning is issued if an even higher level is exceeded.
Valve kits, available as accessories, can be connected to the side
of the unit. The units are supplied with condensation trays that
can be installed below the valve kits. The condensation is
routed and drained through a prepared opening into the
condensation tray of the unit.