Kampmann Lufterhitzer TOP 44 Series Assembly instructions

TOP
► Assembly, installation and operating instructions
Keep these instructions in a safe place for future use!
Issue05/20EN
SAP No.1371885

3
Table of contents
1 General ................................................................................................................................. 6
1.1 About these instructions ......................................................................................................................... 6
1.2 Explanation of Symbols........................................................................................................................... 6
2 Safety.................................................................................................................................... 7
2.1 Correct use.............................................................................................................................................. 7
2.2 Limits of operation and use .................................................................................................................... 8
2.3 Risk from electrocution!.......................................................................................................................... 9
2.4 Personnel requirements - Qualifications ................................................................................................. 10
2.5 Personal Protective Equipment ............................................................................................................... 10
3 Transport, storage and packaging........................................................................................ 11
3.1 General transport instructions ................................................................................................................ 11
3.2 Scope of delivery..................................................................................................................................... 11
3.3 Storage ................................................................................................................................................... 12
3.4 Packaging ............................................................................................................................................... 12
4 Technical data....................................................................................................................... 13
5 Construction and function .................................................................................................... 14
5.1 Overview................................................................................................................................................. 14
5.2 Brief description...................................................................................................................................... 14
5.3 Wear parts list......................................................................................................................................... 14
6 Installation and wiring.......................................................................................................... 15
6.1 Requirements governing the installation site.......................................................................................... 15
6.2 Minimum clearances............................................................................................................................... 15
6.3 Installation.............................................................................................................................................. 15
6.3.1 Installation of sheet steel accessories ....................................................................................................... 16
6.3.2 Suspension points ..................................................................................................................................... 22
6.3.3 Universal 2-point brackets type 30041...................................................................................................... 23
6.3.4 Universal 2-point brackets type 38041...................................................................................................... 23
6.3.5 Universal 4-point brackets type 30042...................................................................................................... 24
6.3.6 Universal 4-point brackets type 38042...................................................................................................... 24
6.3.7 Universal 2-point T-brackets type 30047................................................................................................... 25
6.3.8 Wall brackets, type 3*044, type 3002*..................................................................................................... 25
6.3.9 Ceiling to wall brackets type 3*049 ......................................................................................................... 26
6.3.10 Louvres...................................................................................................................................................... 26
6.4 Installation.............................................................................................................................................. 27
6.4.1 Connection to the pipe network................................................................................................................ 28

4
7 Electrical wiring .................................................................................................................... 29
7.1 Maximum electrical rating values ........................................................................................................... 29
7.2 Electromechanical control type ...58/56/68............................................................................................. 31
7.2.1 Connection (**00) .................................................................................................................................... 31
7.2.2 Cabling TOP (**00), activation via speed controller type 30510............................................................... 33
7.2.3 Cabling TOP (**00), activation via speed controller type 30510 with industrial thermostat type 30058/
30059........................................................................................................................................................
34
7.2.4 Cabling TOP (**00), activation via speed controller type 30510 with room thermostat type 30055 ........ 35
7.2.5 Cabling TOP (**00), activation via speed controller type 30510 with room thermostat type 30056 ........ 36
7.2.6 Cabling TOP (**00), activation via air conditioning controller type 30155, 2-wire valve actuator 230 V
AC, open/closed ........................................................................................................................................
37
7.2.7 Cabling TOP (**00), activation via air conditioning controller type 30256, 2-wire valve actuator 230 V
AC, open/closed ........................................................................................................................................
38
7.2.8 Cabling TOP (*00), activation via speed controller type 30515................................................................. 39
7.2.9 Cabling TOP (**00), activation via DDC/BCT, 2-wire valve actuator 230 V AC, open/closed .................... 40
7.3 KaControl (*C1) ...................................................................................................................................... 41
7.3.1 KaController installation............................................................................................................................ 41
7.3.2 Connection (*C1) ...................................................................................................................................... 42
7.3.3 Cabling TOP (*C1), activation via KaController type 321000x, 2-wire, valve 24 VDC, open/closed .......... 47
7.3.4 Cabling TOP (*C1), activation via KaController type 321000x, 2-wire, valve 24 VDC, open/closed, with
CAN bus card ............................................................................................................................................
48
7.3.5 Cabling TOP (*C1), activation via in situ 0-10 VDC signal ........................................................................ 49
8 Pre-commissioning checks.................................................................................................... 50
9 Operation.............................................................................................................................. 51
9.1 Operation of electromechanical control.................................................................................................. 51
9.2 Operation of the KaController................................................................................................................. 53
9.2.1 Function keys, display elements ................................................................................................................ 53
10 Maintenance ......................................................................................................................... 55
10.1 Securing against reconnection ................................................................................................................ 55
10.2 Maintenance Schedule:........................................................................................................................... 55
10.3 Clean the inside of the unit..................................................................................................................... 56
10.4 Replacing the filter.................................................................................................................................. 57
11 Faults .................................................................................................................................... 58
11.1 Fault table............................................................................................................................................... 59
11.2 Fault table, electromechanical control type ..58/56/68 ........................................................................... 60
11.3 Fault table, KaControl, type ...58C1/ 56C1/ 68C1 ................................................................................... 60
11.4 KaControl faults...................................................................................................................................... 60
11.5 Start-up after rectification of fault .......................................................................................................... 61

5
12 List of KaControl parameters................................................................................................ 62
12.1 TOP parameter list .................................................................................................................................. 62
12.2 KaController parameter list..................................................................................................................... 65
13 Certificates............................................................................................................................ 67
13.1 153_EU-Konformitätserklärung_Lufterhitzer .......................................................................................... 68
13.2 ERP Datenblatt TOP ................................................................................................................................ 70
Table ..................................................................................................................................... 72

TOP
Lufterhitzer mit stufenlosem EC-Wechselstrommotor
Assembly, installation and operating instructions
6
1 General
1.1 About these instructions
These instructions ensure the safe and efficient handling of this equipment. These instructions form an integral part of the
equipment and have to be kept in the direct vicinity of the equipment and available to personnel at all times.
All personnel must have carefully read through these instructions prior to commencing all work on the equipment. A funda-
mental prerequisite for safe working is compliance with all the stated safety instructions and other instructions contained in
this manual.
In addition all local occupational health and safety at work regulations apply, as do general safety provisions governing the
use of the equipment.
Illustrations in this guide are intended to provide a basic understanding and may differ from the actual model.
Ongoing tests and further developments may result in small variations between the unit supplied and the instructions.
1.2 Explanation of Symbols
DANGER!
This combination of symbol and signal word indicates an immediately dangerous situation caused by elec-
trical power, which will cause death or serious injury if not avoided.
WARNING!
This combination of symbol and signal word indicates a possible hazardous situation.
IMPORTANT NOTE!
It represents a potentially hazardous situation, which could lead to damage to property or for a measure to
optimise workflows.
IMPORTANT NOTE!
This symbol highlights useful hints, recommendations and information for efficient and trouble-free opera-
tion.

TOP
Lufterhitzer mit stufenlosem EC-Wechselstrommotor
Assembly, installation and operating instructions
7
2 Safety
This section provides an overview of all important safety aspects to ensure optimum protection of personnel as well as safe
and trouble-free operation. In addition to the safety instructions in these operating instructions, the valid safety, accident pre-
vention and environmental protection regulations must be observed for the area of use of the unit. It is the duty of the oper-
ator to ensure that instructions relating to maintenance (e.g. relating to hygiene) are complied with.
2.1 Correct use
These units are used for the decentralised heating and ventilation of high-ceiling buildings, industrial and commercial work-
places and buildings with a connection to a district heating system or broad temperature spreads. Within the room, the unit
needs to be connected to the building's heating/cooling/ventilation system and to the building's waste water and power net-
work. The operating limits and limits of use described in Chapter 2.2 [}8] must be complied with.
Intended use of the unit also includes adherence to these instructions.
Information in accordance with EN60335-1
This unit can be used by children aged 8 years or more and also by people with reduced physical, sensory or mental cap-
abilities or a lack of experience and knowledge, if they are supervised or have been instructed in the safe use of the unit
and the resulting dangers. Do not allow children to play with the unit. Do not allow children to clean and maintain the
unit without supervision.
This unit is not intended for permanent connection to the drinking water supply system.
This unit is intended for being accessible to the general public.
Any use beyond or other than the stated intended use is considered as misuse.
Any change to the unit or use of non-original spare parts will cause the expiry of the warranty and the manufacturer’s liabil-
ity.

TOP
Lufterhitzer mit stufenlosem EC-Wechselstrommotor
Assembly, installation and operating instructions
8
2.2 Limits of operation and use
Limits of operation
Min./max. water temperature °C 5 - siehe Typenschild
Min./max. air intake temperature °C -20 - (+40)
Min./max. air humidity % 15-75
Min. operating pressure bar/kPa -
Max. operating pressure bar/kPa siehe Typenschild
Min./max. glycol percentage % 25-50
Tab.1: Limits of operation
Maximum flow temperatures
Use Ceiling model Wall-mounted model
Without shut-off valve 100°C 120°C
With shut-off valve 160°C 160°C
Tab.2: Maximum flow temperatures
Operating voltage 230 V/ 50/60 Hz
Power/Current consumption On the type plate
Tab.3: Operating voltage
We would refer to VDI-2035 Sheets 1 & 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 be free of contamination, such as suspended substances and reactive substances.
Water quality
pH value (at 20 °C) 8-9
Conductivity (at 20 °C) μS/cm < 700
Oxygen content (O2) mg/l < 0.1
Hardness °dH 4-8.5
Sulphur ions not measurable
Sodium ions (Na+) mg/l < 100
Iron ions (Fe2+) mg/l < 0.1
Manganese ions (Mn2+) mg/l <0.05
Ammonia ions (NH4+) mg/l < 0.1
Chlorine ions (CI) mg/l < 100
CO2< 50
Sulfate ions (SO4
2-) mg/l < 50
Nitrite ions (NO2-) mg/l < 50
Nitrate ions (NO3-) mg/l < 50
Tab.4: Water quality

TOP
Lufterhitzer mit stufenlosem EC-Wechselstrommotor
Assembly, installation and operating instructions
9
WARNING!
Respect the maximum flow temperatures to protect the EC fan!
Prolonged downtimes can lead to impermissible heating of the EC fan motor if heating media temperatures
are too high. The flow temperatures should therefore be limited depending on the application and the mo-
tor model.
If a temperature limitation is impossible or inappropriate for the purpose concerned, there is also the option
of using suitable valves (thermoelectric, motorised or solenoid) to shut off the heating medium.
This interrupts the flow of heating medium before the EC fan is switched off and the heat exchanger cools
down. Appropriate speed controllers with a fan delay shut-off relay and connection terminals for the motor-
ised valve are available on request.
IMPORTANT NOTE!
Warning of misuse!
In the event of misuse, as itemised below, there is a danger of limited or failing operation of the unit. En-
sure that the airflow can circulate freely.
Never operate the unit in humid areas, such as swimming pools, wet areas etc.
Never operate the unit in rooms with an explosive atmosphere.
Never operate the unit in aggressive or corrosive atmospheres (e.g. sea air).
Never operate the unit above electrical equipment (such as switch cabinets, computers or other electrical
units, or contacts that are not drip-proof).
2.3 Risk from electrocution!
DANGER!
Risk of fatal injury from electrocution!
Contact with live parts will lead to fatal injury from electrocution. Damage to the insulation or individual
components can lead to a fatal injury.
Only permit qualified electricians to work on the electrics.
Immediately disconnect the system and repair it in the event of damage to the insulation.
Keep live parts away from moisture. This can cause a short circuit.
Properly earth the unit.
DANGER!
Risk of fatal injury from electrocution!
Where multiple EC fans are connected in parallel, an electrical charge (>50 C) is present between line
conductor and protective earth conductor when the power is switched off. Before working on the elec-
trical connection, short-circuit the network connections and PE!
The terminals and connectors are still energised even when the unit is switched off. Use a two-pole
voltage tester to establish that the unit has been de-energised. Only open the unit 5 minutes after all
poles of the voltage have been switched off.
The protective earth carries high leakage currents (depending on the frequency, intermediate voltage and
motor capacity). Therefore, check EN-compliant earthing under test conditions (EN 50178, art. 5.2.11).
Without earthing, hazardous voltages can occur on the motor housing. In case of a fault, electrical
voltage will be present on the rotor and impeller. Rotor and impeller are base-insulated. Do not touch!

TOP
Lufterhitzer mit stufenlosem EC-Wechselstrommotor
Assembly, installation and operating instructions
10
2.4 Personnel requirements - Qualifications
Specialist knowledge
The installation of this product requires specialist knowledge of heating, cooling, ventilation, installation and electrical engin-
eering. This knowledge, generally learned in vocational training in one of the fields mentioned above, is not described separ-
ately.
Damage caused by improper installation is the responsibility of the operator or installer. The installer of these units should
have adequate knowledge of the following gained from specialist vocational training
Safety and accident prevention regulations
Guidelines and recognised technical regulations, i.e. Association of German Electricians (VDE) regulations, DIN and EN
standards.
VDI 6022; Maintenance personnel must be trained to Category B (possibly Category C) to comply with hygiene require-
ments (if necessary).
The installation, operation and maintenance of this unit must comply with the applicable laws, standards, provisions and reg-
ulations in the respective country and the current state of the art!
2.5 Personal Protective Equipment
Personal protective equipment is used to protect people from impaired safety and health when working with the unit. The ap-
plicable accident prevention regulations at the place of use apply in all cases.
Personnel have to wear personal protective equipment during maintenance and troubleshooting on and with the unit.