Kampmann Ultra Allround Assembly instructions

Ultra Allround
► Assembly, installation and operating instructions
Keep these instructions in a safe place for future use!
Issue06/23EN
SAP No.1816834

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Table of contents
1 General ................................................................................................................................. 5
1.1 About these instructions ........................................................................................................................ 5
1.2 Explanation of Symbols.......................................................................................................................... 5
2 Safety.................................................................................................................................... 6
2.1 Correct use............................................................................................................................................. 6
2.2 Limits of operation and use.................................................................................................................... 6
2.3 Risk from electrocution!......................................................................................................................... 8
2.4 Personnel requirements - Qualifications ................................................................................................ 9
2.5 Personal Protective Equipment .............................................................................................................. 9
3 Transport, storage and packaging........................................................................................ 10
3.1 General transport instructions ............................................................................................................... 10
3.2 Scope of delivery.................................................................................................................................... 10
3.3 Storage .................................................................................................................................................. 11
3.4 Packaging .............................................................................................................................................. 11
4 Technical data....................................................................................................................... 12
5 Construction and function .................................................................................................... 13
5.1 Overview................................................................................................................................................ 13
5.2 Brief description..................................................................................................................................... 13
5.3 Wear parts list........................................................................................................................................ 14
6 Installation and wiring ......................................................................................................... 15
6.1 Requirements governing the installation site......................................................................................... 15
6.2 Installation height and throws ............................................................................................................... 15
6.3 Minimum clearances.............................................................................................................................. 15
6.4 Installation............................................................................................................................................. 16
6.4.1 Ultra suspension points ............................................................................................................................. 16
6.4.2 Installation of the Ultra Allround............................................................................................................... 18
6.5 Installation............................................................................................................................................. 20
6.5.1 Connection to the pipe network ................................................................................................................ 21
6.6 Condensation connection ...................................................................................................................... 22
6.6.1 Condensate drainage using a condensate pump ....................................................................................... 22
6.6.2 Commissioning and functional checks....................................................................................................... 22
7 Electrical connection............................................................................................................. 23
7.1 Maximum electrical rating values .......................................................................................................... 23
7.2 Electromechanical control...................................................................................................................... 23

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7.2.1 Connection (*00)....................................................................................................................................... 23
7.3 KaControl (*C1) ..................................................................................................................................... 33
7.3.1 KaController installation............................................................................................................................ 33
7.3.2 Connection (*C1)....................................................................................................................................... 34
8 Pre-commissioning checks.................................................................................................... 42
9 Operation.............................................................................................................................. 43
9.1 Operation of electromechanical control ................................................................................................. 43
9.2 Operation of the KaController................................................................................................................ 46
9.2.1 Function keys, display elements ................................................................................................................ 47
10 Maintenance ......................................................................................................................... 49
10.1 Securing against reconnection ............................................................................................................... 49
10.2 Maintenance Schedule:.......................................................................................................................... 49
10.3 Maintenance work................................................................................................................................. 49
10.3.1 Visual checks ............................................................................................................................................. 50
10.3.2 Clean the inside of the unit ....................................................................................................................... 50
10.3.3 Dismantling the housing cover .................................................................................................................. 50
10.3.4 Cleaning the condensate tray .................................................................................................................... 51
10.3.5 Cleaning the condensate pump ................................................................................................................. 52
10.3.6 Replacing the filter. ................................................................................................................................... 53
11 Faults .................................................................................................................................... 54
11.1 Fault table.............................................................................................................................................. 54
11.2 KaControl faults..................................................................................................................................... 54
11.3 Start-up after rectification of fault ......................................................................................................... 55
12 List of KaControl parameters................................................................................................ 56
12.1 KaController parameter list.................................................................................................................... 56
13 Certificates............................................................................................................................ 57

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Assembly, installation and operating instructions
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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.

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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
The units are only intended to be used for heating and cooling air in frost-free and dry rooms. 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 [}6] must be observed.
IMPORTANT NOTE!
Only use the unique after completion of the complete building and system. Site heating is not deemed to be
correct and proper use.
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.
The unit is not intended for operation above 2,000 m.a. s.l.
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.
2.2 Limits of operation and use
Limits of operation
Min./max. water temperature °C 5-90
Min./max. air intake temperature °C -20 - (+40)
Min./max. air humidity % 15-75
Min. operating pressure bar/kPa 16
Max. operating pressure bar/kPa siehe Typenschild
Min./max. glycol percentage % 25-50
Tab.1: Limits of operation
Operating voltage 230 V/ 50/60 Hz
Power/current consumption On the typeplate
Tab.2: 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.

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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.3: Water quality

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IMPORTANT NOTE!
Danger of frost in cooling mode!
There is a risk of the heat exchanger freezing when used in unheated rooms.
Make sure that the unit is equipped with a frost protection sensor and/or thermostat in this case.
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).
Never use the unit as a construction site heater.
Never operate the unit in areas with a high dust content.
IMPORTANT NOTE!
Energy losses due to misuse!
Operating the unit with open windows (or other room openings) can result in significant energy losses.
Heating and cooling modes (particularly when operating different units) need to be coordinated with
each other.
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 electrical system.
Immediately disconnect the system from the power supply and repair it in the event of damage to the in-
sulation.
Keep live parts away from moisture. This can cause a short circuit.
Properly earth the unit.

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Assembly, installation and operating instructions
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2.4 Personnel requirements - Qualifications
Expertise
The installation of this product requires specialist knowledge of heating, cooling, ventilation, installation and electrical engin-
eering. This knowledge, generally learned in professional training in one of the fields mentioned above, is not described sep-
arately.
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 professional 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 (as required).
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.

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Assembly, installation and operating instructions
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3 Transport, storage and packaging
3.1 General transport instructions
Check on delivery for completeness and transport damage.
Proceed as follows in the event of visible damage:
Do not accept delivery or only accept with reservations.
Record any transport damage on the transportation documents or on the transport company's delivery note.
Submit a complaint to the freight forwarder.
IMPORTANT NOTE!
Warranty claims can only be made within the applicable period for complaints. (More information is avail-
able in the T&Cs on the Kampmann website)
IMPORTANT NOTE!
2 people are needed to transport the unit. Wear personal protective clothing when transporting the unit.
Only lift the unit on both sides and not by the pipes / valves.
IMPORTANT NOTE!
Material damage caused by incorrect transport!
Units being transported can drop or topple over if transported wrongly. This can cause serious material
damage.
Proceed carefully when unloading the equipment on delivery and when transporting it on site, and note
the symbols and instructions on the packaging.
Only lift the unit with the outer packaging fitted to avoid damage. Only use the recessed grips provided
in the box.
Only remove the outer packaging once the unit has been assembled. The packaging is used to protect
against dirt and damage on site.
3.2 Scope of delivery
IMPORTANT NOTE!
Check the scope of delivery!
Check the delivery for damage.
Check that the articles and type numbers are correct.
Is the delivery and number of items delivered correct?

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3.3 Storage
Store packaging under the following conditions:
Do not store outdoors.
Store in a dry and dust-free place.
Store in a frost-free place.
Do not expose to aggressive media.
Protect from direct sunlight.
Avoid mechanical vibrations and shocks.
IMPORTANT NOTE!
Under certain circumstances, packages can carry storage instructions that exceed the requirements listed
here. Comply with these instructions accordingly.
3.4 Packaging
Handling packaging materials
IMPORTANT NOTE!
Dispose of packaging materials in line with the applicable statutory requirements and local regulations.
IMPORTANT NOTE!
The packaging is also use to protect the product from site dust and dirt. Only remove packaging shortly be-
fore assembling the unit.
The packaging serves as a transport aid as well as dust and
assembly protection. Only remove the packaging properly
shortly before commissioning.
If the Ultra Allround is carried/mounted without the outer
packaging, lift the device only by the underside!

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Assembly, installation and operating instructions
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4 Technical data
Size 1 2
Water capacity [l] 3 3.5
Weight [kg] 61 80
Sound power level [db(A)] <70 <73
Diameter [mm] 1300 1300
Height [mm] 516 516
Tab.4: Technical specifications Ultra Allround

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5 Construction and function
5.1 Overview
1
2
3
4
6
7
5
Fig.1: Ultra Allround at a glance
1Pre-guide grid 2Air outlet 360°
3Fan unit 4Heat exchanger
5Condensate tray 6Inspection hatch with twist lock and drop safety device (wire
ropes)
7Condensate pump
5.2 Brief description
Ultra Allround ceiling-mounted unit heaters, heating and/or cooling models, are used for the decentralised heating and vent-
ilation of halls, exhibition halls and sales rooms. Air is drawn in through the radial fan and is blown through the circular heat
exchanger into the room. The heated or cooled air is guided into the room on-demand in a circular horizontal or vertical air
stream.

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5.3 Wear parts list
Figure Article Properties For use with Art. no.
Recirculating air filter ele-
ment
For direct mounting on the
unit intake area with recir-
culating air units, coarse
dust filter
Size 1
Size 2

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Assembly, installation and operating instructions
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6 Installation and wiring
6.1 Requirements governing the installation site
Only install and assemble the unit if the following conditions are met:
Make sure that the unit is securely suspended/standing.
Ensure that the airflow can circulate freely.
Provide adequate space for appropriately sized flow and return water connections on site (Connection to the pipe
network [}21]).
There is a power supply on site (Maximum electrical rating values [}23]).
6.2 Installation height and throws
When suspending the units, pay attention to the maximum installation heights and throws! Make sure that the units are sus-
pended vibration-free (using rubber vibration elements if necessary).
With an installation height of < 3.5 m, make sure that the air is discharged horizontally in heating mode to avoid draughts in
the occupied zone.
Fig.2: Maximum installation heights and throws
Type series Voltage [V] Max. installation height Hmax [m]
Models 1 and 2
10 8
8 6.5
6 4.5
4 3
2 2.3

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6.3 Minimum clearances
A minimum distance of 500 mm must be maintained between the unit suction area and the ceiling! Failure to maintain the
minimum distance will reduce the performance of the air heater and increase the noise level.
When using accessories or for maintenance purposes, it is essential to observe the minimum distances!
min. 500
Fig.3: Minimum distances Ultra Allround
6.4 Installation
Appropriate technical lifting equipment or 4 people are required for installation.
CAUTION!
Risk of injury from sharp metal housing!
The inner metal of the casing can have sharp edges.
Wear suitable protective gloves.
IMPORTANT NOTE!
Horizontal installation of units!
When installing the units, ensure that they are completely horizontal to ensure proper operation.
IMPORTANT NOTE!
Avoid draughts!
Consider the occupied zone when installing/suspending the units. Do not expose people to the direct air
flow. Position the unit accordingly and adjust the air outlet if required.

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Assembly, installation and operating instructions
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6.4.1 Ultra suspension points
AB
636
C
Fig.4: Ultra Allround suspension points
Size 1 Size 2
A [mm] 136 86
B [mm] 380 430
C [mm] 516 516

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6.4.2 Installation of the Ultra Allround
The packaging serves as a transport aid as well as dust and
assembly protection. Only remove the packaging properly
shortly before commissioning.
If the Ultra Allround is carried/mounted without the outer
packaging, lift the device only by the underside!

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Assembly, installation and operating instructions
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XX
XX
X
X
XX
XX
Fig.5: Diagram: Suspension of the Ultra Allround
Use threaded rods (by others) to suspend the unit by the 4 mounting brackets.
Lock the threaded rods in place with nuts and washers.

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6.5 Installation
Hydraulic connection
Note the following points when connecting the hydraulic side:
Install and test safety components (expansion vessels, pressure relief valves and overflow valves).
Route condensation lines with a sufficient cross-section without bends and narrow sections with a gradient to the in situ
waste water pipe.
Allow adequate space for the air flow (air inlet and outlet).
Observe the following additional points for cooling operation:
Install continuous, vapor diffusion-tight insulation on all water-bearing components (piping, valves, connections), in each
case up to the unit.
Select suitable pipe hangers (cold clamps) for cooling operation.
Sufficiently dimension the diameter of the condensate pipe.
Protect siphons (if any) in the condensate pipe from drying out.