Kampmann Lufterhitzer TOP 44 Series Assembly instructions

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► Assembly, installation and operating instructions
Keep these instructions in a safe place for future use!
Issue02/21EN
SAP No.1428257

3
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......................................................................................................................................... 13
6 Installation and wiring.......................................................................................................... 14
6.1 Requirements governing the installation site.......................................................................................... 14
6.2 Minimum clearances............................................................................................................................... 14
6.3 Installation.............................................................................................................................................. 14
6.3.1 Installation of sheet steel accessories ....................................................................................................... 15
6.3.2 Suspension points ..................................................................................................................................... 20
6.3.3 Universal 2-point brackets type 30041...................................................................................................... 21
6.3.4 Universal 2-point brackets type 38041...................................................................................................... 22
6.3.5 Universal 4-point brackets type 30042...................................................................................................... 22
6.3.6 Universal 4-point brackets type 38042...................................................................................................... 23
6.3.7 Universal 2-point T-brackets type 30047................................................................................................... 23
6.3.8 Wall brackets, type 3*044, type 3002*..................................................................................................... 24
6.3.9 Ceiling to wall brackets type 3*049 ......................................................................................................... 24
6.3.10 Louvres...................................................................................................................................................... 25
6.4 Installation.............................................................................................................................................. 25
6.4.1 Connection to the pipe network................................................................................................................ 26

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7 Electrical connection............................................................................................................. 27
7.1 Maximum electrical rating values ........................................................................................................... 27
7.2 Electromechanical control type ...58/56/68............................................................................................. 28
7.2.1 Connection (**00) .................................................................................................................................... 28
7.2.2 Cabling, TOP (**00), control by DDC ........................................................................................................ 30
8 Pre-commissioning checks.................................................................................................... 31
9 Maintenance ......................................................................................................................... 32
9.1 Securing against reconnection ................................................................................................................ 32
9.2 Maintenance Schedule:........................................................................................................................... 32
9.3 Clean the inside of the unit..................................................................................................................... 32
9.4 Replacing the filter.................................................................................................................................. 33
10 Faults .................................................................................................................................... 34
10.1 Fault table............................................................................................................................................... 35
10.2 Fault table, electromechanical control type ..58/56/68 ........................................................................... 36
10.3 Start-up after rectification of fault .......................................................................................................... 36
Table ..................................................................................................................................... 37

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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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Assembly, installation and operating instructions
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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
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 [}6] must be observed.
Intended use of the unit also includes adherence to these instructions.
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.
Information in accordance with UL60335-1
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 perman-
ent connection to a heating water circuit, and may not be connected using hose sets.
This unit is not intended to be accessible to the general public. The water network needs to include safety measures to
prevent the danger of overpressure.

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Assembly, installation and operating instructions
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2.2 Limits of operation and use
Limits of operation
Min./max. water temperature °C (°F) 5 (41) – see typeplate
Min./max. air intake temperature °C (°F) -20 (-4) to 40 (104)
Min./max. air humidity % 15-75
Min. operating pressure bar/kPa (psi/ ft H2O) -
Max. operating pressure bar/kPa (psi/ ft H2O) see type plate
Min./max. glycol percentage % 25-50
Tab.1: Limits of operation
Maximum flow temperatures
Use Ceiling-mounted model Wall-mounted model
Without shut-off valve 100°C/ (212°F) 120°C/ (248°F)
With shut-off valve 160°C/ (°320F) 160°C/ (320°F)
Tab.2: Maximum flow temperatures
Operating voltage 208 - 240 V/ 60 Hz
Power/Current consumption On the typeplate
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/68°F) 8-9
Conductivity (at 20 °C/68°F) μS/cm / ppm <700 / <350
Oxygen content (O2) mg/l / (lb/gal) <0.1 / (<0.00000083)
Hardness °dH / ppm CaCO34-8.5 / 0.224-0.476
Sulphur ions not measurable
Sodium ions (Na+) mg/l / (lb/gal) <100 / (<0.00083)
Iron ions (Fe2+) mg/l / (lb/gal) <0.1 / (<0.00000083)
Manganese ions (Mn2+) mg/l / (lb/gal) <0.05 / (<0.000000415)
Ammonia ions (NH4+) mg/l / (lb/gal) <0.1 / (<0.00000083)
Chlorine ions (CI) mg/l / (lb/gal) <100 / (<0.00083)
CO2<50
Sulfate ions (SO4
2-) mg/l / (lb/gal) <50 / (<0.000415)
Nitrite ions (NO2+) mg/l / (lb/gal) <50 / (<0.000415)
Nitrate ions (NO3+) mg/l / (lb/gal) <50 / (<0.000415)
Tab.4: Water quality

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Assembly, installation and operating instructions
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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 electrical system.
Carry out all electrical work in accordance with the National Electric Code (NEC and CEC).
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.
DANGER!
Risk of fatal injury from electrocution!
Where multiple EC fans are connected in parallel, an electrical charge (>50 C) is present between the 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-pin
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 NEC- and CEC-compliant earthing under test or experiment conditions
as well. Without earthing, hazardous voltages can occur on the motor housing. In the event of a fault,
electrical voltage will be present at the rotor and impeller. Rotor and impeller are base-insulated. Do not
touch!

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Assembly, installation and operating instructions
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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, e.g. National Electric Code (NEC) and Canadian Electric Code (CEC).
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 use the holding points provided.
Only remove packaging shortly before assembling the unit.
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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Assembly, installation and operating instructions
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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.

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Assembly, installation and operating instructions
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4 Technical data
Unit TOP
Series 44 45 46 47 48
Water content [l] (US
gal) 1.6 – 6.1 (0.4 – 1.6) 2.2 – 8.2 (0.6 – 2.2) 3.4 – 11.5 (0.9 – 3.0) 4.8 – 16.8 (1.3 – 4.4) 5.3 – 17.0 (1.4 – 4.5)
Weight [kg] (lbs) 25 – 62 (55 – 137) 32 -92 (71 – 203) 45 – 125 (99 – 276) 53 – 158 (117 – 348) 73 – 204 (161 – 450)
Sound pressure level 1
[dB(A)] 13 – 56 19 – 64 20 – 62 22 - 61 26-63
Tab.5: Technical data, TOP
1The sound pressure level was calculated with an assumed room insulation of 16 dB(A). This corresponds to a
clearance of 5 m (16.4 ft), a room volume of 3000 m³ (10600 ft³) and a reverberation time of 2.0 s (in accordance
with VDI 2081).

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Assembly, installation and operating instructions
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5 Construction and function
5.1 Overview
1
2
3 4
56
Fig.1: TOP at a glance
1Fan guard 2Whisper-quiet sickle-blade fan
3Rear panel with nozzle 4Heat exchanger (example - copper/aluminium model)
5Unit heater housing 6Louvre, 1-row (standard)
5.2 Brief description
TOP unit heaters are used for the decentralised heating and ventilation of high-ceilinged buildings, either wall- or ceiling-
mounted. Air is drawn in through the axial fan and is blown through the heat exchanger into the room through the standard
single-row louvre. The air can optionally be discharged through a double-row louvre or other air diffuser (see Accessories).
5.3 Wear parts list
Figure Article Properties Suitable for Art. no.
ISO Coarse 90% spare filter
cartridge
Type 3*611
Suitable for filter box type
3*010
Series 44 198000034611
Series 45 198000035611
Series 46 198000036611
Series 47 198000037611
Series 48 198000038611

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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 wall/ceiling is sufficiently load-bearing to take the weight of the unit (Technical data [}12]).
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 [}26]).
There is a power supply on site (Maximum electrical rating values [}27]).
6.2 Minimum clearances
Air heaters can be installed free-standing or suspended on the wall using the supplied wall brackets or suspended from the
ceiling using the ceiling brackets supplied (Exception: Series 48 for ceiling mounting only). Installation using wall or ceiling
brackets (by others) is likewise possible.
A minimum clearance L in accordance with the table below must be respected between the unit’s intake suction area and the
wall/ceiling! If you do not leave this minimum clearance, the unit heater’s output will be reduced and the noise level will in-
crease.
Be sure to observe the minimum clearances when using accessories or for maintenance purposes!
L min
L min
Fig.2: Minimum clearances, TOP
Series Type Minimum clearance L min Standard clearance L*
44 44_58 / 44_56 160 mm (6.3 in) 285 mm (11.2 in)
45 45_58 / 45_56 180 mm (7.1 in) 285 mm (11.2 in)
46 46_58 230 mm (9.1 in) 335 mm (13.2 in)
47 47_58 / 47_56 300 mm (11.8 in) 345 mm (13.6 in)
48 48_68 620 mm (24.4 in) 660 mm (26.0 in)
Tab.6: Type overview with minimum clearances
* when using wall brackets, type 3_044

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Assembly, installation and operating instructions
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6.3 Installation
2 people are needed to install the unit.
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.
6.3.1 Installation of sheet steel accessories
Figure Description Dimensions [mm] (in) Suitable for
A
A
Two-row louvre, type 3*002
A
495 (19.5) Series 44
595 (23.4) Series 45
695 (27.4) Series 46
795 (31.3) Series 47
4-directional air diffuser, type
3*004 Series 44-47
H
F
Diffuser screen, type 3*005
H F
500 (19.7) 70 (2.8) Series 44
600 (23.6) 70 (2.8) Series 45
700 (27.6) 70 (2.8) Series 46
800 (31.5) 70 (2.8) Series 47
C
A
D
B
Discharge nozzle, type 3*006
A B C D
450 (17.7) 500
(19.7) 250 (9.8) 230 (9.1) Series 44
550 (21.7) 600
(23.6)
300
(11.8) 260 (10.2) Series 45
650 (25.6) 700
(27.6)
350
(13.8) 290 (11.4) Series 46
750 (29.5) 800
(31.5)
400
(15.7) 320 (12.6) Series 47

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Assembly, installation and operating instructions
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Figure Description Dimensions [mm] (in) Suitable for
C
D
E
F
B
A
Wide nozzle, type 3*007
A B C D E F
450
(17.7)
500
(19.7)
300
(11.8)
600
(23.6) 60 (2.4) 50 (2.0) Series 44
550
(21.7)
600
(23.6)
340
(13.4)
700
(27.6) 90 (3.5) 50 (2.0) Series 45
650
(25.6)
700
(27.6)
380
(15.0)
800
(31.5)
120
(4.7) 50 (2.0) Series 46
750
(29.5)
800
(31.5)
420
(16.5)
900
(35.4)
150
(5.9) 50 (2.0) Series 47
A
B
C
Induction louvre, type 3*101
A B C
495 (19.5) 425 (16.7) 100 (3.9) Series 44
595 (23.4) 525 (20.7) 100 (3.9) Series 45
695 (27.4) 625 (24.6) 100 (3.9) Series 46
795 (31.3) 725 (28.5) 100 (3.9) Series 47
RaDeck ceiling air outlet, type
3*087 Series 44-47
KaMAX air outlet, type 3*111 All series
Universal 4-point brackets,
type 30042 Series 44-47
Universal 4-point brackets,
type 38042 Series 48
Ceiling to wall brackets, type
3*049 Series 44-47

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Figure Description Dimensions [mm] (in) Suitable for
Universal bracket extension,
type 30043 All series
F
A
C
D
B
E
A
CD
Wall bracket, type 34044
A B C D E F
Series 44
585
(23.0)
251
(9.9)
160
(6.3) 40 (1.6) 50 (2.0) 340 (13.4)
Wall bracket, type 35044
A B C D E F
Series 45
585
(23.0)
251
(9.9)
160
(6.3) 40 (1.6) 50 (2.0) 440 (17.3)
Wall bracket, type 36044
A B C D E F
Series 46
635
(25.0)
268
(10.6)
187
(7.4) 40 (1.6) 50 (2.0) 540 (21.3)
Wall bracket, type 37044
A B C D E F
Series 47
685
(27.0)
286
(11.3)
204
(8.0) 40 (1.6) 50 (2.0) 640 (25.2)
F
A
C
D
B
E
A
CD
Wall brackets, extended, type
30022
A B C D E F
Series 44
785
(30.9)
321
(12.6)
123
(4.8) 40 (1.6) 50 (2.0) 340 (13.4)
Wall brackets, extended, type
30024
A B C D E F
Series 45
885
(34.8)
355
(14.0)
143
(5.6) 40 (1.6) 50 (2.0) 440 (17.3)
Wall brackets, extended, type
30026
A B C D E F
Series 46
1080
(42.5)
422
(16.6)
175
(6.9) 40 (1.6) 50 (2.0) 540 (21.3)
Wall brackets, extended, type
30020
A B C D E F
Series 47
Dimensions depending on bracket length

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Assembly, installation and operating instructions
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Figure Description Dimensions [mm] (in) Suitable for
Universal 2-point brackets.
Type 30041 Series 44-47
Universal 2-point brackets.
Type 38041 Series 48
Universal 2-point T-brackets,
type 30047 Series 44-47
A
B
Filter box, filter ISO Coarse
90%. Type 3*010
A B
500 (19.7) 250 (7.9) Series 44
600 (23.6) 250 (7.9) Series 45
700 (27.6) 250 (7.9) Series 46
800 (31.5) 250 (7.9) Series 47
Sailcloth connection, type
3*013 Series 44-47

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Figure Description Dimensions [mm] (in) Suitable for
A
A
B
Air duct 90°, type 3*021
A B
500 (19.7) 450 (17.7) Series 44
600 (23.6) 550 (21.7) Series 45
700 (27.6) 650 (25.6) Series 46
800 (31.5) 750 (29.5) Series 47
A
A
B
Air duct T, type 3*022
A B
500 (19.7) 450 (17.7) Series 44
600 (23.6) 550 (21.7) Series 45
700 (27.6) 650 (25.6) Series 46
800 (31.5) 750 (29.5) Series 47
A
B
Air duct, type 3*015
A B
500 (19.7) Variable Series 44
600 (23.6) Variable Series 45
700 (27.6) Variable Series 46
800 (31.5) Variable Series 47
Tab.7: Air-side sheet steel accessories

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Assembly, installation and operating instructions
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Fig.3: Connecting frame dimensions
Series A [mm] (in) B [mm] (in) C [mm] (in) D [mm] (in)
44 _ _ _ _ 500 (19.7) 480 (18.9) 360 (14.2) 400 (15.7)
45 _ _ _ _ 600 (23.6) 580 (22.8) 460 (18.1) 500 (19.7)
46 _ _ _ _ 700 (27.6) 680 (26.8) 560 (22.0) 600 (23.6)
47 _ _ _ _ 800 (31.5) 780 (30.7) 660 (26.0) 700 (27.6)
48 _ _ _ _ 900 (35.4) 880 (34.6) 760 (29.9) 800 (31.5)
Tab.8: Dimensions
Note: With Series 48, a connection is only possible on the air outlet side.