Kampmann Ultra 73 Series Assembly instructions

Ultra
► Assembly, installation and operating instructions
Keep these instructions in a safe place for future use!
Issue12/22EN
SAP No.1389221

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.................................................................................................................... 7
2.3 Risk from electrocution!......................................................................................................................... 9
2.4 Personnel requirements - Qualifications ................................................................................................ 11
2.5 Personal Protective Equipment .............................................................................................................. 11
3 Transport, storage and packaging........................................................................................ 12
3.1 General transport instructions ............................................................................................................... 12
3.2 Scope of delivery.................................................................................................................................... 12
3.3 Storage .................................................................................................................................................. 13
3.4 Packaging .............................................................................................................................................. 13
4 Technical data....................................................................................................................... 14
5 Construction and function .................................................................................................... 15
5.1 Overview................................................................................................................................................ 15
5.2 Brief description..................................................................................................................................... 15
5.3 Wear parts list........................................................................................................................................ 16
6 Installation and wiring ......................................................................................................... 17
6.1 Requirements governing the installation site......................................................................................... 17
6.2 Installation height and throws ............................................................................................................... 17
6.3 Installation............................................................................................................................................. 18
6.3.1 Ultra suspension points ............................................................................................................................. 18
6.3.2 Installation on a solid ceiling..................................................................................................................... 20
6.3.3 Installation on a suspended ceiling ........................................................................................................... 21
6.3.4 Assembly of the intake crown ................................................................................................................... 21
6.3.5 Filter assembly (accessory) ........................................................................................................................ 23
6.4 Installation............................................................................................................................................. 23
6.4.1 Connection to the pipe network ................................................................................................................ 24
6.5 Condensation connection ...................................................................................................................... 25
6.5.1 Installing the condensation drain (with cooling units)............................................................................... 25
6.5.2 Condensate drainage using a condensate pump ....................................................................................... 26
6.5.3 Ultra without KaControl module fitted, recirculating air............................................................................ 26
6.5.4 Ultra with KaControl module fitted, recirculating air................................................................................. 27

4
6.5.5 Commissioning and functional checks....................................................................................................... 28
7 Electrical connection............................................................................................................. 29
7.1 Maximum electrical rating values .......................................................................................................... 29
7.2 Electromechanical control...................................................................................................................... 30
7.2.1 Connection (**00)..................................................................................................................................... 31
7.2.2 Cabling of Ultra (**00), actuation by speed controller type 30510........................................................... 33
7.2.3 Cabling of Ultra (**00), actuation by speed controller type 30510 with industrial thermostat type
30058/ 30059 ............................................................................................................................................
34
7.2.4 Cabling of Ultra (**00), actuation by speed controller type 30510 with room thermostat type 30055..... 35
7.2.5 Cabling of Ultra(**00), actuation by speed controller type 30510 with clock thermostat type 30056...... 36
7.2.6 Cabling of Ultra (**00), actuation by Climate controller type 30155, 2-pipe valve actuator 230 V AC,
Open/Close ................................................................................................................................................
37
7.2.7 Cabling of Ultra (**00), actuation by Climate controller type 30256, 2-pipe valve actuator 230 V AC,
Open/Close ................................................................................................................................................
38
7.2.8 Cabling of Ultra (**00), actuation by speed controller type 30515........................................................... 39
7.2.9 Cabling of Ultra (**00), actuation by DDC/BMS, 2-pipe valve actuator 230 V AC, Open/Close ................ 40
7.3 KaControl (*C1) ..................................................................................................................................... 41
7.3.1 KaController installation............................................................................................................................ 41
7.3.2 Connection (*C1)....................................................................................................................................... 42
7.3.3 Cabling of Ultra (*C1), actuation by KaController type 321000x, 2-pipe, 24 V DC valve, Open/Close ...... 46
7.3.4 Cabling of Ultra (*C1), actuation by KaController type 321000x, 2-pipe, 24 V DC valve, Open/Close,
with CANbus card......................................................................................................................................
47
7.3.5 Cabling of Ultra (*C1), actuation by 0-10 V DC signal by others............................................................... 48
8 Pre-commissioning checks.................................................................................................... 49
9 Operation.............................................................................................................................. 51
9.1 Operation of electromechanical control ................................................................................................. 51
9.2 Operation of the KaController................................................................................................................ 52
9.2.1 Function keys, display elements ................................................................................................................ 52
10 Maintenance ......................................................................................................................... 55
10.1 Securing against reconnection ............................................................................................................... 55
10.2 Maintenance Schedule:.......................................................................................................................... 55
10.3 Maintenance work................................................................................................................................. 56
10.3.1 Visual checks ............................................................................................................................................. 56
10.3.2 Clean the inside of the unit ....................................................................................................................... 56
10.3.3 Dismantling the housing cover .................................................................................................................. 56
10.3.4 Cleaning the condensate tray .................................................................................................................... 57
10.3.5 Cleaning the float switch........................................................................................................................... 58
10.3.6 Replacing the filter. ................................................................................................................................... 58

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11 Faults .................................................................................................................................... 59
11.1 Fault table.............................................................................................................................................. 60
11.2 Fault table, electromechanical control ................................................................................................... 61
11.3 Fault table, KaControl, type ..58C1/ 56C1.............................................................................................. 61
11.4 KaControl faults..................................................................................................................................... 61
11.5 Start-up after rectification of fault ......................................................................................................... 62
12 List of KaControl parameters................................................................................................ 63
12.1 Ultra parameter list................................................................................................................................ 63
12.2 KaController parameter list.................................................................................................................... 66
13 Certificates............................................................................................................................ 68
13.1 153_EU-Konformitätserklärung_Lufterhitzer ......................................................................................... 69

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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.

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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 [}7] must be observed.
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.

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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
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.
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!
Information and limits of operation for cooling mode
Pay attention to specific settings and operating modes for cooling with dehumidification of the air:
Only operate units of type 963158/964158 with an air flow rate of max. 2900 m³/h.
Do not move the outlet louvre slats to their end positions, as high air velocities can be produced at high
speeds and water droplets can be carried along.
The use of valves (e.g. thermoelectric shut-off valves in recirculation air mode) is recommended to pre-
vent the housing from impermissibly cooling down too far when the fan is idle.
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.

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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.
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!

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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 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 Ultra
Series 73 84 85 96
Water content [l] 1.6 - 2.3 2.0 - 2.9 2.0 – 3.8 2.2 - 4.4
Weight [kg] 28 - 30 34 - 43 35 – 45 45 - 55
EC, 230 V standard 73_58 84_58 85_58 96_58 96_56
Heating or cooling applications
EC, 230 V type - 843158 853158
854158
963158
964158
963156
964156
Dry cooling - yes yes yes yes
Cooling with dehumidifica-
tion - yes yes no yes
Tab.4: Technical data – Ultra

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Assembly, installation and operating instructions
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5 Construction and function
5.1 Overview
2
1
3
4
5
6
7
8
Fig.1: Ultra at a glance
1Base panel 2Plastic condensate tray (only with cooling unit)
3Air guide (only with cooling unit) 4Cu/Al heat exchanger
5Whisper-quiet, sickle-blade fan, conforms to ErP 2015 6Self-supporting plastic housing
7Condensate pump (hidden), only with cooling unit 86-section intake crown
5.2 Brief description
The heating and/or cooling models of Ultra unit heaters are used as ceiling-mounted units for the decentralised heating and
ventilation of halls, exhibition halls and sales rooms. Air is drawn in through the axial fan and is blown through the circular
heat exchanger into the room. The heated or cooling air is guided into the room on-demand through the pre(settable) louvre
slats. Models with large heat exchanger capacity are ideal for use with low water temperatures.

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5.3 Wear parts list
Figure Article Properties Suitable for Art. no.
Recirculating air filter ele-
ment
For direct installation onto
the intake area of the unit
with recirculating air units,
ISO Coarse 45% (G3) filter
Model 73 and 84 (cannot
be used with under-ceiling
installation!)
154000064050
Model 85 (cannot be used
with under-ceiling installa-
tion!)
154000065050
Model 96 (cannot be used
with under-ceiling installa-
tion!)
154000066050

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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 ceiling is sufficiently load-bearing to take the weight of the unit (Technical data [}14]).
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 [}24]).
There is a power supply on site (Maximum electrical rating values [}29]).
If need be, provide a condensation connection with a sufficient gradient on site.
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).
W
H
Fig.2: Maximum installation heights and throws
Type series Voltage [V] Speed [rpm] Max. installation height
H [m]
Throw W[m]
73_ _58
10 940 2.5 4.3
8 795 2.4 3.9
6 650 2.4 3.5
4 505 2.3 3.1
2 365 2.3 2.7
84_ _58
10 1070 2.9 4.8
8 950 2.7 4.4
6 730 2.4 3.4
4 490 2.4 2.4
2 280 2.3 1.5
85_ _58
10 1000 3.4 5.6
8 890 3.2 5.2
6 700 3.0 4.6
4 480 2.7 3.9
2 260 2.4 3.1
96_ _56 10 680 3.6 5.7

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Assembly, installation and operating instructions
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Type series Voltage [V] Speed [rpm] Max. installation height
H [m]
Throw W[m]
8 550 3.4 5.1
6 410 3.2 4.4
4 270 3.0 3.8
2 100 2.7 3.0
96_ _58
10 1000 4.1 7.2
8 800 3.8 6.2
6 580 3.5 5.2
4 370 3.2 4.2
2 170 2.8 3.3
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.
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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6.3.1 Ultra suspension points
IMPORTANT NOTE!
Cutting out the drilling template.
The cardboard drilling template is part of the packaging and should be used to position the fixing points on
the ceiling. Cut out the drilling template before disposing of the packaging!
22
22
1
2
1
**
6
5
4
3
6
5
Fig.3: Ultra suspension points

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Assembly, installation and operating instructions
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6.3.2 Installation on a solid ceiling
1
2
3
4
5
6
7
8
9
10
A
B
Fig.4: Ultra installation, solid ceiling
1Solid ceiling 2Rawlplug
3Washer 4M8 screw
5Bracket 6Intake crown
7Corrugated-head screw M8 x
16
8Torsion prevention mechanism
9Ultra base plate 10 Louvre
A: by others
B: Scope of delivery
x: Maintain this gap to undertake any service work on
the intake crown! Make sure that the gap is not filled by
subsequent work on the ceiling, such as plastering, as it
would then be impossible to fit or remove the intake
crown!
Use all four fixing points!