Klingenburg AS2 User manual

AS2 Cleaning Device for
Cleaning Rotary Heat Exchangers
ENERGY RECOVERY
1. Cleaning Options
2. Cleaning Device
3. Cleaning Sensors
4. AS2 Cleaning Control System
5. Menu navigation
6. Troubleshooting
7. Technical Data
Page 2
Page 3
Page 6
Page 10
Page 16
Page 23
Page 25

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1. Cleaning options
Self-cleaning effect
Under the usual conditions for the operation of ventilation systems and air conditioning systems, rotary heat
exchangers do not tend to become contaminated. This is due to the laminar airflow in the rotor mass and the
counter-current circuitry.
Air filtration before the rotor is only necessary for viscous, greasy and coarse contamination. As the self-clea-
ning effect occurs only when the rotor is rotating, idle rotors tend to become contaminated.
A cleaning cycle circuit offers a remedy here. The rotor mass is periodically rotated further in order to prevent
one-sided accumulation. This cleaning run cycle, also described as interval mode, is integrated in the rotor
control system (see control system description for the twist switch – latched controller).
Outside air
Extract air
Supply air
Exhaust air
Counterflow Circuit:

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2. Cleaning device
If strongly adhesive contamination is present in the air, the installation of an automatic cleaning apparatus may
be sensible. Usually, blowing out with compressed air is sufficient.
Cleaning with high-pressure warm water is necessary only with tenacious viscous and greasy contamination.
Please note that the residual water is to be blown out of the rotor following cleaning.
For water purification, a compressed air nozzle is therefore always required.
Compressed air cleaning High-pressure warm water cleaning
Exhaust air
Air
Air
Water
Air Water Air
Exhaust air

4
The slide is moved by an AC motor, and the power transmission is through a toothed belt.
Contactless proximity switches send an alert when the slide reaches either end position. Another proximity
switch is installed in the rotor casing and records the rotor speed.
A slide travels on a track over the radius of the rotor. The cleaning nozzles
for compressed air and possibly for water, depending on requirements, are
installed here.
Pulse sensor (for rotor speed) is located in the rotor casing
Rotor circumference sensor*
Rotor centre sensor*
A
BC
C
C
B
B
2 543
1
A
A
* Sensors are installed on
the inside of the cleaning
track
A
(1) AS2 drive motor
(2) Nozzle slide
(3) Toothed belt
(4) Idler
(5) Clamping screw

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Following each rotation of the rotor, the cleaning apparatus advances by the width of a nozzle stream. This
allows gap-free cleaning.
When the cleaning apparatus is switched off, the carriage is positioned on the periphery of the rotor. The
cleaning procedure can be started either by a built-in weekly time switch, by an external switch or by the Start
switch under the display.
Caution: Ensure that the heat exchanger wheel is released when starting cleaning and is turning for the whole
time the program is running. When the cleaning device is operating, the nozzle slide continuously travels to the
centre of the rotor. When the sensor reaches the centre, the air and possibly water cleaning begins.
A relay output for warm water and a compressed air valve are available. When the carriage reaches the
periphery of the rotor, the water valve relay falls and the rotor is dried with compressed air during the return
movement.
On reaching the centre sensor, the air relay switches off and the carriage travels to the starting position. During
the cleaning procedure, the rotor runs with variable speed under the control of the AS2 control system.
The external control signal (0 - 10 Volt) is not processed during the cleaning procedure, so this process should
be carried out during the idle times.

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3. Cleaning Sensors
Manufacturer Klingenburg
Model MMG 120BDKX, PNP Switch
magnetic
IP code IP67
Power supply 10-30 V=
Contact Magnet
Sensing distance <=30 mm
Connect. wire colours blue / brown / black
Usage Rotors Sorption wheel,
Pulse sensor cleaning device Klingenburg Secatec
Connection to controller:
KR4/7
KR15 and Premium
KS 4/7/15
Clamp 4 = blue; Clamp 5 = brown; Clamp 6 = black
Clamp 6 = blue; Clamp 7 = brown; Clamp 8 = black
Clamp 4 = blue; Clamp 5 = brown; Clamp 6 = black
to cleaning device
AS2
+Ub = brown
Sensor Pulse Tkt = black
GND = blue

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Manufacturer Steute
Model
EEX-RC-M 14W
Chanceover contact
Reed contact
IP code IP67 Atex
Power supply changeover contact up to 250V
AC/DC
Contact Magnet
Sensing distance <=7 mm
Connect. wire colours gr-yel / grey / brown / black
Usage Rotor, End position switch slide,
pulse sensor cleaning device
Steute
Connection to controller:
KR4/7
KR15, Premium
KS 4/7/15
Clamp 5 = brown; Clamp 6 = black
Clamp 7 = brown; Clamp 8 = black
Clamp 5 = brown; Clamp 6 = black
to cleaning device
AS2
+Ub = brown; Sensor centre Mit = black
Sensor circumference = black
Sensor pulse Tkt = black

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Manufacturer Schmersal
Model
IFL-N4-12-10P
PNP N/O
Inductively
IP code IP67
Power supply 10-30 Volt =
Contact Steel contact tabs
Sensing distance <=3 mm
Connect. wire colours blue / brown / black
Usage Cleaning device standard Schmersal
Connection to controller
KR4/7
KR15 and Premium
KS 4/7/15
clamp 4 = blue; clamp 5 = brown; clamp 6 = black
clamp 6 = blue; clamp 7 = brown; clamp 8 = black
clamp 4 = blue; clamp 5 = brown; clamp 6 = black
to cleaning device
AS2
+Ub = brown
Sensor centre Mit = black
Sensor circumference Umf = black
GND = blue

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Manufacturer Pepperl & Fuchs
Model
NBB 8-18GM50-E2-3G-3D
PNP N/O
Inductively
IP code IP67Atex
Power supply 10-30 Volt=
Contact Steel contact tabs
Sensing distance <=7 mm
Connect. wire colours blue / brown / black
Usage ATEX cleaning decice, Rotors
Pepperl & Fuchs
Connection to controller
KR4/7
KR 15 and Premium
KS 4/7/15
clamp 4 = blue; clamp 5 = brown; clamp 6 = black
clamp 6 = blue clamp 7 = brown; clamp 8 = black
clamp 4 = blue; clamp 5 = brown; clamp 6 = black
to cleaning device
AS2
+Ub = brown
sensor centre Mit = black; sensor circumference Umf = black
sensor pulse Tkt = black
GND = blue

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4. AS2 Cleaning Control System
Functional characteristics
Processor-controlled monitoring of the cleaning sequence
Coloured display
Detailed error messages
Menu navigation
Cleaning takes place from the inside to the outside
(the contaminated water runs towards the outside)

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Functional description
The cleaning control system enables the automatic, electronic cleaning of the contaminated thermal mass of a
rotary heat exchanger.
Standby indicates readiness for operation. A start signal from an external contact, the start button or an
optional time switch activates the cleaning procedure.
Following the start command, the carriage travels without media to the centre of the rotor. When the sensor
reaches the centre, the cleaning procedure itself begins and the rotor rotates. Caution: The heat exchanger
wheel must be released at all times while cleaning.
The relays switch on the solenoid valves for air and water. Due to the rotation of the rotor, the clock sensor
receives the first pulse and the carriage is driven towards the periphery. The carriage should advance by no
more than one nozzle width; otherwise, the cleaning will not be so effective.
This procedure is repeated until the cleaning carriage reaches the periphery of the sensor. The direction of
travel then changes and the water relay falls. In order to remove the water from the thermal mass, the clea-
ning carriage then executes return movement with compressed air.
On reaching the centre of the sensor, the relay for air switches off and the carriage travels to the park position
at the periphery of the rotor. The cleaning procedure is now completed.

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Scope of delivery
The standard version of the cleaning device includes the following:
Control box for AS 2 cleaning control system, degree of protection IP 54
(dimensions: see dimension sheet: page 25
Cleaning mechanism for compressed air cleaning
Standard guide rail with covering on the inlet side
Carriage with corresponding nozzle supports
Pneumatic nozzle, including hose connections
ca. 5 m pneumatic hose
3/2-way pneumatic valve (230 Volt, nominal flow = 9.6 m3/h),
including hose connections
Sensors (three pre-mounted)
Three-phase motor (400 Volt)
Cleaning mechanism with high-pressure hot-water cleaning
with high pressure nozzle pipe: 150 - 170 bar at 750 - 900 l/h, external diameter of the nozzle pipe
12 mm with screw threads for connecting attachments
with high pressure hose, and optional high pressure fittings
Cleaning medium collector tray on the output side

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In the inspection window, the display shows the status of the cleaning procedure
(Selection) (Enter) (Selection)
Reset Start Stop
With the three buttons, during commissioning the
cleaning procedure can be started, stopped and
driven to the start position.
Button description
for menu navigation
Parkingposition
Standby

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3.4 Connection and commissioning
The mechanical components (rail, carriage, motor, supports, and sensors) are pre-mounted and must be
attached to the frame with screws. The frame is also prepared with rivet-down nuts.
Adjust the pneumatic nozzles and, if necessary, the high-pressure nozzles so that these end around 20 - 30
mm before the thermal mass.
Attention: The nozzle stream must impinge perpendicular to the thermal mass!
Control whether the inductive proximity switches are correctly positioned. The metal vanes of the carriage
must be positioned around 2 mm away from the sensors. This requires adjusting the clamping block at the
end of the rail to loosen the toothed belt. After setting the position switches, position the cleaning carriage in
its centre position and tension the toothed belt again. For the correct connection of the centre and peripheral
sensors, an LED in the AS 2 control system lights up over the respective terminals on contact.
Connect the AS 2 control system according to the terminal plan.
Switch on the mains voltage.
Adjust the clock sensor on the periphery of the rotor. The clock sensor must receive one pulse per rotor
revolution. (sensing distance around 20 mm)
For commissioning, the cleaning control is equipped with three buttons:
Reset (return to the start position), Start and Stop.
.

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Start the cleaning procedure with the Start button. The cleaning carriage must continuously drive towards the
centre of the rotor. If this is not the case, stop cleaning and reverse the direction of rotation of the motor by
switching two phases of the motor.
Whenthedirectionoftraveliscorrect(afterchangingthedirectionofrotation,restartthecleaningcontrol),thecarriage
drivestothecentreofthesensorandthenbeginstheactualcleaningprocess.Youcannowcontrolthecarriagefeed.
Per clock signal, the carriage may not travel more than one nozzle width. In the cleaning control menu,
the operating time of the carriage can be set to a value between 0.5 – 2.5 seconds (default setting 1 second).
After mechanically and electrically controlling the cleaning procedure, execute a so-called teach-in run with
the AS 2 control system (see Section 5 Menu navigation on page 16).
During the teach-in run the cleaning carriage travels without media at maximum wheel speed over the entire
cleaning procedure and counts the pulses during cleaning and during dry travel and stores these internally
with 5% safety margin as limit values.
This procedure serves for the monitoring of the sensors in normal cleaning operation. In the case of a defect
with the sensors, the AS 2 cleaning control system issues an error message due to exceeding the internal limit
value, which remains and switches the media off. This prevents the mechanical destruction of the cleaning
apparatus and the continued flow of the media.
Attention: When the operating time or the tolerance values are changed in the menu, a teach-in run automat-
ically takes place with the next start of the cleaning procedure.

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5. Menu navigation
The operational readiness of the AS2 is indicated by:
To access the menu hold down the Stop button ( ) and press the Reset and the Enter buttons ( ).
Attention: The cleaning procedure can be stopped and then started again with these buttons. When the carriage
is not in the park position or the cleaning procedure is running and someone wants to access the menu, it is
necessary to stop the process. One then starts the reset travel and immediately stops it again with the Stop button
(). The display shows:
Hold down the Stop button and press the Reset and Enter buttons ( ) to return to the menu.
Layout of Menu :
Language Set Clock Startingtimes Calibration Runtime p. Clock
R-RPM Linit Tresholds Drying Cycles Limits (Menuend)
Navigate: with the right button right step, with left button left step
with the central button Enter to access the menu
Parkingposition
Standby
bxxxx
Resetting stop Standby

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Prog. mode
Deutsch
Holding down the Stop button ( ) and then pressing the Reset and Enter buttons ( )
takes you to the Settings menu
The Enter button then takes you to the sub-menu.
Language selection:
Confirm the entry with the Enter button The display then jumps to the next menu item.
Clock setting:
The time is only required if start times are to be programmed (see next menu item).
Select using and . confirms the entry and the display jumps to the next selection.
Sequence: Week day (Mon, Tue, Wed, Thu, Fri, Sat, Sun) Hour setting Minute setting.
Language
English
day hour minSet clock?
Mo 12 33

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Starting times:
Up to 7 start times (start time 1: to start time 7) can be selected. Select using and . The day is set in the
second line (off / Mon / Tue / Wed / Thu / Fri / Sat / Sun). confirms the entry and the display jumps to the next
menu item. If no automatic start is to take place, the start times must be set to “off”.
Calibration:
After mechanically and electrically controlling the cleaning procedure, execute the teach-in run!
Pressing takes you to the following setting options:
After setting the teach-in run, program the start of the AS2. It is immaterial where the nozzle carriage is positi-
oned, as the initial movement is the reset travel. Following the teach-in run, the AS2 automatically switches to
normal operation, followed by:
Confirm the entry with the Enter button The display then jumps to the next menu item.
Normal mode Learning mode
Calibration
Startingtimes
off
Starttime 1:

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Runtime:
In this menu item, you can set the travel time for the cleaning carriage. The nozzles should advance by a
maximum of 10 mm per clock pulse. The default value is 1.5 seconds. Pressing takes you to:
Speedlimit:
To improve the cleaning effect, the maximum rotor speed can be restricted in this menu item (100% max. speed).
Caution: If the rotor speed is restricted, the cleaning process will take longer.
For large wheels with long cleaning tracks (>1.5m), due to the variable speed, the rotor only turns very slowly
as cleaning progresses, so that cleaning takes a very long time (3-5 hours). This can be avoided by setting a
minimum rotor speed limit using this menu item. Adjustment range from 10 - 50% in relation to the control signal
in Volts (e.g.: 30 % = 3 Volt control signal. That corresponds to about 3 rpm at normal rotor speeds (10 rpm)).
Press to continue to the tolerance limit setting:
Runtime p. clock
Taktimpuls 1,5
Runtime per
R-Speedlimit
100%
RinseSpeedlimi t
R-Min-Limit
min: 30%
Coilspeedlimit

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Tolerance limit:
Here, a safety margin is set in % (5, 10 and 20%) for the steps / cycles counted in the learning trip. This is used to
compensate for mechanical gear tolerances and to balance out heat technology-related situations (hot / cold).
Caution: The greater the safety margin, the later the switch-off in the event of a fault. With very long cleaning
distances (>2m), the 5% setting can lead to premature switch-off. After entering the threshold and confirming it
with , you are then taken to the next menu item:
Drying cycles:
Tolerance limit
limits: 10%
Tolerance
Drying cycles
turns/clock 01
Rinse-Drying-