robatherm RMC Series Guide

Air Handling Units
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Installation
Commissioning
Maintenance
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Translation of the original instructions
Englische Version – English Version
Keep for future use
=== Ende der Liste für Textmarke Inhalt2 ===

Copyright by
robatherm GmbH + Co. KG
Industriestrasse 26
89331 Burgau
Germany
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This manual accords with current technology at the time of writing. As the printed version is not regularly updated, please obtain
the latest version before using it, by downloading from www.robatherm.com or on request from robatherm.
The copyright to this work, including all illustrations, is reserved. No use which exceeds the limits of copyright law is allowable
without our permission, and such use will be prosecuted. This applies, in particular to duplication, translation, microfilming and
storage and processing in electronic systems.
Subject to modifications.
=== Ende der Liste für Textmarke Inhalt3 ===
04 / 2015

Contents
Introduction 1
General 1
Safety Instructions 3
Emergency Provisions 4
Maintenance and Cleaning Instructions 4
Installation RMC / RZ / RM / RL 6
Delivery 6
Unloading and Transport 6
Assembly and Installation 8
Sealing of the Roof of Weatherproof Units 17
Commissioning and Maintenance 19
Damper 19
Fan and Motor 21
Filters 28
Silencer 30
Heating Coil (Hot Water, Steam) 31
Electric Heater 35
Cooling Coil (CW – DX Coil) 37
Refrigeration Installations and Heat Pump 40
Rotary Heat Exchanger 42
Plate Heat Exchangers 45
Heat Pipe 46
Desiccant Rotor 47
Combustion Chamber 49
Gas Surface Burner 53
Spray Humidifier 58
High Pressure Spray Humidifier 64
Pressure Relief Damper 66
Controlling Systems 68
Hydraulic Set 71
Shut Down 74
Shut Down 74
Disassembly, Disposal 74

Introduction
© robatherm 1
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General
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Attention
These installation, commissioning and maintenance instructions must be read and
observed by all people who carry out work on the unit. For components which are not
described, the individual instructions are to be observed (request if required).
robatherm will not be held liable for damage or faults which result from non-observance of
these instructions.
The manufacturer’s warranty and the certificate of installation/conformity do not apply for
unofficial or unapproved conversions and changes to the appliance.
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Use for Intended Purpose
The unit supplied by robatherm must only be used for air handling. This includes filtering,
heating, cooling, humidifying, dehumidifying and transporting of air. robatherm expressly
forbids any other use.
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Units with the „Ex“-mark (subsequently described as ATEX-units) are to be used in
accordance with the unit identification on the nameplate and on the technical data sheet in
accordance with the ATEX directive. Be sure to observe any restrictions on use.
ATEX units must not be used near:
High frequency sources (e.g. transmitters)
Strong light sources (e.g. lasers)
Ionising radiation sources (e.g. X-ray tubes)
Ultrasound sources (e.g. ultrasound echo testing equipment)
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Mechanical Equipment Room
The requirements of mechanical equipment rooms must be observed in accordance with the
VDI 2050 for operations and maintenance. This also includes sufficient maintenance space,
ventilation as well as compliance with the temperature and humidity requirements.
In front of heating and cooling coils, it is recommended to allow an obstacle-free area, at
least as wide as the AHU’s depth for maintaining those coils.
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Transport and Storage
All units and components must be transported and stored in such a way that damage,
adverse effects through weather factors, condensation (ensure sufficient rear ventilation
within the packaging) or contamination are avoided. When storing for over 3 months, loosen
belt drives and turn rotating components such as e.g. on ventilators, motors, pumps, HRS
rotors on a monthly basis.
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Installation
If units are supplied in separate sections, these shall be assembled in accordance with these
assembly instructions and professionally connected to the ductwork. All protective devices
shall be applied.
The person responsible for assembly on site and changing non-runable components to
complete ready to operate units is also responsible for issuing the certificate of conformity
and the CE marking.
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Before Commissioning
The unit can only be taken into operation if it has been assembled in accordance with these
instructions. All protective devices must be effective. A lockable service switch must be
installed near the fan unit access door.
Introduction

Introduction
2 © robatherm
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Fire Protection
Possible spreading of fire between supply- and exhaust air sections of the AHU (e.g. via the
heat recovery system or recirculating air) must be prevented by appropriate precautionary
measures in the building site’s system (e.g. fire dampers) by others.
A possibly required down gradient grid, according to DIN EN 1886 and AHU-Guideline 01,
must be installed within the system to prevent any carry-over of flammable parts from filters,
mist eliminators or contact humidifiers into the supply air duct.
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Handover
AHUs with integrated control technology may only be taken into operation after to
robatherm’s initial commissioning and after handover and customer’s briefing has been
concluded.
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Freeze Protection
In case of ambient temperatures below the freezing point, it can make sense not to switch
down the unit, e.g. in order to prevent dampers from freezing or to avoid any failures during a
later restart.
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Introduction
© robatherm 3
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Safety Instructions
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Caution
Serious bodily injuries and even loss of life and material damage can result from non-
observation of the following instructions of the valid national and international safety
regulations.
Even if the unit is switched off, certain regulating functions can lead to sudden switching on
of unit components such as e.g. resumption of power supply, compressor pump-out, fan
overshoot, frost protection, timer programs.
When the fan is in operation, there is perilous voltage on the permanent-magnet
synchronous motor --> danger to life.
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Do not commission ATEX units until the following requirements are met:
Conditions of use in accordance with the purpose for which the unit is intended.
No substances nearby that are prone to spontaneous combustion e.g. pyrophoric
substances under EN 1127-1.
Constant and adequate ventilation of the installation site (mechanical equipment room)
in the case of ATEX units without a specified exterior ex zone so that unavoidable
leakage to the exterior of the unit does not result in an explosive atmosphere.
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Only enter the unit or work on it when the following conditions are met:
All-pole disconnection of power supply.
Minimum waiting period of frequency converter 15 minutes (due to remaining voltage).
Protected against switching on by installations in accordance with DIN EN 60204 (VDE
0113) (e.g. lockable service switch).
Standstill of all moving parts, especially fan impeller, belt drive, motor, rotary heat
exchanger.
Heat exchanger and hydraulic systems adapted to ambient temperature.
Pressure bearing systems must be free of pressure.
Wear protective clothing.
No explosive atmosphere present. (rinse unit beforehand if necessary)
The following requirements must be met before the unit is switched on:
Protective devices must be fitted and effective in accordance with DIN EN ISO 12100
(e.g. protective grille).
Check that no persons are in the danger area, e.g. inside the unit.
Work must only be carried out by a qualified expert.
The floor loading in the AHU must not exceed 100 kg/m² of floor surface.
Basically, the units’ roof is not designed to any additional load. In case of need, please
contact robatherm directly.
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Introduction
4 © robatherm
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Emergency Provisions
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Fire
The local fire provisions must generally be complied with. If there is a fire, disconnect all-pole
power supply to the unit immediately. Close dampers and fire dampers in order to stop the
oxygen supply and the spread of fire. Direct fire-fighting and first aid measures immediately.
Inform the fire brigade. Protection of people has priority over protection of property.
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Caution
Serious damage to health or even loss of life if fire gases are breathed in. In a fire building
materials used may generate toxic substances. Use heavy duty breathing protection!
Serious damage may be caused to health and property by bursting of pressure vessels or
pipelines during a fire. Keep away from danger area!
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Maintenance and Cleaning Instructions
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Equipment
When performing maintenance and cleaning work in explosion hazard zones, only suitable
tools which e.g. prevent sparks may be used in accordance with EN 1127-1 . Conductive
footwear must be used to prevent personnel from accumulating static charge in accordance
with BGR 132.
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Maintenance Intervals
AHUs are machines which require regular maintenance. The maintenance intervals given
are approximate and relate to normally polluted air according to VDI 6022. If air is heavily
polluted, the maintenance intervals must be shortened accordingly. Regular maintenance
does not absolve the operator from his duty of care which involves checking the unit for
function and damage on a daily basis.
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Cleaning and Maintenance of the Casing (including Pans)
Coarse contamination must be removed dry with an industrial vacuum cleaner.
Other fouling: Use damp cloth; with grease and oil dissolving cleaners if necessary
(neutral cleaner with pH value between 7 and 9 in the concentrate).
To completely clean pans with limited accessibility, (eg. under coils) obstructive elements
might have to be disassembled prior to cleaning.
Treat galvanized parts with preservative spray.
All moving parts such as door handles, hinges must be treated with lubricating spray
regularly.
Check sealings, especially door sealings regularly for damage and function.
Immediately eliminate damage to the coating or traces of corrosion by using touch up
paint.
Remove pollution and dirt in gaps or grooves using damp cloth with applicable cleansers
or a vacuum cleaner.

Introduction
© robatherm 5
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To prevent danger of ignition due to electrostatic charge, all surfaces of ATEX units may
only be cleaned with a damp cloth.
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Disinfectants
Only use disinfectants with an alcohol base with country specific approval (e.g. RKI, VAH,
DGKH).
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Recommissioning
After carrying out maintenance or disinfecting measures, ensure the unit is sufficiently clean
before returning to operation. Toxic or odorous substances must not come into the supply
air.
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Leak Test
In clean areas where there must be no transfer of particles from exhaust air to supply air, the
relevant parts must be tested for leakage annually or following any servicing (e.g. by means
of a suitable test gas). Observe manufacturer’s safety instructions! If necessary take suitable
measures to eliminate any leaks in consultation with the manufacturer.
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Supply of Spare Parts / Customer Service / Repair
Changes to the unit must only be carried out by qualified personnel. After carrying out
changes (e.g. installation of spare parts) a new assessment of conformity must be carried
out in accordance with the health and safety requirements of the ATEX guideline by a
qualified person with the relevant documentation before the unit is switched back on. Spare
parts must meet the specific requirements of the ATEX classification applied (category,
atmosphere, temperature classification). It is preferable to use identical original
components. If inappropriate changes are made to the unit by third parties, the robatherm
declaration of conformity ceases to apply.
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Installation RMC / RZ / RM / RL
6 © robatherm
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Delivery
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Goods Inspection
On receipt of the goods they must be checked for damage and completeness. Missing parts
and damage must be noted immediately on the consignment note and be confirmed by the
driver. Details relating to procedures when damage is discovered are noted in detail on the
delivery note. If no such procedures are followed, no liability for defects will be accepted.
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Unloading and Transport
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All units are equipped with lifting eyes or transport loops.
Units without their own base frame are equipped for transportation with expendable pallets.
Only transport unit in usage position (not inclined or lying).
Unloading and transport should preferably be carried out with a crane or fork lift truck.
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Caution
Serious bodily damage or material damage may be caused by falling loads.
Observe the safety instructions of the transporting vehicles.
Do not stop under an airborne load!
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Unloading and Transport by Crane
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Attention
Only use suitable and approved slinging devices (ropes, chains, lifting belts) for unloading
and transporting the units and only fasten them to the lifting eyes or transportation loops in
accordance with VBG 9a (UVV 18.4).
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Installation
RMC / RZ /
RM / RL

Installation RMC / RZ / RM / RL
© robatherm 7
Unloading by Means of Lifting Eyes (image to left)
Fasten slinging device to lifting eyes. If the angle of inclination between the slinging device
and load is less than 45°, then a lifting harness is to be used.
Unloading by Means of Transport Loops (image to right)
The transport loops must be used for unit parts which are fully mounted on a DIN-frame.
For DIN-frame units with six transport shackles and by means of a suitable onsite lifting
equipment (e.g. cargo gear), it is imperative that an even load distribution on all transport
shackles must be ensured.
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Unloading and Transport by Fork Lift Truck
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Attention
When unloading and transporting with fork lift trucks, use forks which go fully underneath
the unit. Only transport units on the base frame or on the pallet.
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Unloading Fork Lift Truck
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Installation RMC / RZ / RM / RL
8 © robatherm
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Assembly and Installation
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Unit Installation
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Attention
robatherm units must not take on any functions of the building itself.
If a unit is misused, for example by substituting base of unit for building roof or by allocating
static functions to the unit, all warranty obligations on the part of robatherm will lapse.
Observe the notes in VDI 3803.
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Foundation
Install units on a firm and flat foundation. Any unevenness, leading to non-parallel frames of
connecting parts, must be flattened out with suitable supports (metal strips or equivalent).
Maximum tolerance to the horizontal is s = 0.5 % (max angle of inclination: 0.3°).
The foundation must conform to the building requirements in terms of statics, acoustics and
proper water drainage (drip pan, air humidifier, etc.). Structural beams must be one single
piece over their entire length. The maximum beam distortion is 1/1000 of the beam length.
The distance between horizontal beams may not exceed 24 modules (2.5 m) (see robatherm
planning recommendations).
The natural frequency of the supporting structure, especially steel supports, must be
separated adequately from the exciter frequency of rotating components of e.g. fans, motors,
pumps, compressors etc,
Standing Safety
Units installed outside must be secured to the foundations in accordance with the expected
wind speed at the place of installation. This applies for all units with integrated motor
extraction device.
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Lifting Gear
Only use suitable and permitted lifting gear for assembly. Only apply lifting gear at the top
edge of the base frame to avoid any deformations.
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Mechanical Equipment Room
The requirements of mechanical equipment rooms must be observed in accordance with the
VDI 2050 for operations and maintenance. This also includes sufficient maintenance space,
ventilation as well as compliance with the temperature and humidity requirements.
In front of heating and cooling coils, it is recommended to allow an obstacle-free area, at
least as wide as the AHU’s depth for maintaining those coils.

Installation RMC / RZ / RM / RL
© robatherm 9
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Note
Check arrangement of functional components and unit design in accordance with data sheet
and drawing prior to starting unit installation.
Sound Reduction
In order to adhere to the permissible sound emission values, sound reducing components
are to be installed at suction and pressure points or on the unit housing (e.g. duct sound
damper, sound proofing walls) if they are not or insufficiently integrated into the unit.
Structure Borne Sound Insulation
Unit bases for structure borne sound insulation e.g. Mafund, Silomer or Ilmod Kompri Band
are to be used in a lengthways and downwards direction.
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Base Frame with Thermal Break
Misalignment of the casing connecting holes through different compression of the decoupling
profile on the basis of weight differences of neighbouring appliance parts must be balanced
out for unit installation e.g. by means of suitable lifting gear.
Lifting Eyes / Transport Loops
Following assembly remove the lifting eyes / transport loops and seal the openings by
means of plugs.
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Unit Connection
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All connecting parts such as screws, sealing tapes and roofing strips (only for weatherproof
units) are included in the units – mostly in the fan unit.
The unit sections are connected by bolts used through the inside. If no access doors are
provided at connection points, the marked covering panels must be removed for better
access.
If unit sections are only accessible from one side, there will be threaded bushes in the frame.
For the stainless steel version only use stainless steel connecting elements.
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Through Bolt Connection
1 – Self-adhesive sealing

Installation RMC / RZ / RM / RL
10 © robatherm
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Bolt with Thread Bushes
1 – Self-adhesive sealing
In order to connect the unit parts, proceed as follows:
Stick self-adhesive sealing along the circumference of the section frame at each division
area of a unit
Note
The sealing must be stuck between the covering panel and the row of holes.
Cut out holes or threaded bushes in the sealing.
If necessary remove marked covering panels.
If necessary press unit parts together with screw clamps.
Connect components.
Refit covering panels which have been removed.
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Sealing of Unit Section Joints
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For residue free cleaning of the unit, all unit casing splits in the base area are to be sealed
with microbially inert PU jointing compound.
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Units in Weatherproof Version
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All unit openings (e.g. duct discharge, electrical connecting box etc.) must be sealed or
equipped with weather protection in order to prevent water ingress into the unit. Do not
position the suction and discharge openings in the main wind direction. Plan the installation
height of the unit in accordance with max. snow level. Connected ducts must be drained
professionally on site.
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Installation RMC / RZ / RM / RL
© robatherm 11
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Connection Air Duct
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All air ducts shall be installed stress-free. Any flexible connectors must not be extended to
their max length. Adjust its installation length at 100 to 120 mm. Air ducts including
connection profiles and flexible connectors should be professionally insulated and protected
from the elements. Provide the same to the units’ frames.
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Flexible Connection
1 – Unit frame, 2 – Flexible connection, 3 – Building duct
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Decoupled Section Frame
1 – Unit frame, 2 – Decoupled section frame, 3 – Building duct, 4 – Sealing
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Installation RMC / RZ / RM / RL
12 © robatherm
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Equipotential Bonding
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Attention
To prevent ignition through electrostatic charge all electrically non-conductive connection
points must be by-passed with equipotential bonding, e.g. decoupled section frame, flexible
connections, vibration isolation. All metallic parts of the units must be included in the local
equipotential bonding measures. The unit must be earthed on the base frame in
accordance with current best practice (foundation electrode). For this purpose a bore hole
at the base frame or a rivet on the floor (for units without base frame) is provided for ATEX
units and marked with an earthing sticker. All connections must be secured against coming
loose.
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Lightning Protection of Outdoor Installations
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For reasons of operating safety a suitable lightning conductor system must be provided in
accordance with local regulations (e.g. DIN VDE 0185).
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Connection of Heat Exchangers
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When connecting heating and cooling water piping (inlet and outlet), care must be taken to
ensure that the inlet and outlet connections are not confused (counterflow principle with
water inlet and air outlet side).
Connection of the Heating and Cooling Water Piping – Example
1 – Inlet, 2 – Outlet, Arrow – Direction of Air
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Installation RMC / RZ / RM / RL
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Attention
Plan and fit pipework to and from the unit so that the heat exchanger is not subject to
stress and strain e.g. as a result of heavy weights, vibration, tensional forces, heat
expansion etc. Use compensators if necessary.
When tightening the threaded connections of the heat exchanger on site use e.g. a pipe
wrench for counter pressure as the inner pipes may otherwise be twisted and damaged.
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The pipes must be flanged in such a way that problem free removal of the heat exchangers
for maintenance or exchange purposes is possible.
Connection of Refrigerating Piping
Prior to connection check the heat exchangers and pipes for leaks, i.e. whether the inert gas
charge on the operation side is still under pressure.
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Connection of the Condensate, Discharge and Overflow Piping
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Provide all outlets with a siphon (with non-return valve and self-filling device) and remove
waste water appropriately. The height of the siphon must be set in accordance with the low
pressure or overpressure of the ventilation unit so that suction or blowing out of the air in
relation to the connected waste water pipe is prevented.
The water must flow directly from the siphon into a catch pit or funnel. Do not under any
circumstances connect the siphon directly to the sewage network.
Connection Siphon
1 – Opening for recharge, 2 – Do not connect any horizontal extension
Calculation of Siphon Trap
The height of the siphon is determined as follows:
Under pressure in the device:
H1(mm) = p/10
HS(mm) = p x 0.075
Overpressure in the device:
H1(mm) = 35 mm
HS(mm) = (p/10) + 50
p = Unit pressure in Pa (always enter positive value)

Installation RMC / RZ / RM / RL
14 © robatherm
Connect siphon directly to appropriate connection and fill with water.
Connection Air Washer
Separately connect drainage pipe of washer and outflow of pan at the front at the waste
water duct.
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Electrical Connection
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Attention
Electrical work must only be carried out by a qualified expert.
Make sure that the electrical connection of weatherproof units is water tight. Connection
from below or waterproof unions (at least protection rating IP 65, use sealings) with
sufficient cable radius.
Check all electrical connections (switch cabinet, frequency converter, motor etc.) for correct
seating and retighten if necessary (see also DIN 46200).
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Electrical components such as electric air heaters, electric motors, actuators, etc. should be
connected and grounded according to manufacturer’s specifications, local electrical
regulations as well as general recommendations concerning the prevention of
electromagnetic interferences (grounding, cable lengths, cable shields, etc.).
The connection tags are attached in the terminal box.
All existing ground straps (equipotential bondings) shall be inspected and, if necessary,
readjusted/retightened.
Electrical safety inspections should take place in accordance with DIN EN 60204 (VDE
0113) and by adhering to all required safety precautions.
The on-site power supply must fulfill the requirements cited in DIN EN 60204, Table 10.
According to nationally valid regulations, the operator is obligated to repeat these inspections
on a regular basis.
In Germany, the periodic intervals of the repeated inspections according to VBG 4 §5 Table
1A (Repeated inspections of stationary electrical units and equipment) must be observed.
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Motor Protection
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Protect motors against overload in accordance with DIN EN 60204 (VDE 0113).
Provide motor protection switch and adjust to the motor nominal current (see nameplate).
A higher set value is not permissible!
Protect motors with integrated PTC thermistor sensors via a PTC release device.
Motors with a nominal power up to 3 kW can generally be switched on directly (observe
power limitations of the responsible energy supply company). For larger motors provide
star-delta circuit or soft start up.
Permanent-magnet synchronous motors must not be operated directly on the net without
extra motor electronic (e.g. appropriate frequency converter) (net-bypass-operation is not
possible).

Installation RMC / RZ / RM / RL
© robatherm 15
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Motors which are operated in an explosive atmosphere and with a frequency converter must
be equipped with an ATEX tested PTC control element. The correct connection of the motor
and with it the application of a tested monitoring element must be assured by the
customer/operator.
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Attention
Fuses and circuit breakers are not sufficient motor protection.
For damage due to insufficient motor protection the manufacturer’s warranty lapses.

Installation RMC / RZ / RM / RL
16 © robatherm
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Clean Up
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When assembly is complete all components must be inspected for contamination and
cleaned if necessary in accordance with VDI 6022. Metal swarf in particular must be
removed carefully as it can lead to corrosion.
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Caution
Observe general safety instructions on page 3!
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Access Door
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On completion of the assembly work all access doors must be checked for freedom of
movement. Depending on the operating conditions it can be necessary to align the access
doors accordingly. Bolt torque: 3 Nm.
Hinge side (image left): The long holes in the hinge carrier enable vertical alignment of
the door leaf, the long holes in the hinge bracket allow horizontal alignment.
Lock side (image right): Following alignment of the door leaf on the hinge side, an
adjustment of the outer lock may be necessary. For this purpose the ramp of the closing
cam can be adjusted vertically and the closing housing horizontally.
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Rotary Heat Exchanger
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For rotor housings which are supplied separately the rotor housing must be bolted in position
as instructed by the rotor manufacturer prior to installation of thermal mass.
For this it is necessary to lower the upper rotor housing accordingly.
Assembly of Rotors
In case assembly of a rotor is provided by the customer, the client is responsible that the
connection between rotor and unit casing will be professionally made and tightened (e.g.
with elastic joint seal).
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