Wolf KG Gigant Series User manual

1
Gigant
Art.-Nr. 30 40 549
Installation and
maintenance instructions
Air-conditioning units KG/KGW Gigant
10/00 TV GB
Wolf GmbH · 84048 Mainburg · Postfach 1380 · Telefon [phone] · Telefax 08751/741600

2
Gigant
Contents
Contents...................................................................................... Page
Information signs / Safety information ................................................ 3
Standards............................................................................................ 4
Delivery / Transportation..................................................................... 5
Installation information................................................................... 6-12
Electrical connection ....................................................................13-14
Commissioning of the unit............................................................ 15-17
Maintenance.................................................................................18-19
Maintenance / Frost protection.......................................................... 19

3
Gigant
Caution
These installation and maintenance instructions apply exclusively to WOLF
KG/KGW Gigant air-conditioning units.
Before installation, commissioning or maintenance, these instructions must
be studied by the personnel responsible for the respective operations.
The specifications contained in these instructions must be complied with.
Any non-compliance with the installation and maintenance instructions
invalidates all guarantees issued by WOLF.
These installation and maintenance instructions use the following symbols
and information signs:
Non-compliance with information displaying this sign can lead to personal
injuries.
Non-compliance with information displaying this sign can lead to damage of
the air-conditioning unit or its components.
Apartfromtheinformationsignsintheinstallationandmaintenanceinstructions,
corresponding labels are also attached to the machine.
These have the same importance.
- The air-conditioning unit may only be installed, commissioned, maintained
and operated by qualified and trained personnel.
- Electrical work may only be carried out by qualified electricians.
- All electrical installation work must comply with the VDE regulations and
conditions specified by the local electricity board.
- The air-conditioning unit may only be operated within the performance range
specified in the WOLF technical documentation.
- The air-conditioning unit is specified to be used exclusively for ventilation
purposes.
The unit may only convey air.
The air may not contain any harmful, combustible, explosive, aggressive, or
corrosion-enhancing constituents or constituents representing any other
hazards.
(With special ”intrinsically safe” air-conditioning units according to VDMA
directive 24169/1, the conveyance of air mixed with explosive gases, vapours
or mist is permitted in hazardous zones 1 or 2, depending on the type of unit.)
- Safety and control equipment may not be removed, bypassed or taken out of
action in any other way.
- Only air-conditioning units in perfect technical condition may be operated.
Faults or damage adversely affecting or impairing the safety of the unit,
require immediate expert attention.
- Faulty parts and components of the unit may only be replaced by original
WOLF spare parts.
General
Information signs
Safety information
Information signs /
Safety information

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Gigant
The following standards and regulations apply to the air-conditioning units of
the KG/KGW Gigant series:
- EC Directive 89/392/EEC incl. amendment 93/44/EEC
(Ninth Regulation relating to the Safety of Equipment Act)
- EC Directive 89/336/EEC incl. amendment 92/31/EEC
(Electromagnetic Compatibility of Equipment Act)
- EC Directive 73/23/EEC (Low-Voltage Directive)
(First Regulation relating to the Safety of Equipment Act)
- DIN 31001/1 Safe design of technical products
- DIN EN 292 Machine safety; design guidelines
- DIN EN 294 Machine safety; safety distances
- DIN EN 349 Machine safety; minimum distances
- DIN ISO 1940/1 Mechanical vibrations; balance quality
- VMDA 24167 Fans; safety requirements
- VDE 0100 Regulationsfortheconstructionofhigh-voltageinstallations
up to 1000 V
- VDE 0105 Operation of high-voltage installations
- VDE 0700/500 Safetyofelectricalequipment used for domestic andsimilar
purposes
- VDE 0701/1 Maintenance, alteration and testing of electrical equipment
- VGB 5 Powered tools
- VGB 7w Fans
additionally only for intrinsically safe types of air-conditioning units:
- VMDA 24169/1 Directive for fans conveying atmospheres containing
combustible gases, vapours or mists
additionally only for weatherproof types of air-conditioning units:
- VMDA 24175 Roof-mounted central units for air-conditioning systems
Standards
Standards

5
Gigant
Caution
Delivery / Transportation
Delivery to site
Transportation
Required space
Air-conditioning units KG/KGW Gigant are supplied in transportable units.
Upon arrival on site, the unit or its components must be checked for any
transportation damage.
Incaseofdamage or suspected damage, thismustbespecified on the shipping
note by the recipient and countersigned by the forwarder.
The recipient must relay the respective details directly to WOLF.
Units may only be transported in their fitting position.
Exception: KGXD 250 is laid flat (90° turn) for transportation.
Transport units with carrying straps!
When using fork lift trucks or rollers, ensure that the lifting fork or rollers are
positionedunderneaththeframeprofilesandnot underneath the bottom panels.
When using lifting eye bolts (on request), the length of the lifting cable must
correspond to at least the distance L between the eye bolts. Ensure identical
cable lengths!
Units with more than 4 eye bolts must be lifted with the aid of a lifting beam!
For assembly, operation and maintenance, at least a space equivalent to the
width of the unit should be available on the operating side (see table below).
Space required for assembly, operation and maintenance:
Fan section 0.8 x unit width
Cooling coil/heating coil and
surrounding coil 1 x unit width + 250 mm
Filter section up to KG 100 1 x unit width
from KG 160 0.5 x unit width
Fordoubleunitsinstalled side-by-side, the above spaceforassembly, operation
and maintenance is required on both sides.
Unitsrequiring a draintrap (washer,humidifier, cooling coils, KGX/KGXD, drop
eliminator) must be installed in such a way, that the proper installation and
function of the drain trap is guaranteed (pay attention to foundation height).

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Gigant
Caution
Installation information
Foundation /
Base frame
Insulation
stripson site
x = unit width - 30mm
KGW:
To avoid the transfer of structure-borne sound from the air-conditioning
unit to the building, a permanently elastic intermediate layer must be
provided between the installation surface or foundation and the air-
conditioning unit. This intermediate layer should preferably consist of
insulation strips fitted along the frame profiles of the unit.
KGW: For the installation and assembly of the units and unit components a
base frame or foundation base is required.
The unit may not be placed on level ground as this would damage the
throating (see illustration). To avoid any damage, the unit may, if
necessary, placed on timber strips.
Base frames must be horizontally aligned and the foundation base must be level
and horizontal.
Thewholeundersideoftheequipmentframemustbeincontactwiththesupporting
surface; gaps underneath the frame are not permissible.
Timberstrip
WOLF base frames are supplied either pre-fitted to the unit or as separate
modules (shipped in advance).
Separately supplied base frames are supplied as individual sections and must
be assembled, aligned and fixed to the installation surface on site, according
to the instructions supplied with the base frame.
For units pre-fitted with base frames but supplied in sections, the base frame
sections correspond with the relevant unit sections.
KGW: Theinsulation of thebase frame and its integration into the roofsealing
layermust be carriedout on site. For base frames supplied inadvance,
it is recommended to install the insulation on the inside of the base
frame, as this makes the integration into the roof sealing layer
considerably easier.
Washer
Screw
Cinnecting
bracket
Bolt
Dripedge
Baseframe
When positioning on the base frame or the foundation base, the units
must be aligned in such a way that a gap of approx. 15 mm between
the base frame or foundation base and the throating remains on all
sides.
After the completion of the assembly, the air-conditioning units must
be secured to the base frame foundation base with the brackets
supplied.
Insulation
stripson site
Insulation
Sealing
Insulationstrips onsite
KG:
Grundrahmen
vorabgeliefert Grundrahmen angebaut
KG: For the assembly and installation of the units and unit components, a
level and horizontal floor, with the right load-bearing capacity, is
required.
Base frames must be horizontally aligned, foundation bases must be
level and horizontal.
The whole underside of the equipment frame must be in contact with
the supporting surface; gaps underneath the frame are not permissible.

7
GigantInstallation information
The weatherproof KGW units have a lid made of galvanised steel panels.
On units supplied as a complete unit, all lid sections have been fitted.
In the case of separately supplied units, the lid section of the supplied units
has been pre-installed. Should the separation points of the unit not correspond
with the division of the lid sections, the necessary individual lid section is
supplied as a loose part and must be installed on site after the unit has been
assembled. The required fixing and sealing material is supplied with the unit.
Use a plastic mallet for fitting the cover strip!
Roof
Foamstrip
Spacerwasher
Distanzscheibe
Self-tappingscrew
andsealingwasher Cover strip
For units with washers, a base frame or foundation base must be used for KG
and KGW units, as the washer protrudes from the bottom of the unit. The
required height of the base frame depends on the type of washer and will be
separately specified during the design of the housing.
For units that have the inlet and outlet facing downwards, install short duct
sections before positioning the units onto the foundation.
Shortductsections
Baseframe
Roofsection

8
GigantInstallation information
Unit connection The cubical unit sections are connected to one another with M8 screws. For
this purpose, the cubes contain bore holes at respective locations.
All small assembly parts and loosely supplied accessory are packed in a
component fitted with an inspection door (preferably fan component). The
respective component is identified by the label ”Accessory inside
component”.
Before screwing together the cubes, the self-adhesive sealing tape (KG) or
the permanently elastic sealing material (KGW) must be applied to one side.
To ensure maximum sealing, the dimensions shown in the following
illustrations must be observed.
After tightening the connecting screws, the respective loosely supplied frame
cappingsections must be assembledand secured to theinternal frame corners
(sheet metal screws).
In cases where, for design reasons, the frame capping sections cannot be
removed, respective holes in the frame capping sections will be provided by
the manufacturer. These holes must be sealed with the supplied plastic plug
after the units have been screwed together.
KG KGW
Double frame
capping section
Internal frame corner
Frame capping
section

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Gigant
The joints between two unit cubes are covered, as far as possible, with a
double frame capping section. In some instances, however, double frame
capping sections cannot be used for design reasons. In these cases, single
framecapping sections are usedand the gapremaining on all sides,is covered
with a plastic cover strip or a plastic sealing section.
A sufficient number of parts of the appropriate dimensions, required for the
assembly (double frame capping section, plastic sealing strip, plastic sealing
section) are supplied with the unit.
To ensure their correct assignment to the individual components of the unit,
they are numbered accordingly.
The double frame capping section is screwed to the internal frame corners
after the assembly of the unit sections.
The plastic cover strip is glued to the unit cube frame before the unit cubes
are assembled. For this purpose, it has an adhesive strip on one side.
In the case of disassembled units, for which the frame capping cannot be
installed by the manufacturer and which at the same time use plastic internal
framecorners, these internal framecorners cannot be pre-installedin the cube.
In this case, the required number of plastic internal corners - labelled
accordingly- are supplied with the unit.
For assembly, the internal plastic corners are, after removal of the unit panels,
inserted into the corners of the unit frame and screwed to the frame with the
capping sections.
Installation information
Double frame capping section
Plastic
cover strip

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Gigant
Piggyback units For piggyback units, where the top and bottom units are supplied separately,
the units must be secured to each other on site.
The manufacturer makes provisions for the connections to be made with self-
tapping screws. The required number of self-tapping screws are supplied with
the air-conditioning unit.
The top and bottom unit can only be screwed together after the individual
cubes of the top and bottom units have been assembled.
In some cases, permanent elastic sealing strips or plastic sealing strips must
be applied before positioning the top onto the bottom unit (see page 8/9).
To simplify the assembly, the manufacturer provides holes in the cube frame
and frame capping of the bottom unit at the intended joints.
The holes in the frame capping must be sealed with the supplied plastic plugs
after the top and bottom unit have been screwed together.
In some cases, plastic sealing sections must also be applied (see page 9).
The areas intended to be joined are identified by the manufacturer with a label
on the covering panels on the external side of the unit (”Remove cover panel
for assembly of unit”).
The label can be removed from the panel without leaving any marks.
Installation information
Demountable version
(on request) Theunits are supplied inassembled condition. They maybe demounted before
transportation and be reassembled on site.
The frame sections of the demountable version are separated in the centre
and bolted together with a steel plate.
For demounting, the internal frame cover must be removed and reassembled
after assembly of the cubes.
Frameof topunit
Frameof bottomunit
Framecapping
Self-tappingscrew
Plasticplug