Wolf KGW Series User manual

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Art.-Nr. 30 40 530
Installation and
Maintenance
Instructions
KG / KGW Standard air-conditioning units
10/00 TV GB
Wolf GmbH · 84048 Mainburg · Postfach 1380 · Telefon [phone] · Telefax 08751/741600

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Contents
Contents ...................................................................................... Page
Warnings / Notes on safety.................................................................. 3
Standards ............................................................................................ 4
Deliverytosite/Transportation ............................................................ 5
Notesoninstallation........................................................................ 6-12
Connection to electricity supply .................................................... 13-14
Initialoperation .............................................................................. 15-17
Maintenance ................................................................................. 18-19
Protectionagainstfrost ...................................................................... 19

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TheseInstallationandMaintenanceInstructionsapplyonlytoWOLFKGandKGW
Standardair-conditioningunits.
Thepersonschargedwiththeinstallation,initialoperationormaintenanceofthe
equipmentmustreadthese instructionsbeforecommencingwork.
Compliance with these instructions is mandatory.
Non-compliancewiththeinstallationormaintenanceinstructionsvoidstheWOLF
guarantee.
The following symbols and warnings are used in these Installation and Mainte-
nanceInstructions:
Non-compliancewithnotesmarkedin this way can endanger persons.
Non-compliance with notes marked in this way can result in damage to the air-
conditioning unit or its components.
In addition to the warnings in these Installation and Maintenance Instructions,
adhesivewarninglabelsareaffixedtotheair-conditioningunit.
Compliancewith these warnings, too, is mandatory.
- Installation,initialoperation,maintenanceandoperationoftheair-conditioning
unitmustbeentrustedtoadequatelyqualified and trained persons.
- All work on electrical systems must be performed by a trained and qualified
electrician.
- Work on electrical systems is subject to VDE regulations and the regulations
of the local power utility.
- Operatetheair-conditioningunitonlywithinthenominalrangespecifiedinthe
WOLFtechnicaldocumentation.
- Use as designated by the manufacturer is use solely for the purposes of
ventilation.
Atmospheric air is the only permitted medium.
Thisairmustbefreeofnoxious,flammable,explosive,aggressive,corrosion-
promotingorotherwisehazardousconstituents.
(Air-conditioningunitsrated"Ex-Schutz"incompliancewithVDMAGuideline
24169/1(suitableforuseinhazardousenvironments)canbeusedtohandleair
mixedwithexplosivegases,vapoursormistsinaccordancewiththeequipment
ratingsforhazardous-environmentclasses1and2).
- Donotremoveorbypasssafetydevicesormonitoringdevices,orrendersuch
devicesineffectiveinanyotherway.
- Do not operate the air-conditioning unit unless it is in perfect working order.
Faultsanddamage detrimental to orpotentially detrimental to safetymustbe
repaired immediately by a specialist.
- UseonlygenuineWOLFcomponentsasreplacementsfordamagedordefective
partsandcomponents.
General
Warnings
Notesonsafety
Warnings /
Notes on safety
Caution

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ThestandardsandregulationsapplicabletotheKG15-250Standardseriesand
theKG/KGW630-1000seriesair-conditioningunitsare as follows:
- ECDirective89/392/ECwithAddendum93/44/EC
(9thOrdinance,EquipmentSafetyLaw)
- EDirective89/336/ECwithAddendum92/31/EC
(LawconcerningElectromagneticCompatibilityofDevices)
- ECDirective73/23/EC(LowVoltageDirective)
(1stOrdinance,EquipmentSafetyLaw)
- DIN31001/1 Safetydesign of technical products
- DINEN292 Safety of machinery, basic concepts
- DINEN294 Safety of machinery, safety distances
- DINEN349 Safetyofmachinery, minimum gaps
- DINISO1940/1 Mechanicalvibration,balancequalityrequirements
- VDMA24167 Fans;safetyrequirements
- VDE0100 Erectionofpowerinstallationswithratedvoltagesbelow
1000V
- VDE0105 Operationofpowerinstallations
- VDE0700/Part500 Safetyofhouseholdandsimilarelectricalappliances
- VDE0701/Part1 Repair,modificationandinspectionofelectrical
appliances
- VBG 5 Poweredequipment
- VBG 7w Fans
Plus the following, only for special air-conditioning units for use in hazardous
environments:
- VDMA24169/1 Guidelineforfansforhandlingatmospherecontaining
flammablegases,vapoursormist.
Plusthefollowing,onlyforweatherproofedair-conditioningunits:
- VDMA24175 Roof-mountedair-handlingunits
Standards
Standards

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Delivery to site / Transportation
Delivery to site
Transport
Clearances
KG15-250andKG/KWG630-1000seriesairconditionersaredeliveredtositein
transportableunits.
Check all incoming goods for signs of damage in transit.
Make a note of all damage or suspected damage on the waybill and have this
damagereportcountersignedbythedeliveringfreightforwarder.
Immediately report the situation to WOLF.
The equipment must always be transported right way up, in other words in the
positioncorrespondingtotheas-installedposition.
Exception:KGXD160/250uprightistransportedonitsside (turnedthrough90°).
Usestrapsofadequateload-bearing strengthtocarrythesuspendedload.
Ifyouuseafork-liftor rollers tomovetheequipment,alwaysmakesurethatthe
forksor rollers are beneaththe frame sections, notbeneath the floor panels.
If you suspend the load by means of eyebolts (on request), make sure that the
lengthofeachrope run is at leastequalto the distance between the eyeboltsL.
Make sure all ropes are the same length.
TheweatherproofedKGW630to1000air-conditioningunitsarefittedwithlifting
eyes as standard.
Alwaysusecross-barswhenliftingitemsofequipmentfittedwithmorethanfour
eyebolts.
Clearanceon the operating side should be atleast equal tothe width of theunit
to permit access for installation, operation and maintenance (see list below).
Spacerequiredforinstallation,operationandmaintenance:
Fan section 0.8 x widthofunit
Chiller, heater section, KVS 1 x width of unit + 250 mm
Filter section up to KG 100 1 x widthofunit
KG160and larger 0.5 x with of unit
Inaside-by-sideconfiguration,allowtheclearancesasstatedaboveforinstalla-
tion,operationandmaintenanceoneachside.
Thoseunitswhichrequireasiphon(washer,humidifier,chiller,KGX/KGXD,drip
separator) must be installed in such a way as to ensure correct installation and
operationofthesiphon(donotforgettoallowforheightoffoundation).
In Germany, special statutory conditions apply to extractor systems for en-
closed parking lots. Comparable legislation may apply in other countries.
Caution

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Notes on installation
Foundation Install the units and components on a surface which is smooth, level and of
adequateload-bearingstrength.
Thebaseframesmustbehorizontalandthefoundationsmustbesmooth-topped
andhorizontal.
Makesurethatthebottomoftheframeisinfull-facecontactwith thesupporting
surface: spot support is not permissible.
Permanently elastic inserts must be placed between supporting surface or
foundationandair-conditioningunitor,moreaccurately,baseframe,inorderto
preventtheoperatingnoiseoftheair-conditioningunitcarryingintothebuildingas
structure-borne sound. By prefence, these inserts should be in the form of
insulatingstripsplacedlengthwaysunderthesectionalframemembers.
KG 40-250:
Insulating strips
(by others)
55
min. 200
Insulation
by others
Base frame
Strip foundation
X
Caution
KG/KGW 630-1000:
KGW 630-1000: Theunitsandcomponentsmustbeinstalledonabaseframeorstripfoundation.
Height to suit local snowfall, min. 200 mm.
X = width or length of unit, as appropriate - 20 mm
Thebaseframesmustbehorizontalandthefoundationsmustbesmooth-topped
andhorizontal.
Makesurethatthebottomoftheframeisinfull-facecontactwith thesupporting
surface: spot support is not permissible.
Permanently elastic inserts must be placed between supporting surface or
foundationandair-conditioningunitor,moreaccurately,baseframe,inorderto
preventtheoperatingnoiseoftheair-conditioningunitcarryingintothebuildingas
structure-borne sound. By prefence, these inserts should be in the form of
insulatingstripsplacedlengthwaysunderthesectionalframemembers.
Wooden batten
Donotsetdowntheunitonaflatsurface,asthiswoulddamagethedripnose(see
drawing). Use wooden battens of adequate thickness as supports to avoid this
difficulty.
Insulating strips,
supplied by others
Base frame, delivered
in advance Base frame,
installed

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KGandKGWconfigurationsincorporatingawashersectionrequireabaseframe
or foundation lower at the floor of the washer unit than elsewhere, because the
bottomofthewashersection islowerthanthatoftheothersections. Theheight
ofthebaseframedependsonthetypeofwasherandisspecifiedwhenthedesign
oftheair-conditioningsystemisconfigured.
Iftheunithasintakefrombelowordischargedownwards,remembertoinstallshort
lengthsofductingbeforeloweringtheunitontothefoundation.
Baseframesareeithersecuredtotheunitordeliveredseparately(inadvance).
Baseframesdeliveredinadvanceareinsectionsandmustbeassembledonsite
inaccordancewiththeinstructionsenclosedwiththeshipment,thenalignedand
securedtothesupporting surface.
The matrix of base frames of sectional units delivered complete with their base
frames matches that of the units.
KGW: The base frame has to be insulated and integrated into the roof sealing
systemonsite.Itisadvisabletoinsulatebaseframesdeliveredinadvance
ontheinside,becausethismakesitconsiderablyeasiertointegratethe
weathersealinto the roof sealing system.
Theunitshavetobeloweredontothebaseframeorfoundationandalignedinsuch
awaythatthegapbetweenbaseframeorfoundationanddripnoseisapprox.10
mm all round.
Short lengths of
ducting
Base frame
Roof
Insulating strip
by others Weather-
seal
Insulation
Notes on installation

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Notes on installation
Securingthesections Sections with angle-section frames (KG 40-250) are secured by means of M6
threadedfastenersandclipspacers.Sectionswithsquare-sectiontubularframes
(KG/KGW630-1000)requireM12bolts.
Thecubeshavepre-drilledholestoaccommodatethethreadedfasteners.Allthe
smallitemsrequiredforassemblyareshippedalongwiththeaccessoriespacked
inside a section with an inspection door (usually the fan section). This section
bearsanadhesivelabelmarked “ZubehörimGerät”(accessoriesinside)byway
ofidentification.
Toensurethatthesectionsarefullysealed,beforeboltingthecubestogethermake
sure that the self-adhesive sealing tape (KG) or the permanently elastic sealing
compound (KGW) supplied with the sections is correctly installed.
KG15-250
KG630-1000
KG40-250
KGW630-1000
Sealing tape
Sealing tape
Sealing compound
Onlyforrecirculating-airflap
andhex.self-tapperØ8x25
Sealing tape

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Notes on installation
Configurations:
stackedorside-by-side Sectionsforstackedconfigurationsaredeliveredtositeseparatelyandmustbe securedtogetheronsitewiththeaidoftheenclosedself-tappingscrews (KG40-
250)orenclosedaccessories(KG/KGW630-1000).
Thesectionswhichmakeupthestackedorside-by-sideconfigurationcannotbe
securedtogetheruntilthevarioustransportableunitshavebeeninstalledonsite
in their final positions.
To facilitate assembly on site, the frame of the bottom section for a stacked
configurationoronesidesectionforaside-by-sideconfigurationispre-drilledex-
works to accommodate the self-tapping screws. After securing the sections
together,donotforgettofittheenclosedplasticcapstothetipsoftheself-tapping
screws(KG40-250).
An adhesive label on the face of the skinning panel bearing the words “Zur
Gerätemontage Verkleidungsplatte abnehmen” (remove panel for assembly)
indicatesthe positions of the pre-drilled holes.
The unit is delivered to site fully assembled. The sections can be separated for
handlingandreassembledatthe finallocation.
Thesectionalframesofaseparableunitareintwopartsheldtogetherbyasteel
flator an angle.
Separatingthesectionsofa KG40-250entailsremovingtheframeinsulation(if
fitted).Donotforgetto reinstalltheinsulationbeforeboltingthecubestogether.
For separation
(onrequest)
Plastic cap
Frame, top section
Frame, bottom section
Self-tapping screw
KG 40-250 KG 630-1000

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Notes on installation
The weatherproofed KGW 630-1000 air-coinditioning units have a UV-resistant,
weatherproof skinned roof.
Fully assembled units are supplied complete with the roof pre-installed.
Each section of a sectionalized unit has its own roof; the butt joints in the roof must be
sealed on site once the sections are installed. The appropriate quantities of sealing
materials (Rhepanol paste, self-adhesive strips of roofing material, bonding material)
are enclosed with the sections.
Have the work of sealing the roof carried out by a specialist company. Cleanliness and
meticulous care are important for an adequate seal.
The roof is not resistant to organic solvents (e.g. benzine) or substances which contain
solvents (e.g. paints). Use only the bonding agent, Rhepanol paste and adhesive
supplied with the air-conditioning unit.
KGW roof
Unscrew the lifting eyes after the secrtions have been bolted together. Cut out a plug of
theroofmaterialdirectlyaboveeachofthetappedboresfortheliftingeyes.Inserttheplugs
supplied for the purpose to seal the tapped bores and apply patches of self-adhesive
roofingmaterial (10x10cm).Coatthejointswithbondingagent,removethebackingpaper
and press the patches down firmly.
Coat the butt joints between the sections with bonding agent and position the strips of self-
adhesive roofing material over the joints, remove the backing paper and press down firmly.
Fillthejointsbetweensectionswhichcarryairaboveatmosphericpressure(thosedownstream
of the fan, in other words) with Rhepanol paste before applying the strips of roofing material.
At the intersections of longitudinal and transverse joints between sections, run a bead
of Rhepanol paste approx. 5 mm thick and at least 12 mm long as illustrated before
affixing the topmost strip of roofing material.
Where the roofing material overlaps at a joint (e.g. projection), apply a bead of black
Rhepanol paste 5 mm thick and at least 12 cm long at the overlap as illustrated before
affixing the strip of roofing material.
Where two adjacent sections are of different heights, affix the flap of roofing material
to the vertical sidewall with adhesive and use the metal strips to secure the flap in
position. Run a bead of transparent sealing compound allong the top edge of the metal
strips to seal.
Liftingeye
Long.andtrans.joints
Flat to stacked transition
Long. and transverse joints
Joint Lifting eye
Flat to stacked
transition Overlap
Plug
Roof mat.
Strip of roofing
material
Joint between sections
Rhepanol paste
Strips of roof. mat.
Rhepanol paste
Strip of roofing
material
Overlap
Roofing material
Metal strip
Seal. compound