Wolf KGW Series User manual

1
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

2
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

3
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

4
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

5
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

6
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

7
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

8
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

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Notes on installation
Thefan shaft mustalways be horizontal.
Remember to remove the transportation locking devices of fans mounted on
vibrationdampersprings.
Wheninstalling,bearinmindthatthemaximumpermissibledistancebetweenthe
connecting flanges is 100 mm, in order to ensure that the sailcloth adapter has
fullfreedomofmovement.
Sailcloth adapters might require on-site insulation against acoustic emissions
andcondensation.
Theheatexchangers(chillers,heaters)workonthecounter-flowprinciple,inother
wordstheheatingorchillingmediumflowsinthedirectionoppositetothatofthe
airstream.This,inturn,meansthattheflowconnectionforthemediumisalways
situated on the air-outlet side of the heat exchanger.
Connect the heat exchangers in such a way that no mechanical stresses and
strains from the piping system are transferred to the heat exchangers.
Alsoprovidereliablemeansofpreventingthetransmissionofvibrationfromair-
conditioning unit to piping system.
Makesurethattheconnectingpipeworkdoesnothinderaccesstootherpartsof
theair-conditioningunit(fan,filter,washer, etc.).
Thesteaminletofsteamregistersisalwaysatthetop(large-diameterport)and
the condensate drain must always be at the bottom.
When connecting the flow and return pipes, always counter-hold the threaded
adaptersoftheheatexchangertoavoidtorsionalloading.
Makesurethatadequateprovisionismadeonsiteforbleedinganddraining.
Makesurethatasiphon isconnectedtothecondensatedrainofthe chillertray.
Outside the skinning panels, the pipes must be insulated on site.
Heat exchanger
Fan section
Sailcloth adapter
Locking
devices
Caution
Caution
Caution
Chiller installed on site:
Air flow
Cond. drain, siphon
Drip separator
Chiller
Remove the side panel and remove the drip separator with condensate tray (the unit
is shipped with the drip separator located in the guide rails).
Run a bead of sealing compound around the drip-separator frame and secure it to the chiller
element.
Caution: Make sure that the condensate drain apertures of the drip separator are at
the bottom.
Secure the clip-on shield to the collector side of the chiller element at the air inlet: note
that the arrangement depends on the direction of air flow.
Arrangement of components along the direction of air flow:
Chiller element, drip separator, condensate drain.
Slide the fully assembled unit into the chiller section; the chiller element is held in the
guides.
Reinstall the side panel.
Flow Return
Dir. of air flow Dir. of air flow
Return Flow

12
Wheninstalling,takecaretoensurethatnodirtorotherforeignmatter penetratesinside
the washer.
The water used for the washer under normal conditions must meet the following
minimum quality requirements (VDI 3803):
Appearance clear, colorless, no settlement
pH value 7 to 8.5
Total salt content <800 g/m³
Electrical conductivity <100 mS/m (at 20°C)
Calcium ion content >0.5 mol/m³
Carbonate hardness <4.0 °d
Carbonate hardness in conjunction
with hardness stabilizers <20 °d
Chloride content <180 g/m³
Sulfate content <290 g/m³
KMnO4consumption <50 g/m³
Germ count <1000 ml-1
Connection of the washer to the public water supply is subject to the stipulations of DIN 1988.
Asiphonmust be connectedtothe condensate drainsfromchiller tray,washeroverflow
and KGX/KGXD tray to ensure the reliable removal of condensate.
Each condensate drain requires an siphon of its own.
It is not permissible to connect two or more drains to a common siphon.
Siphons are available from WOLF as accessories. In this case the height of the siphon
is calculated ex-works.
If the siphon is obtained from other sources, calculate the height as shown in the
illustration on the left.
The effective odor-trap height H (mm) must be greater than the maximum partial
vacuum or overpressure (in Pa) in the air conditioning unit (1 mm WG = 10 Pa).
The difference in height between the drain outlet and the siphon overflow must also be
H (mm).
Itisalwaysimportantto takethe heightofthe foundationinto account,inordertoensure
that sufficient clearance is available for installing the siphon.
The siphon must drain to the open, and not directly to the waste-water drainage system
(see illustration). Long drain lines require ventilation in order to avoid a build up of
condensation in the line.
Fill the siphon with water prior to initial operation and after long stoppages.
Notes on installation
Washersection
Odor trap
Odor trap connection
1 1/4” outside thread
Theweatherproofenclosureismadeofsandwichpanelswithaninspectiondoor.
Thepipes have to be insulated on site.
Connectionsinsidetheenclosure,eitherinoropposedtothedirectionofairflow.
Installation of the pipes and fittings in an adjacent section.
Connectionstotheside,outsidetheside panel. Installation of the pipes on site.
KGW630-1000weatherproofenclosure:
Caution
Insulating strips
by others

13
Caution
Connection to electricity supply
The air-conditioning unit must be wired by a trained, qualified electrician in
accordance with the applicable regulations (VDE, local power utility, etc.).
If the intake fan or discharge fan is switched off or fails, all control valves
mustcloseautomaticallyandthehot-water/cold-waterandwasherpumps
mustshutdown.
Install only control valves which are closed when de-energized and a frost-
protectionthermostatwithoutrestartdisabler.
Install a lockable repair switch for each drive motor to ensure that the air-
conditioning unit can be reliably shut down.
Completionoftheelectricalwiringworkmust be followedbyasafetyinspection
oftheinstallationinaccordancewithVDE0701Part1andVDE0700Part500or
comparablenationalsafetycodes.
Use only electric motors designed to drive fans.
Always comply with the wiring diagram in the terminal box.
Use a thermistor-type trigger for a motor with PTC thermistor, an interlock
contactor for a motor with thermo-contacts, or a thermal overcurrent relay for a
motorwithoutPTCthermistoror therm-contacts.
Connection to electricity
supply
5-stagecontrol
1 unit: Switch: E5-3
2 units parallel: Switch: E5-7
Switch type E5-3 E5-7
Voltage 230V 230V
Currentmax. 3A 7A
Weight 4.7 kg 8.5 kg
Protection IP40 IP40
5-stagecontrol
1 unit: Switch:E5-7T
2 units parallel: Switch:E5-14T
Switch type E5-7T E5-14T
Voltage 230V 230V
Currentmax. 7A 14A
Weight 8.5 kg 12.5 kg
Protection IP40 IP20
KG15 KG20
Mains
230V~
Mains
230V~ Fan Fan with
thermo-contact
*Removejumperifaroom thermostatisconnected
* Removejumperifaroom thermostatisconnected
H1=Operation
H2= Fault

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Connecting to electricity supply
Wiring for single-speed drive
Motors up to 2.2 kW usually have direct startup,
whereas a star-delta circuit is usual as of 3 kW.
Wiring for two-speed drive with 1:2 ratio
(Dahlander winding)
For example, for 1500/3000 rpm or 750/1500 rpm
Wiring for two-speed drive
(2 separate windings)
For example, for 1000/1500 rpm or 750/1000 rpm
Wiring for three-speed drive
(2 separate windings, 1 is a Dahlander winding)
For fan drives with speeds of 750/1000/1500 rpm or
8/6/4-pole; 750/1500 rpm with Dahlander winding.
Wiring for three-speed drive
(2 separate windings, 1 is a Dahlander winding)
For fan drives with speeds of 500/1000/1500 rpm or
8/6/4-pole;500/1000rpmwithDahlanderwinding.
Contactorcontrol
Wiringofthewindingphases
Wiringat terminalboard
Theendsofthethree
windingphasesconnectto
theY/deltaswitch
Deltacircuit Y-circuit
Y/deltaswitch
Low speed Highspeed
Contactorcontrol Polechanger
Low speed Highspeed
Contactorcontrol Polechanger
Matchthewindinglayoutformulti-speedoutputtoatorquecurvefor
fan-driveconfigurations
or
Contactorcontrol Polechanger
Windingconfiguration
Polechanger
500 min-1
Winding configuration 1000 min-1 1500 min-1

15
Caution
Caution
Initial operation
Wait until the fan or fans run down to a complete standstill before you open the
inspectiondoor.
Checkthatsafetydevicesandmonitoringdevicesarecorrectlyinstalledandfully
functional.
- Donotstarttheunituntilallductshavebeenconnectedandtheinspectiondoors
closed.Otherwise,thereisadangerofmotoroverload.
- CheckthattheVee-beltpulleysandthelockingscrewsoftheclampingsleeves
aresecure.
TheadjustableVee-beltpulleydisksarenotadjustedbeforetheunitleavesthe
factory.Thediskshavetobeadjustedonsitebeforetheair-conditioningunitis
started for the first time.
This adjustment allows for a 10% change in the speed of the fan.
Adjusting:
Theeffectivediameterofthepulleycanbechangedbymovingthe adjustable
diskaxially on athreaded adapter (seedrawing on left).
Toadjustthedisk, relievethetensionoftheVee beltanduseanAllenwrench
toslackenthesecuringscrewsontheadjustablepulleydisk.Adjustthepulley
disk,retightenallscrewsandtensiontheVeebelt.Makesurethatbothsecuring
screwsare seated againstthe flats ofthe threaded adapter.
- CheckthattheVeebeltiscorrectlytensioned(SeePage18/Maintenancefor
instructions on tensioning the Vee belt).
Make sure that the Vee-belt pulleys are in correct alignment.
- Switch on the mains switch.
- Briefly switch on the drive motor and check that the fan impeller's direction of
rotationis correct. Reverse the direction of rotation ifnecessary.
The inspection door of the fan section has to be opened for this purpose, so
proceed with the utmost caution.
- Measuretheairthroughput.Checkpressurelosses.
- Measure the current draw of the fan motor: Make sure that the motor current
does not exceed the value stated on the motor rating plate.
Iftheair-conditioningunithasavariable-speedmotorand/orvariablerecirculating-
air section, measure maximum current draw over the entire variable-speed
controlrange.
Ifnecessary,correcttheairthroughputratebychangingtheVee-beltpulleys(or
byadjustingthevariablepulleys,iffitted,seeabove).
Checkthatall louver flaps andlinkages move easily.
Checkthattheflap positioningmotor(s)ofthelouverflap(s) rotateinthecorrect
direction.Ifnecessary,reversethedirectionofrotationbymeansofswitchS(see
illustrationonleft).
Iftheunithasinternallyfittedflaps,consulttheenclosedinstallationinstructions
fortheflappositioningmotor.
Fan section
KG40-100
KG160-250
Louverflaps
Securing screws for
Vee-belt pulley disks
Adjustable disk Locking screw
Switch S
for reversing direction
of rotation
Vee-belt
tensioning screw

16
Airconditioner KG 15 20 25F 40F 40 63 100-1000
Min.airflow (m³/h) 550* 900 900 1600 1600 2500 dependson
horizontal + verticalédesign
Min.airflow (m³/h) 800* 1300 1300 2200 2200 3200 dependson
verticalêdesign
*for 15kW heating power
Caution
Initial operation
Heater
(Warmwater/hotwater/steam)
Electric heater
Chiller
(coldwater)
Air-conditioningunitswithmulti-speedorvariable-speedmotorsmustcomplywith
these specifications for minimum air flow rate at the lowest motor speed,
irrespectiveoftheheatingpoweroftheelectricheater.
Always comply with all applicable safety regulations.
Itisalwaysimportanttoensurethatiftheairflowisinterruptedtheelectricheater
shuts down automatically. Also ensure that the contactor or contactor array
which switches the electric heater incorporates the series-connected safety
temperaturemonitor (STW) inits control circuit.Make sure thatthere is atleast
oneoverheadSTWsecuredto theceilingoftheheatercompartment.
The electric heater must be protected against humidity and water.
Check the entire piping system for leaks before initial startup.
- Bleed the heat exchanger and the piping system.
- Make sure that condensation drains correctly to prevent the condensate tray
fromoverflowing.
- Before starting up a cold-water chiller for the first time, check that the
concentration of antifreeze agent in the chilling water is adequate for the
anticipated temperature range. If antifreeze has to be added, note that the
chiller'scoolingpowerdiminishesinproportiontotheincreaseinconcentration
ofantifreezeagenttocoldwater.
Antifreezeagentsarehazardoustohealth.Compliancewiththemanufacturer's
safety instructions is mandatory if antifreeze agents are used on site.
Check the entire piping system for leaks before initial startup.
- Bleed the heat exchanger and the piping system.
- Makesurethatcondensationdrainscorrectlyfromthesteamregister,iffitted,
toavoid the danger ofsteam shocks damaging theregister.
- Donotswitchonthehot-waterpumporopenthewater/steamvalveunlessthe
fanisrunning,toavoidoverheatingduetoinsufficientremovalofheat.
- Check the discharge air temperature: the max. permissible discharge-air
temperature for a configuration with the heater on the intake side is 40 °C,
becausehighertemperaturescouldcausethemotortooverheat.
Bewareofhotsurfacesofheatexchangersandpipe adapters.
To avoid overheating, make sure that the air flow rates are not less than the
minimum rates as stated in the table below (in m³/h):

17
Caution
Initial operation
Beforefillingthechillersystemwithrefrigerant,adoptsuitablemeasurestoensure
that no traces of moisture are left in the piping system (e.g. by evacuation or by
flushingwithdrynitrogen).
Checktheair-dischargetemperature:min.air-dischargetemperature+2°C,atair-
dischargeandrefrigeranttemperatureslowerthan+2°Cthereisadangerofthe
heatexchangericing.
Caution: The direct evaporator can achieve its rated performance only if the
refrigerantemployedasthebasisforcalculatingthedesignratingisused(R22or
R134a).
Donotpermitrefrigeranttoevaporateintotheatmosphere:useasuitablevacuum
extractor.
- Check the piping and the pump for leaks.
- Make sure the nozzle stem and the nozzles are securely seated.
- Check that the siphon drain line is free of obstruction.
- Fill the siphon with water.
- Fill the washer tray until water drains off through the siphon.
- Briefly start the washer pump and check the direction of rotation; reverse the
directionofrotationif necessary.
Checkthe current consumption of thepump motor.
Do not permit the washer pump to run dry.
Thepumpwillsuffersevere damageifitrunsdry.
- Switch on the air-intake fan.
- Switch on the washer pump.
- Adjustthefloatvalve:thewaterlevelinthetraymustbeat least10mmabove
thepump intake and max. 10 mm below the overflowoutlet.
- Iffitted:adjustdry-runcut-offandautomaticdesalination(seeseparateenclosed
instructions).
Note: On account of its surface structure, a new drip separator will sweat
dropsof water fora limited periodof time.
This is not a technical defect.
Adjustthemanuallyoperatedvalvetosetthesludge-removalrate.
(Thisratedependsonthehardnessofthewaterandthequantityofdustintheair.
As a rule of thumb, take twice the quality of evaporated water).
Chiller
(directevaporator)
Washer
Sludge remover:
(option)

18
Caution
Caution
Maintenance
Beforestartingmaintenancework,alwaysswitchoffthemainswitchandrepair
switch(es) and lock them in the OFF position.
Wait until the fan runs down to a standstill before opening the inspection door.
Lubricatablefanbearingsmustbelubricatedwithlithium-saponifiedgreaseevery
2500operatinghours.
Maintenance-freebearingshavelife-longlubricationandarelabeledaccordingly.
Standardthree-phasemotorsaremaintenance-free.
Complywiththemanufacturer'sinstructionsforspecial motors.
Retension the Vee-belts for the first time after 50 operating hours. Thereafter,
checktensionatregularintervalsdependingonoperatingconditions, but every
4 months at the latest.
Always replace the belts of a multi-groove drive as a complete set.
ThedrivemotoroftheKG40-100Standardismountedonarocker.Totensionthe
drive belt, slacken the locknut on the tensioning screw, tighten the tensioning
screw until belt tension is correct and retighten the locknut.
ThedrivemotoroftheKG160/250and630-1000canbemovedonitsrectangular-
section mounts. To tension the drive belt slacken the securing screws of the
rectangular-sectionmountsandthelocknutsofthetensioningscrews.Tightenthe
tensioningscrewsuntilbelttensioniscorrect,whilecheckingthatthebeltpulleys
areinperfectalignment.
Tighten the locknuts and the securing screws.
CorrectVee-belttension:
The Vee belt is correctly tensioned if thumb pressure applied midway between
motor and fan shaft deflects the belt approximately 15 mm.
Make sure that the vee-belt pulleys are in correct alignment.
Atregularintervals,checkforforeign-matteraccretionsandclean.
Cleanthe heat exchangers by:
- Vacuumextraction
- Blowingcleanwithcompressedair
- Sprayingwithwater or steam
Make sure the pressure of the air/water/steam for cleaning is not in excess of
5bar.
Checkthecondensatedrains.
Openthe siphon, clean and refill with water.
Usecommerciallyavailablescaleremoverstocleanthedrip-separatorsections.
Donotoilthelouver-flapshaft.
Blowclean with compressed air:no other maintenance isrequired.
Fan section
Heat exchangers
(heater/chiller)
Louverflaps
Vee-belt
tensioning screw
Vee-belt
tensioning screws

19
Caution
Caution
Maintenance / Frost protection
Thewasheranddripseparatormustbecleanedatregularintervals.Thecleaning
cycledependsontheoperatingmode,theconditionoftheairandthewaterquality.
Thetrayhastobedrainedformaintenanceandrinsedwithcleanwaterorwitha
high-pressurecleaner.
Reduce the spray pressure when cleaning pipes and nozzle stem. Risk of
breakage.
Commerciallyavailabledescalingagentscanbeused.
Do not use cleaning agents which foam.
Thewasherpumpismaintenance-free.
It is, however, advisable to rinse the pump and piping with clean water when
cleaningthewasher.
If the washer is out of use for a prolonged period of time, operate the pump for
approximately5minutesonceaweektopreventthebearingsseizing(donotrundry).
ThefilterelementsoftheKG40-1000pullsidewaysoutofthehousingforcleaning
orreplacementoncethe inspectiondoorhasbeenopened.
The quality class G4 synthetic-fiber mats used for the filter elements can be
regenerated. They can be tapped clean, blown clean with compressed air, or
washedinlukewarmwatercontainingadetergentforsensitivefabrics.Allowthe
mats to drip-dry - do not wring out.
Thebag-typefilterscannotberegeneratedandmustbereplacedwhenclogged
totheextentthatthepressurelossincreasestothemaximumpermissiblelimit.
Washer
Filter
Heat exchangers
Warm-water/hot-waterheatersandcold-waterchillers:
- Operation with commercially available antifreeze agents and frost-protection
thermostat.
- Iftheheatingsystem isswitchedoffdrainallwater-retaining componentsand
blowoutresidualwaterwithcompressedair.
Steamregisters:
- Iftheheatingsystem isswitchedoffdrainallwater-retaining componentsand
blowoutresidualwaterwithcompressedair.
Electricheater:
- Nofrost-protectionmeasuresnecessary.
Washer
Insulate the water supply pipe on site; install pipe heating if necessary.
Draintray and pipes and blow residual water out ofpipes with compressed air.
Drainthepump(seepumpmanufacturer's enclosedinstructions).
Siphon
Provideadequateon-sitemeasurestoensurethatsiphondoesnotfreeze.
Frostprotection

20
Designationofequipment Airconditioning units for indoor installation
Airconditioning units for outdoor installation
Airconditioning units with indirectly fired air heater
Typedesignation: KG
KGW
KG/WO
Applicable EC Machinery Directive 89/293/EEC as amended 93/44/EEC
ECdirectives EC Explosion-Protection Directive 94/9/EC (explosion-proof devices)
Appliedharmonised DIN EN 292 Part 1 and 2 Safety of machines – Basic terms, general design
standards: principles
DIN EN 294 Safety distances to prevent upper limbs from touching
danger points
DIN EN 349 Safety of machines – Minimum distances to prevent
crushing of body parts
DIN EN 418 Safety of machines – EMERGENCY STOP device
Appliednational DIN 31001 Part 1 Protection devices
standards, e.g. DIN VDE 0700 Part 1 Safety of electric equipment (IEC 335-1)
BG Chemie explosion (explosion-proof devices)
protection guideline
VDMA 24169 Part 1 Structural measures for explosion protection in fans
(explosion-proof devices)
We hereby declare that the electrical equipment for Wolf airconditioning units type KG, KGW and KG/WO including the special
control cabinets for said products and the control accessories:
room thermostats, room-thermostat timers, remote-control units, actuating motors, valves, valve drives, channel sensors,
room-temperature sensors, room-temperature sensors with setpoint generators, antifreeze thermostats, remote setpoint
generators, differential-pressure sensors, safety temperature monitors, double safety thermostats airflow monitors, repair
switches, auxiliary switches, mixer motors, mixers, pumps and motors
are in compliance with the following guidelines, standards and directives:
Low Voltage Directive: 72 / 23 / EEC
EMC Directives: 89 / 336 / EEC
EN 50081-1
EN 50082-2
Product standards: EN 60730
Mainburg,16.10.2000
EC DECLARATION OF CONFORMITY
WOLF GmbH
Industriestraße 1
D-84048 Mainburg
Germany
We hereby declare that on account of their design and construction and in the versions placed in circulation by us, the
machines listed below are in compliance with the applicable basic health and safety requirements of the EC Directive.
Modifications to the machines undertaken without our prior consent void this Declaration of Conformity.
NorbertGruber
Managingdirectorsectorairhandling -ventilation