Wolf KG Standard User manual

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Part no.: 3040530_201503 Subjecttomodications GB
Installation and Maintenance Instructions
Air handling unit KG Standard
(Translation of the original)

2 3040530_201503
Contents
Contents.............................................................................Page
Reference symbols / Safety instructions ................................... 3
Standards .................................................................................. 4
Delivery / Handling .................................................................... 5
Installation information.......................................................... 6-11
Electrical connection........................................................... 11-13
Commissioning................................................................... 14-17
Maintenance....................................................................... 18-20
Frost protection........................................................................ 20
Checklist.................................................................................. 21
Notes ..................................................................................22-23
Order-specicappliancedetails,suchasweights,dimensions,
noisedata,spareparts,energydata,etc.,canbefoundinthe
order datasheets.
Original WOLF spare parts can be obtained quickly by
faxing +49 (0) 8751/74-1574, and stating the order number
(onthetypeplate).

3040530_201503 3
Referencesymbols/Safetyinstructions
These installation, operating and maintenance instructions apply only to Wolf KG
Standard air handling units.
Before installation, carefully read and observe these "Installation, operating and
maintenance instructions - Wolf air handling units KG Standard".
The installation instructions should be considered an integral part of the unit supplied,
and should be retained in an easily accessible location.
Failure to observe the installation and operating instructions voids any Wolf warranty.
General information
Referencesymbols Thefollowingsymbolsareusedintheseinstallationandmaintenanceinstructions.
This important information concerns personal safety, as well as operational
reliability.
"Safetyinstructions" areinstructionswith whichyoumust comply exactly, to
preventinjuryandmateriallosses.
Danger through 'live' electrical components!
Please note: Turn OFF the ON/OFF switch before removing the casing.
Never touch electrical components or contacts when the ON/OFF switch is in the
ONposition.Thiswouldresultinariskofelectrocutionthatmayleadtoinjury
or death.
Themainsupplyterminalsare'live'evenwhentheON/OFFswitchisintheOFF
position.
"Pleasenote"indicatestechnicalinstructionsthatyoumustobservetoprevent
material losses and appliance malfunctions.
Inadditiontotheinstallationandmaintenanceinstructions,informationlabels
are attached to the unit.
These must also be observed.
Please note
Safetyinstructions Only qualied and trained personnel may be appointed for the installation, commissioning,
servicing and operation of the unit.
VDE regulations [or local regulations] and those of your local power supply utility are
applicable to electrical installation work.
Only operate the unit within its output range, which is stated in the technical documentation
supplied by Wolf.
Correct use of the unit includes using it only for ventilation purposes. The unit may
only be used for handling air. The air must not contain any harmful, combustible,
explosive, aggressive, corrosive
or
otherwise dangerous substances.
Only operate the unit when it is in perfect technical condition. Any faults or damage which
impact or might impact upon the safety or correct function of the unit must be remedied
immediately by qualied personnel. Only replace faulty components and equipment
with original WOLF spare parts.
Work on electrical equipment or component assemblies may only be carried out by an
approved electrician in accordance with electrical appliance regulations.
Never carry out any work out in the immediate vicinity of an operational fan, as this
poses a risk of injury.
In the event of a re, the air handling unit must shut down automatically via suitable
means, e.g. a re damper (on site), as otherwise harmful substances will be blown into
the connected rooms.
Check the unit's electrical equipment regularly. Rectify any loose connections or faulty
cables immediately.

4 3040530_201503
Standards
The following standards and regulations apply to air handling units in the
KG 15-100 Standard series:
- Machinery Directive 2006/42/EC
- Low Voltage Directive 2006/95/EC
- EMC Directive 2004/108/EC
- Pressure Equipment Directive 97/23/EC
- DIN EN 953 Safety of machinery -
Guards
- DIN EN ISO 12100 Safety of machinery -
Basic concepts, general principles for design
- DIN EN ISO 13857 Safety of machinery -
Safety distances to prevent hazard zones being
reached by upper and lower limbs
- DIN EN 349 Safety of machinery -
Minimum gaps to avoid crushing parts of the
human body
- DIN EN 60204-1
Safety of machinery -
Electrical equipment of machines
- DIN EN 60730 Automatic electrical controls
- DIN EN61000-6-2 and -3 Electromagnetic compatibility
- VO (EU) 327/2011 Fans
- VO (EU) 640/2009 Electric motors
Forinstallationandmaintenance,thefollowingregulationsandsafety
instructions must be observed:
- VDE 0100 Erection of power installations with rated
voltages below 1000 V
- VDE 0105-100 Operation of electrical installations - General
requirements
- VDE 0701-0702 Inspection after repair, modication of electrical
appliances
Standards

3040530_201503 5
Delivery/Handling
Space requirement On the operating side, there should be at least one unit's width for installation,
operation and maintenance (see list below).
Space requirement for installation, operation and maintenance:
Fan section 0.8 x unit width
Cooler and heater section, RCS 1 x unit width + 250 mm
Filter section 1 x unit width
If units are arranged next to one another, the space listed above is required on
both sides for installation, operation and maintenance.
Units that require a siphon (scrubber, humidier, cooler, KGX/KGXD plate heat
exchanger, mist eliminator) must be sited in such a way that the siphon can be
installed and operated unimpeded (observe height of foundations).
For units with a humidier and/or cooler above rooms containing moisture-
sensitive equipment (e.g. computer rooms, etc.), we recommend waterproof
foundations.
For garage extractor fans, observe the conditions of the garage systems
regulations [or local regulations].
Delivery KG 15-100 air handling units are delivered in transportable units.
Upon receipt of the goods, check the appliance or components for transport
damage.
If there is any damage or even a suspicion of damage, the recipient must
indicate this on the consignment note and have it countersigned by the haulier.
The recipient of the goods must notify WOLF of the relevant facts without delay.
Installation room Only site the KG air handling units in a room that is free from the risk of frost.
If a risk of frost in the installation room cannot be excluded, take suitable steps
to prevent water-carrying components from freezing.
(See chapter "Frost protection measures".)
Please note
The units must only be transported in their installation position.
Otherwise the installed components will be damaged which can lead to
malfunctions.
Handle the units with lifting straps.
If moving the units with a forklift truck or on rollers, ensure that the supporting
forks or rollers are positioned underneath the frame sections and not under
the oor plates.
When lifting the units with the aid of eye bolts (on request), use lifting ropes
that give you a minimum eye bolt distance L. Keep ropes at the same length.
Units with more than 4 eye bolts must be lifted with a lifting beam.
Please note
Handling
L
m
a
x.
6
0
°
min L

6 3040530_201503
Insulation strips
on-site
KG 40-100:
Installation information
When being positioned on the base frame or foundation plinth, align the units
in such a way that a gap of approximately 10 mm is maintained between the
base frame or foundation plinth and the drip guard.
When installation is complete, securely x the air handling units to the base
frame or foundation plinth using the clips provided.
Washer
Screw
Clip
Stud
Drip guard
Base frame
LR
Base frames are delivered either securely tted to the unit or loose (in advance).
If the base frame is delivered in advance, replace the screw with the
stud provided.
Loose base frames are delivered in individual sections and must be assembled
on site in accordance with the instructions supplied with the base frame, levelled,
and secured to the plinth.
If units are delivered in sections with the base frame tted, the base frame and
unit will be split at the same points.
Unit connection The connection is made using M6 screws and spacer clips, for which holes
are provided at the appropriate points in the cubes. All small parts required
for assembly, plus loose accessories, are supplied in a unit with an inspection
door (preferably a fan section). This unit will be marked with a label reading
"Accessories inside unit".
In order to completely waterproof the unit, apply the self-adhesive sealing tape
supplied with the unit to one side before the cubes are joined.
For units with a scrubber, use a base frame or foundation plinth because the
scrubber base is lower than the remaining unit base. The required height of
this base frame depends on the type of scrubber and is determined individually
when designing the unit.
Foundation A level, horizontal and load-bearing surface is required to site and install the
units and unit components.
Base frames must be levelled horizontally; foundation plinths must also be
level and horizontal.
The entire lower unit frame must sit on the foundation; point loads are not
permissible.
To prevent structure-borne noise being transmitted from air handling units to
the building, insert a permanently exible intermediate layer between the plinth/
foundation and the unit/base frame. This intermediate layer should ideally take
the form of insulation strips, tted lengthwise below the unit frame sections.
Please note

3040530_201503 7
Installation information
KG 40-100
Only with recirculation air damper with
self-tapping hexagon screws Ø 8x25
Sealing tape
KG 15-100
Sealing tape
Unit arrangement:
stacked or adjacent
Stacked units are delivered separately and must be linked together on site
using the unit connectors and drilling screws provided.
Upper and lower or adjacent unit sections cannot be tted together until the
various transport units have been assembled at the nal installation site.
Stacked units
60
A
B
A
B
Length
Transport unit
Length
Transport unit
Stacked units
Mat. no. 6609800
Drilling screw
5.5 x 19
Mat. no. 3490234
Drilling screw
6.3 x 25
Mat. no. 3480038

8 3040530_201503
Installation information
The units are delivered fully assembled. To facilitate handling, they can be
taken apart and reassembled in the installation room.
With the version for disassembly, the frame sections split in the centre and are
secured with a at steel bar or angle bracket (secured with screws).
To split the KG 40-100, remove any frame insulation that is in place and ret
after the cubes have been assembled.
Versionfordisassembly
(on request)
KG 40-100
Canvasange/
louvre damper
Shipping
brackets
The fan shaft must always be horizontal.
With fans mounted on anti-vibration spring mounts, remove the transport brackets.
When installing, ensure that the distance between the connection anges is
not greater than 100 mm, to enable the canvas ange to move fully.
The canvas ange and louvre damper may need to be insulated on site against
both sound emission and the formation of condensate.
Please note
Fan section
Heat exchanger
Heat exchanger
Flange
Mist eliminator
Vorlauf
Vorlauf
Rücklauf
Rücklauf
Luftrichtung Luftrichtung
The heat exchangers (cooler, heater) operate using the countercurrent principle,
i.e. the heat transfer medium or refrigerant is channelled in the opposite direction
to the air ow. The relevant ow connection is therefore always located on the
air discharge side of the heat exchanger.
The heat exchangers must be connected in such a way that no mechanical
stress from the pipework is transferred to the heat exchangers.
Furthermore, the transmission of vibrations and thermal expansion between
the air handling unit and the pipework must be reliably prevented.
Ensure that the connection lines do not hinder access to other parts of the unit
(fan, lter, scrubber, etc.).
Regarding the heat exchanger (with ange), we recommend making the
connection with bends, so that the heat exchanger and mist eliminator can
later be extracted from the side for cleaning.
With steam coils, always arrange the steam intake at the top (large connection ø)
and the condensate drain at the bottom.
When connecting the ow and return lines, counterhold the threaded heat
exchanger connectors to prevent them from being twisted, otherwise the
application of mechanical force may detach the collector from the heat exchanger.
This would destroy the heat exchanger.
Ensure there are ventilation and drainage facilities on site.
Connect a siphon to the condensate drain connector on the cooler pan.
The connection pipes outside the external casing are insulated on site.
Please note
Please note
Flow
Flow
Return
Return
Air direction Air direction

3040530_201503 9
Installation information
On-site cooler installation:
Direction of air ow
Condensate drain, siphon
Mist eliminator
Cooler
Remove casing and mist eliminator with condensate pan (mist eliminator is
placed in the guide rails for shipping).
Apply sealant to the mist eliminator frame and secure to the cooler bank.
The condensate drain apertures in the mist eliminator must be facing downwards.
Depending on the direction of the air ow, the removable cover panel must be
tted at the air intake on the collector side of the cooler bank.
Arrangement of mounting parts in the direction of the air ow:
Cooler bank, mist eliminator, condensate drain.
Insert the fully assembled unit into the cooler section; the cooler bank will be
held in place in the guide rails.
Fit casing.
Please note
When installing the scrubber, ensure that no dirt or other solid matter enters
the scrubber, as this would block the pump impeller and seriously impair or
completely destroy the pump.
If standard requirements apply, the water used for the scrubber must have at
least the following quality:
Appearance clear, colourless, no sediment
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
if using hardness stabilisers < 20 °d
Chloride content < 180 g/m3
Sulphate content < 290 g/m3
KMnO4consumption < 50 g/m3
Bacteria count < 1000 ml-1
If connecting the scrubber to the public water supply system, observe
DIN 1988 [or local standards].
Please note
Scrubber section

10 3040530_201503
Installation information
H
H
If the siphon is provided on site, establish the height of the siphon with reference
to the adjacent diagram.
The effective siphon height H (mm) must be greater than the maximum under-
or overpressure (in Pa) in the air handling unit (1 mmWC = 10 Pa).
The height differential between the unit discharge and the siphon overow
should also equal H (mm).
Double siphon
(on site)
Ball siphon
h
In order to drain away the condensate reliably, join a ball siphon to the condensate
drain connector onto the drain pan for the cooler/direct evaporator and onto
the KGX/KGXD plate heat exchanger pan.
Please note that a siphon must be tted to every condensate drain connector.
It is not permissible to join several drains to a common siphon.
The ball siphon is self-lling. A oat ball prevents air being drawn in when the
system is dry, so the initial condensate created can ll the siphon. The ball also
acts as a non-return valve and prevents the siphon from being completely drained.
In order to be able to t the siphon, ensure that the foundation is of the correct
height.
The effective siphon height h (mm) must be greater than the maximum under-
or overpressure at the condensate connector (1 mmWC = 10 Pa).
h = 1.5 x p (mmWC) + 50 mm (min.)
The siphon drain line must not be connected directly to the public sewage
system, but rather must be able to run out freely. Vent longer drain lines to
prevent condensate backing up in the line.
p Under- or overpressure in mmWC
according to appliance design
50 mm (WC) Reserve (imprecision in design, evaporation)
1.5 Additional safety factor