Wolf KG User manual

WOLF GMBH /POSTFACH 1380 /D-84048 MAINBURG /TEL. [phone] /FAX [phone] /www.WOLF.eu
Art.-Nr.: 3062049_201610 Subjecttotechnicalmodications GB
Installationandmaintenanceinstructions
Air-handling unit KG/KGW Top
(Translation of the original)

23062049_201610
KG TopContents
Standards ....................................................................................................3
Function symbols.........................................................................................4
Symbols /Safety instructions .......................................................................5
Delivery / Handling ......................................................................................7
Installation instructions ................................................................................9
Power connection......................................................................................22
Commissioning..........................................................................................24
Maintenance..............................................................................................28
Frost protection..........................................................................................31
Shutdown / Fire / End-of-life disposal........................................................32
Checklist ...................................................................................................33
Fortypeofdevice,serialnumberandordernumber,seetypeplateontheequipment.
Order-relateddevicespecicationssuchasweights,dimensions,sounddata,spareparts,energydataetc.
aretobetakenfromtheorderdatasheets.
OriginalWolfsparepartscanbeprocuredatshortnotice,statingtheordernumber(onthetypeplate),by
faxto0049(0)8751/74-1574.

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The following standards and regulations apply to the KG/KGW Top series air-handling
units:
- Machine directive 2006/42/EU
- Low voltage directive 2014/35/EU
- EMC directive 2014/30/EU
- Pressure vessel directive 97/23/EU
- DIN EN ISO Safety of machinery; design guidelines
12100
- DIN EN ISO 13857 Safety of machinery; safety distances
- DIN EN 349 Safety of machinery; minimum clearances
- DIN EN ISO 14120 Safety of machinery – Guards –
- DIN EN 1886 Ventilation for buildings - central air-handling units
- DIN ISO 1940/1 Mechanical vibration; balance quality
- DIN EN 60335-1 Safety of electrical appliances for domestic use
and similar purposes
- DIN EN 13053 Ventilation of buildings - central ventilation appliances
Section 6 Performance characteristics for appliances, components
and assemblies
- VDMA 24167 Fans; safety requirements
- RLT Guideline 01
- VDI 3803 Technical requirements for ventilation appliances
Section 5
The following regulations and safety instructions are to be observed for installation
and servicing:
- DIN VDE 0100 Requirements for high voltage installations up to 1000 V
- DIN VDE 0105 Operation of high voltage installations
- DINVDE0701-0702 Repair,modicationandtestingofelectricalappliances
Standards
Standards

43062049_201610
KG TopFunctionsymbols
Functionsymbols
+
++
°C
-
_
Fan section Fan section
Bagltersection Heater section
KGXD section KGX section
Empty section Empty section with
damper
Empty section with
damper and tray
Empty section with
tray
Silencer section Humidiersection
Heater section with
frost protection frame
Cooling section
Rotary heat ex-
changer section
GS-PWT section

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General These installation and maintenance instructions apply only to WOLF KG/KGW Top
series air-handling units.
Each person tasked with installing, commissioning or maintaining the equipment must
read through these instructions before commencing work.
Compliance with these instructions is mandatory.
Onlysuitablytrainedandqualiedpersonnelarepermittedtoundertakeinstallation,
commissioning and maintenance work.
The assembly and maintenance instructions are an element of the appliance supplied
and must be kept in an accessible place.
Non-compliance with the installation and maintenance instructions voids all WOLF
warranties.
Symbols Thefollowingsymbolsandwarningsareusedintheseinstallationandmaintenance
instructions.Theseimportantinstructionsapplytotheprotectionofpersonnel
andtotechnicaloperationalsafety.
"Safetyinstruction"identiesinstructionsthatmustbepreciselycompliedwithin
ordertoavoidendangeringorinjuringpersonsandtopreventtheriskofdamage
totheequipment.
Electricshockhazardduetoelectricallylivecomponents.
Note:SwitchOFFtheON/OFFswitchbeforeremovingthecasing.
Neverattempttotouchelectricalcomponentsorcontactswhilethemasterswitch
isON.Electricshockhazardwithriskstohealthorfatalinjury.
TerminalsremainliveevenaftertheON/OFFswitchhasbeenswitchedOFF.
"Note"identiestechnicalinstructions thatmust be complied with toprevent
equipmentdamageandmalfunctions.
Inadditiontotheinstallationandmaintenanceinstructions,labelsafxedtothe
equipmentbearinformation.
Compliancewiththese,too,ismandatory.
Note
- The persons tasked with installation, commissioning, maintenance and operation of
theair-handlingunitmustbeadequatelyqualiedandmusthavereceivedsuitable
instruction.
- Onlytrainedandqualiedelectriciansarepermittedtoundertakeworkontheelectrical
system.
- All electrical work must be in compliance with VDE requirements [or local regulations]
and the regulations of the local power supply utility.
- The air-handling unit must always be operated within the range of operating parameters
stipulated in the technical documentation supplied by WOLF.
-
Correct use of the air-handling unit means exclusively the use for ventilation purposes.
Air is the only medium that can be handled by the equipment.
- Never remove, jumper, bypass or by any other means render inoperative safety
devices and monitoring devices.
- Never operate the air-handling unit unless it is in full working order. Malfunctions
and damage that impair or could impair safety must be repaired immediately and
professionally.
- Intheeventofaretheair-handlingunitmustshutdownautomaticallybysuitable
meanssuchasareprotectiondamper(installedonsite),asotherwisehazardous
substances can be transported into the rooms downstream of the air-handling unit.
- Check the electrical equipment of the appliance regularly. Tighten loose connections
and replace faulty cables immediately.
Safetyinstructions
Symbols/Safetyinstructions

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IntendedUse Intended use of the Wolf air conditioning units is exclusively restricted to their use for
ventilation purposes. The air conditioning units are to be used only for the transport
andconditioningofnormalair.Thisincludestheltering,heating,cooling,humidify-
ing and dehumidifying of the air. Compliance with the instructions supplied with the
appliance are also part of its use for the intended purpose!
Unintendeduse Uses of the appliance for purposes other than those described above are considered
unintended. Wolf GmbH accepts no liability whatsoever for damages resulting from
unintended use. The user bears the risk alone.
On no account may air be transported that contains any constituents that are inju-
rioustohealth,inammable,explosive,aggressive,corrosiveordangerousinany
other way, since these substances can otherwise be spread throughout the duct
system and the building and impair the health of people, animals or plants living there
or even kill them.
Airconditioningunitsforthetransportofinammableorexplosivegasesmustbe
specially designed. Normal air conditioning units may not be operated in these dan-
ger areas unless there are remarks to this effect in our technical documents.
Technicaldescription Wolf air conditioning units are central air conditioning units and are used for the sup-
ply and exhaust ventilation of rooms. The modular structure of the appliances allows
themostdiverserequirementsforairconditioningtobemetbyconguration.The
transportedaircanbeltered,heated,cooled,dehumidiedandhumidied.
InformationSigns/Safety
Instructions

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KG TopDelivery / Handling
Delivery KG Top air-handling units are delivered to site as transportable subassemblies.
On receipt of the incoming goods, check the unit or components to ensure no damage
has occurred in transit.
If damage is evident or if there is a suspicion that damage might have occurred, the
recipient must make a note to this effect on the freight papers and have this countersigned
by the carrier.
Notify WOLF immediately of such circumstances.
Always transport the equipment upright.
Exception:Plate-typeheatexchangers(subjecttotypeandsize)andheatwheelheat
exchangersarelaidat(turned90°)fortransportation.
Otherwise the internal components will suffer damage and this can result in malfunctions.
Handle the appliances with slings.
Tall appliances on a small footprint (e.g. RWT) are connected with an increased risk of
tipping over during unloading and handling on site.
This requires additional measures
on site to prevent tipping over (e.g. securing with straps).
If a forklift or rollers are used to move the units, always ensure that the forks or rollers are
located underneath the frame sections at all times, so that weight is never allowed to rest
ontheoorpanels.
With lifting eyes (available on request), use slings at minimum centres L between lifting
eyes. Ensure that the slings are of uniform length.
Always use a crane lifting beam to lift appliances with more than 4 lifting eyes.
On no account may cladding panels be removed in order to lift the device, since the
cladding panels are structurally integrated in the device's bracing system.
No additional loads may be lifted together with the transport unit supplied by Wolf.
Note
Handling

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Final location Always install KG air-handling units in rooms where frost cannot occur.
Iftheoccurrenceoffrostatthenallocationcannotberuledout,adoptsuitablemeasures
to prevent water-containing components from freezing. If an outside thermostat is
installed ensure it is adequately insulated to prevent the air-handling unit from shutting
down inadvertently (see frost protection measures, page 25).
KGW air conditioning units are designed to be installed outdoors.
Note
Spacerequirements Make sure a clear space equal to at least the width of the equipment units is available
on the operator side; this is the minimum space necessary for installation, operation
and maintenance (see the table below).
Footprint of space required for installation, operation and maintenance:
Fan section 0.8 x appliance width
Cooling coil, heating coil, KVS 1 x appliance width + 250 mm
Filter section up to KG 96 1 x appliance width
from KG 130 0.5 x appliance width
Inback-to-backcongurationswithside-by-sideunits,leaveclearancesasstatedabove
on both sides for installation, operation and maintenance.
Install units that require a siphon (scrubber, humidier, cooling coil, plate-type heat
exchanger, mist eliminator) in such a way as to ensure correct installation and operation
of the siphon (make adequate provision for the foundation height).
Itisadvisabletoinstallawaterprooffoundationforunitswithhumidiersand/orcooling
coils installed above rooms containing moisture-sensitive equipment (e.g. IT rooms, etc.).
Delivery / Handling

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Equipmentinstallation Appliances for weatherproof installation must not take on any static load or act as a
substitute for the roof of the building.
When assembling and installing combined ventilation and extract appliances with heat
recovery (KGXD, RWT), observe the correct sequence of assembly and installation
(see diagram). For this, one complete appliance train should always be assembled/
installed completely. The second appliance should then be installed from the heat
recovery onwards.
This offers the most effective prevention of alignment errors and installation inaccuracies.
Appliance example - top view:
Note
Note
When installing high or perhaps smaller appliance components (e.g. RWT, RWT duct
components or standing appliance layouts with several components above each
other),securetheseduringassembly/installationagainsttippinguntiltheyarenally
connected to other components that ensure that tipping is prevented.
Requires permanent securing against tipping over.
Note
Risk of tipping
Baseframe/foundation
base
Internalunitbaseframe
WOLF internal unit base frames (suitable only for internal installation) are always sup-
plied loose (in advance).
Base frames delivered loose are knocked down for shipping and must be assembled,
aligned and secured to the base on site in accordance with the instructions enclosed
with the base frame.

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KG TopInstallationinstructions
A base frame or plinth is required for air-handling units installed as weatherproof version
to support the appliances and their components.
The height of the base frame or plinth is subject to the local snow depth; however, it
should be at least 180 mm.
Subject to the prevailing wind force, secure the appliances with bolts to the base frame
or plinth (observe the transmission of structure-borne noise).
Baseframesmustbehorizontalandperpendicular;thefoundationbasemustbelevel
andhorizontal.
Weatherproofdevicesmaynotassumeanybuildingsupportfunctions
ortasksoftheroofofthebuilding(VDI38035.1/BSEN130536.2).
Thelowerbaseframemustmakefull-surfacecontactwiththebase;
padorpointcontactisnotpermissible.
Note
It is essential to ensure that the base on which the units and components are to be
assembledandinstalledislevel,horizontalandofadequateload-bearingcapacity.
Thebaseframemustbehorizontal,andthefoundationmustbelevelandhorizontal
(check with browning rod).
To prevent the inspection doors from jamming, the lower base frame must make full-
surface contact with the base; pad or point contact is not permissible.
Provideapermanentlyexiblelayerbetweentheinstallationsurfaceorfoundation/plinth
and the air-handling unit to prevent the transmission of structure-borne noise from the
appliance to the building. Preferably, this intermediate layer should take the form of
insulation strips that are positioned longitudinally underneath the appliance frame or
underneath the base frame.
Note
Baseframe/
foundationbase
KG:
Strip insulation, on site
Fitted base
frame
50
Sealing tape
Baseframeprole
with drip strip
Insulation on site
On-site roof
membrane
Insulatingstriptted
on-site
Screwttedon-sitewith
sound decoupling, e.g.
neoprene washer
KGW:

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WOLFbaseframes(includingintegrateddripstrip)areeitherpermanentlyxedto
the appliance or supplied loose.
Base frames delivered loose are knocked down for shipping and must be assembled,
aligned and secured to the base on site in accordance with the instructions enclosed
with the base frame.
The base-frame pitch and the appliance pitch match when appliances with pre-
installed base frames are split for shipping.
Supportbracket,item6,incaseof
factory-ttedbaseframe,ifdifferent
weightsleadtoanoffsetatcube
joints(assemblyonsite)
6
6
Insulatingstripttedon-site Insulatingstripttedon-site
Offset
Connecting brackets, items 4 and 5, if air conditioning units are positioned next to
each other (assembly on site)
5
4
SW 8
Connecting bracket, item 1, in case of connection to, for example, a rotary heat ex-
changer (assembly on site)
1
SW 8
RWT

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If the unit has a bottom discharge/intake, install short sections of duct before lowering
the unit onto its foundation.
A base frame or plinth (height approx. 305 mm) is always required for KG or KGW
appliances with scrubber, because the scrubber bottom lies lower than the underside
of the remaining appliance. The required height of the base frame depends on the type
ofscrubberandisspeciedseparatelyinthecourseofthedesigncalculations.
The WOLF base frame must be insulated and integrated into the roof sealing system
on site.
The base frame can be insulated on the inside or the outside of the base frame.
When installing the KG TOP on its own stands (KGW on an on-site base frame),
secure it against the wind load.
Drop
ledge
Structure-
borne sound
insulation
+
Short sections
of duct
Base frame
Roof
Thetraybridgeisalreadyttedinthefactoryifthefunctionalcomponentsaredeliveredas
a single transport unit.
In case of delivery as separate individual function units, the tray bridge is supplied loose
and must be installed on site.
If slide-in rails are in use, the tray bridge must be adapted to the local conditions.
Tray bridge

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Sealant
Immediatelybeforeassemblingtheverticalhollowsectionswiththeoorandceiling
panels, seal the hollow sections with the sealant supplied. Otherwise the water tightness
of the appliance cannot be guaranteed.
For this it is recommended that some of the sealant is poured into a at vessel of
adequatesize,andthentodipbothendsoftheverticalhollowsectionapprox.2mm
deep into the sealant.
The appliances are assembled in reverse order.
Appliancesthatcan
bedismantled
The equipment is shipped to site preassembled. It can be disassembled before being
movedintopositionandreassembledatthenallocation.
Disassembly entails removing the casing and carefully removing internal components
such as heating or cooling coil (take care not to damage the components). Remove the
screws from the corners of the frame to permit removal of the frame.
Undo
screws
KG Top 21 - 380 KG Top 450 - 1000
Hollow
prole

14 3062049_201610
KG Top
TheweatherproofedKGWversionalwayshasafullyinstalledroofmadeofzinc-plated
sheet steel.
Splitunitsaredeliveredtositewiththeroofsectionsprettedtotheindividualsections.
If the interface at which two units are split does not line up with the pitch of the roof
sections, the requisite single roof section is supplied loose and must be installed on site
once the air-handling unit has been assembled and installed. The requisite fasteners
and sealing materials are supplied with the appliance.
The lifting eyes can remain in the unit as sealed in the factory.
Roof
Use a plastic-headed mallet to tap the cover strip into place.
Note
Pack space of sealing strip with sealing compound
Installationinstructions
The roofs of the weatherproof appliances can be stepped on for assembly. Attention
must be paid here to the area distribution of the load (boards).
No static point loads may be applied to the roofs.

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KG TopInstallationinstructions
Connectingunits All the small items required for assembly are packed inside a component with inspection
door (preferably fan section), along with the accessories supplied loose.Alabel inscribed
"ZubehörimGerät"(Accessoriesinside)identiesthecomponentinquestion.
KG Top 21-380 Self-drilling/tapping screw
X6.3 x 90 Mat. no. 3490238
KG Top 450-1000 Self-drilling/tapping screw
X6.3 x 120 Mat. no. 3490252
Self-drilling/tapping screw Self-drilling/tapping
screw
with washer
Appliance connection bracket
Part no. 6616824
X6.3 x 62 Mat. no. 3480031
Self-drilling/tapping screws
Appliance connection bracket
Part no. 6616824
X
8 x 120 Mat. no. 3418502
6.3 x 25 Mat. no. 3480038
6.3 x 62 Mat. no. 3480031

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KG TopInstallationinstructions
Connectingunits
withscrews
M8screwsareusedtojointhecubesunit.Theframesectionsareprovidedwithxing
elements at the appropriate points. Alwaysensurethattheindividualapplianceparts
arepushedrmlytogetherbeforettingtheM8screws.
Iftheconnectorsareontheoutside,theunitsinquestioncanbeconnectedbut
undernocircumstancescantheassemblybemovedasasingleunit.
Note
External appliance connection
Tensioning straps may be used to make the assembly of the cube units easier. Position
the appliance parts next to each other and close the gap between them with tensioning
straps. Then bolt the components together by means of the connectors supplied.
The individual transport units can always be lifted and transported when units are joined
internally.
External appliance connection

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KG TopInstallationinstructions
Fixing elements M8 screw
When tightening screws and nuts, always counterhold with
a second open-ended spanner.
Internal appliance connection The individual transport units can always be lifted and transported when units are joined
internally.
Variant1
Variant2

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KG TopInstallationinstructions
Piggybackunits
(airintake/exhaustairunits
stackedoneontopoftheother)
Piggyback units supplied with top and bottom units separated must be securely connected
on site (after the units have been positioned) and sealed tight on the whole perimeter
against rainwater penetration by means of a permanently elastic seal (weatherproof
version KGW).
UnitsaresecuredbymeansofxingelementsandSelf-drilling/tappingscrew5,5x19
on the outside, as shown (on site).
Therequisitenumberofxingelementsissuppliedwiththeair-handlingunit.
Only secure the top and bottom units together after the individual cubes unit and the
top and bottom units have been assembled.
Ifrequired,installpermanentlyresilientsealingstripsorplasticsealingprolesbefore
loweringthetopunitintopositiononthebottomunit.
KGW projection
KGW top view
KGW projection
KGW 450-1000
Projection
Self-drilling/
tapping screw
5.5 x 19
Sealing tape
ViewA
Projection
Self-drilling/
tapping screw
5.5 x 19
Sealing
tape
ViewB,C,D
Projection
Roof
Sealing tape
ViewE
KGW 21-380
Projection
Self-drilling/
tapping screw
5.5 x 19
Sealing tape
ViewA
Projection
Roof
Self-drilling/
tapping screw
5.5 x 19
Sealing tape
Sealing tape
ViewEViewB,C,D
Self-drilling/
tapping screw
5.5 x 19
Sealing tape
Projection

19
3062049_201610
KG TopInstallationinstructions
Flexibleconnections Remove the transportation locking devices.
Duringinstallationensurethattheconnectingangesarenomorethan100mmapart
toensurethattheexibleconnectionshavetheirfullrangeofmovement.
It may be necessary to fully insulate the exible connections on site against
acousticemissionsandcondensation.
Ensurethatthefanshaftishorizontalinitsbearings.Iftheshaftisnotperfectlyhorizontal
the ball bearing will suffer damage and service life will be substantially reduced.
Remove the transportation locking devices from fans mounted on spring-loaded vibration
dampers.
Note
Fansection
Transportation
locking devices
The heat exchangers (cooling coil, heating coil) operate on the countercurrent principle.
This means that the heat transfer medium or refrigerant moves in the opposite direction
totheairow.Consequently,theowconnectionforthemediumisalwaysontheair
discharge side of the heat exchanger.
Connect the heat exchangers so that no mechanical stresses and strains are transmitted
from the pipework to the heat exchangers.
It is also important to ensure that the transmission of vibrations and longitudinal expansion
and contraction between the air-handling unit and the pipework is effectively prevented.
Ensure that the connecting lines never obstruct access to the other parts of the unit
(fan,lter,scrubber,etc.).
For the heat exchanger (with ange) it is recommended to use bends to make the
connections.Thiscongurationwillensurethattheheatexchangerandthemisteliminator
can be extracted to one side for subsequent cleaning.
Always install steam registers so that the steam inlet is always at the top (large diameter
connector) and the condensate drain is always at the bottom.
When connecting the ow and return lines, always use a wrench of correct size to
counterhold the threaded connectors of the heat exchanger. Otherwise the mechanical
force could separate the header from the heat exchanger. Damage of this nature would
effectively ruin the heat exchanger.
It is important to ensure that facilities for venting and draining are installed on site.
Always connect a siphon to the condensate drain connector of the cooling coil drip tray
(see "Siphon").
KGW: If the heat exchanger connections are on the inside, run the pipework through
the empty section provided for the purpose downstream of the heat exchanger.
Make adequate provision for venting.
Make suitable apertures through the removable base to accommodate the pipes.
Seal these apertures by suitable means after insulating the pipework.
The weatherproof projection is not thermally insulated. Consequently,thepipes
andvalvesmustbeadequatelyinsulatedand,ifnecessary,heatedonsite.
 Ifaninverterisusedforoperationitisadvisabletoprovideexternalventilation
insummertopreventoverheating(max.permissibletemperature45°C).
 Providesuitableaperturesthroughtheremovablebaseoftheprojection
toaccommodatethepipes.
Note
Note
Heat exchanger
Removable heater exchanger
Flange
Removable mist eliminator
Empty section
Flow
FlowReturn
Return
Directionofairow Directionofairow
+

20 3062049_201610
KG TopInstallationinstructions
When installing the scrubber take care not to permit dirt or other foreign matter to enter
the scrubber, as otherwise the pump impeller will be obstructed and this will either
signicantlyimpairpumpoperationorresultinitsdestruction.
Given normal requirements, the water for the scrubber must comply at least with the
minimumqualityspeciedbelow:
Appearance clear, colourless, no sediment
pH value 7 to 8.5
Total salt content < 800 g/m3
Electr.conductivity <100 mS/m(at20°C)
Calcium ion content > 0.5 mol/m3
Carbonatehardness <4.0 °d
Carbonate hardness with
hardnessstabilizers <20 °d
Chloride content < 180 g/m3
Sulphate content < 290 g/m3
KMnO4consumption < 50 g/m3
Germination index < 1000 ml-1
If the scrubber is connected to the mains water system, ensure compliance with DIN
1988 [or local regulations].
Note
Scrubbersection
If the siphon is provided on site, calculate the height of the siphon in accordance with
the sketch shown here.
The effective siphon height H (mm) must be greater than the max. negative or positive
pressure (in Pa) inside the air-handling unit (1 mm WS = 10 Pa).
Thedifferenceinheightbetweentheunitoutletandthesiphonoverowshouldalso
be equal to H (in mm).
Doublesiphon
(onsite)
Ballsiphon
h
Never connect the siphon discharge directly to the wastewater system. Instead, leave
the end of the discharge open so that it can drain freely. Long discharge lines must be
vented to prevent condensate from backing up in the pipe (provide an additional opening
in the siphon discharge pipe).
To permit reliable draining of condensate, it is important to connect a ball siphon to the
condensate drain connector from the drain tray for the cooling coil / direct-expansion
evaporator, plate-type heat exchanger and outside air intake tray of the KGW.
Also observe that each condensate drain connector must have a siphon connected to it.
It is not permissible to run two or more condensate drain connectors into a shared siphon.
Theballsiphonisself-lling.Aoatingballpreventsairbeinginductedwhenthesystem
isdry,whichmeansthatcondensateinitiallyhastollthesiphonasitisproduced.The
ball also acts as a non-return valve and prevents the siphon from sucking dry.
It is very important to ensure that the foundation is of adequate height to permit
installation of the siphon.
The effective siphon height H (mm) must be greater than the max. negative or positive
pressure at the condensate connector (1 mm WS = 10 Pa).
  H=1.5xp(mmwatercolumn)+50mm(min.)
p = Negativeorpositivepressureinmmofwatercolumnasperappliancedesign
50 mm (water column) = Reserve (to allow for design inaccuracies, evaporation)
1.5 = Additional safety factor