Airblock FG

Kampmann.de/installation_manuals

I498/11/14/1 GB I SAP-Nr. 1201142

Airblock FG

Air handling unit with EC single-phase motor

Airblock FG modules for heating, cooling and ventilating

Installation and Operating Instructions

Keep these instructions in a safe place for future use!

1.50

Airblock FG

Slimline air handling unit for decentralized, dynamic air treatment


Key to symbols:

1. Intended Use ................................................................................. 4

Caution! Danger!

2. Safety Information ....................................................................... 5

Failure to comply with these instructions can result in serious personal injury ordamage to property.

Danger from

electrocution!

Failure to comply with these instructions can result in serious personal injury or damage to property from electrocution.

Please read these instructions carefully before starting assembly and installation work!

All persons involved in installation, commissioning and use of this product have a duty to pass these instructions onto parallel or subsequent trades right through to the end user or operator. Please retain these instructions until the unit is finally decommissioned!

3. Operation ...................................................................................... 6

4. Standard System Set-up ............................................................... 7

5. Supply Air Module (incl. heat exchanger and F7-filter) ............ 10

5.1 Unit Construction .......................................................................... 10

5.2 Installation ..................................................................................... 11

5.3 Hydraulic Connection .................................................................... 11

5.4 Electrical Wiring ............................................................................. 12

5.5 Control Components ..................................................................... 13

5.6 Maintenance ................................................................................. 14

5.6.1 Safety Information ...................................................................... 14

5.6.2 Opening the Service Hatch ......................................................... 14

5.6.3 Housing ...................................................................................... 15

5.6.4 Fan Motor .................................................................................. 15

5.6.5 Cu/Al Heat Exchanger ................................................................. 15

5.6.6 Filter Change .............................................................................. 16

6. Exhaust Air Module ...................................................................... 17


6.2 Installation ..................................................................................... 18

6.3 Electrical Wiring ............................................................................. 18


6.5 Maintenance ................................................................................. 21


6.5.2 Opening the Service Hatch ......................................................... 21

6.5.3 Housing ...................................................................................... 22

6.5.4 Fan Motor .................................................................................. 22

7. Commissioning the Fan Modules ................................................ 23

8. Connecting Airblock Modules ..................................................... 24

Changes to the content or design can be made without prior notification!

9. Heat Recovery Module ................................................................. 25


9.2 Installation ..................................................................................... 26


9.4 Maintenance ................................................................................. 27


9.4.2 Opening the Service Hatches ...................................................... 28

9.4.3 Housing ...................................................................................... 29

9.4.4 Counterflow Heat Exchanger ...................................................... 29

9.4.5 Filter Change .............................................................................. 32

Airblock FG 1.50



10. Chiller Module ............................................................................. 33

10.1 Unit Construction ........................................................................ 33

10.2 Installation ................................................................................... 34

10.3 Hydraulic Connection .................................................................. 35

10.4 Control Components ................................................................... 36

10.5 Maintenance ............................................................................... 37

10.5.1 Safety Information .................................................................... 37

10.5.2 Opening the Service Hatches .................................................... 37

10.5.3 Housing .................................................................................... 38

10.5.4 Cu/Al Heat Exchanger ............................................................... 38

10.5.5 Filter Change (Optional) ............................................................ 39

11. Bag Filter Module ....................................................................... 40


11.2 Installation ................................................................................... 41


11.4 Maintenance ............................................................................... 43



11.4.3 Housing .................................................................................... 44

11.4.4 Filter Change ............................................................................ 44

12. Particle Filter Module ................................................................. 45


12.2 Installation ................................................................................... 46


12.4 Maintenance ............................................................................... 48



12.4.3 Housing .................................................................................... 49

12.4.4 Filter Change ............................................................................ 49

13. Spare Parts .................................................................................. 50

13.1 Filter ............................................................................................ 50


3

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Airblock FG



1. Intended Use

The Kampmann Airblock range offers an all-purpose air handling system for a range of different applications. Kampmann Airblock units are built in line with the state of the art and recognised safety regulations. Nevertheless their use can result in danger to people or damage to the unit or other material property if they are not properly installed or properly used.

The units are solely intended for heating, cooling and ventilation. Any use other than the use specified above is deemed not to be correct and proper.

The user/operator of the unit alone will be liable for any damage resulting from this. Correct and proper use is deemed to include observing the instructions relating to safety, operation and commissioning/maintenance.

Any sound-absorbing measures needed, such as isolation of the air ducts, have to be done on site!

Protect the products from any moisture during storage and installation.

Check the application with the manufacturer in case of any doubt. Any use other than the use specified above is deemed not to be correct and proper.

The operator of the unit is solely responsible for any damage arising as a result of this.

The installation of this product requires specialist knowledge of heating, cooling, ventilation and electrical engineering. This knowledge, generally learned in vocational training in the fields mentioned in section 2, is not described separately. Damage caused by improper installation is the responsibility of the operator.

Airblock supply air modules are not suitable for connecting to cold water!

Chiller modules from the accessories range are intended for use for cooling mode. These are suitable for connection to CPW (cold potable water, type

**302140) or for refrigerant (type **302230) and have an integral condensation tray below the heat exchanger for a horizontal fitting position.

Operating limits for the unit

Caution! Frost protection must always be used if there is a risk of frost!

Place of installation

Airblock FG is intended for use in dry, dust-free and frost-free interior rooms and must be protected from the wind and weather. Temperatures should ideally be between 5 °C and 30 °C.




2. Safety Information

Installation, assembly and maintenance work on electrical units should only be performed by a qualified electrician in compliance with the VDE guidelines. Ensure that the connection complies with the applicable VDE regulations and provisions laid down by the regional electricity providers.

Non-compliance with the regulations and operating instructions can result in the units malfunctioning with consequential damage and danger to people. The units can be incorrectly wired by the wires being swapped – danger of fatal injury!

Disconnect all parts of the system from the mains power supply and prevent them from being reconnected before starting any connection and maintenance work!

Check the electrical equipment on the fan regularly (see fan operating instructions). Replace loose connections and defective cables immediately.

Electrical charge (>50 C) between the mains conductor and protective conductor connection after disconnecting the mains supply with the parallel connection of several fans (e.g. model size 7 and 9).

• Ensure that sufficient protection against accidental contact is provided.

The mains supply and PE must be short-circuited before working on the electrical supply.

There is voltage at terminals and connections even when the unit is switched off.

• Do not only the unit until 5 minutes after disconnecting the voltage at all poles.

There is electrical voltage on the rotor and impeller in the event of a fault.

The rotor and impeller have basic insulation.

• Do not touch when installed!

The fan will start up again automatically if control voltage is applied or when a speed setpoint is stored, e.g. after a power failure.

• Therefore, do not stand in the danger zone of the unit.

• Disconnect the mains voltage when working on the unit and secure it again being switched on again.

• Wait until the unit is at a standstill.

• Remove any tools used, the short-circuiting equipment or other objects from the unit after working on the unit.

High temperatures occur on the electronics housing of the fan.

• Risk of burns.

The fan has anti-lock protection.

5

6

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Airblock FG



3. Operation

The supply air module draws in room air or fresh air via the filter through the integral radial fan or fans and delivers this though the heat exchanger

(heating medium LPHW). The heated air is fed into the room using suitable attachments. The exhaust air module consists of the fan section. The

Airblock FG with attachments can be used for cooling (CPW, direct evaporator) or as an overpressure system with a particle filter class H13 for food stores. A bag filter module F7 (in accordance with DIN EN 779) can also be fitted.

The components described in these instructions have a connection (electrics, hydraulics, condensation connection) with the direction of the air flow to the left.

The installation and maintenance of units with the connection to the right are carried out in the same way.

Heat recovery module

Chiller module with evaporator

Chiller module

Particle filter module

Bag filter module

Exhaust air module

Supply air module

7

8

5

6

9

3

4

1

2

Weather protection grille

Weather protection grille frame

Wall duct

Mixed air unit, short

Sound absorber

Insulated connections

Airblock supply air module

Airblock chiller module CPW

Flexible pipe connection unit




4. Standard System Set-up

Top view

Example 1: Mixed air system

Installation in a suspended ceiling, fresh air intake through the wall; horizontal installation of the Airblock FG supply air module in a suspended ceiling.

• Recirculating air /fresh air through the mixed air unit, short, regulated.

• Height alignment to the suspended ceiling using sliding supports.

• Recirculating air intake through linear grille.

• Supply air and intake side with sound absorber for noise reduction.

• Supply air side with optional chiller module.

7

8

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Airblock FG



2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17


Sound absorber

Compact filter unit


Airblock exhaust air module

T-piece, compact

Heat recovery module (counterflow)

Louvre

Louvre, compact

90° bend, long

Empty duct

Wall duct



Airblock supply air module

Airblock chiller module CPW

Example 2: Heat recovery system

Installation in a suspended ceiling, fresh air intake and extract air discharge through the wall; horizontal installation of the Airblock FG supply air module in a suspended ceiling.

• Fresh air intake via a weather protection grille through the wall

• Air routing through the heat recovery module for controllable heat recovery via a bypass.

• Recirculating air / heat recovery operation through a combined mixed air unit, compact (optional), regulated.

• Post-heating of the supply air through the LPHW element in the supply air module or cooling in the chiller module (optional).

• Supply of exhaust air through a flexible pipe connection unit, air routing through the heat recovery module for heat recovery.

• Extract air routing via a louvre and weather protection grille through the outer wall.

Note: The exhaust air module is arranged on the pressure side when using the mixed air unit (optional); an arrangement on the suction side is recommended for optimum flow of the heat recovery module!

8

9

6

7

4

5

2

3


Sound absorber


Pre-filter as slide-in filter G4

Airblock chiller module

Droplet separator


Particle filter module




Example 3: Overpressure system (as recirculating air system)

Installation in a suspended ceiling; horizontal installation of the Airblock FG exhaust air module in a suspended ceiling.

• Recirculating air intake through a flexible pipe connection unit and sound absorber.

• Cooling of the air (as required) through the chiller module with a mounting option for a droplet separator (optional).

• Filter insert G4 (optional) can be used as a pre-filter in the filter holder of the chiller module.

• Downstream particle filter H13.

• Air discharge through a flexible pipe connection unit with distribution to several flexible pipes (spiral ducts) and supply air slot outlets above the sales counter.

8

9

6

7

4

5

2

3


Sound absorber



Louvre

Wall duct



Top view

Example 4: Exhaust air system

Installation in a suspended ceiling, exhaust air intake through the ceiling; horizontal installation of the Airblock FG exhaust air module in a suspended ceiling.

• Air intake through a flexible pipe connection unit and sound absorber.

• Extract air routing via a louvre and weather protection grille through the outer wall.

9

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Airblock FG



5. Supply Air Module (incl. Heat Exchanger and F7 Filter)

5.1 Unit Construction

1

2

L

15

5

1

13

14

10

11

3

4

9

6

12

7

6

8

10

Airblock FG supply air module

7

Fig.: Securing the suspension

brackets

1

2

3

4

5

6

7

Suspension bracket with slot

(4 no., included in pack)

Flow rate transmitter (optional accessory)

Motor terminal box

Service hatch, pre-fitted*

(indicated as an opening)

Housing

230 V EC fan

Screw-on hinge for service hatch*

(2 no. pre-fitted)

8

9

10

11

12

13

14

15

Connecting strut on air discharge side

Connecting strut on air intake side

Direction of air flow

Filter insert F7

Heat exchanger

Flow connection

Return connection

Differential pressure transmitter

(optional accessory)

* The service hatch and screw-on hinges can be rotated 180° and fitted on site depending on the space requirements; the screw-in hinges can be fixed to the connecting strut on the air discharge side and the connecting strut on the air intake side. Screw the screw-in hinges to the desired connecting strut using two M6x16 countersunk screws.

Module dimensions

Model

Model 6

Model 7

Model 8

Model 9

Length

L [mm]

1000

1000

1100

1100

All dimensions are external dimensions.

Supply air module

Width W

[mm]

740

940

940

1140

Height H

[mm]

390

390

490

490

Weight

[kg]

73

87

98

119

10




5.2 Installation

The Airblock housing

5

has four suspension points

1

as standard as screwable mounting brackets with a slot fixing for universal installation.

All Airblock modules are suitable for the installation of accessories or attachments with standard duct connection profiles thanks to the connecting flange with several fixing holes.

• Seal all joints with sealing tape. Screws and sealing tape are included in the delivery.

• Several Airblock filter or chiller modules can be screwed together from the inside using the connection sets included.

• Make sure that there is adequate working space for the operation and maintenance of the respective Airblock modules and attachments when installing the units. This applies in particular to the connection side area

(heating medium / electrical connection

13

/

14

+

3

etc.).

• Provide rubber pads on site to decouple noises.

• Align the unit in a horizontal position.

• Please note the following: The filter

11

can only be removed from below for maintenance purposes!

• Caution: Remove the F7 filter from the supply air module with a heat recovery module combination! Only one filter level is provided for the design of the Airblock units.

• Connect the frost and filter monitoring

15

to the control (see wiring diagrams).

Note: Service hatches are to be provided on site below and alongside the modules (connection side) for the installation and maintenance of the

Airblock modules!

5.3 Hydraulic Connections

• Connect the flow and return lines

13

+

14

according to the labelling on the housing.

• Provide for a shut-off, ventilation and drainage.

Please note the following for connecting the heat exchanger

12

:

• Hold the connections on the heat exchanger with a wrench or other suitable tool when connecting the pipework.

• Note: It is intended that the heat exchanger will be removed from

the side for maintenance purposes!

11

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Airblock FG



5.4 Electrical Wiring

Damage can be caused by the use of incompatible switching devices and by the use of inadequate protective equipment. The manufacturer does not accept any warranty in these cases.

Only connect up in systems that have an all-pole trip breaker from the mains power with a minimum contact opening of 3 mm! Lay electrical cables so that they are tension-free and not under stress!

6

7

8

9

All models require a 230 V/ 50/60 Hz power supply and can be controlled via a combined 0-10V / PWM control input. Models 8 and 9 can be operated alternatively via an integrated MODBUS RTU interface. A 24 V power supply is also required for the operation of a flow rate and/or differential pressure transmitter.

When using residual current circuit breakers for motors with EC technology these must be sensitive to all types of current (type B). We recommend a tripping current of 300 mA and time-delayed tripping (super-resistant, characteristic K) for optimum operating safety.

First connect up the protective conductor „PE“ on the motor terminal box.

Connect the unit according to the applicable wiring diagram as indicated in the table:

Model Without flow rate transmitter

Factory-fitted CAD no.

13084

13085

13086

13087

With flow rate transmitter


not possible not possible

13228

13229

A potential-free 250 V / 6 A (AC1) / 2 A (AC3) changeover contact is available in the motor terminal box for the switch position 0 or power failure message. A fan error message is signalled for models 8 and 9 regardless of the control type.

Electrical data for EC motor

Type

06300300/06300600

07300300/07300600

08300300/08300600

09300300/09300600

Voltage/frequency

230 V/50/60 Hz

230 V/50/60 Hz

230 V/50/60 Hz

230 V/50/60 Hz

Please refer to the fan operating instructions for more information!

Max. current

1.4 A

2.8 A

3.2 A

6.4 A

Output

0.17 kW

0.34 kW

0.73 kW

1.46 kW

12

Description of accessory

Frost protection thermostat




5.5 Control Components

Please refer to the enclosed technical information for technical data on the following accessories delivered separately or fitted at the factory.

Type suffix for

Airblock type

...0F0

...00D

Type of accessory/ spare part supplied separately

Model 6: 30468

Models 7, 8, 9: 30668

30267

Enclosed technical information from manufacturer

enclosed

Filter differential switch, for use with supply air module type **300300, chiller module type **302140, heat recovery module type **301700, particle filter module type ** 303130 and bag filter module type **303170

Differential pressure transmitter, filter or fan

Flow rate transmitter for flow rate control

It is possible to combine the components, e.g. ...VFP.

...00P or ...P00

...V00

enclosed enclosed

1 2 3 4

5

1

2

3

4

5

Motor terminal box

Flow rate transmitter


Differential pressure switch PS 600

Cable duct for the frost protection

thermostats installed on the inside

13

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Airblock FG



5.6 Maintenance

5.6.1 Safety Information

Disconnect all parts of the system and secure them against being switched on again before any wiring and maintenance work!

The housing must only be opened once the motor has come to a standstill.

Risk of injury!

Check the function of all components after completing the work.

5.6.2 Opening the Service Hatches

Stand on a solid surface to carry out maintenance on the Airblock FG, e.g. a lifting platform. Do not use a ladder! Do not stand within the swivel range of the hatch!

Caution! Two people are needed to open the service hatch

4

! The hatch weights up to 20 kg depending on the model. Never open the service hatch further than 90°!

Steps:

1. Rotate the turning bolt (4 or 6 no. per service hatch) 90° inwards using the square box spanner enclosed.

2. Lower the service hatch until the safety hook automatically hooks into the lug of the housing connecting strut; the safety hook prevents the service hatch suddenly flapping downwards.

3. Lift the service hatch slightly; push back the safety hook until it can be moved past the lug of the housing connecting strut.

4. Carefully lower the service hatch to the desired position.

Opening the service hatch (simplified diagram of a module)

14

Detailed view from below

Detail: Security hooks




5.6.3 Housing

The galvanised, double-walled housing

5

of the Airblock modules is maintenance-free. Dirt on the outer housing has no influence on the operation of the unit. Dirt on the inside of the housing indicates a lack of maintenance.

5.6.4 Fan Motor

The external rotor motor

6

of the Airblock is maintenance-free. The motor‘s ball bearings, sealed on both sides, are greased for life. In contrast, deposits on the fan and inlet nozzle reduce the air volume and must be removed:

• Unscrew the turn bolt fasteners and open the service hatch

4

. Swivel the service hatch fully downwards. The fans are now freely accessible for cleaning purposes.

• Check the fan and inside of the housing at regular intervals (at least once a year) and clean if dirty.

Please refer to the respective fan operating instructions for more information!

Remove the protection securing the system from being switched on after completing the work.

5.6.5 Cu/Al Heat Exchanger

The heat exchanger

12

requires no maintenance if the system is properly maintained, i.e. if the filter is monitored and changed regularly. However, please proceed as follows if maintenance or repairs are required:

• Carry out a visual inspection of the heat exchanger. To do this, open the service hatch

4

.

• The heat exchanger can be removed through the side service hatch. First remove the flow and return pipes. Then loosen the screws on the heat exchanger fastenings and pull out the heat exchanger sideways.

• Observe the safety information in 5.3.

• Residual water may remain in the heat exchanger once it has been emptied.

Cleaning the heat exchanger:

• Blast the Airblock CU/AL heat exchanger with appropriate compressed air or flush the heat exchanger with a suitable medium to remove accumulated dust. Proceed extremely carefully as the aluminium fins bend very easily and then restrict the air flow! (Bent fins have to be straightened with an appropriate tool).

15

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Airblock FG



5.6.6 Filter Change

Filter change on the supply air module (service hatch hidden)

Observe the safety information on page 14, sections 5.6.1 and 5.6.2! Filter cartridge in a Fiberplast frame

11

(with supply air module).

• Check the filter cartridge F7

11

at least once a year (more often if necessary). The filter cartridge must be changed if it is dirty.

• Open the service hatch

4

and unlock the safety catches. Pull out the filter cartridge F7 downwards. Use a collection bag if necessary to avoid dirt and dust dropping down.

• This filter folds in the middle with model 9 units. This makes it easier to remove and it can be folded to save space with disposal so that very little dirt can drop out.

• Push the replacement filter cartridge into the filter opening and lock the filter catches. Replacement filter cartridges F7 are available as accessories.

Filter cartridges F7 cannot be recycled.

• Dispose of the dirty filter. Filter cartridges F7 are metal-free and fully incinerable.

16

Fig.: Securing the suspension brackets




6. Exhaust Air Module


L

2

1

10

1

5

3

6

4

9

6

7

10

8

7

1

2

3

4

5

Suspension bracket with a slot


Flow rate transmitter (optional accessory)

Motor terminal box



Housing

6

7

8

9

10

EC fan


(2 no. pre-fitted)




* The service hatch and screw-on hinges can be rotated 180° and fitted on site depending on the space requirements; the screw-in hinges can be fixed to the connecting strut on the air

discharge side and the connecting strut on the air intake side. Screw the screw-in hinges to the desired connecting strut using two M6x16 countersunk screws.

Module dimensions

Model

Model 6

Model 7

Model 8

Model 9

Length L

[mm]

600

600

700

700


Exhaust air module

Width W

[mm]

Height H

[mm]

740

940

940

1140

390

390

490

490

Weight

[kg]

43

51

61

77

17

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Airblock FG





5


1






(electrical connection

3

etc.).



Note: Service hatches are to be provided on site below and alongside the modules (connection side) in the case of suspended ceilings or encased units for the installation and maintenance of the Airblock modules!

6.3 Electrical Wiring

6

7

8

9

Damage can be caused by the use of incompatible switching devices and by the use of inadequate protective equipment. The manufacturer does not accept any warranty in these cases.

All models require a 230 V/ 50/60 Hz power supply and can be controlled via a combined 0-10V / PWM control input. Models 8 and 9 can be operated alternatively via an integrated MODBUS RTU interface. A 24 V power supply is also required for the operation of a flow rate and/or differential pressure transmitter.

When using residual current circuit breakers for motors with EC technology these must be sensitive to all types of current (type B). We recommend a tripping current of 300 mA and time-delayed tripping (super-resistant, characteristic K) for optimum operating safety.

Then connect up the protective conductor „PE“.

Connect the unit according to the applicable wiring diagram as indicated in the table:

Model Without flow rate transmitter


13084

13085

13086

13087

With flow rate transmitter


not possible not possible

13228

13229

18




A potential-free 250 V / 6 A (AC1) / 2 A (AC3) changeover contact is available in the motor terminal box for the switch position 0 or power failure message. A fan error message is signalled for models 8 and 9 regardless of the control type.

Electrical data for EC motor

Type

06300300/06300600

07300300/07300600

08300300/08300600

09300300/09300600

Voltage/frequency

230 V/50/60 Hz

230 V/50/60 Hz

230 V/50/60 Hz

230 V/50/60 Hz


Max. current

1.4 A

2.8 A

3.2 A

6.4 A

Output

0.17 kW

0.34 kW

0.73 kW

1.46 kW

19

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Airblock FG






Fan differential pressure transmitter

Flow rate transmitter for flow rate control

Type suffix for

Airblock type

...P00

...V00



enclosed enclosed

20




6.5 Maintenance




Risk of injury!





4


Steps:








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Airblock FG



6.5.3 Housing


5


6.5.4 Fan Motor

The external rotor motor

6

of the Airblock is maintenance-free. The motor‘s ball bearings, sealed on both sides, are greased for life. In contrast, deposits on the fan and inlet nozzle reduce the air volume and must be removed:

• Unscrew the turn bolt fasteners and open the service hatch

4

. Swivel the service hatch fully downwards. The fans are now freely accessible for cleaning purposes.

• Check the fan and inside of the housing at regular intervals (at least once a year) and clean if dirty.


Remove the protection securing the system from being switched on after completing the work.

22




7. Commissioning the Fan Modules

Check the following before commissioning the unit:

- Is the protective conductor connected properly on all units?

- Are all the lines connected properly as per the wiring diagrams?

- Do all cables comply with the necessary cross-sections?

- Are both DIP switches set correctly when controlled via the MODBUS RTU interface?

Model 8: ON

Model 9: OFF

- With a flow rate and/or differential pressure transmitter: Is the voltage

24 V in each case?

• Take into account information on the commissioning of other parts of the system.

• The Airblock can be put into operation after conducting the above checks by switching on the power supply to the motor terminal box, switching on the fan modules on the motor terminal box and changing the

0-10 VDC input signal or by transmitting a signal via the MODBUS RTU interface.

Check the following after commissioning the unit:

- Are all the impellers running smoothly or are grinding noises audible?

Determine the cause as soon as grinding noises become audible.

Switching off the units:

- Switch off the unit during operation via the control input.

- Do not switch the unit off and on (e.g. in cycle mode) via the mains power.

- Make sure that the earth conductor connection is disconnected last when disconnecting the unit.

- Observe the safety information in section 2.

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Airblock FG



8. Connecting Airblock Modules

4

3

1

2

4

5

1

2

3

4

5

Node profile

Node profile guide

M8 x 16 ratchet screw

Housing

Service hatch

Fig. Airblock module (simplified diagram)

Screw the modules together using the connecting elements included in the pack. Screw two modules to four connection points in the corners of the housing.

Installation steps for a connection point:

The corners of the housing can be accessed through the service hatch. The filter inserts (M5, F7 or H13) must be removed from the module if necessary to ensure optimum accessibility.

1. Open service hatch

5

.

2. Use two tapping screws to screw the node profile

1

to the housing

4

.

3. Use two tapping screws to screw the node profile guide

2

to the adjacent housing.

4. Position the modules in such a way that the drill holes of the screwed node profile

1

, node profile guide

2

and housing are located one above the other; use the M8 x 16 ratchet screw to screw the modules to the connection point.

24

1

2

7

16




9. Heat Recovery Module


Note: 2 service hatches are fitted on the top and underside of the units to ensure optimum accessibility for maintenance purposes.

2

1

14

L

1

W

B

12

11 4

15

9

4

10

13

8

3

4

7

6

5

7

13

17

7

1

2

3

4

5

6

7





Counterflow heat exchanger



Housing

Bypass flap


(2 no. pre-fitted)

8

9

10

11

12

13

14

15

16

17



Condensation tray

Drain connection on condensation tray

Flap servomotor (accessory)

Filter

Extract air

Fresh air

Supply air

Exhaust air


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Airblock FG



Module dimensions

Model

Model 6

Model 7

Model 8

Model 9

Length L

[mm]

1600

1600

1900

1900


Heat Recovery Module

Width W

[mm]

1640

Height H

[mm]

390

2040

2040

2440

390

490

490

Weight

[kg]

211

237

322

361



5

has six suspension points

1

as standard as screwable mounting brackets with a slot fixing for universal installation. All Airblock modules are suitable for the installation of accessories or attachments with standard duct connection profiles thanks to the connecting flange with several fixing holes.

The heat recovery module has a condensation tray

10

with a gradient on all sides and a condensation drain connection on the side

11

.

• Align the unit in a horizontal position!

• Any condensation produced has to be drained off individually or through a collecting line via the siphon connected to the condensation drain connection.

• Condensation must be able to drain freely. Make sure that the condensation drain connection has an appropriate free area.

• Lay a condensation line without any kinks or restrictions with a gradient to the sewage pipe on site.

• Choose the correct condensation line diameter.

• Protect the siphon in the condensation line against drying out (use a ball siphon if necessary).


Airblock modules!

Note: The filters

13

can be removed from above and below for maintenance purposes!

26




Condensation drains

• A siphon needs to be connected to all available condensation drain connections.

• Ensure an adequate sealing water height (Hs) (see adjacent Fig.)

Sealing water height:

Hs = H + 50 mm

H = static negative pressure in the unit (mm H

2

(1 mm H

2

O = 9.81 Pa)

O)

Min. water trapp height = 60 mm

Sealing water height Hs



Description of accessory Type suffix for

Airblock type

Filter differential pressure switch, for use with supply air module type **300300, chiller module type **302140, heat recovery type **301700, particle filter module type ** 303130 and bag filter module type **303170

Filter differential pressure transmitter

...00D

...00P

A 24 V power supply is also required for the operation of a filter differential pressure transmitter.



30267 enclosed

9.4 Maintenance

Observe the maintenance intervals prescribed by the legislature. The intervals are dependent on various factors (e.g. structural conditions, level of dirt, etc.) and may therefore differ from the manufacturer‘s recommendations.

If an increased level of dirty is detected during regular checks, adjust the required maintenance intervals according to the actual wear and tear.

27

1.50

Airblock FG






Risk of injury!





4


Steps:








28




9.4.3 Housing


5


Heat recovery modules are fitted with two service hatches

4

on the top and underside.

9.4.4 Counterflow Heat Exchanger

Counterflow heat exchangers

3

require no maintenance if the system is properly maintained, i.e. if the filter is monitored and changed regularly (see page 32). However, please proceed as follows if maintenance or repairs are required: Open the service hatches and carry out a visual inspection of the counterflow heat exchanger to check for dirt.

Proceed as follows if a high level of dirt is visible:

1. Unscrew the M6 flat-head screws (2 no.) from the central support and remove the central support.

2. Remove the condensation tray; loosen the M6 ratchet screws (4 no.).

• Pull out the condensation tray with drain connection from the side panel on the connection side and remove it in a downward direction.

• Please note that residual water may remain in the condensation tray.

3. Remove the counterflow heat exchanger; – unscrew the wing screws

(2 no.) until the clamping profile can move freely.

• Push the clamping profile to the side via the slots until the counterflow heat exchanger can be removed in a downward direction.

• Remove and clean the heat exchangers one by one.

• Install the components in the reverse order to removing them.

Note: The removal of the components described refers to vertically installed units. Maintenance is carried out in the same way with horizontally installed units as the service hatches and central supports are installed on both the top and underside. Only the condensation tray is installed on the underside.

The removal of the condensation tray with vertically installed units is therefore not applicable.

Cleaning the condensation tray:

Clean the condensation tray and droplet separator (optional) at regular intervals.


• Blast the counterflow Airblock modules with appropriate compressed air or flush the heat exchanger with a suitable medium to remove accumulated dust. Proceed extremely carefully as the aluminium fins bend very easily and then restrict the air flow! (Bent fins have to be straightened with an appropriate tool).

29

1.50

Airblock FG



Unscrewing the central support

Removing the condensation tray (details)

30

Removing the condensation tray




Removing heat recovery units

X

X

31

1.50

Airblock FG




Observe the safety information on page 27 + 28, sections 9.4.1 and 9.4.2!

Filter cartridge in a Fiberplast frame

13

(filter class: M5 for exhaust air and

F7 for fresh air as per DIN EN 779).

• Check the filter cartridges

13

at least once a year (more often if necessary).

The filter cartridge must be changed if it is dirty.

• Open the service hatches

4

and unlock the safety catches. Then pull out the filter cartridges downwards or upwards. The filter must be moved past the service hatch when the service hatches are fully opened to the bottom (swivel range = 1780 mm). To do this, the slide-in rail in which the filter sits can be swivelled 10°. The filter can be pulled out easily in a downward direction in a swivelled state (see dimension 1780 mm). Use a collection bag if necessary to avoid dirt and dust dropping down.


• Push the replacement filter cartridge into the filter opening and lock the filter catches. Replacement filter cartridges are available as accessories.

Filter cartridges cannot be recycled.

• Caution: Swivel the filter holder back into the vertical position before closing the service hatches!

• Dispose of the dirty filter. Filter cartridges are metal-free and fully incinerable.

X

X

X

0 - 10°

X

0 - 20°

32




10. Chiller Module


L

1

W

B

1

2

10

7

8 6

Please refer to the enclosed instructions from the pump manufacturer for technical data on the condensation pump!


9

4

5

13

14

12

3

11

10

13

1

2

3

4

5

6





Heat exchanger



Housing

Filter

7

8

9

10

11

12

13

14

Flow connection

Return connection

Drain connection on condensation tray





(2 no. pre-fitted)

Condensation tray


Module dimensions

Model

Model 6

Model 7

Model 8

Model 9

Length L

[mm]

700

700

700

700


Chiller module

Width W

[mm]

Height H

[mm]

740

940

940

1140

390

390

490

490

Weight

[kg]

49

57

63

71

33

1.50

Airblock FG





5


1



The chiller module has a condensation tray

14

with a gradient on all sides and a condensation drain connection on the side

9

.

• Align the unit in a horizontal position!

• Any condensation produced has to be drained off individually or through a collecting line via the siphon connected to the condensation drain connection.

• Provide all water-bearing components (pipes, valves, connections) all the way to the unit with vapour diffusion-tight insulation!

• Only use suitable pipe brackets for cooling mode (refrigeration clamps).

• Install safety-related components (e.g. expansion tanks, positive pressure and overflow valves).

• Condensation must be able to drain freely. Make sure that the condensation drain connection has an appropriate free area.

• Lay a condensation line without any kinks or restrictions with a gradient to the sewage pipe on site.

• Choose the correct condensation line diameter.

• Protect the siphon in the condensation line against drying out (use a ball siphon if necessary).


Airblock modules!

Condensation drains

• A siphon needs to be connected to all available condensation drain connections.

• Ensure an adequate sealing water height (Hs) (see adjacent Fig.)

Sealing water height:

Hs = H + 50 mm

H = static negative pressure in the unit (mm H

2

(1 mm WS = 9.81 Pa)

O)

Min. water trapp height = 60 mm

Sealing water height Hs

34




10.3 Hydraulic Connections

• Connect the flow and return lines

7

+

8

according to the labelling on the housing.

• Provide for a shut-off, ventilation and drainage.

Please note the following for connecting the heat exchanger:

• Hold the connections on the heat exchanger with a wrench or other suitable tool when connecting the pipework.


(heating medium / electrical connection

7

/

8

+

2

etc.).

• Note: It is intended that the heat exchanger

3

will be removed from the side for maintenance purposes!

35

1.50

Airblock FG







Type suffix for

Airblock type

...0F0



...00D

...00P

It is possible to combine the components, e.g. …0FP




enclosed Model 6: 30468

Models 7, 8, 9: 30668

30267 enclosed

36




10.5 Maintenance

Observe the maintenance intervals prescribed by the legislature. Periodic maintenance is dependent on the basic conditions, see also maintenance of the heat exchanger and maintenance of the filter

6

on pages 38 and 39.




Risk of injury!



Note: 2 service hatches are fitted on the top and underside of the units to ensure optimum accessibility for maintenance purposes.



4


Steps:





37

1.50

Airblock FG




38



10.5.3 Housing


5


Chiller modules are fitted with two service hatches

4

on the top and underside.

10.5.4 Cu/Al Heat Exchanger

The heat exchanger

3

requires no maintenance if the system is properly maintained, i.e. if the filter is monitored and changed regularly (see page

39). However, please proceed as follows if maintenance or repairs are required:

• Carry out a visual inspection of the heat exchanger. To do this, open the service hatch

4

.

• The heat exchanger can be removed through the side service hatch. To do this, first remove the flow and return pipes

7

+

8

. Then loosen the screws on the heat exchanger fastenings and pull out the heat exchanger sideways.

Check the condensation tray

14

and droplet separator (if fitted) at regular intervals and clean them if necessary.





• Blast the Airblock CU/AL heat exchanger with appropriate compressed air or flush the heat exchanger with a suitable medium to remove accumulated dust. Proceed extremely carefully as the aluminium fins bend very easily and then restrict the air flow! (Bent fins have to be straightened with an appropriate tool).

10.5.5 Filter Change (Optional)

Observe the safety information on page 37, sections 10.5.1 and 10.5.2!

Filter cartridge in a Fiberplast frame

6

(optional with the chiller unit).

If your chiller module is fitted with a filter:

• Check the filter cartridge

6

at least once a year (more often if necessary).

The filter cartridge must be changed if it is dirty.

• Open the service hatch

4

and unlock the safety catches. Pull out the filter cartridge downwards. Use a collection bag if necessary to avoid dirt and dust dropping down.


• Push the replacement filter cartridge into the filter opening and lock the filter catches. Replacement filter cartridges are available as accessories.

Filter cartridges cannot be recycled.

• Dispose of the dirty filter. Filter cartridges are metal-free and fully incinerable.

39

1.50

Airblock FG



11. Bag Filter Module


L

1

9

1

2

Airblock FG bag filter module


5

3

4

8

9

6

7

6

1

2

3

4





Bag filter



5

6

7

8

9

Housing


(2 no. pre-fitted)





Module dimensions

Model

Model 6

Model 7

Model 8

Model 9

Length L

[mm]

700

700

700

700


Bag filter module

Width W

[mm]

Height H

[mm]

740

940

940

1140

390

390

490

490

Weight

[kg]

40

46

49

55

40






5


1







2

etc.).



• Note: The filter

3



Airblock modules!

41

1.50

Airblock FG






Airblock type



...00D

...00P




30267 enclosed

42








Risk of injury!





4


Steps:








43

1.50

Airblock FG



11.4.3 Housing


5



• Check the filter cartridge F7

3

at least once a year (more often if necessary). The bag filter must be changed if it is dirty.

• To do this, open the service hatch

4

of the bag filter module and pull out the bag filter downwards. The filter on the discharge side can be gently pressed together. Use a collection bag if necessary to avoid dirt and dust dropping down.

• Insert a replacement bag filter F7 (available as an accessory).

Bag filters F7 cannot be recycled.

Filter change on the bag filter module

(service hatch hidden)

44




12 Particle Filter Module


L

1

W

B

9

1

2

5

4

3

8

9

6

7

Airblock FG particle filter module


6

1

2

3

4





Particle filter



5

6

7

8

9

Housing


(2 no. pre-fitted)





Module dimensions

Model

Model 7

Model 8

Model 9

Length L

[mm]

700

700

700


Particle filter module

Width W

[mm]

Height H

[mm]

940

940

1140

390

490

490

Weight

[kg]

62

63

72

45

1.50

Airblock FG





5


1







2

etc.).



• Note: The filter

3



Airblock modules!

46







Airblock type



...00D

...00P




30267 enclosed

47

1.50

Airblock FG







Risk of injury!





4


Steps:






48






12.4.3 Housing


5


Filter change on the particle filter module

(service hatch hidden)


The particle filter class H13

3

must be checked at least once a year and replaced on reaching the filter service life or final pressure drop:

• To do this, open the service hatch

4

on the particle filter module.

• Then loosen the clamping rod on the clamping mechanism and remove this.

• Pull out the filter carefully. Use a collection bag if necessary to avoid dirt or dust dropping down!

• Insert the replacement particle filter class H13. Pay attention to the correct direction of air flow (see arrow).

• Insert the clamping rod again and tighten this carefully to ensure that there is a good seal to the counter frame.

• Dispose of the dirty filter.

49

1.50

Airblock FG



13. Spare Parts

13.1 Filter

Overview of replacement filter types

Model Unit size

Replacement bag filter F7 for bag filter module

Replacement particle filter H13 for particle filter module

Replacement filter cartridge G4 for supply air and compact filter module, in Fiberplast frame

Replacement filter cartridge M5 for heat recovery, supply air and compact filter module, in Fiberplast frame

Replacement filter cartridge F7 for heat recovery, supply air and compact filter module, in Fiberplast frame

Model 06

06013170

06013130

06013240

06013250

06013270

Model 07

07013170

07013130

07013240

07013250

07013270

Model 08

08013170

08013130

08013240

08013250

08013270

Model 09

09013170

09013130

09013240

09013250

09013270




Type suffix for

Airblock type

...0F0



enclosed Model 6: 30468

Models 7, 8, 9: 30668

30267 Filter differential pressure switch, for use with supply air module type **300300, chiller module type **302140, heat recovery type **301700, particle filter module type ** 303130 and bag filter module type **303170

Differential pressure transmitter, filter or fan

...00D

...00P or ...P00

Flow rate transmitter for flow rate control ...V00

It is possible to combine the components, e.g. ...VFP.

A 24 V power supply is also required for the operation of a flow rate and / or differential pressure transmitter.

enclosed enclosed

50

Kampmann.co.uk/Airblock_FG

Kampmann GmbH

Friedrich-Ebert-Str. 128 - 130

49811 Lingen (Ems)

Germany

T

+49 591 7108-0

F

+49 591 7108-300

E

[email protected]

W

Kampmann.de

Kampmann UK Ltd.

Dial House, Govett Avenue

Shepperton, Middlesex, TW17 8AG

Great Britain

T

+44 (0)1932 228592

F

+44 (0)1932 228949

E

[email protected]

W

Kampmann.co.uk

Airblock FG

Airblock FG

Air handling unit with EC single-phase motor

Airblock FG modules for heating, cooling and ventilating

Slimline air handling unit for decentralized, dynamic air treatment

Slimline air handling unit for decentralized, dynamic air treatment

Slimline air handling unit for decentralized, dynamic air treatment

1. Intended Use

Slimline air handling unit for decentralized, dynamic air treatment

2. Safety Information

Slimline air handling unit for decentralized, dynamic air treatment

3. Operation

Slimline air handling unit for decentralized, dynamic air treatment

4. Standard System Set-up

Slimline air handling unit for decentralized, dynamic air treatment

Slimline air handling unit for decentralized, dynamic air treatment

Slimline air handling unit for decentralized, dynamic air treatment

5. Supply Air Module (incl. Heat Exchanger and F7 Filter)

5.1 Unit Construction

Slimline air handling unit for decentralized, dynamic air treatment

5.2 Installation

5.3 Hydraulic Connections

Slimline air handling unit for decentralized, dynamic air treatment

5.4 Electrical Wiring

Slimline air handling unit for decentralized, dynamic air treatment

5.5 Control Components

Slimline air handling unit for decentralized, dynamic air treatment

5.6 Maintenance

5.6.1 Safety Information

5.6.2 Opening the Service Hatches

Slimline air handling unit for decentralized, dynamic air treatment

5.6.3 Housing

5.6.4 Fan Motor

5.6.5 Cu/Al Heat Exchanger

Slimline air handling unit for decentralized, dynamic air treatment

5.6.6 Filter Change

Slimline air handling unit for decentralized, dynamic air treatment

6. Exhaust Air Module

6.1 Unit Construction

Slimline air handling unit for decentralized, dynamic air treatment

6.2 Installation

6.3 Electrical Wiring

Slimline air handling unit for decentralized, dynamic air treatment

Slimline air handling unit for decentralized, dynamic air treatment

6.4 Control Components

Slimline air handling unit for decentralized, dynamic air treatment

6.5 Maintenance

6.5.1 Safety Information

6.5.2 Opening the Service Hatches

Slimline air handling unit for decentralized, dynamic air treatment

6.5.3 Housing

6.5.4 Fan Motor

Slimline air handling unit for decentralized, dynamic air treatment

7. Commissioning the Fan Modules

Slimline air handling unit for decentralized, dynamic air treatment

8. Connecting Airblock Modules

Slimline air handling unit for decentralized, dynamic air treatment

9. Heat Recovery Module

9.1 Unit Construction

Slimline air handling unit for decentralized, dynamic air treatment

9.2 Installation

Slimline air handling unit for decentralized, dynamic air treatment

9.3 Control Components

9.4 Maintenance

Slimline air handling unit for decentralized, dynamic air treatment

9.4.1 Safety Information

9.4.2 Opening the Service Hatches

Slimline air handling unit for decentralized, dynamic air treatment

9.4.3 Housing

9.4.4 Counterflow Heat Exchanger

Slimline air handling unit for decentralized, dynamic air treatment

Slimline air handling unit for decentralized, dynamic air treatment

Slimline air handling unit for decentralized, dynamic air treatment

9.4.5 Filter Change

Slimline air handling unit for decentralized, dynamic air treatment

10. Chiller Module

10.1 Unit Construction

Slimline air handling unit for decentralized, dynamic air treatment

10.2 Installation

Slimline air handling unit for decentralized, dynamic air treatment