gea fil382 atpicco uk dh-drift

7/25/2019 GEA Fil382 ATpicco UK DH-Drift

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GEA Air Handling Units

Low-profile air handling in smallest space

GEA AT

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GEA Air Treatment Product Range GEA ATpicco

2 PR-2012-0052-GB Subject to modifications K0-04/2013


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GEA ATpicco Contents

PR-2012-0052-GB Subject to modifications K0-04/2013 3

Contents

1 Safety and User Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.1 Availability of this operation manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.2 Scope of validity of this operation manual . . . . . . . . . . . . . . . . . . . . . . . 6

1.3 Icons used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.3.1 Designation of the special notices / special information . . . . . . 8

1.3.2 Designation of the functional elements . . . . . . . . . . . . . . . . . . . 9

1.4 Safety-conscious working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.5 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.6 Safety regulations and safety standards. . . . . . . . . . . . . . . . . . . . . . . . 11

1.7 Modifications and changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.8 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.9 Selection and qualification of personnel . . . . . . . . . . . . . . . . . . . . . . . . 12

2 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.1 Unit description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.2 Unit design and working procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.3 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.4 Range of application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3 Shipping and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173.1 Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.2 Handling and shipping the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.2.1 Transport by means of lifting trolley or fork-lift truck . . . . . . . . 18

3.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.1 Load-bearing capacity of the installation site . . . . . . . . . . . . . . . . . . . . 19

4.2 Assembly of the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.3 Sound attenuation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.4 Assembly of the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.4.1 Ceiling mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.4.2 Floor assembly / subfloor mounting. . . . . . . . . . . . . . . . . . . . . 21

4.4.3 Wall mounting (vertical air routing) . . . . . . . . . . . . . . . . . . . . . 22

4.4.4 Wall mounting (horizontal air routing) . . . . . . . . . . . . . . . . . . . 23

4.5 Component and accessory assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.5.1 General conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234.5.2 Connection of the air-treatment piping . . . . . . . . . . . . . . . . . . 23

4.5.3 Medium connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.5.4 Heating or cooling circuit connections. . . . . . . . . . . . . . . . . . . 24

4.5.5 Installation of the direct evaporator/condenser components. . 25

4.5.6 Installation of the humidification plant . . . . . . . . . . . . . . . . . . . 26

4.5.7 Connection of the siphon and the drain pipe . . . . . . . . . . . . . . 27

4.6 Heater bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.7 Accessory assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28


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Contents GEA ATpicco


5 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295.1 General conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.1.1 Installation of the cable (clamp terminal) . . . . . . . . . . . . . . . . . 29

5.2 Connecting the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.2.1 Motor protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.2.2 Connecting the electric motors . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.2.3 Service switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.2.4 Installation and connection of the actuators(e.g. for damper blades) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.2.5 Heater bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.2.6 Additional electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . 34

6 Commissioning and Maintenance . . . . . . . . . . . . . . . . . . . . . .356.1 Basic obligations for cleaning and maintenance . . . . . . . . . . . . . . . . . . 36

6.1.1 Basic information on cleaning the heat exchanger fins . . . . . . 36

6.2 Overview of the maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.3 Units in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.3.1 Commissioning the units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.3.2 Maintenance of the units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.4 Fan chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.4.1 Commissioning of the EC motor fans41

6.4.2 Commissioning of the AC motor fans 41

6.4.3 Maintenance of the AC and EC motor fans . . . . . . . . . . . . . . . 41

6.5 Filter chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.5.1 Commissioning the filter chamber . . . . . . . . . . . . . . . . . . . . . . 42

6.5.2 Basic maintenance work on all filter assemblies . . . . . . . . . . . 42

6.5.3 Maintenance of the bag filter inserts and HEPA filter . . . . . . . . 436.5.4 Maintenance of the activated-carbon filter . . . . . . . . . . . . . . . . 43

6.5.5 Maintenance of the grease filter . . . . . . . . . . . . . . . . . . . . . . . . 44

6.5.6 Maintenance of other special filters . . . . . . . . . . . . . . . . . . . . . 44

6.6 Air heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.6.1 Commissioning the water-based air heater . . . . . . . . . . . . . . . 44

6.6.2 Maintenance of the water-air heater . . . . . . . . . . . . . . . . . . . . . 45

6.6.3 Commissioning the steam-based air heater . . . . . . . . . . . . . . . 45

6.6.4 Maintenance of the steam-based air heater . . . . . . . . . . . . . . . 45

6.6.5 Commissioning the electric-air heater . . . . . . . . . . . . . . . . . . . 46

6.6.6 Maintenance of the electric air heater. . . . . . . . . . . . . . . . . . . . 46

6.7 Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.7.1 Commissioning the cooler with/without droplet separator . . . . 47

6.7.2 Maintenance of cooler with/without droplet separator . . . . . . . 47

6.8 Evaporator / condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.8.1 Commissioning the evaporator/condenser . . . . . . . . . . . . . . . . 48

6.8.2 Maintenance of the evaporator/condenser . . . . . . . . . . . . . . . . 48

6.9 Energy recovery: heat pipe (ECOSTAT) . . . . . . . . . . . . . . . . . . . . . . . . 48

6.9.1 Commissioning the heat pipe . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.9.2 Maintenance of the heat pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.10 Energy recovery: heat exchanger (ECOFLOW) . . . . . . . . . . . . . . . . . . 49

6.10.1 Commissioning the heat exchanger . . . . . . . . . . . . . . . . . . . . . 49

6.10.2 Maintenance of the heat exchanger . . . . . . . . . . . . . . . . . . . . . 49

6.11 Energy recovery: plate heat exchanger (ECOPLAT) . . . . . . . . . . . . . . . 49


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GEA ATpicco Contents


6.11.1 Commissioning the plate heat exchanger . . . . . . . . . . . . . . . . 49

6.11.2 Maintenance of the plate-type heat exchanger . . . . . . . . . . . . 50

6.11.3 Air flow through plate heat exchanger. . . . . . . . . . . . . . . . . . . 50

6.12 Damper louvres and sealing damper . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.12.1 Commissioning the damper louvres and sealing dampers . . . 51

6.12.2 Maintenance of the damper louvres and sealing dampers . . . 51

6.13 Sound attenuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.13.1 Maintenance of sound attenuator . . . . . . . . . . . . . . . . . . . . . . 51

7 Disassembly and Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

8 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55


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Safety and User Instructions GEA ATpicco


1 Safety and User InstructionsThis is an original operation manual verified by the manufacturer.

ATpicco Low-Profile Air Handling Units are developed and manufactured accord-

ing to the state-of-the-art technological standards, established technical safety

codes and EC Directive on Machinery.

ATpicco low-profile air-handling units ensure maximum operational safety and

meet the highest quality standards.

The technological standard meets the high expectations of users concerning easy

maintenance.

However, every low-profile air-handling unit can pose an unavoidable residual

risk of injury or risk of equipment or other property. Therefore your personal safety

and the proper operation of the unit depend on the strict observance of the safety

instructions. Failure to follow the safety precautions could result to risk of death,

injury, environmental damage and/or other property damage. The unit must be

operated and serviced according to regulations and the user instructions.Observing the safety instructions in this operation manual will help avoid injuries,

damages to the unit, and other damages and promote the safe and reliable oper-

ation of the unit and to ensure the economical operation and enjoyment of full

product utility of the ATpicco unit.

The safety aspects treated in this chapter are valid for the entire operation man-

ual.

1.1 Availability of this operation manualThe attached operation manual contains important notices on the designated use

and safe operation of the unit.

The operation manual is intended for workers in assembly and installation com-

panies, construction engineers, technical personnel, training personnel, as well

as for electrical installation experts and project engineers for ventilation systems.

This operation manual must always be readily available at the location where the

unit is installed. Everyone who works on the unit or in its vicinity is obligated to

become acquainted and observe the notices (information) mentioned in this op-

eration manual. Especially all the safety notices must be observed.

1.2 Scope of validity of this operation manualThis operation manual provides critical information about the following:

Shipping

Mounting

Installation Electrical connection

Medium connection

Commissioning

Operation

Maintenance, cleaning and disposal


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GEA ATpicco Safety and User Instructions


1.3 Icons used

The following icons are used to highlight specific text sections in this operation

manual:

Indicates text paragraphs Indicates process instructions

Indicates work results.

The following indicators are employed in the operation manual for safety notices:

NOTE!

You will find supplementary information on the use of the low-profile unit ATp-

icco and its economical handling here.

HAZARDOUS VOLTAGE!

This icon indicates a risk of accident due to electric shock.

PERSONAL INJURY!

This section specifies procedures and precautions for preventing personal

injury.

DANGER DUE TO OVERHEAD LOADS!

This icon warns about personal injury and damage caused by overhead loads

and suspended heavy objects.

DANGER OF HOT SURFACES!


injury resulting from contact with hot surfaces.

DANGER SHARP CUTTING EDGES!


injury resulting from cuts caused by sheet metal.

WARNING: RISK OF ROTATING COMPONENTS!

Here you can find special notices, injunctions, and prohibitions for avoiding per-

sonal injury or other damages caused by rotating unit components.

RISK OF ACCIDENT DUE TO HOT MEDIUM!Special notices, injunctions, and prohibitions for avoiding personal injury from

hot media are given here.

UNFALLGEFAHR DURCH FEUERGEFHRLICHE STOFFE!

Special notices, injunctions and prohibitions for the avoidance of personal

injury from fire hazards are found here.

ENVIRONMENTAL DAMAGE!

This icon warns about damage to the environment or refers to all existing

national environmental protection regulations.


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1.3.1 Designation of the special notices / special information

EQUIPMENT DAMAGE!

Special notices, injunctions and prohibitions for avoiding damages to the unit,

accessories, or the controls are given here.

The unit can be furnished with the following indicators:

For the assembly of the piping, it is necessary to grip the heat exchanger cou-

pling sleeve with a pipe spanner or pliers in order to avoid rotation.

Notice: Fire hazard.

Soiled filters (filters congested by dust) are combustible.

Switch OFF the main switch before opening.

Risk of accident. Only open when the blower (motor fan) is shut down.

The technical sheet and the operation manual are kept inside the section.

Be sure to remove these documents before commissioning the unit.

Do not switch the fan on when the dampers are closed.

Earthing!

Because of potential equalization, the unit must be connected to an external

protective conductor.


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1.3.2 Designation of the functional elements

Indicator for the fan section or

compressor with a descrip-

tion of the direction of airflow

Indicator for the cooler/evapora-

tor section, air/refrigerant

Indicator for the sound ab-

sorber in the unit

Indicator for the energy recovery

section with separated heat ex-

changer, air / water

ECOFLOW

Indicator for the air filter with

description of the direction of

airflow

Indicator for the energy recovery

section with heating tubes,

air / refrigerants

ECOSTAT

Indicator for the HEPA filer

section with description of the

direction of airflow

Indicator for the plate energy re-

covery section, air/air

ECOPLAT

Indicator for the damper with

counter-directional blades

Indicator for the air humidification

chamber

Indicator for the heating sec-

tion, air/water

Indicator for the designation of

the control system

Indicator for the electric

heating unit section

Indicator for the droplet

separator

Indicator for the cooler

section, air/water


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1.4 Safety-conscious working

Observe the following safety notice for your own safety:

When working with electrical voltage:

For all kinds of work:

Any kind of work on the unit can only be carried out if:

All power is removed from the low-profile unit and the unit is electrically dead

The unit is secured against unintentional subsequent switch-on (see also

"Risk of accidents by electrical current"),

All movable parts such as the fan impeller, blower, controller and damper

blades are switched off,

After the unit has been switched off, wait at least 5 min.

Allow the heat exchanger to cool down to room temperature.

After repair / maintenance work, once again assemble all previously removed

cover plates such as, for example, the fan guard plate (axle and belt shield

depending on equipment specifications)

HAZARDOUS VOLTAGE!

Disconnect all electric power of the unit and ensure that power cannot be inad-

vertently switched on, earth, short-circuit and block off all neighbouring live

parts. Non-compliance can lead to death or serious injury.

PERSONAL INJURY!

If the unit is in operation, there is a threat of personal injury!

Impact danger the door at the pressure side can tear open.

Demolition danger as a result of the negative pressure at the door on theinlet side

Risk of personal injuries by rotating unit components.

EQUIPMENT DAMAGE!

The operation against closed louvre dampers can lead to serious damage to

the plant from positive or negative pressure, especially if the louvre dampers

suddenly slam shut.

DANGER SHARP CUTTING EDGES!

For any work at the unit, there is a risk of danger of being cut by the thin metal

sheets or fins. This especially concerns the maintenance or cleaning of theheating unit or cooler fin surfaces.


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1.5 Proper use

GEA ATpicco low-profile air handling units are exclusively designed for the follow-

ing use:

Air filtration

Filtering in clean rooms,

Heating and/or cooling

Humidifying and/or dehumidifying,

Cooling down or heat recovery

Combination of the above-mentioned functions.

Proper use not only consists of observing the contents of this user information,

but also observing the inspection and maintenance intervals.

Improper use Any other (than the above-mentioned) use or use that goes beyond that

described as proper use is deemed as not proper use. In this case, the manufac-

turer / supplier is not liable for resulting damages. The user alone bears the risk.Possible resulting complaints are not taken into consideration.

1.6 Safety regulations and safety standards

For the assembly, electrical connection, commissioning, repair and maintenance

work of GEA low-profile air handling units, observe the respective safety regula-

tions, accident-prevention regulations and standards as well as generally recogni-

zed rules of technology.

EN 13501-1+A1 Fire classification of construction products and building

elements Part 1: Classification using data from

reaction to fire tests.

1.7 Modifications and changes

No changes, add-ons or modifications may be performed on the GEA ATpicco air

treatment unit or its components.

Changes or modifications on the unit or its components will invalidate the the CE

conformity and render all warranty claims as null and void.

1.8 Spare parts

Only original spare parts are exclusively allowed, since the manufacturer is not

liable for damages or injuries from the use of third-party-spare parts.

PERSONAL INJURY!

The GEA ATpicco low-profile air handling unit may not be operated:

Outdoors,

In areas subject to explosion risk,

In rooms with high dust and/or humidity,

In rooms with strong electromagnetic fields,

In rooms with an aggressive atmosphere (aggressive environment), which,

for example, can cause damage to the plastic parts (e.g. which attack plastic

parts).


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1.9 Selection and qualification of personnel

NOTE!

Every person working on the ATpicco low-profile unit must completely read andhave fully understood this operation manual.

The assembly / commissioning / maintenance and repair work may only be car-

ried out by trained and instructed specialists in "Heating and Air Technology".

Electrical installation: Only trained specialists in the "Electrotechnology".

All skilled staff must be capable of evaluating the entrusted work, and to recognize

and avoid any possible risks.


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GEA ATpicco Technical Specifications


2 Technical Specifications

2.1 Unit description

One of the primary functions of the GEA ATpicco low-profile air handling unit is

the assurance of energy-saving room air exchange. The unit's chamber structure

permits an adaptation to the individual requirements of heating ventilation and air

conditioning equipment technology. Depending on the configuration, the supply

air can be filtered, heated, cooled, humidified, or dehumidified. Thanks to heat

recovery in recuperators, energetic operation demands (energy costs) are con-

siderably lower. The offer includes the recuperators in the form of plate-type heat

exchangers, heat pipes, or liquid-coupled heat exchangers.

Our goal is to ensure that the air volume and air quality correspond precisely to

customer demands. The GEA ATpicco low-profile air-handling units are funda-

mentally used for transporting and treating "normal air" in recreational rooms or

in commercial/industrial premises.

The operation manual is an integrated (indispensable) component of the unit, and

should be read through completely and observed in practice.

The units can be delivered in various model sizes and power capacities. Depend-

ing on the operating mode (type of use), the GEA ATpicco low-profile air handling

units are delivered with vertical or horizontal air routing; the units can be arranged

next to each other or one over the other. The installation may only take place in

interior spaces.

The chamber structure of the GEA ATpicco low-profile air handling unit permits

the division of the unit into smaller components suitable for shipping, which facil-

itates the handling at the installation site. Since the units can be ordered in various

model sizes as well as split into smaller shipping packages, the GEA ATpicco low-

profile air handling unit is also suited for the modernization of existing buildings.

2.2 Unit design and working procedure

Thanks to the chamber unit design and an entire series of versions, there are dif-

ferent installation possibilities.


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Technical Specifications GEA ATpicco


Combination examples

SUPPLY AIR

Extract-air unit

Supply-air unit

SUPPLY AIR

Extract-air unit with intake and air-discharge chamber

Supply-air unit

Supply-air unit

Combined supply- and extract-air unit

Icons

ST1 - Flexible canvas connection AK K4 - Intake/discharge-air chamber

VKL - Fan chamber FI - Bag-filter chamber

J1 - Damper blades DM KK 44 - Double in-line mixed-air chamber

STW1 - Front wall with opening AK 07 - Mixed-air chamber

EFKI - Heating chamber EKFIK - Heating unit/cooler/filter/droplet separator chamber


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GEA ATpicco Technical Specifications


Type 10.05 15.05 15.06

Width x height [mm] 660 x 355 965 x 355 965 x 450

Cross-section [m2] 0.186 0.279 0.366

Volume flow[m3/h] at 1.5 m/s

1005 1507 1977

Volume flow [m3/h] at

2.5 m/s1674 2512 3294


3.0 m/s2009 3014 3953


3.5 m/s2344 3516 4612

EC Motor fan R3G280 R3G280 (Double) R3G310

Control voltage 1.5 - 10 V 1.5 - 10 V 1.5 - 10 V

Motor speed rpm 3400 3400 4100

Max. power

consumption[kW] 1.03 1.03 2.92

Noise power

level Lwa [dB]*88 91 92

Noise power

level Lwa [dB]**91 91 104

AC motor fan RG31S RG35S RG40S

Motor speed rpm 1440 1450 1310

Max. power

consumption

[kW]

1.25 1.75 3.00

Noise power

level Lwa [dB]*85 84 87

Max ptat 3.0 m/s cca 1600 Pa cca 1250 Pa cca 1200 Pa

Number of rows

Cooler1, 2, 3, 4, 6 a 8 rows 1, 2, 3, 4, 6 a 8 rows 1, 2, 3, 4, 6 a 8 rows

Number of rows

heater1, 2, 3, 4, 6 a 8 rows 1, 2, 3, 4, 6 a 8 rows 1, 2, 3, 4, 6 a 8 rows

Number of rows

Cooler standing

variant

2, 3 a 4 rows 2, 3 a 4 rows 2, 3 a 4 rows

Electric heating battery max. 18 kW max. 30 kW max. 36 kW

Sound attenuator SD 04, 06, 08, 10, 12 SD 04, 06, 08, 10, 12 SD 04, 06, 08, 10, 12

Pocket filter class G3, G4, F5, F7, F9 G3, G4, F5, F7, F9 G3, G4, F5, F7, F9

Grease filter G3 G3 G3

Activated carbon

Filter8 Cartridges 12 Cartridges 15 Cartridges

HEPA Filter H13 H13 H13

TA - Droplet separator

* noise level at 2 m/s and 750 Pa total

** motor noise in its max. operating point


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Technical Specifications GEA ATpicco


2.3 Technical Specifications

See documentation of specific ATpicco unit construction according to the order

(drawing with measurements and technical details).

2.4 Range of application

Max. permitted ambient

temperature

-20 C to +40 C

Air humidity In addition to the air temperature/air humidity of the transported medium, the tem-

perature/humidity of the ambient air is also critical. Observe condensation limits

Environmental factors such as proximity to sea or ocean must be taken into

account when selecting material quality.

Max. operating pressure and

temperature

Heat exchanger Cu/Al 1.6 MPa / 90 C

Heat exchanger Fe/Fe 0.8 MPa / 160C

Min. evaporating tempera-

ture:

Evaporator Cu/Al 6 C

Protection class including

terminal block:

IP54

Supply voltage See unit documentation

Heatrecovery

system Type ECOFLOW ECOSTAT ECOPLAT ECOFLOW ECOSTAT ECOPLAT ECOFLOW ECOSTAT ECOPLAT

Max. volume

flow without TA

[m3/h]

1200 1150 1500 2000 1750 2120 2800 2500 2900

Max. volume

flow with TA [m3/

h]

2000 2000 2000 3000 3000 3000 4000 4000 4000

Type 10.05 15.05 15.06

TA - Droplet separator

* noise level at 2 m/s and 750 Pa total

** motor noise in its max. operating point

NOTE!

You will find all remaining important information in the catalog "Data and facts

GEA ATpicco Air Treatment Unit ".


17/56

GEA ATpicco Shipping and Storage


3 Shipping and Storage

3.1 ShippingThe unit can either be delivered in its entirety (entire unit) or as individually pack-

aged sub-components on shipping pallets.

Observe the manufacturers instructions regarding shipping and storing the unit

(see labels on the packing).

3.2 Handling and shipping the unit

Only use technical aids (cables) with sufficient loading capacity. Fordimensions and weights, see enclosed documentation (data sheets).

For raising with cables, only hang in the provided eyelets of the supportbracket with spring snap hooks (Fig. 3-1)

Before shipping, always make certain that all doors and panels are closed withlocks and correctly assured.

Only use lifting gear with sufficient load-bearing capacity. Do not use any damaged hoisting gear. Do not connect cables or chains; they may not come into contact with sharp

edges (cutting edges).

Only use cables or chains of the same length.

NOTICE!

After unpacking the low-profile air-handling unit, check that the delivery is

correct according to the despatch note.

Ship and store GEA unit in original packing!

EQUIPMENT DAMAGE!

After shipment, check to make sure the unit is not damaged.

NOTICE!

Claims for quantitative errors or transport damages can only be filed with the

shipping insurance company, if the shipping damage is confirmed by an author-

ized employee of the transportation company.

NOTICE!

Only use the original packing for shipping the device. Remove the packing from

the unit only shortly before beginning the installation work.

PERSONAL INJURY!

For handling, wear safety gloves, protective shoes, and protective clothing.

DANGER DUE TO OVERHEAD LOADS!

Do not move air-handling units over people.


18/56

Shipping and Storage GEA ATpicco


Move the unit slowly, avoid sudden or abrupt movements. Do not lower the unit suddenly or allow it to slam down on the ground.

3.2.1 Transport by means of lifting trolley or fork-lift truck

When transporting by means of lifting trolley or fork-lift truck, always use thepallet as a supporting surface.

Pay attention to the center of gravity and load distribution during handling.

3.3 StorageProtect GEA ATpiccoHVAC equipment against moisture, soiling (dust and sand),

sun and radiant heat.

Store units only in weather-protected rooms without special risk of mold, fungus,

or rodents, and protect against vibrations.

Do not operate the HVAC equipment or its controls and accessories in salt-mistyareas.

Protect unit from shocks and blows which could damage the unit casing,overhanging unit components, or the interior fittings.

Rotate the motor and fan shaft at least by two turns every 3 months.

PERSONAL INJURY!

No other load can be lifted with the unit.

Fig. 3-1: Hang the unit in the support bracket

EQUIPMENT DAMAGE!Never stack units on top of one another for shipping. Always transport units

individually. Do not stack units or accessories which are not equipment compo-

nents on top of each other.

NOTICE!

Permissible storage conditions:

Air temperature: -10C to +50C

Humidity: 50 to 85% (rel. humidity, non-condensing atmosphere)


19/56

GEA ATpicco Mounting


4 Mounting

4.1 Load-bearing capacity of the installation site

4.2 Installation of the unit

The unit must be installed at a location which completely satisfies the following

requirements:

A suitable location is a frost-free and weather-protected room in the building

interior.

The unit's foundation must be level and stable. The maximum inclination can

be one mm per meter.

For units with condensate drainage, the lower side must be at least the same

height as the trap (see Trap). Make certain that a possible loss of medium cannot cause damage to the

installation site or the environment.

4.3 Sound attenuator

In order to reduce the transfer of vibrations to the load-bearing structure, anti-

vibration support plates and connecting pieces must be installed to dampen the

noise through the load-bearing structure.

Wherever there are no special requirements on the insulation of the noise transfer

by load-bearing structures, it is recommended to insulate/separate the load-bear-

ing structure from the unit by means of rubber plates (e.g. at contact points of theunit with the ground).

For ceiling mounting, we recommend using spring dampers.

For special requirements on acoustics (noise conditions), consult an acoustics

specialist for selecting the most suitable noise and vibration damping.

NOTICE!

The installation site must be suited as a durable weight bearer of the air treat-

ment unit and be checked by a structural engineer or planner (architect) if nec-

essary. The units can only be assembled on the basis of the attached

documentation in accordance with the order.

NOTICE!

Before and after connection of the piping systems, ensure that no dirt or con-

tamination gets into the unit.


20/56

Mounting GEA ATpicco


4.4 Mounting the unit

4.4.1 Ceiling mounting

The unit can be suspended by standard commercial channel rails or threadedrods. It is recommended to use standard spring elements in order to minimize the

remaining structure-borne noise.

Fig. 4-1: Suspension of the unit

Pos. 1: channel rails

Pos. 2: profilePos. 3: threaded rods

Turn operating side downwards, remove foil. Lift the pallet with unit to the ceiling with a suitable lifting machine (lifting trolley,

fork-lift truck), guide the threaded rods through all fastening brackets and tight-

en with nuts and washers (see Fig. 4-1).

Align the unit horizontally (check with a spirit level). Tighten counter nut (for threaded rods). Procedure as previously described, however before final adjustment, center

and connect the casing chamber (casing modules) with the provided hexagon

screws (see Fig. 4-2). Two M8-hexagon head for each connection.

After all casing chambers are connected with each other, oriented and se-cured, remove protective foil from the service panels.

Carefully close the sash lock of the service panel.

Fig. 4-2: Connection of the casing chamber

NOTICE!For more detailed information, see the enclosed documentation. The supplied

small parts and accessory parts can be found in the designated chamber.

EQUIPMENT DAMAGE!The instrument / joining elements etc. which are not delivered by the manufac-

turer and can cause leakage may not be mounted on the walls or frame of the

unit. The functionality of the unit must be maintained.


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Fig. 4-3: Between-floor installation

4.4.2 Floor assembly / subfloor mounting

Mount units with cooling elements so that a trap required for draining off conden-

sate can be attached with the corresponding accessory

(see Fig. 4-8and Fig. 4-9)

Set the unit on the on-site foundation with suitable lifting machines (lifting trol-ley, crane, wire hitching with spring snap hook).

Align the unit horizontally (check with a spirit level). Screw unit on tight Divided units: proceed as previously described, however before final adjust-

ment, center and connect the casing chamber (casing module) with the pro-

vided hexagon screws (2 M8 hexagon screws for each connection) - see

Fig. 4-2.

After all casing chambers are connected with each other, oriented and se-cured, remove protective foil from the service panels.

Avoid transmission of structure-borne noise with suitable insulation materials.

Fig. 4-4: Underfloor mounting

NOTICE!All provided support brackets must be used for ceiling mounting!

Ceiling

SuspendedOpenings forService panels intermediate

ceiling

NOTICE!Provide openings for maintenance and repair work for suspended ceiling instal-

lation. Observe a minimum distance of 500 to 900 mm between unit and wall, see

Fig. 4-3.

Raised floorOpenings forService panels

FloorFloor


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4.4.3 Wall mounting (vertical air routing)

Do not use spring elements for wall mounting.

Assemble the unit at the on-site wall mounting with suitable lifting machines(lifting trolley, crane, wire hitching with spring snap hook).

Align unit vertically and horizontally (check with spirit level). Screw unit on tight Divided units: proceed as previously described, however before final

adjustment, center and connect the casing chamber (casing module) with the

provided hexagon screws (2 M8 hexagon screws for each connection) - seeFig. 4-2.

After all casing chambers are connected with each other, oriented andsecured, remove protective foil from the service panels.

Avoid transmission of structure-borne noise with suitable insulation materials.

Fig. 4-5: Wall mounting

NOTICE!Provide openings for maintenance and repair work for suspended ceiling instal-

lation. Observe a minimum distance of 500 to 900 mm between unit and wall,

see Fig. 4-4.

NOTICE!Observe a minimum distance of 500 mm or 900 mm between unit and ceiling

or floor see Fig. 4-5

Ceiling

Attention! Cooling op-

eration not possible

with this air routing

Floor

NOTICE!For cooling, only an air stream from bottom-up is possible.


23/56



4.4.4 Wall mounting (horizontal air routing)

4.5 Component and accessory assembly

4.5.1 General conditions

Examine the unit for possible visible damages, correct assembly andfastenings.

Examine whether the unit has been insulated against vibrations and structure-borne noise. This means that:

- wherever the unit is installed on the floor and where there is no special

requirements on insulation against structure-borne noise, isolate the

foundation from the unit (e.g. by means of rubber plates).

- Use spring sound attenuators for ceiling mounting

- for special requirements on the acoustics, suitable noise and vibration

insulation types were selected.

Before you begin to connect the water system, check the following points:- all deepest locations of the water system must be furnished with an outlet

valve (drain valve) in order to make it possible to completely empty the water

circulation system in case of need (for maintenance or repair work).

- easily accessible air vent valves must be installed at all highest locations of

the water system.

Convince yourself that the piping is filled and that the pipes were previously

cleaned, and that there is a cleaning comment to this effect.

4.5.2 Connection of the air-treatment piping

In order to avoid transmission of structure-borne noise, an empty connection must

be made between the unit and the air-treatment piping by constructing a flexible

canvas connection or other sound attenuator (see also chapter Sound attenua-

tor on Page 19).

When connecting the air-treatment piping to the unit with the flexible canvas con-

nection, make sure the installation distance is less than the length of the flexible

canvas supports in an extended state.

NOTICE!Like vertical air routing, however:

- cooling in only one air direction (from the floor to the ceiling, see Fig. 4-5), noheat recovery possible.

- Venting and emptying the heating unit heat exchanger is not possible in this

version.

When assembling the individual components, take care that there is uniform air

flow for all modules (installations). When needed, use empty chambers for

improved air distribution!

Procedure similar to the connection of the heat exchanger, humidifier etc. the

water system may only be connected by qualified skilled workers who possesssufficient knowledge of safety regulations on accident prevention and regula-

tions for safety and health at the workplace


24/56



4.5.3 Medium connections

Recommended water quality for the heat exchangers which work with hot water

under low pressure and cooling water:

Good water quality e.g. drinking water without salts and calcium compounds

increases the service life and effectiveness of the heat exchanger.

Check the limit values annually (see the table below). This way you will avoiddamage to the medium distribution system and its components. Add a water

softener if needed.

NOTICE!

These water quality limit val-

ues only apply as standard

values (guidelines) and do

not justify a guarantee claim!

4.5.4 Heating or cooling circuit connections

Fig. 4-6: Connection of the piping to the heat exchanger connection fittings

Description Description Value Impact in the event of de-viation

Concentration of the hydrogen

ions

pH 7.5 9 < 7> 9

Corrosion

Deposit formation

Calcium and magnesium

content

Tvrdost

(Ca/Mg)

4 8.5 > 8.5 Deposit formation

Chlorine ions Cl < 50 ppm Corrosion

Iron ions Fe+ < 0.5 ppm Corrosion

Magnesium ions Mg+ < 0.05 ppm Corrosion

Carbon dioxide CO2 < 10 ppm Corrosion

Hydrogen sulphide H2S < 50 ppb Corrosion

Oxygen O2 < 0.1 ppm Corrosion

Chlorine Cl2 < 0.5 ppm Corrosion

Ammonia NH3 < 0.5 ppm Corrosion

Carbonate/sulphate share HCO3-/SO4

- > 1 < 1 Corrosion

1/1.78 D = 1 Fr with 1 Fr = 10 g CaCO3/m

ppm = parts per million (mg/l)

ppb = parts per billion (g/l)

EQUIPMENT DAMAGE!

When connecting the on-site piping to the heat exchanger, counter the connec-

tion fittings with a pipe wrench so that they do not turn (see Fig. 4-6).

Make sure that all connections to heat exchangers made by others on-site are

done under zero-voltage conditions. Do not apply mechanical and static loads

to the connection fittings.


25/56



The heat exchanger must always be connected in the counterflow arrangement

(air and water currents flow in opposite directions).

Protect the fin surface of the heat exchanger from damage!

Connect the piping system (pipes) to the water inlet / water outlet. The mediumconnections at the heat exchanger are marked with adhesive labels (seeFig. 4-7).

The pipes must be insulated

Fig. 4-7: Connection in the counterflow arrangement

Additionally for air engineering components with cooler function:

Insulate connections and pipes immediately (without delay) after completingthe installation work against the formation of condensed water.

The condensate collects in a stainless steel pan and is drained off (through the

condensate drain outlet).

In order to ensure safe condensate drainage, the unit must be mountedhorizontally (condensate drain outlet flat or at lowest point).

Connect trap (see "Connection of the trap and the drain pipe" on the Page 26).

In addition for units in which only mixed air or in part also recirculating air flows:

4.5.5 Installation of the direct evaporator/condenser components

Direct

ionof

thea

ircurr

ent

EQUIPMENT DAMAGE!

The heat exchanger built into the unit must be protected from frost and icing

when outside temperatures are below freezing.

In case of need, add an anti-freeze mixture into the medium circuit.

NOTICE!One can use glycol as anti-freeze, however only if the quantity does not exceed

50% of the total volume.

A higher concentration can lead to functional damage.


Dispose any shaken out cooling fluid (refrigerant) in an environmentally friendly

way and according to local regulations.


26/56



Assembly, connection and repair work must be exclusively carried out byspecialized personnel for refrigeration technology.

For opening the connections/handling connections, exclusively use specialtools/special apparatus.

Units are filled with inert gas, which audibly escapes after removing the

coverings.

4.5.6 Installation of the humidification plant

Information about the assembly and installation see enclosed documents. Also

take the drinking water hardness into consideration.

4.5.7 Connection of the trap and the drain pipe

Normal climaterequirements

Conditions for theelectronics

Sterile and cleansurroundings

pH value 7 ... 8.5

Total salt content g/m < 800 < 250 < 100Electrical conductivity (at 20C air tem-

perature)

mS/m

S/cm

< 100

< 1000

< 30

< 300

< 12

< 120

Calcium (Ca2+) mol/m3

g/m3> 0.5

> 20

Carbonate hardness dH < 4

Carbonate hardness with hardness

stabilization

dH< 20

Chloride (Cl-) mol/m3

g/m3< 5

< 180

Sulfate (SO42-) mol/m3

g/m3< 3

< 290

Consumption of KMnO4 g/m3 < 50 < 20 < 10

Bacterial content Organisms/ml < 1000 < 100 < 10

Legionella bacteria Organisms/ml < 1

NOTICE!

We recommend to carry out another water analysis after installation of the

water softening system. The total salt content may not exceed 250g/m3. The

electrical conductivity may not exceed 300 S.

NOTICE!

Connection of the trap and the drain pipeFill the trap(s) with water before commissioning or after extended standstill of

the unit.


27/56



The height of the water column "H" must be greater

than maximum unit positive pressure or negative pres-

sure (mm WS; 1mm WS = 10 Pa).

Determination by the equation:

The difference in height between the condensate drain-

age and trap must also match the height H (mm water

column).

Connect the trap to the drain on the basis of Fig. 4-8and Fig. 4-9.

4.6 Electric heater bank

The electric heater bank is equipped with a connection box.

Before connection, examine whether the operating voltage specified on theunit identification plate corresponds to the existing supply voltage.

Make the connection exactly according to the connection diagram. The connection may only be carried out by licensed skilled workers.

4.7 Accessory assembly

Instructions for the accessory assembly and installation are provided in the

respective accompanying documentation.

Fig. 4-8: Trap: Unit overview

H mmVS( )Unit positive or negative pressure Pa( )

10------------------------------------------------------------------------------------------------------=

Fig. 4-9: Trap: unit negative pressure

H

1,5

H2,5

H

NOTICE!

If there is the risk of icing, isolate the drain

pipe and keep the temperature above freez-

ing; e.g. by means of a radiator

NOTICE!A trap must be connected to every condensate drain outlet. Negative and pos-

itive pressure traps must be connected to an individual collecting pipe.

Several drain pipes may not flow into a common trap.

RISK OF ACCIDENT DUE TO ELECTRICAL CURRENT!

When working on the electrical plant, make sure that the unit is switched off and

no wires are live.

The connection diagrams do not specify any protective measures. These must

be provided by others on-site.


28/56

Electrical connection GEA ATpicco


5 Electrical connection

5.1 General conditions

Visual inspection of all me-

chanical parts

Conduct a visual inspection of the entire unit and all installed components The following points must be examined before connecting the electrical instal-

lation:

The characteristics of the main power supply (main current supply) must con-

form to the requirements stipulated in the EN 60204-1 ed.2 standards and the

unit's requirements for power feed.

Select the correct protection class based on the evaluation of the unit's power

characteristics.

Ensure that the main voltage supply is between 95 105% of the electric mo-

tor nominal voltage.

NOTICE!

Electrical installations of the GEA ATpicco HVAC equipment may only be car-ried out by qualified specialists.

In performing the electrical connection of the units, make sure to observe all the

valid safety instructions and generally approved technical practice.

Earthing!Make certain that the grounding and protective circuits of low-profile units and

their components were carried out. The protective earth cross-section must

conform to EN 61800-5-1 standards.

Passive switch contacts must be exclusively used for safe electrical electric cir-

cuits.

NOTICE!If the unit is not furnished with a service switch (repair switch), an all-pole dis-connecting switch must be installed on-site in accordance with the relevant

standards! If the installation requires the use of an earth leakage circuit breaker

for EC motors, it is necessary to use types sensitive to universal current (type

B or B+, current 300 mA, with delay).


Disconnect all electric power to the unit and ensure the power cannot be inad-

vertently switched on. Examine the unit for zero-voltage, then earth and short-

circuit all live parts. Non-compliance can lead to death or serious injury. An

electrical load can occur in the parallel circuit between the network and circuit

breaker.

NOTICE!

An asymmetrical supply or phase failure may cause an increase of the leakage

currents above the nominal values specified by the motor manufacturer. Also

during motor fan standstill, idle current is measurable at the unit (


29/56

GEA ATpicco Electrical connection


5.1.1 Installation of the cable (clamp terminal)

The cable connections must be performed in compliance with the local regula-

tions and code of practice.

An authorized electrician determines the type of cable and wire cross-section.

The connections carried out on-site and the terminal distribution must be suited

for high temperatures.

For the connection of the thermal motor protection as well as for the control of the

EC motor, shielded terminals are recommended, whereby the shielding is con-

nected on one side of the switch box with the protective conductor terminal (PE).

The decision to apply electrical shielding at both ends can only be made on site

(e.g. in case of severe interference) in observance with the relevant applicable

local regulations and codes of practice.

After successful cable installation all cable entry points must be sealed in a

splash-proof (protection against splash water).

Avoid installing the cable glands or laying cable in the vicinity of service pan-els, entry panels, panel connections, and cover strips.

The cable glands are not allowed to be the cause of any leaks.

The control and feed line should be laid separately on-site; a distance of 10 cm is

recommended.

5.2 Connecting the unit

Separate grounding of every chamber with an electrical connection is required.

5.2.1 Motor protectionAC motor protection with thermal contact

Thermal contacts are temperature-dependent operating elements for automatic

monitoring of the motor winding temperature. Thermal contacts are integrated in

motor windings and enable additional protection compared to motor protection or

thermal cut-outs:

insufficient cooling

high ambient temperature

extreme speed reduction in the course of control and regulation operations

motor disconnection in case of control-voltage line failure

faulty contacts and cable breakage in the control circuit.

The thermal contact opens if the allowed winding temperature is exceeded. As a

result, the mains circuit of the control unit is interrupted. The fan protection takes

hold (the fan relay opens) and separates the motor from the mains.

The motor protection is intrinsically safe.

EC motor protection with collective error message

The electronic motor full protection function is based on the principle of a closed

circuit. An error message is produced using relay contacts (NC, COM). In the

event of a motor fault, the relay is activated and the motor is separated. It is nec-

essary to remove the malfunction to continue operation.


30/56



5.2.2 Connecting the electric motors

In order to guarantee the correct function of the unit, you must connect the motors

so that they turn in the correct direction.

The terminals of a three-phase motor are labeled in such a way that the alphabet-

ical sequence of the terminal designation U1, V1, W2 corresponds to the temporal

sequence of the phases L1, L2, L3.

The electric motor rotation direction can be reversed by exchanging two connect-

ing wires:

One-speed single-phase AC

motors:

Exchange the connecting cables, e.g. U1 with V1

One-speed three-phase AC

motor with Y/D start-up:

Y-circuitry: exchange the connecting wires, e.g. U1 with V1

-circuitry: exchange the connecting wires, e.g. U2 with V2

Three-phase EC motors with

continuous speed control:

The phase sequence is unimportant.

Voltage fluctuations Make certain that motors at rated frequency are supplied with a voltage be-tween 95% and 105% of the nominal voltage. Only under these conditions can

motors deliver their nominal power, otherwise there is a risk of damage.

When connecting the unit, proceed as follows:

Connect the unit according to the wiring diagram.

One-stage AC motor: voltage 1 x 230 V~, 50 Hz

1-speed: 1450 U/min

max. output: 1.25 kW for type 10.05

1.75 kW for type 15.05

Motor connection: with operating capacitor

Motor protection: thermal contact

EQUIPMENT DAMAGE!

Before connecting the electric motor, check for the correct assignment of the

phase sequence for the prescribed rotation direction. The electric motor can be

damaged if incorrectly connected.

Switch box cabinet connection


31/56



One-stage AC motor, voltage 3 x 400 V~ or 3 x 230 V~, 50 Hz

1-speed: 1310 rpm

max. power: 3 kW

Motor switching: 3 x 230 V in switch3 x 400 V in Y switch

Motor protection: thermal contact

The wiring on the electrical control box terminal strip is

carried out on-site depending on the voltage type.

EC motor with continuously variable control, voltage 3 x 400 V~, 50 Hz

max. speed: type 10.05 - 3400 rpm

type 15.06 - 4100 rpm

max. power: type 10.05 - 1.03 kW

type 15.06 - 2.92 kW

Motor protection: collective error message

Control voltage: 1,5 - 10V DC

Possible speed control

- with 10V DC voltage supply (the min. control circuit

voltage of 1.5V is necessary for stable motor opera-

tion. Do not operate the motor at an input voltage low-

er than 1.5V. Set the control voltage to 0V after motor

switch-off.)

- with the potentiometer

- with the GEA MATRIX control system

Fig. 5-1:Possible speed control of an EC motor

Check the current consumption at all speeds and compare these with thespecification on the motor nameplate or with the specifications in the enclosed

documentation.

Check the symmetric load of the electric motor, and measure all terminal blocsat all speeds. If the setpoint values are exceeded or the current consumption

different in individual phases, it is necessary to determine the cause.

3 x 230V, switch 3 x 400V, Y switch

Switch box connection Switch box connection

R3G280 R3G310(Types 10.05 and 15.05) (Type 15.06)

Switch box connection Switch box connection

with the power supply10V DC

with the potentiometer


32/56



5.2.3 Service switch

Install a lockable repair switch in the vicinity of the inspection door of the fan

chamber.

The wires for the service switch are installed at the factory and lead to the motor.

Connection service switch, voltage 1x230V

Type 982745

4-pole repair switch

Switch rating 3 kW

Plastic casing with lockable rotary switch

Dimensions: 82 x 82 x 172 mm

Protection class IP65

Connections repair switch, voltage 3x400V

Type 982746

6-pole repair switchSwitch rating 5.5 kW

Plastic casing with lockable rotary switch

Dimensions: 82 x 82 x 93 mm

Protection class IP65

The wiring on the electrical control box terminal strip is

carried out on-site depending on the voltage type.

AHUContacts

AHUContacts

Connections AC motor

AHUContacts


33/56



5.2.4 Installation and connection of the actuators (e.g. for damper blades)

If the GEA actuator was delivered factory mounted, connect it in according tothe actuator rating plate.

If another actuator was installed on-site, comply with the attached documen-tation.

5.2.5 Electrical heater Connect the electrical heating unit according to the instructions contained in

the wiring diagram in the enclosed documentation.

Connect the thermostat Check the thermostat for correct function (functional readiness). The heating unit can only be switched on if at least the minimal air volume nec-

essary for the correct function of the heating unit flows through the heating

chamber.

Take care that the control system activates the fan to run for at least 3 minutesafter switching off the heating unit.

5.2.6 Additional electrical equipment Connect additional electrical equipment according to the respective documen-

tation or wiring diagram.

Connections EC motor (only 3 x 400V)


34/56

Commissioning and Maintenance GEA ATpicco


6 Commissioning and Maintenance

A few partial systems and components should be taken into operation separately.

Appropriate steps are described in the following chapter.

Maintenance intervals The prescribed maintenance intervals apply to air with a normal degree of soiling.

Shorten the maintenance intervals if necessary, especially in an environment with

a high degree of soiling.

NOTICE!

Inside the chamber, where this label sticker is attached, there is a TechnicalSheet and an Operation Manual. Remove these documents from the unit before

commissioning.


The following applies for all maintenance and cleaning jobs: only open the unit's

door after switching off the unit and tagging out the system to prevent inadvert-

ent re-activation.

WARNING: RISK OF ROTATING COMPONENTS!

The fan does not stop immediately after the unit is switched off. Wait at least 5

min for maintenance / repair work until the fan stops completely.

PERSONAL INJURY!

After concluding the work on the unit, before sealing all the unit's doors be sure

to hang the doors on the safety spring snap hooks.

NOTICE!

If the air contains fat vapors, the unit must be cleaned more often because the

materials employed for the seal are only resistant against fat for a limited time.

Only use alcohol-based disinfectants.

PERSONAL INJURY!

Wear a mask and protective gloves during cleaning or maintenance work.


35/56

GEA ATpicco Commissioning and Maintenance


6.1 Basic obligations for cleaning and maintenance

Dirt deposits should be removed with a dry cloth or, if necessary, with an industrial

vacuum cleaner.

Remove the contaminants accumulated during assembly or additional

installation.

Miscellaneous contaminants and dirt: wipe off with a dry cloth or, if necessary,

clean with a little water and cleaning agent.

Do not use fabrics or materials for cleaning which damage the user interface

protective coating and could thus cause irremediable damage.

Care for metallized parts with a protective agent.

Use a lubricating oil for all movable parts such as the service panel sash lock, with

the exception of the damper blades.

Clean the service panels and examine them for leak tightness.

It is recommended that you protectively treat the seal with a moisture-repelling

substance.

Check the electrical connection.

Check the earthing!

6.1.1 Basic information on cleaning the heat exchanger fins

Regularly clean the heat exchanger fins in order to achieve the specified effi-

ciency of the heat exchanger. The fins should be cleaned with a brush (not a

scrub brush) or with a suction unit. Do not use any hard or sharp tools for clean-

ing!

Copper or aluminum fins can be cleaned against the direction of airflow with com-

pressed air or low-pressure water.

Metallized steel heat exchangers or heat exchangers with reinforced fins can also

be cleaned with pressurized water (pressurized steam).

RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLI-ANCE PARTS AND PERSONAL INJURY!

Take into account the safety notice on Page 34.



DANGER FROM SHARP EDGES

There is a danger of cuts when cleaning heat exchanger fins.


36/56



6.2 Overview of the maintenance intervals

It is necessary to observe the prescribed maintenance intervals .

RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLI-ANCE PARTS, CUTTING EDGE AND PERSONAL INJURY!

For the maintenance work cited below, take into account the safety notice on

the Page 34and Page 35.

Mainte-nance in-terval

ComponentTask

Cont inu-

ous ly

Bag filter - filter

chamber

Replace bag filter element as soon as the pressure drop has reached the

prescribed maximum.

Other filter types Observe recommendations of the filter manufacturer.

Humidifer Observe the recommendations of the humidifier manufacturer.

1 Month Cooler, humidifier,

energy recovery

unit

Clean traps and replenish with liquid.

3 months Entire unit Check casing for damages, check unit for hardness of the bedding.

Check/repair seals on all inspection doors.

Check panel surfaces for damage and corrosion. Renew the anticorrosion

layer if necessary.

Check functional readiness of the service panel latch.

Hygienic inspection: check for contamination of the interior equipment,clean if necessary. Wash and clean the disinfection surfaces affected by

mold or microorganisms.

EC motor fan Check fixation of the motor fan. Remove contaminants and corrosion.

AC motor fan Check fixation of the motor fan. Remove contaminants and corrosion.

Check fan rotor.

Filter chamber Replace filter insert as soon as the pressure drop reaches the prescribed

maximum.

Clean filter chamber

Grease filter Wash filter in a cleaning bath.


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6 months Filter chamber Hygienic inspection: the replacement of the filter is recommended even ifthere are no visible indicators of soiling. The filter can be contaminated by

mold or microorganisms after a longer useful life.

Activated-carbon

filter

Check whether the cartridge is firmly embedded in the frame.

Replace filling or cartridge with active carbon when its capacity is

exhausted (determined according to the weight of the filling).

Dampers and

louvres

Open dampers and carefully vacuum: clean but never lubricate them.

Switch off actuator of the dampers and check manually for smooth

movement.

Check whether the actuator correctly reaches the limit values.

Sound attenuator Check chamber and damping inserts for soiling. If required, clean or

replace.

12 mon ths Water and steam

heater

Check seal of the heat exchanger and medium connection.

Check heat exchanger fins and clean with compressed air or low-pressure

water.

If there is a risk of icing, check safety precautions and the concentration of

the anti-freeze.

Completely vent medium cycle.

Electric heater Clean heater bank no wet cleaning!

Water cooler Check seal of the heat exchanger and medium connection.


water.

If there is a risk of icing, check safety precautions and the concentration of

the anti-freeze.

Completely vent medium cycle.

Clean condensate tray and condensate drainage.

Check traps and replenish with water.

Clean droplet separator with calcium removal materials.

If there is no anti-freeze in the cooling system, then the cooling system

must always be emptied before the winter season.


ComponentTask


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6.3 Units in general

6.3.1 Commissioning the units

Carefully check the complete casing and components, such as:

- service panels, panels- seals

- sash lock of the service panels

for damages and correct installation (correct assembly).

Remove protective foil Make sure there are no foreign objects in the interior space. Test unit for tightness Clean unit observing the notices in Chapter Basic obligations for cleaning and

maintenanceon Page 35.

12 mon ths Cooler evaporator Check seal of the heat exchanger and medium connection.


water.




Check all parts of the cooler circuit.

Energy recovery:

heat pipe

ECOSTAT


water.




If a bypass at the heat recovery system is installed, observe the

instructions in the paragraph "Dampers and louvres".

Energy recovery:

ECOFLOW liquid-

coupled energy

recovery system

Observe the instructions in the paragraph "Water cooler".

Energy recovery:

plate-type heatexchanger

ECOPLAT

Ensure cleaning of the heat exchanger depending on the type of soiling.

Remove fat deposits

Only use wet cleaning if condensate drainage is installed.

Check bypass damper according to the instructions in the paragraph

"Dampers and louvres".


ComponentTask


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6.3.2 Maintenance of the units

Observe the following steps for maintenance work:

Carefully check the complete casing and components, such as:

- service panels, panels

- seals

- sash lock of the service panels

for damages and correct installation.

Inspection doors

Check the seal, replace if required. Check the latches of the service panels (locks) for correct function.

Panels

Check for damages and corrosion.

If required, replace (exchange) or apply a protective agent against corrosion(paint), impregnation.

Trap

Clean the trap and replenish with water.

Hygienic inspection

Observe the relevant valid

regulations!

Check all installed parts for soiling, clean if necessary. Spray with a disinfectant (the disinfectant may not have any aggressive effects

on the materials employed, only alcohol-based disinfectants are permissible).

Check the seals for contamination (whether microorganisms or fungi arepresent). Clean or replace seals if required.

6.4 Fan section

6.4.1 Commissioning of the EC motor fans



NOTICE!

If the air contains grease vapors, then the unit must be cleaned more often,

because the materials employed for the seal are only resistant against grease

for a limited time.




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Observe the following steps (points) when commissioning:

Check casing and all parts of the unit for damages and correct installation. Measure motor power consumption. Under no operating conditions may the

nominal values specified on the unit identification plate be exceeded.

Check correct working of the motor thermo-protection (see wiring diagramand/or Chapter Motor protectionon Page 29).

Check correct installation and functional readiness of all unit components(control and closing of the damper blades, fire protection louvres, mixing-air

section).

6.4.2 Commissioning of the AC motor fans

After assembly, remove all remaining contaminants and foreign bodies in thefan section.

Check the motor protection for correct switching (see wiring diagram and/orChapter "Motor protection" on Page 29).

6.4.3 Maintenance of the AC and EC motor fans

For maintenance work, carry out the following points:

Check the electric motors for soiling, damages, and corrosion as well as cor-rect fixation.

Check fan rotor for damages (especially welds, and whether there are anycracks); replace the fan assembly if necessary.

6.5 Filter chamber

6.5.1 Commissioning the filter chamber

Before commissioning. the following points must be carry out:

Check filter chamber and filter insert for damages. Examine whether the filter insert is correctly seated in the tensioning frame

(embedded).

Clean filter chamber and all unit components located before the filter chamber(against direction of airflow).

EQUIPMENT DAMAGE!

Do not let a fan start up against closed damper blades.








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Before installation of the filter inserts class F9 and higher, once again cleanthe complete unit and the air routings.

Switch fan on and determine initial pressure drop (register).

6.5.2 Basic maintenance work on all filter assemblies

Fundamentally, all filters must be checked at regular intervals with regard to the

given operating conditions, and replaced if necessary. It is necessary to carry out

the following maintenance work:

Check that the filter insert is not soiled or damaged, and it does not stink. Clean filter chamber Check that the max. permissible pressure loss was not exceeded. If yes, then

exchange the filter.

Hygienic inspection

Observe prevailing regula-

tions!

Even if the filter shows no indication of soiling, after long-term use the filter can

accrue molds and microorganisms.

Exchange the filter regularly (at least every 6-9 months), also if soiling is hardlyvisible.

6.5.3 Maintenance of the bag filter inserts and HEPA filter

For maintenance work, carry out the following:

Check filter insert with frame for soiling, corrosion and damages, and replacethese parts if required.

The final pressure loss of the bag filter insert differs, and can be found in the

appropriate technical documentation (see "Filter unit identification plate").

Exchange the filter insert when the max. pressure loss is reached.



DANGER OF INFLAMMABLE SUBSTANCES!

Filter inserts are composed of flammable materials and are thus easily combus-

tible. Kept away filter inserts from open fire!

NOTICE!

It is not recommended to operate the unit without a filter; always keep areplacement filter kit in stock. Protect the filter insert surface from damage, oth-

erwise the filter insert will not work.


Heavily soiled filters can be detrimental to health and adversely affect the pro-

duction process. The used filters should be treated as hazardous waste.




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Exchanging the filter insert

Open service panels during unit standstill. Detach return spring in the filter frame or filter quick release clamp.

Pull out filter pockets Replace damaged/soiled filter bags. Attach filter frame. Check whether its embedding is air-tight. Clamp the return spring or filter quick release clamp in place. Install filter bags only in the upright position! Close inspection doors (service panels).

6.5.4 Maintenance of the activated-carbon filter

For maintenance work, carry out the following:

If the activated carbon is consumed (planned operating hours have expired),exchange the filter.

Check whether the cartridges are properly fastened on the mounting plate. Inorder to preserve the service life of the activated-carbon filter, it is necessary

to check the pre-filter for damages and soiling.

Replacement of the activated-carbon filter (cartridge)

Switch unit off

The cartridges are secured with a bayonet locking system.

Turn the filter cartridge as indicated by the rotation arrow and remove from theframe.

When replacing the activated carbon, also replace the pre-filter.

Dispose the filter properly according to valid local regulations.

6.5.5 Maintenance of the grease filter

Proceed as follows for maintenance work:

The individual filter inserts were produced from aluminum netting and every filter

insert equipped with a installed grease trap (trough).

Wash the filter insert every 3-6 months in a cleaning bath and clean the greasetrap.






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6.5.6 Maintenance of other special filters

For information about maintenance, see the special filter documentation.

6.6 Air heater

6.6.1 Commissioning the water-based air heater

Observe the following steps during commissioning:

Necessary prerequisites: Check whether the arrangement of medium connections is correctly connect-ed. Observe the principle of water and air counterflow (especially for multi-bank

heat exchangers)

Check whether the control valve and pipes were correctly assembled.

Commissioning: The heat exchanger has no air vent valves. Adjust the heat exchanger togeth-er with the ventilation of the entire medium circulation.

Let the medium circulation in at the lowest location. After the letting in the medium, close the air vent valves. Check the system for tightness Set frost protection

6.6.2 Maintenance of the water-air heater

The following points must be carried out for maintenance:

Check leak effectiveness and eliminate possible air-side soiling.

If there is a risk of icing, also check the safety device regularly. Take safetyprecautions against icing, such as emptying the plant or adding anti-freeze.

Check the pipe connections and armatures. Clean the air side if necessary (clean heating unit by means of compressed air

or low-pressure water).

Air vent.

6.6.3 Commissioning the steam-based air heater

RISK OF ACCIDENTS BY ELECTRICAL CURRENT, RISK OF ACCIDENTSBY ROTATING APPLIANCE PARTS, RISK OF ACCIDENTS BY CUTTINGEDGES AND PERSONAL INJURY!

For the maintenance work cited below, observe the safety notice on Page 34

and Page 35.



and Page 35.



and Page 35.


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Observe the following steps during commissioning:

Open the draining and air-vent valves.

Open steam valves a bit and wait until the steam begins to escape via thedraining and air-vent valves.

Close the draining and air-vent valves.

6.6.4 Maintenance of the steam-based air heater

The following points must be carried out for maintenance:

Check leak effectiveness and eliminate possible air-side soiling. If there is a risk of icing, also check the safety device regularly. Take safety

precautions against icing, such as emptying the plant or adding anti-freeze. Check the pipe connections and armatures. Clean the air side if necessary (clean heating unit by means of compressed air

or low-pressure water).

Check steam admission and condensate drainage for correct functioning. Air vent. If required, examine control loop for correct functioning.

6.6.5 Commissioning the electric air heater

The electric heater bank can only be put into operation if at least the minimalnecessary air volume for the heating unit function flows by the heating unit.

Check whether the fan still runs for least 3 min. after switching the heater off.

6.6.6 Maintenance of the electric air heater

Clean on the air side using dry methods.

RISK OF SCALDING ACCIDENTS!

Hot steam escapes when the air vent valves are opened!

There is a risk of scalding. Carefully open the air vent valves.

Before starting work, always take suitable preliminary measures.



and Page 35.

RISK OF SCALDING ACCIDENTS!

Hot steam escapes when the air vent valves are opened!

There is a risk of scalding. Carefully open the air vent valves.

Before starting work, always take suitable preliminary measures.






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6.7 Cooling

6.7.1 Commissioning the cooler with/without droplet separator

The following must be carried out for commissioning:

Clean condensate tray and condensate drainage. Fill the trap with water, see Chapter "Connection of the trap and the drain pipe"

on Page 26; the trap collecting pipe must always match the positive or nega-

tive pressure in the unit.

with droplet separator If required, flush droplet separator with water.

If required, dust with chalk.

If the design of the droplet separator is not totally effective:

Check whether the installation position of the droplet separator is correct. Check the air volume streaming by the droplet separator.Standard droplet

separator wmax= 3.8 m/s

6.7.2 Commissioning the cooler with/without droplet separator

For maintenance, carry out the following.

Check leak effectiveness and eliminate possible air-side soiling. If icing threatens, examine both the safety devices regularly. Take safety pre-

cautions against icing, such as emptying the plant or adding anti-freeze.

Check the pipe connections and armatures.

Clean the air side if necessary (clean heating unit by means of compressed airor low-pressure water).

Check steam admission and condensate drainage for correct functioning. Air vent. Clean condensate tray and condensate drainage. Check the trap and replenish with water if required. Treat droplet eliminator with a liquid spray for removing calcium.

Additional measures before the winter period

If required, empty cooler before winter period. Since the piping systems in thesystem have a fairly small cross-section, observe that residual water remains

in the unit after emptying. For safety reasons, remove the residual water from

the system with compressed air.



and Page 35.

RISK OF ACCIDENTS BY ELECTRICAL CURRENT, RISK OF ACCIDENTSBY ROTATING APPLIANCE PARTS, RISK OF ACCIDENTS BY CUTTING

EDGES AND PERSONAL INJURY!For the maintenance work cited below, observe the safety notice on Page 34

and Page 35.


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Commissioning an

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