Installation and Maintenance Instructions KG / KGW Standard air-conditioning units Wolf GmbH · 84048 Mainburg · Postfach 1380 · Telefon 08751/74-0 · Telefax 08751/741600 Art.-Nr.
Contents Contents ...................................................................................... Page Warnings / Notes on safety .................................................................. 3 Standards ............................................................................................ 4 Delivery to site / Transportation ............................................................ 5 Notes on installation........................................................................
Warnings / Notes on safety General These Installation and Maintenance Instructions apply only to WOLF KG and KGW Standard air-conditioning units. The persons charged with the installation, initial operation or maintenance of the equipment must read these instructions before commencing work. Compliance with these instructions is mandatory. Non-compliance with the installation or maintenance instructions voids the WOLF guarantee.
Standards Standards The standards and regulations applicable to the KG 15-250 Standard series and the KG/KGW 630-1000 series air-conditioning units are as follows: - EC Directive 89/392/EC with Addendum 93/44/EC (9th Ordinance, Equipment Safety Law) - E Directive 89/336/EC with Addendum 92/31/EC (Law concerning Electromagnetic Compatibility of Devices) - EC Directive 73/23/EC (Low Voltage Directive) (1st Ordinance, Equipment Safety Law) - DIN 31001/1 Safety design of technical products - DIN EN 292 Safe
Delivery to site / Transportation Delivery to site Transport KG 15-250 and KG/KWG 630-1000 series air conditioners are delivered to site in transportable units. Check all incoming goods for signs of damage in transit. Make a note of all damage or suspected damage on the waybill and have this damage report countersigned by the delivering freight forwarder. Immediately report the situation to WOLF.
Notes on installation Foundation Caution KG 40-250: Install the units and components on a surface which is smooth, level and of adequate load-bearing strength. The base frames must be horizontal and the foundations must be smooth-topped and horizontal. Make sure that the bottom of the frame is in full-face contact with the supporting surface: spot support is not permissible.
Notes on installation Base frames are either secured to the unit or delivered separately (in advance). Base frames delivered in advance are in sections and must be assembled on site in accordance with the instructions enclosed with the shipment, then aligned and secured to the supporting surface. The matrix of base frames of sectional units delivered complete with their base frames matches that of the units.
Notes on installation Securing the sections Sections with angle-section frames (KG 40-250) are secured by means of M6 threaded fasteners and clip spacers. Sections with square-section tubular frames (KG/KGW 630-1000) require M12 bolts. The cubes have pre-drilled holes to accommodate the threaded fasteners. All the small items required for assembly are shipped along with the accessories packed inside a section with an inspection door (usually the fan section).
Notes on installation Configurations: stacked or side-by-side Sections for stacked configurations are delivered to site separately and must be secured together on site with the aid of the enclosed self-tapping screws (KG 40250) or enclosed accessories (KG/KGW 630-1000). The sections which make up the stacked or side-by-side configuration cannot be secured together until the various transportable units have been installed on site in their final positions.
Notes on installation KGW roof The weatherproofed KGW 630-1000 air-coinditioning units have a UV-resistant, weatherproof skinned roof. Fully assembled units are supplied complete with the roof pre-installed. Each section of a sectionalized unit has its own roof; the butt joints in the roof must be sealed on site once the sections are installed. The appropriate quantities of sealing materials (Rhepanol paste, self-adhesive strips of roofing material, bonding material) are enclosed with the sections.
Notes on installation Fan section Caution The fan shaft must always be horizontal. Remember to remove the transportation locking devices of fans mounted on vibration damper springs. Locking devices When installing, bear in mind that the maximum permissible distance between the connecting flanges is 100 mm, in order to ensure that the sailcloth adapter has full freedom of movement. Sailcloth adapters might require on-site insulation against acoustic emissions and condensation.
Notes on installation KGW 630 - 1000 weatherproof enclosure: The weatherproof enclosure is made of sandwich panels with an inspection door. The pipes have to be insulated on site. Connections inside the enclosure, either in or opposed to the direction of air flow. Installation of the pipes and fittings in an adjacent section. Connections to the side, outside the side panel. Installation of the pipes on site.
Connection to electricity supply Connection to electricity supply The air-conditioning unit must be wired by a trained, qualified electrician in accordance with the applicable regulations (VDE, local power utility, etc.). If the intake fan or discharge fan is switched off or fails, all control valves must close automatically and the hot-water/cold-water and washer pumps must shut down. Install only control valves which are closed when de-energized and a frostprotection thermostat without restart disabler.
Connecting to electricity supply Wiring for single-speed drive Wiring for three-speed drive Motors up to 2.2 kW usually have direct startup, whereas a star-delta circuit is usual as of 3 kW. (2 separate windings, 1 is a Dahlander winding) For fan drives with speeds of 500/1000/1500 rpm or 8/6/4-pole; 500/1000 rpm with Dahlander winding.
Initial operation Wait until the fan or fans run down to a complete standstill before you open the inspection door. Check that safety devices and monitoring devices are correctly installed and fully functional. Fan section Caution Securing screws for Vee-belt pulley disks Locking screw Adjustable disk KG 40-100 Vee-belt tensioning screw - Do not start the unit until all ducts have been connected and the inspection doors closed. Otherwise, there is a danger of motor overload.
Initial operation Heater (Warm water/hot water/steam) Check the entire piping system for leaks before initial startup. - Bleed the heat exchanger and the piping system. - Make sure that condensation drains correctly from the steam register, if fitted, to avoid the danger of steam shocks damaging the register. - Do not switch on the hot-water pump or open the water/steam valve unless the fan is running, to avoid overheating due to insufficient removal of heat. - Check the discharge air temperature: the max.
Initial operation Before filling the chiller system with refrigerant, adopt suitable measures to ensure that no traces of moisture are left in the piping system (e.g. by evacuation or by flushing with dry nitrogen). Chiller (direct evaporator) Check the air-discharge temperature: min. air-discharge temperature +2 °C, at airdischarge and refrigerant temperatures lower than + 2 °C there is a danger of the heat exchanger icing.
Maintenance Before starting maintenance work, always switch off the main switch and repair switch(es) and lock them in the OFF position. Wait until the fan runs down to a standstill before opening the inspection door. Lubricatable fan bearings must be lubricated with lithium-saponified grease every 2500 operating hours. Maintenance-free bearings have life-long lubrication and are labeled accordingly. Fan section Standard three-phase motors are maintenance-free.
Maintenance / Frost protection Washer The washer and drip separator must be cleaned at regular intervals. The cleaning cycle depends on the operating mode, the condition of the air and the water quality. The tray has to be drained for maintenance and rinsed with clean water or with a high-pressure cleaner. Caution Reduce the spray pressure when cleaning pipes and nozzle stem. Risk of breakage. Commercially available descaling agents can be used. Do not use cleaning agents which foam.
EC DECLARATION OF CONFORMITY WOLF GmbH Industriestraße 1 D-84048 Mainburg Germany We hereby declare that on account of their design and construction and in the versions placed in circulation by us, the machines listed below are in compliance with the applicable basic health and safety requirements of the EC Directive. Modifications to the machines undertaken without our prior consent void this Declaration of Conformity.
