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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

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

GEA ATpicco

Contents

Contents
1

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


1.1
1.2
1.3

1.4
1.5
1.6
1.7
1.8
1.9

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1
2.2
2.3
2.4

Unit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit design and working procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Range of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13
13
16
16

Shipping and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17


3.1
3.2
3.3

Availability of this operation manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 6


Scope of validity of this operation manual . . . . . . . . . . . . . . . . . . . . . . . 6
Icons used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.1 Designation of the special notices / special information . . . . . . 8
1.3.2 Designation of the functional elements . . . . . . . . . . . . . . . . . . . 9
Safety-conscious working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety regulations and safety standards. . . . . . . . . . . . . . . . . . . . . . . . 11
Modifications and changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Selection and qualification of personnel . . . . . . . . . . . . . . . . . . . . . . . . 12

Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling and shipping the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1 Transport by means of lifting trolley or fork-lift truck . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17
17
18
18

Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1
4.2
4.3
4.4

4.5

4.6
4.7

Load-bearing capacity of the installation site . . . . . . . . . . . . . . . . . . . .


Assembly of the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound attenuation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Ceiling mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2 Floor assembly / subfloor mounting. . . . . . . . . . . . . . . . . . . . .
4.4.3 Wall mounting (vertical air routing) . . . . . . . . . . . . . . . . . . . . .
4.4.4 Wall mounting (horizontal air routing) . . . . . . . . . . . . . . . . . . .
Component and accessory assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 General conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.2 Connection of the air-treatment piping . . . . . . . . . . . . . . . . . .
4.5.3 Medium connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.4 Heating or cooling circuit connections . . . . . . . . . . . . . . . . . . .
4.5.5 Installation of the direct evaporator/condenser components . .
4.5.6 Installation of the humidification plant . . . . . . . . . . . . . . . . . . .
4.5.7 Connection of the siphon and the drain pipe . . . . . . . . . . . . . .
Heater bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessory assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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19
19
19
20
20
21
22
23
23
23
23
24
24
25
26
27
28
28

Contents

GEA ATpicco

Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1
5.2

Commissioning and Maintenance . . . . . . . . . . . . . . . . . . . . . . 35


6.1
6.2
6.3

6.4

6.5

6.6

6.7

6.8

6.9

6.10

6.11

General conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1.1 Installation of the cable (clamp terminal) . . . . . . . . . . . . . . . . . 29
Connecting the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2.1 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

Basic obligations for cleaning and maintenance . . . . . . . . . . . . . . . . . . 36


6.1.1 Basic information on cleaning the heat exchanger fins . . . . . . 36
Overview of the maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . 37
Units in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.3.1 Commissioning the units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.3.2 Maintenance of the units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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
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 . . . . . . . . 43
6.5.4 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
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
Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.7.1 Commissioning the cooler with/without droplet separator . . . . 47
6.7.2 Maintenance of cooler with/without droplet separator . . . . . . . 47
Evaporator / condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.8.1 Commissioning the evaporator/condenser . . . . . . . . . . . . . . . . 48
6.8.2 Maintenance of the evaporator/condenser . . . . . . . . . . . . . . . . 48
Energy recovery: heat pipe (ECOSTAT) . . . . . . . . . . . . . . . . . . . . . . . . 48
6.9.1 Commissioning the heat pipe . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.9.2 Maintenance of the heat pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Energy recovery: heat exchanger (ECOFLOW) . . . . . . . . . . . . . . . . . . 49
6.10.1 Commissioning the heat exchanger . . . . . . . . . . . . . . . . . . . . . 49
6.10.2 Maintenance of the heat exchanger . . . . . . . . . . . . . . . . . . . . . 49
Energy recovery: plate heat exchanger (ECOPLAT) . . . . . . . . . . . . . . . 49

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

GEA ATpicco

Contents

6.12

6.13

49
50
50
51
51
51
51
51

Disassembly and Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52


7.1
7.2

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


6.11.2 Maintenance of the plate-type heat exchanger . . . . . . . . . . . .
6.11.3 Air flow through plate heat exchanger . . . . . . . . . . . . . . . . . . .
Damper louvres and sealing damper . . . . . . . . . . . . . . . . . . . . . . . . . .
6.12.1 Commissioning the damper louvres and sealing dampers . . .
6.12.2 Maintenance of the damper louvres and sealing dampers . . .
Sound attenuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.13.1 Maintenance of sound attenuator . . . . . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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

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

Safety and User Instructions

GEA ATpicco

Safety and User Instructions


This is an original operation manual verified by the manufacturer.
ATpicco Low-Profile Air Handling Units are developed and manufactured according 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 operation 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 manual.

1.1

Availability of this operation manual


The 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 companies, 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 operation manual. Especially all the safety notices must be observed.

1.2

Scope of validity of this operation manual


This operation manual provides critical information about the following:

Shipping
Mounting
Installation
Electrical connection
Medium connection
Commissioning
Operation
Maintenance, cleaning and disposal

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

GEA ATpicco

1.3

Safety and User Instructions

Icons used
The following icons are used to highlight specific text sections in this operation
manual:
Indicates text paragraphs
Indicates process instructions
9 Indicates work results
.

NOTE!
You will find supplementary information on the use of the low-profile unit ATpicco and its economical handling here.

The following indicators are employed in the operation manual for safety notices:
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!
This section specifies procedures and precautions for preventing personal
injury resulting from contact with hot surfaces.
DANGER SHARP CUTTING EDGES!
This section specifies procedures and precautions for preventing personal
injury resulting from cuts caused by sheet metal.
WARNING: RISK OF ROTATING COMPONENTS!
Here you can find special notices, injunctions, and prohibitions for avoiding personal 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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Safety and User Instructions

GEA ATpicco

EQUIPMENT DAMAGE!
Special notices, injunctions and prohibitions for avoiding damages to the unit,
accessories, or the controls are given here.

1.3.1 Designation of the special notices / special information


The unit can be furnished with the following indicators:
For the assembly of the piping, it is necessary to grip the heat exchanger coupling 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.

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

GEA ATpicco

Safety and User Instructions

1.3.2 Designation of the functional elements


Indicator for the fan section or
compressor with a description of the direction of airflow

Indicator for the cooler/evaporator section, air/refrigerant

Indicator for the sound absorber in the unit

Indicator for the energy recovery


section with separated heat exchanger, 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 recovery section, air/air

Indicator for the damper with


counter-directional blades

Indicator for the air humidification


chamber

Indicator for the heating section, air/water

Indicator for the designation of


the control system

Indicator for the electric


heating unit section

Indicator for the droplet


separator

ECOPLAT

Indicator for the cooler


section, air/water

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Safety and User Instructions

1.4

GEA ATpicco

Safety-conscious working
Observe the following safety notice for your own safety:
When working with electrical voltage:
HAZARDOUS VOLTAGE!
Disconnect all electric power of the unit and ensure that power cannot be inadvertently switched on, earth, short-circuit and block off all neighbouring live
parts. Non-compliance can lead to death or serious injury.
For all kinds of work:
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 the
inlet 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 the
heating unit or cooler fin surfaces.
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)

10

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GEA ATpicco

1.5

Safety and User Instructions

Proper use
GEA ATpicco low-profile air handling units are exclusively designed for the following 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 manufacturer / supplier is not liable for resulting damages. The user alone bears the risk.
Possible resulting complaints are not taken into consideration.
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).

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 regulations, accident-prevention regulations and standards as well as generally recognized rules of technology.

1.7

EN 13501-1+A1

Fire classification of construction products and building


elements Part 1: Classification using data from
reaction to fire tests.

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.

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11

Safety and User Instructions

1.9

GEA ATpicco

Selection and qualification of personnel


NOTE!
Every person working on the ATpicco low-profile unit must completely read and
have fully understood this operation manual.
The assembly / commissioning / maintenance and repair work may only be carried 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

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 considerably 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 fundamentally 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. Depending 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 facilitates 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 lowprofile 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 different installation possibilities.

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13

Technical Specifications

GEA ATpicco

Combination examples
Extract-air unit

SUPPLY AIR

Supply-air unit

Extract-air unit with intake and air-discharge chamber

SUPPLY AIR

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

14

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GEA ATpicco

Type
Width x height [mm]
Cross-section [m2]
Volume flow
[m3/h] at 1.5 m/s
Volume flow [m3/h] at
2.5 m/s
Volume flow [m3/h] at
3.0 m/s
Volume flow [m3/h] at
3.5 m/s
EC Motor fan
Control voltage
Motor speed rpm
Max. power
consumption
[kW]
Noise power
level Lwa [dB]*
Noise power
level Lwa [dB]**
AC motor fan
Motor speed rpm
Max. power
consumption
[kW]
Noise power
level Lwa [dB]*
Max pt at 3.0 m/s
Number of rows
Cooler
Number of rows
heater
Number of rows
Cooler standing
variant
Electric heating battery
Sound attenuator
Pocket filter class
Grease filter
Activated carbon
Filter
HEPA Filter

Technical Specifications

10.05
660 x 355
0.186

15.05
965 x 355
0.279

15.06
965 x 450
0.366

1005

1507

1977

1674

2512

3294

2009

3014

3953

2344

3516

4612

R3G280
1.5 - 10 V
3400

R3G280 (Double)
1.5 - 10 V
3400

R3G310
1.5 - 10 V
4100

1.03

1.03

2.92

88

91

92

91

91

104

RG31S
1440

RG35S
1450

RG40S
1310

1.25

1.75

3.00

85

84

87

cca 1600 Pa

cca 1250 Pa

cca 1200 Pa

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

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

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

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

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

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

2, 3 a 4 rows

2, 3 a 4 rows

2, 3 a 4 rows

max. 18 kW
SD 04, 06, 08, 10, 12
G3, G4, F5, F7, F9
G3

max. 30 kW
SD 04, 06, 08, 10, 12
G3, G4, F5, F7, F9
G3

max. 36 kW
SD 04, 06, 08, 10, 12
G3, G4, F5, F7, F9
G3

8 Cartridges

12 Cartridges

15 Cartridges

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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15

Technical Specifications

Heat recovery system

Type
Type
Max. volume
flow without TA
[m3/h]
Max. volume
flow with TA [m3/
h]

GEA ATpicco

10.05
15.05
15.06
ECOFLOW ECOSTAT ECOPLAT ECOFLOW ECOSTAT ECOPLAT ECOFLOW ECOSTAT ECOPLAT
1200

1150

1500

2000

1750

2120

2800

2500

2900

2000

2000

2000

3000

3000

3000

4000

4000

4000

TA - Droplet separator
* noise level at 2 m/s and 750 Pa total
** motor noise in its max. operating point

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
NOTE!
You will find all remaining important information in the catalog "Data and facts
GEA ATpicco Air Treatment Unit ".

Max. permitted ambient


temperature
Air humidity

-20 C to +40 C
In addition to the air temperature/air humidity of the transported medium, the temperature/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
Min. evaporating temperature:
Protection class including
terminal block:
Supply voltage

16

Heat exchanger Cu/Al 1.6 MPa / 90 C


Heat exchanger Fe/Fe 0.8 MPa / 160C
Evaporator Cu/Al 6 C
IP54
See unit documentation

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GEA ATpicco

Shipping and Storage

Shipping and Storage

3.1

Shipping
The unit can either be delivered in its entirety (entire unit) or as individually packaged sub-components on shipping pallets.
Observe the manufacturers instructions regarding shipping and storing the unit
(see labels on the packing).
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 authorized employee of the transportation company.

3.2

Handling and shipping the unit


NOTICE!
Only use the original packing for shipping the device. Remove the packing from
the unit only shortly before beginning the installation work.

Only use technical aids (cables) with sufficient loading capacity. For

dimensions and weights, see enclosed documentation (data sheets).


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

Before shipping, always make certain that all doors and panels are closed with
locks 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.

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17

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.
PERSONAL INJURY!
No other load can be lifted with the unit.

Fig. 3-1:

Hang the unit in the support bracket

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 the

pallet as a supporting surface.


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

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 components on top of each other.

3.3

Storage
Protect GEA ATpicco HVAC 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-misty
areas.
NOTICE!
Permissible storage conditions:
Air temperature: -10C to +50C
Humidity: 50 to 85% (rel. humidity, non-condensing atmosphere)

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.

18

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GEA ATpicco

Mounting

Mounting

4.1

Load-bearing capacity of the installation site


NOTICE!
The installation site must be suited as a durable weight bearer of the air treatment unit and be checked by a structural engineer or planner (architect) if necessary. The units can only be assembled on the basis of the attached
documentation in accordance with the order.

4.2

Installation of the unit


NOTICE!
Before and after connection of the piping systems, ensure that no dirt or contamination gets into 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, antivibration 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-bearing structure from the unit by means of rubber plates (e.g. at contact points of the
unit 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.

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19

Mounting

4.4

GEA ATpicco

Mounting the unit


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 manufacturer and can cause leakage may not be mounted on the walls or frame of the
unit. The functionality of the unit must be maintained.

4.4.1 Ceiling mounting


The unit can be suspended by standard commercial channel rails or threaded
rods. 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: profile
Pos. 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 tighten 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 secured, remove protective foil from the service panels.
Carefully close the sash lock of the service panel.

Fig. 4-2:

20

Connection of the casing chamber

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GEA ATpicco

Mounting

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

Ceiling

Openings for
Service panels

Fig. 4-3:

Suspended
intermediate
ceiling

Between-floor installation

NOTICE!
Provide openings for maintenance and repair work for suspended ceiling installation. Observe a minimum distance of 500 to 900 mm between unit and wall, see
Fig. 4-3.
4.4.2 Floor assembly / subfloor mounting
Mount units with cooling elements so that a trap required for draining off condensate can be attached with the corresponding accessory
(see Fig. 4-8 and 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 adjustment, center and connect the casing chamber (casing module) with the provided hexagon screws (2 M8 hexagon screws for each connection) - see
Fig. 4-2.
After all casing chambers are connected with each other, oriented and secured, remove protective foil from the service panels.
Avoid transmission of structure-borne noise with suitable insulation materials.
Openings for
Service panels

Raised floor

Floor

Fig. 4-4:

Floor

Underfloor mounting

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21

Mounting

GEA ATpicco

NOTICE!
Provide openings for maintenance and repair work for suspended ceiling installation. Observe a minimum distance of 500 to 900 mm between unit and wall,
see Fig. 4-4.

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) - see
Fig. 4-2.
After all casing chambers are connected with each other, oriented and
secured, remove protective foil from the service panels.
Avoid transmission of structure-borne noise with suitable insulation materials.
NOTICE!
Observe a minimum distance of 500 mm or 900 mm between unit and ceiling
or floor see Fig. 4-5

Ceiling

Attention! Cooling operation not possible


with this air routing

Floor

Fig. 4-5:

Wall mounting

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

22

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GEA ATpicco

Mounting

4.4.4 Wall mounting (horizontal air routing)


NOTICE!
Like vertical air routing, however:
- cooling in only one air direction (from the floor to the ceiling, see Fig. 4-5), no
heat 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!

4.5

Component and accessory assembly


Procedure similar to the connection of the heat exchanger, humidifier etc. the
water system may only be connected by qualified skilled workers who possess
sufficient knowledge of safety regulations on accident prevention and regulations for safety and health at the workplace

4.5.1 General conditions

Examine the unit for possible visible damages, correct assembly and
fastenings.

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 attenuator on Page 19).
When connecting the air-treatment piping to the unit with the flexible canvas connection, make sure the installation distance is less than the length of the flexible
canvas supports in an extended state.

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23

Mounting

GEA ATpicco

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 avoid
damage to the medium distribution system and its components. Add a water
softener if needed.
NOTICE!
These water quality limit values only apply as standard
values (guidelines) and do
not justify a guarantee claim!

Value

Impact in the event of deviation

Concentration of the hydrogen pH


ions

7.5 9

<7
>9

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

H 2S

< 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

Description

Description

<1

Corrosion
Deposit formation

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)

4.5.4 Heating or cooling circuit connections


EQUIPMENT DAMAGE!
When connecting the on-site piping to the heat exchanger, counter the connection 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.

Fig. 4-6:

24

Connection of the piping to the heat exchanger connection fittings

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GEA ATpicco

Mounting

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 medium

connections at the heat exchanger are marked with adhesive labels (see
Fig. 4-7).
The pipes must be insulated

n
ctio
Dire

Fig. 4-7:

of

a
th e

urre
ir c

nt

Connection in the counterflow arrangement

Additionally for air engineering components with cooler function:

Insulate connections and pipes immediately (without delay) after completing


the installation work against the formation of condensed water.
9 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 mounted
horizontally (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:
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.

4.5.5 Installation of the direct evaporator/condenser components


ENVIRONMENTAL DAMAGE!
Dispose any shaken out cooling fluid (refrigerant) in an environmentally friendly
way and according to local regulations.

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25

Mounting

GEA ATpicco

Assembly, connection and repair work must be exclusively carried out by


specialized personnel for refrigeration technology.

For opening the connections/handling connections, exclusively use special


tools/special apparatus.
9 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.
Normal climate
requirements

Conditions for the


electronics

pH value
Total salt content

Sterile and clean


surroundings

7 ... 8.5
g/m

Electrical conductivity (at 20C air tem- mS/m


perature)
S/cm
Calcium (Ca2+)

mol/m3
g/m3

< 800

< 250

< 100

< 100
< 1000

< 30
< 300

< 12
< 120

> 0.5
> 20

<4

Carbonate hardness

dH

Carbonate hardness with hardness


stabilization

dH

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

< 100

< 10

Legionella bacteria

Organisms/ml

< 20

< 1000

<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.

4.5.7 Connection of the trap and the drain pipe


NOTICE!
Connection of the trap and the drain pipe
Fill the trap(s) with water before commissioning or after extended standstill of
the unit.

26

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GEA ATpicco

Mounting

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


than maximum unit positive pressure or negative pressure (mm WS; 1mm WS = 10 Pa).
Determination by the equation:

Unit positive or negative pressure ( Pa )


H ( mmVS ) = -----------------------------------------------------------------------------------------------------10
The difference in height between the condensate drainage and trap must also match the height H (mm water
column).
Fig. 4-8:

Trap: Unit overview

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

2,5 H

1,5 H H

8 and Fig. 4-9.

Fig. 4-9:

NOTICE!
If there is the risk of icing, isolate the drain
pipe and keep the temperature above freezing; e.g. by means of a radiator

Trap: unit negative pressure


NOTICE!
A trap must be connected to every condensate drain outlet. Negative and positive pressure traps must be connected to an individual collecting pipe.
Several drain pipes may not flow into a common trap.

4.6

Electric heater bank


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.
The electric heater bank is equipped with a connection box.

Before connection, examine whether the operating voltage specified on the


unit 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.

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27

Electrical connection

GEA ATpicco

Electrical connection
NOTICE!
Electrical installations of the GEA ATpicco HVAC equipment may only be carried 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 circuits.
NOTICE!
If the unit is not furnished with a service switch (repair switch), an all-pole disconnecting 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).
RISK OF ACCIDENT DUE TO ELECTRICAL CURRENT!
Disconnect all electric power to the unit and ensure the power cannot be inadvertently switched on. Examine the unit for zero-voltage, then earth and shortcircuit 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 (<250mA). The
energy consumed at standstill is <5W.
After switching the unit voltage-free, the electrical control current circuit of an
EC motor remains switched (0-10); deactivate the control voltage (0V).

5.1

General conditions

Visual inspection of all mechanical parts

Conduct a visual inspection of the entire unit and all installed components
The following points must be examined before connecting the electrical installation:
The characteristics of the main power supply (main current supply) must conform 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 motor nominal voltage.

28

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GEA ATpicco

Electrical connection

5.1.1 Installation of the cable (clamp terminal)


The cable connections must be performed in compliance with the local regulations 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 connected 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 protection


AC 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 necessary to remove the malfunction to continue operation.

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29

Electrical connection

GEA ATpicco

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.
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.
The terminals of a three-phase motor are labeled in such a way that the alphabetical sequence of the terminal designation U1, V1, W2 corresponds to the temporal
sequence of the phases L1, L2, L3.

One-speed single-phase AC
motors:
One-speed three-phase AC
motor with Y/D start-up:
Three-phase EC motors with
continuous speed control:
Voltage fluctuations

The electric motor rotation direction can be reversed by exchanging two connecting wires:
Exchange the connecting cables, e.g. U1 with V1
Y-circuitry: exchange the connecting wires, e.g. U1 with V1
-circuitry: exchange the connecting wires, e.g. U2 with V2
The phase sequence is unimportant.

Make certain that motors at rated frequency are supplied with a voltage between 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

Switch box cabinet connection

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Electrical connection

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


3 x 230V, switch

3 x 400V, Y switch

1-speed: 1310 rpm


max. power: 3 kW
Motor switching: 3 x 230 V in switch
3 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.

Switch box connection

Switch box connection

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


R3G280
(Types 10.05 and 15.05)

Switch box connection

with the power supply


10V DC

R3G310
(Type 15.06)

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

Switch box connection

with the potentiometer

Possible speed control


- with 10V DC voltage supply (the min. control circuit
voltage of 1.5V is necessary for stable motor operation. Do not operate the motor at an input voltage lower 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 the

specification on the motor nameplate or with the specifications in the enclosed


documentation.
Check the symmetric load of the electric motor, and measure all terminal blocs
at all speeds. If the setpoint values are exceeded or the current consumption
different in individual phases, it is necessary to determine the cause.

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31

Electrical connection

GEA ATpicco

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

AHU
Contacts

Connections repair switch, voltage 3x400V


Type 982746

Connections AC motor

6-pole repair switch


Switch rating 5.5 kW
Plastic casing with lockable rotary switch
Dimensions: 82 x 82 x 93 mm
Protection class IP65

AHU
Contacts

The wiring on the electrical control box terminal strip is


carried out on-site depending on the voltage type.

AHU
Contacts

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Electrical connection

Connections EC motor (only 3 x 400V)

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 to


the actuator rating plate.

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

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 necessary 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 minutes
after switching off the heating unit.

5.2.6 Additional electrical equipment

Connect additional electrical equipment according to the respective documentation or wiring diagram.

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33

Commissioning and Maintenance

GEA ATpicco

Commissioning and Maintenance


NOTICE!
Inside the chamber, where this label sticker is attached, there is a Technical
Sheet and an Operation Manual. Remove these documents from the unit before
commissioning.
A few partial systems and components should be taken into operation separately.
Appropriate steps are described in the following chapter.
RISK OF ACCIDENT DUE TO ELECTRICAL CURRENT!
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 inadvertent 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.

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!
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.

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6.1

Commissioning and Maintenance

Basic obligations for cleaning and maintenance


RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.
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


RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE 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.
Regularly clean the heat exchanger fins in order to achieve the specified efficiency 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 cleaning!
Copper or aluminum fins can be cleaned against the direction of airflow with compressed air or low-pressure water.
Metallized steel heat exchangers or heat exchangers with reinforced fins can also
be cleaned with pressurized water (pressurized steam).

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35

Commissioning and Maintenance

6.2

GEA ATpicco

Overview of the maintenance intervals


It is necessary to observe the prescribed maintenance intervals .
RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS, CUTTING EDGE AND PERSONAL INJURY!
For the maintenance work cited below, take into account the safety notice on
the Page 34 and Page 35.

Maintenance interval

Component

Continuously

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.

Task

1 Month

Cooler, humidifier, Clean traps and replenish with liquid.


energy recovery
unit

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

36

Wash filter in a cleaning bath.

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Commissioning and Maintenance

Maintenance interval

Component

6 months

Filter chamber

Hygienic inspection: the replacement of the filter is recommended even if


there 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.

Dampers and
louvres

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

Task

Replace filling or cartridge with active carbon when its capacity is


exhausted (determined according to the weight of the filling).
Switch off actuator of the dampers and check manually for smooth
movement.
Check whether the actuator correctly reaches the limit values.

Sound attenuator
12 months Water and steam
heater

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


replace.
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.


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.
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.

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37

Commissioning and Maintenance

Maintenance interval

Component

GEA ATpicco

Task

12 months Cooler evaporator Check seal of the heat exchanger and medium connection.
Check heat exchanger fins and clean with compressed air or low-pressure
water.
Clean condensate tray and condensate drainage.
Check traps and replenish with water.
Clean droplet separator with calcium removal materials.
Check all parts of the cooler circuit.
Energy recovery:
heat pipe
ECOSTAT

Check heat exchanger fins and clean with compressed air or low-pressure
water.
Clean condensate tray and condensate drainage.
Check traps and replenish with water.
Clean droplet separator with calcium removal materials.
If a bypass at the heat recovery system is installed, observe the
instructions in the paragraph "Dampers and louvres".

Energy recovery: Observe the instructions in the paragraph "Water cooler".


ECOFLOW liquidcoupled energy
recovery system
Energy recovery:
plate-type heat
exchanger
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".

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
maintenance on Page 35 .

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Commissioning and Maintenance

6.3.2 Maintenance of the units


RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.
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.
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

6.4

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


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

Fan section

6.4.1 Commissioning of the EC motor fans


RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.

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39

Commissioning and Maintenance

GEA ATpicco

EQUIPMENT DAMAGE!
Do not let a fan start up against closed damper blades.
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 diagram
and/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
RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.

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

Check the motor protection for correct switching (see wiring diagram and/or
Chapter "Motor protection" on Page 29).
6.4.3 Maintenance of the AC and EC motor fans
RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.
For maintenance work, carry out the following points:

Check the electric motors for soiling, damages, and corrosion as well as cor

6.5

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

Filter chamber

6.5.1 Commissioning the filter chamber


RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.
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

40

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

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GEA ATpicco

Commissioning and Maintenance

Before installation of the filter inserts class F9 and higher, once again clean
the 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
RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.
DANGER OF INFLAMMABLE SUBSTANCES!
Filter inserts are composed of flammable materials and are thus easily combustible. Kept away filter inserts from open fire!
NOTICE!
It is not recommended to operate the unit without a filter; always keep a
replacement filter kit in stock. Protect the filter insert surface from damage, otherwise the filter insert will not work.
ENVIRONMENTAL DAMAGE!
Heavily soiled filters can be detrimental to health and adversely affect the production process. The used filters should be treated as hazardous waste.
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 regulations!

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 hardly
visible.

6.5.3 Maintenance of the bag filter inserts and HEPA filter


RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.
For maintenance work, carry out the following:
Check filter insert with frame for soiling, corrosion and damages, and replace
these 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.

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41

Commissioning and Maintenance

GEA ATpicco

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


RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.
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. In
order 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 the
frame.
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


RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.
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 grease
trap.

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Commissioning and Maintenance

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


RISK OF ACCIDENTS BY ELECTRICAL CURRENT, RISK OF ACCIDENTS
BY 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.
Observe the following steps during commissioning:
Necessary prerequisites:

Check whether the arrangement of medium connections is correctly connect

Commissioning:

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.

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


RISK OF ACCIDENTS BY ELECTRICAL CURRENT, RISK OF ACCIDENTS
BY 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.
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).
Air vent.

6.6.3 Commissioning the steam-based air heater


RISK OF ACCIDENTS BY ELECTRICAL CURRENT, RISK OF ACCIDENTS
BY 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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43

Commissioning and Maintenance

GEA ATpicco

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.
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 the
draining and air-vent valves.
Close the draining and air-vent valves.
6.6.4 Maintenance of the steam-based air heater
RISK OF ACCIDENTS BY ELECTRICAL CURRENT, RISK OF ACCIDENTS
BY 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.
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.
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
RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.

The electric heater bank can only be put into operation if at least the minimal
necessary 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
RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.

Clean on the air side using dry methods.

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6.7

Commissioning and Maintenance

Cooling

6.7.1 Commissioning the cooler with/without droplet separator


RISK OF ACCIDENTS BY ELECTRICAL CURRENT, RISK OF ACCIDENTS
BY 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.
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 negative 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
RISK OF ACCIDENTS BY ELECTRICAL CURRENT, RISK OF ACCIDENTS
BY 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.
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 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.
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 the
system 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.

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45

Commissioning and Maintenance

6.8

GEA ATpicco

Evaporator / condenser
NOTICE!
The following tasks and repair work may only be exclusively carried out by
refrigeration engineering specialists!
Be sure to observe all provisions with respect to refrigerants!

6.8.1 Commissioning the evaporator/condenser


RISK OF ACCIDENTS BY ELECTRICAL CURRENT, RISK OF ACCIDENTS
BY 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.
EQUIPMENT DAMAGE!
Make certain that the evaporator or condenser is exposed to higher temperatures than 60C (on switch off and/or at water temperature > 60C / air heater).
The following points should be observed on commissioning:
When connecting, an inert gas filling must be available.
Check whether the cooling circuit is correctly connected (evaporator: gas at
the entry / liquid at the exit; vice-versa for the condenser).
The refrigerant in the evaporator or in the condenser changes its state.
Check whether the cut-off valve and other fixtures are correctly connected; i.e.
a counterflow arrangement of the cooling medium supply line compared to the
air flow (for multi-row heat exchangers).
Check whether pipe connections and fixtures are properly secured.
Fill cooling circuit with the refrigerant prescribed for the respective system.
Check for leak effectiveness of the system.
Check safety valves for correct functioning.
Check max. temperature and pressure when the system is in operation (especially when using the refrigerant R410A).Saturated steam temperature =
60C / limit pressure = 3.8 MPa.
6.8.2 Maintenance of the evaporator/condenser
RISK OF ACCIDENTS BY ELECTRICAL CURRENT, RISK OF ACCIDENTS
BY 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.
For servicing:
Clean and check the evaporator/condenser while observing the safety notices
in Chapter "Basic information on cleaning the heat exchanger fins" on the
Page 35.
Direct evaporator:

Check all components of the direct evaporator cooling circuit (cooling system,
direct evaporator, distributor, cooling piping, etc.) for correct functioning.

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6.9

Commissioning and Maintenance

Energy recovery: heat pipe (ECOSTAT)

6.9.1 Commissioning the heat pipe


RISK OF ACCIDENTS BY ELECTRICAL CURRENT, RISK OF ACCIDENTS
BY ROTATING APPLIANCE PARTS, RISK OF ACCIDENTS BY CUTTING
EDGES AND PERSONAL INJURY!
For the maintenance work cited below, observe the safety notice on the
Page 34 and Page 35.
For commissioning, observe:
Vertical pipes

The warm air (extract air) must be below and cold air (outside air) above.

Pipes horizontal with fixed inclination:

The warm air (extract air) must be below and cold air (outside air) above.

Vertical or horizontal pipes


with control of the bypass
damper:

For details on commissioning, see Chapter "Commissioning the damper louvres


and sealing dampers" on Page 49.

6.9.2 Maintenance of the heat pipe


RISK OF ACCIDENTS BY ELECTRICAL CURRENT, RISK OF ACCIDENTS
BY 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.
Observe during maintenance:
Regularly clean heat exchanger fins:
with compressed air against direction of airflow
or
only with low-pressure water!
Clean condensate drainage.
Check the trap. Replenish water if required.
If a heat pipe is used with bypass, the cap should be checked on the basis of
the maintenance notices (see Chapter "Maintenance of the damper louvres
and sealing dampers" on Page 49).

6.10 Energy recovery: heat exchanger (ECOFLOW)


6.10.1 Commissioning the heat exchanger
See Chapter "Commissioning the water-based air heater" on Page 43 and "Commissioning the cooler with/without droplet separator" on Page 45.
6.10.2 Maintenance of the heat exchanger
See Chapter "Maintenance of the water-air heater" on Page 43 and "Commissioning the cooler with/without droplet separator" on Page 45.

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47

Commissioning and Maintenance

GEA ATpicco

6.11 Energy recovery: plate heat exchanger (ECOPLAT)


6.11.1 Commissioning the plate heat exchanger
RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.

When using an energy recovery system with bypass, check the efficiency of

the louvre (see Chapter "Maintenance of the damper louvres and sealing
dampers" on Page 49).
If required, check the bypass function of the louvres.

6.11.2 Maintenance of the plate-type heat exchanger


RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.
The plate-type heat exchanger works independently of any external, mechanical,
or electrical control elements, contains no mechanical movable parts, and its
service life can only be impaired by corrosion.
During maintenance, observe the following:
Appropriately clean off any soiling in the plate heat exchanger. Sweep out dry
dust and fibers at the heat exchanger entry with a hairbrush (remove) and subsequently blow out. If required, check bypass damper for correct functioning.
Wet cleaning can only take place if drainage has been provided!
Oil and grease (air exhaust
from the kitchen)

Remove oil and grease with hot water and a fat-dissolving liquid.

6.11.3 Air flow through plate heat exchanger

The condensate is carried out by


gravity and current into a cooling
zone.
If there is a lot of condensate, the
danger of icing drops.
If there is little condensate, the
danger of icing is greater.

Fig. 6-1:

48

The condensate is carried out by


gravity and current into a cooling
zone.
If there is a lot of condensate, the
danger of icing drops.
If there is little condensate, the
danger of icing is greater.

cold corner

1 = The air is cooled down.

Condensate water

2 = The air is warmed up.

The condensate is carried out


by gravity and current into a
warm zone.
The danger of icing drops.

The condensate is carried out


by gravity and current into a
warm zone.
The danger of icing drops.

Air flow through plate heat exchanger

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

GEA ATpicco

Commissioning and Maintenance

6.12 Damper louvres and sealing damper


6.12.1 Commissioning the damper louvres and sealing dampers
RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.
The following points should be observed on commissioning:
If several damper louvres are connected with each other, check for the correct
use of the connections (rods) and simple movability.
Check for proper fastening of all screwed connections.
For control elements

Set the guide so that the rotation angle of 90C is ensured and that the damper

louvre achieves its limit value (end position) on closing (pay attention to the
tightening torque).
Check whether the louvre actuator reaches its limit values.

6.12.2 Maintenance of the damper louvres and sealing dampers


RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.
For maintenance carry out the following.

Clean louvre with vacuum cleaner, never grease!


Release the actuator from the louvre rods and check by hand whether the louvre moves freely.

Check whether the louvre actuator has reached its limit values.
6.13 Sound attenuator
6.13.1 Maintenance of the sound attenuator
RISK OF ACCIDENTS FROM ELECTRICAL VOLTAGE, ROTATING APPLIANCE PARTS AND PERSONAL INJURY!
Take into account the safety notice on Page 34.
For maintenance carry out the following.
Check for soiling or contaminants in the sound attenuator chamber and on the
sound absorber insets. If needed, clean with a vacuum cleaner.

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

49

Disassembly and Disposal

GEA ATpicco

Disassembly and Disposal


ENVIRONMENTAL DAMAGE!
Disassembly and waste disposal of the ATpicco air treatment units may only be
carried out by authorized specialists!

7.1

Disassembly
The disassembly of the ATpicco air handling units proceeds as follows:
RISK OF ACCIDENTS BY ELECTRICAL CURRENT!
Before beginning all work on the decommissioning and disassembly of the ATpicco
air handling units, switch off all power supply lines. This way you avoid accidents
caused by electricity. Make certain that the unit is without power and secure
against subsequent inadvertent switch-on at a suitable place (location of power
supply feed).

Make certain that the medium circulation is closed.


Close all shut-off valves.
Disconnect all terminal supply lines make sure that no operating fluid

escapes (such as refrigerant and water-glycol mixture). Since the system


piping has a relatively small cross-section, ensure that no medium remains in
the unit after draining.
Dismantle the unit from the ceiling, floor, or wall construction.
PERSONAL INJURY!
Secure the air handling unit against slippage. Observe the shipping notices.

9 The unit is now ready for transport.


Please observe all notices cited in the Chapter "Shipping" on Page 17 .

7.2

Disposal
RECYCLING!
Ensure safe and environmentally-friendly disposal of operating, auxiliary and packing materials as well as spare parts. Take into account and observe local recycling
regulations as well as options.
For disposal, the unit components must be separated in the best possible way
and sorted according to material types.
ENVIRONMENTAL DAMAGE!
Dispose of all operating materials (e.g. oil, refrigerant and water-glycol mix) and
components in an environmentally-friendly manner and in compliance with
local laws and regulations

50

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

GEA ATpicco

Troubleshooting

Troubleshooting
Faults and malfunctions may only be sought and remedied by qualified specialists with the appropriate knowledge (due to special training and experience) in
the safety regulations for accident prevention and regulations for safety and
health at the workplace.
Since the extensive offering of an entire series of installation components
includes special applications, one cannot provide a simple plan for searching and
removing all errors (faults).
For maintenance and effective troubleshooting, consult your supplier.
Fault

Possible reason

Unit cannot be switched No voltage


on
Cable incorrectly attached

Fuses trigger

Removal of the fault


Ensure voltage
Check the wiring and attach
cable correctly

Not connected

Connect interrupted cable

Fan incorrectly connected

Connect fan correctly

Actual total resistance of the air Ensure respective air


flow is less than calculated
resistance, or preferably adapt
the fan speed to the requirements
Drive motor of the fan
sets to malfunction

Motor is too warm

Check whether the ambient


temperature is not too high

Motor defective

Send motor to repair or replace


with a new motor

Wrong rotation direction


(applies to AC motor)

Reconnect motor connecting


cables

External air-side pressure too


small

Set fan speed lower

Filter soiled

Clean filter or replace with new


filter media

Actual EC fan speed too low

Correct control voltage on EC


motor

Air flow rate too high

Required EC fan speed too


high

Correct control voltage on EC


motor

Unit too loud

No sound attenuators

Install correctly dimensioned


sound attenuators

Air flow rate is too low

Incorrectly dimensioned sound Install correctly-dimensioned


attenuators are installed
sound absorbers on-site
Thermal output too low Heat exchanger dimensioned
too small

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

Replace heat exchanger by a


more effective one

Heating medium too low

Increase inlet temperature

The Cu/EA heat exchangers


are not connected in crosscounterflow

Correct connections

Unit switches off due to frost


protection thermostat

Attach heating medium,


remove infiltrated air

Air in heat exchanger

De-aerate heat exchanger

51

Troubleshooting

GEA ATpicco

Fault

Possible reason

Removal of the fault

Thermal output too high Inlet temperature of the heating Reduce inlet temperature of the
medium too high
heating medium
Heating medium is not correctly Feed temperature of the
regulated
heating medium too high
Cooling capacities too
low

Heat exchanger dimensioned


too small

Replace heat exchanger by a


more effective one

Cooling agent insufficient

Set inlet temperature lower

The Cu/EA heat exchangers


are not connected in crosscounterflow

Correct connections

For fluid temperature below


Secure with a suitable control
0C, icing can occur on the fins or increase inlet temperature
(reduced output for cooling and
air flow rate)
Cooling capacity too
high

Extraneous noise

Water penetration
through the droplet
separator

Inlet temperature of the coolant Increase inlet temperature of


too low
the coolant
Coolant is not correctly
regulated

Check and set control components of the cooling system

Unit leaks (air side)

Seal points of leakage on the


unit or duct connections

Bearing damage on turning


components

Determine defective bearings


and replace with new ones

Air velocity too high

Correct air flow rate

Turbulence due to installations Shift installation so that no


too near the droplet separator turbulence occurs
Fins of the heat exchanger are Comb the fins
damaged

Condensate does not


drain

Trap not correctly dimensioned Install trap with the required


dimensions and provide appropriate slope
Trap has no water receiver

52

Fill with water

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

GEA ATpicco

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

53

GEA ATpicco

54

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

EC Declaration of Conformity
pursuant to Directive 2006/42/EC of the European Parliament and of the Council
(original EC Declaration of Conformity)
Manufacturer:
*($+HDW([FKDQJHUVDV6ORYDQVNi/LEHUHF;;9- Vesec, Czech Republic; ID No.: 46708375
Entity authorized to compile technical documentation:
*($+HDW([FKDQJHUVDV6ORYDQVNi/LEHUHF;;9- Vesec, Czech Republic; ID No.: 46708375

Description and identification of machinery:

GEA ATpicco flat air-handling units


type designation 10.05, 15.05, 15.06
including accessories, with regulation and control
The air-conditioning units AT picco are intended for ventilation, heating, filtration, cooling, humidification and
dehumidification.
Main parts of the air-conditioning unit:
fan chamber - it comprises a directly powered radial single-sided exhaust fan or a direct driven radial fan with EC motor
heater chamber - LWFRPSULVHVDILOWHUHOHPHQWFODVV*SXUVXDQWWR61(1DQH[FKDQJHU&X$O PD[-rowed) or an
extra exchanger Cu/Al (max. 8-rowed - for cooling), a demister and a tank of stainless steel for gripping of condensate
electric heater chamber - it comprises electric heater switchable in several degrees
heater chamber - it comprises an exchanger Cu/Al (max. 8-rowed)
cooler chamber - it comprises an exchanger Cu/Al (max. 8-rowed), a tank of stainless steel for gripping of condensate, a
demister
damper chamber - it comprises wings and other parts which provide noise damping on the basis of chamber absorption
distribution chamber - it comprises a ring terminal unit for air channel feeding
pocket filter chamber - it comprises a pocket filter FODVV*WR)SXUVXDQWWR61(1
chamber with a filter for gripping of grease - it comprises filters and tanks for gripping of grease
chamber of filter with activated carbon - it comprises filter cartridge with active carbon
chamber of high-efficiency filters - it comprises pocket filters class H13 pursuant to EN 18222
empty, suction, discharge, mixer (double) chamber
chamber of humidification
modules of heat recovery - they comprise a plate exchanger or heat pipes or exchangers with their own circuit

Declaration:
The machinery complies with all relevant provisions of Directives 2006/42/EC, 2006/95/EC and 2004/108/EC.
List of harmonized standards applied in the conformity assessment:
EN ISO 12100:2010; EN 953+A1:2009; EN ISO 13857:2008; EN ISO 11202:2010; EN ISO 3746:2010;
EN 60335-1:2002; EN 60335-2-30:2009; EN 60335-2-40:2003; EN 62233:2008, EN 55014-2:1997
This declaration relates exclusively to the machinery in the state in which it was placed on the market, and excludes
components which are added and/or operations carried out subsequently by the final user.

Issued at:
Name:
Title:

Liberec
,QJ,YDQ3ROtYND
Director of joint-stock company

On:
Signed:

December 17, 2012

GEA Heat Exchangers a.s.


6ORYDQVNi/LEHUHF;;9- 9HVHFHVNiUHSXEOLND7HOwww.gea-heatexchangers.cz
5HJX25.UDMVNpKRVRXGXYVWtQ/- %,',

................................................................................................................................................................

xxxxxx

55

We live our values.


Excellence r Passion r Integrity r Responsibility r)'#XGTUKV[
GEA Group is a global engineering company with multi-billion euro sales and operations in more than
|EQWPVTKGU(QWPFGFKPVJGEQORCP[KUQPGQHVJGNCTIGUVRTQXKFGTUQHKPPQXCVKXGGSWKROGPVCPF
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