BLAUBERG KFK Duct Coolers User Manual

BLAUBERG KFK Duct Coolers

SAFETY REQUIREMENTS

• All user’s manual requirements as well as the provisions of all the applicable local and national construction, electrical, and technical norms and standards must be observed when installing and operating the unit.

• Check the unit for any visible damages of the casing before starting installation. The casing internals must be free of any foreign objects.
  While mounting the unit, avoid compression of the casing!

• Misuse of the unit and any unauthorized modifications are not allowed.

• Do not expose the unit to adverse atmospheric agents (rain, sun, etc.).

• Transported air must not contain any dust or other solid impurities, sticky substances, or fibrous materials. Do not use the unit in a hazardous or explosive environment containing spirits, gasoline, insecticides, etc.
  Do not sit on the unit and do not put objects on it.

• The information in this user’s manual was correct at the time of the document’s preparation.

• The Company reserves the right to modify the technical characteristics, design, or configuration of its products at any time in order to incorporate the latest  technological developments.

PURPOSE

The duct coolers are designed for supply air cooling in supply or air handling units integrated into rectangular ventilation systems. The cooler is a component part and is not designed for independent operation.
Transported air must not contain any flammable or explosive mixtures, evaporation of chemicals, sticky substances, fibrous materials, coarse dust, soot and oil particles or environments favourable for the formation of hazardous substances (toxic substances, dust, pathogenic germs).

DELIVERY SET

DESIGNATION KEY

TECHNICAL DATA

• Duct water cooler KWK (KWK1):
• Maximum operating pressure: 1.5 MPa (15 bar).
• Direct expansion cooler KFK (KFK1):
• Maximum  operating pressure: 2.8 MPa (28 bar).

Each cooler is subjected to a pressure and a tightness test. The cooler design is constantly being improved, so some models can slightly differ from those ones described in this manual.

Dimensions

DESIGN AND OPERATING PRINCIPLE

• The cooler casing is made of polymer-coated steel, the tube collectors are made of copper and the heat exchanger surface is made of aluminium plates. The cooler casing has a dismountable design that provides easy access to the heat exchanger and the droplet separator. The cooling coils are available in 3 rows modification.
• The internal operating medium of the KFK (KFK1) duct cooler is an evaporating refrigerant, i.e. R123, R134a, R152a, R404a, R407c, R410a, R507, R12, R22.
• The internal operating medium of the KWK (KWK1) duct cooler is water or antifreeze.
• If necessary change the service side by turning the cooling coil through 180°. The KFK1 and KWK1 do not have this option. By default the service side is on the right in the direction of the air flow.

To attain the maximum cooling capacity the cooler must be connected on counter-flow basis

MOUNTING AND SET-UP

The cooler is connected to the air duct with a flange connection

Outdoor installation of the cooler is allowed only if the refrigerant is an antifreeze (ethylene glycol solution). During mounting consider the operating characteristics of the mixing unit actuator. While mounting the cooler provide quick and easy dismantling of the heat exchanger, the drain pan and the drain pipe.

• The cooler can be installed only horizontally to enable condensate drainage.
• Mounting the cooler provides enough access for servicing and repair operations.
• The duct cooler may be installed upstream and downstream of the ventilation unit. If the cooler is installed downstream of the fan, provide at least 1-1.5 m air duct between the cooler and the fan for air flow stabilization.

Prior to starting mounting check the tube, plates and the tube collector condition. Flanges of the system components are mounted with galvanized bolts and M8 nuts. For KWK1 and KFK1 the flanges of the system components are mounted with galvanized bolts and M8 nuts, pre-installed in the cooler. Prior to mounting remove the bolts and after the mounting screw them back. Prior to starting operation and after a long downtime fill the U-trap with water. Negative pressure coolers can be equipped with a U-trap and a ball valve. Such U-trap must not be filled with water.

CONDENSATE DRAINAGE
A drain pan with a drain pipe connected to a sewage system is designed for condensate drainage. While selecting the U-trap dimension type consider the total fan pressure. The U-trap must ensure correct operation of the ventilation system.
Connect the drain pipe, the U-trap (not included in the standard delivery set) and the sewage system with metal, plastic or rubber pipes. The pipe slope downwards must be at least 3°. Before starting the cooler fill the system with water and check that the U-trap is always filled with water. Make sure that the water drainage is correct. The wrong connection to the sewage system may result in condensate accumulation inside the cooler.
The condensate drainage system is designed for operation at an ambient temperature above 0 °С!
If the ambient temperature is below 0 °C, the condensate drainage system must be heat-insulated and pre-heated.

TECHNICAL MAINTENANCE

Maintenance means regular preventive measures during operation. The aluminium ribs and the droplet separator must be cleaned at least once per year by vacuum cleaner or pressure water flushing. The cleaning periodicity depends on air pollution degree and maintenance quality of the filters and equipment. If the internal environment is clean enough, the cleaning may be performed more seldom, as required. The U-trap maintenance includes regular control of water level and sufficient U-trap and drain pipes clearance.

WARNING! WHILE CLEANING THE RIBBED BATTERY BE CAREFUL NOT TO DAMAGE THE RIBBED SURFACE.

TROUBLESHOOTING

Clean the heat exchanger and the droplet separator.

Water leakage

| ****

The drainage system is soiled, damaged or arranged not correctly.

| Clean the drain line. Check the drain line slope angle. Make sure that the U-trap is filled with water and the drain pipes are frost protected.

If troubleshooting steps have failed, contact the Seller of the product. In case of faults not described in the table, contact the Seller for further information.

STORAGE AND TRANSPORTATION REGULATIONS

• Store the unit in the manufacturer’s original packaging box in a dry closed ventilated premise with temperature range from +5 ˚С to +40 ˚С and relative humidity up to 70 %.
• Storage environment must not contain aggressive vapors and chemical mixtures provoking corrosion, insulation, and sealing deformation.
• Use suitable hoist machinery for handling and storage operations to prevent possible damage to the unit.
• Follow the handling requirements applicable for the particular type of cargo.
• The unit can be carried in the original packaging by any mode of transport provided proper protection against precipitation and mechanical damage. The unit must be transported only in the working position.
• Avoid sharp blows, scratches, or rough handling during loading and unloading.
• Prior to the initial power-up after transportation at low temperatures, allow the unit to warm up at operating temperature for at least 3- 4 hours.

WARRANTY

MANUFACTURER’S WARRANTY

The product is in compliance with EU norms and standards on low voltage guidelines and electromagnetic compatibility. We hereby declare that the product complies with the provisions of Electromagnetic Compatibility (EMC) Directive 2014/30/EU of the European Parliament and of the Council, Low Voltage Directive (LVD) 2014/35/EU of the European Parliament and of the Council and CE-marking Council Directive 93/68/EEC. This certificate is issued following test carried out on samples of the product referred to above.
The manufacturer hereby warrants normal operation of the unit for 24 months after the retail sale date provided the user’s observance of the transportation, storage, installation, and operation regulations. Should any malfunctions occur in the course of the unit operation through the Manufacturer’s fault during the guaranteed period of operation, the user is entitled to get all the faults eliminated by the manufacturer by means of warranty repair at the factory free of charge. The warranty repair includes work specific to elimination of faults in the unit operation to ensure its intended use by the user within the guaranteed period of operation. The faults are eliminated by means of replacement or repair of the unit components or a specific part of such unit component.
The warranty repair does not includ e:

• routine technical maintenance
• unit installation/dismantling
•  unit setupTo benefit from warranty repair, the user must provide the unit, the user’s manual with the purchase date stamp, and the payment paperwork certifying the purchase. The unit model must comply with the one stated in the user’s manual. Contact the Seller for warranty service.

The manufacturer’s warranty does not apply to the following cases:

• User’s failure to submit the unit with the entire delivery package as stated in the user’s manual including submission with missing component parts previously dismounted by the user.
• Mismatch of the unit model and the brand name with the information stated on the unit packaging and in the user’s manual.
• User’s failure to ensure timely technical maintenance of the unit.
• External damage to the unit casing (excluding external modifications as required for installation) and internal components caused by the user.
• Redesign or engineering changes to the unit.
• Replacement and use of any assemblies, parts and components not approved by the manufacturer.
• Unit misuse.
• Violation of the unit installation regulations by the user.
• Violation of the unit control regulations by the user.
• Unit connection to power mains with a voltage different from the one stated in the user’s manual.
• Unit breakdown due to voltage surges in power mains.
• Discretionary repair of the unit by the user.
• Unit repair by any persons without the manufacturer’s authorization.
• Expiration of the unit warranty period.
• Violation of the unit transportation regulations by the user.
• Violation of the unit storage regulations by the user.
• Wrongful actions against the unit committed by third parties.
• Unit breakdown due to circumstances of insuperable force (fire, flood, earthquake, war, hostilities of any kind, blockades).
• Missing seals if provided by the user’s manual.
• Failure to submit the user’s manual with the unit purchase date stamp.
• Missing payment paperwork certifying the unit purchase.

FOLLOWING THE REGULATIONS STIPULATED HEREIN WILL ENSURE A LONG AND TROUBLE- FREE OPERATION OF THE UNIT
USER’S WARRANTY CLAIMS SHALL BE SUBJECT TO REVIEW ONLY UPON PRESENTATION OF THE UNIT, THE PAYMENT DOCUMENT AND THE USER’S MANUAL WITH THE PURCHASE DATE STAMP

CERTIFICATE OF ACCEPTANCE

Quality Inspector’s Stamp

|

SELLER INFORMATION

Seller|
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Address|
Phone Number|
E- mail|
Purchase Date|
This is to certify acceptance of the complete unit delivery with the user’s manual. The warranty terms are acknowledged and accepted.
Customer’s Signature| V

INSTALLATION CERTIFICATE

The __  unit is installed pursuant to the requirements stated in the present user’s manual.

Company name|
Address|
Phone Number|
Installation Technician’s Full Name|
Installation Date:| Signature:
The unit has been installed in accordance with the provisions of all the applicable local and national construction, electrical and technical codes and standards. The unit operates normally as intended by the manufacturer.
Signature:|

WARRANTY CARD

THE PRODUCT MUST BE DISPOSED SEPARATELY AT THE END OF ITS SERVICE LIFE. DO NOT DISPOSE THE UNIT AS UNSORTED DOMESTIC WASTE.

www.blaubergventilatoren.de

B63EN-05

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