FläktGroup CAIRplus_Multiflow Operating instructions

Brand: FläktGroup

Model: CAIRplus_Multiflow

Type: Operating instructions

Multiflow

Liquid-Coupled System

SUPPLEMENT TO OPERATION MANUAL



CAIRplus

Table of Contents Multiflow Liquid-coupled system

2FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications

1 Safety and User Instructions ........................................................... 3

1.1 Icons and safety notices used in this manual ................................................. 3

1.2 Proper use ....................................................................................................... 3

2 Technical description and data ....................................................... 4

2.1 Scope of performance of the high-performance 

liquid-coupled heat exchanger Multiflow ......................................................... 4

2.2 Additional mounting parts ................................................................................ 6

2.3 Control cabinet ................................................................................................ 8

3 Shipping and storage ....................................................................... 9

3.2 Transport ......................................................................................................... 9

4 Assembly ......................................................................................... 11

4.1 On-site performances .................................................................................... 11

4.2 Install heat exchanger pipework .................................................................... 12

5 Commissioning ............................................................................... 14

5.1 Requirements ................................................................................................ 14

5.2 Commissioning Procedure ............................................................................ 14

6 Servicing and maintenance ........................................................... 16

6.1 Servicing and cleaning .................................................................................. 16

6.2 Maintenance ................................................................................................. 16

7 Dismantling and Disposal .............................................................. 19

7.1 Dismantling ................................................................................................... 19

7.2 Disposal ........................................................................................................ 19

8 Appendix .......................................................................................... 20

NOTICE!

This supplement to operation manual is not a substitute of the operation

manual! Use the current supplement only in conjucntion with the main ope-

ration manual for the CAIRplus unit and consider all specified safety notices!

CAIRplus

Multiflow Liquid-coupled system Safety and User Instructions

FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications3

1 Safety and User Instructions

Read the Safety Notice in the Operating Manual CAIRplus and comply with it !

1.1 Icons and safety notices used in this manual

The following icons are used to highlight particular text sections in this operation ma-

nual:

– This symbol is used to indicate normal lists.

•This symbol indicates handling instructions.

This symbol indicates the result of an action.

The following names/icons are used to designate safety notices:

1.2 Proper use

The Multiflow integrated recycling systems provide the heat recovery within the

CAIRplus air handling units. It permits the heat and/or cold supply in the brine circuit.

Improper use Any use other than that described above is considered improper. If necessary, check

if your CAIR unit is suitable for your intended purpose and application. The manufactu-

rer/supplier is not liable for any damages arising from improper use. The user alone

bears the risk.

NOTICE!

This symbol denotes additional instructions on using the unit.

HAZARDOUS VOLTAGE!

This symbol indicates a risk of electric shock when working on the equipment.

PERSONAL INJURY!

This section specifies procedures and precautions for the prevention of personal

injury.

HIGH PRESSURE HAZARD!

This section specifies procedures and precautions for the prevention of personal

injury due to high pressure.

ENVIRONMENTAL DAMAGE!

This section specifies procedures and precautions for preventing environmental

damage with reference to the valid national regulations on environmental protec-

tion.

DAMAGE TO THE UNIT!

This section specifies procedures and precautions regarding the prevention of

equipment damage.

CAIRplus

Technical description and data Multiflow Liquid-coupled system

4FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications

2 Technical description and data

2.1 Scope of performance of the high-performance liquid-coupled heat exchanger

Multiflow

Fig. 2-1: CAIRplus and hydraulic assembly

High-performance liquid-coupled system for heal and cold recovery Thermodynami-

cally optimized heat exchangers with high counterflow exposure ensure a maximum

degree of transmission between media.

Exact proportion of the brine volume is regulated by the frequency-controlled circula-

ting pumps and is decisive for high efficiency levels. The highest heat recovery rates

can be achieved with the same heat flows on the air and brine side. Temperature chan-

ges in the brine flow, supply air and return air flows are then as a rule of the same pro-

portion.The control system regulates air and water-side temperatures as well as the

pump to achieve maximum energy recovery rate.

(56

(56 (56

(56

Supply air Outdoor air

Exhaust air

Extract air

Pumped warm

Chilled water pump

CAIRplus

Multiflow Liquid-coupled system Technical description and data

FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications5

Technical benefits – Transmission of germs, pollutants and offensive odors is prevented

– Separated air ducts offer significant optimization potential during the layout stage of

the air ventilation system. As a result, enhanced explosion and fire protection can

be achieved.

– Great operational reliability of the unit results in reduced maintenance costs

The finned overall depth of each heat exchanger meets the standards stipulated by

VDI 3803, VDI 6022, DIN 1946, DIN EN 13053 and enables most thorough cleanability.

2.1.1 Regulation anti-freeze Protection

Anti-icing control for maintaining the maximum possible energy recuperation. Return

air temperature and humidity make it possible to determine the dew point of the current

air condition.

If the outdoor-air temperature is within the freezing range, the 2-way valve (SV1) is

used to adjust the brine temperature to the dew point temperature of return air before

it enters the return-air heat exchanger.

Through exact measuring of the dew point, energy recovery can be even better utilized

at low brine temperatures rather than in situations where conventional medium tempe-

rature-dependent anti-icing control would be applied.

Option: – Adiabatic humidification of return air (indirect evaporative cooling) for the minimiza-

tion of mechanical cooling in summer operating mode.

– Possibility to feed both heating and cooling energy into the brine circuit of the ener-

gy-recovery system using a water/brine plate heat exchanger.

2.1.2 Hydraulic module for inside installation

– Frame construction with an integrated tray for fixation of hydraulic components. The

frame is galvanized and additionally painted in RAL 9002.

– Built-in components are properly retained by rubber clips on the frame construction.

Pipework for supply-air, return-air, as well as coil connections are located on the

upper side of the pump assembly group. Connections with threading or flange PN

16.

– Servicing and operation shall be performed on one side. All fittings are suitable for

water/glycol mixture with 25 to 30% concentration.

Option: – Installed in unit empty chamber for indoor and outdoor installation.

Pump: – Vertical, standard-suction centrifugal pump with oppositely arranged suction and

pressure nozzles of the same diameter (inline model).

– Pump hydraulic system includes a base piece, head piece with corrosion-proof cata-

phoretic dip painting and stainless-steel wheel sets with float-mounted Teflon split

rings.

– Head and base pieces are connected together through stay bolts and a stainless-

steel pump casing.

– Motor and pump shaft are connected together with a balanced sleeve coupling.

– Maintenance-friendly, highly wear-resistant mechanical cartridge seal can be re-

placed from the outside (material combination SiC/SiC).

Motor for pump CRE 5-5 and

CRE 10-3: – The pump is equipped with a 3-phase, fan-cooled permanent magnet synchronous

motor. For speed regulation, the motor has a frequency converter and PI controller

accommodated in the terminal box of the motor. The electronic speed regulation

permits a continuous adaptation of the motor speed so that the pump capacity al-

ways meets the current requirements. The motor with associated frequency conver-

ter surpasses the efficiency requirements of the highest energy efficiency class IE4

(Super Premium Efficiency), which are specified in the IEC 60034-30-1 output 1

(CD).

CAIRplus

Technical description and data Multiflow Liquid-coupled system

6FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications

Motor for pump CRE 15-2

and CRE 15-3: – Surface-cooled 3-phase electric motor of efficiency rating IE 3 with an integrated fre-

quency inverter.

– Motor and electronics are furnished with an integrated overload and temperature

protection, an external motor protection is not required.

Tab. 2-1: Pump data

Option: Two parallel-switched pumps for redundant operation including non-return valves and

shut-off device.

2.2 Additional mounting parts

Diaphragm pressure expansion vessel for closed cooling water systems (built

according to DIN 4807, approval according to EU Pressure Device Directive 97/

23/EG)

– Foot design for fixation. Pre-pressure 6 bar

– Quick coupling for diaphragm pressure expansion vessels in closed-circuit cooling

water installations. Equipped with a shut-off mechanism secured against inadvertent

closing and a draining device to comply with DIN EN 12828, certified by TÜV.

– Pressure gauge is mounted before and after pump. Spring-tube measuring system

DIN EN 837-1, steel casing, display range 0 to 6 bar, bottom connection G ¼“, medi-

um-carrying brass components

– Diaphragm safety valve, certified and type-tested, spring-loaded, for closed-circuit

hydraulic installations, actuation overpressure 6 bar

Pump: CRE 5-5 A-FGJ-A-E CRE 10-3 A-FJ-A-E CRE 15-2 A-F-A-E CRE 15-3 A-F-A-E

Shaft seals HQQE

Inspection notices on the unit identification

plate CE, TR

Characteristics tolerance ISO 9906: 1999 Annex A

Pump casing material Cast iron, EN-JL 1030, ASTM A48-30 B

Rotor material Stainless steel, DIN W.-Nr 1.4301, AISI 304

Rotor material °C 50 40

Max. Pressure at preselected temperature 25 bar at120 °C

25 bar at-20 °C 16 bar at 120 °C

16 bar at -20 °C

Connection DIN W.-No. 1.4301

Nominal diameter DN 25/DN 32 DN 40 DN 50

Rated pressure bar PN 16/PN 25 PN16

Flange size of the motor FT115 FT130

Type of the motor 90SC 90LD 100LC 112MC

Motor rated output P2 kW 1,5 2,2 3 4

Network frequency Hz

Rated voltage 3 x 380 - 500 3 x 380-480

Rated current A2.90 - 2.40 4.15 - 3.40 6.20 - 5.00 8.10 - 6.60

Performance factor Cos phi 0.92 - 0.85 0.93 - 0.87 0.94 - 0.92

Nominal speed 1/

min 360 - 4000 360 - 3490 360 - 3530

Efficiency % 88,0 89,0 87,1 88,1

Efficiency class

(IEC 60034-30-1 Edition 1 (CD))  IE4 IE3

Protection class(IEC 34-5 IP55

Insulation class (IEC 85) F

CAIRplus

Multiflow Liquid-coupled system Technical description and data

FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications7

– On-site removal or retainer device for an inadvertent possible discharge of water/

glycol mixture from the valve or into the catch basin. Version according to Water

Resources Law.

– Isolating valves attached before and after pump, with hand wheel or hand lever, with

maintenance-free spindle seal

– Emptying and filling armature, with socket wrench set and loose square wrench with

closure cap

– Shut-off ball valves/dampers attached at the supply and return line of the external

energy supply, intake and exhaust air heat exchanger, for water/glycol with hand

wheel or hand lever, with maintenance-free spindle seal.

– Dirt traps, Y-shaped, overall length DIN EN 558-1 with normal sieve, threaded hole

and closure stoppers in the cleaning closure

– Pressure sensor for monitoring the min. pressure with electrical output signal in the

switch cabinet

Fig. 2-2: Diaphragm pressure expansion vessel

Tab. 2-2

2-way valve with drive for anti-icing protection regulation (SV1)

PN 16, basic body made of cast iron and casing made of plastic, cones made of brass,

spindle made of non-rusting steel, spindle seal with double O-ring made of EPDM,

electric servo drive, actuating signal 0 (2) to 10 V, with switch for end position notifica-

tion, with mechanical manual adjustment.

– Actuator and drive are assembled, valve tightly closing in the end position, automatic

self-calibration for commissioning, signal processing with a non-wearing path-mea-

suring system by means of Hall sensor, mechanical position indication

Option: Water/glycol plate heat exchanger made of stainless steel for warming the brine

circuit in heating operation

– 2-way valve (SV3) for the regulation of the input heating output with drive, PN 16,

casing made of cast iron, with primer, cone made of brass, spindle made of non-

rusting steel, material No. 1.4305, spindle seal with double O-Ring made of EPDM,

electrical servo drive, supply voltage 24 V DC, actuating signal 0 (2) to 10 V, with

switch for end position notification, with mechanical manual adjustment, actuator

and drive are assembled, with mechanical position indication

– On the building side it must be ensured that the heating medium is available without

delay.

Vn Nominal vo-

lume/liter Weight [kg] Ø D

[mm]

6 bar/120 °C

N50 12,5 441 495 175 R¾

N80 17,0 512 570 175 R1

N100 20,5 512 680 175 R1

N 140 28,6 512 890 175 R1

N200 36,7 634 760 205 R1

CAIRplus

Technical description and data Multiflow Liquid-coupled system

8FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications

Option: Water/glycol plate heat exchanger made of stainless steel cooling the brine

water quantity in cooling operation

– 2 way-valve (SV4) for the regulation of the input cooling capacity with drive, PN 16,

casing made of cast iron, with primer, cone made of brass, spindle made of non-

rusting steel, material No. 1.4305, spindle seal with double O-Ring made of EPDM,

electrical servo drive, supply voltage 24 V DC, actuating signal 0 (2) to 10 V, with

switch for limit position message with mechanical manual adjustment, assembled

actuator and drive, with mechanical position indication.

– 3-way valve (SV2) for bypassing the exhaust air heat exchanger, PN 16, casing

made of cast iron, cone made of brass, spindle made of non-rusting steel, spindle

seal with double O-Ring made of EPDM, electrical servo drive, supply voltage 24 V

DC, actuating signal 0 (2) to 10 V, with switch for end position notification, with

mechanical manual adjustment, assembled actuator and drive, tightly closing valve

in the end position, automatic self-calibration for commissioning, signal processing

by a non-wearing path-measuring system by means of Hall sensor, mechanical

position indication.

– On the building side, it should be ensured that the cooling medium is available

without delay.

2.2.1 Dimensions of the pump module

Fig. 2-3: Pump module

2.3 Control cabinet

The switch cabinet is fitted to the hydraulics module and wired with all attached field

equipment at the pump assembly; the standard door stop is on the right.

You will find more information in the separate Operating Manual

“Control and Monitoring System Multiflow”.

Pipe

nominal size Heat supply Cold supply Length

[mm]

Width

[mm]

Height

[mm]

Water capa-

city [l]

DN32/DN40 2500 650 1370 15

DN32/DN40 X2850 650 1370 15

DN32/DN40 X 2850 650 1370 15

DN32/DN40 X X 3200 650 1370 15

DN50/DN65 2850 800 1370 35

DN50/DN65 X3200 800 1370 35

DN50/DN65 X 3200 800 1370 35

DN50/DN65 X X 3550 800 1370 35

CAIRplus

Multiflow Liquid-coupled system Shipping and storage

FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications9

3 Shipping and storage

3.1 Delivery

The unit is delivered in individual delivery units. The delivery is done on shipping pal-

lets.

•When the unit is delivered, check that the shipment is correct according to the

despatch note, and also check for completeness.

What steps should you

should take in the event of

shipping damage?

The exterior of the packaging is damaged

1 Unpack the equipment in the presence of the truck driver and have him confirm the

damage on the shipping order.

2 Inform the FläktGroup Sales Company immediately.

Exterior packaging is O.K., contents are damaged.

1 Once you have established the extent of the damage, report the damage to the

FläktGroup Sales Company in writing.

2 Take photographs of the damaged parts.

3 Possible shipping damage must be reported no later than 4 days after delivery.

It will not be possible to process claims if the above-mentioned points are not fulfilled.

In both cases, consult the FläktGroup Sales Company installing the units.

3.2 Transport

•For safety reasons, protective clothing when lifting or transporting the unit.

•Use only slips and the front flaps at the pump station to transport the unit.

NOTICE!

Consider instructions relating to the procedures in case of shipping damage pro-

vided on the unit packaging or in despatch documents!

NOTICE!

Transport the unit only in its original packing. Remove the original packaging

only just before installation.

CAIRplus

Shipping and storage Multiflow Liquid-coupled system

10 FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications

•Before lifting or shipping the unit, make sure that all doors, dampers and panels are

fixed and secured.

•Only use lifting gear with sufficient load-bearing capacity.

•Never use damaged lifting equipment.

•Ropes/chains must not be knotted and/or be exposed to sharp edges.

•Only use ropes/chains of the same length.

•Move the unit carefully without jerky movements.

•Do not set the unit down abruptly or bump it.

3.2.1 Shipping with a (folk) lift truck

•On shipping, always use the supplied pallet as a supporting surface.

•Verify proper center of gravity lift point and uniform distribution of weight.

3.3 Storage

•Always place components on a level surface for storage or interim storage!

•Protect components against bumps and knocks to avoid damages.

Allowable storage conditions / allowable air condition for non-installed units

Air temperature 0 °C to +50 °C

Air humidity Store units in a dry, non-condensing atmosphere

DANGER OF OVERHEAD LOADS!

Never stand beneath suspended loads, since there is always a risk that the lifting

gear, tackle, ropes or slings are faulty or damaged. Failure to follow safety

precautions could result in death or serious injury.

NOTICE!

If you store the components, observe the permissible storage conditions.

Remove the original packaging only just before installation.

Up to commissioning, protect the components from building dust and dirt as well

as from damages!

If components were delivered without packaging, then they must be protected

from building dust and dirt by suitable measures until commissioning. If packing

takes place on site by others, make sure that condensate cannot form below the

packaging (consider relevant clearance between the packaging and casing).

DAMAGE TO THE UNIT!

Ensure that the pump modules are stored frost-free, since residual water might

be in the pipes.

CAIRplus

Multiflow Liquid-coupled system Assembly

FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications11

4 Assembly

4.1 On-site performances

– Pipework of the air-side heat exchanger (supply air/extract air) between each other

– Pipework between hydraulic assembly and the air-side heat exchangers (supply air/

extract air)

– The nominal pipe size of the heat exchangers can deviate from the nominal width of

the pump module. For the pipework, the nominal pipe size of the pump module is

recommended.

– The pump module may not be burdened by the weight of the external pipework

– For integrated heat input, the pipework between the hydraulic assembly and the

external heat generator (network) (water inlet/return line)

– For integrated refrigeration supply, the pipework between the hydraulic assembly

and the external heat generator (network) (water inlet/return line)

– Proper leakage test, filling and venting of the system (including filling with predeter-

mined ethylene-glycol ratio (Antifrogen N))

– Sufficient venting of the heat exchanger is only possible for greater flow possibilities

– Insulation of all on-site piping systems for the HCR system

– Wiring (including attachment in the HCR switch cabinet) of all required sensors and

the supply lines at the HCR switch cabinet. Corresponding circuit diagrams are pro-

vided.

– All points according to enclosed contract-oriented HCR scheme

– Removal or retainer device for the possible outlet of water glycol in the fault case

with the drain pan and the safety valve. Version according to Water Resources Law

– Venting possibilities must be provided at the highest location of the pipework

– The connection lines between the heat exchangers must also be equipped at the

highest point with a vent

NOTE ON ASSEMBLING AND INSTALLING THE UNIT!

Here you will find information on how to assemble and install the unit.

Placement, installation and assembly must only be carried out by qualified licen-

sed staff or other individuals with proper professional training and experience in

the relevant accident prevention regulations, as well as other generally recognized

safety and occupational health codes.

NOTICE ON MOVING THE UNIT!

If the units have been moved from one plant/location to another, repeated commis-

sioning is required. Refer to the description in the chapter "Commissioning".

CAIRplus

Assembly Multiflow Liquid-coupled system

12 FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications

4.2 Install heat exchanger pipework

High transmission capacity can be achieved if the heat exchanger is connected in

cross-counterflow mode. This means:

– Air intake = brine outlet

– Air outlet = brine entry

•Venting possibilities must be provided at the highest location of the pipework.

•Carry out the pipework for heat exchangers with different heights according to the

Tichelmann principle.

Fig. 4-1: Intake air device without filter preheating

Outdoor air Supply air Outdoor airSupply air

CAIRplus

Multiflow Liquid-coupled system Assembly

FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications13

Fig. 4-2: Extract air unit with/without filter preheating

Fig. 4-3: Intake air device with filter preheating

Extract air Exhaust air Extract air Exhaust air

Outside

air Supply air Outside

air

Supply air

Outside

air

Outside

air

CAIRplus

Commissioning Multiflow Liquid-coupled system

14 FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications

5 Commissioning

5.1 Requirements

Complete the following commissioning steps:

– Use an external circulation pump for filling

– Use pre-mixed water/glycol solution

– Check dirt traps and clean if necessary

– Thoroughly vent plant

– The pump module may not be burdened with the weight of the external pipework

– Check supply and return lines for proper connection

– Cross-counterflow principle with water inlet on the air-discharge side

– Check shut-off devices and other fixtures for proper installation

– Venting possibilities should be installed on all higher-positioned pipe sections

– The connecting lines between in-series connected heat exchangers must also be

equipped at the highest point with a vent.

– Supply voltage for the switching cabinet must be available.

– If the switching cabinet is switched to an on-site regulation, these connections must

be completed before commissioning.

– For warm or chilled water supply, this media must be connected and operational for

commissioning.

– To adjust the plant, the air ventilation equipment must be operated.

5.2 Commissioning Procedure

•Clean all condensate trays and drains in the area around the HCR and after the HCR

(in the intake and extract air unit).

•Fill trap with water (see “Connect trap and water drains” in the Operating Manual);

the water receiving tank of the trap must always at least correspond to the positive

or negative pressure of the unit. Droplet separator (DS) reaches its full capacity

following a start-up phase of 4 weeks once the separating agent has volatized.

•If necessary, rinse the droplet separator with water.

•Dust with lime if necessary.

•In case of insufficient performance of the droplet separator:

•Inspect droplet separator for correct installation position.

•Check airflow velocity in droplet separator.

DS Standard wmax = 3.8 m/s

DS 100 high performance wmax =5:8m/s

•Open provided air vent if automatic air-venting is not installed.

•Rinse out the system in order to completely remove any soiling from the assembly

process.

•Clean dirt trap.

•Slowly fill the system from lowest point with pre-mixed water-glycol brine, in order to

avoid air cushions and water hammer.

This information applies to initial commissioning of the units as well as re-commis-

sioning after an extended shut-down period.

All commissioning work must be entrusted only to qualified licensed staff or other

individuals with proper professional training and experience in the relevant regula-

tions and codes of practice!

CAIRplus

Multiflow Liquid-coupled system Commissioning

FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications15

•Glycol concentration of the brine must be at least 25%.

•Open vent a bit and wait until the brine has filled the heat exchanger.

•Open air vent completely.

•Close air vent if the levels are different: close air vent gradually until the brine flows

free of air.

•Adjust system pressure to 2 - 3 bar.

•Adjust inlet pressure of the expansion tank to the system pressure according to

manufacturer's instructions.

•Check rotating field voltage supply (phase monitoring OK?).

•Switch on pump, check direction of rotation and operate the system for an ample

time period.

•Switch on pump adiabatic humidification, check direction of rotation. (if available)

•Vent pump if there is a running noise.

•Set all HCR brine control valves successively in opposite position.

•Perform a subsequent check by repeated opening of air vent.

•Check for leak-free condition.

•Check drain valve adiabatic humidification function (if available).

•Check fresh water valve adiabatic humidification function (if available).

•Check warm water supply actuation valve (SV3) (if available).

•Check chilled water supply actuation valve (SV4) (if available).

•Check anti-icing protection actuation valve (SV1).

•Check exhaust air bypassing actuation valve (SV2).

•Check outdoor-air temperature (external/active sensor) (T2).

•Check supply-air temperature (external/active sensor) (T1).

•Check outgoing air temperature (external/active sensor) (T3).

•Check icing sensor (TZ1).

•Check anti-freeze sensor (TZ2).

•Brine temperature return line - extract-air register (T5).

•Brine temperature of water inlet - supply-air equipment register (T6).

•Check extract-air temperature (T1).

•Check extract-air humidity (F1).

•Check system pressure monitoring (PZL).

•Check external release plant.

•Check external release start-up.

•Check setpoint supply-air equipment temperature (only external control).

•Check setpoint of heating-cooling (only for MATRIX).

•Check setpoint for energy recuperation system (ERS) (only for MATRIX).

•System charging pressure about 1.0 - 2 bar, without pump operation

•Adjust min. pressure switch between 0.3 - 0.6 bar!

•The maximum brine temperature may be 50 °C!

•Air vent the system after about 30 minutes of HCR operation at full pump capacity.

If there is still air left in the system, vent again, replenish and operate the pump at

full load with all possible valve positions.

•Clean dirt traps again.

•Repeat this procedure until no air escapes from the vent.

NOTICE!

You must send the commissioning report to FläktGroup! If you do not send the com-

missioning report to FläktGroup, the warranty for your unit will be rendered null

and void!

CAIRplus

Servicing and maintenance Multiflow Liquid-coupled system

16 FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications

6 Servicing and maintenance

6.1 Servicing and cleaning

For all maintenance and cleaning jobs, observe the Operating Manual CAIRplus.

6.2 Maintenance

Carry out the following maintenance work regularly:

– Examine and if necessary repair pumping station on possible leakage

– Examine unit on damage/corrosion

– Examine screw connectors and seals

– Examine instruments for ease of movement and, if necessary, service according to

manufacturer information

– Test system pressure

– Examine control drives and pumps according to manufacturer information

6.2.1 Vent unit regularly

Important reasons for

regular venting:

After filling the plant with water-glycol, many small air bubbles are often deposited on

the cladding of the pipeline network, the hydraulic components as well as in the area

of the heat exchanger. These are only slowly detached from the cladding during pump

operation and finally collect in the relatively high points. The greater the flow velocity

of the medium, the sooner it is possible that possible air bubbles are pressed to the

respectively higher points. A sufficient venting is hence only possible while the pump

is running.

Fig. 6-1: Collected air in the pipe

Fig. 6-2: Vent pot

CAIRplus

Multiflow Liquid-coupled system Servicing and maintenance

FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications17

Fig. 6-3: Vent at the highest point

6.2.2 Clean sieve of the dirt trap

The sieve of the dirt trap must be cleaned at regular intervals. (The cleaning intervals

depend on the soiling of the medium.)

•Before all maintenance and cleaning jobs, close the shut-off valves before and

behind the dirt traps.

No medium may continue to flow any longer and the dirt traps must be

unpressurized.

•Loosen the lid stopper with a suitable tool.

•Keep a suitable vessel at hand for collecting the fluid.

•Carefully screw off the lid stopper.

•Screw out the nuts of the deck flange– in crosswise sequence (!), in order to prevent

tilting the cover.

•Keep a suitable vessel at hand for collecting the fluid.

•take off the lid downwards.

•Pull out the sieve downwards from the dirt trap.

•Clean off any dirt or deposits from the sieve using special cleaning fluid or a brush,

depending on the perfusion medium water.

•Observe your operational regulations concerning Operational Safety and

Environmental Protection.

•Check the sieve after cleaning for possible damages.

•Exchange the sieve in case it shows holes or damages.

PERSONAL INJURY!

The system must be absolutely pressure-free for all servicing and cleaning work.

DAMAGE TO THE UNIT!

Only flawless and undamaged sieves can be re-used after cleaning.

CAIRplus

Servicing and maintenance Multiflow Liquid-coupled system

18 FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications

•Push the sieve carefully into the dirt trap from below.

•Remove the lid seal from the lid for visual inspection.

•If the lid seal shows any damage, definitely replace the seal! Only a flawless lid seal

ensures reliable sealing of the dirt trap!

•Set the undamaged/new seal in the appropriate slot directly on the dirt trap (not in

the lid!).

•Set the deck flange on the dirt trap.

•At first, screw the nuts in gently in crosswise sequence on the threading

•Tighten the nuts with a torque of 50 Nm.

•Re-insert the lid stopper in the lid.

•Re-start the system by first slowly opening the rear and then the front shut-off valve.

CAIRplus

Multiflow Liquid-coupled system Dismantling and Disposal

FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications19

7 Dismantling and Disposal

7.1 Dismantling

To dismantle the units proceed as follows:

•Close all hydraulic shut-off valves.

•Isolate all connections and ensure there are no leaking materials such as oil,

refrigerant or water-glycol mix.

•Release the fixing to the floor.

The unit is ready for transport.

•Consider all instructions on shipping (refer to chapter 6).

7.2 Disposal

An authorized appointed contractor specializing in waste processing must dispose

of the unit or its individual components. This appointed contractor must ensure that:

– the components are separated according to material types

– the used operating materials are sorted and separated according to their respective

properties.

– fluorinated greenhouse gases are properly recycled or disposed.

ENVIRONMENTAL DAMAGE!

Have qualified licensed staff dismantle and dispose of the unit!

DANGER OF ELECTRICAL CURRENT!

When carrying out decommissioning and dismantling work on the unit, disconnect

all power supply connections, ensure the power cannot be inadvertently energized

and verify that electric lines have been disconnected. Earth and short-circuit them,

and cover or otherwise isolate any neighboring live parts. Non-compliance can

lead to death or serious injury.

HIGH PRESSURE HAZARD!

When carrying out decommissioning and dismantling jobs on the unit, shut off and

empty all connected pipework until the system pressure has equalized with the

ambient air pressure. Failure to follow safety precautions can result in serious

injury.

PERSONAL INJURY

Secure the unit against slipping.

NOTICE!

The operator of the refrigeration unit is responsible for taking all necessary precau-

tionary measures and ensures that only certified and licensed staff properly

recovers, recycles, processes and disposes of fluorinated refrigerants containing

greenhouse gases (F-Gases).

ENVIRONMENTAL DAMAGE!

Dispose of all components and materials (such as oil, refrigerants and water-glycol

mixture) in an environmentally friendly manner in accordance with the local codes,

practices and environmental regulations.

CAIRplus

Appendix Multiflow Liquid-coupled system

20 FläktGroup DC-2014-0111-GB 2019-08/R3 • Subject to modifications

8Appendix

The following reports are on the following pages

Appendix 1: Commissioning Report

See Appendix 1 For commissioning

The checklist must be filled in and sent back to FläktGroup.

Appendix 2: Measuring Report

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FläktGroup CAIRplus_Multiflow Operating instructions

FläktGroup CAIRplus_Multiflow Operating instructions

FläktGroup CAIRplus_Multiflow Operating instructions

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