Remak CAKE Manuale utente

INSTALLATION AND OPERATING INSTRUCTIONS

Air-handling units

03/2017

CAKE

Table of Contents

Application, Operating Conditions and Design...............................................................................................................................................................3

Manufacturer's Notiﬁcation ......................................................................................................................................................................................................................3

Application and Operating Conditions...................................................................................................................................................................................................3

Base Frame.....................................................................................................................................................................................................................................................3

Air-Handling Unit Designation..................................................................................................................................................................................................................3

Side Variability of Unit Connections.......................................................................................................................................................................................................4

Dispatch and Packaging: ....................................................................................................................................................................................................4

Delivery Contents .........................................................................................................................................................................................................................................4

Information and Safety Labels.................................................................................................................................................................................................................4

Safety Devices...............................................................................................................................................................................................................................................5

Installation ............................................................................................................................................................................................................................5

Location...........................................................................................................................................................................................................................................................5

Service Access...............................................................................................................................................................................................................................................6

Door Closures ................................................................................................................................................................................................................................................6

Pre-Installation Inspection.........................................................................................................................................................................................................................6

Identiﬁcation of Air-handling Unit Components.................................................................................................................................................................................6

Base frame......................................................................................................................................................................................................................................................6

Assembly of Air-handling Unit Sections ................................................................................................................................................................................................6

Unit Alignment...............................................................................................................................................................................................................................................6

Connection of Individual Blocks...............................................................................................................................................................................................................7

Rotary Heat Exchanger ..............................................................................................................................................................................................................................7

Media Connection, Condensate Drainage and Air-Handling Duct Connection..........................................................................................................7

Connection of Heating and Cooling Media Feeds..............................................................................................................................................................................7

Steam Humidiﬁcation .................................................................................................................................................................................................................................8

Condensate Drainage..................................................................................................................................................................................................................................8

Air-handling Duct Connection...................................................................................................................................................................................................................9

Wiring ...................................................................................................................................................................................................................................9

Wiring Diagrams of Components ...........................................................................................................................................................................................................9

Fan EC Motors................................................................................................................................................................................................................................................9

Single-Phase EC Motors.............................................................................................................................................................................................................................9

ree-Phase EC Motors..............................................................................................................................................................................................................................9

Rotary Heat Exchangers ............................................................................................................................................................................................................................9

Electrical Equipment Wiring .....................................................................................................................................................................................................................9

Sheet Metal Box for Electrical Equipment........................................................................................................................................................................................10

Instructions for Cabling............................................................................................................................................................................................................................10

Wiring Procedure.............................................................................................................................................................................................................. 11

Control Unit and Control Unit Communication...............................................................................................................................................................................11

Electric Heater............................................................................................................................................................................................................................................11

EC motors ....................................................................................................................................................................................................................................................11

Rotary Regenerator..................................................................................................................................................................................................................................12

Master Switch.............................................................................................................................................................................................................................................12

Preparation for Commissioning ..................................................................................................................................................................................... 12

Inspection before First Start-Up...........................................................................................................................................................................................................12

Commissioning - Inspection...................................................................................................................................................................................................................13

Commissioning...........................................................................................................................................................................................................................................13

Checks during First Start-Up..................................................................................................................................................................................................................14

Operating Checks and Service Regulations................................................................................................................................................................. 13

Service Regulations..................................................................................................................................................................................................................................14

Unit Operation Screening Checks........................................................................................................................................................................................................14

Regular Inspections ..................................................................................................................................................................................................................................14

Check of Cooling and Heating Circuit Liquids..................................................................................................................................................................................15

Service and Disposal ........................................................................................................................................................................................................ 16

Spare Parts..................................................................................................................................................................................................................................................16

Service...........................................................................................................................................................................................................................................................16

Disposal and Recycling............................................................................................................................................................................................................................16

Waste Classiﬁcation.................................................................................................................................................................................................................................16

General Information

CAKE air handling units are manufactured in accordance with valid Czech and European regulations and technical standards.

CAKE air handling units must be installed and used only in accordance with this documentation.

e customer is responsible for any damages resulting from use other than intended.

e installation and operating documentation must be available for the operating and servicing staﬀ.

It is advisable to store this documentation close to the installed air handling unit.

When handling, installing, wiring, commissioning, repairing or servicing the CAKE air handling units, it is necessary to observe valid safety rules, standards

and generally recognized technical rules. In particular, it is necessary to use personal protective work aids (e.g. gloves) because of sharp edges and corners when

performing any handling, installing, dismounting, repairing or checking of CAKE air handling units. All equipment connections must comply with the respective safety

standards and regulations.

Any changes or modiﬁcations to individual components of the CAKE air handling units which could aﬀect its safety and proper functioning are forbidden.

Before installing and using the CAKE air handling units, it is necessary to familiarize yourself with and observe the directions and recommendations included in the

following chapters.

e CAKE air handling units, including their individual parts, are not intended, due to their concept, for direct sale to end customers.

Each installation must be performed in accordance with a professional project created by a qualiﬁed air-handling designer who is responsible for the proper selection and

dimensioning of components concerning their suitability for a given application.

e installation and commissioning may be performed only by an authorized company licensed in accordance with generally valid regulations.

When disposing of components and materials, it is necessary to observe the respective environmental protection and waste disposal regulations. In case of ﬁnal unit

liquidation, it is necessary to follow the policy of diﬀerential waste disposal. We recommend metal parts be scrapped and other parts be disposed of in accordance with

separated waste regulations.

Further information can be found in the CAKE Catalogue and in the AeroCAD designing soware..

Up-to-date version of this document is available at website www.remak.eu

CAKE Air-handling units

Application, Operating Conditions and Construction

Manufacturer's Notiﬁcation

CAKE compact units are manufactured in accordance with valid

Czech and European regulations and technical standards. ese

units must be installed and used only in accordance with this do-

cumentation. e installation and operating documentation must

be available to the operating and servicing staﬀ, and it is advisable

to store this documentation close to the installed air-handling unit.

Application and Operating Conditions

CAKE compact units are designed for the ventilation and air-

-conditioning of building interiors, especially commercial facilities

with low air ﬂow rates of approx. 500 to 3,000 m3/h (e.g., small

commercial premises, oﬃces, restaurants and schools). ey are

designed to transport air without solid, ﬁbrous, sticky, aggressive,

respectively explosive impurities. e inlet air must be drawn from

a hygienically wholesome environment. If not stated otherwise,

the transported air must be free of chemicals or chemicals corro-

sive to metal or aggressive zinc and aluminium.

CAKE compact air-handling units can be used in normal rooms

(IEC 60364-5-51, resp. ČSN 33 2000-5-51 ed. 3, ČSN 33 2000-

1 ed. 2) and in rooms with an extended ambient temperature

range ranging from -20 to +40°C without additional measures,

respectively -40°C to +55°C (customization). When designing the

air-handling assembly lay-out, it is necessary to take into account

the temperature and humidity of the inlet and outlet air in rela-

tion to the ambient temperature and humidity. is is especially

important for suﬃcient ventilation of the air-handling plant. For

outdoor installations where excessively humid air is exhausted

from the room (e.g., applications with a humidiﬁer or other source

of humidity), it is necessary to consult this environment with the

manufacturer (for additional installation of a condensate drainage

tray inside the device). Failure to meet these conditions will result

in excessive condensation (misting and leaking) and possible

freezing. If the device is designed for outdoor environments (out-

door version), it is advisable to protect it with a roof. Degree of

protection against foreign matters and water is IP 44. e unit's

accessories (M&C) are not included – they must be assessed

separately according to their documentation.

CAKE compact air-handling units are designed to be installed on

the ﬂoor or a supporting structure. CAKE compact air-handling

units can be connected to a 1x230V+N+PE /50Hz or 3x400V+-

N+PE/50Hz powersupply system (dependingon themotortype).

The unit's operation is possible only with a measuring and

control system, ensuring control and safety functions. e main

precondition is the installation of functional antifreeze protection

elements of heat-exchangers, plate or rotary heat exchangers,

including active protection of the unit when reaching the ﬁnal

pressure loss of ﬁlters.

is device must not be used (operated) by young (children, etc.)

or disabled persons.

Air-Handling unit Construction

is air-handling unit is designed as a panel and compact system.

All the panels are of sandwich construction with a total thickness

of 50 mm, and are made of hot–dip galvanized sheet steel in

accordance with ČSN EN 10 346 Z275 g/m2with basic corrosion

resistance for the C2 environment class in accordance with ČSN

EN ISO 14713. Alternatively, the panels can be provided with

additional surface ﬁnish:

Continuous polyester paint 25 μm, RAL 9002 ČSN

EN10169, corrosion resistance for the C3 environment class in

accordance with ČSN EN ISO 14713

Powder polyester paint 60 μm, RAL 9002 ČSN EN10169,

corrosion resistance for the C3 environment class in accordan-

ce with ČSN EN ISO 14713

Powder EP/PES paint, min. 60 μm, RAL 3020 ČSN

EN10169, corrosion resistance for environments with a higher

content of chloramine (swimming pools). Insulation of the pa-

nels is created by 50mm thick non-combustible mineral wool,

50 kg/m2.

e ﬁxed panels are attached with screw joints – the

M6x20 metric Allen screws or alternatively the 4,2x16 self-

-tapping hexagon-head screws (DIN 7504-K) and plugs. To

install and remove the panels attached with metric screws, it

is necessary to use an Allen wrench, size 5 and for the panels

attached with self-tapping screws, it is recommended to use

a magnetic screwdriver inner hexagon bit, size 7 (BN 31522,

length 75 mm).

e panels, which are supposed to be regularly used to

access the internal assemblies in order to perform checks,

periodic maintenance, service operations or unit cleaning, have

doors equipped with rotary safety closures.

e contact surfaces of the panels are ﬁtted with the 12x3

self-adhesive PE sealing, temperature resistance from -40 °C to

+80 °C and rate of volume absorption below 5%. e contact

surfaces of the doors are ﬁtted with the moisture-resisting EPDM

sealing, temperature resistance from -40 °C to +80 °C. e per-

manent joints are sealed with non-silicone sealant of temperature

resistance from -40 °C to +90 °C.

If the compact unit includes an integrated control unit, the

access to the switchboard box is ensured through the inspection

door from the service side. is door can be opened using a special

tool (Triangular 8). e box degree of protection is IP44.

e complete CAKE compact air-handling unit is manufactured as

a compact block, delivered in separate sub-blocks designed to be

assembled on the site or in special cases delivered disassembled

into separate assemblies. Basic versions according to the internal

arrangement of CAKE compact air-handling units:

VZ – a vertical unit equipped with a plate heat exchanger

(counter-ﬂow version)

VR – a vertical unit equipped with a rotary exchanger

Base Frame

e base frame is an integral part of the compact air-handling

unit. It can be equipped with ﬁxed or adjustable support legs. e

height of the base frame without legs is 85 mm and the height of

the base frame with legs is 185 mm.

Air-Handling Unit Designation

Each block of the compact air-handling unit is provided with a type

(name) plate indicating the following data (if applicable):

Manufacturer's name

Type, size and code designation

Order number

Weight

Power supply connecting data (electric distribution system)

Side Arrangement and Dispatch

Figure 1 – Side arrangement

Figure 2 – Handling using handling equipment

LEFT version displayed.

Side Arrangement of Air-handling unit

e connection side is always determined according to the inlet

air ﬂow direction.

Connecting boxes, terminals in the integrated control

unit and the main switch terminals are marked with

warning labels: “Attention! The device is under

voltage even if the main switch is switched oﬀ!“

Dispatch and Packaging

Delivery Contents

e following items are enclosed to each delivery of the compact

air-handling unit:

Accompanying technical documentation

Commercial and technical documentation, including

the compact air-handling unit assembly drawing

Connecting material kit

Installation kit

Measuring & control components, respectively accessories

in accordance with the bill of delivery

A key to access the integrated switchboard box

(if included in the delivery)

Packaging

As standard, the transport blocks of the CAKE compact air- han-

dling unit are packed in PE foil and provided with cardboard and

polystyrene protecting guards. If the compact air-handling unit is

delivered assembled, it is always equipped with the mounted base

frame. If the compact air-handling unit is delivered disassembled,

each block is dispatched separately. If the base frame includes

ﬁxed support legs, the compact air-handling unit is dispatched

without handling means (i.e., on the support legs without the

pallet) as standard.

On the pallet, it is delivered a compact air-handling unit which:

includes a base frame without support legs

is delivered disassembled and the block does not include

a base frame;

is delivered disassembled;

includes a base frame with ﬁxed support legs and delivery

on the base frame is required by the costumer's option

Information and Safety Labels

CAKE air handling units are labelled with the warning and infor-

mation stickers and manufacturer's logo on the external side of

the casing. Inside the unit, safety labels are ﬁtted, and a summary

information label, including a description of components, is

ﬁtted on the doors.

e "Other Danger" warning label situated on the face

side of the service door indicates the hazard of catching

by movable parts.

The switchboard box, block of the electric heater,

wiring boxes and service panels covering other elect-

rical equipment are labelled with the "ATTENTION!

ELECTRICAL EQUIPMENT" warning label. Spots

intended for the grounding connection are labelled

with a grounding symbol.

Transport and Handling of Components

Loading and unloading can be performed by a fork-li truck or a

crane. If a crane is used, the unit (or its parts) can be transported

on a pallet (the transported block must be securely attached to

the pallet using straps), or suitable handling devices can be used,

using the base frame openings to handle the unit.

CAKE Air-handling units

Installation

Spacer bars must be inserted between the liing wires above the

unit to protect the product from being damaged. When handling

the unit using a fork-li truck, the used liing forks of the fork-li

truck must be long enough to reach across the whole width of

the unit (or its block), i.e., they must support both side beams of

the base frame.

Storage Conditions

As standard, the air-handling units are packed in PE foil. ey must

be storedin indoorroomscomplying withthefollowing conditions:

Maximum relative air humidity must not exceed 85%.

Condensation must be eliminated and the ambient tempe-

rature must be in the range of -20°C to+40°C.

e air-handling unit must be protected against penetration

by dust and caustic vapours, or other chemical substances

which could cause corrosion of the air-handling unit’s structural

components.

e air-handling unit must not be exposed to the direct

eﬀects of solar radiation.

CAKE compact air-handling unit blocks, as well as its sepa-

rate blocks, may only be stored in the same position in which

they are operated.

Stacking

Stocking of the transport blocks of the CAKE compact air-handling

units is prohibited!

Air-handling Unit Safety

Personnel Protection Measures:

Protection against Dangerous with Non-Live Parts

e protection against dangerous contact with non-live parts

is performed by mechanical connections ensuring electrical

conductivity or by interconnection with a protective conductor

(PE) in accordance with ČSN EN 60204-1 ed.2.

Protection against Dangerous with Live Parts

To connect the grounding, a

groundconnection point isprepa-

red on the base frame on which a

lightning conductor clampcanbe

connected. Another grounding

connection point is situated on

the upper casing of the unit. e

entire unit is conductively inter-

connected so there is no need

for additional interconnection.

Protection is ensured as follows:

Integrated removable covers (motor drives, measuring and

control elements and terminal boxes) which can only be re-

moved using tools and internal parts accessible only using the

service doors of the compact air-handling unit.

By door of the sheet metal switchboard box (this box serves

to place electrical equipment inside the air-handling unit) can

only be unlocked using a special tool and are accessible from

the service side, degree of protection IP44 (ČSN EN 60529-1).

Protection of the frequency inverters situated inside the air-han-

dling unit against dangerous contact of live parts is ensured by

the degree of protection IP20 of the built-in devices in accordance

with ČSN EN 60529.

Staﬀ qualiﬁcation requirements

Installation, connection, commissioning, repairs and maintenance

can only be performed by properly qualiﬁed personnel. Electrical

wiring, interconnection of individual parts, initial inspection, ope-

ration and maintenance must be performed in accordance with

applicable standards and regulations. e user is responsible for

device use in accordance with applicable standards.

Working on Air-handling Unit

When performing any work, repairs, maintenance or cleaning,

the device must always be safely disconnected from the power

supply. When planning or installing the air-handling unit, observe

normative requirements for safe access to the air-handling

unit. When reinstalling the covers also restore their conductive

connections (properly tighten the screws using fan washers or

interconnectthem bythe groundingwire).Maintain theprescribed

degree of protection..

Installation

Location

e surface of the site for the air-handling unit installation must be

level and ﬂat. Maximum misalignment of the ﬂoor or supporting

structure intended for the compact air-handling unit installation

must not exceed 1 mm per 1 meter. To eliminate ﬂoor slope or

other ﬂoor inequalities, the adjustable feet must be used (for

adjustment, refer to the chapter "Adjustable and Fixed Feet").

Observance of this condition is important for installation as well as

for the air-handling unit operation. e CAKE compact air-handling

unit does not need any special anchoring. To eliminate possible

vibrations, it is advisable to put grooved rubber stripes under

the air-handling unit. It is recommended to place the compact

air-handling unit so that the gap between the unit and wall will

be at least 50 mm (to eliminate growth of mould on the walls).

Pay extra attention, if it is necessary to place the air- handling

unit close to combustible materials. In this case it must always

be assessed maximum temperature of the unit's casing and ﬂash

point of the combustible material.

Service Access

When planning the air-handling unit location, it is necessary to

keep suﬃcient space for maintenance, service and operating.

It is essential to ensure suﬃcient space for opening the doors,

removing all ﬁltration inserts, full extension of all heat-exchangers,

including heat recovery heat-exchangers.

Figure 3

Installation

Door Closures

e compact air-handling unit service doors are equipped with

safety closures. When the door handle is moved down, the safety

closure keeps the doors just ajar. To fully open the door, the door

handle must be moved back to the horizontal position. en the

door is released. To close the door, proceed in the reverse order of

steps. Each door is equipped with one lockable closer.

Figure 4 – Safety door lock

Pre-installation Inspection

Prior to installation, the following must be checked:

Intactness of the delivery (completeness according to the

bill of delivery)

Volubility of rotary components (fans, dampers, rotary heat

exchanger)

Parameters of the power supply and connected energy

media sources. Any fault must be removed before starting the

installation.

Identiﬁcation of Air-handling Unit Components

The association to the particular purchase order number is

indicated on the name plate of the CAKE compact air-handling

unit or of each block (if the unit is delivered disassembled), i.e. the

device number or block position number. e name plate is visibly

situated on the service side of the unit.

Base Frame

e base frame’s adjustable feet are protected by corner covers

intended only for the transport and handling of the unit. ere

covers should be removed aer installation.

Assembly of Air-handling Unit Sections

e basic version of the compact air-handling unit is delivered

assembled. If the compact air-handling unit is delivered disassem-

bled, the individual parts of the unit are assembled on the site,

i.e., the base frames are connected ﬁrst and then the blocks are

connected together. For the recommended installation procedure

of the frame adjustable or ﬁxed legs, refer to the appendix to this

document. e centre block of the disassembled unit is delivered

including the base frame and other parts of the compact air-hand-

ling unit are delivered with the base frames and block separated,

please see the picture.

Unit Alignment

Place the unit as close to the installation site as possible*

and remove the cover plate from the base frame.

Figure 7 – Base frame assembly

Figure 5 – Delivery of disassembled unit

Figure 6 – Application of the sealing on the contact surfaces

Connection using the M6x20 Allen screws. To For installation

it is necessary to use an Allen wrench, size 5 (number of

screws according the width of the unit).

Base Frame Assembly

Set the unit in the installation site* and check the prescri-

bed distances from walls*. If the unit is being assembled from

separate blocks, perform the assembly in accordance with the

following chapter "Assembly of Air-handling Unit Sections".

Install or check the anti-vibration damping of the unit from

the ﬂoor or supporting structure.

Check the unit adjustment to the level plane.

Check the air-handling outputs for proper connection.

Check the upper terminal boxes and media outputs for free

access.

Check the free space around the condensate drainage out-

put neck under the unit.

Check the minimum service space for free opening of the

doors (see the chapter "Service Access"). .

CAKE Air-handling units

Installation, Connection of Heat Exchangers

Rotary Heat Exchanger

A rotary heat exchanger is oneof the most expensive components

in the air-handling assembly; poor and/or incorrect installation can

result in costly repairs. During improper handling, transport or if

the installation conditions are not met, the heat-exchanger rotor

can be misaligned or permanently damaged. To enable service or

cleaning of the rotor, it is necessary to ensure suﬃcient free space

in front of the unit so that the rotary heat exchanger can be fully

extended from the unit.

Media Connection, Condensate Drainage

and Air-handling Duct Connection

Connection of Heating and Cooling Media Feeds

e heating and cooling water feeds are connected to the outer

side of the air-handling unit. e internal interconnection is made

during production in the factory. External outlets are terminated

with external threaded connections. e heat exchangers are

counter-current connected to achieve maximum output.

e heat exchangers are not equipped with air-venting valves.

erefore, the inlet and outlet line venting must be vented during

installation – at the highest points.

Connection of direct evaporators is carried out by routing the

piping into the air-handling unit through rubber grommets in the

casing and connecting it to the cooler necks. Direct evaporators

must be connected by a specialized contractor authorized to

install refrigerating equipment. e direct evaporators are ﬁlled

with nitrogen in the factory. e water heat exchanger connec-

Figure 11 – Connection of heat-exchangers (cap nuts)

tions must cause no mechanical stress. Forces arising from the

dilatation and weight of feeding pipes and ﬁttings must not be

transferred to the air-handling unit.

e corresponding connection points are marked with labels

on the unit side panel (heating water inlet, heating water outlet,

coolant inlet, coolant outlet).

Aer connecting the water heat exchangers (heaters and coolers,

including mixing sets) to the distributing piping, it is necessary to

pressurize (ﬂush with water) and vent the entire circuit, including

the heat exchanger. en it is necessary to perform leak-tightness

checks of all pipe joints and of the exchanger itself (including

inspection of the unit interior with the water heat exchanger).

e manufacturer does not provide any guarantee covering

any damage resulting from liquid leakage from leaky joints or a

damaged exchanger, except the internal interconnection which

was carried out by the manufacturer.

Figure 8 – Installation of the unit to the base frame

Figure 9 – Connection of the unit in the upper part

Figure 10 – Connection of the unit in the lower part

Connection of the upper part using the connecting kit

and the M 8 Allen head screw.

Connection of the unit in the lower part using the pressure

element and the M6x20 Allen screws.

Connection of Individual Blocks

Connection of Heat Exchangers, Condensate Outlet

Steam Humidiﬁcation

Steam humidiﬁcation is only delivered as an accessory. Steam

humidiﬁcation is installed into the inlet air duct line. Air ducts lea-

ding through cold areas must be insulated to avoid condensation.

e entire humidiﬁcation assembly (steam generators, including

steam distribution piping) should be situated in a non-freezing

room. Otherwise, anti-freeze protection must be installed.

e following minimum distances (distances between the steam

humidiﬁer and the following air-handling unit components, where

H representsthe minimumevaporatingdistance calculatedfor the

given conditions) must be observed to ensure proper operation

of the steam humidiﬁer:

Humidistat piping, humidity sensor, temp. sensor: 5x H

Very ﬁne ﬁlter: 2.5 x H

Heating elements, ﬁlter: 1.5 x H

Duct branch piece, duct elbow, air outlet, fan: 1x H

Notes:

e steam generator can be noisy (switching of solenoid valves);

therefore, it is advisable to install it away from quiet areas. 100°C

hot and heavily mineralized water is drained from the steam

humidiﬁer. If the H value is not known, it is advisable to make the

calculation with a minimum value of 1.0 m.

Condensate Drainage

Stainless trays for collection of the condensate are installed inside

the compact air-handling unit in places where condensation is

expected. e tray outlet is routed through the lower panel and

terminatedwith aneckand theDN40connection.e condensate

drainage system is connected to this outlet.

econdensate drainagekitsareavailable asoptional accessories.

A separate condensate drainage kit must be used for each indivi-

dual block. e siphon height depends on the total pressure of the

fan, and ensures its proper functioning. e type of condensate

Figure 12 – Condensate draining

draining kit must be designed in the course of the air-handling

unit calculation. e standard CAKE unit condensate drainage is

always in negative pressure.

e correct installation and correct minimum level heights have

crucial inﬂuence on the correct and reliable condensate drainage

from the unit. e condensate draining piping must end in free

atmosphere, i.e. it must not end directly in the closed sewerage

system.

Before operating the air-handling unit or aer being out of ope-

ration for a longer period, it is necessary to ﬁll the siphon in each

tray with min. 0.5l of water.

If there is a risk of freezing, it is necessary to insulate the siphon and

condensate draining piping, respectively keep the ambient tem-

perature above freezing point, e.g. with an electric heating cable.

If the outdoor version of the unit is speciﬁed in the order and

includes the manufacturer's control system, the delivery includes

a heating cable.

Air-handling Duct Connection

e air ducting must be connected to the air-handling unit via an

elastic element to avoid the transfer of vibrations. e connection

of the air-handlingducting mustbe performed so thatnoload from

the air duct will be transferred to the inlet panel of the air-handling

unit. e accessories must be installed in accordance with the

air-handling unit speciﬁcation and the Installation Instructions of

the manufacturers of such accessories.

No connections, including insulation and associated structures,

must prevent opening of the air-handling unit and control unit

doors, but they must allow access to the media connections

(electric connections, cooling and heating water supply and

output) and must not limit the service room needed for proper

operation and maintenance. If the compact air-handling unit is

delivered disassembled, the internal cable interconnection is

made using connectors. ese connectors must be connected

when the individual unit blocks are assembled.

CAKE Air-handling units

Wiring

EC motor single speed ree-phase EC Motor

L– power supply

N– neutral conductor

PE – safety conductor

11, 14 – fan summary fault

(contact load 250 V AC, 2 A)

E1 – 0–10 V DC input

D1 – digital input (on/oﬀ)

10 V – 10 V DC voltage source

GND – ground

Fan motors

Control unit with step motor

Regeneration Exchanger

L1, L2, L3 – power supply

PE – safety conductor

11, 14 – fan summary fault

(contact load 250 V AC, 2 A)

250 V AC, 2 A)

E1 – 0–10 V DC input

D1 – digital input (on/oﬀ)

10 V – 10 V DC voltage source

GND – ground

L– power supply

N– neutral conductor

PE – safety conductor

13, 15 – fan summary fault

(contact load 250 V AC, 2 A)

2– 0–10 V DC(+) input

3– 0–10 V DC(–) input

Figure 13 – Assembly of the round output

Electrical Equipment Wiring

Wiring of Drives and Internal M&C Elements

If the delivery includes the integrated control unit, all the

wiring (connections of motors, internal damper drives and mea-

suring and control elements, hereinaer M&C) is performed by

the manufacturer, i.e., connected to the control unit inside the

switchboard box where all the connecting terminals are also

situated.

If the compact unit includes an external control unit which is

a part of the delivery, the entire internal wiring is prepared and

connected to the prepared connecting terminals in the terminal

box inside the unit. All the connections between the control unit

and internal M&C elements are performed through the com-

mon grommet and terminal inside the terminal box.

If the control system is not included in the speciﬁcation of

the CAKE compact unit order, only internal protective interco-

nnections are performed and all the internal wiring, including

M&C elements, will be performed on the site.

Wiring of External M&C Elements

External measuring and control elements, not ﬁrmly attached

to the air-handling unit, are installed on site and connected to:

a prepared terminal box on the top of the unit casing (CAKE

version with an integrated control unit);

a terminal box (CAKE version with an external control unit

included in the delivery)

Main Supply Cable Connection

If the device is equipped with the integrated control unit, the

supply cable is connected to the main terminal box situated on

the top of the compact air-handling unit casing.

If an external control unit is used, the supply cable is conne-

cted to the terminal of the main switch situated in the control

unit.

e wiring and installation of the M&C system’s external au-

xiliary elements must be performed by qualiﬁed professionals

authorized to perform wiring of the given type of device. e

wiring must be performed in accordance with the directives

and standards of the country of installation, and in accordance

with the Installation and Operating Instructions of individual

pieces of equipment (frequency converters, pressure and

temperature sensors, etc.). Conformity of the power supply

voltage, frequency and protection with the data in the technical

documentation and on the type plate of the connected device

and cross-section of the connecting cables must be checked

before connecting the electrical equipment to the power supp-

ly. Before putting the air-handling unit into operation, a wiring

inspection must be performed.

Wiring

Sheet Metal Switchboard Box

is box is intended for installation of electrical elements. It is

integrated into the interior of the compact air-handling unit

and accessible through the door on the service side. e door is

equipped with a safety closure opened by a triangular key no. 8

which must be stored on a dedicated place under supervision of

a responsible person.

Instructions for Cabling

All interconnections of the distribution board and installed

elements must be made using intact double insulated cables

which must be properly dimensioned for the given load and

lead length.

Every cable leading out through the sheet metal parts must

be led through the preinstalled cable grommets. All unused gro-

mmets must be blinded to maintain the degree of protection.

e main power supply cable harness must be dimensioned

for the total current of the unit.

A central sheet metal cable trough with outlets ﬁtted with

grommets is installed along the rear wall to ensure safe leading

of the cables.

When connecting and leading the cables, it is necessary to

take into account their properties. e conductors must not be

exposed to strains which decrease their service life. Avoid cable

slack;

Always use cable protectors and troughs (wire, plastic, or

metal) of suﬃcient size and length.

WAGO screw-free terminals are used to connect the con-

ductors. If stranded conductors are used, it is recommended to

provide their insinuated ends with cable tubes.

Properly ﬁx all cables and maintain minimum bending radi-

uses.

e M&C cable lines must be led separately from the power

cables to avoid their interference. We recommend running the

power cable lines along the base frame and the M&C cable

lines along the front edge of the top panel.

e cable lines must never interfere with the service panels

(doors) of the unit and control unit and obstruct routine operati-

on and servicing. Please respect the reserved servicing space.

Figure 14 – Interconnection of blocks using the connectors

Figure 17 – Box closure with a triangular key

e degree of protection

of the sheet metal box is

IP IP44 when the door is

closedand IP20when the

door is closed.

All box parts are made of

bent sheet steel galvani-

zed with a 275 g/m2 zinc

layer and finished with

powder coating.

If the outdoor version of

the air-handling unit is

ordered, the integrated

sheet metalswitchboardboxis heatedby aheating mattoprotect

electrical elements.

If the integrated control unit is included in the delivery, the

sheet metal box contains all the parts of the control unit and its

associated elements, including protection, controller, transfor-

mer, connecting terminals and main switch with the red handle

in the yellow ﬁeld.

If the air-handling

device is ordered with

an externally connected

control unit, the air-han-

dling device is equipped

with an integrated sheet

metal terminal box –

connecting box. . e

degree of protection of

the sheet metal box is

IP IP44 when the lid is

closed.

Figure 15

Figure 16

e terminals can only be accessed aer opening the air-hand-

ling device's service doors and removing the lid.

Indice

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