GEA COM4plus - CS Klimateknik

GEA COM4plusProduct Type Code1 Product Type CodeBeispiel: Com4plus C 1 K # I H Ü K Z 1 2 8 0 6 4 V B V APrefix General Unit part 1Product family/Product groupSeriesUnitclassThermal separationcasingType of applicationInstallation siteAir flowConfigurationCasing typeFunctionAir flowUnit widthUnit heightMaterialInternal skinMaterialExternal skinMaterialComponentsMaterial profilesCom4plusC C-unit1 Standard without accessoriesK without (T3/TB3)# StandardIIndoor installationA Outdoor installationH HorizontalÜ Double deckK Combined casingZ Supply airUnit width internal sizeUnit height internal size entire casing/2V Aluzink AZ185B RAL 9002 coatedV Aluzink AZ185B RAL 9002 coatedV GalvanizedA Natural AluPR-2009-0022-GB • Subject to modifications • Status 04/2009 3

Safety and User InformationGEA COM4plus2 Safety and User InformationThe GEA COM4plus units are constructed in accordance with the current technicalstandards and recognised technical safety regulations.Units may only be used in a proper way and in working order. Observe the operationmanual and consider the dangers and safety precautions, otherwise there may be riskof death or injury to the user or third persons. Adverse affects to the unit, connectedunits or other equipment may also occur.Have all faults repaired professionally without delay.Also observe the (safety) information provided by the manufacturers of individualcomponents.2.1 Availability of the operation manualThe accompanying operation manual includes important information about the safeand correct operation of the unit.The operation manual is intended for use by fitting and installation companies, buildingservices engineers, technical personnel or trained persons as well as electrical and airconditioningengineering specialists.This manual must always be available at the site where unit is in operation. Everyperson working with or around the unit must read and apply the information containedin the manual, paying particular attention to the safety instructions.2.2 Scope of the operation manualThis operation manual provides you with the necessary information about the followingsubjects:– Transport and storage– Installation and assembly of the unit– Installation of components and accessories and electrical connection– Commissioning and maintenance– Disassembly and disposal2.3 Symbols usedThe following symbols are used to draw your attention to particular text sections inthese operating instructions:– This symbol is used for normal lists.• This symbol indicates instructions to act. This symbol denotes the results of an action.NOTEThis symbol denotes additional information on use of the units.You will find the danger symbols in section „Labelling of the safety information“ onpage 7.4 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusSafety and User Information2.3.1 Special warning/caution signsThe following warning/caution signs may be attached to the unit:When connecting, apply counter pressure using pipe wrench.Caution: risk of fire. Dirty filters are inflammable.Switch off main isolator before opening.Danger of injury. Only open when at a standstill.Data sheet and assembly instructions on the interior side.These documents must be removed prior to commissioning.Do not start up the fan against closed dampers.Potential equalisation.The unit must be connected to an external protective conductor at the points onthe base frame designated by this symbol to achieve potential equalisation.PR-2009-0022-GB • Subject to modifications • Status 04/2009 5

GEA COM4plusSafety and User Information2.4 Labelling of the safety informationThe following designations and symbols are used in this manual to denote safetyinformation:ELECTRICAL HAZARD!This symbol indicates that there is a risk of electrical shock when carrying outthe relevant task(s).PERSONAL INJURY!Here you will find special information as well as requirements and restrictionsfor preventing personal injury.DANGER FROM ROTATING UNIT PARTS!Here you will find special information as well as rules and restrictions for theprevention of personal injury due to rotating parts of the unit.DANGER DUE TO OVERHEAD LOADS!Here you can find special information as well as rules and restrictions for theprevention of personal injury and damage to units due to falling parts.DANGER DUE TO HOT SURFACES!Here you can find special information as well as rules and restrictions for theprevention of personal injury due to hot surfaces.DANGER OF SCALDING!Here you can find special information as well as rules and restrictions for theprevention of personal injury due to scalding, e.g. by steam.DANGER DUE TO EXPLOSION RISK AREA!Here you can find special information as well as rules and restrictions for theprevention of personal injury and damage to units in explosion risk areas.DANGER DUE TO INFLAMMABLE SUBSTANCES!Here you will find special information as well as requirements and regulationsfor the prevention of personal injury due to fire.DANGER OF SHARP EDGES!Here you can find special information as well as rules and restrictions for theprevention of personal injury due to cutting by thin sheet metal.ENVIRONMENTAL DAMAGE!Here you will find special information, rules and restrictions for the preventionof damage to the environment including information on any national environmentalprotection regulations in force.DAMAGE TO THE UNIT!Here you will find special information, rules and restrictions regarding the preventionof damage to the unit.PR-2009-0022-GB • Subject to modifications • Status 04/2009 7

Safety and User InformationGEA COM4plus2.5 Safety-conscious workingObserve the following when carrying out installation, maintenance and repair work:When working on or around the mains power supplyELECTRICAL HAZARD!All power supply connections must be switched off and checked to see if theyare voltage-free and then secured against unintentional switching on. Earth andshort-circuit them and cover over any neighbouring electrically conducting partsor block them off. Failure to do so may lead to serious injury or death.Working in explosion risk areasDANGER DUE TO EXPLOSION RISK AREA!The unit may only be operated under the conditions described on the type plate.An explosion risk area may be present inside and/or outside the unit when it isin operation and also when it has been shut down – it must therefore beassumed that an explosion risk area is present, even when the unit has beenshut down.When carrying out work in general:PERSONAL INJURY!A danger of injury exists when the units are in operation:– Danger of impacts – doors on the discharge side may be flung open– Danger of crushing due to underpressure at doors on suction side– Danger due to rotating parts such as fans etc.DAMAGE TO THE UNIT!If dampers are closed when the system is in operation, the units may be damagedbeyond repair by under- or overpressure, particularly if the dampers areclosed abruptly.2.6 Proper useDANGER FROM SHARP EDGES!When working on the unit in general there is a danger of cuts being inflicted bythin sheet metal and fins. This applies in particular when carrying out maintenanceand cleaning work on the surfaces of heater and cooler coil fins.Work may only be carried out on the unit if– all poles of the power supply have been disconnected,– the unit is secured to prevent it being switched back on(also see “Electrical hazard”),– all moving parts – particularly the fan impeller, motor, rotary heat exchanger,control and shut-off dampers – have come to a standstill: wait at least5 minutes after switching off the unit,– the heat exchangers have cooled down to ambient temperature.Once work on the unit has been carried out, it must be ensured that– all protective devices are functioning effectively – for example, the protectiveenclosure for the fan (contact protection grille, safety guard) must be locked– no persons are present in danger areas.The GEA CompactLine units are intended exclusively for air handling for the followingpurposes:– air filtering with normal levels of contamination,– air heating and/or cooling,8 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusSafety and User Information– air humidification and/or dehumidification,– heat extraction and/or heat recovery,– or combinations of the above-mentioned tasks.Proper use also stipulates observance of the operation manual as well as inspectionand maintenance intervals specified by GEA.Improper useAny use other than that described above is considered improper. If necessary, checkwhether your GEA CompactLine units are suitable for your intended purposes. Themanufacturer/supplier is not liable for any damages arising from improper use. Theuser alone bears the risk.The GEA CompactLine unit is not suitable for handling of abrasive media.PERSONAL INJURY!The GEA CompactLine units may not be operated in the following environments:– in explosion risk areas,– indoors where conductive dust is present;– indoors where strong electromagnetic fields are present;– indoors with aggressive environments that may attack plastics or cause corrosion(especially in environments where zinc is particularly susceptible tocorrosion).2.7 Safety devices2.8 Modifications and changes2.9 Spare parts2.10 Disposal2.11 Selection and qualifications of personnelThe following means are installed depending on the equipment supplied with the unit:– Panels with sash fasteners and doors with switch cabinet locks/lockable handles– Contact protection grilles on fan sections– Doors with door stop devices.You must not modify, add to, or convert, the unit in any way. Any conversions or modificationsto the unit will invalidate the CE conformity. If the delivered units aredisassembled by others on-site, the factory warranty is invalidated. In this case professionalsupervision by GEA Happel Service GmbH should be organized in advance.You may use only genuine GEA spare parts as GEA will not be held liable for claimsarising from the use of third party spare parts.Operating and auxiliary materials, components and filters must be disposed of in a safeand environmentally friendly manner.Every person authorised to work on or around the unit must have read this entire operationmanual and understood it completely – particularly the chapter on safety. It is toolate to do this during work.All work must only be carried out by specialists with sufficient knowledge based on professionaltraining and experience in the following:– Regulations concerning health and safety in the workplace– Accident prevention regulations– Directives and recognised codes of practiceAll skilled persons must be able to assess what the work entrusted to them entails andmust be able to recognise and avoid all inherent dangers.PR-2009-0022-GB • Subject to modifications • Status 04/2009 9

Technical DescriptionGEA COM4plus3 Technical Description3.1 Performance range3.1.1 GEA COM4plus basic unitsGEA COM4plus basic units are air handling units used for energy efficient ventilationof normally contaminated air in multiparty, office, public and similar buildings.Supply and exhaust air is filtered, heat and humidity is recovered between these airflows which means that:– if the weather is cold and dry (e.g. in winter) and before cold and dry outdoor air issupplied into the building - it is preheated by warm and humid exhaust air.– if the weather is warm (e.g. in summer) and before warm and possibly humidoutdoor air is supplied into the building - it is precooled by cool and dry exhaust air.In order to adapt the GEA COM4plus units to individual capacity requirements of buildings- the units are available in nine sizes that correspond to nine different capacitystages.The three-part configuration of the GEA COM4plus basic unit makes it possible to fitthe unit into narrow openings (e.g. through narrow doors). In such a way the unit is ideallysuitable for a subsequent installation in case of modernisation projects.3.1.2 GEA COM4plus with an air handling moduleOptionally the basic units can be equipped with an air handling module enabling additionalheating or cooling of supply air. Depending on the order, suitable air handlingmodules for heating (using warm water or electricity) or cooling (using chilled water ordirect evaporator) can be installed.10 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusTechnical Description3.2 Unit components and operation3.2.1 Unit componetsThe GEA COM4plus basic unit is designed with three separable modules.Both outdoor modules consist of a supply or exhaust fan and a filter unit for air filtering.The intermediate module contains a rotation heat exchanger wheel (ECOROT) and aswitch cabinet with controls.Switch cabinet/controlsFan supply/exhaust airFilter fresh/exhaust airFilter fresh/exhaust airFan supply/exhaust airECOROTFig. 3-1:Unit configuration of the GEA COM4plus basic unit3.2.2 Operation without air handling moduleAir flow: rightECOROTExtract airExhaustairRoomOutdoor airSupplyairFig. 3-2:Operation with right air flowIndoor exhaust air is removed by the fan through the filter system and rotation heatexchanger (ECOROT) and is released outdoors (extract air). Exhaust air heat is recoveredby the ECOROT and transferred to outdoor air. The second fan supplies fresh airthrough the filter system and the ECOROT to the indoor space.By utilizing heat and humidity transfer supply air is approximated to the condition ofexhaust air. An optional rotation heat exchanger wheel with increased recovery rate(up to 90%) or with increased humidity transfer can be used.PR-2009-0022-GB • Subject to modifications • Status 04/2009 11

Technical DescriptionGEA COM4plusAir flow: leftECOROTSupplyairOutdoor airRoomExhaustairExtract airFig. 3-3:Operation with left air flow3.2.3 Operation with air handling moduleAs an option air handling modules can be mounted in supply air flow of the basic module(maximum one heater and one cooler).Basic moduleECOOTswitch cabinetBasic moduleA B CFig. 3-4:Possible air handling modules (A-C)The above drawing demonstrates possible air handling modules (A-C).A Heating supply air with warm water pump (WWP)B Heating supply air using electric heating batteryC Cooling supply air using chilled water pump or direct evaporatorA - CB - CFollowing combinations of air handling modules are possible:Warm and chilled water or warm water and direct evaporatorElectric heating battery with warm water pump or electric heating battery with directevaporator12 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusTechnical Description3.3 Compact system controlCOM4plusExtractairExhaustairFresh airSupplyairRoomDistributioncontrolInjectionswitchFrost protec.Components and functions● Scope of supply or controls GEASupply air fan with frequency converter ● mounted Direct drive 3~400 Volt/50 HzExhaust air fan with frequency converter ● mounted Direct drive 3~400 Volt/50 HzFresh and exhaust air dampers ● mounted Opposed dampers with gear actuatorFresh and exhaust air filter ● mounted Fresh air F7 / exhaust air F5Energy recovery ● ECOROT GEA rotation heat exchangerL.P.H.W. heating ● no steam Steam heating on requestChilled water cooling ● no refrigerant Cooling with refrigerant on requestCompact controls unit ● mounted ready-for-use pre-wiredExternal sensor ● loose GEA NTC sensor with IP54 casingActuator motors for fresh/exhaust air dampers ● mounted GEA motor actuator 230 VoltDifference pressure switch fresh air filter/exhaustair filter● mounted Lower response sensitivity 40 PaFrost protection thermostat ● mounted GEA thermostat with change-over contactPressure sensors for air flow control ● mounted Volume or pressure or external signal 0 ... 10 VoltFrequency converter supply air/exhaust air ● mounted For fan motor speed controlSupply air minimum limitation sensor ● mounted GEA NTC mounted sensorMounted exhaust air sensor and/or loose indoorsensor● mounted/loose GEA NTC mounted sensor or with IP21 casingDrive motors rotation heat exchange wheel ● mounted For rotor speed controlActuator 3-way mixing valve L.P.H.W. heating ● loose GEA motor actuator 230 VoltActuator 3-way valve chilled water cooling ● losoe GEA motor actuator 230 Volt3-way valvesHydraulicA Return line heat exchanger Part medium volume Water or brine as mediumB Supply line bypass Part medium volume Water or brine as mediumAB Return line energy source Total medium volume Water or brine as mediumMechanical throttle valves field provided For hydraulic balance by othersSecondary pump heating circuit ● field provided GEA on/off controlPR-2009-0022-GB • Subject to modifications • Status 04/2009 13

Technical DescriptionGEA COM4plus3.4 Scope of supplyCOM4plusSupply airExhaust airECOROT Exhaust 22 °CHeating outputLPHWHeating outputCWCooling outputElectricheating coilRecovery rate kW kW kW kW kW kW kW kWSize 10 1 m/s 2 m/s 1 m/s 2 m/s 1 m/s 2 m/s 1 m/s 2 m/s 1 m/s 2 m/s 1 m/s 2 m/sAir flow rate 1.600 m³/h 3.200 m³/h 0,85 0,76 16 28 2 8 7 14 12Max. ext. pressure 400 Pa 200 PaAir intake TL1 °C -12 17 14 32/40% r.h. 17 14Air discharge TL2 °C 17 14 21 21 23 17Size 20Air flow rate 2.100 m³/h 4.200 m³/h 0,84 0,76 20 36 3 10 9 17 15Max. ext. pressure 400 Pa 200 PaAir intake TL1 °C -12 17 14 32/40% r.h. 17 14Air discharge TL2 °C 17 14 21 21 23 17Size 30Air flow rate 2.800 m³/h 5.700 m³/h 0,85 0,76 27 50 4 14 11 25 21Max. ext. pressure 400 Pa 200 PaAir intake TL1 °C -12 17 14 32/40% r.h. 17 14Air discharge TL2 °C 17 14 21 21 23 17Size 40Air flow rate 3.900 m³/h 7.700 m³/h 0,85 0,77 38 68 5 18 17 32 28Max. ext. pressure 400 Pa 200 PaAir intake TL1 °C -12 17 14 32/40% r.h. 17 14Air discharge TL2 °C 17 14 21 21 23 17Size 50Air flow rate 4.800 m³/h 9.200 m³/h 0,84 0,76 46 80 7 22 21 40 33Max. ext. pressure 400 Pa 200 PaAir intake TL1 °C -12 17 14 32/40% r.h. 17 14Air discharge TL2 °C 17 14 21 21 23 17Size 60Air flow rate 6.500 m³/h 13.200 m³/h 0,84 0,76 63 114 9 33 28 55 47Max. ext. pressure 400 Pa 200 PaAir intake TL1 °C -12 17 14 32/40% r.h. 17 14Air discharge TL2 °C 17 14 21 21 23 17Size 70Air flow rate 8.000 m³/h 16.200 m³/h 0,84 0,76 77 140 12 40 35 69 58Max. ext. pressure 400 Pa 200 PaAir intake TL1 °C -12 17 14 32/40% r.h. 17 14Air discharge TL2 °C 17 14 21 21 23 17Size 80Air flow rate 9.500 m³/h 18.700 m³/h 0,84 0,76 92 162 14 45 43 78 68Max. ext. pressure 400 Pa 200 PaAir intake TL1 °C -12 17 14 32/40% r.h. 17 14Air discharge TL2 °C 17 14 21 21 23 17Size 90Air flow rate 12.500 m³/h 25.000 m³/h 0,84 0,76 121 216 18 62 55 106 90Max. ext. pressure 400 Pa 200 PaAir intake TL1 °C -12 17 14 32/40% r.h. 17 14Air discharge TL2 °C 17 14 21 21 23 17Heating LPHW 70/50 °C Cooling Chilled water 6/12 °C ECOROT = Rotation heat exchanger to recover energyPerformance data for energy recovery for High-Performance-ECOROT, with relationship of air flows 1/1Recovery rates up to max. 0,90 by using of XL-ECOROT possible; in case of high air side resistance14 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusTechnical Description3.5 Acoustic dataSound power level outside unit at air flow rate Supply air Exhaust airm 3 /h m 3 /h db db(A) db db(A)Size min max min max min max min max min maxCL10 Suction side 1.600 3.200 74 70 77 73 74 70 77 73Discharge side 81 79 84 83 81 79 84 83Externally, on fan casing 56 50 60 54 56 50 60 54CL20 Suction side 2.100 4.200 71 69 75 72 71 69 75 72Discharge side 82 81 85 84 82 81 85 84Externally, on fan casing 57 52 81 55 57 52 81 55CL30 Suction side 2.800 5.700 75 71 81 77 75 71 81 77Discharge side 84 81 90 87 84 81 90 87Externally, on fan casing 61 54 67 59 61 54 67 59CL40 Suction side 3.900 7.700 79 71 79 75 79 70 79 75Discharge side 86 81 88 85 85 81 88 85Externally, on fan casing 65 55 65 58 65 55 64 58CL50 Suction side 4.800 9.200 81 72 85 75 81 72 85 75Discharge side 87 82 90 85 87 82 90 85Externally, on fan casing 67 56 70 59 67 56 70 59CL60 Suction side 6.500 13.200 80 72 85 78 79 72 85 78Discharge side 87 82 93 87 87 81 93 87Externally, on fan casing 68 56 73 62 67 56 73 62CL70 Suction side 8.000 16.200 82 74 88 80 82 74 88 80Discharge side 89 83 95 89 89 83 95 89Externally, on fan casing 70 58 75 64 69 58 75 64CL80 Suction side 9.500 18.700 82 74 87 79 82 74 87 79Discharge side 91 84 95 89 91 84 95 89Externally, on fan casing 71 60 76 64 71 60 76 64CL90 Suction side 12.500 25.000 83 74 92 84 83 74 92 84Discharge side 91 84 101 94 91 84 101 94Externally, on fan casing 72 60 81 70 71 60 81 703.6 Motor capacity and SFPSupply air SFP Exhaust air SFPMotor capacity Rated Rated Rated kW/m 3 /s Rated Rated Rated kW/m 3 /sand SFP kW A speed at at kW A speed at atSize 1 m/s 2 m/s 1 m/s 2 m/sCL10 1,1 2,55 2.850 1,19 1,17 1,1 2,55 2.850 1,19 1,17CL20 1,5 3,41 2.860 1,24 1,20 1,5 3,41 2.860 1,24 1,20CL30 2,2 4,61 2.850 1,19 1,03 2,2 4,61 2.850 1,19 1,03CL40 2,2 4,84 1.420 1,03 0,98 2,2 4,84 1.420 1,03 0,98CL50 2,2 4,84 1.420 1,10 0,94 2,2 4,84 1.420 1,10 0,94CL60 4,0 8,30 1.420 1,05 1,01 4,0 8,30 1.420 1,05 1,01CL70 5,5 11,4 1.440 1,13 1,02 5,5 11,4 1.440 1,13 1,02CL80 5,5 13,7 960 1,16 1,13 5,5 13,7 960 1,16 1,13CL90 7,5 16,0 960 1,05 1,12 7,5 16,0 960 1,05 1,12PR-2009-0022-GB • Subject to modifications • Status 04/2009 15

Technical DescriptionGEA COM4plus3.7 DimensionsFunction Height DepthSize [mm] b b b b b b L1 L2 H TSize max max max max max max max max max maxCL10 660 440 320 320 640 660 2.720 1.760 1.265 1.080CL20 820 440 320 320 640 820 3.040 2.080 1.385 1.200CL30 860 440 320 320 640 860 3.120 2.160 1.585 1.400CL40 980 440 320 320 640 980 3.360 2.400 1.785 1.600CL50 1.100 440 320 320 640 1.100 3.600 2.640 1.905 1.720CL60 1.140 440 320 320 640 1.140 3.680 2.720 2.185 2.000CL70 1.300 440 320 320 640 1.300 4.000 3.040 2.385 2.200CL80 1.540 440 320 320 640 1.540 4.480 3.520 2.505 2.320CL90 1.540 440 320 320 840 1.540 4.680 3.520 2.825 2.640Individual unit max. 5 max. 3Basic unit with integrated add-on moduleswith adjusting dummy sectionfor use with integrated heat exchangersBasic unit without integrated add-onmodulese.g. for use withduct heat exchangersExhaust airExhaust airSupply airSupply airMaximum 5 individual unitsMaximum 3 individual unitsExhaust air fan direct driven with frequency converterFresh air filter F7 with integrated damperRotation heat exchanger ECOROTExhaust air filter F5 with integrated damperSupply air fan direct driven with frequency converterAdjusting dummy sectionHeating max. 3 rows Cu-AlAdjusting dummy sectionHeating max. 3 rows Cu-AlAdjusting dummy sectionElectric heating coilHeater for duct installationCooler for duct installationElectric heater for duct installationSpecial accessories for individual units on request16 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusTechnical Description3.8 Unit weightFunctionWeight approx. kg kg kg kg kg kg L1 L2Size max max max max max max max maxCL10 190 160 100 110 120 190 770 540CL20 260 200 130 140 150 260 1.010 720CL30 280 240 160 170 180 280 1.150 800CL40 390 290 190 200 210 390 1.480 1.070CL50 420 330 220 230 240 420 1.640 1.170CL60 540 410 270 290 300 540 2.080 1.490CL70 680 480 310 330 340 680 2.510 1.840CL80 860 530 350 370 380 860 3.000 2.250CL90 990 650 430 450 520 990 3.600 2.630Individual unit max. 5 max. 3Duct heat exchangerFunctionb b b H T 3 rows 3 rows bDuct heat exchanger mm mm mm mm mm kg kg kgLPHW CW Electric SizeCL10CL20CL30CL40CL50CL60on request or field-provided by othersCL70CL80CL90PR-2009-0022-GB • Subject to modifications • Status 04/2009 17

Technical DescriptionGEA COM4plus3.9 Operating limits and range of applicationIt is allowed to use the GEA COM4plus units within the following operating limits:– Outdoor air from -20° to +40 °C– Exhaust air from 0° to +40 °C– Maximum 60 % relative humidity in exhaust airNOTE!Please carefully observe the unit type plate and the operation manuals for the suppliedaccessories.Please refer to the accompanying documentation for the range of application ofspecial built-in/mounted components.NOTE ON EXTREME CONDITIONS!Under extreme conditions and especially at outdoor temperatures of the lower applicationrange condensate may occasionally occur in the exhaust fan section. Wheninstalling the unit make sure that minor quantities of condensate do not lead todamage.NOTE FOR USING AIR HANDLING MODULES!In case of frost danger use antifreeze agents for heating and cooling media.3.9.1 Ambient conditionsNOTE ON EXTREME CONDITIONS!Besides air temperature/air humidity of the flow medium, temperature/humidity ofsurrounding air is critical as well. Observe the condensation limits.Environmental impact like proximity to sea or ocean must be taken into accountwhen selecting material quality.3.9.2 Permitted storage conditions / permitted air condition for units which have not yet been installedAir temperature -10 °C to +50 °CAir humidity Store units in a dry, non-condensing environment3.9.3 Supply voltageGEA COM4plus basic units require the following supply voltage:3x400 V/N/PE/50 Hz.3.9.4 Condensation limitsPlease pay due attention to condensation limits!The following diagrams illustrate condensation limits in relation to temperature and relativehumidity at the installation site.The diagrams are based on normal air values and are calculated using a model box.The given values are approximate figures and can not be used as a guarantee foravoiding condensation. As far as different casing components are concerned - deviationsmay occur.18 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusTechnical DescriptionRead sample:Air temperature unit exterior side in °CCondensation diagram for kb-value: 0,5Air temperature unit interior side in °CAir temperature unit interior side in °CAir temperature unit exterior side in °CPR-2009-0022-GB • Subject to modifications • Status 04/2009 19

Transport and StorageGEA COM4plus4 Transport and Storage4.1 DeliveryThe unit can be delivered as a complete unit or as individual sections on transport pallets.• When the unit is delivered, check that the delivery is correct according to thedelivery note and verify that the shipment is complete.NOTEObserve the information regarding transit damage on the packaging or in thedelivery notes.What steps should you takein the event of transitdamage?Packaging damaged externally1 Unpack the equipment in the presence of the lorry driver and have the damageacknowledged in the shipping order.2 Inform the GEA sales subsidiary immediately.No signs of external damage to packaging, contents damaged1 Once you have established the extent of the damage, notify the GEA salessubsidiary in writing.2 Document the situation photographically.3 Any transit damage must be reported no later than 4 days following delivery.Processing of claims will not be possible unless the above steps have been taken.In both cases consult the GEA sales subsidiary before installing the units.4.2 TransportationNOTEOnly transport the unit in its original packaging.Only remove the original packaging just before the installation starts.• Only transport the unit using the transport lugs/devices provided by themanufacturer.• Wear safety footwear and gloves when transporting the unit to ensure your safety.DANGER DUE TO OVERHEAD LOADS!Never enter the area beneath freely suspended loads as there is always thedanger that hoisting devices, lifting accessories or ropes/chains may be damaged,which may lead to serious injury or death.• Before transporting the unit, make sure that all doors, panels with sash fastenersand panels are closed and secured.• Only use hoisting devices with sufficient load-carrying capacity.• Never use damaged hoisting devices.• Ropes/slings should not be knotted or come into contact with sharp edges.• Only use ropes/chains of the same length.• Move the unit carefully without sudden or jerky movements.• Do not set the unit down abruptly or bump it.20 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusTransport and Storage4.2.1 Lifting the unit – transport lugs on roof (provided for sections weighing up to 1500 kg)PERSONAL INJURY!Only use the transport lugs provided by GEA! Make sure that these are firmlyseated before lifting the equipment.• Transport lugs may be used only once.• They may not be used to suspend the unit on a permanentbasis.• Transport lugs may not be loaded laterally(lateral pulling of unit)• No other loads should be lifted together with the deliveriedunit.• When installing units outdoors, particular care should betaken to ensure that the roof sheeting is not damaged by thehoisting devices.Fig. 4-1:Transport lugs for sections weighing upto 1500 kgPR-2009-0022-GB • Subject to modifications • Status 04/2009 21

Transport and StorageGEA COM4plus4.2.2 Lifting the unit – transport device on base frame (provided for sections weighing up to 4000 kg)PERSONAL INJURY!Only use the transport devices provided by GEA! Make sure that these arefirmly seated before lifting the equipment.Fig. 4-2:max. 60°Transport lugs for sections weighing upto 4000 kg• The units may only be lifted using the transport devicesattached to the base frame.• Use the hoisting device (not included in scope of GEAdelivery) as shown.• Use the timber spacers supplied to provide protection at theedges.• The suspension angle must not exceed 60°.• To make sure that the load does not slip or tilt, pay attentionto its centre of gravity when lifting it.• Transport devices may be used only once.• They may not be used to suspend the unit on a permanentbasis.• No other loads should be lifted together with the delivery unit.• When installing units outdoors, particular care should betaken to ensure that the roof sheeting is not damaged by thehoisting devices.4.2.3 Transportation with pallet truck or forklift truck• Always use the unit base frame or the pallet supplied as the supporting surfaceduring transportation.• Units must not be lifted without the base frame unless the unit profiles aresufficiently protected.• When transporting the unit using a forklift, both base frame profiles must be restingon the forks.• The centre of gravity and load distribution must be taken into account.DAMAGE TO THE UNIT!Never stack units on top of one another for transportation.Always transport units/sections separately.The stacking of units and other components that are not part of the unit is notpermitted.This is only permissible if the necessary load-bearing capacity has been speciallyincorporated into the units delivered by the GEA works.22 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusTransport and Storage4.3 StorageNOTEObserve the permissible storage conditions when storing the unit. Only removethe original packaging just before the installation starts.Protect the unit before commissioning against building dust and dirt as well asdamage.Suitable measures must be taken to protect units delivered without packagingagainst building dust and dirt prior to commissioning. Care must be taken toensure that condensation cannot form below packaging supplied by others (byensuring the correct distance between the packaging and the casing).• Always place units on an even surface during storage or intermediate storage.• Protect units from bumps and knocks which may damage the casing and projectingcomponents.• If commissioning is not carried out within three months of the delivery the belt drivemust be slackened.• Turn the motor axle and fan through at least 2 revolutions every 3 months.Permitted storage conditions / air conditions for non-installed units.Air temperatureAir humidity-10°C to +50°CStore units in a dry, non-condensing environmentPR-2009-0022-GB • Subject to modifications • Status 04/2009 23

Installation and AssemblyGEA COM4plus5 Installation and AssemblyIn the current chapter you will find information regarding the assembly andinstallation of the unit.The installation may only be carried out by specialists with the appropriate trainingand experience in the relevant accident prevention regulations and otherstandard regulations relevant to health and safety in the workplace,The unit should be installed in such a way that it is accessible only to technicalpersonnel with the appropriate authorisation and training.The unit may only be assembled in accordance with the application shown inthe technical information supplied with the unit.The units must not be stacked with other components that are not part of theunit.The latter is only allowed if the necessary load-bearing capacity has been speciallyincorporated into the units delivered from the GEA works.When connecting the duct it must be ensured that no foreign matter can enter the unit.If necessary, a suitable wire mesh guard can be installed by others at the opening onthe discharge/intake side of the unit.DAMAGE TO THE UNIT!When mounting GEA CompactLine units care must be taken to ensure that noloads are applied on the floor panels. During assembly work suitable measuresshould be taken to ensure that any loads are spread across the bottom profiles(e.g. using grid walkways).5.1 Installation5.1.1 Installation locationThe unit must be installed at a location that fulfils the following requirements:– The substructure must be level and stable.– The maximum deflection of the substructure may not exceed 4 mm per metre.– In units where a condensate drain is installed, the height of the substructure mustbe at least the same as to the required siphon height (see siphon).– Make sure that no damage to the installation location or the environment can becaused by escaping media.Fig. 5-1:Installation location24 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusInstallation and Assembly5.1.2 Minimum clearances• In order to be able to remove fans, heat exchangers, dropleteliminators, etc. and also perform servicing andmaintenance, a minimum clearance of one unit width mustbe maintained on the operating side.• A minimum clearance of 600 mm between the rear of the unitand the wall must be maintained if the internaldividing joint connectors cannot be used due to the unitconfiguration.Fig. 5-2:Minimum clearance5.1.3 Foundation construction for indoor installation• The subconstruction may project a maximum of 20 mm beyond the outer edge ofthe unit to facilitate the installation of cover panels or accessories, such as siphons.• The bearing points for the subconstruction must be located at every unit’s dividingjoint and the maximum distance between bearing points in the longitudinal directionmust not exceed 1600 mm.5.1.4 Foundation construction for outdoor installation (weatherproof, roof frame)NOTE!GEA units for outdoor installation are not a substitution for roof!In compliance with prEN 13053 and VDI 3803 it is not allowed to use surfacesof weatherproof units to support parts of a building or in a similar way substitutea roof.• Instructions for „Foundation construction for indoor installation“ on page 23 shouldbe applied.• Choose an installation location where the fresh air intake will not be facing the mainwind direction.• In areas where there is a heavy amount of snowfall, the unit must be installed in alocation where its operation will not be affected by snow. A suitable height for thesubconstruction must be selected.• If the unit is to be mounted on a roof, then the load-bearing capability of the roof andits supporting structure must be checked. Consult a structural engineer ifnecessary.• The roof edge below the unit, as well as ducts and other roof openings must beperformed waterproof by others.• The roof frame must be insulated to prevent condensation. For information oninstallation, see „Sample installation of single unit“ on page 30.• The units must be protected from excessive winds and appropriately secured byothers on site.PR-2009-0022-GB • Subject to modifications • Status 04/2009 25

Installation and AssemblyGEA COM4plusFig. 5-3:Foundation constructionon a concrete baseFig. 5-4:Foundation construction ona steam beam by othersFig. 5-5:Foundation construction on steel supports by othersNOTEParticular care must be taken to ensure compliance with the precise dimensionsof roof openings and to ensure that the foundation is level.5.1.5 Structure-borne sound attenuationIn order to reduce the transfer of vibrations from the unit to the supportingstructure, anti-vibration mounts and structure-borne sound attenuatingmats must be installed.– We recommend that the foundation is isolated from the unit using rubberplates, for example, where the unit is installed on level ground and no specialstructure-borne sound isolation requirements exist.– We recommend the use of commercially available spring elements for ceilingmounting.– For very special acoustic requirements please consult an acoustics engineerto select the most suitable structure-borne sound attenuation method.26 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusInstallation and Assembly5.2 Assembling the unitNOTEFor detailed information, please refer only to the documentation enclosed withthe unit. Data sheet, installation instructions, small parts and accessories suppliedloose can be found in the unit part specified in the parts list.DAMAGE TO THE UNIT!Fittings/attachments etc. not provided by the manufacturer that could cause aleak must not be mounted on the walls or frame of the unit. The unit’s operabilitymust be maintained.Tools required: – Electric screwdriver, drill– Holder for bits/sockets– Sockets, sizes 8, 10– Slotted head screw bits, sizes 2, 3– Open-ended spanners sizes 8, 13, 17– Screw drivers 4.5-6.5– Hexagon socket size 6– Tensioning belts or suitable hoisting device5.2.1 Removing transportation lugs/device/locks• All transportation lugs/device/locks marked yellow on and in the unit must beremoved prior to assembly.• Remove the transportation locks on the fan.Transport lug for roof• The transportation lugs on the roof must be removed.• Remove the screws on the end walls and secure thesupplied M8 x 70 screw.• Remove the lug, screw and bushing at the dividingjoint, then secure the supplied M8 x 30 screw.Plastic washerSupport bushingCylinder screwFig. 5-6:Transport lugs – roof, end wall anddividing joint• Remove the transport lug on the base frame.Fig. 5-7:Transport lug on base framePR-2009-0022-GB • Subject to modifications • Status 04/2009 27

Installation and AssemblyGEA COM4plusNOTETransportation lugs/device must not be used to suspend the units on a permanentbasis.Transportation lugs/device may be used only once.5.2.2 Installation of individual modulesTo assemble individual modules (dividing joint) proceed as follows:• Affix provided sealings to the dividing joint(speacial assembly instructions provided with the sealings).Fig. 5-8:Installing individual modulesDAMAGE TO THE UNIT!Do not attach tensioning belts/hoisting devices to heat exchanger connections,condensate drains and door handles or use these to pull or push the equipment!•• Position the unit parts as close to one another as possibleprior to assembly. Only use the unit base frame to pull theindividual components together. Units that do not have abase frame must be pulled together with tensioning belts.These must be positioned round the profiles in the base orroof area.Fig. 5-9:Unit with base frame28 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusInstallation and Assembly• First of all, screw the exterior dividing joint connectors together.• Mount caps.Fig. 5-10: Interior view• An additional dividing joint connector is provided in the middle of the profile(internally), where the internal unit width or height amounts to or exceeds 1280 mm,and must also be screwed tight.Fig. 5-11: Internal view• Seal pipe and cable ducts to prevent air leakage and condensation using PURfoam, for example (not included in GEA scope of supply).Fig. 5-12: Pipe ductAdditionally for double-deck/side by side units• Connect both unit parts at the pre-drilled positions using the provided plates.Fig. 5-13: Connectingunit partsPR-2009-0022-GB • Subject to modifications • Status 04/2009 29

Installation and AssemblyGEA COM4plus5.2.3 Additional procedures for outdoor units (weatherproof)DAMAGE TO THE UNIT!Defective insulation by others can lead to water leaking into the unit andcausing further damage. Insulate all components carefully.Roof installation of single, side by side units and Ecorot 1The roof installation of a single, side by side units and Ecorot 1 is similar. That is whya sample installation of single unit is shown below:1• Remove all transport lugs (1).• Use seal washers to tighten all screws.1123Installing cover panels and clamping profiles• Cover all dividing joints with clamping profiles (2).• Apply the glue evenly on all surface (3).• Slide on the cover panels (4).4• Make a concave groove in the glue (5).• Remove the last cramp (6) and seal this point with glue aswell.5 6Fig. 5-14: Sample installation of single unit30 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusInstallation and AssemblyRoof installation double deck unit• Use seal washers to tighten all screws.• Install cover panels and clamping profiles (1)as described in section „Installing cover panels and clampingprofiles“ on page 30.1Installing intermediate panel• Apply the glue evenly on all surface (2).2• Make a concave groove in the glue (3).• Screw the intermediate panel with front wall profile (4).34Fig. 5-15: Installing double deck unitPR-2009-0022-GB • Subject to modifications • Status 04/2009 31

Installation and AssemblyGEA COM4plusMounting cover panels and switch box hood for outdoor installation.Fig. 5-16: COM4plus outdoor installation1: Unit cover panels2: Switch box hood (fold-away)3: Cable duct4: Middle panel (with opening for switch box)32 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusInstallation of Components and Accessories6 Installation of Components and AccessoriesIn line with the connection of heat exchangers, humidifiers etc., the coil connectionmay only be carried out by specialists with the necessary knowledge of relevantaccident prevention regulations and other standard regulations relevantto health and safety in the workplace, based on their training and experience.DAMAGE TO THE UNIT!When mounting GEA CompactLine units care must be taken to ensure that noloads are applied to the floor panels. During installation work suitable measuresshould be taken to ensure that all loads are spread across the bottom profiles(e.g. using grid walkways).6.1 Prerequisites• Check the unit for external damage and check whether it has been properlyassembled and anchored.• Check whether anti-vibration and structure-borne sound attenuating mats havebeen provided. This means that either:– The foundation has been isolated from the unit using rubber plates (for example)where the unit is installed on level ground and no special structure-borne sound isolationrequirements exist;– or, in the case of ceiling mounting, commercially available spring elements havebeen used;– or, where very special acoustic requirements exist, an acoustics engineer has beenconsulted when selecting the most suitable structure-borne sound attenuationmethod.• Before you start with the coil connection, check the following:– Drain valves must be installed at all low points in the water system to ensure thatthe water circuit can be fully drained in order to carry out maintenance or repairs.– A water drain with shut-off valve must be installed in order to drain the unit’s watersystem.– Air vents must be installed at all the high points of the water system at easily accessiblelocations.• Ensure that the piping system is flushed through until it is clean by others and acleaning record compiled.6.2 Installation of air control and air conveying componentsIn order to prevent the transmission of structure-borne sound, a tension-free connectionbetween air ducts and the unit must be made using elastic connectorsor structure-borne sound attenuators(also refer to „Structure-borne sound attenuation“ on page 26).If you are connecting air ducts to the units via flexible connectors, the installation lengthof the connectors must be less than their extended length.PR-2009-0022-GB • Subject to modifications • Status 04/2009 33

Installation of Components and AccessoriesGEA COM4plus6.3 Installation of air handling components with coil connectionRecommendations on water quality for heat exchangers that operate using lowpressure hot water (LPHW) and chilled water:A good water quality – e.g. salt and lime-free drinking water – increases the lifetimeand efficiency of the heat exchanger.• Check the limiting values shown in the table annually to prevent damage to thehydraulic system and its components.If necessary inhibitors must be added.NoteThese limiting values areonly basic informationabout the water qualityand do not form anybasis for a guarantee!Description Symbol ValuesHydrogen ion concentration pH 7.5 − 9 < 7> 9Calcium and magnesiumcontentHardness(Ca/Mg)Effects in event ofdeviationCorrosionFouling4 − 8.5 °D > 8.5 FoulingChloride ions Cl – < 50 ppm CorrosionIron ions Fe³ + < 0.5 ppm CorrosionMagnesium ions Mg² + < 0.05 ppm CorrosionCarbon dioxide CO 2 < 10 ppm CorrosionHydrogen sulphate H 2 S < 50 ppb CorrosionOxygen O 2 < 0.1 ppm CorrosionChlorine Cl 2 < 0.5 ppm CorrosionAmmonia NH 3 < 0.5 ppm CorrosionRatio of carbons/sulphates HCO 3 ² - /SO 4 ² - > 1 < 1 Corrosion1/1.78 °D = 1 °Fr with 1 °Fr = 10 g CaCO 3 /m³ppm = parts per million (mg/l)ppb = parts per billion (μg/l)6.3.1 Installation of air handling components for cooling/heatingDAMAGE TO THE UNIT!When connecting the heat exchanger, counter force must be applied using pliersto prevent damage.The connections to the heat exchanger by others must always be tension-free.Mechanical and static loads must not be applied to the connecting piece.The heat exchanger must be connected in accordance with the counter flow principle(air and water heat exchanger flow in opposite directions).• Protect the surfaces of the fins in the heat exchanger from damage.• Connect pipe system by others to the water inlet and outlet. The inlet and outlet coilconnections are marked using adhesive labels.• Insulate pipes by others.Additional instructions for air handling components with cooling:• Insulate coil connections and pipes once the installation has been carried out toprevent the formation of condensation water. Condensate water that is formed accumulates in the stainless steel condensate trayand is drained via a drain spigot mounted on the condensate tray.• Install a siphon (see „Connecting siphon (trap) and water drains“ on page 35).34 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusInstallation of Components and AccessoriesAdditional instruction for units with fresh air or mixed air operation:DAMAGE TO THE UNIT!The heat exchanger in the unit must be protected from the formation of ice andfreezing at ambient temperatures below the freezing point.Use antifreeze in the water circuit if necessary.NOTEGlycol may be used if its concentration does not exceed 50 % of the total volume.A higher concentration can cause operating malfunctions.6.3.2 Installation of evaporator/condenserENVIRONMENTAL DAMAGE!Dispose of any liquid spills (refrigerant) in an environmentally sustainable mannerin accordance with the locally applicable laws and regulations.• Open and use the service connections using only special tools and fittings. The units are filled with protective gas that audibly discharges when the connectioncaps are removed.6.3.3 Connecting siphon (trap) and water drainsNOTEThe equipment must not be connected directly to the waste water system!Fill the siphon with water before commissioning and also following longer periodsof downtime.The hydraulic seal in the siphon H must be greater than themaximum overpressure or underpressure (mm WC) in theunit (1 mm WC = 10 Pa).The dimensioning is performed using the equation below:H( mmWC)=Unit over-/underpressure( Pa)------------------------------------------------------------------------------10Fig. 6-1:Siphon: overpressure in unitThe height difference between the water drain and hydraulicseal must also correspond to size H(mm WC).• Connect the siphon to the waste water system as shownin the illustration.2,5 HH1,5 HNOTE ON RISK OF FROST.If there is a risk of frost, the discharge pipemust be insulated and kept warm using aheating cable, for example.Fig. 6-2:Siphon: underpressure in unitPR-2009-0022-GB • Subject to modifications • Status 04/2009 35

Installation of Components and AccessoriesGEA COM4plusFig. 6-3:A siphon must be connected to each condensate drain or overflow pipe. Several discharge pipes must notbe routed to one shared siphon (* drain blocked).NOTEUnderpressure and overpressure siphons must be connected to separate collectingpipes (refer to Fig. 6-3).6.4 Installation of accessoriesRefer to the relevant documentation provided for descriptions of the assembly andinstallation of accessories or accessory parts by others.36 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusElectrical Connection7 Electrical ConnectionThe electrical connection may only be completed by a qualified licensed electrician.The qualified staff must have appropriate training, experience and sufficient knowledgeof the relevant accident prevention regulations as well as other generallyrecognized safety and occupational health regulations.Take protective measures.When installing and connecting the unit, protective measures for low-voltagesystems according to the EU Directive as well as regulations and codes of the localutility provider shall be observed.Ensure earthing and potential equalization of the individual sections and all connectedcomponents. Passive switch contacts may only be used in intrinsically safeelectric circuits.DANGER OF ELECTRICAL CURRENT!All power supply connections must be switched off and be voltage-free and securedagainst unintentional switching on. Failure to do so may lead to serious injury ordeath.NOTE:The cabling must be completed according to the enclosed unit-specific wiringdiagrams, documentation on the control system as well as national codes andregulations.Only separate mains power cable may be used. Never connect other units to thismains power cable.7.1 RequirementsVisual inspection ofmechanical components• Carry out a full visual inspection of the entire unit and installed components.• Before you start setting up the unit electrical connections, check the following:– The properties of the mains power supply must comply with EN 60204-1regulations and the power requirements of the unit.– The size of the backup fuse must be determined by a qualified electricianon the basis of the unit rated current.– The motors must be able to operate at their rated capacity where the input voltagewith rated frequency is between 95 % and 105 % of the nominal voltage.7.1.1 Running and routing cables on site by others• The installation of cable grommets and the routing of cables near doors, panels withsash fasteners, panel connections and cover strips should be avoided.• Screw/bolt connections and cable openings must not cause any leaks.• The connecting cables within the fan sections must be long enough to allow themotor to be moved without difficulty (e.g. for belt tightening).PR-2009-0022-GB • Subject to modifications • Status 04/2009 37

Electrical ConnectionGEA COM4plus7.2 Connecting unitEach assembly with an electrical connection must be earthed separately.7.2.1 Running electric linesWith separately supplied modules the pre-assembled electric lines are provided withplugs and wound in the fan (1) and sections (2).After the unit components are assembled the cables harnesses must be run throughthe provided openings in the unit switch cabinet.Running electric lines in the switch cabinet from the fan sectionFan section (1)Switch cabinet structureSwitch cabinet casing (3)Small flanged panel (4)Partition (7) Fan section (1)Filter section (2)Opening (5)FanFilterLarge flange panel (6)Switch cabinetwith controlsFig. 7-1:Running electric lines in the switch cabinet from the fan sectionThe cable harness from the fan section (1) is equipped with two flange panels ofdifferent size (4 and 6).• Run the cable harness with the smaller flange panel (4) through the opening (5) inthe partition (6) of the fan section.• Run the cables and the relevant plugs in the casing of the switch cabinet (3).• For sealing screw the flange panel with casing of the switch cabinet (3). The mountingis completed from the fan section through the opening (5) of the partition (7).• For sealing screw the large flange panel (6) with the partition (7) in the fan section.Running electric lines in the switch cabinet from the filter section• Run cables from the filter section (2) directly through the appropriate opening of theswitch cabinet.• For sealing of the filter section screw the flange panel directly with the switchcabinet casing.38 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusElectrical ConnectionRunning electric lines for supply voltageRear unit view:Openings for other electric lines (if necessary) (3)Opening for remotecontrol line (2)Opening for supply voltage line(power supply) (1)Filter sectionECOROTFan section• Run the electric lines for power supply from the unit rear into the switch cabinetassembly on the unit top:– the larger opening (1) is provided for power supply (3x400 V/N/PE/50 Hz)– the smaller opening (2) for remote control line– Openings for other possible lines by others (3) can be provided.Fig. 7-2:Running electric lines for supply voltage7.2.2 Connecting electric motorsSingle speed electric motorswith direct start:Single speed electric motorswith Y/Δ-start:For proper unit operation it is important that the unit is connected with the clockwiserotating field.• If necessary, check the rotating field using an instrument specifically designed forthis purpose.DAMAGE TO THE UNIT.Correct assignment of the phase sequence to the specified rotating direction mustbe checked before the motor is connected. In case of incorrect connection the motor/fan may be damaged.The terminals of AC motors are labelled in such a way that the alphabetical sequenceof the terminal designation U1, V1, W1 corresponds with the temporal sequence of thephases L1, L2, L3 (with clockwise rotation).The rotating direction can be reversed by exchanging two connecting cables:– Exchange the connecting cables, e.g. U1 and V1– Y-switch: exchange the connecting cables, e.g. U1 and V1– Δ-switch: exchange the connecting cables, e.g. U2 and V2Voltage fluctuations • Make sure that the supply voltage with mains frequency amounts tobetween 95 % and 105 % of the rated voltage. Only then motors can operate at theirrated output, otherwise they may be damaged.To carry out the connection, proceed as follows:• Connect the unit according to the wiring diagrams.PR-2009-0022-GB • Subject to modifications • Status 04/2009 39

Electrical ConnectionGEA COM4plus7.2.3 Service switchA lockable main isolator (circuit breaker) installed in the unit switch cabinet can be usedas a service switch. The wiring for service switches installed at the manufacturer’s isled to the motor7.2.4 Installing and connecting actuator motor• If a GEA actuator is pre-installed in the factory, connect the latter in accordance withthe actuator motor data sheet.• If other actuators are used - refer to the relevant documentation.7.2.5 Additional electrical components• Connect additional electrical components in accordance with the relevant provideddocumentation and wiring diagrams.40 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusCommissioning and Testing8 Commissioning and TestingNOTE!The data sheet and assembly instructions are located on the unit inside in the designatedposition! These documents must be removed prior to the commissioning.Several assembly groups and components must be commissioned separately. The relevantinstructions are listed in the following chapter.DANGER OF ELECTRICAL CURRENT!The following applies for all maintenance and cleaning work: the doors of the unitmay only be opened if the unit has been switched off and it is ensured that the powercannot be inadvertently energized.DANGER OF EXPLOSION RISK AREA!Particular attention must be paid to safety instruction and procedures for (electrical)installation of units operating in explosion risk areas. Failure to comply with theseregulations may result in explosions causing severe personal injury or material damage!DANGER OF ROTATING UNIT PARTSFans do not come to a standstill immediately if the unit is powered down. Beforemaintenance and cleaning you should wait for at least 5 minutes until the fans havecome to a standstill.DAMAGE TO THE UNIT.When mounting GEA CompactLine units it must be ensured that no loads are appliedto the bottom panels. During all installation and maintenance prcocedured appropriatemeasures must be taken to ensure that all load is spread across the bottom profiles(e.g. using grid walkways).Maintenance intervalsThe specified maintenance intervals apply for air with a normal level of contamination.The maintenance intervals must be reduced according to the level of air contamination.NOTE!More intensive cleaning should be carried out in case air contains oil. Sealant materialis oil-proof only for a limited time.Only use alcohol-based disinfectants.PERSONAL PROTECTION!Wear a mask and protective gloves when carrying out cleaning and specified maintenanceof the unit.PR-2009-0022-GB • Subject to modifications • Status 04/2009 41

Commissioning and TestingGEA COM4plus8.1 Basic cleaning and maintenance proceduresELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS! OBSERVEPERSONAL PROTECTION MEASURESPlease consider the safety instructions on page 41.• Using a dry cloth or an industrial vacuum cleaner, if necessary, to remove excessdirt.• Remove dirt that is left after the installation of add-on accessory parts.• Other contamination types: use a dry cloth to remove dirt or wash off using somewater with added alkaline cleaning agent if necessary.• Do not use abrasive cloths or tools that may scratch or scrape the protective surfaceduring cleaning.• Treat galvanized parts with a preservative spray.• Apply a lubricant spray to all moving parts, such as door levers and hinges exceptdampers and louvres.• Clean the seals on the inspection panels and check for leaks. It is recommended totreat seals with a waterproof preservative.• Check electrical connections.• Check earthing.8.1.1 Basic cleaning of finsELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS! OBSERVEPERSONAL PROTECTION MEASURESPlease consider the safety instructions on page 41.DANGER – SHARP CUTTING EDGES!Exercise due care when cleaning due to risk of cuts on tin and sharp edges.The fins must be cleaned to ensure that the heat exchanger continues to operate at fullcapacity. The cleaning can be carried out using a brush (not wire brush) or an industrialvacuum cleaner. Do not use hard or sharp cleaning tools!Use compressed air stream against airflow direction or water spray at low pressure toclean copper or aluminium fins.Steel galvanized heat exchangers or heat exchangers with reinforced fins may also becleaned using steam jet cleaning appliances.8.2 Maintenance interval checklistMaintenance intervals as defined by the European guidelines and standards (e.g. VDI6022) must be observed.ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITHSHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES!Please consider the safety instructions for all described maintenance procedurespage 41 and page 42!42 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusCommissioning and TestingUnit part Interval TaskUnits for indoor installation(refer topage 45)1 month • Clean and refill available siphons.3 months • Check casing for damage/correct seat.• Check/renew seals of all service openings.• Check panels for damage and corrosion, renew corrosion protection andcheck function of door safety catch (on discharge side).✓Units for outdoorinstallation(weatherproofunits for roof installationrefer topage 46)Direct driven fan(refer to page 47)Basic requirementsfor all filters(refer to page 47)Bag/panel/finedust filters (referto page 48)Heater section(warm waterpump) (refer topage 49)• Hygiene inspection (we recommend the maintenance steps and intervalsspecified in VDI 6022!): check built-in parts for contamination and clean asnecessary; carry out wipe disinfection; check seal materials for mould andfungi, clean/replace as necessary.• Carry out procedures listed under “units for indoor installation”.12 months • Check tightness of unit roof.• Check side panels and cover strips, reseal as necessary.• Check base frame and base cover panels.• Clean weather protection grille for fresh and extract air.3 months • Check fan motors for debris, damage and corrosion.• Check motors for noise in bearings, replace bearings if necessary.• Check impeller (especially welded seams) for cracks; replace bearings ifnecessary.3 months • Check filters for debris, damage and smell.• Clean filter section.6 months • Check if the maximum allowed pressure difference (refer to e.g. HVACGuideline RLT 01) or pressure difference specified by manufacturer isexceeded - in this case - replace filter.at leastevery 6-9monthscontinuousmeasurementreplaceevery 3months• Hygiene inspection (we recommend maintenance procedures and intervalsspecified in VDI 6022!): Even if the filter shows no visible signs ofcontamination, fungi and mould may propagate through the filter during longtermuse (in air with low dust content).• Replace the filter when the maximum pressure difference is reached.12 months • Check for tightness and possible debris on the air side.• In case of frost risk check the safety devices regularly, or take appropriateprecautions such as draining the equipment or adding antifreeze agents.• Make sure that pipe connections and mountings are secure.• Clean on air side as necessary (blow through heat exchanger usingcompressed air or low pressure water).• Provide air venting.PR-2009-0022-GB • Subject to modifications • Status 04/2009 43

Commissioning and TestingGEA COM4plusUnit part Interval TaskCooler with/withoutdroplet eliminator(refer topage 50)Cooler with/withoutdroplet eliminator(refer topage 50)Evaporator (referto page 51)Rotation heatexchanger (refer topage 52)Dampers and shutoffdampers (referto page 53)Sound attenuator(refer to page 53)12 months • Check for tightness and possible debris on the air side.Beforeeachwinter• In case of frost risk check the safety devices regularly, or take appropriateprecautions such as draining the equipment or adding antifreeze agents.• Make sure that pipe connections and mountings are secure.• Clean on air side as necessary (blow through heat exchanger usingcompressed air or low pressure water).• Provide air venting.• Clean condensate tray/drain.• Check siphon/trap, top up as necessary.• Clean droplet eliminator with descaling spray.• Drain cooling coil before each winter if necessary.12 months • Clean and check evaporator/condenser.• Make sure that all refrigeration components in direct evaporators(refrigeration cycle, direct evaporator, distribution manifold, refrigerant lines,etc.) are functioning efficiently.3 months • Check tension of drive belt, tighten as necessary.12 months • Clean heat exchanger fins – wet cleaning may only be carried out with aninstalled tray – never clean the heat exchanger fins with high pressure wateror steam.• Remove dirt from the section.• Check proper operation of damper where energy recovery system withbypass configuration is used.• Check peripheral gasket, adjust as necessary.• Check motor alignment.6 months • Vacuum clean dampers (blow out), never apply grease!• Detach the drive from the dampers and check dampers for ease ofmovement.• Check that the drive (damper actuator) reaches its end positions.6 months • Check the sound attenuator section and sound insulating splitters forcontamination, clean as necessary.✓44 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusCommissioning and Testing8.3 Unit in general8.3.1 Commissioning of units for indoor installationThe following procedures for commissioning must be carried out:• Carefully check the entire casing and components for damage and firm seat:– Doors and service openings– Seals and gaskets– Handles and levers– Connections with foam rubber seals– Inspection windows– Panels• Remove protective film, if present.• Remove all transportation locks.• Make sure that there are no loose items inside the unit.• Check that the unit is airtight.• Clean the unit as described in „Basic cleaning and maintenance procedures“ onpage 42.8.3.2 Maintenance of units for indoor installationELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS! OBSERVEPERSONAL PROTECTION MEASURESPlease consider the safety instructions on page 41.The following procedures for maintenance must be carried out:• Carefully check the entire casing and components for damage and firm seat:– Doors and service openings– Seals and gaskets– Handles and levers– Connections with foam rubber seals– Inspection windows– PanelsDoors and service openings• Check seal and gaskets, replace if necessary.• Check proper operation of door stop device (on pressure side).Panels• Check for damage and corrosion.• If necessary, renew or apply new corrosion protection (paint) impregnate, etc.Syphon/trap• Clean and refill available siphons.Hygiene inspectionObserve current codes andstandards! We recommendmaintenance proceduresand intervals specified in VDI6022 or current regulations.• Check installed components for contamination, clean as necessary.• Carry out disinfection (disinfectant must not attack cleaned materials, only usealcohol-based disinfectant).• Check the sealing materials for mould and fungi. Clean or replace the sealingmaterials as required.PR-2009-0022-GB • Subject to modifications • Status 04/2009 45

Commissioning and TestingGEA COM4plus8.3.3 Commissioning of units for outdoor installation (weatherproof roof units)The following procedures for commissioning must be carried out:• First carry out all procedures as described in „Commissioning of units for indoorinstallation“ on page 45.• Checks weatherproof seals (refer to „Foundation construction for outdoorinstallation (weatherproof, roof frame)“ on page 25).8.3.4 Maintenance of units for outdoor installation (weatherproof roof units)The following procedures for maintenance must be carried out:• First carry out all procedures as described in „Maintenance of units for indoorinstallation“ on page 45.• Check tightness of unit roof.• Check side panels and cover strips and renew the seal material in individualcomponents.• Clean weather protection grille for fresh and extract air once a year.Hygiene inspectionObserve current codes andstandards! We recommendmaintenance proceduresand intervals specified in VDI6022.• Check installed components for contamination, clean as necessary.• Carry out disinfection (disinfectant must not attack cleaned materials, only usealcohol-based disinfectant).• Check the sealing materials for mould and fungi. Clean or replace the sealingmaterials as required.8.4 Fan unit and drives8.4.1 Commissioning of fan unitELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS! OBSERVEPERSONAL PROTECTION MEASURESPlease consider the safety instructions on page 41.DAMAGE TO THE UNIT!Do not start up the fan against closed dampers.The following procedures for commissioning must be carried out:• In general check the entire casing and all components for damage and correct seat.• Remove transportation locks.• Check the fan rotation direction at all speed stages.• Measure the motor power consumption. The rated motor current as specified on theidentification plate may not be exceeded in any operating state.• Ensure the proper operation of the motor protection device.• Check and open all system components (air control and shut-off dampers, fireprotection dampers, flow rate controller), ensure their proper operation.46 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusCommissioning and Testing8.4.2 Maintenance of direct driven fanELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS!Please consider the safety instructions on page 41.The following procedures for maintenance must be carried out:• Check electric motors for debris, damage and corrosion and correct mounting.• Check electric motors for noise in bearings, have bearings replaced by specialistpersonnel if required.• Check impeller, especially welded seams for possible cracks; have bearingsreplaced by specialist personnel, if necessary.8.5 Filter sections8.5.1 Commissioning of filter sectionELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS! OBSERVEPERSONAL PROTECTION MEASURESPlease consider the safety instructions on page 41.The following procedures for commissioning must be carried out:• Check filter section and installed filters for damage.• Check that the filter section is correctly seated in the mounting frame.• If required, clean the filter section and system components in the airflow directionbefore the filter to remove installation dust.• The air handling unit and air ducts must be cleaned again before F9 filters andhigher are installed.• Put the fan into operation and record the initial pressure difference shown on thedisplay (if available).8.5.2 Basic maintenance procedures for all filtersELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS! OBSERVEPERSONAL PROTECTION MEASURESPlease consider the safety instructions on page 41.DANGER OF INFLAMMABLE SUBSTANCES!The filter material can be inflammable and may easily catch fire. Depending on thefiltered substances the risk of fire can increase. Keep filters away from open fire!NOTE!We recommend that you never operate the system without a filter and always keepa set of spare filters on stock. Ensure that the filter surface is not damaged as thiscan cause the filter to tear during operation which means that the filter class can nolonger be guaranteed.ENVIRONMENTAL DAMAGE!Heavily contaminated filters pose a health risk and may adversely affect productionprocesses. Depending on the filtered substances contaminated filters may need tobe treated as special waste and therefore disposed of in an environmentally friendlymanner and in accordance with current codes and regulations.PR-2009-0022-GB • Subject to modifications • Status 04/2009 47

Commissioning and TestingGEA COM4plusIn general and depending on the operating conditions, all filters must be checked atregular intervals and replaced if necessary. The following procedures for maintenancemust be carried out:• Check filters for debris, damage and smell.• Clean filter section.• Check if the maximum allowed pressure difference (refer to HVAC Guideline RLT01) or pressure difference specified by manufacturer is exceeded - in this casereplace the filter.Hygiene inspectionObserve current codes andstandards! We recommendmaintenance proceduresand intervals specified in VDI6022 or your country-specificregulations.Even if the filter shows no visible signs of contamination, fungi and mould may propagatethrough the filter during its long-term use (in air with low dust content).• The filters must be replaced regularly (at least every 6-9 months), even ifcontamination is barely visible.8.5.3 Maintenance of bag filters/panel filters/fine-dust filtersELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS! OBSERVEPERSONAL PROTECTION MEASURESPlease consider the safety instructions on page 41.The following procedures for maintenance must be carried out:• Check filter and filter frame for dirt, corrosion and damage, replace if necessary.The final pressure difference of the bag filter varies and can be obtained from the relevanttechnical data (refer to filter identification plate).• Replace the filter when the maximum pressure difference is reached.Replacing filter medium• Open the service door/panel when the unit is deactivated• Open the retaining brackets at the top and bottom guide rails or open the quickreleasefilter frame.• Pull out the filter frame.• Replace the damaged or dirty filter.• Insert the filter frame. Make sure the filter seat is air-tight!• Close the retaining brackets at the top and bottom guide rails or close the quickreleasefilter frame.• Bag filters may only be mounted in the upright position!• Close the service door/panel.48 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusCommissioning and Testing8.6 Heater section8.6.1 Commissioning of heater section (LPHW)ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITHSHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES!Please consider the safety instructions on page 41 and page 42.The following procedures for commissioning must be carried out:Requirement: • Check proper connection and operation of water inlet and outlet.• Counter flow principle with water inlet on the air discharge side.• Check proper installation of shut-off devices and other fixtures.Commissioning: • Open air vents if automatic air vents are not installed.• Charge the system starting at the lowest point to prevent air cushions and watersurges.• Open air vents slightly and wait until water fills the heat exchanger.• Open air vents fully.• Close air vents; if the levels are different - close air vents gradually until air-freewater runs out.• Switch on primary and secondary pump, check rotating direction and let the systemoperate for enough time.• Reverse the position of the control valves (three-way valves).• Perform another check by opening the air vents again.• Check if the system is air-tight.• Regulate the operation of the frost protection switch to prevent over-conditioning.8.6.2 Maintenance of heater section (LPHW)ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITHSHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES!Please consider the safety instructions on page 41 and page 42.The following procedures for maintenance must be carried out:• Check for tightness and possible debris on the air side.• In case of frost risk check the safety devices regularly, or take appropriateprecautions such as draining the equipment or adding antifreeze agents.• Make sure that pipe connections and mountings are secure.• If necessary clean on air side (blow through heat exchanger using compressed airor low pressure water).• Provide air venting.The following procedures for maintenance must be carried out:• Check for tightness and possible debris on the air side.• In case of frost risk check the safety devices regularly, or take appropriateprecautions such as draining the equipment or adding antifreeze agents.• Make sure that pipe connections and mountings are secure.• If necessary clean on air side (blow through heat exchanger using compressed airor low pressure water).• Check proper operation of steam inlet and condensate drain.• Provide air venting.• Check control functions if available.PR-2009-0022-GB • Subject to modifications • Status 04/2009 49

Commissioning and TestingGEA COM4plus8.7 Cooler section8.7.1 Commissioning of cooler section with/without droplet eliminatorELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITHSHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES!Please consider the safety instructions on page 41 and page 42.The following procedures for commissioning must be carried out:For droplet eliminator• Clean condensate tray and drain.• Fill trap with water, refer to „Connecting siphon (trap) and water drains“ on page 35;as a minimum requirement the water receiver for the trap must always correspondto the overpressure/low pressure of the unit.The droplet eliminator (DE) reaches its full operating limits once the separating agentvolatizes after a start-up phase amounting to around 4 weeks.• If necessary, clean the droplet eliminator by rinsing with water.• Dust with lime if necessary.In case the operating performance of the droplet eliminator is insufficient:• Ensure that the installation position of the droplet eliminator is correct:• Check the air flow velocity through the droplet eliminator.Standard DE w max =3.8 m/sDE (droplet eliminator) 100 High-performance w max =5.8 m/s8.7.2 Maintenance of cooler with/without droplet eliminatorELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITHSHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES!Please consider the safety instructions on page 41 and page 42.The following procedures for maintenance must be carried out:• Check for tightness and possible debris on the air side.• In case of frost risk check the safety devices regularly, or take appropriateprecautions such as draining the equipment or adding antifreeze agents.• Make sure that pipe connections and mountings are secure.• If necessary clean on air side (blow through heat exchanger using compressed airor low pressure water).• Provide air venting.• Clean condensate tray and drain.• Check siphon/trap, top up as necessary.• Clean droplet eliminator with descaling spray.Additional measures before cold season• Drain cooling coil before each winter if necessary. As the piping in this case has arelatively small diameter, it must always be assumed that some water remains inthe unit following normal drainage. For safety reasons, the system must also beblown through with compressed air to remove all remaining water.50 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusCommissioning and Testing8.8 EvaporatorNOTE!The following procedures and all necessary repairs may only be carried out by refrigerationengineering personnel!Observe the relevant standards and regulations regarding refrigerants.8.8.1 Commissioning of evaporatorELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITHSHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES!Please consider the safety instructions on page 41 and page 42.DAMAGE TO THE UNIT.Ensure that the evaporator or condenser is never exposed to ambient temperaturesexceeding 60 °C (e.g. as a result of fan shutdown and/or water temperatures (heatingcoil) > 60 °C).The following procedures for commissioning must be carried out:• During connections protective gas charge must be available.• Check proper connection and operation of water inlet and outlet.• Check proper installation of shut-off devices and other fixtures, counter flowprinciple with medium inlet on the air discharge side.• Make sure that pipe connections and mountings are secure.• Charge the refrigeration circuit with a medium specifically designed for the system.• Check if the system is air-tight.• Check proper operation of safety valves.• Check the maximum temperature and pressure of the operating system(particularly with R410A refrigerant)Saturation temperature = 60 °C/Burst pressure: 38 bar.8.8.2 Maintenance of evaporatorELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITHSHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES!Please consider the safety instructions on page 41 and page 42.The following procedures for maintenance must be carried out:• Clean and check the evaporator as described in „Maintenance of heater section(LPHW)“ on page 49.Direct evaporator • Make sure that all refrigeration components in direct evaporators (refrigerationcycle, direct evaporator, distribution manifold, refrigerant lines, etc.) are functioningefficiently.PR-2009-0022-GB • Subject to modifications • Status 04/2009 51

Commissioning and TestingGEA COM4plus8.9 Rotation heat exchanger8.9.1 Installation arrangement of rotation heat exchanger in air handling unitsSupply airExhaust airFig. 8-1:The ECOROT energy recovery system is always mounted on suction side ofCOM4plus units.8.9.2 Commissioning of rotation heat exchangerELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITHSHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES!Please consider the safety instructions on page 41 and page 42.The following procedures for commissioning must be carried out:• Check tension of drive belt, tighten if necessary.• Check rotating direction.• Check position of flush sections.• Check seals for correct position.• Check peripheral gasket, adjust as necessary.• Check motor alignment.• Check correct operation of dampers where energy recovery system with a bypassconfiguration is used (refer to „Maintenance of louvres, dampers and shut-offdampers“ on page 53).8.9.3 Maintenance of rotation heat exchangerThe following procedures for maintenance must be carried out:ELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS WITHSHARP EDGES! OBSERVE PERSONAL PROTECTION MEASURES!Please consider the safety instructions on page 41 and page 42.• Use a vacuum cleaner to clean heat exchanger fins regularly – wet cleaning mayonly be carried out with an installed tray – never clean heat exchanger fins with highpressure water or steam.• Remove dirt from the section.• Check correct operation of dampers where energy recovery system with a bypassconfiguration is used (refer to „Maintenance of louvres, dampers and shut-offdampers“ on page 53).• Check peripheral gasket, adjust as necessary.• Check tension of drive belt, tighten if necessary.• Check motor alignment.52 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusCommissioning and Testing8.10 Louvres, dampers and shut-off dampers8.10.1 Commissioning of louvres, dampers and shut-off dampersELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS! OBSERVEPERSONAL PROTECTION MEASURESPlease consider the safety instructions on page 41.The following procedures for commissioning must be carried out:• If several dampers are linked together, ensure that the linkage is seated correctlyand check for ease of movement.• Check all screw connections for firm seat.For actuators • Adjust the linkage so that a rotation angle of 90° is ensured and dampers reach theirfinal position when closed (observe tightening torques).• Check that the drive (damper actuator) reaches its end positions.8.10.2 Maintenance of louvres, dampers and shut-off dampersELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS! OBSERVEPERSONAL PROTECTION MEASURESPlease consider the safety instructions on page 41.The following procedures for maintenance must be carried out:• Vacuum clean dampers (blow out), never apply grease!• Detach the drive from the dampers and check dampers for ease of movement.• Check that the drive (damper actuator) reaches its end positions.8.11 Sound attenuator8.11.1 Maintenance of sound attenuatorELECTRICAL HAZARD AND DANGER OF ROTATING UNIT PARTS! OBSERVEPERSONAL PROTECTION MEASURESPlease consider the safety instructions on page 41.The following procedures for maintenance must be carried out:• Check the sound attenuator section and sound insulating splitters forcontamination, vacuum clean, if necessary.PR-2009-0022-GB • Subject to modifications • Status 04/2009 53

Disassembly and DisposalGEA COM4plus9 Disassembly and DisposalENVIRONMENTAL DAMAGE!Only appropriately trained staff may dismantle and dispose of the unit!9.1 DismantlingTo dismantle the unit proceed as follows:DANGER OF ELECTRICAL CURRENT!When carrying out any decommissioning and dismantling work on the unit, switch offall power supply connections, ensure the power cannot be inadvertently energizedand verify that they have been disconnected. Earth and short-circuit them, and coveror otherwise isolate any neighbouring live parts. Failure to do so may lead to seriousinjury or death.• Make sure that the hydraulic circuit is switched off.• Close all hydraulic shut-off valves.• Isolate all connections, at the same time ensure that there are no leakages of suchmaterials as oil, refrigerant and water-glycol mixture. As the piping in this case hasa relatively small diameter, it must always be assumed that some water remains inthe unit following normal drainage. For safety reasons, the system must also beblown through with compressed air to remove all remaining water.• Release the fixing to the base or wall.PERSONAL INJURYSecure the unit against slipping. The unit is ready for transporting.• Please observe all instructions in section „Transportation“ on page 20.9.2 DisposalAn appropriately authorized technical services department shall dispose of the unitor individual components. This technical services department shall ensure that:– the components are separated according to material types– the used operating materials are sorted and separated according to their respectiveproperties.ENVIRONMENTAL DAMAGE!• Dispose of all components (e.g. filters) and materials (e.g. oil, refrigerant andwater-glycol mixture) in an environmentally friendly manner in accordance withthe local codes, practices and environmental regulations.54 PR-2009-0022-GB • Subject to modifications • Status 04/2009

GEA COM4plusTroubleshooting10 TroubleshootingThe repair procedures may only be completed by a qualified licensed electrician. Thequalified staff must have appropriate training, experience and sufficient knowledgeof the relevant accident prevention regulations as well as other generally recognizedsafety and occupational health regulations.Due to the wide variety of built-in components and special applications, a simple plancontaining information on troubleshooting and remedy measures cannot be provided.Therefore contact your supplier regarding maintenance and repairs.PR-2009-0022-GB • Subject to modifications • Status 04/2009 55

Customer proximity, sales structuresReachable always and everywhere!ABBGBIHBYCHCZCZDDGEA KlimatechnikGmbH & Co KGA-4673 GaspoltshofenTel. +43 / 7735 / 8000-0GEA Happel Belgium N. V.B-1130 BrusselsTel. +32 / 2 / 2406161EVISS Ltd.BG-7000 RousseTel . +359 / 82 / 81000GEA KlimatechnikGmbH & Co KGRS-11070 Novi BeogradTel. +381 / 11 / 3193955GEA Klimatechnik UABLT-01141 VilniusTel. +370 / 5 / 2106060ATC Klimatec Schweiz AGCH-3065 Bolligen-StationTel. +41 / 31 / 9171919GEA LVZ, a.s.CZ-46312 LiberecTel. +420 / 48 / 5225-111GEA Klimatizace spol. s r.o.CZ-46312 LiberecTel. +420 / 48 / 5225-303GEA HappelKlimatechnik GmbHD-44625 HerneTel. +49 / 2325 / 468-00GEA HappelWieland GmbHD-44625 HerneTel. +49 / 2325 / 468-754DDDKEESTFFFINGBGEA DelbagLufttechnik GmbHD-44625 HerneTel. +49 / 2325 / 468-700GEA Delbag-LuftfilterVertriebsgesellschaft mbHD-10709 BerlinTel. +49 / 30 / 43592-3GEA Klimateknik ApSDK-2610 RødovreTel . +45 / 38 / 887070GEA Air TreatmentMarketing Services Int.GmbH – oficina EspañaE-28036 MadridTel. +34 / 91 / 3837701GEA Klimatechnik UABLT-01141 VilniusTel. +370 / 5 / 2106060GEA DelbagFiltration d l‘airF-77450 MontryTel. +33 / 1 / 60043355GEA Happel France sarlF-59436 Roncq CedexTel. +33 / 3 / 20689020OY TEKNOCALOR ABFIN-01300 VantaaTel. + 358 / 9 / 82546020GEA Denco Ltd.UK-HR4 8DS HerefordTel. +44 / 1432 / 277 277HHRIEISLLTLVMWENNLGEA Klimatechnika KftH-1037 BudapestTel. +36 / 1 / 4393200GEA Klima-rashladnatehnika d.o.o.HR-10000 ZagrebTel. +385 / 1 / 6064900Aspect Environmental Ltd.Ardee, Co. Louth IrelandTel. +353 / 41 / 6858983Rafn JenssonIS-110 ReykjavikTel. +354 / 56 / 780-30GEA Happel LuxembourgL-4940 BascharageTel. +352 / 26 / 502970GEA Klimatechnik UABLT-01141 VilniusTel. +370 / 5 / 2106060GEA Klimatechnik UABLT-01141 VilniusTel. +370 / 5 / 2106060GEA KlimatechnikGmbH & Co KGRS-110 70 Novi BeogradTel. +381 / 11 / 3193955GEA Klimaprodukter ASN-0484 OsloTel. +47 / 220 / 27990GEA Happel Nederland B.V.NL-2909 LLCapelle a/d IjsselTel. +31 / 10 / 2350606PPLRORUSSSKSLOSRBTRUANónio, Lda.P-1269-090 LisboaTel. +351 / 21 / 3826160GEA Klimatyzacja Sp. z o.o.PL-54610 WroclawTel. +48 / 71 / 3737952GEA Klimatechnik s.r.l.RO-300222 TimisoaraTel. +40 / 356 / 423703GEA KlimatechnikGmbH & Co KGRU-105094 MoskvaTel. +7 / 495 / 9566674GEA EXOS Ventilation ABS-74528 EnköpingTel. +46 / 171 / 85530GEA Klimatizácia s.r.o.SK-83104 BratislavaTel. +421 / 7 / 44457917GEA KlimatizacijskaTehnika d.o.o.SI-1000 LjubljanaTel. +386 / 1 / 2573850GEA KlimatechnikGmbH & Co KGRS-11070 Novi BeogradTel. +381 / 11 / 3193955GEA ISISANTR-80700Balmumcu IstanbulTel. +90 / 212 / 2757171GEA Ukraina t.o.v.UA-01135 KyivTel. +38 / 044 / 4619356The complete addresses are available on theInternet under: www.gea-air-eco2nomy.com.moJOMMVJMMOOJd_=•=pìÄàÉÅí=íç=ãçÇáÑáÅ~íáçåëPR - xxxx -xxxx - xxx • Subject to modificationpí~íìë=MQLOMMV=•=`çéóêáÖÜí=db^=^áê=qêÉ~íãÉåíIssue xx/ xxxx • Copyright GEA Air Treatmentwww.gea-air-eco2nomy.com