Al Ko Air Handling Units Catalog 2011

AIr-hAndlIng-unIts

AL-KO – QUALITY FOR LIFE

I Living for indoor-air-quality

AL-KO AIR-HANDLING-UNITS

I Air-handling-unit AT4 – optimised

by functionality and quality

I Quick selection air-handling-units AT4

I Integrated cooling and heat-pump technology in

air-conditioning-units with control technology

I Air-handling-units AT6 (big air-volumes)

I Air-handling-units for the chemical /

pharmaceutical sectors

I Air-handling-unit AT4 compliant

with EU guideline ATEX 95

I Air-handling-units AT4 with smoke-discharge function

I AT4-T air-handling in tropical design

I POOLAIR® climatisation and

dehumidifi cation of indoor swimming halls

I AT4 marine air-handling-units

AL-KO HUMID-OFF®

I Energy-effi cient climatisation and dehumidifi cation

AL-KO HOSPITAIR® (HYGIENIC APPLICATION)

I AT4 hygienic application according

to guideline VDI 6022

AL-KO AFTER SALES/SERVICE

I AL-KO Acceptance tests

AL-KO COMPACT DESIGNED AIR-HANDLING-UNITS

I EASYAIR ®

I EASYAIR® fl at (will be launched 2011)

AL-KO PROCESS AIR-HANDLING

I Air-handling AT4 – painting and drying

AL-KO SAVE ENERGY AND “LIFE-CYCLE-COSTS”

I The reduction of “Life-Cycle-Costs”

is a question of foresight

I Simple selection of air-handling-units with calculation

of “Life-Cycle-Costs”

I Optimized air-handling-units with high energy-cost-

saving by heat-pump-technology

I Energy-recovery-systems

AL-KO CONTROL-SYSTEMS FOR AHU‘S

I Energy effi cient control systems for ventilation

and air-conditioning-units

AL-KO AIR HEATER AND AIR COOLER

I New generation of air heating and air cooling

ZERTIFICATES

TABLE OF CONTENTS

LIVING FOR INDOOR-AIR-QUALITY

PREISENTWICKLUNG VON ÖL

AL-KO KOBER GROUP

2

The AL-KO KOBER GROUP is a fi nancially strong concern,

operating globally with more than 4 200 employees at 51 sites.

In the core business areas of automotive engineering,

Garden+Hobby and ventilation and air-conditioning technology,

AL-KO belongs to the market leaders.

AL-KO ventilation and air-conditioning technology is a world-

wide specialist for air-handling-units. Thereby, the newest

technologies, consistent highest quality and delivery reliability,

as well as the implementation of customer-specifi c require-

ments, are the basis of our success.

AL-KO

AUTOMOTIVE

AL-KO

DAMPING TECHNOLOGY

AL-KO

AMC CHASSIS

AL-KO

TRAILER COMPONENTS

3

AL-KO

INDUSTRIAL COMPONENTS

AL-KO

PLASTIC TECHNOLOGY

AL-KO

GARDEN+HOBBY

AL-KO

EXTRACTION TECHNOLOGY

AL-KO ventilation and air-conditioning technology

4

Walter Mayer, Vice-President Sales

We develop the best solutions for the air-conditioning requirements of our

customers. The development of energy-effi cient technology for environmental

relief and cost reduction for the operating companies are in the forefront.

5

We provide a perfect climate and, therefore, also

for quality of life – with individual, effi cient and

ecological air-handling conceptions that distinguish

themselves through the newest technologies,

quality and reliability. Aligned to the individual

customer requirements, we develop sophisticated

high-tech air-handling for best indoor-air-quality in

offi ce buildings or hospitals, precisely conditioned

air in production plants, as well as effi cient solu-

tions for large industrial or recreational complexes.

Details at a glance – in the interest of our customers

6

Our engineers develop the most energy

effi cient air-conditioning system solution for

your application.

7

Quality

We offer highest quality to the professional planner

of ventilation and air-conditioning-units as well as the

general contractors in manufacturing and logistics

processes and much competency in engineering with

regard to ventilation and air-conditioning technology.

As entrepreneur, AL-KO offers the investors, construc-

tors and operators of buildings energy effi cient and,

therefore, economic ventilation and air-conditioning

technology. This seldom means higher investment

costs – AL-KO engineers have an eye for the details.

Integral thinking for more customer benefi ts

8

I AL-KO planning competence

You can count on us. We assist you

in your demand analysis and planning

your air-handling projects.

Lean back …

… we assist your effi cient planning

I AL-KO project planning

Our competent project team

assists you in implementing your

air-handling project. From com-

ponent parts to complete system

solutions – we are by your side.

9

I AL-KO engineering competence

Our competent engineering-teams

transpose your individual require-

ments with innovative AL-KO

technologies, down to the smallest

detail.

I AL-KO Manufacturing

Our specialists manufacture your

individual ventilation and air condi-

tioning units quickly and effi ciently,

in proven AL-KO quality, on state-

of-the-art manufacturing lines.

I AL-KO Service and

commissioning

Do not make comprises and trust

the capabilities of AL-KO for service

and commissioning of your air-

handling-units. We are there for

you world-wide.

Energy effi cient buildings and building techniques

require an integral approach in planning, engineering,

project planning. Effi cient system solutions evolve

from the selection of the best suppliers and the

complementary technologies and lead to higher

customer satisfaction.

The planner converse with each other in order to

plan the most effi cient technology. With AL-KO, the

planner fi nds the competent partner for ventilation

and air-conditioning.

Optimized systems save energy and costs

10

I Low “Life-Cycle-Costs” = “SAVE ENERGY”

I “SAVE ENERGY” = “SAVE MONEY” + “SAVE CO2-EMISSIONS”

As a result, companies, constructors and investors profi t. Therefore,

it is necessary to consider the following costs – especially for primary

energy, but also for maintenance. Then, it has been shown that high

quality technology and optimized system confi gurations contribute to

signifi cantly reduce the annual energy costs – and this only restriction

of the ventilation and air-conditioning functions.

technology are the basis for energy

effi cient ventilation and air-condi-

tioning.

Energetic non-optimized air-condi-

tioning is one of the main primary

energy consumers in buildings and,

therefore, cost driver. In order to

counter this cost explosion, bid ma-

nagement in accordance with low

“Life-Cycle-Costs” is necessary.

Competence and innovations deve-

lop through highly qualifi ed staff, as

well as target-oriented research and

development that fulfi ll the present

and future market requirements. For

this, the analysis of the “Life-Cycle-

Costs” and optimization also count

to that effect. The interdisciplinary

combination of control units, cooling

and heating pump technology with

the ventilation and air-conditioning

11

Prof. Dr.-Ing. Michael Haibel, University of Applied Sciences Biberach,

worldwide renowned expert for technique building, ventilation and

air-conditioning technology and energy systems.

Consultant to the departments “research & development” as well as “business

development” of AL-KO Air-Technology.

Air-conditioning technology for the greatest demands – Chemical /Pharmaceutical

12

CHEMIE/PHARMA

13

Production reliability through the highest air-

conditioning quality: Chemical and pharmaceutical

development and production processes place high

demands on the ventilation and air-conditioning

systems concerned, with regard to safety, preci-

sion, reliability and stability.

EXCERPT FROM THE REFERENCES

14

We supply branch-specifi c solutions for industry,

because we know the industrial processes very

well. Our industrial units stand for a high degree

of robustness and, thus, provide reliability for your

production. Furthermore, effi ciency as the basis

of profi t and competitiveness for industrial enter-

prises stands in the forefront.

Industrial air-conditioning and process ventilation technology – effi ciency in the forefront

Process ventilation technology –

suitable concepts for painting and drying

Your optimum production process is our motivation. Specially designed

for application in the spraying and drying booths as well as for drying

plants for grain, tobacco and wood treatment, AL-KO manufactures appli-

cable process ventilation units.

INDUSTRY

15


Marine – top class ship climatisation

16

MARINE

17

Besides the different air ratios in cabins, restau-

rants, theatres, wellness-centres and casinos,

the different specifi c climatic conditions of the

continents visited also place high demands on the

ventilation and air-conditioning-units. For many

years we feel at home in this special discipline of

air conditioning technology and supply perfectly

balanced maritime air-conditioning systems.


In indoor swimming halls there is a high degree of

humidity. People fi nd a highly humid atmospheric

environment unpleasant. Furthermore, the building

can incur extensive damage.

Here, AL-KO provides a remedy. AL-KO air-conditioning-

units dehumidify, heat and ventilate every type of

indoor swimming halls and their adjoining rooms.

Swimming hall climate control –high technology in demand

18

With our efficiently operating venti-

lation and air-conditioning-units, we

provide for optimum humidity and,

therefore, for an optimum climate in

all indoor pools.

SWIMMING POOL CLIMATE CONTROL

19


ATEX – explosion protection for the highest safety

20

ATEX – EXPLOSION PROTECTION

The explosion protection of our units is committed

to a maximum protection function. Reliability and

employee safety always have priority. The design of

our units consistently conforms to the EU Guideline

ATEX 95 (100a) for the intended use in potentially

explosive rooms and buildings or for the general

increase in safety of injuries to persons or damage

to property.

21


22

Highest reliability for reduced investment costs for

building technique: Ventilation units can be used for

smoke removal in the event of a fi re in buildings with

a sprinkler system. That saves space and investment

costs! However, the increased safety of occupants

of the premises is defi nitely at the forefront.

© FFMichaeliburg

Smoke removal – the reliable solution in the event of an emergency

SMOKE REMOVAL

23


Hygiene – a supreme discipline

24

I unconditional implementation

of greater hygienic demands

I best room air quality enhances

patient convalescence and staff

productivity

“AL-KO HospitAir” –

perfect air-conditioning for clinics

I complete solutions from one

source reduce investment costs

I signifi cant reduction of the

energy and operating costs

We design, produce and deliver ventilation and

air-conditioning-units in hygienic construction in

accordance with VDI 6022. This sensitive area

of clean room technology requires leading-edge

Knowhow – one of our supreme disciplines.

25

REFERENCES

26

Air heater and cooler for shops, industrial and production facilities.

Besides the standard version for industrial use, AL-KO has developed a new

generation of air heaters and air coolers that are suitable for the greater demands

on architecture and room design. Ventilation and air-conditioning technology

as an element of the interior architecture.

Air heating and air cooling units

Our air heater is, therefore, also the preferred recognized application in

all localities with customer access, such as, e.g. shops and showrooms,

shopping centre and miscellaneous industrial buildings.

The new generation of air heater also has the fi elds cooling and energy

recovery fi rmly under control.

AIR HEATER AND AIR COOLER “DESIGN”

27


EASYAIR®

28

29

One of the compact designedair-handling-units EASYAIR®

(e.g. RO-01) decreases CO2

-emissons about - 14.29 tons (approx. ~ 1 ton per year)*

Throughout the year 2009 AL-KO has tend to reduce CO2 -emissons

about - 14,285 tons, based onAL-KO SAVE ENERGY-

Technologies.

This is equivalent to thetotal energy consumption of

approx. 892 private real estates.

AL-KO will save until 2016p.a. approx. - 17,316 tonsCO2 -emissons based onAL-KO SAVE ENERGY-

Technologies.


approx. 1,082 private real estates.

* for further information:

www.al-ko.de/green-building-

technology.htm


approx. 1,082 private real estates.

EASYAIR® – The easy way to a good climate

I Most effi cient energy recovery with an effi ciency of 80 – 90 %

I Energy-saving fan motors by using EC technology for lowest energy consumption

I Noise reduction by using sound absorption casing for the air handling unit and optimized components

I Easy operation by using most intelligent control and regulation

I High quality manufacturing, easy to install, reduced maintenance costs

30

32


Strong in the ability to deliver and logistics

32

AL-KO Air-Technology is fi rmly anchored in the AL-KO KOBER GROUP.

From the fi nancial strength results a formidable ability to deliver and

logistics – irrespective of the size of the project. And that worldwide!

Whether Europe, Asia or other continents:

AL-KO OS stands for “on-site” and, therefore, for worldwide smooth

logistics processes for ventilation and air-conditioning-units “Made in

Germany”.

33

AL-KO On-Site consists of the core competencies “transportation”,

“assembly” and “service” and is synonymous for worldwide logistics

and quality management of our high quality ventilation and air-conditioning

technology at marketable prices in each country of destination.

Worldwide Presence

AL-KO is “QUALITY FOR LIFE”

Carsten Stuck, Managing Director

34

“QUALITY FOR LIFE” is for us the commitment to

deal with the medium air, so that the high demands

are always optimally fulfi lled for an optimum climate

in industrial, commercial and private buildings.

35

“QUALITY FOR LIFE”

also distinguishes itself for the quality and long service life of our ventilation

and air-conditioning-units, as well as the benefi ts that result from perfect

ventilation and air-conditioning. At the forefront is the person, as user of the

buildings, whose well-being and productivity increases considerably through

prime air-conditioning.

AL-KO THERM GMBH

Hauptstraße 248 -250

89343 Jet tingen-Scheppach

Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

AIR-HANDLING-UNIT AT4 – OPTIMISED BY FUNCTIONALITY AND QUALITY

AIR-HANDLING-UNITS

2

AT4 – optimised by functionality and quality

3

Convincing advantages

I variable and optimized adjustment

for all system-specifi c applications

I high product quality using the very

latest production technology

I customer-oriented process control

guarantees maximum reliability of

deliveries

I designing and calculating supported

by Klim@Soft®, the professional

design tool for planers and customers

I unit version according to VDI 6022

(Standard of German Association of

Engineers)

Design with experience

construction features

I maximum corrosion protection by

galvanized and additional powder-

coated casing panels

I high heat and noise insulation due

to 47 mm panel thickness

I noise and heat insulation material

made of mineral wool; building

material class A1; non-fl ammable

pursuant to DIN 4102

I patented thermal isolation between

the panel shells

I minimized thermal transmittance

due to optimized casing covers

I unit construction dismantled

I optimal adjustment to building

situation due to a variable pitch

dimension of 76.5 mm

4

Internal walls hygienically smooth

AT4 – with this we convince

Patented thermal isolation

5

Conforms to all national and European standards

Effi ciency and economy

I reduced energy consumption and

minimized internal pressure losses

by optimized air-fl ow through the air-

treatment components

I selection of fans adapted to the

operating point

I use of all conventional heat

recoverysystems; layout to the

actual application

I “Life-Cycle-Costs”-optimized

air-handling-units

Top quality for all applications

I suitable for interior

and exterior installation

I hygienic fi nish

I integrated cooling units

I various material versions

designed to be dismantled

I large and special units

I DCS (Desiccant Cooling System)

2007-2010

CONFORMITY

AT4 – quick selection

6

12 x 08

08 x 08

12 x 08

16 x 08

12 x 12

16 x 12

20 x 12

24 x 12

16 x 16

20 x 16

24 x 16

32 x 16

20 x 20

24 x 20

41 x 20

24 x 24

28 x 24

32 x 24

28 x 28

32 x 28

32 x 32

41 x 28

41 x 32

49 x 32

0 10 000 20 000 30 000 40 000 50 000 60 000 70 000 80 000 90 000 100 000 110 000

0 2.78 5.56 8.33 11.1 13.89 16.67 19.44 22.22 25 27.78 30.56

Air-volume-fl ow in m3/h

Air-volume-fl ow in m3/s

Velocity in blower stream in m /sec.,

cross-section of unit with clearance

2 2.5 3 3.5

Speed range

7

2 300 – 5 300 12 x 06 995 536 918 459

2 000 – 4 700 08 x 08 689 689 612 612

3 000 – 7 100 12 x 08 995 689 918 612

4 000 – 9 400 16 x 08 1 301 689 1 224 612

4 600 – 10 600 12 x 12 995 995 918 918

6 100 – 14 200 16 x 12 1 301 995 1 224 918

7 600 – 17 700 20 x 12 1 607 995 1 530 918

9 100 – 21 200 24 x 12 1 913 995 1 836 918

8 100 – 18 900 16 x 16 1 301 1 301 1 224 1 224

10 100 – 23 600 20 x 16 1 607 1 301 1 530 1 224

12 100 – 28 300 24 x 16 1 913 1 301 1 836 1 224

16 200 – 37 800 32 x 16 2 525 1 301 2 448 1 224

12 600 – 29 500 20 x 20 1 607 1 607 1 530 1 530

15 200 – 35 400 24 x 20 1 913 1 607 1 836 1 530

25 900 – 60 500 41 x 20 3 213 1 607 3 137 1 530

18 200 – 42 500 24 x 24 1 913 1 913 1 836 1 836

21 200 – 49 600 28 x 24 2 219 1 913 2 142 1 836

24 300 – 56 600 32 x 24 2 525 1 913 2 448 1 836

24 800 – 57 800 28 x 28 2 219 2 219 2 142 2 142

28 300 – 66 100 32 x 28 2 525 2 219 2 448 2 142

32 400 – 75 500 32 x 32 2 525 2 525 2 448 2 448

36 300 – 84 700 41 x 28 3 213 2 219 3 137 2 142

41 500 – 96 700 41 x 32 3 213 2 525 3 137 2 448

49 600 – 115 600 49 x 32 3 825 2 525 3 749 2 448

Width (mm) *Height (mm) Width (mm) *Height (mm)

Air-fl ow Unit size Outer dimensions Inner dimensions

m3/h

Subject to dimensional and design changes. Further sizes on demand.

*Height without installation frame, installation frame = + 110 mm

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

QUICK SELECTION ENERGYEFFICIENT VENTILATION AND AIR CONDITIONING UNITS SERIES AT4

AIR-HANDLING-UNITS

2

Energy effi ciency is AL-KO standard

2

HTTP://PLANER.AL-KO.DE

HTTP://LCC.AL-KO.DE

3

Energy efficient ventilation and

air conditioning units are standard

at AL-KO

The only question for AL-KO is with

regard to the energy recovery units:

Which type of energy recovery is

expedient for the application?

By using AT4 modular system and the

design software “Klim@Soft”, AL-KO

is in the position to store complete

air supply and extraction units with

high energy efficiency as standard and,

therefore, ensuring quick execution of

projekts and short delivery times.

3

Conforming to all national and european standards

CONFORMITY

Energy recovery – plate heat exchanger

4

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(mm)(mm)(mm) Maintenance

8 x 8 3 370 600 1 750 8 447 689 1 608 50 230 383 765 F7 F-Quick-release 383 459 3 383 1 377

12 x 8 5 060 600 2 242 8 523 995 1 608 50 230 383 765 F7 F-Quick-release 383 459 3 - 1 377

16 x 8 6 740 600 2 810 8 905 1 301 1 608 50 230 383 765 F7 F-Quick-release 383 536 4 - 1 377

12 x 12 7 580 600 2 878 9 287 995 2 220 50 230 383 765 F7 F-Quick-release 459 459 3 383 1 377

16 x 12 10 100 600 3 518 9 364 1 301 2 220 50 230 383 765 F7 F-Quick-release 459 536 4 383 1 377




24 x 16 20 230 600 5 894 10 436 1 913 2 832 50 230 - 765 F7 S-Fuel-laden air side 612 536 4 383 1 377

32 x 16 26 970 600 7 312 10 665 2 525 2 832 50 230 - 765 F7 S-Fuel-laden air side 612 536 2 383 1 377


24 x 20 25 280 600 7 104 11 200 1 913 3 444 50 230 383 765 F7 S-Fuel-laden air side 765 536 4 383 1 377


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536 6 765 90 RLM 56-315 1 377 1 301 765 F5 F-Quick-release 1 377 765 90 RLM 56-315 1 377 383 918

536 4 765 100 RLM 56-400 1 377 1 301 765 F5 F-Quick-release 1 377 765 100 RLM 56-400 1 377 383 1 148






536 6 1 071 160 RLM 56-710 1 377 1 989 765 F5 F-Quick-release 1 377 995 132 RLM 56-710 1 377 612 1 071

765 8 1 071 160 RLM 56-710 1 377 1 989 765 F5 S-Fuel-laden air side 1 377 1 071 160 RLM 56-710 1 377 612 1 071


765 6 1 148 160 RLM 56-800 1 377 2 295 765 F5 F-Quick-release 1 377 1 071 160 RLM 56-710 1 377 765 1 071



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Energy recovery – high effi cient run-around-coil-system

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8 x 8 3 370 600 1 589 7 298 689 1 608 50 230 230 765 F7 F-Quick-release 612 12 383 459 8 306 1 377


16 x 8 6 740 600 2 394 7 298 1 301 1 608 50 230 230 765 F7 F-Quick-release 536 12 383 459 3 306 1 377







32 x 16 26 970 600 6 726 9 211 2 525 2 832 50 230 230 765 F7 S-Fuel-laden air side 612 12 689 536 4 383 1 377






28 x 28 41 290 600 9 380 9 747 4 458 2 329 50 230 689 765 F7 S-Fuel-laden air side 612 12 1 148 536 2 383 1 377






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536 4 765 90 RLM 56-315 1 377 765 F5 F-Quick-release 1377 765 90 RLM 56-315 1377 383 842 12 230

536 6 842 112 RLM 56-400 1 377 765 F5 F-Quick-release 1 377 765 100 RLM 56-400 1377 383 918 12 230

536 6 842 112 RLM 56-400 1 377 765 F5 F-Quick-release 1 377 842 112 RLM 56-400 1 377 383 765 12 230





536 6 1 071 160 RLM 56-710 1 377 765 F5 F-Quick-release 1 377 1 071 160 RLM 56-710 1 377 689 765 12 230


765 6 1 148 160 RLM 56-800 1 377 765 F5 S-Fuel-laden air side 1 377 1 148 160 RLM 56-800 1 377 689 995 12 230






765 6 1 377 200 RLM 56-1000 1 377 765 F5 S-Fuel-laden air side 1 377 1 377 200 RLM 56-1000 1 377 1 148 995 12 230






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41 x 32 69 090 600 19 127 13 877 6 446 4 241 50 230 230 765 F7 S-Fuel-laden air side 612 3 459 1 377 1 148

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Tube

ar-

rays

Co

ole

r

Fa

n

Fil

ter

Fa

n

Class Fan

size

Fan

size

Fan

type

Fan

type

Maintenance

536 6 765 90 RLM 56-315 1 377 995 765 F5 F-Quick-release 1 377 765 90 RLM 56-315 1 377 230



612 8 842 112 RLM 56-500 1 377 1 377 765 F5 F-Quick-release 1 377 842 100 RLM 56-500 1 377 230



612 8 995 132 RLM 56-710 1 377 1 377 765 F5 F-Quick-release 1 377 995 132 ERC-630 1 377 230

612 8 1 071 160 RLM 56-710 1 377 1 377 765 F5 F-Quick-release 1 377 995 132 RLM 56-710 1 377 230

765 8 1 071 160 RLM 56-710 1 377 1 377 765 F5 F-Quick-release 1 377 1 071 160 RLM 56-710 1 377 230

765 6 1 148 160 ERC-800 1 377 1 377 765 F5 S-Fuel-laden air side 1 377 1 148 160 ERC-800 1 377 230

765 6 1 148 160 ERC-710 1 377 1 760 765 F5 F-Quick-release 1 377 1 148 160 ERC-800 1 377 230


765 6 1 301 180 RLM 56-900 1 377 1 760 765 F5 S-Fuel-laden air side 1 377 1 301 180 ERC-900 1 377 230




842 8 1 377 200 RLM 56-1000 1 377 3 902 765 F5 S-Fuel-laden air side 1 377 1 377 200 RLM 56-1000 1 377 230



765 6 2 066 280 RLM 56-1400 1 377 3 213 765 F5 S-Fuel-laden air side 1 377 1 989 250 RLM 56-1400 1 377 1 148

So

un

d a

bso

rbe

r

Ro

tary

he

at

exc

ha

ng

er

So

un

d a

bso

rbe

r

So

un

d a

bso

rbe

r

Vo

id c

ha

mb

er

Klima-

soft

meas.

Klima-

soft

meas.

Klima-

soft

meas.

Klima-

soft

meas.

Klima-

soft

meas.

Klima-

soft

meas.

Klima-

soft

meas.

Klima-

soft

meas.

Klima-

soft

meas.

Extracted airMulti-

purpose

Additional components

10

Type External dimensions W x H*

ContactFresh water

ContactCirculating water

WashersType B

L1kgL1

8 x 8 688 x 688 612 a.A. 1 148 a.A. 1 300 288

12 x 8 994 x 688 612 a.A. 1 148 a.A. 1 300 472

12 x 12 1 300 x 688 612 a.A. 1 148 a.A. 1 300 544

20 x 12 994 x 994 612 a.A. 1 148 a.A. 1 300 522

20 x 16 1 300 x 994 612 a.A. 1 148 a.A. 1 300 767

32 x 16 1 606 x 994 918 a.A. 1 148 a.A. 1 300 902

24 x 20 1 300 x 1 300 612 a.A. 1 148 a.A. 1 300 922

28 x 24 1 606 x 1 300 918 a.A. 1 148 a.A. 1 300 922

28 x 28 1 912 x 1 300 918 a.A. 1 148 a.A. 1 300 922

32 x 32 2 524 x 1 300 918 a.A. 1 148 a.A. 1 300 1 173

41 x 32 1 606 x 1 606 1 148 a.A. 1 148 a.A. 1 300 1 029

16 x 08 1 912 x 1 606 1 148 a.A. 1 148 a.A. 1 300 1 029

16 x 12 1 912 x 1 912 1 148 a.A. 1 148 a.A. 1 300 1 029

16 x 16 2 218 x 1 912 1 148 a.A. 1 148 a.A. 1 300 1 400

24 x 16 2 524 x 1 912 1 148 a.A. 1 148 a.A. a.A.

20 x 20 2 218 x 2 218 1 148 a.A. 1 148 a.A. a.A.

24 x 24 2 524 x 2 218 1 148 a.A. 1 148 a.A. a.A.

32 x 24 2 524 x 2 524 1 148 a.A. 1 148 a.A. a.A.

32 x 28 3 213 x 2 218 1 148 a.A. 1 148 a.A. a.A.

41 x 28 3 213 x 2 524 1 148 a.A. 1 148 a.A. a.A.

49 x 32 3 825 x 2 524 1 148 a.A. 1 148 a.A. a.A.

kgL2kg

* plus base frame H +110 mm Complete humidifi er unit removable from the

side. Fully wired to the exterior terminal box.

Discharge nozzle DN 32

The standard values refer to a low pressure

manifold with a rated air fl ow. With the following

fi ne particle fi lter-sectors, the given sector must

be extended by 306 mm or 612 mm.

H

B

Humidifi er

11

SteamLmin standard value at 18 °C

Lamella cover

Weather protec-tion screen

High pressure Suction hood

10 g / kg7 g / kg4 g / kg

918 1 224 1 530 1 530 a.A. 1 1 612 612 510

918 1 224 1 530 1 530 a.A. 1 1 918 612 510

918 1 224 1 530 1 530 a.A. 1 1 1 224 612 510

918 1 224 1 530 1 530 a.A. 1 1 918 918 725

918 1 224 1 530 1 530 a.A. 1 1 1 224 918 725

918 1 224 1 530 1 530 a.A. 1 1 1 530 918 725

918 1 224 1 530 1 530 a.A. 1 1 1 224 1 224 945

918 1 224 1 530 1 530 a.A. 1 1 1 530 1 224 945

918 1 224 1 530 1 530 a.A. 1 1 1 836 1 224 945

918 1 224 1 530 1 530 a.A. 1 2 2 448 1 224 945

918 1 224 1 530 1 530 a.A. 1 1 1 530 1 530 1 160

918 1 224 1 530 1 530 a.A. 1 1 1 836 1 530 1 160

918 1 224 1 530 1 530 a.A. 2 1 1 836 1 836 1 375

918 1 224 1 530 1 530 a.A. 4 2 2 142 1 836 1 375

918 1 224 1 530 1 530 a.A. 2 2 2 448 1 836 1 375

918 1 224 1 530 1 530 a.A. 2 2 2 142 2 142 1 591

918 1 224 1 530 1 530 a.A. 4 2 2 448 2 142 1 591

918 1 224 1 530 1 530 a.A. 4 2 2 448 2 448 1 807

918 1 224 1 530 1 530 a.A. 4 2 3 136* 2 142* 1 591*

918 1 224 1 530 1 530 a.A. 4 2 3 136* 2 448* 1 807*

918 1 224 1 530 1 530 a.A. 4 2 3 748* 2 448* 1 807*

Component parts Component parts Width Height LengthkgL1

*Suction hood divided in two

Weather protection equipment

Accessories

12

Type External di-mensions W x H*

Base frame Type 1 Type 2 Type 3 Type 4

h1h2h1h

8 x 8 688 x 688 110 133 160 183 210 233 260 283 310

12 x 8 994 x 688 110 133 160 183 210 233 260 283 310

12 x 12 1300 x 688 110 133 160 183 210 233 260 283 310

20 x 12 994 x 994 110 133 160 183 210 233 260 283 310

20 x 16 1 300 x 994 110 133 160 183 210 233 260 283 310

32 x 16 1 606 x 994 110 133 160 183 210 233 260 283 310

24 x 20 1 300 x 1 300 110 133 160 183 210 233 260 283 310

28 x 24 1 606 x 1 300 110 – – 183 210 233 260 283 310

28 x 28 1 912 x 1 300 110 – – 183 210 233 260 283 310

32 x 32 2 524 x 1 300 110 – – 183 210 233 260 283 310

41 x 32 1 606 x 1 606 110 – – 183 210 233 260 283 310

16 x 08 1 912 x 1 606 110 – – 183 210 233 260 283 310

16 x 12 1 912 x 1 912 110 – – 183 210 233 260 283 310

16 x 16 2 218 x 1 912 110 – – 183 210 233 260 283 310

24 x 16 2 524 x 1 912 110 – – 183 210 233 260 283 310

20 x 20 2 218 x 2 218 110 – – 183 210 233 260 283 310

24 x 24 2 524 x 2 218 110 – – 183 210 233 260 283 310

32 x 24 2 524 x 2 524 110 – – 183 210 233 260 283 310

32 x 28 3 213 x 2 218 208 – – 183 210 233 260 283 310

41 x 28 3 213 x 2 524 208 – – 183 210 233 260 283 310

49 x 32 3 825 x 2 524 208 – – 183 210 233 260 283 310

h2 h2h1 h1h2

* plus base frame H +110 mm Optional base frame heights (except superimposed top row)

208 / 308 / 408

with a unit width 41, 49 Standard

Option of combinations of base frames (max. height 400 mm)

H

B

Base frame adjustable feet

Adjustable feet only in connection with separate assembly frame

Material classifi cation for the AT4 series

13v = promat- or electrolyte galv.

bv = (in bath) galvanized

sv = sendzimir galvanized

ph = phosphated

pb = powder-coated min. 60 μm

ep = epoxy resin coated

pp = Polypropylene

V2A = e.g. 1.4301

V4A = e.g. 1.4571

Subject to material

change

1. Housing walls

Double-shell construction

with intermediary insulation

2. Design components

3. Purchased built-in components

4. External components

5. For installation outdoors

Parameter profi les

Outer panel

Inner panel: Walls and cover

Base

Insulation: Temp. stab up to 110 °C

Filter sector base for recirculating air

With fresh air intake

Assembly components

Moisture separator

Drip trays

Hinges

Handles

Attachment and outer

connecting parts inner

Filter frame

Cooler installation rails

Fan: Housing

Impeller

Shaft

Motor: Housing

Shaft end

V-belt pulley

Baffl e lamellae

Inner and Shafts and rods

outer: Pinions

Casing

Air heater: Lamellae

Frame

Pipes

Collectors

Air cooler: Lamellae

Frame

Pipes

Collectors

Humidifi er

Silencer casing

Silencer cover

Rotary exchanger housing

Plate exchanger

Flexible sleeves

Circuit connection plug frame

Base frame

Roof

Attachment parts outside

Feet and assembly frame

v

sv + pb

sv + pb

sv + pb

sv + pb

sv + pb

sv

V2A / pp

V2A

Aluminium

Plastic

v

v

sv

V2A/sv

sv

sv + pb

St

painted

St

ph

sv / Aluminium

v

Plastic

sv

Aluminium

sv

Cu

Cu / St painted

Aluminium

Aluminium

Cu

Cu

on request

sv

Fibre-glass

Aluminium / sv

Aluminium / sv

PVC / EP9M

sv

sv + pb

v

v

v + pb

sv + pb

sv + pb

V2A

V2A

V2A

sv + pb

V2A / pp

V2A

Aluminium

Plastic

v

V2A

sv + pb

V2A

sv + pb

sv + pb

St

painted

St

ph and painted

sv / Aluminium + pb

v

Plastic

sv

Aluminium

sv + ep

sv

–

Aluminium + ep

V2A

V2A

–

on request

sv + pb

Fibre-glass

Aluminium / sv

Aluminium / sv

sv

sv + pb

v

v + pb

GFK / V2A / V4A

–

V2A / V4A

V4A

–

–

–

–

–

–

Plastic

–

–

V2A

–

–

–

V2A

–

V2A

–

V2A

V2A

–

V2A

ep

V2A

V2A

–

V2A

–

–

–

on request

V2A

Fibre-glass

Aluminium / sv

Aluminium / sv

–

–

–

V2A

–

Unit components

Standard Option I Option II

Special design at extra cost

Quality levels

Gewebe BK VI q 3, temp.-best bis 110 °C

weatherproof roof panel accessible

Mineral fi bre sheets / Flammability rating A

14

Unit design AT4

14

Unit design and construction in accordance with EN 1886 and VDI 6022

The housing frame construction con-

sists of 38 mm sendzimir galvanized

square section with a wall thickness

of 1.5 mm, connected by unit angles:

plastic angles for unit sizes 08 x 08 to

16 x 16, diecast aluminium angles for

sizes 20 x 16 to 49 x 32. This method

of construction makes sure that the

unit can be fully disassembled, because

welded joints are dispersed with.

All sealing material used is closed

porous and microbial inert.

Humidity-relevant components are

generally from corrosion resistant

material – exclusively stainless steel

– and contain a tank, which assures a

continuous and total removal of con-

densate. Commensurate with the highest

standards of the valid hygiene guide-

lines, all components are cleaned at

the works and packaged in foil for

transportation.

The functional units are easily

accessible on both sides for cleaning.

Therefore, all heat exchangers can be

cleaned to the core with low technical

and time effort.

All Filter, fan and humidifi er compo-

nents, from a unit height of 1.3 m, have

lighting and sight glasses. Thus, there

is an option for continuous inspection

without having to open the unit.

The mechanical stability conforms to

EN 1886. Thanks to the raster construc-

tion, it is a fl exible unit construction

with the virtue that it can be adapted

to the diverse designs.

The detachable cladding panels, 47 mm

thick and double-shelled, are lined in-

side for heat and noise insulation with

a non-fl ammable rock wool, in accord-

ance with DIN 4102 building material

Class A1, density of 55 kg /m3.

The panel of the inner and outer shell

is from 1 mm sendzimir galvanized

steel sheet. After manufacture, the

panel is completely powder-coated,

layer thickness min. 60 μm, RAL 7001.

Thus, there are no open cut edges.

Furthermore, there is no risk of corro-

sion. Cold and thermal bridges are

prevented from forming by a patented

thermal decoupling between the shells

of the panel.

1515

Unit components AT4 AT4 (Tropic) The housing inner surfaces fi t fl ush

with the frame. The inner surfaces

are completely smooth and have no

cut edges.

All joints and grooves in the unit are

resistant to disinfectant, sealed with

a microbial internal sealing material

and can be cleaned residue-free.

The base frame is galvanized and

powder-coated.

The door construction corresponds to

the housing panels (no cut edges, corro-

sion resistant), accessible units have

manual lever catches. Alternative is an

operation cover detachable at the side.

I Mechanic stability Class 1A / D2 Class 1A / D2

I Housing leakage Class 1B / L2 Class 1B / L2

I Thermal insulation Class T3 Class T2

I Thermal bridge factor Class TB3 Class TB2

I Average sound insulation 41 dB 41 dB

125 250 500 1 k 2 k 4 k 8 k Hz

15.8 24.4 30.2 35.1 35.4 35.8 36.5 dB AT4

16 27 31 33 35 36 36 dB AT4-Tropic

Insert insulation DE, in accordance with EN 1886:

16

Housing design

Housing outer shell

I detachable frame construction

I unit panels galvanized with powder

coating (RAL 7001) layer thickness

60 μ

I plastic angles, inclusive unit

size 16 x 16

I aluminium diecast angles, from

unit size 20 x 16

I unit panels with expanded foam,

long term robust seal, attached from

the outside, thus, detachable

Option AT4-T:

I frame construction from GRP, with

thermally decoupled unit panels

Option:

I frame section construction additionally

powder-coated in the colour of the unit

I frame section construction, stainless

steel

Housing inner shell

I units completely smooth inside,

no cut edges and welding seam

I unit panels inside, galvanized with

powder coating (RAL 7001)

Option: Sanitary construction

I joints between the unit frame and

panels in the area of the base sealed

I discharge for each functional unit

16

Housing

17

Unit linking

I easy to install unit linking through

compact gusset plate, attached

inside on the unit frame

I connecting angle, extra from unit

size 16 x 12

Option AT4-T:

I unit connections galvanized and

powder-coated

Operation door

I door construction same as housing

panels

I hinge mounted with locking catch

I with manual lever catch, on request

lockable

I in the overpressure area, standard

with door catch locking accessories:

Sight glass

17

18

Housing construction

18

Filter quick-release device

up to including unit height 1 836 mm

(clearance)

I complete fi lter element for durable

seal seat in special assembly frame

installed with quick-release device

in the housing.

I fi lter element removable from

the side.

Option:

I powder-coated frame components

1919

Pocket fi lter

Filter element in the Euro assembly

frame. Nylon spacer between the fi lter

bags. Filter class / fi lter element design:

I coarse dust fi lter G3 / G4

Filter elements from synthetic

fi bre mat

I fi ne particle fi lter

Filter elements from synthetic

fi bre mat

Suspended particle fi lter

Attached circular seal from neoprene,

spacer from textile fi lament.

Filter class / fi lter element design:

I fi lter Class R – (H 11)

I fi lter Class S – (H 13)

Filter medium from high quality,

wet strength glass fi bre paper

Recommendation:

Superpose fi lter F9

I fi lter type A26

Cartridges consist of an outer and

inner perforated cylinder with inter-

mediate activated carbon

Recommendation: Superpose fi lter

F7 alternative: Activated carbon

cartridges with quick-release device

I fi lter cartridges

Grease separation fi lter

Filter element attached in

the special retainer frame.

Filter class / design:

I G3 – Metal fi lter, recyclable,

galvanized wire mesh gauze,

Accessories: Differential pressure

gauge or: Hood fi lter for oil and

paint mist

I electric fi lter on request

Fine particle fi lter cartridge

V-Cell fi lter with a module length of 360

mm. Made from plied fi lter material.

I fi lter Class F5-F9

Planar fi lter / panel fi lter

Panel fi lter with a thickness of 94 mm

for shortened fi lter units (module

length 250 mm). In Euro assembly

frame up to unit size 16 x 16, remov-

able from the side.

I fi lter Class G4, F5 and F7

Activated carbon fi lter

Leak-free attaching both cylinders

with bayonet coupling on a special

baseplate. Filter type /cartridge design:

I fi lter type A20

20

Functional units

20

Heater

I removable from the side of the

housing

I seamless copper pipe with mecha-

nical integrally moulded aluminium

lamellae

I enclosed in galvanized sheet steel

frame

I manifold from steel or copper

Accessories: Sensor frame to pull

out, anti-frost thermostat, fl ange and

counterfl ange, electric heating coils

on request

Option:

I steel heater galvanized/stainless steel

I coolant liquefi er

Cooler

I removable from the side of the

housing

I seamless copper pipe with mecha-

nical integrally moulded aluminium

lamellae

I enclosed in corrosion resistant frame

I manifold from copper

I wall fairlead with insulation diffusion

resistant, bleeding and draining

On-site design versions:

I cooler st / gv, on request

I cooler cu / cu, on request

I cooler cu / al – lamellae epoxy

resin coated

I frame from stainless steel

I direct heat exchanger

Accessories: Flange and counter-

fl ange, syphon

Coalescer and tank

I coalescer from heat resistant Poly-

propylene plastic section, removable

from the side, frame from stainless

steel 1.4301

I condensate tub from stainless steel

1.4301 with all-round incline

I discharge nozzles Ø 40 PVC – leading

out of the installation frame at the side

2121

Sound absorber

I vertically arranged connecting links

from noise-absorbing mineral fi bre

sheets

I surfaces from glass fi bre abrasion

resistant up to a max. fl ow velocity

of 20 m/s

I connecting links installed over angle

tracks in the housing

I removable from the side, optional.

I aerodynamically shaped frame

for reducing pressure losses and

turbulence

Radial fan

I fan and AC motor installed on a

common base frame

I motor slide clamps for easy belt

tensioning without tools

I belt drive, V-belt pulley with Taperlock

lock bush system

Option: Energy saving fl at belt drive

I fl exible sealing between the fan air

outlet and unit chamber using an

airtight fl exible sleeve

I potential equalization between fan

motor unit and unit housing

I complete drive unit mounted on spring

shock-mounts

I fan unit removable from the side

I transportation safety device

I tested by EUROVENT with max. design

compensation of 5 %.

Design:

I fan with forward curved blades

I fan with rearward curved blades,

strengthened housing and bearing

Option: Diagonal tie-bar with motor

tension beam

Accessories: Grid barrier, closed

pipeline, pressure transducer, needle

gauge, frequency converter, main-

tenance switch incl. wiring

22

Functional units

22

Fan with free-wheeling rotary

wheel (AIR-vent)

I one-sided suction rotary fan with

rearward curved blades, powder-

coated

I rotor directly attached to the motor

shaft (Taperlock lock bush)

I AC motor Type B motor protection

by posistor

I complete drive unit mounted on

Frequency convertor

I installed on unit

Option:

Motor with integrated frequency

convertor

compression-loaded spring shock-

mounts

I fan unit removable from the side

I transportation safety device

I tested by EUROVENT

Accessories: Grid barrier, closed pipe-

line, needle gauge, frequency converter,

pressure transducer, maintenance switch

incl. wiring

Option:

Drive motors with increased effi ciency

2323

Diagonal plate heat exchanger WRD

I plate exchanger from corrosion

resistant aluminium

I condensate tank from stainless steel

1.4301

I discharge nozzles Ø 40 PVC – leading

out of the installation frame at the side

I bypass valves for summer bypass or

protection against icing

I coalescer from heat resistant Polypro-

pylene plastic sections, removable from

the side

I effi ciency to 75 %

Option:

I frame from stainless steel 1.4301

I plate exchanger and fi tting epoxy resin

coated

Accessories: Syphon

Rotary heat exchanger

(thermal wheel) WRR

I choice of with or without humidity

recovery

I special housing from salt-water

resistant aluminium

I accumulator from alternating smooth

and corrugated aluminium sheet

I detachable cover panel

I sealed housing – rotor with adjustable

felt seal partition of the housing from

rotor diameter 2 500 mm

Option:

I sorption rotor with epoxy resin

coating

I rotor epoxy resin coated

I standard with integrated high quality

AT4 housing

I rotor control

Speed control with operation

monitoring installed in the housing

and internally wired.

24

Functional units

24

Contact humidifi er circulation (UWS)

and fresh water system (FWS)

I contact humidifi er for enclosed

components

I inspection doors over the whole

unit height (for FWS from 20 x 20)

I contact body from impregnated,

inorganic, glass fi bre mounted in the

frame from stainless steel and remo-

veable sideways or in the direction of

the air

I desalination pipe with regulating

valve directly in the drain line

I water tank from stainless steel with

three-sided incline to the operating

side, with integrated safety overfl ow

directly in the drain line (UWS)

I electronic water level control (UWS)

I solenoid valve installed for supply in

the fresh water pipe (UWS)

I solenoid valve, with manual operation

possible, installed in the drain line

(UWS)

I immersion pump in plastic/stainless

steel construction, insulation Class F

(UWS)

I water distribution pump from stain-

less steel, short vertically installed

plastic distribution pipes to the

individual contact body cartridges

(UWS)

Standard options:

I coalescer cartridges from plastic

sections PPTV with stainless steel

frame

I design for use of osmotic water

I stage control by the solenoid valves

I bypass with stage control by

the solenoid valves and integrated

control valve with constant actua-

ting drive

I complete wiring to external terminal

boxes

I dry operation protection, pump

(UWS)

I contact body from aluminium,

stainless steel and impregnated

paper fi bre material (UWS)

I external water inlet fi ttings (FWS)

2525

High pressure humidifi er

I housing with inspection doors

and double-glazed sight glass and

lighting

I base with a continuous condensate

tank and 2 discharge nozzles with

thread from chrome steel

I integral humidifi er, consisting of

nozzle screen, injector body with

Vapour humidifi er section

I housing with inspection doors and

double-glazed sight glass and lighting

I base below vapour distributor with

a continuous condensate tank and

discharge nozzles with thread from

chrome steel

Accessories:

I vapour distributor installed ready

for connection

I compact vapour generator complete

with control and vapour connection

hose

Air washer: on request

molecular diffuser nozzles and spray

pipes, separator elements easily

removed

I pump station with controller installed

on the ventilation unit, incl. connection

pipes to the nozzle screen

I prototype test with verifi cation of con-

formity to the requirement of VDI 6022

Water quality: VE water < 10 μs / cm

Accessories:

I measurement and pressure

increasing device 4-8 bar

I sterilization by silver-ionization

I integrated water processing system

I central unit not fi xed for on-site,

external installation

I master-Slave systems with a pump

station

High effi cient energy recovery

(run-around-coil-system)

(hydraulic station)

Option:

I piping unit for linking the supply and

exhaust air heat exchanger, complete

with all functional parts integrated in

the unit or attached externally

I high performance energy recovery

system with effi ciency up to 80 %

I heat exchanger verifi able, can

be cleaned to the core

26

Weatherproof design

26

Suction chamber

I internal louver damper with

adjustment lever

I base tub from stainless steel 1.4301

– centre discharge, discharge nozz-

les Ø 40 PVC routed outside through

the installation frame

I drainage area

Lamellae suction hood

I suction hood coated – integrated

screen for protection against birds

I unit roof covered with special

plastic sheet

I drainage area circumferential top

and bottom

I base frame galvanized and

powder-coated with aperture for

crane transportation

Optional:

Powder-coated weather protection

screen or suction hood

27

Accessories and special details

27

Louver damper

I up to size 20 x 16:

With counter-rotating, warp resistant

hollow section, aluminium lamellae,

sealed using special lip seals. Internal

plastic gears, frame from galvanized

steel plate, depth 125 mm

I from size 20 x 20:

With counter-rotating, warp resistant

galvanized steel section lamellae,

sealed using special lip seals. One-

sided external connecting rods,

frame from galvanized steel plate,

depth 190 mm

Ambient and exhaust air hatches and

insulated fl exible connections.

Accessories: Hatch adjustment motor,

adjustment lever for louver damper

adjustment, selection of external or

internal, standard for Hygiene design

– louver dampers DIN 1946 Part 4

available.

Options:

I rods

I powder-coated damper unit

I damper from stainless steel 1.4301

I damper leak tightness class iaw EN 1751

Class 2 and Class 4

Canvas connections

I from polyester fabric especially

tear resistant

I circumferential duct connection

fl ange air-tight, connected both sides

I potential equalization

Optional:

temperature resistant designed

(up to 160 ºC)

Duct connection

28

Accessories and special details

28

Acoustic decoupled unit rubber

connections

(Standard for Hygiene design and

RAL)

I connection section with intermediate

expanded rubber

I attached to frame by bolts washers

I potential equalization

Maintenance switch

I installed on the fan, or, up to 7.5 KW,

integrated in the installed frequency

convertor

I circuit breaker with 2 auxiliary con-

tacts (1 opener, 1 closer) protection

Type IP 65, from 15 kW only as

control switch

I with integrated posistor connection

Option:

Wiring with motor, incl. posistor

For weatherproof construction:

UV protection on the cables

2929

Installation frame for crane

transportation

Installation frame galvanized and

powder-coated with aperture for crane

transportation up to unit size 32 x 32

accessories: Transportation tubes

Option:

I lifting eyes (only in connection

with aluminium angles)

Integrated cooling

I integrated cooling circuit with power

control for optimum cooling and

dehumidifi cation

I highest operating reliability of the

cooling circuit by factory installed

piping and wiring

I environmental friendly cooling by

using R 407C.

I multi-circuit systems or multi-

compressor systems with optimized

power adjustment

Integrated cable duct

I cable routing in the unit base, or,

for two-tiered units, additionally

in the centre area

I location outside of the air fl ow

I ensures easier cleaning, especially

the air-ducting elements of the units

I easy access to the wiring

I less wiring required on-site

I especially expedient for weather-

proof units, or sanitary design units

30

Integrated control switch cabinet

(for weatherproof units)

Integral control system for central

ventilation units. Optional switch

cabinet integrated in the unit (for

weatherproof design), attached or

remote switch cabinet.

Control switch cabinet attached to

the unit, complete with wiring.

30

Control systems

Advantages of the AL-KO control

concept

I freely programmable controller (DDC)

I high fl exibility in hardware and

software

I international usability (up to 10

languages)

I PC-based programming and service

tools

I open communication and integration

I use of future-oriented technologies

The modular AL-KO controller concept

not only convinces by its optimum

hardware components for HLK and

cooling applications, it also underlines

its high fl exibility by its free program-

mability of the functions, the I /O’s and

the operating structure. Because of the

selection options for the operating

language, commissioning and operation

abroad is made easier. Here, interna-

tional character sets are used.

All means are free for controller com-

munication and integration in existing

systems. The controller has two slots

for the optional communication plug-in

module, in which the RCC card, LON

card, EIB card or Quadcomm card can

be selectively integrated.

31

Example of an AT4 control diagram

31

I/O-allocation:

I Universal inputs

UI01 = Ambient air sensor

UI02 = Room sensor or exhaust

air sensor

UI03 = Supply air sensor

UI04 = Frost sensor (heater)

UI05 = Supply air sensor

(after preheater)

UI06 = Humidity sensor (supply air,

room, exhaust air)

UI07 = Frost sensor (preheater)

UI08 = Overload heating pump heater /

preheater

UI09 = Filter monitoring

UI10 = Overload cooling pump /

malfunction cooling

UI11 = Overload fan

UI12 = Operation monitoring fan

UI13 = CO2 sensor (optional)

UI14 = Fire alarm (optional)

I Digital outputs

D01 = Heating pump

D02 = Cooling pump / enable cooling

D03 = Fan level 1

D04 = Fan level 2

D05 = Hatches (OPEN / FOL valves)

D06 = Heating pump preheater

D07 = Alarm output for A-alarms

D08 = Alarm output for B-alarm

I Analog outputs (0 to 10V)

A01 = Heating valve

A02 = Cooling valve / throttle suction

or hot gas bypass

A03 = WRG activation

A04 = Humidifi er

A05 = Mixing air valves (optional)

A06 = Heating valve preheater

Allocation of the inputs and outputs

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

INTEGRATED COOLING ANDHEAT-PUMP TECHNOLOGY IN AIR-CONDITIONING UNITS WITH AUTOMATION ENGINEERING

AIR-CONDITIONING-UNITS | PLUG-AND-PLAY

2

In many cases of application, cooling generation in the air-conditioning units presents a technically and economic-ally interesting alternative to central cooling. Over 20 years experience, our own development centre and highly qualified staff make AL-KO a strong partner for your projects.

3D-construction AL-KO Klim@Soft: air-handling- / air-conditioning-unit with

integrated cooling generation and energy recovery

I No costs for the hydraulic connection to a possible further detached central cooling unit.

I There are no distribution losses.I Modern methods of performance

control guarantee high partial load efficiency.

I By equipping the regrigeration system with heating pump control for the reversal of the refrigeration system, in many cases the residual heat portion of the exhaust air can be used very efficiently.

I The direct heat transfer through direct sublimation provides efficient dehumi-difying of air.

Many points speak for an integrated solution:I Less space requirement, through the

integration of a cooling unit in the air-conditioning unit.

I External heat exchange units or roof condensers for many air-conditioning applications are dispensed with, because the exhaust air can be used for the heat exchange.

I The complete solution from one source reduces your engineering effort and develops clear guaranteed limits.

3

The application of modern, highly efficient scroll-, reciprocating- and screw-type-compressors from a notable manufacturer, as well as the selection of the applicable partial load control for your application, guarantees the best performance data and optimum control.

The AL-KO solution spectrum: I Fully hermetic, in the application of the

optimized scroll compressor used in the air-conditioning technology

I Multi-compressor refrigeration systems for performance adjustment with up to three compressors per cooling circuit

I Up to two cooling circuits are manu-facturable

I Hot-gas bypass control adjusted to the multi-compressor refrigeration systems

I Digital scroll compressor for pulse-width modulated performance control

I Speed controlled reciprocating com-pressor

I Refrigerant R407C, R410a, R134a, according to the requirement.

Measurement and Automation Engineering:Fundamentally, all AL-KO cooling machines are supplied with their own measurement and control. AL-KO has developed their own controller for

AL-KO stands for energy efficiency

Carel Controller Saia Controller

standard uses with predominantly cooling function. The “AL-KO cooling controller” provides the connection to the on-site measurement control and forms a clear guarantee limit. Many functions are implemented as standard:I Compressor management and protec-

tion functionsI Performance controlI Automatic performance limitation

at overload or not sufficient heat

exchange guaranteed, ensures operation also when used outside of the design limits.

I Alarm management with history memory

I Linked to the on-site measurement and control through conventional signals (dry contacts or 0…10 Volt signal)

I Bus connection via MOD bus or LON (other systems on request)

I Operating point monitoring (optional)

Carel touch-panel

4

TM

M

M

P

P

Supply air

FU pF7

FU

MSR

Measurement and control

Exhaust airExhaust

airStandard

III

T

pF7

T

T

Con-denser

M

M

Out-door air

DX

MVF

ODA

EHT

EHT Condenser bypass

SUP

ETA

* at climate conditions of t0 / tc 10° / 55°

Example of application of air-conditioning-unit with rotary heat exchanger

h (kJ / kg)

QD p

12

34

QC

p(bar)

Integrated cooling unit for cooling out-door air I Cooling performances from 8 to approx.

270 kW per cooling circuit* with multi- compressor refrigertation systems.

I Bigger multi-compressor refrigeration systems are equipped with screw-type-compressors.

I Direct heat exchanger in the ambient air.I Internal condenser in the exhaust air - Uses the exhaust air, cooler in

comparison to the ambient air, for heat exchange

- Uses no mounting surface outside of the building or the unit

- Optional downstream bypass to bypass the condenser outside of the cooling period.

I If no, or unusable, exhaust air the combination with external liquefaction possible.

I Optional circiut of heat pumps uses the residual heat of the exhaust air.

5

Integrated cooling unitfor cooling out-door air I For complete delivery of the cooling

assemblies, pre-commissioning of the cooling unit is possible at the factory. No soldering on site.

I Systems can be equipped with heat- pump-mode for heating of supply-air after heat-recovery-system.

EHT

ODA

SUP

ETA

P

P

F

F

T

T

Out-door air

Exhaust air

FU pMSR

Exhaust airMeasurement

and control

AirQ

Supply air

T FU

p

Con-denser

VF DXp

M

M MM

Example of Application of Air-Conditioning Unit (Roof Top) with Plate Heat Exchanger

6

For the external cooling and dehumidi-fying with heat recovery (reheat) from the cooling circuitI Using the waste heat of the cooling

plant for reheating in dehumidifying mode. No unnecessary operation of the boiler in summer necessary.

I High specific cooling performance

feasible through additional use of ambient air for heat exchange.

I As necessary, also forced-air cooling by heat exchange using the ambient air.

I Heat extraction from the cooling circuit through hot-gas heat dissi-pation or partial-flow condensation.

I Application for greater cooling performances.

I Reheating using additional condenser. I Performance control using condensate

mixing or hot-gas distribution.I More efficient controlling of cooling-

performance due to extention of rotation speed of the compressors.

Example of application of air-conditioning-unit

MM

TM

M

M

M

Out-door air

FU p

FU

MSRExhaust air

III

p

Con-denser

Exhaust airMeasurement and control

DX

T

M

Supply airCon-

denser

VF

VF

ODA

EHT

EHT Condenser bypass

Reheat Condenser

SUP

ETA

7

Pre-dehumidification for a sorption dehumidifier using the condensationheat regenerationI Direct heat exchanger, transfers the heat

directly from the air to the evaporating of the cold media. No heat transfer from the cold media to a heat carrier (water or sole) required. The evapora-ting temperature can be applied approximately 4 to 7 K higher. The surface temperatures necessary for dehumidification are generated more

efficiently.

I After the direct heat exchanger, an abso-lute humidity of 5 g / kg can be attained.

I An adjusted control of performance and exchange prevents icing and reduces the energy input in partial load mode.

I The waste heat of the cooling unit can be used, completely or in part, during the sorption process to preheat the regeneration airflow.

Example of application of process technology

TM

TM

P

P

F

F

T

T

FU p

FU

MSR

DX

Exhaust air

III

pProzess air

Extract AirCon-denser

Out-door air

T

M

DX

VFMeasurement

and control

ODA

EHT Extract

air

Process air

-

8

Main station Berlin – energy-efficient air-conditioning with integrated cooling

I 6 air-conditioning-unitsI approx. 170 000 m3/ h air-volumeI 1051 KW cooling capacity

-

9

Main station Berlin – installation of the air-conditioning-units by helicopter.

The reconstruction of the Berlin main railway station was spectacular, because, above all, two office towers were tilted from both sides over the actual station to form the roof of the station.

The building work for the two office

towers represented the last section of completing the station. Both buildings are 46 metres high and, therefore, higher than the nearby Federal Chan-cellery, which is 36 metres height. Both construction frames overhang the East-West glass roof of the station like bridges, there-fore the designation “bow”.

Both bow constructions, totalling 12 floors, encompass approximately 50 000 square metres gross area. They are designed for office use. For the retention of occupant productivity in the large office area, the responsible

parties decided on total air-conditio-ning. Naturally, it was assumed that this air-conditioning can be operated with the least primary energy consumption.

10

Internal absorption in the unit rotary heat exchanger with humidity recovery

Because of the high percentage of glass area as facade of the bow construction, in summer, much of the thermal load must be dissipated by the air-conditio-ning units. For the selective promotion of this procedure, there are still some surface cooling elements and window convectors existing in the rooms.

parties involved in the construction and, not least, one of the great precedence‘s of a dismountable unit construction.

All units were accurately inscribed, so that they could be allocated easily at the installation site on the roof and helicop-ter for transportation. Installation was

However, the air-conditioning accom-plishes the majority of the remainder. A total of 6 AT4 air-conditioning-units were supplied, with integrated cooling, rotors for energy recovery and dehu-midification units. All air-conditioning-

units are tailored to the installation site because of the restricted space available.

On delivery of the central units, the foundations required and the retainer housing for the roof air-conditioning casings design were available.

The media pipelines for supplying the units in the roof casings were laid and the air connections and ducts in the building for connection of the units provided. Therefore, the missing air- conditioning units had to be transported by helicopter. Again a highlight for all

11

External absorption unit in the accessible roof casings

carried out immediately on the roof – 20 fitters were employed at this period

on each of the two bow constructions.

In total, the new air-conditioning-units accomplish a volume flow of approx.

170000 m³/h. For the application of office air-conditioning, 6 AT4 central

units were equipped with rotary heat exchangers. Because the supply air and exhaust air units are not separated spatially, rotors are, therefore, not very expedient, because humidity recovery can also be accomplished for. In the event of failure in summer, the heat recovery rate in the supply air is between 71.2 % and 72.4 % and also analog the re-humidification rate be-

tween 42.5 % and 46.6 %. On winter days, the heat recovery rate is an average of between 70.7 % and 72.0 %, as well as a re-humidification rate of

75.4 % to 78.8 %. Therefore, not only can the primary heating energy be saved, but also the required energy supply to the humidification units is

reduced.

AIR-HANDLING-UNITS AT6 – FOR BIG AIR-VOLUMES

VENTILATION AND AIR-CONDITIONING-UNITS

2

AT6 – for big air-volumes

3

Advantages that convince

I variable and optimized customization

for all specifi c applications

I high product quality using state-of-

the-art manufacturing technology

I customer-orientated process control

guarantees maximum delivery reliability

I planning and evaluation using Klim@

Soft®, the professional design pro-

gram for planners and architects

I unit design in accordance with VDI

6022

Design with excellent construction

characteristics

I maximum corrosion protection using

galvanized housing panels and powder-

coated

I high thermal and noise insulation

using 58 mm panel thickness

I noise and thermal insulation made

from rock wool; building material class

A1; non-combustible in accordance

with DIN 4102

I patented thermal decoupling between

the inner and outer shell

I minimized thermal bridge using opti-

mized housing capping

I unit designed for disassembly

I optimum adaptation to structural

conditions using a variable module

dimension of 102 mm

4

Inner walls hygienically smooth

AT6 – large units

Patented thermal decoupling

5

Conforms to all national and European standards

Effi ciency and economy

I reduced energy consumption through

optimized incident air-fl ow to the func-

tion units and therefore minimizing the

internal pressure posses

I version of fan adapted to the location

of operation

I application of all established heat re-

covery systems; adapted to the respec-

tive application zone

I “Life-Cycle-Costs” optimized units

Top quality for all application zones

I inside and outside installation

I hygienic construction

I integrated cooling

I various types of material

I big air-handling-volumes and also

splitted units for easy transportation

I DEC-Systems

CONFORMITY

AT6 – quick selection

6

12 700 - 29 600 15 x 15 1 632 1 632 1 532 1 532

15 200 - 35 500 18 x 15 1 938 1 632 1 838 1 532

20 300 - 47 300 24 x 15 2 550 1 632 2 450 1 532

26 200 - 61 100 31 x 15 3 264 1 632 3 164 1 532

18 200 - 42 600 18 x 18 1 938 1 938 1 838 1 838

21 300 - 49 700 21 x 18 2 244 1 938 2 144 1 838

24 300 - 56 700 24 x 18 2 550 1 938 2 450 1 838

31 400 - 73 300 31 x 18 3 264 1 938 3 164 1 838

37 500 - 87 400 37 x 18 3 876 1 938 3 776 1 838

24 800 - 57 900 21 x 21 2 244 2 244 2 144 2 144

28 400 - 66 200 24 x 21 2 550 2 244 2 450 2 144

31 900 - 74 500 27 x 21 2 856 2 244 2 756 2 144

36 600 - 85 500 31 x 21 3 264 2 244 3 164 2 144

40 200 - 93 700 34 x 21 3 570 2 244 3 470 2 144

43 700 - 102 000 37 x 21 3 876 2 244 3 776 2 144

47 300 - 110 300 40 x 21 4 182 2 244 4 082 2 144

50 800 - 118 500 43 x 21 4 488 2 244 4 388 2 144

32 400 - 75 600 24 x 24 2 550 2 550 2 450 2 450

36 500 - 85 100 27 x 24 2 856 2 550 2 756 2 450

41 900 - 97 700 31 x 24 3 264 2 550 3 164 2 450

45 900 - 107 100 34 x 24 3 570 2 550 3 470 2 450

50 000 - 116 600 37 x 24 3 876 2 550 3 776 2 450

54 000 - 126 000 40 x 24 4 182 2 550 4 082 2 450

58 100 - 135 500 43 x 24 4 488 2 550 4 388 2 450

62 100 - 144 900 46 x 24 4 794 2 550 4 694 2 450

66 200 - 154 400 49 x 24 5 100 2 550 5 000 2 450

41 000 - 95 700 27 x 27 2 856 2 856 2 756 2 756

47 100 - 109 900 31 x 27 3 264 2 856 3 164 2 756

51 600 - 120 500 34 x 27 3 570 2 856 3 470 2 756

56 200 - 131 100 37 x 27 3 876 2 856 3 776 2 756

60 700 - 141 700 40 x 27 4 182 2 856 4 082 2 756

65 300 - 152 400 43 x 27 4 488 2 856 4 388 2 756

69 900 - 163 000 46 x 27 4 794 2 856 4 694 2 756

74 400 - 173 600 49 x 27 5 100 2 856 5 000 2 756

79 000 - 184 300 52 x 27 5 406 2 856 5 306 2 756

83 500 - 194 900 55 x 27 5 712 2 856 5 612 2 756

Width (mm) *Height (mm) Width (mm) *Height (mm)

Air-Volume Size of unit External dimensions Internal dimensions

m3/h

Subject to dimension and design changes. Further sizes of unit available on request.

* Height without installation frame.

Installation frame up to a width of 3 876 = 150 mm



7

Exhibition halls

I Düsseldorf trade fair

I Exhibition hall 2, Essen

I Exhibition hall 3 and 9, Frankfurt

I Exhibition hall 3, Essen

I Trade fair / Expo 2000, Hannover

I Trade fair Friedrichshafen

I Exhibition centre Berlin

Pharmaceutical / Chemical

I Höchst | Frankfurt

I Bayer AG | Leverkusen

I Boehringer Ingelheim | Pharma-

ceutical Zaire works (Africa)

I Biochemie | Frankfurt

I Arche | Brazil

General

I Toho Tenax | Heinsberg

I St. Johannis Hospital | Landstuhl

I SAP | Walldorf

I Ato Tech | Trebur

I Wikus Hall 7

I Famila | Oldenburg

I ZF-gearbox dispatch building |

Saarbrücken

I CLID SAS | France, Turkey

I Sachsenbatterie | Zwickau

AT6 large units – abstract from the reference list

Automobile industry

I SVW | Kaluga (Russia)

I Nissan | St. Petersburg (Russia)

I Honda | Swindon (England)

I Ford | Erlangen

I Daimler R & D-dept. | Ulm

I VW Halle 28 | Hannover

I BMW | Dingolfi ng, Leipzig, München,

Regensburg, South Africa

I Daimler Chrysler | Wörth, Bremen,

Stuttgart, Rastatt, Untertürkheim,

Ulm, Sindelfi ngen

I VW | Wolfsburg, Hannover, Bremen,

Mexico

I Opel | Rüsselsheim, Eisenach,

Portugal

I Audi | Ingolstadt

I Peugeot | Mulhouse, Poissy, Nigeria,

München, Madrid, Vigo (Spain), Trnava

(Slovakia)

I Renault | Bursa (Turkey), Dacia

(Rumania), Valladolid (Spain)

I Honda | Swindon (UK)

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

AIR-HANDLING-UNITS FOR THECHEMICAL / PHARMACEUTICAL SECTORS

AIR-HANDLING-UNITS

Production safetythrough maximum unit quality

Together we are working for the right solution

2

I designs compliant with ATEX 95

I specialised coatings for every

application

I process-oriented hygiene

solutions

Chemical and pharmaceutical deve-

lopment and production processes

place extremely high demands on the

involved air-handling and climate

systems with regard to safety, preci-

sion, reliability, reproducibility,

and durability.

In chemical and pharmaceutical pro-

cesses, safety is the top priority. Whether

in handling with aggressive and explo-

sive substances or when handling toxic

and environmentally harmful, natural

or genetically modifi ed biomaterials, it

is always valid to use controlled supply

and exhaust via suitable air-handling-

systems.

The demands for material purity on the

one hand and economy on the other place

extremely high demands on the precis-

ion and reliability of modern chemical

and pharmaceutical production pro-

cesses. The air-handling-systems used

must, among other things, assure

the thermodynamic, air-handling, and

climatic environmental conditions re-

quired for this and must therefore fulfi l

the same precision and reliability re-

quirements as the actual systems

themselves.

Air-handling and climate systems re-

present an essential component of the

primary development and production

apparatuses in the chemical and phar-

maceutical process chain. From a quality

management standpoint, these systems

are therefore subject to the same de-

mands as for the actual development

and production plants themselves. The

requirement for “best practice perfor-

mance” therefore sets the quality bar

for reliability and reproducibility, which

must also apply to the air-handling-

systems used.

In addition to the actual process

sequences, achieving the necessary

level of economy and product quality

requires all apparatuses and systems to

be of extremely high durability and

intrinsic value. Particularly in the fi eld

of chemical and pharmaceutical produc-

tion, this requires the use of the best

materials as well as special, adapted,

and optimised structural, global, and

detailed solutions.

AL-KO Air-Technology has been involved

for decades in the development and

production of air-handling-units that

fulfi l all of the requirements mentioned

above of chemical and pharmaceutical

development and production. The special

material adaptations, structural features,

modular design, and optimised energy

consumption of the AT4 and AT6 unit

series assure a client-specifi c applica-

tion for every process situation.

3

4

Air-handling-unitsfor the pharmaceutical sector

The pharmaceutical development and

production of synthetic or biotech sub-

stances and their formulation (galenics)


design and function of air-handling-

units. This is true for the sectors of

both “bench engineering” and large-

scale production.

With its AT4 and AT6 unit series, AL-KO

Air-Technology offers a modular system

that fulfi ls all of the requirements of the

pharmaceutical industry:

I the highest level of hygiene design

I easy, quick and complete cleanability

I precisely targeted application to the

process requirements

I precision of thermal air-handling

I durability and longevity

I operational and process safety

A few of the special structural features

of the AT4 and AT6 unit series:

I entirely smooth inner surfaces without

undercuts and cavities thanks to

patented housing construction

I free and complete access to all func-

tional units and components through

optimised supply and exhaust chambers

I can be fully inspected from outside

through mandatory large sight glasses

and internal lighting

I extremely high resistance to housing

leakage F9 in compliance with EN 1886

I extremely high corrosion protection

through adapted material selection at

all quality levels of stainless steel

I low operating costs due to optimised

fan units and minimised pressure

losses

I performance certifi cation in complian-

cebwith with EUROVENT

I hygiene certifi cation in compliance

with with VDI 6022, DIN 1946 and

VDI 3803

I ATEX certifi cation zone 21 and 22

5

I Bayer AG

I Aventis Pharma AG

I Boehringer Ingelheim

I Merck KGaA

I Schering AG

I Altana AG

I Merckle GmbH

I Pfi zer Gruppe

and many more

REFERENCES

6

Air-handling-unitsfor the chemical sector

All areas of the chemical process

chain, from the laboratory through

technical production, in the sectors of

development, synthesis and analysis


design, function and durability of the

involved air-handling-units.

With its AT4 and AT6 unit series, AL-KO

Air-Technology offers a modular system,

that fulfi ls all of the requirements of the

chemical industry:

I resistant to almost all substances and

gaseous combinations of substances

I client-specifi c application in compli-

ance with process requirements

I easy, quick and complete cleanability

I precision of thermal air-handling with

regard to temperature, humidity and

airfl ow

I durability and lasting quality

I energy effi ciency

I operational and process safety

A few of the special structural features

of the AT4 and AT6 unit series:

I extremely high corrosion protection

and durability through adapted material

selection at all quality levels of

stainless steel

I surface textures available in powder

coating, epoxy resin coating, and wet

lacquer coating

I fully explosion-protected designs

I extremely high resistance to housing

leakage F9 in compliance with EN 1886

I low operating costs due to optimised

fan units and minimised pressure

losses

I entirely smooth inner surfaces without

undercuts and cavities thanks to

patented housing construction

I free and complete access to all

functional units and components

through mandatory operating doors

and optimised supply and exhaust

chambers

I can be fully inspected from outside

through mandatory large sight glasses

and internal lighting

I performance certifi cation in compli-

ance with EUROVENT

I hygiene certifi cation compliant with

with VDI 6022, DIN 1946 and VDI 3803

I ATEX certifi cation zone 1 and 2

7

I BASF AG

I Degussa AG

I Henkel KGaA

I Fresenius AG

I Beiersdorf AG

I B. Braun Melsungen AG

and many more

REFERENCES

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

AIR-HANDLING-UNIT AT4 COMPLIANT WITH EU GUIDELINE ATEX 95

SAFETY CERTIFIED QUALITY

AIR-HANDLING-UNITS

ATEX 95 unit categories

According to the ATEX guideline (94 / 9 /

EG), units are grouped into categories

for use in the corresponding zones.

There are three different unit categories

for the unit group II, which correspond

to the different zones. This makes it

possible to associate explosion-proof

products with operational Ex zones.

Category 1 includes units for zones 0

and 20 (very high degree of safety).

AT4-classifi cation

Category 2 includes units that are struc-

turally designed so that they can be

operated in compliance with the para-

meters furnished by the manufacturer

and assure a high degree of safety. Units

of this category can, upon approval, be

operated in zones 1 and 21.

Category 3 includes units that are struc-

turally designed so that they can be

operated in compliance with the para-

meters furnished by the manufacturer

and assure a normal degree of safety.

Units of this category can, upon appro-

val, be operated in zones 2 and 22. DIN

EN 50281-1-2 differentiates between

conductive and nonconductive dust.

When there is conductive dust in zone

22, equipment from category 2 D must

be used.

EX-suitable unit components

I EX models of direct-driven fans for

zone 1 to T4 or 21 to T 120 °C com-

bined with a pressure-tight encapsu-

lated motor

I belt-driven EX fans for only zone 2

and temperature class T3!

I electrically conductive fan drive belt

I fl exible connection made of electric-

ally conductive material

I air fi lter cannot be statically charged

– for Explosionsgroups (IIA – IIC)

I inspection portholes made of glass

I drip eliminator cannot be statically

charged – new development

I all electrical components ATEX-

certifi ed, all mechanical components

with manufacturer confi rmation

I unit construction is completely

earthed

I earthing of louvre damper vanes

I run around coil system or plate heat

exchanger can be used for heat

recovery

CE II 2G/D c IIC T4 (x)

Unit situated inside the EX-zone

I dischargeable fl exible connection

I earthed damper vanes

I electrically conductive fi lter G4 – H13

I heat recovery provided by a run

around coil system or heat recovery

I electrically conductive droplet eliminator

I EX models of direct-driven fans for zone

1 to T4 or 21 to T 120 °C combined with

a pressure-tight encapsulated motor

I belt-driven EX ventilators only for zone

2 and temperature class T3

I drive motor encapsulated in pressure-

tight fashion with FC = frequency

converter operation

I sound absorber

I weatherproof grille at exhaust

Unit design 1

Exhaust air unit situated outside

EX-zone

Same components as in unit design 1

Unit design 2

Intake and exhaust air unit situated

inside the EX-zone

I intake and exhaust air units must

be EX-models

I all electrical components must be

EX- models

Unit arrangement

Intake and exhaust air unit situated

outside the EX-zone

I exhaust air unit must be an EX-model

I intake air unit (EX-model not required)

with louvre damper at air outlet to

prevent return fl ow

I electrical components situated

outside the EX-zone do not have to be

EX-models

for zone 1, T3 to T4,

or zone 21 to T 120 °C

for zone 2, T3

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

© F

FM

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HIGHEST RELIABILITY FOR REDUCED INVESTMENT COSTS FOR BUILDING SERVICES


2

Only someone who can breathe,has a chance of survival

In most cases, the victims of fi re

in buildings suffocate before the

temperature for combustion has

been reached. More than 95 % of

all fatalities and more than 70 %

of all damage to property and in-

surance loss by fi re are a result

of smoke.

In building fi res, it is long-standing

knowledge that smoke represents

the greatest source of danger. Only

when the people affected have air

to breathe can they orientate them-

selves and get to safety.

Origin of fi re

Time

SMOKE TEMPERA-TURE

For example, 10 kg of fl ammable

foam rubber generates 25 000 m3

of fumes in only one hour. In this

case, the source of fi re is only as

big as an armchair.

3

As part of a building, air-conditioning

plants must generally conform to the

fi re protection requirements. Air-con-

ditioning plants that are exclusively

used for ventilation must be switched

off in the event of a fi re.

Air-conditioning-units can be used for

smoke discharge and/or for supplying

air in the event of a fi re in the areas of

buildings with a sprinkler system.

Here, components that are checked for

temperature resistant must be used, as

well as checking for further ancillary

conditions.

Smoke discharge in areas with a sprinkler system

Temperature of fumes, 100 °C to 300 °C

Smoke discharge in the event of fi re, using ventilation appliances

I The smoke discharge concept is designed for smoke discharge up to a max. of 300 °C over a maximum period of two hours (for areas with sprinkler system).

I The unit design to be used, AT4-E, is equipped accordingly and has been tested under these conditions.

I All integrated components have a national technical approval.I In particular cases, an approval from the competent authority is required.I The ductwork for the smoke discharge must be checked. Outside of the area on fi re,

exhaust air ducts from L90 must be designed.I The ventilation appliance must be installed outside of the area on fi re. The room must not

conform to further F90 specifi cations.I Smoke discharge and ventilation can be carried out by a 2-stage fan. Currently, the use of a

frequency converter is not permitted.

In all cases, the use of an air-conditioning unit with a smoke discharge function must be clarifi ed with the appropriate authorization body, because use of air-conditioning-units for the assistance of smoke discharge is not explicitly defi ned in the building laws.

Air-conditioning-unit

Air-conditioning-unit deployable with smoke discharge function

Without smoke discharge function

Switch off in the event of a fi re

Smoke discharge in areas without sprinkler

system

Temperature of fumes > 300 °C

Air-conditioning-unit cannot be applied for

smoke discharge

Temperature of fumes,100 °C bis 120 °C

Air-conditioning-unit with temperature resistant components in conjunc-

tion with a manufacturer‘s declaration

Temperature of fumes,maximum 300 °C

Air-conditioning-unit with corresponding test at a test centre

4

Smoke discharge solutions with AT4 ventilation appliances

Case 1

Smoke discharge by the

exhaust duct system

The ventilation appliance has a supply

air and exhaust air fan as standard.

In the event of smoke discharge, the

supply air fan is switched off. The air

circulation channel is closed by a fi re

protection valve. The two-stage exhaust

fan sucks the fumes from the exhaust

duct and conveys them outside, through

the exhaust air duct.

Case 2

Smoke discharge by the

supply air duct system

Because of spatial circumstances, the

supply air duct system is often more

suitable for fume extraction. In this

case, in the smoke discharge mode of

operation, the exhaust air duct, as well

as all components of the air supply unit,

are closed from the exhaust air channel

using smoke protection valves.

EHA

ODA SUP

EHAETA ETA

EHA

ODA

ETA

SUP

ETA

Ventilation mode of operation with air circulation Smoke discharge by the supply air

Ventilation mode of operation with air circulation Smoke discharge by the supply air

5

Case 3

Smoke discharge by

an exhaust air unit

Smoke discharge by an exhaust air unit

is possible, providing that the fl ammable

components in the exhaust air unit can

be circumvented through a bypass.

Case 4

Ventilation appliance with

parallel smoke discharge fans

The discharge of smoke is carried out

through additional smoke discharge

fans, connected laterally directly on

the supply air outlet and / or on the

exhaust air inlet. The complete ventila-

tion unit is shut off from the smoke

discharge duct by smoke protection

valves, so that all fl ammable compo-

nents can be bypassed.

EHA ETA

EHA ETA

EHA ETA

EHA SUP

Ventilation mode smoke discharge via bypass

Ventilation mode Smoke discharge

AT4 ventilation appliancewith smoke discharge function

6

I Cost and space saving by a multi-

functional ventilation system. No

additional independent mechanical

smoke discharge system necessary.

I Even in cases where no smoke

discharge is mandatory, the AT4

provides the required safety.

I The ventilation unit with smoke

discharge function must not be

installed in a F90 room.

I The smoke discharge can be architec-

turally better integrated in the building.

What advantages does a ventilation system with smoke discharge function offer?

LTU-Arena Düsseldorf – Example of an AL-KO

ventilation technology air-conditioning unit

with smoke discharge function (maximum

fume temperature 300 °C)

7

Experimental setup at the TU-Munich; Unit

details after successful test – 2 hours at 300 °C

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

AT4-T AIR-HANDLINGIN TROPICAL DESIGN

AIR-HANDLING-UNITS

AT4-T air-handlingin tropical design

Air-handling-units are exposed

to different environmental- and

operating conditions which require

highest demands on the characteri-

stics of the construction.

Specifi cations for AT4-T

So, the thermal performance of the air-

handling-unit casing is a most important

part. Heat losses and thermal bridges,

just as appearances of condensate and

infi ltrations caused by design of air-

handling-unit casings, can lead to loss

of energy or damages which are well-

known from various problems in the con-

struction business. AL-KO Air-Techno-

logy has taken care of this subjects and

therefore designed a product which is

fulfi lling all requests for state-of-the-

art air-handling-unit constructions. To

meet this high requirements as quality

and functionality also in future, AL-KO

Air-Technology has set a signal with the

new casing construction AT4-T. The use

of most modern materials in combina-

tion with an optimized structure work

allowes no thermal bridges even under

extreme operating conditions.

Unit construction totally smooth inner

surface without edges, joints and grooves.

Thermal optimized casing structure by GRP

(Glass fi bre re-inforced plasic)-profi les and

panels.

In spite of this thermal optimisation

of the casing, the main characteristic

advantage of the AT4 series will not

be changed: The smooth inner surface

without edges, joints and grooves.

I thermal optimized casing structure

by GRP (Glass fi bre re-inforce plastic)

-profi les and panel

I specifi cations of the casing tested and

approved by TÜV-SÜD according to the

EN 1886

I mechanical stability: class 1A

I casing leakage: class B

I fi lter-bypass-leakage: F9

I thermal isolation: T2

I factor of thermal bridges: TB2

The specifi cs of AT4-Tropic

Contents of the essential characteristics of the AT4 range with the optimized casing system AT4-T

This appears as a very high advantage

regarding to the guideline VDI 6022.

(Hygienic applications) The design

criteria for cleaning and service are

considered completely.

I units consistent geometric spacing of

76,5 mm for optimisation of casing di-

mensions

I all components are optimized by using

the certifi ed Software Klim@Soft®

I all units are absolutely accessible and

the components are removable for clea-

ning and maintenance works.

I certifi cations:

EUROVENT

Guideline VDI 6022 regarding

hygienic air-handling

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com


POOLAIR

CLIMATISATION ANDDEHUMIDIFICATION OFINDOOR SWIMMING HALLS

Cutting-edge technology in swimming hall climatisation and dehumidifi cation

In indoor swimming pools, especially

when open to the public, there is a high

level of humidity. People fi nd humidity

levels above the sultry limit extremely

unpleasant, considerable damage can

occur to the structure. The humidity

released by the water can only be dis-

charged by the air. Because of the areal

restrictions of indoor pools, as well as

the necessary areal purging with dehu-

midifi ed air, only mechanical ventilation

can be used to achieve this. Modern air-

conditioning-units, specially designed

for the special requirements of indoor

pools, dehumidify, heat and ventilate

every type of indoor pool and their

adjoining rooms.

Economic ventilation and

dehumidifi cation

Through the mixing of extracted air –

in the heat recovery unit already

predehumidifi ed – and fresh air (from

out-side), it is very possible to prepare

optimum dehumidifi cation of condi-

tioned mixed air economically on the

basis of the acknowledged ranges of

application in the VDI 2089.

The mixed air is heated by the heat re-

covery and subsequently heated to the

required operating temperature using

a pump-hot-water heater or a highly

effi cient heating pump.

We are taking care of economical

operation for optimal humidity and

therefor the very best indoor air

climate in swimming halls.

CLIMATISATION OF INDOOR SWIMMING HALLS

ApplicationAT4 POOLAIR®

Capacity Heat-RecoveryODA -14 °C / 90 % r.H. – EHA 30 °C / 53,5 % r.H.

Dehumidifi cation CapacityIAW VDI2089

Air volume(max.)

Lenght Width Hight Weight approx.

08 x 08 with HP* 3 300 21 77 4 667 689 1 608 1 342

08 x 08 without HP* 3 300 21 76 4 132 689 1 608 1 150

12 x 08 with HP* 5 000 32 77 4 667 995 1 608 1 625

12 x 08 without HP* 5 000 32 76 4 132 995 1 608 1 394

12 x 12 with HP* 7 500 48 84 5 355 995 2 220 2 169

12 x 12 without HP* 7 500 48 82 4 743 995 2 220 1 792

16 x 12 with HP* 10 000 64 84 5 585 1 301 2 220 2 418

16 x 12 without HP* 10 000 64 82 4 820 1 301 2 220 2 099

20 x 12 with HP* 12 500 80 84 5 508 1 607 2 220 3 075

20 x 12 without HP* 12 500 80 82 5 049 1 607 2 220 2 643

24 x 12 with HP* 16 500 105 83 5 967 1 913 2 220 3 728

24 x 12 without HP* 16 500 105 82 5 432 1 913 2 220 3 243

24 x 16 with HP* 20 000 127 88 6 350 1 913 2 830 4 505

24 x 16 without HP* 20 000 127 87 5 814 1 913 2 830 3 855

28 x 16 with HP* 23 000 146 88 6 427 2 219 2 830 4 896

28 x 16 without HP* 23 000 146 87 5 814 2 219 2 830 4 401

28 x 20 with HP* 29 000 184 82 7 192 2 219 3 444 5 637

28 x 20 without HP* 29 000 184 81 6 504 2 219 3 444 5 049

32 x 20 with HP* 34 000 216 82 7 268 2 525 3444 6555

32 x 20 without HP* 34 000 216 81 6 503 2 525 3 444 5 546

32 x 24 with HP* 40 000 254 83 8 339 2 525 4 055 8 119

32 x 24 without HP* 40 000 254 82 7 497 2 525 4 055 6 892

(%) (mm) (mm) (mm) (kg)(m3/h) (kg/h)

ODA

EHT SUP

ETA

AL-KO AT4 POOLAIR®: plate-heat-exchanger

* HP=heatpump

Application /unit design with heat-pipe for heat-recovery possible.

Please ask for it!

AL-KO AT4 POOLAIR® (plate heat exchanger)

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

THE LUXURY CLASS OF MARINE AIR-HANDLING-UNITS

AIR-HANDLING-UNITS AT4

The modular construction of AL-KO

AT4 air-handling-units offers the

highest fl exibility regarding unit

dimensions.

AT4 marine air-handling-units can be

produced in more than 25 standard

unit sizes. Especially in the sector of

air treatment for marine applications

with its extreme air-conditions and

corrosive sea air as well as the static

demands of the shipbuilding the ap-

proven AT4 construction satisfi es the

highest demands. One of the biggest

advantages is the material suitability.

Standard AL-KO AT4 units are powder-

coated and therefore perfectly pro-

tected against corrosion.

The application variety of AT4 marine

air-handling-units ranges from contai-

ner ships to cruising vessels and even

up to luxury yachts.

AL-KO has long-time experiences for

planning, production and engineering if

it comes to marine applications.

You are in good hands with AL-KO for

all kinds of marine air-handling-units.

The special advantages of the AL-KO AT4 marine air-handling-units

Quality of great value

HIGH-TECH-COMPONENTS

Hygiene construction for easy cleanability

The inner surfaces of the units are

completely smooth, which plays an

important role for the cleaning and

servicing of the units.

The AT4 unit type serie is predestined

for the operation in the hygienic area.

Low heat losses as well as high sound

insulation with incombustible materials

are achieved by the constructions of

our 47 mm thick panels.

The AL-KO AT4 typifi es an air-handling-

unit with fl exible materials in inner and

outer walls. With our special construc-

tion different material confi gurations are

possible. Every air-handling-unit can be

individually designed by the use of

Salty air and extreme climate conditions require an adaptable unit concept

panels and installations in galvanized

steel, powder coating (standard color

RAL 7001, other color on demand),

and stainless steel V2A (SS304) as

well as V4A (SS316L).

Space-saving installation

The AT4 air-handling-unit system can

be delivered in divided construction,

so that the placement and on-site

assembly can be carried out very

easy. Besides this, the full functiona-

lity is maintained. Additionally,

costs are saved due to the fact that

no expensive openings are necessary

for the insertion of the units.

For every application in the marine air-

conditioning, we will fi nd the right so-

lution just for you. This also includes

planning and production of the units

with the corresponding functional units.

Today the choice and planning of the

suitable energy recovery system is

most important for an energy-saving

operation of air-handling-units.

Our unit range encloses air-fl ows from

1 000 m³/h up to 100 000 m³/h.

Ship builders and installation com-

panies all over the world can count

on our air-handling-units and on our

engineering. AL-KO belongs to the in-

ternationally leading manufacturers of

air-handling-units for shipbuilding.

Our adaptable air-handling-unit concept offers fi tted solutions including high energy effi ciency.

Excerpt from our references

Year of delivery

Name of ship / Name of project

Shipping company Shipyard

2008 Gorch Fock (Conversion) Deutsche Marine Elsfl ether Werft

2008 MY Talitha

2008 MY Crystal Privat Lürrsen Werft

2007 MV Balmoral Waverley Excursions Lloyd Werft

2007 SF 99 Privat

2006 MSC Poesia MSC Aker Yards France

2006 MSC Magnifi ca MSC Aker Yards France

2005 Norwegian Gem NCL Meyer Werft Papenburg

2005 MSC Orchestra MSC Aker Yards France

2004 MSC Musica MSC Aker Yards France

2002 Flussfahrgastschiff Peenewerft Wolgast

2001 Brilliance of the seas RCCL Meyer Werft

2001 European Dream Festival Cruises Chantiers de l´Atlantique

2000 Gorch Fock (Conversion) Deutsche Marine Elsfl ether+Jade Werft

2000 Maersk Volkswerft Stralsund

99/00 Radiance of the Seas RCCL Meyer Werft

99/00 Olympic Explorer Royal Olympic Blohm + Voss

98/99 Olympic Voyager Royal Olympic Blohm + Voss

1998 Mistral Festival Cruises Chantiers de l’Atlantique

1997 Div. Nordsee Bohrinseln NAM

95/96 Galaxy Chandris-Line Meyer Werft

94/95 Century Chandris-Line Meyer Werft

1994 Hochseefi schfänger Boitzenburger Werft

93/94 Oriana P+O Line Meyer Werft

1993 Horizon Chandris-Line Meyer Werft

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

ENERGY-EFFICIENT CLIMATISATIONAND DEHUMIDIFICATION

Compared to other techniques, the AL-KO

air conditioning technology with rotary

dehumidifi cation reduces the yearly energy

costs. A signifi cantly smaller dimensioned

cooling unit is integrated in the AHU unit

instead of a standard cooling coil. Additio-

nally a rotary energy recovery / thermal

wheel is included.

Thereby an extensive pre-dehumidifi cation

of the supply air will be ensured. The

required dehumidifi cation performance

is considerably lower than other systems

without recovery of the cooling energy

from the extract air.

AL-KO Climate System with Dehumidifi cation – Save more than 40 % of energy costs

Ordinary Cooling and Dehumidifi cation System

WITHOUT sorption rotor

EHA

ODA

ETA

SUP

extracted

air fan

exhaust air

damper

External

air damper

fi lter EU7 electrical

heater

coils

supply

air fan

supply

air

extracted

air

cooler

exhaust

air

external

air

damper

damper fi lter F7 sorption

wheel

evaporator /

condenser

drop

seperator

cooler run-arround

coil

supply

air fan

extracted

air fan fi lter F7

supply

air

run-

arround

coil

EHA = Exhaust Air

ETA = Extract Air

ODA = Outdoor Air

SUP = Supply Air

Systems comparison

AL-KO Cooling and Dehumidifi cation System

WITH sorption rotor

condenser /evaporator

Example of a calculation for a standard offi ce building:

l Size: 15.000 m² on 12 storey

l Technical Concept

Chiller: Using compact chiller for serving ahu‘s and fcu‘s

Ahu: Is serving fresh outside-air 4 m³/hm² (6 ahu a‘10.000 m³/h)

Fcu: Is serving the additional chilling demand

l Climate Conditions:

Hanoi Climate Conditions with 38° C and 85 % r.h. maximum

Investment costs (ordinary air conditioning system):

l Air-Handling-Units 57.855 USD

l Chilling (Cooling) Equipment 568.807 USD

l Electrical Equipment 490.860 USD

Total investment costs 1.117.522 USD

Investment costs (AL-KO air conditioning system):

l Air-Handling-Units 284.761 USD

l Chilling (Cooling) Equipment 354.804 USD

l Electrical Equipment 443.971 USD

Total investment costs 1.083.536 USD

Compare Investment Costs

The yearly energy costs and operating costs of an AL-KO HVAC

with the rotary dehumidifi cation „Humid-off®“ are at least

40 % lower than the ordinary systems for dehumidifi cation and

climatisation due to the smaller dimensioned cooling unit (Life-

Cycle-Costs).

In addition the portion of investment costs of this “ventilation and

air conditioning” is lower!

Life-Cycle-Costs

Low Investment Costs and Operating Costs

The supply air is cooled and dehumidifi ed with the cooling

recovery out of the exhaust air by using a sorptive coated

rotary heat exchanger. This is how the necessary cooling

supply can be realized with a small integrated cooling machine

or a distance cooling connection with low quantities in order

to reach the desired interior air state.

Planning

HUMID-OFF®

reduces investment costs

HUMID-OFF®

reduces energy costs and operating costs

Energy costs and

operating costs

Optimization, maintenance

Disposal according

to Life-Cycle

Planning and construction DisposalOperations

20 % of the total costs in Life-Cycle

Period under

observation

(5 – 15 years)

5 10 15

80 % of the total costs in Life-Cycle

Investment and

installation

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

AT4 HYGIENIC APPLICATIONACCORDING TO GUIDELINE VDI 6022

AIR-HANDLING-UNITS

2

AT4 AHU for hygienic application

… defi nes the hygienic

requirements for AHU with

regard to:

I planning

I design

I operation

I service

I maintenance

… according to highest technical

standard

… represents a qualifi ed hygienic

standard providing planning security

and avoidance of problems AL-KO AHU

comply to these requirements

We recommend a design check

(research institute for hygienic air)

The VDI guideline 6022, part 1 and 3

General requirements of VDI

6022 for manufacturers of AHU:

I all materials must comply with health

requirements and prevent microbio-

logical growth

I sandwich panel construction

I low condensation tendency

I smooth internal surfaces

I grooves easily cleanable

I bottom panel surface powder coated

or made in stainless steel

I all units and components are easily

accessible and equipped with lighting

where necessary and sight glasses

(possible to darken)

I continuous and complete condensate

drainage

I use of fans with access for cleaning

I sealing materials must be closed-cell

type and not absorb moisture, give

out odours or form a nutritive medium

for microorganisums

I hygienically appropriate manufacture,

transportation and intermediatestorage

at the place of installation

2007-2010

3

Construction

I providing enough maintenance space

I consideration of excellent air fl ow

conditions for connections and air

dampers

I the outside air dampers have to be

installed internally to avoid conden-

sation

I a drain pan under outside air fi lter

ensure better cleaning

I all relevant components are available

either fully powder coated or in

stainless steel

I various design for all applications with

AL-KO software Klima@Soft

Not approved (e.g.):

I place silencer immediately downstream

the fan, eliminator always behind

cooler. Alternative: Fan and cooler in

the direction of air fl ow

I the use of a direct driven fan or a fan

with fl at belt drive requires only fi lter

class F7 for the supply air

Examples:

I fi lter or silencer downstream

a humidifi er

I cooling coil without eliminator

Housing construction

I sandwich panels

I no condensation tendency (category

T3 / TB 3 or T2 / TB 2)

AL-KO solutions:

I smooth internal surfaces without

corners and edges

I powder coated panels or internal

panels in stainless steel

I avoidance of corrosive tin-plated

panel surfaces with unprotected

cutting edges

I door and panel seals are foamed

seamlessly, have a high density,

and are non-ageing

I all sections are easily accessible,

have the necessary lighting, access

doors, and sight glasses

I possibility of cabling mainly outside

the casing: no additional dirty corners

4

AT4 AHU for hygienic application

Filter construction:

I microbiological inert fi lter materials

I only use of closed – cell type sealing

I mechanically suffi ciently stable

materials even during humidity

I fi lter differential pressure control

optically or electrically as standard

I use of quality fi lters with test certifi ca-

tes

Filter installation:

I correct installation of fi lter to prevent

mechanical stress on the fi lter medium

I fi lter maintenance with easy access by

using fi lter quick snap device

I cleanable fi lter section optional with

drain pan

Filter

Prevention of belt wear through:

I use of direct driven fans (plug fans)

I use of fl at belts for belt driven fans

Casing with water drainage and cleaning

access (from size 400 onwards)

Fans

All used materials:

I have been tested extensively

I prevent microbacterial growth

I are resistant to disinfectants

I permit physical and chemical disin-

fection

Sealing materials

Reduction of relative humidity at the

outside air fi lter:

I heating of outside air through prehea-

ter or heat recovery (run-around-coil)

I providing warm air from heating coil to

the outside air fi lter section

I use of biostatic air fi lters

I closing of outside air damper and

heating of fi lter section

5

I built-in automatic shut-off for humidi-

fi er to allow the humidifi er to dry out

I eliminator with stainless steel frame

can be cleaned, pulled out and

dismantled

I exclusive use of humidifi ers complying

with VDI 6022

Air humidifi er

I sound absorber is usually located in

the AHU, not in inaccessible air ducts

Individual columns can be replaced

I avoidance of loose fi bres

I columns can be removed easily

without tools by using the installed

handlevers

I access panels on the front for easy

access

Sound absorber

I all sections are easily accessible (can

be pulled out)

I frame of coolers are specially pro-

tected against corrosion

I fi n space are > 2.0 mm and can be

cleaned up to the core by using a

steam cleaner

I drain tray made in stainless steel and

guarantees continuous and complete

drainage

I installation of an eliminator with the

cooler, can be pulled out and dis-

mantled

I complete insulation of pipes through

the panel to avoid condensation

I coil frame made out of aluminium,

pipes and collector made out of copper

Heat exchanger

6

Checklist VDI 6022

all materials meet health requirements

sealing materials are closed – cell type

service space for maintenance to be foreseen

all units and components are easily accessible,

equipped with lighting and sight glasses (for

fi lter, humidifi er, fans with height > 1.3 m)

continuous and complete drainage for wet

componentsdrain tray and fl oor pan in stainless

steel with suffi cient gradient

tray in outside air section pan with drainage

(for external installation)

air velocity through eliminator max. 3.5 m /s

cleaning after manufacturing

hygienically appropriate manufacture, transportation

and intermediate storage at the place of installation

Unit construction

prevention of belt wear:

I fi lter F7 downstream fan with V-belt drive

or

I use of direct driven fans

or

I use of fl at belt driven fans

casing fan with water drainage and access

(from size 400 onwards)

Fan

sandwich panel construction from permanently

corrosion-proof materials, e.g powder coated

smooth internal surfaces without grooves

surface can easily be cleaned

wet sections are from non-corroding material

Casing for single stage fi ltering F7, for two-stage fi ltering

F5 + F7

use of microbiological inert (biostatic) fi lter materials

use of exclusively non-porous sealing profi les

dust side fi lter maintenance with service chamber or

fast fi lter release device

Filter

bottom permanently non-corrosive with powder coating

or in stainless steel

fi lter with sight glass and lighting from

height > 1.3 m onwards

7

sight glass (possible to darken)

completely dryable

fl ushing installation for circulating water

automatic shut-off for humidifi er

drip eliminator can be cleaned, removed and

dismantled

Humidifi er

use of materials harmless to health

mechanically stable surfaces, easy to clean

silencer columns positioned in AHU

individual columns are easy to replace and service

glass fi ber surface to avoid loose fi bres and for

easier cleanability

access panels at maintenance side Arrangement

preferable in the AHU

Sound absorber

fi n space minimum 2,0 mm

deep cleaning to the core possible

all sections are easily accessibly

(can be pulled out or accessed)

frame protected against corrosion, for cooler made

of aluminium or stainless steel

condensate drain (cooler) for continuous and

complete drainage

removable and dismantable eliminator after cooler

continuous insulation of pipe through the panel

Heat exchanger

fi lter differential pressure monitoring optically or

electrically for each fi lter stage

correct air fi lter installation with low mechanical stress

on fi lter medium

fi lter section with drain pan (optional)

low humidity at outside air fi lters through:

I heating of outside air through preheater or heat

recovery (KVS system)

I return of partial air stream from the supply air side

for preheating (optional or customer-fi tted)

I use of biostatic air fi lters

I closing outside air damper and heating the fi lter

section

fi lter description fi xed outside on the unit

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

SUCTION SIDE TEST CHAMBER IAW DIN 24163

AL-KO WORKS ACCEPTANCE TESTS

AL-KO works acceptance tests

I Perfect and precise ventilation and

air-conditioning-unit design using

EUROVENT certifi ed software “AL-KO

Klim@Soft”

I Production / assembly of the

ventilation and air-conditioning-

units in DIN ISO 9001 certifi ed

manufacture

Verifi able quality and technical data

Installation of the complete ventilation

and air-conditioning-unit central

controller on the suction side test

chamber to verify the ventilation system

data:

I ultimate reliability regarding

the technical data supplied (unit

characteristics)

I ultimate reliability regarding the

ventilation and air-conditioning-units

I energy effi ciency (electrical power

input fan, as well as air-side pressure

losses of all functional units

In the framework of the AL-KO works

acceptance test on the suction side test

chamber, the customer has the option

to already appraise their ventilation and

air-conditioning-units weeks before

delivery / installation on-site.

Here at the AL-KO factory, the customer

can assure himself, especially with regard

to the required unit dimensions and the

quality of the installed function units as

well as the quality of manufacturing.

Also, a check of the required inspec-

tion doors and interfaces (e.g. heat

exchanger, control cabinets etc.) to-

gether with the customer is an element

of the AL-KO works acceptance test.

Presentation of the air-handling-units to the customer

Assure yourself by an AL-KO works

acceptance test of the AL-KO pro-

duction and manufacturing quality!

¹ max. testable unit sizes: 12 m long x 4.5 m wide x 3.3 m high

² The test is carried out either in the supply or exhaust airway,

depending on the customer‘s request

³ A valve on the pressure side of the air-handling-unit is required

to represent the external pressure

STATIC FAN PRESSURE INCREASE3

Checking the necessary air-handling-data with the aid of a suction side test chamber

Using the AL-KO test chamber (DIN

24163), air-handling-units can be tested

in the presence of the customer up to an

air fl ow of 120 000 m³/h¹.

The accuracy attained here greatly ex-

ceeded the accuracy of measurement

on building sites².

The test chamber is monitored by the

TÜV Süd (Technical Inspection Authority,

south). The injection nozzles, used for

air-fl ow volume measurement, attain

an accuracy of +/- 1.5 %!

As test documentation, the customer

receives the measured unit characteris-

tics.

Assure yourself personally of the

effectiveness and energy effi ciency

of the AL-KO ventilation and air-condi-

tioning-units!

2 000

1 500

1 000

500

0

0 10 000 20 000 30 000 40 000 50 000

Sta

tic

fan

pre

ssu

re i

ncr

ease

p s

G [

PA

]

airfl ow V [m3/h]

AL-KO works acceptance tests

General services regarding ventilation

and air-conditioning-units

I design

I surfaces / corrosion protection

I leak tightness

I integrity

I compliance with data sheets /

drawings

I lighting

I attaching parts

I inspection doors

I safety equipment

Our services regarding AL-KO works acceptance test

Supply and exhaust air components

I fi lter

I heat recovery units /

energy recovery units

I heat exchanger

I fans

I sound absorber

I air connections

Determination of the air-handling

data and customer documentation

I fan installation characteristic

(pressure increase pfa through

the air-fl ow rate)

I unit characteristics (external pressure

through the air-fl ow rate)

I fan power input through the air-fl ow

rate

Fan vibration measurements

AL-KO THERM GMBH

Hauptstraße 248 - 250


Germany

PLEASE CONTACT YOUR COMPETENT PROJECT MANAGER AT AL-KO!

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

The compacT uniT series from aL-KoEASYAIR

EASYAIR

EASYAIR

2

The new EASYAIR® air handling units are equippedwith a high efficient energy recovery system. The air handling units guarantee an efficiency of 80 – 90 % in

accordance with the European Guideline DIN EN 308.

All components are designed to optimize the efficiency. The aerodynamic efficient arrangement of the components

in connection with reduced pressure losses on the air side

and the fans with modern EC drive technology*, enables an

extremely energy saving operation throughout the year.

By using these components and the high quality casing of the unit, acoustic emission is greatly reduced.

The intelligent control of the EASYAIR® is easy to

handle. The control unit assumes the energy-optimized

operation of all components. The complete unit is wired as

a plug-and-play system. You only require the connections for power (and optional cooling and heating medium) and

you can immediately start the EASYAIR®.

You will always find the correct air handling unit for all

applications in the range of air volume between 650 and

13.000 m³/h.

EASYAIR® – The easy way to a good climate

i Most efficient energy recovery with an efficiency of 80 – 90 %

i Energy-saving fan motors by using EC technology for lowest energy consumption

i Noise reduction by using sound absorption casing for the air handling unit and optimized components

i Easy operation by using most intelligent control and regulation

i High quality manufacturing, easy to install, reduced maintenance costs

* EC = electronic commutated

33

Automatische Luftqualitätsregelung

Im Komplettgerät SE

Automatische Luftqualitätsregelung

Im Komplettgerät SEplate heat exchanger

i Supply and exhaust air is completely

separated (no cross flow contamination)

i Optimized energy recovery

i Reduced maintenance costs

applications:

i Exhaust air for toilets

i Locker rooms

i Medical buildings, health centres

i Retirement homes

note: Due to the separation of the

supply and exhaust air, the application of

plate heat exchangers for hygienic systems

is possible without any restrictions.

fan with ec motor

i Maximum motor efficiency

i Compact construction

i Integrated vibration decoupling

i Energy efficient operation

i Extended life cycle

i Low maintenance costs

The modern motor technology of the

EASYAIR® air handling units ensures

quiet and energy efficient operation in all

applications.

rotary heat exchanger

i Optimized energy recovery

i Particularly suitable for variable

air flows

i Compact construction

applications:

i Schools, offices, administrative buildings

i Club houses, function rooms

i Shops

i Sport halls

SYSTEM COMPONENTS AND APPLICATIONS

4

EASYAIR®

Performance data

rotary heat exchanger options

Type air volume1 (m³/h) / efficiency2 (%) / sound power level3 dB(a) sfp4 sa /ra Length11 Width5 heigth a6 B6 c6 Duct connection (mm)11 Weight max. connection power electric heater hW chW

min nominal max W/m³·s mm mm mm mm mm mm Width Height kg kW A7,8 kW A7 kW9 kW10

ro-01 650 / 90 / 79 1.350 / 82 / 82 1.700 / 79 / 85 954 / 824 1.530 712 963 - - - 612 306 307 3,1 6,9 3,0 4,5 2,8 4,5

ro-02 1.000 / 90 / 81 2.000 / 83 / 81 2.600 / 79 / 83 867 / 652 1.530 865 1.269 - - - 765 459 378 2,1 6,7 4,5 6,5 4,0 6,8

ro-03 1.500 / 90 / 80 3.000 / 82 / 82 3.800 / 79 / 84 764 / 603 1.530 1.018 1.269 - - - 918 459 448 4,2 8,5 7,0 10,1 6,2 10,2

ro-04 2.000 / 90 / 79 4.000 / 83 / 86 5.100 / 79 / 89 694 / 561 1.683 1.171 1.575 689 382 612 1.071 612 640 6,9 12,5 9,0 13,0 8,2 13,8

ro-05 2.700 / 90 / 81 5.400 / 82 / 88 6.500 / 80 / 92 724 / 574 1.683 1.324 1.575 689 382 612 1.224 612 705 6,9 12,5 12,0 17,3 11,0 18,2

ro-06 3.300 / 88 / 83 6.300 / 80 / 90 7.500 / 78 / 89 737 / 649 1.683 1.324 2.187 689 382 612 1.224 918 815 6,9 12,5 15,0 21,7 14,5 21,5

ro-07 4.200 / 90 / 86 8.400 / 82 / 87 10.200 / 80 / 91 747 / 598 1.989 1.630 1.881 765 536 689 1.530 765 1.008 9,7 16,5 – – 17,2 28,4

ro-08 5.000 / 88 / 84 10.000 / 80 / 90 11.000 / 77 / 90 780 / 679 2.142 1.630 2.187 842 536 765 1.530 918 1.133 9,7 16,5 – – 23,6 34,6

ro-09 6.000 / 90 / 88 12.000 / 82 / 89 13.000 / 81 / 92 681 / 579 2.142 1.936 2.187 842 536 765 1.836 918 1.280 10,4 17,5 – – 24,7 40,9

plate heat exchanger options



pL-01 650 / 85 / 78 1.350 / 82 / 82 1.700 / 81 / 85 925 / 737 2.066 712 963 – – – 612 306 365 3,1 6,9 3,0 4,5 2,8 4,5

pL-02 1.000 / 85 / 78 2.000 / 82 / 81 2.500 / 81 / 83 780 / 581 2.066 1.018 963 – – – 918 306 428 3,1 6,9 4,5 6,5 4,0 6,8

pL-03 1.500 / 85 / 78 3.000 / 82 / 85 3.700 / 82 / 87 784 / 656 2.372 1.018 1.269 – – – 918 459 556 4,2 8,5 7,0 10,1 6,2 10,2

pL-04 2.000 / 85 / 78 4.000 / 82 / 86 5.000 / 82 / 87 748 / 608 2.525 1.324 1.269 612 1377 536 1.224 459 730 4,2 8,5 9,0 13,0 8,2 13,8

pL-05 2.500 / 85 / 79 5.000 / 82 / 87 6.200 / 82 / 91 748 / 608 2.601 1.630 1.269 688 1377 536 1.530 459 846 7,2 12,9 11,6 16,7 10,5 17,1

1 External pressure loss supply air 300 Pa, exhaust air 250 Pa

2 Efficiency of heat recovery according to DIN EN 308

(without condensation)

3 Sound power level in the supply air duct with dampers

4 Specific Fan Power (SFP) in accordance with EnEV 2009 at nominal air

volume and external duct pressure losses supply air 300 Pa, exhaust air

250 Pa, incl. dampers and filters (F7 / F5)

5 Additional width for repair switch 80 mm (detachable during transport)

TEChNICAL DATA

E K TA

B

Heig

th

765

A C

Length


Heater/cooler module (option)

(heater only, L=229 mm)

ea(exhaust air)

oa(outside air)

sa(supply air)

ra(return air)

5

rotary heat exchanger options



ro-01 650 / 90 / 79 1.350 / 82 / 82 1.700 / 79 / 85 954 / 824 1.530 712 963 - - - 612 306 307 3,1 6,9 3,0 4,5 2,8 4,5

ro-02 1.000 / 90 / 81 2.000 / 83 / 81 2.600 / 79 / 83 867 / 652 1.530 865 1.269 - - - 765 459 378 2,1 6,7 4,5 6,5 4,0 6,8

ro-03 1.500 / 90 / 80 3.000 / 82 / 82 3.800 / 79 / 84 764 / 603 1.530 1.018 1.269 - - - 918 459 448 4,2 8,5 7,0 10,1 6,2 10,2

ro-04 2.000 / 90 / 79 4.000 / 83 / 86 5.100 / 79 / 89 694 / 561 1.683 1.171 1.575 689 382 612 1.071 612 640 6,9 12,5 9,0 13,0 8,2 13,8

ro-05 2.700 / 90 / 81 5.400 / 82 / 88 6.500 / 80 / 92 724 / 574 1.683 1.324 1.575 689 382 612 1.224 612 705 6,9 12,5 12,0 17,3 11,0 18,2

ro-06 3.300 / 88 / 83 6.300 / 80 / 90 7.500 / 78 / 89 737 / 649 1.683 1.324 2.187 689 382 612 1.224 918 815 6,9 12,5 15,0 21,7 14,5 21,5

ro-07 4.200 / 90 / 86 8.400 / 82 / 87 10.200 / 80 / 91 747 / 598 1.989 1.630 1.881 765 536 689 1.530 765 1.008 9,7 16,5 – – 17,2 28,4

ro-08 5.000 / 88 / 84 10.000 / 80 / 90 11.000 / 77 / 90 780 / 679 2.142 1.630 2.187 842 536 765 1.530 918 1.133 9,7 16,5 – – 23,6 34,6

ro-09 6.000 / 90 / 88 12.000 / 82 / 89 13.000 / 81 / 92 681 / 579 2.142 1.936 2.187 842 536 765 1.836 918 1.280 10,4 17,5 – – 24,7 40,9

plate heat exchanger options



pL-01 650 / 85 / 78 1.350 / 82 / 82 1.700 / 81 / 85 925 / 737 2.066 712 963 – – – 612 306 365 3,1 6,9 3,0 4,5 2,8 4,5

pL-02 1.000 / 85 / 78 2.000 / 82 / 81 2.500 / 81 / 83 780 / 581 2.066 1.018 963 – – – 918 306 428 3,1 6,9 4,5 6,5 4,0 6,8

pL-03 1.500 / 85 / 78 3.000 / 82 / 85 3.700 / 82 / 87 784 / 656 2.372 1.018 1.269 – – – 918 459 556 4,2 8,5 7,0 10,1 6,2 10,2

pL-04 2.000 / 85 / 78 4.000 / 82 / 86 5.000 / 82 / 87 748 / 608 2.525 1.324 1.269 612 1377 536 1.224 459 730 4,2 8,5 9,0 13,0 8,2 13,8

pL-05 2.500 / 85 / 79 5.000 / 82 / 87 6.200 / 82 / 91 748 / 608 2.601 1.630 1.269 688 1377 536 1.530 459 846 7,2 12,9 11,6 16,7 10,5 17,1

6 Module dimensions for unit in split execution

7 Power supply 3 × 400 V, 50 Hz 8 without power for optional electric air heater

9 Heating capacity for temperature difference 6 K, medium 50 / 35 °C

10 Cooling capacity for temperature difference 10K (27 °C >> 17 °C),

medium 6 / 12 °C

11 With duct connections (option), the unit length increases on both

sides about 65 mm

E K TA

765

Heig

th

C A B

Length

Plate heat exchanger

(heater only, L=229 mm)

oa(outside air)

ea(exhaust air)

Heater/cooler module (option)

ra(return air)

sa(supply air)

6

EASYAIR®

Unit execution and options

eneV 2009 (energy saving regulation)

EASYAIR® air handling units are manufactured and designed according

to the European Guideline EnEV 2009. It must be also highlighted that due to

the high efficiency of the heat recovery

(80 – 90 %), due to the most energy

efficient motor technology for the fans

and due to the intelligent control of all

components all EASYAIR® air handling units are actually better than

the todays requirements of the EnEV

2009.

VDi 6022 (hygienic requirements)

All EASYAIR® air handling units are manufactured and designed ac-

cording to the European Guideline VDI

6022. The casings of all EASYAIR® air handling units are powder-coated

on both sides. Other components are made from galvanized steel. All

EASYAIR® air handling units warrantees full access for service and maintenance in accordance with the VDI 6022.

heat recovery

Selection can be done between rotary or plate heat exchanger. Rotary

heat exchangers are preferred when recirculating air operation is

possible. To prevent cross-flow-

contamination between supply and

exhaust air, the use of plate heat

exchangers is recommended.

i ro- = with rotary heat exchanger

i pL- = with plate heat exchanger

i RO-04-R-X = Casing in non-split execution

i RO-04-R-T = Casing in split execution

i RO-04-R-W = Casing for outdoor installation

i RO-04-R-W = Casing for outdoor installation with an

intake and exhaust hood

filter classes

As standard, the EASYAIR® is supplied with high efficient air filters. In the supply air there is a F7 and in the

exhaust air there is a F5 filter installed.

The quality of the filters are according

to VDI 6022.

i RO-04-R-X-75 = Supply air f7, exhaust air f5

i RO-04-R-X-e75 = Supply air f7, exhaust air f5 incl.

spare filters

Dampers

The EASYAIR® is supplied with internal, air tight dampers (tightness

class 2). One damper at the air inlet

for outside air and one damper at the

air outlet for exhaust air. Thus, no

additional dampers are required to be

installed in most of the applications

in the supply and/or exhaust air duct.

The internal dampers are supplied

with actuators. A further advantage:

No additionally thermal insulation is

required. As an alternative, you can get

the EASYAIR® also without these

internal dampers.

i RO-04-R-X-75-mK = with internal dampers

i RO-04-R-X-75-oK = without internal dampers

unit sizes

Both types of heat recovery units are

available in various sizes. For each size,

with their optimized air volumes, please

refer to page 4 and 5.

i RO-04 = Size 04, for air volume

between 2.000 to 5.100 m³/h.

Sample for selection is done by

choosing an EASYAIR® with rotary

heat exchanger (RO-), size 04 (RO-04).

service side

Of course, you can easily select the

service side of the EASYAIR®.

Doors ensure good access for main-

tenance and service works. The

indication for the service side is always

based on the direction of the supply air.

The service side in supply air direction

right conforms to the demonstration

given on page 4 and 5.

i RO-04-r = Service side in supply air

direction righti RO-04-L = Service side in supply air

direction left

split and outdoor execution

From unit size 04, there is the possibility

to order EASYAIR® in a split execu-

tion. Thus, the air handling unit can be

installed very easily, even e.g. when the

access openings are limited. Please refer

to the dimension table on page 4 and 5.

All EASYAIR® units can be ordered

for outdoor installation as a weather-

proof unit. Weatherproof units are only

available in one part and have a weatherproof roof with drip tray. As an option,

weatherproof units are available with an

intake and exhaust hood.

7

Duct connections

For all EASYAIR® air handling units acoustically isolated duct connections

are available that utilize the complete

open cross-section of the unit. Using

these duct connections, the duct of

the EASYAIR® air handling unit is well isolated against the transmission

of sound and vibration. External noise

transmission is substantially reduced.

i RO-04-R-X-75-MK-Z = with duct

connections

i RO-04-R-X-75-MK-o = without duct connections

control

The EASYAIR® air handling units have an integrated controller as

standard. All internal components of the

units are prewired and ready for use.

An exhaust air temperature sensor in

combination with heating and / cooling

coil warrantees a constant supply air

temperature. Many energy efficient

control functions are integrated in the

software and easy to extend by using

additional options.

The available options are as follows:

i -ra = Room sensor

i -DK = Constant pressure control

i -VK = Constant air volume control

i - aQ = AL-KO air quality control in the

exhaust duct

i -rc = Remote control with 10 m cable

i -BL = Bus module LON

i -Bm = Bus module Modbus

i -BB = Bus module Bacnet/Ethernet

i -cX = Without control

note: The measurement values (data

points) and communication commands

are permanently configured and are

independent of the Bus module and

cannot be changed.

Without control: All field devices are

wired for easy connection to an on-site

controller, on a terminal strip. There-

fore, there is no wiring required in the

unit on-site. Furthermore, a main switch

for all-phase switching is installed on

the unit. The power fuse is not included

in the design and must be supplied on

site. For EASYAIR® units with rotary

heat exchanger, the connections of the

drive motor are supplied through the terminal strip. The unit has no integrated

rotor control. Only a rotor drive with

integrated speed set point input is provided. The operation is additionally

monitored using a potential-free (closing)

contact fed through the terminal strip.

The AL-KO air quality controller

AIRQUALITIZER® is supervising

the quality of the exhaust air. If this

sensor detects odours or emissions in

the exhaust air (VOC = Volatile Organic

Compounds), the quantity of air is

increased and, within a short period of time, you will have a good quality of air in the room again. If there are e.g. only a few people in the room, the

AIRQUALITIZER® can reduce

the air volume (partial load operation)

and you save operating costs. By using

this intelligent air flow management,

only the required air flow is conveyed.

electric air heater (option)

An electric air heater can be connected

to each EASYAIR® (up to unit size

-06). This electric air heater is directly

installed on the air outlet and is

available with a rating between 3 and 15 kW. During a few days with low out-

side air temperatures, you can slightly

increase the room temperature till

desired temperature has been reached.

i -eLe = with electric air heater

hot water air heater (option)

Each EASYAIR® can be supplied

with a hot water air heater. This heater

is directly installed at the air outlet.

Here, you also have the simple option

to slightly increase the room temper-

ature during cold weather conditions

and to provide a comfortable room

temperature. Heater includes frost

protection.

i -WWe = with hot water air heater

(LPHW)

heater/cooler module (option)

For demanding applications, you can

also connect an additional module to

the EASYAIR® (refer to page 4

and 5). In this module you will find all

accessory that you require for a wide

range of application for cooling and

heating. The module is equipped with a drip separator.

i -WKe = module with heater (LPHW),

cooler (LPCW) and drip

separator

7

i eLe (option)

with electric air heater

i WWe (option)

hot water heater

(LPHW)

i WKe (option)

module with heater

(LPHW) and cooler

(LPCW) and drip

separator

i o

Without duct

connections

i Z

With duct

connections

i X

Casing in non-split

execution

i T

Casing in split

execution

i W

Casing for outdoor

installation

i h

Casing for outdoor

installation with intake

and exhaust hood

i 75

Supply air f7,

exhaust air f5

i e75

Supply air f7,

exhaust air f5 incl.

spare filters

i mK

With internal

dampers

i oK

Without internal

dampers

i r

Service side in

supply air direction

right

i L

Service side in

supply air direction

left

i heat recovery type and size of appliance refer to Page 4/5

i note: For the order codes and for the controller options, refer to Page 7. 04

/20

10;

Su

bje

ct t

o t

ech

nic

al m

od

ifica

tio

ns.

ro-04-r-X-75-mK-0-hhh

EASYAIR®

Order Code

AL-KO THERM GmbH

Hauptstrasse 248 - 250

89343 Jettingen-Scheppach

Phone +49 (0) 8225 39-0

Fax +49 (0) 8225 39-113

Mail [email protected]

www.al-ko.com

The easy way to EASYAIR®

http://easyair.al-ko.de

PROCESS AIR-HANDLINGAT4 – PAINTING AND DRYING

PROCESS HEAT

Compact appliances for Painting and Drying

Compact units series AT4 – Painting

and Drying (AT4 – PD) are designed

for application in the spraying and

drying booths.

Equipment design is carried out

using three modules:

I Heat exchanger components

I Components for fresh air/circulating

air supply with integrated fi lter

I Components for exhaust air with

change-over hatch

Circulating air or supply / exhaust air

mode can be selected as an option by

using a change-over hatch. In circulating

air mode, the exhaust air fan switches

off. The supply air portion can be ad-

justed during the drying phase by an

adjustable fresh air hatch (this hatch is

set once when the plant is commissioned

and then locked by a locking device).

Advantages

I balanced heating and air volume fl ow

I compatible modules

I long service life

I lower energy consumption due

to high furnace effi ciency

I easy assembly

I easy to maintain

I lower noise level

Operating point adjustment

For more than 45 years AL-KO manufac-

tures process air appliances with free-

wheeling fan rotors.

In order to obtain the operating point ad-

justment and optimum energy saving of

the fans, frequency converters must be

used.

Description of units

AT4 – PD COMPACT APPLIANCE

Com

plet

ed

dim

ensi

ons

Com

plet

ed d

imen

sion

s Fa

nCo

mpl

eted

dim

ensi

ons

Heat

exc

hang

er

Control side

øR o

utsi

de

= Operation coverOc

Oc

Oc

Oc

Oc

Oc Oc

Com

plet

ed d

imen

-si

ons,

filte

r

Painting

I the change-over hatch is in /

goes to the position “Painting”

I the supply and exhaust air fans

operate permanently

I the burner is regulated by the air

temperature

Drying

I the change-over hatches is in /

goes to the position “Drying”

I the exhaust air fan is stationary

I the supply air fan operates as a

circulating air fan

I the burner is regulated by the

temperature of the circulating air

I fresh air can be added through an

adjustable hatch

Circ

ulat

ing

air

Ambi

ent a

ir

Exha

ust a

ir

Painting and Drying booth

Easy access to the fan assemblies, as well

as a pull-out fi lter, enables easy and inex-

pensive maintenance.

Quick access is obtained through a separate

operator cover to the apertures for cleaning

the heat exchanger. Thus, the regular main-

tenance, the requisite for a long service life,

is considerably easier.

* m. AV = Air Volume ** HEC = Heat Exchanger Capacity

Function description

MAINTENANCEDIMENSIONS AT4 – PD Size PD 12 x 12 PD 12 x 16 PD 16 x 16 PD 20 x 16 PD 20 x 20 PD 20 x 20

m. AM*(m3/h) 14 000 22 500 28 500 35 000 38 000 55 000

HEC** 128 / 145 186 / 232 232/267/325 267/ 343 407/ 490 523 / 650

A2 1 300 1 606 1 606 1 606 1 989 2 295

A1 1 300 1 377 1 377 1 606 1 989 1 989

B 994 994 1 300 1 606 1 606 1 606

C 994 1 300 1 300 1 300 1 606 1 606

D 1 300 1 300 1 300 1 300 1 606 1 606

F 612 612 612 612 918 918

F1 535 612 612 841 918 918

G 918 918 1 224 1 530 1 530 1 530

R 180 / 180 180 / 180 180 / 250 / 250 250 / 250 300 / 300 300 / 300

b max. 88.5 max. 51.5 max. 209 max. 237 max. 140 0

f 497 497 max. 577 577 max. 753 753

WA 1 370 1 670 1 715 1 715 1 920 2 320

VA max. 609 max. 679 max. 823 max. 989 max. 989 max. 1039

FA 918 918 612 612 918 918

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

“ MILE-STONES” IN REDUCTION OF “ LIFE-CYCLE-COSTS”

AIR-HANDLING-UNITS AT4 | SAVE ENERGY


Shortages of fossil fuels and the political will

to reduce C02 emissions in accordance with

Agenda 21 are leading to a dramatic increase in

operating costs of energy-intensive systems.

2

PRICE TREND OF OIL

Foreword

system confi gurations have been shown

to contribute to a signifi cant reduction

in the annual energy costs – and this

without limiting the ventilation and air-

conditioning functions.

Thus a low investment price or low op-

erating costs alone are not the decisive

factor that determines the economic

effi ciency of air-handling-systems. In

addition to unlimited and proper func-

tion of the units and systems, the “Life-

Cycle-Costs” (LCC) – a sum of all costs

from installation to decommissioning –

are the only criteria to measure the

economic effi ciency of ventilation and

air conditioning systems.

Come see the kind of economic and

ecological potential that can open up in

buildings. Learn how you can harness

this potential for yourself.

Sincerely yours,

Prof. Dr.-Ing. Michael Haibel

“You get what you pay for.” This simple

bit of folk wisdom that‘s so easy to say

can turn into bitter truth rather quickly

for just about any investment in which

the follow-up costs are not taken into

account. This rude awakening can be

even worse if the follow-up costs are the

same or even higher than the original

investment costs.

This is especially true for ventilation and

air-conditioning-systems in buildings.

The annual operating costs, i.e. the costs

for energy, maintenance, and service of

the systems can end up being as high

as the one-time investment costs. But

high-quality technology and optimized

3

Air-handling-systems with low investment costs frequently resultin much higher operating costs than necessary!

Prof. Dr.-Ing. Michael Haibel University of Applied Sciences Biberach

An internationally recognised expert in buildings, air-handling and energy

systems and furthermore R&D consultant of AL-KO Air-Technology

Factor analysis

The primary goal in conceiving buildings

that last is to signifi cantly reduce energy

requirements and to create a comfortable

interior climate. The primary basis for

sustainable ventilation and air-condi-

tioning concepts is the climatic data of

the location. Creating a comfortable and

productive interior climate requires the

logical implementation of thermodyna-

mic function units. The goal of the

planning must be the energy effi cient

implementation of these requirements,

taking into account the “Life-Cycle-Costs”

(LCC) of the system. Air-conditioning

that is not energy-optimized will be the

cost factor of the future.

In order to counteract this cost explo-

sion, it is necessary to invite bids for

“Life-Cycle-Costs”.

1. Climate data of your location

The starting point for optimum design

of air-handling-systems is the correct

climate data of the location. The dimen-

sions are selected based on the recorded

outside air temperatures, as set forth in

DIN 4710/TRY

4

2. Healthy and comfortable

Maximum productivity can only be

achieved in a comfortable environment

at optimum room temperatures between

21 °C and 26 °C, in combination with

an interior humidity of 40 % to 60 %.

The main requirement for the building

air-conditioning, therefore, is to create

a healthy, comfortable interior climate

with the appropriate air quality in order

to increase motivation and productivity

in the work force.

-15-10-505

101520253035

J F M A M J J A S O N D

ParisOsloHongkong

BerlinRom

Moskau

Temperature °C

Economy has a starting point –knowing what‘s really needed

5

3. Requirements of the air-handling-

system

Depending on their location, air-handling-

systems must reliably perform a variety

of functions such as cleaning, heating,

cooling, ventilating, humidifying, de-

humidifying, and combinations of these.

For economically meaningful planning,

it is imperative to precisely defi ne the

array of functions of the air-handling-

system and the air quality it will be

required to achieve.

4. Important – taking into account the

energy quantities of the air-hand-

ling-system

Productivity-enhancing air-conditioning

does not have to be expensive. When it

comes to energy and economy, most

conventional systems currently in use

require new capital investment.

When planning an air-handling-system

according to the “Life-Cycle-Costs” prin-

ciple, more emphasis is thus placed on

the electrical connected load of the

ventilator and on the effi ciency of the

heat and moisture recovery.

Intelligent control and regulation sys-

tems assure that the optimum climate

is achieved right where it is needed. No

room is unnecessarily heated or cooled.

This reduces long-term costs.

Factor analysis

6

You determine the specifi c key data.

AL-KO will furnish you with an individual

system design optimized for your needs.

The essential requirement for economic-

ally meaningful consideration is the joint

establishment of the relevant parameters

such as system operating time, energy

costs, period under consideration, rising

prices.

Estimated price increase 5 %

Estimated price increase

7

1. You get what you pay for

When deciding between conventional

air-handling-systems and ones that are

“Life-Cycle-Cost”-optimized, taking

the short view by considering only the

initial investment costs usually turns

out to be a grave error. The user must

accept and allocate funds for very high

operating costs in the coming years.

But when you consider the fact that in-

vestment costs only occur once, and

on average, amount to only 10 % of the

overall costs in the life cycle, then it is

clear that decisions must favour air-

handling-systems that are optimized in

terms of “Life-Cycle-Costs”. As a rule,

these systems are amortized within the

fi rst year by the drastic reduction in

ongoing operating costs.

2. The difference is crucial

Different sites place different demands

on ventilation and air-conditioning-

systems. The specifi c requirements and

operating times play a pivotal role in the

design concept and cost considerations.

A school places different demands on

the air-handling-system than a hospital.

Sample consideration of operating times:

hospital 24 h/day, 7 days/week

school 10 h/day, 5 days/week

(taking into account holidays)

3. Intelligent design for lower

operating costs

Innovative ventilation and air-condition-

ing-systems have signifi cantly reduced

cleaning, inspection, and maintenance

costs. Intelligent measurement and

regulating units reduce the operating

complexity further. This saves time and

money.

4. Energetically thought through –

challenge us

The “Life-Cycle-Cost”-optimized com-

ponents, e.g. fans and heat exchangers,

feature lower power consumption and

better efficiency and make a decisive

contribution to signifi cantly reducing

the consumptionbased annual costs.

We stand by our power ratings and

consumption values.

Save more than 50 % of the annual operating costs over the life cycle of your air-handling-system – we‘ll tell you how!

Total competence

8

Economically thought-through and opti-

mized air-handling-systems guarantee

you high future profi ts on the investment

you make today. Correct and compre-

hensive consideration, in terms of both

energy and economy, is the essential

prerequisite for the bid invitation and

planning of effi cient air-handling-systems.

AL-KO Air-Technology will be your

competent partner at the beginning

and throughout all the phases of your

project. You can count on it!

1. AL-KO planning competence

You can rely on us. We‘ll help you

analyse your needs and plan your

air-handling projects.

2. AL-KO project management

Our competent project teams support

you in the implementation of your air-

handling project. From subcomponents

to complete system solutions – we are

by your side.

3. AL-KO engineering competence

Our competent engineering teams im-

plement your individual requirements

down to the smallest detail with inno-

vative AL-KO technologies.

4. AL-KO production

Our specialists produce your individual

ventilation and air-conditioning-unit

quickly and effi ciently on ultramodern

production lines, with proven AL-KO

quality.

5. AL-KO service and installation

Don‘t compromise on the service and

installation of your air-handling-system:

trust in the expertise of AL-KO. All over

the world, we‘re there for you.

AL-KO air-handling-units comply with all national and European norms and

quality standards.

Sit back and relax – with the great feeling of being able to leave all of the phases to a competent team

CONFORMANCE

9

AL-KO FULL SERVICE AND SUPPORT

Facts & Service

10

I The quick and easy way to air-handling-unit-

confi guration with display of the elected com-

ponents, price and overall size as well as data

sheets and drawings.

I Thus you will be able to select in few steps

the air-handling-units and its components

for your project, that will lead you to an easy

confi guration of the air-handling-units with

automatic calculation of the “Life-Cycle-Costs”

regarding your project.

SOFTWARE: “LIFE-CYCLE-COSTS” AND “SAVE ENERGY”

Send an email to [email protected] in order to receive

your personal access data. Thereby you will be

able to store your projects you been working on

and to use the software in full extent.

www.al-ko.de or directly by

http://planer.al-ko.de.

m i t L i f e - C y c l e - C o s t s - B e r e c h n u n g


11

The European guideline 2002/91/EG “Overall

Energy Effi ciency of Buildings” is implemented in

accordance with EnEV 2006 and DIN V 18599.

The essential requirement in Article one of

guideline 2002/91/EG is:

(...) The goal of this guideline is to support the

improvement of the overall energy effi ciency

of buildings in the European Union by taking

into account the respective outdoor climatic

and local conditions as well as the require-

ments of the interior climate. (...)

We want you to make the right choice

and we will support you from the start

in the planning and design of your air-

handling-system. With the innovative

AL-KO “Life-Cycle-Cost”-optimize soft-

ware, a few simple steps is all it takes

to fi nd the energy cost optimized so-

lution for your ventilation and air-

conditioning concept.

Step 2:

The AL-KO software automatically

provides you the optimized solution

in terms of operating economy, as

set forth in VDI 2067-1.

Enter a few key data of your project into

the calculation tool and have your in-

dividual system comparison calculated

online. Access to this AL-KO software

on our homepage www.al-ko.de.

Get your personal access directly:

[email protected]

Step 1:

Calculating the energy needs with AL-KO

“Life-Cycle-Cost”-optimize (“Life-Cycle-

Cost”-optimize is part of this software)

is based on DIN V 18599, part 3, of the

implementation of the EU guidelines for

overall energy effi ciency of buildings.

(2002/91/EG). The main focus in calcu-

lating the energy quantities is the elec-

trical power con-sumption of the fan and

the effi ciency of the heat and humid

recovery.

AL-KO software for quick selection of air-handling-units and calculation of “Life-Cycle-Costs”

With regard to non-residential buildings, in ad-

dition to the evaluation of the building shell,

the guideline requires inclusion of the entire

engineering of the building. The focus here is

air-conditioning engineering, lighting, and hot

water production. In the air-conditioning fi eld,

the essential requirements are getting energy

certifi cates and establishing inspection mea-

sures. Optimizing the operating economy and

energy consumption of the ventilation and air-

conditioning-unit is only possible by classifying

new and existing units. This makes air-condi-

tioning-systems signifi cantly more economical

to operate.

LCC methodology

12

The power consumption of the fan

has a big influence on energy costs.

Although the fan constitutes at most

only 3 % of the initial investment cost,

all by itself, it can comprise up to 70 %

of the air-handling-system‘s annual

operating costs! “Life-Cycle-Costs”-

optimized AL-KO units feature a rapid

amortization with low additional

investment expenses.

Fan selection:

The right fan concept saves you several

times the initial investment cost by

reducing the energy costs over the life

cycle.

Standard van

Power costs 355.463 € 300.347 €

Capital costs 10.694 € 17.342 €

Linitial investment costs 7.400 € 12.000 €

Price of electricity acc. to EUROVENT 14.74 kW 12.46 kW

Calculation basis air-fl ow-volume: 31,000 m3 / h, static pressure: 1,000 Pa

LCC-optimized van

Choosing the right fan allows you to reduce your power costs over the life-cycle

DIFFERENCE LCC

13

Excessive operating costs in air-hand-

ling-systems are chiefl y caused by in-

suffi cient device cross sections and

excessive fl ow speeds.

An increase in the unit cross section

results in a signifi cant reduction in fl ow

speeds and the accompanying energy

costs.

To reduce costs further, it is therefore

necessary to adapt the air-fl ow-volumes

to the actual needs. Selecting the opti-

mum unit cross section in terms of

operating economy and the optimum

operating mode enables a signifi cant

reduction in “Life-Cycle-Costs”.

Optimized unit geometries and operating modeshelp you reduce your long-term costs

Price change factors (VDI 2067-1)

Capital 1.0 %

Energy consumption 5.0 %

Operation 1.0 %

Repairs 1.0 %

General data years (VDI 2067-1)

Consideration period 15 years

Service life 15 years

Effective annual interest 5.00 %

Maintenance / Service 6.00 %

Energy costs (VDI 2067-1)

Heating 0.070 €/kWh

Cooling 0.025 €/kWh

Power customer price 0.100 €/kWh

Power annual energy price 0.000 €/kWh

Energy consumption humidifi er 0.070 €/kWh

Key data / Sample calculation Key data / Sample calculation

UNIT SIZES

LCC methodology

14

The use of heat recovery should no

longer be left out of ventilation and air-

conditioning-systems. Higher effi cien-

cies and the selection of the optimum

heat recovery system reduce costs

enormously over the life cycle.

The right selection of the optimized

rotor diameter for operating economy

provides a lasting reduction in “Life-

Cycle-Costs”. Choosing the most eco-

nomical components depends on the

individual requirements, operating con-

ditions, rotor selection, and energy

prices.

ROTOR SELECTION

Reducing costs with “Life-Cycle-Costs”-optimized heat recovery

Price change factors (VDI 2067-1)

Capital 1.0 %

Energy consumption 5.0 %

Operation 1.0 %

Repairs 1.0 %

General data years (VDI 2067-1)

Consideration period 15 years

Service life 15 years

Effective annual interest 5.00 %

Maintenance / Service 6.00 %

Energy costs (VDI 2067-1)

Heating 0.070 €/kWh

Cooling 0.025 €/kWh

Power customer price 0.100 €/kWh

Power annual energy price 0.000 €/kWh

Energy consumption humidifi er 0.070 €/kWh

Key data / sample calculation

15

World-wide presence

Service and support – AL-KO Air-Technology: All over the world, we‘re there for you

TALK TO US ABOUT YOUR POSSIBILITIES: [email protected]

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

SIMPLE SELECTION OF ENERGY EFFI-CIENT AIR-CONDITIONING-UNITS WITH CALCULATION OF “LIFE-CYCLE-COSTS”


Energy effi cient air-handling-units: AL-KO software for LCC-calculation

The evaluation, design and tender of

ventilation and air-conditioning units

in accordance with “Life-Cycle-Costs”

is not only surety for lowest possible

energy consumption costs, but also

considers further consequential costs,

such as maintenance and repair.

The energy effi cient concept and design

of air-conditioning units is the basis

for the requirements of the sustainable

building industry. Buildings must be

more effi cient – this is not only associa-

ted with the decisions of global climate

protection objectives and reduction of

the CO2 emission, but especially also

with signifi cant increase in the supply

cost of primary energy and the depend-

ence on the delivery of large quantities

of energy.

However, the most important:

Energy effi ciency saves much money!

Often, the cost of investment for air-

conditioning units does not increase

signifi cantly, however, the energy effi -

ciency and the potential for cost saving

increases enormously. This factor incre-

ases the profi t of the operating compa-

nies (at constant best air quality in the

rooms of the building), because of sub-

stantially lower units operating costs

and contributes to the competitiveness

and location security.

Energy quantity calculation iaw DIN V 18599-3 and economic calculation iaw VDI 2067-1 for lower “Life-Cycle-Costs”

AL-KO engineers will fi nd the most

energy-effi cient air-handling-solution

for your application

Energy effi cient air-handling-engineering means: low “Life-Cycle-Costs” Low “Life-Cycle-Costs” for air-condi-

tioning units are the result of energy

effi cient air-conditioning and adjust-

ment of a few parameters with the future

building operator (investor, builder,

owner, contractor).

Especially the operating time and op-

erating conditions, as well as the data

of the site of the air-conditioning are

decisive for the desired reduction in

the life cycle costs of air-conditioning

units.

In order to conceive the optimal (cost

reduced), air-conditioning unit for the

respective application (respective

operator), the appraisal of energy

effi ciency classes is indeed expedient,

but not suffi cient.

Alone, the calculation and evaluation of

the “Life-Cycle-Costs” of air-conditio-

ning units lead to the correct inform-

ative result. The air-handling-concept

with the lowest life cycle costs is the

most economic.

“Life-Cycle-Costs” are the result of

investment mathematical calculations,

which are implemented in the VDI 2067.

Basis for this calculation are energy

quantity calculations, in accordance

with DIN V 18599.

With the new software for design of

air-conditioning units with “Life-Cycle-

Costs” calculation, AL-KO offers the

specialist designer a selection of pre-

confi gured unit versions from a list and

then to compare these, with regard to

their expected „Life-Cycle-Costs“.

Through our homepage www.al-ko.de

you get to the business domain ventila-

tion and air-conditioning technology.

From there you can go directly to the

software navigation by clicking on the

link in the right Teaser domain.

Alternatively to logging on through the

homepage, you can also logon directly

via the path http://planer.al-ko.de

or the path http://lcc.al-ko.de.

In order to create and save projects,

to fully utilize the software with “Life-

Cycle-Costs” calculation, please send

an Email to [email protected]. You will

then receive your personal login data

and the operating instructions.

AL-KO software for design of air-conditioning units with “Life-Cycle-Costs” calculation

http://planer.al-ko.de

Just choose only a few

parameters

http://planer.al-ko.de

Homepage

Select a suitable airfl ow for your project,

decide on internal or external installati-

on and which air supply unit or air supply

and extractor unit and also about the

heat recovery. The appropriate units are

listed together with the respective fl ow

chart and unit dimensions, data sheets

and drawings. Select up to 3 versions,

which you want to compare with regard

to the effi ciency of their “Life-Cycle-

Costs”. A diagram is generated within

the software desktop that now appears

(“LCC-optimize”) that gives a clear and

explicit view of the cost differences.

Moreover, it is also possible to, for

example, to change the application

times and periods of the air-conditio-

ning units in accordance with the

general conditions of your project,

which of course will infl uence the

“Life-Cycle-Costs”. In this way, you not

only signifi cantly reduce your labour

costs, but distinguish yourself to your

client, with regard to an energy sustai-

nable air-conditioning unit design.

Quick selection of your air-handling- unit and easy “Life-Cycle-Costs” comparison

www.al-ko.de

http://planer.al-ko.de or

http://lcc.al-ko.de

HTTP://PLANER.AL-KO.DE OR E-MAIL TO:[email protected]

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

HIGH ENERGY-COST-SAVINGBY 100 % HEAT-RECOVERY

AIR-CONDITIONING-UNITS

Optimized air-handling systems with heat-pump-technology to save energy

AL-KO system-solution…

AL-KO system-solution for an economic

air-handling system:

I The system-solution becomes a “plugin”

air-handling-unit by an integrated

control-system and guarantees the

highest level of energy saving in every

operating mode.

… Air-handling-units with 100% heat

recovery by heat-pump-technology:

I The cooling machine, designed for

summer-operation, is used during

winter-operation for increasing the

heat-recovery-capacity. This means

the cooling machine operates like a

heat-pump.

I The patented hydraulic-system assures

very high energy saving.

I The investment fpr the additional profi t

of heat-recovery by heat-pump will be

amortized within 1 to 3 years.

I Autarc operation of the air-handling-

unit without additional energy. Pump

hot water is not necessary.

I Because of the individual design of

the heat-pump this solution is also

appropriate for refurbishment.

I One single heat-pump can supply

several air-handling-units.

I High energy saving with heat- and

cooling-demand at the same time.

I Very low level of fl uid required even

with high cooling capacities.

Fail-safe

An intelligent capacity regulation guar-

antees a secure operation with 100%

cooling capacity even with high humid-

ity or thermal loads.

Benefi t from a maximum

degree of effectiveness.

Heat-pump-technology

COP =coeffi cient of

performance

QWP power output

Pel power input

Operating hours h/a and COP of the

cooling machine / heat-pump

(Climatic conditions Mannheim):

System with two compressors:

I average COP = 6.9 (heating-period)

I average COP = 4.5 (cooling-period)

The technology achieves an annual

average COP of 6.0. This means: 1 kW

electrical power input provides 6 kW

heating capacity.

Effi ciency

The AL-KO system technology with heat-

pump decreases the price for heating

down to approx.0.02 € / kWh. (COP =

6.0; ref. average price of electricity =

0.12 € / kWh). This means: The costs for

heating in the building will be cut down

to 20 % compared with prices for heat-

ing with oil or gas.

cooling

ETA

SUP

EHA

ODA

Hydraulic…

AL-KO heat-pump

AL-KO AT4 unit

…takes care of optimized operating

mode and guarantees effi cient and

economic function.

Description of function mode for

“cooling”.

charge buffer with cold medium

(compressor “turned on”)

1. The cooling machine is turned on.

2. The buffer is charged with hot medium.

3. The cold medium out of the evaporator

dislodges some of the hot medium in

the buffer.

4. At the buffer valve the required

temperature for cooling is generated.

5. The buffer is charged with surplus

thermal energy.

discharge buffer with cold medium

(compressor “turned off”)

6. The buffer is completely fi lled with

cold medium.

7. The cooling machine is turned off.

8. The hot medium out of the cooler fl ows

through the evaporator.

9. The hot medium out of the evaporator

dislodges some of the cold medium in

the buffer.

10. At the buffer valve the required temper-

ature for cooling is generated.

11. The buffer is discharged completely and

the cooling machine will be turned on.

100 % heat recovery.

I The fi rst step of the heat-recovery is realized

by a rotation-heat-exchanger, plate-heat-ex-

changer or a combined coil system.

I The second step of the heat-recovery is real-

ized by a cooling machine with integrated

heat-pump-function, which is necessary in

any case.

SYSTEM DESCRIPTION

Summary of AL-KO software: LCC-optimize

Operating time: 16 h / 7 days / 52 weeks

Period under observation: 15 years

Energy costs:

I For heating / humidifi cation je 0,070 € / kWh

I For cooling 0,040 € / kWh

I For electrical power 0,100 € / kWh

Calculated rise of energy-costs during period

under observation: 5% (Ref.: bases on individual

defaults of operator

High energy effi ciency for signifi cant

decreasing of “Life-Cycle-Costs”.

I The AL-KO software “LCC-optimize”

displays the extraordinary economic

effi ciency based on individual require-

ments.

I Contact us at [email protected]

for assistance.

AL-KO Air-Technology – abstract of our references

air-handling-units

with heat-pump-technology

I Spielbank Bad Homburg

17 800 m3/h | 87.4 kW

I Kulturrathaus Dresden

5 000 m3/h | 24.8 kW

I Alemanniahaus FFM

6 100 m3/h | 32.0 kW

I Kreissparkasse Thalheim

3 900 m3/h | 15.0 kW

I Therragens Bingen

3 800 m3/h | 27.5 kW

I Schloß Fechenbach

13 000 m3/h | 78.0 kW

I Sparkasse Bensheim

3 000 m3/h | 37.5 kW

I Sparkasse Auerbach

3 000 m3/h | 37.5 kW

I Atrium Weimar

210 000 m3/h | 1 169.0 kW

I Landtagsgebäude Mainz

12 800 m3/h | 80.4 kW

I Museum für Kommunikation FFM

25 000 m3/h | 161.0 kW

I SAP Campus, Walldorf

500 000 m3/h | 2 600.0 kW

and many more …

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

ENERGY RECOVERY

AIR-HANDLING-UNITS

2

Heat recovery and energy recovery is nota philosophy but an economic necessity

Heat recovery in air-conditioning systems with

nor-mal utilisation is always an extremely rewarding

business for operators and users of air-conditioning

systems because primary energy is saved (costs for

energy continually increase).

Even the government has responded and estab-

lished useful basic conditions by ratifying energy

conservation regulations (EnEV 2009 ff.) that

prescribe compulsory consideration of heat

recovery in Germany.

3

This does not only involve heat recovery

itself, but also the recovery of cooling

energy as well as moisture recovery or

dehumidification. In this way, the right

energy recovery system can be chosen

for each climate zone on the planet.

Today, we no longer have to discuss the

pros and cons of heat recovery, we just

have to choose the most economic

energy recovery system for the respec-

tive project.

Supporting frame for hydraulic components

4

Run-around-coil-systems

The thermal energy which is transmitted

into the supply air does not need to be

generated but is collected by using ener-

gy recovery systems out of the exhaust

air. By using energy-recovery-systems

in air-handling-units the investment-

cost will increase just a little bit but the

usage of energy- recovery-systems will

decrease the energy-cost signifi cantly.

An economic calculation of “life-cycle-

costs” will point the advantages of

energy- recovery-systems very well.

Reasons for using an energy-

recovery-system:

I saving thermal energy (heating

energy)

I decreasing of annual heating power

demand

I Saving thermal energy (cooling energy).

This means a smaller design of heat

exchanger, tubes and pumps as well

as the entire cooling equipment (com-

pressors, cooling units and exhangers)

and therefore less investment-costs.

I decreasing of annual cooling power

demand

I decreasing of CO2 -emissions

High performance run-around-coil-

system

I out-door-air is separated

from exhaust-air

I high performance series connection

of heat exchanger

I every exchange performance within

the run-around-coil-system is possible

I effi ciency of energy recovery up to 90 %

Circulation composite system

I effi ciency up to 75 % with

high performance circulation

composite system

I supply and exhaust air can be

located separately

I low space requirement

I good for retrofi tting,

suitable for old systems

I multifunctional solutions possible

ODA

EHA

SUP

ETA

Heat exchangers with special

water conduit circuit

5

System description

Operation of the AL-KO

run-around-coil-system

I Use of high performance heat exchan-

gers in a multiple countercurrent

circuit. This achieves high annual

utilisation ratios of 80 %.

I Each heat exchanger has only one

mode of air-flowing through (fresh or

extract air) so that germs and contami-

nation cannot be transferred.

I The system is used during the winter

period to pre-heat the fresh air and in

the summer to pre-cool the fresh air

through adiabatic cooling of the ex-

tract air.

I Because of humidification of the ex-

tract air during summer period the air

is cooled and the cooling transferred

to the supply air. Humidity cannot be

transferred between the air-flows be-

cause the exhaust air temperature is

raised in the exhaust air heat exchan-

ger, it leaves the building without

moisture.

I Depending on the type of humidifier

(evaporation humidifier, high pressure

nebuliser, air washer) the humidifica-

tion is able to use service water, demin-

eralized or adul terate water.

I The AL-KO outside air heater can be

divided in accordance with VDI 6022.

The defroster with wide fin spacing, in-

stalled before the filter, raises the out-

side air temperature sufficiently to

avoid frost formation on the filter

medium and thus ensures compliance

with the relative humidity required by

VDI 6022.

I For dehumidifying an additional heat

recovery system exchanger is installed

after the dehumidifying cooler.

ETA

SUP

EHA

ODA

Hybrid humidifier

DVE

performancecontrol

pump-hot-water 50/30

HydraulicModul

pump-hot-water 50/30

SN

MID

ZL

VE

PTH

M

M

M

5 2 4 3 2

6

Rotary heat exchangers

So-called rotary heat exchangers

(rotors) are another highly effi cient

alternative for heat recovery. The heat

is not generated but recovered from

exhaust air. The advantages of rotary

heat exchangers are obvious:

On the one hand, the space require-

ments in the air-conditioning unit are

relatively small. On the other hand,

not only heat energy but also the cold

(e.g. summer operation of the plant)

or the moisture (sorption rotors) in the

exhaust air can be recovered and fed to

the supply air. Conversely, dehumidifi -

cation can also be achieved with sorp-

tion rotors. Firstly, in contrast to other

systems for energy recovery, thermal

energy (heat, cold) can be recovered

throughout the year and it doesn‘t have

to be regenerated involving sometimes

extremely high costs. Secondly, even

without a humidifi cation unit, (in winter)

a certain amount of moisture from the

exhaust air can be partially fed to the

dry incoming air from outside (fresh

air).

Open air-conditioning unit (supply air/exhaust

air on top of each other) with rotary heat

exchanger (sorption rotor)

Rotors require little longitudinal space. The

rotors are effi ciently driven by special small

motors (permanent magnet motors)

Rotary heat exchanger (sorption rotor)

exhaust air part of unit

Rotary heat exchanger (sorption rotor)

supply air part of unit

Rotary heat exchangeer

I heat transfer opt. moisture transfer

I can be controlled very well via

rotation speed

I for large air outputs

I bypass possible

I low pressure loss

I return heat figure up to

around 80 %

ODA

EHA

SUP

ETA

7

Cross-fl ow heat exchangers

So-called cross-flow heat exchangers

(often called plate heat exchangers)

are a commonly used alternative for

heat recovery. Cross-flow plate heat

exchangers are sometimes relatively

cost-effective (depending on the size).

In contrast to circulation composite

systems or rotary heat exchangers, no

rotating parts and motors or pumps are

necessary. The return heat figures with

this system are lower, although they can

still reach up to 80 %. In these cases, the

investment costs are somewhat similar

to those for a rotary heat exchanger.

Another advantage of the cross-flow heat

exchanger is the prevention of contami-

nation of the supply air that can occur

due to any odours or emissions in the

exhaust air; this is achieved by the 100%

separation of supply air and exhaust air.

Heat recovery system

cross-fl ow heat recovery

Plate heat exchanger

I low wear and reliable

I simple design

I air currents not mixed

I bypass possible

I very economical solution

I return heat figure up to

around 75 %

ODA

EHA SUP

ETA

8

More heat recovery means less heating costsand a lot of savings

The more effi cient the heat recovery,

the less energy is used for heating or

cooling. In many cases, the operation

of a re-heater (e.g. electric heat exchan-

ger) is only needed on a few cold days

in the year. With high effi ciency levels

(return heat fi gure), often more than

90 % of the required heat energy can

often be covered.

00

10

20

30

40

50

60

70

80

90

100

10 20 30 40 50Heat recovery efficiency (%)

Ener

gy-s

avin

g (%

)

60 70 80 90

ENEV 2007defines standardas 45%

ENEV 2009defines standardas 70%

Energy savings depending on the efficiency of heat recovery.

9

Energy recoveryand life cycle costs

0 €

200.000 €

400.000 €

600.000 €

800.000 €

1.000.000 €

1.200.000 €

– €Maintenance/service – € 256.092 €Humidification costs 269.720 € 380.988 €Electricity costs 160.352 € 64.414 €Cooling costs 54.626 €

276.167 €Heating costs 167.957 € 89.598 €Capital costs 115.611 €

– € 58.840 € 145.884 € 52.254 € 7.355 € 161.855 €

1.126.602 €Total of costs LCC 768.266 € 62.000 €Investment costs 80.000 €

426.188 € 112.000 €

Air-handling-system 1



The observation period is always 15 years.

Costs for maintenance and repairs are not

included. This life cycle cost comparison

clearly shows the relatively small differences

in the additional investment costs and also the

very large differences in the total costs

(investment and energy costs in 15 years).

The investment costs are already included in

the total costs (sum of costs LCC).

An energy assessment and comparison

is initially made when comparing energy

recovery systems with each other. These

energy values expressed in money and

costs appear very impressive and

striking. This economic assessment

involves the so-called „life cycle costs

analysis“ and provides reliable values to

decide on one energy recovery system

or another. This calculation of profitabili-

ty according to VDI 2067-1 (based on

the calculation for the amount of energy

according to DIN 18599-3) also consi-

ders specific basic conditions such as

the utilisation times of the system or

special energy buy-off prices.

To illustrate this, the calculation of

profitability was conducted for a central

ventilation and air conditioning system

with an air feed volume of 31,000 m³/h

with the following system comparisons

and heat recovery:

10

Heat recovery systems and theiradvantages at a glance

Advantages

I effi ciency up to 80 %

I option for moisture transfer

I easy to maintain

I space-saving unit length

I low pressure losses

I low risk of icing

I maximum cost-effectiveness

ODA

EHA

SUP

ETA


Advantages

I effi ciency up to 80 %

I no moving parts

I virtually maintenance-free

I supply air and exhaust air

must be located in one unit

ODA

EHA SUP

ETA

Cross-fl ow plate heat exchanger

11

Advantages

I effi ciency up to 75 % with high performance

circulation composite system

I supply and exhaust air can be located separately

I low space requirement

I goof for retrofi tting, suitable for old systems

I multifunctional solutions possible

ODA

EHA

SUP

ETACirculation composite system

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

ENERGY EFFICIENT CONTROLSYSTEMS FOR VENTILATION AND AIR-CONDITIONING-UNITS

AIR-HANDLING-UNITS

Systems, functions, scope of supply

Special advantages of a ventilation

and air-conditioning-units with an

AL-KO control system

I simple processing, as only one

supplier is involved

I tuned technology

I modular system

I minimal assembly / installation

costs on site due to preassembly

The general constructor has the oppor-

tunity to obtain two important parts of

his system, namely the main air-han-

dling-units and control systems, from

a competent and responsible partner.

We offer a completely standard control

system, which is tuned to the require-

ments of each and every individual use.

This guarantees the optimal operation

of every sections. Interface and tuning

problems are practically eliminated.

Example regulation functions

I supply air temperature control

I room or exhaust air

temperature control

I min. supply air limitation

I max. supply air limitation

I mixture damper

I mixture damper

I winter sequence control

I shut-off damper

I pressure control

I volume fl ow control

I cascade control

I many additional options

and extensions

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

NEW GENERATION OF AIR HEATING AND AIR COOLING

INDUSTRIAL APPLICATION | CONVENIENCE APPLICATIONS |

HIGH ENERGY EFFICIENCY | AUTOMATION

AL-KO “DESIGN”

2

Air heating for commercial rooms

The symbiosis from energy aspects, new functions and elegance!

Heating for room heights up to 7 m Heating for room heights up to 5.7 m

Regarding the area of application and

buildings in which air heating and

cooling units are preferably employed,

a very important point is clear:

Many buildings are accessible to the

public. Often it is hardware stores,

supermarkets, exhibition halls, show-

rooms, shopping centres and all types

of commercial premises, which – for

the customers of our customers – are

conspicuously equipped with air heating

and cooling units.

The “DESIGN” distinguishes itself by its

appealing optics, the lower noise level

and special fi re protection class “V-0” of

the plastic cover.

The AL-KO air heater “DESIGN” distin-

guishes itself through a low noise level

combined with fi re protection assurance

and energy effi ciency. By virtue of the

elegant external of the “DESIGN”, the

professional planner must no longer

“hide” the air-conditioning units from

the architects, builders, but above all,

from the customers of our customers.

The symbiosis from energy aspects,

new functions and elegance:

AL-KO “DESIGN” – air heating and

cooling units aesthetically packaged!

I Best room perfusion through variable

directions of exhaust.

I Depending on the height of the room,

the direction of air can be selected

horizontal or vertical.

3

Heating:

Installation size ED-H1-C1 ED-H1-C2 ED-H1-C3 ED-H2-C1 ED-H2-C2 ED-H2-C3 ED-H3-C1 ED-H3-C2 ED-H3-C3

max. air mass (m3/h) 2 030 1 960 1 610 3 110 2 900 2 850 4 300 4 150 3 900

max. thermal capacity (KW) 7.4 12.2 16 8.5 16.7 21.6 11 18.5 28.1

(at PWW 70 / 50, Le +20 °C)

Drive (2-stage) 3 x 400 V / 50 Hz

TECHNICAL DATA

AL-KO “DESIGN”

4

Cooling for room heights up to 10 m Cooling for room heights up to 5.7 m

Air cooling for commercial rooms

Aesthetics and comfort

For rooms with a high comfort require-

ment, AL-KO has developed the pump-

cold-water air cooling unit “DESIGN”.

Used in buildings with much public

access. The air cooling unit can heat as

well as cool according to each season‘s

requirement. Thus, it is possible to

implement air-conditioning in such

buildings such as hardware stores,

supermarkets, exhibition halls, show-

rooms, shopping centres etc. at low cost.

The “DESIGN” distinguishes itself by its

appealing optics, the lower noise level

and special fi re protection class “V-0” of

the plastic cover.

necessary. Therewith, it is possible to

extend an already installed DESIGN

heating unit for the cooling function.

The appropriate system components

must be retrofi tted on-site. Extensive

new piping is dispensed with, because

the existing heating circuit (provided

that it is only designed for “DESIGN”

units) can be used.

The symbiosis from energy aspects,

new functions and elegance: AL-KO

“DESIGN”. Air heating and cooling

units aesthetically packaged!

Best room perfusion through variable

directions of exhaust. The basic concept

of the cooling unit is based on the tech-

nology of the DESIGN heating unit. For

the extension, only a condensate pump

and miscellaneous component sets are

5

Cold water producer

Condensate removal

Change-over valveopen/closed

Hea

ting

syst

em

TECHNICAL DATA

Cooling:

Installation size ED-K1-C1 ED-K1-C2 ED-K1-C3 ED-K2-C1 ED-K2-C2 ED-K2-C3 ED-K3-C1 ED-K3-C2 ED-K3-C3

max. air mass (m3/h) 2 030 1 960 1 610 3 110 2 900 2 850 4 300 4 150 3 900

max. cooling capacity (KW) (at 3.5 5.6 7.4 3.8 7.6 9.8 5.1 10.0 12.8

PKW 10 / 16, Le +32 °C / 40 % rF)


AL-KO “INDUSTRIE”

6

Recirculating air

Gate air

Energy optimization Low halls Angle Mixed air Filter Ambient air

High halls

Fresh air

Intake accessories

Wall assembly Ceiling assembly

Air heating

Weather protection screen

MODULAR SYSTEM / ACCESSORIES

The AL-KO air heater “INDUSTRIE” is

designed for application in storerooms,

production facilities, assembly shops

and hardware stores.

The AL-KO “INDUSTRIE” distinguishes

itself through its robust construction,

the optional assembly on the wall or

ceiling and energy effi ciency and ex-

tensive accessories.

Provided with special accessories, this

unit is best suited for the combination

with door air blasts. Advantage of the

series is the universal application,

thanks to modular construction and

simple installation.

7

AL-KO “INDUSTRIE” air heater for universal application

AL-KO “INDUSTRIE” air heater with effi cient

control and continuous speed control, as well as

injection blind for accelerated room air heating.

Heating:

Installation size 140 250 400 650 1 000

min. - max. air mass (m3/h) 1 230 - 2 140 2 230 - 3 610 3 110 - 5 500 4 760 - 8 600 6 080 - 10 280

max. heating capacity (KW) 5.8 - 10.6 9.3 - 21.7 17.4 - 38.8 26.4 - 53.8 36.2 - 73

(at PWW 70 / 50, Le +20 °C)


TECHNICAL DATA

AL-KO “INDUSTRIE”

8

Air cooling

The AL-KO air cooler “INDUSTRIE” is


production facilities, assembly shops

and hardware stores. The AL-KO “IN-

DUSTRIE” especially distinguishes itself

through its robust construction, as well

as energy effi ciency and extensive

accessories.

The air cooler “INDUSTRIE” is designed

with a condensate tank for unrestricted

condensate discharge. A comprehensive

accessories program completes the

system.

The fi gure shows the air cooling unit

“INDUSTRIE” for recirculating air

operation, for wall installation.

9

TECHNICAL DATA

Cooling:

Installation size LK 140-N.. LK 250-N.. LK 400-N.. LK 650-N.. LK 1000-N..

max. air mass m3/h 1 750 3 050 4 600 7 600 9 400

min. - max. cooling capacity KW 4.9 - 11.2 8.4 - 19.8 13.4 - 33.6 20.3 - 50.4 25.3 - 66.1

(bei PKW 6 / 12, Le +32 °C / 40 % rF)


AL-KO “INDUSTRIE-ATEX”

10

Air heating for application in potentially explosive atmospheres

The AL-KO air heater “INDUSTRIE-

ATEX” is designed for application in

storerooms, production facilities,

assembly shops. This series is desig-

ned in accordance with the guidelines

for explosion protection and is,

therefore, predestined for applica-

tion in the potentially explosive

production environment.

The components are suitable for gas

in potentially explosive rooms in Zone

1 and 2.

The air heaters “INDUSTRIE” in the

ATEX design are tested by the TÜV

Süd (Technical Inspection Authority,

south) in accordance with the Explo-

sion Protection Guideline 94/9/EU.

11

TECHNICAL DATA

Heating (heat exchanger, steel construction)

Installation size: LH 140-Atex H.. LH 250-Atex H.. LH 400-Atex H.. LH 650-Atex H..

max. air mass (m3/h) 2 070 3 720 5 590 8 800

thermal capacity (KW) 14.5 25.8 36.6 60.5

(bei PWW 80 / 60 Le + 20 °C)

Drive (2-stage), posistor 3 x 400 V / 50 Hz Y / Δ

AL-KO “ENERGIE”

12

Air recirculation unit for energy-saving heat recovery

The AL-KO air heater “ENERGIE” is


production facilities and assembly

shops. In the recirculation air mode,

the AL-KO “ENERGIE” pulls in in the

hot air accumulated on the hall ceiling,

caused by the thermal uplift and returns

this purposefully to the centre of the

room. Thus, the AL-KO “ENERGIE” is

a perfect supplement to the AL-KO air

heaters, to return already heated am-

bient air to the centre of the room and

must not be continually reheated. The

AL-KO “ENERGIE” also recommends

itself to supplement static heating

systems.

Accumulated waste heat recovery

From a physical point of view, warm air

in rooms rises. The resulting tempera-

ture lamination is approx. 1 K per metre

height of the hall. This behaviour vehe-

mently counteracts the objective, simply

to provide the lounge area with heat.

Operation of AL-KO “ENERGIE”

The ceiling fan ENERGIE pulls in the

hot air accumulated below the hall

ceiling and conveys this back into the

lounge area. Simultaneously, the air

fl ow directed downwards counteracts

the emerging warm air. The “ENERGIE”

is controlled by a separate control

cabinet with selectable switch-on

temperature.

Application areas

AL-KO ceiling fans “ENERGIE” can be

expediently used in all high halls in which

heat accumulates in the ceiling area. Be-

cause the units operate independent of

the system, a check should be carried out

after retrofi tting existing installations.

13

TECHNICAL DATA

Temperature

characteristics

with AL-KO

“Energie”Temperature

characteristics

without AL-KO

“Energie”

Temperature in °C

He

igh

t in

m

“ENERGIE” TYPE DL-140-E DL-250-E DL-400-E DL-650-E

max. air mass (m3/h) 2 070 4 000 5 500 8 400

Trajectory distance, vertical (m) 11 12 13 14

Drive (2-stage) 3 x 400 V Y / Δ

14

The door air blast from AL-KO provides separation of two different

climatic surroundings without a barrier. Application areas are rooms

that must be protected against cold ambient air or two rooms with

different temperature levels.

AL-KO “door air blast”

Type: STANDESSE

Application areas: Shopping centres, restaurants, hotels, production shops

Air fl ow range: 670 to 9 500 m³/h

Heating medium: Hot water or electric heater

Type: OPTIMAL

Application areas: Shopping centres, restaurants, hotels, production shops

Air fl ow range: 2 150 to 4 300 m³/h


Features: Suitable for door heights up to 4 m

Type: ECONOMIC

Application areas: Small shops, store, service centres, bars



Features: Available with wireless remote control

14

15

Type: COMTESSE

Application areas: Comfort areas with high requirement on design, such as reception,

banks, modern offi ce buildings



Features: The integrated fl uorescent lamps particularly accentuates the design

Type: INTESSE





Features: Coloured edging strips (selection from the colour palette possible), optional

with fragrance cartridge (available with aroma agent for ambient air e.g. alps, green,

fl owers, citrus), silent

Type: STYLESSE





Features: Coloured edging strips (selection from the colour palette possible), optional with

fragrance cartridge (available with aroma agent for ambient air e.g. alps, green, fl owers,

citrus), silent

15

Type: VENESS





Features: Vertical installation and sound insulated external jacket

AL-KO THERM GMBH



Germany

Fon +49 82 25 39 - 0

Fax +49 82 25 39 - 113

[email protected]

www.al-ko.com

Al Ko Air Handling Units Catalog 2011

Documents

Transcript of Al Ko Air Handling Units Catalog 2011