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GEA Heat Exchangers / HVAC Systems
GEA CAIRfricostar
Air conditioning of swimming pools | Data & Facts
Air conditioning of swimming pools with comfort units
Table of Contents
GEA CAIRfricostar
2 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Air Recirculating Dehumidifier with Heat Pump, Type CAUFunctional Description .......................................................................................... 3System and Controls Scheme .............................................................................. 3Components ......................................................................................................... 4Technical Data ..................................................................................................... 6Accessories .......................................................................................................... 6
Air Mixing Dehumidifier with Heat Pump, Type CMU Functional Description ........................................................................................... 7System and Controls Scheme .............................................................................. 8Components ......................................................................................................... 8Technical Data ................................................................................................... 13
Air Mixing Dehumidifier with Heat Pump, Type CAM Functional Description ........................................................................................ 14System and Controls Scheme ............................................................................ 15Components ....................................................................................................... 15Technical Data ................................................................................................... 20
Air Mixing Dehumidifier with Heat Pump, Type CMPFunctional Description ........................................................................................ 22System and Controls Scheme ............................................................................ 23Components ....................................................................................................... 23Technical Data ................................................................................................... 28
Air Mixing Dehumidifier, Type CWR Functional Description ........................................................................................ 29System and Controls Scheme ............................................................................ 30Components........................................................................................................ 30Technical Data ................................................................................................... 34
Air Mixing Dehumidifier, Type CWPFunctional Description ........................................................................................ 36System and Controls Scheme ............................................................................ 37Komponenten ..................................................................................................... 37Technische Daten .............................................................................................. 42
Compact GEA Fricostar Micro unitsAir Mixing Dehumidifier, Type CAC
Functional Description ........................................................................................ 43System and Controls Scheme ............................................................................ 44Components ....................................................................................................... 44Technical Data ................................................................................................... 48
Air Mixing Dehumidifier with Heat Pump Type CWCFunctional Description ........................................................................................ 49System and Controls Scheme ............................................................................ 50Components ....................................................................................................... 50Technical Data ................................................................................................... 53
Electric Integration, Overview of Cable ConnectionsGEA CAIRfricostar air mixing units .................................................................... 54GEA CAIRfricostar air recirculating units ........................................................... 55
Unit Selection as Relates to Water SurfaceUnit Model Range as Relates to Water Surface, Unit Type: Standard .............. 56Unit Model Range as Relates to Water Surface, Unit Type: Performance ........ 56
Configuration Variants and Accessories Configuration Variants ........................................................................................ 57Accessories (Component Version only for DDC-Controller) .............................. 58
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Dehumidifier with Air Recirculating and Heat Pump Function
GEA CAIRfricostar Type CAU
PR-2008-0327-GB • Subject to modifications • Status 05/2009 3
Functional description of the unit
The GEA CAIRfricostar CAU is mainly designed for private swimming pools and can be delivered in 4 sizes. The unit's function is to dehumidify and heat air in swimming pools in circulating air mode. The unit is supplied with a fully electronic control system that automatically regulates system functions.
In circulating air mode without dehumidification the air is recirculated in the swimming pool. The multifunction humidistat that is installed in the swimming pool switches the unit into dehumidification mode as soon as the humidity setpoint has been exceeded. At this point the fan is switched into speed 2 and the refrigeration circuit is activated. The dehumidification process is carried out until the setpoint is reached. After that the fan is switched into speed 1 and the circuit compressor is stopped. Using an optional pool water condenser a certain amount of excess energy produced by the heat pump cycle can be fed back into swimming pool water or similar circuit system.
Operation mode with dehumidification demand
System and controls scheme
Supply air fan runs at high speed. The necessary transmission heat is provided by the reheater coil. Us-ing an optional pool water condenser a certain amount of excess energy can be fed back into swimming pool water.
DI
AI
DO
AO
M
MP
P
MM
M
MM
MM
pp
ppp
M1
Air recirculating dehumidifier C
AU
Dehumidifier with Air Recirculating and Heat Pump FunctionType CAU GEA CAIRfricostar
4 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Components
Casing: Indoor installation– 50 mm panels, inside and outside skins are painted; (corresponds to RAL 9002),
the series includes casing frame and service door in casing panel thickness togeth-er with a full profile rubber gasket in EPDM quality. All outside and inside surfaces are completely smooth.
– Leak tightness class G II according to VDI 3803. Thermal and sound bridges are minimized.
– Non combustible insulation (fire classification A1 according to DIN 4102; Ö-Norm B3800; CFC-free)
– Heat transfer coefficient k = 0,57 W/m2 K– Sound insulation performance Rw = 44 dB according to DIN 52210/T4– Casing features according to EN1886– Filter bypass leakage F9 – Leak tightness class according to prEN 1886 (10/2005) L1– Casing leakage B– Mechanical stability 1A– Thermal insulation T2– Thermal bridging factor TB2 (in risk areas)– Frame profiles AlMgSi 0,5– Flexible connector with potential equalisation, temperature resistant from -30 °C to
+120 °C– Duct connection using 30 mm frame with 4 hole bolt connection– Interior installation parts for swimming pool mode with special corrosion protection
Heat pump for dehumidification:
– Direct evaporator according to VDI 6022: heat exchanger as Cu/Alu model forR 407c refrigerant, fins made of aluminium, frame elements made of AlMg3, pipes made of oxygen-free copper.
– Condensate water tray in bottom panel for evaporator and heat recovery system, with a slope in the direction of condensate drain, made of stainless steel V4A pow-der coated, including drain tray, conform with VDI 6022
– Air-cooled condenser according to VDI 6022: heat exchanger as Cu/Alu model for R 407c refrigerant, fins made of aluminium, frame elements made of AlMg3, pipes made of oxygen-free copper
– Compressor unit: refrigeration circuit with a fully hermetic scroll compressor– With optimized heat exchanger combination for maximum COP values, mounted on
anti-vibration mounts. Circuit includes filter drier, liquid collector, thermostatic expansion valve with MOP and external pressure equalisation, all necessary shut-off valves, monitoring and safety devices (pressostat, icing sensor, etc.)
Droplet eliminator – Made of plastic with an aluminium frame at air velocities on supply and exhaust side exceeding 2,5 m/s is necessary
Fan unit: GEA centrifugal fan „LESS ENERGY SYSTEM“– Optimized operating point, double side suction, coated surface model– Three phase motor, protection class IP55 , model type B3, complete belt drive, easy
service thanks to one bolt tensioning sled– Fan/motor unit mounted on anti-vibration mounts
Filter for exhaust air: – Filter unit according to DIN– Including bag filter as of DIN/EN 779, synthetic fiber filter medium– All filters are fitted with a differential pressure switch for filter monitoring
Heating section: – L.P.H.W. air heater, heat exchanger with copper pipes and drawn aluminium fins in aluminium frame AlMg3 (max. temp. 110°C, Pmax 16 bar) removable in accord-ance with VDI 6022
Dehumidifier with Air Recirculating and Heat Pump Function
GEA CAIRfricostar Type CAU
PR-2008-0327-GB • Subject to modifications • Status 05/2009 5
GEA motor 3-way mixingvalve:
– Supplied loose for air reheating coil including actuator 230 V with an automatic step measurement system for fine adjustment of water flow rate
– Supplied loose, installation by others
Control and regulation system
– Consists of a separate switch cabinet for mounting on units with all necessary com-ponents for control functions, wired according to VDE specifications.
– Electrical connection (via plug or screw terminals) between control cabinet and unit using factory prepared and fully assembled lines.
– Mains voltage for control of mixing valve and reheater pump (including controls)– Possible output for pool water pump– The switch cabinet is supplied loose, including fixing material for mounting on the
unit– All electronic control and regulation components can be easily replaced
The switch cabinet is supplied with the following
main components:
– Main isolating switch for all pole shut-down of the electrical unit– Group fuses for fan and compressor
Safety fuse for pump reheater circuit 230VControl fuse and control voltage supply unit 24V (safety extra-low voltage or SELV) Control of supply air fan using motor full protection device via PTCtemperature sensor and electronic motor tripping device
– Control of compressor motor with thermal motor protection and interlock for safety chain and control card, control of icing protection, low and high pressure.
– Electronic control card for compressor regulation with minimum run and standstill time as clock protection, service reset button, status messages for timer control and light diode for faults of the refrigeration circuit.
– Humidistat with remote control for mounting in the swimming pool, with status and fault lamp and operation switch.Operation with safety extra-low voltage.Setpoint setting 30-90 % r.h.Colour: whiteOn-wall mountingDimensions: W/H/D 145/80/30 (mm) supplied loose
– Electronic three point PI-controller for exhaust air temperature control with setpoint setting on the switch cabinet including installed NTC exhaust air temperature sen-sor.
– Output 230V for modulating 3-way valve motor in reheater circuit– If necessary GEA pool water temperature control for controlling pool water pump
consisting of an integrated immersion thermostat, interlocking with compressor operation and output for pool water pump 230V (only control output max. 2A) and time control for registration of actual values (only in combination with pool water condenser)
– Output for collective error message signal (floating change-over contact)– Control possibility of an exhaust fan by others, 2-speed, 230 V/max. 150 W
Air recirculating dehumidifier C
AU
Dehumidifier with Air Recirculating and Heat Pump FunctionType CAU GEA CAIRfricostar
6 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Technical data
Tab. 1: Technical data CAIRfricostar CAU1) Swimming pool air condition 30 °C/54 %r.h.;2) Inlet/outlet temperature 70 °C/50 °C; maximum heating capacity; 2 rows3) plus controls/regulation/pumps etc.(All data are approximate values and summarize most important features.Subject to modifications. Exact data are available in the current Lplus design software)
Accessories
Valve final position switch for on demand controls of reheater pump 9349W20
Pool water pump, self suction; industrial quality F8ZBP
Unit series CAU…SU.. (standard model, maximum air velocity for supply and exhaust air approx. 2,8 m/s),fans in casing
Type Unit dimensions Air volume flowDehumidi-
fication capacity
Heating capacityPres-sure drop
Motor rated power/current
Current consump-
tion
CA
U_S
U
Tota
l wid
th
Tota
l hei
ght
Tota
l len
gth
Min
imum
Max
imum
Rat
ed (w
ith d
ehum
idifi
catio
n)
Rat
ed (w
ith v
entil
atio
n)
Rec
ircul
atie
d ai
r mod
e 1)
Air
cond
ense
r, w
ith in
activ
epo
ol w
ater
con
dens
er
Air
cond
ense
r, w
ith a
ctiv
epo
ol w
ater
con
dens
er
Pool
wat
er c
onde
nser
(acc
esso
ry)
Reh
eate
r 2)
Tota
l ext
erna
l pre
ssur
e
Supp
ly a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Com
pres
sor,
with
out
pool
wat
er c
onde
nser
Uni
t tot
al 3)
[mm] [m3/h] [kg/h] [kW] [Pa] [kW/A] [A]015 760 1120 1680 750 750 500 3.1 7.0 4.6 2.3 5.9 400 0.4/1.4 1.5/2.9 4.3015 760 1120 1680 1842 1842 1228 1.4 8.0 6.0 2.0 9.4 400 1.7/3.8 1.5/2.9 6.7025 760 1360 1800 1842 1842 1228 4.2 13.0 10.6 2.5 11.1 400 0.8/2.1 2.4/4.6 6.7025 760 1360 1800 2755 2755 1836 3.3 13.8 11.3 2.1 14.1 400 1.7/3.8 2.4/4.6 8.4030 760 1360 1800 2755 2755 1836 4.3 16.2 13.3 2.6 14.1 400 1.7/3.8 2.8/5.5 9.3030 760 1360 1880 3355 3355 2236 3.6 16.6 13.9 2.5 15.8 400 3.0/6.7 2.8/5.5 12.2037 760 1600 1720 3354 3354 2236 4.9 19.8 16.3 3.3 18.3 400 1.7/3.8 3.7/7.5 11.3037 760 1600 1800 4129 4129 2752 3.9 20.1 17.0 3.1 20.5 400 3.0/6.7 3.7/7.5 14.2
Dehumidification unit with air mixing and heat pump function
GEA CAIRfricostar Type CMU
PR-2008-0327-GB • Subject to modifications • Status 05/2009 7
Functional description of the unit
The GEA CAIRfricostar CMU is designed for private and small public swimming pools. The series is available in 6 sizes. The unit's function is to dehumidify and heat air in swimming pools in air mixing mode. The unit is delivered with a DDC controls which regulates all functions of the system on a fully automated basis.
When in idle mode without dehumidification the air is recirculated in the swimming pool. When the humidity setpoint has been exceeded the unit switches into dehumidification mode. At this point the supply air fan is switched into speed 2 and the exhaust air fan maintains air circulation at speed 1. The refrigeration unit is activated in order to start dehumidification. Using the bypass damper a certain part of return air is mixed without further treatment with dehumidified air that has passed through the refrigeration cycle. The dehumidification stage continues until the actual humidity value lies below that of the humidity setpoint. After that the fan is switched back into previous speed and the refrigeration cycle is stopped.
When in active hours swimming pool mode the fresh and exhaust air dampers are opened, the bypass damper is closed. The dehumidification takes place via the activa-tion of the refrigeration cycle with both fans switched into speed 2.
Using an optional pool water condenser a certain amount of excess energy produced by the refrigeration cycle can be fed back into swimming pool water.
Sample selection of operating modes:
Idle mode without dehumidificationdemand
Idle mode with dehumidification demand
Active hours operation mode withdehumidification demand
Bypass damper mode, exhaust air fan is de-activated, supply air fan runs at low speed.
Bypass damper mode, exhaust air fan runs atlow speed, supply air fan runs at high speed.
The reheater provides the missing residualheat supply.
Air mixing operation according to VDI, ex-haust and supply air fans run at high speed.
Compressor is switched on. The reheaterprovides the missing residual heat supply.
Using a pool water condenser a certainamount of excess energy can be fed back
into swimming pool water.
H
Option
H
Option
28°C
H
Option
Transition and summer mode with/without dehumidification demand Summer mode inactive period „free night cooling“
In case of overheating of the swimming pool and high outdoor tem-peratures the heat pump is blocked. The unit operates for ventilationand dehumidification in air mixing or only outdoor/exhaust air mode.The fans run at high speed. In case of an optional bypass of the heat
recovery system the latter is not used thanks to a damper system.
If the swimming pool is overheated during the night time or idle periodthe unit ventilates only in outdoor/exhaust air mode. The fans run at
high speed and provide cooling of the swimming pool to reach thesetpoint temperature.
H
Option
Air m
ixing dehumidifier C
MU
Dehumidification unit with air mixing and heat pump functionType CMU GEA CAIRfricostar
8 PR-2008-0327-GB • Subject to modifications • Status 05/2009
System and controls scheme
Components
Casing: Indoor installation– 50 mm panels, inside and outside skins are painted; (corresponds to RAL 9002),
the series includes casing frame and service door in casing panel thickness togeth-er with a full profile rubber gasket in EPDM quality. All outside and inside surfaces are completely smooth.
– Leak tightness class G II according to VDI 3803. Thermal and sound bridges are minimized.
– Non combustible insulation (fire classification A1 according to DIN 4102; Ö-Norm B3800; CFC-free)
– Heat transfer coefficient k = 0,57 W/m2 K– Sound insulation performance Rw = 44 dB according to DIN 52210/T4– Casing features according to EN1886– Filter bypass leakage F9 – Leak tightness class according to prEN 1886 (10/2005) L1– Casing leakage B– Mechanical stability 1A– Thermal insulation T2– Thermal bridging factor TB2 (in risk areas)– Frame profiles AlMgSi 0,5– Flexible connection with potential equalisation, temperature resistant from -30 °C to
120 °C– Duct connection using 30 mm frame with 4 hole bolt connection– Interior installation parts for swimming pool mode with special corrosion protection
DI
AI
DO
AO
M
MP
P
MM
.
M
M
MM
MM
MM
MM
MM
MMpp
ppp
MVSMVS
MVSMVS
M2
M1
Dehumidification unit with air mixing and heat pump function
GEA CAIRfricostar Type CMU
PR-2008-0327-GB • Subject to modifications • Status 05/2009 9
Heat pump fordehumidification:
– Direct evaporator according to VDI 6022: heat exchanger as Cu/Alu model for R 407c refrigerant, fins made of aluminium, frame elements made of AlMg3, pipes made of oxygen-free copper.
– Condensate water tray in bottom panel for evaporator and heat recovery system, with a slope in the direction of condensate drain, made of stainless steel V4A pow-der coated, including drain tray, conform with VDI 6022
– Air-cooled condenser according to VDI 6022: heat exchanger as Cu/Alu model for R 407c refrigerant, fins made of aluminium, frame elements made of AlMg3, pipes made of oxygen-free copper
– Compressor unit: refrigeration circuit with a fully hermetic scroll compressor– With optimized heat exchanger combination for maximum COP values, mounted on
anti-vibration mounts, circuit includes filter drier, liquid collector, thermostatic expansion valve with MOP (maximum operating pressure) and external pressure equalisation, all necessary shut-off valves, monitoring and safety devices(pressostat, icing sensor, etc.)
Droplet eliminator – Made of plastic with an aluminium frame at air velocities on supply and exhaust side exceeding 2,5 m/s is necessary
Fan unit: GEA centrifugal fan „LESS ENERGY SYSTEM“– Optimized operating point, double side suction, coated surface model– Three phase motor, protection class IP55 , model type B3, complete belt drive, easy
service thanks to one bolt tensioning sled– Fan/motor unit mounted on anti-vibration mounts
Alternative fan unit: GEA „OPTIVENT“ high performance fan impellers– Surface coated one side suction with backward curved blades that are directly con-
nected to motor shaft; performance optimized three-phase motor, B3 model type, protection type IP55, insulation class F adjusted for operation with a frequency con-verter. Fan and motor unit including coated intake nozzle mounted on buckling resistant and coated base construction, motor and fan have sound attenuatedbearings.
– Continuous measurement of pressure effects– Statically and dynamically balanced according to DIN ISO 1940, part 1, G2,5).
Continuous monitoring of operation using DDC. Frequency converter for each motor installed in or mounted on the unit, control via GEA DDC with a separate ana-logue signal for both motors. Frequency converters are adjusted and set for both motors. Limit values for motor current and fan speed are set by the programme
– Resonance frequency band/fade out set by factory– Automatic energy optimization for optimal energy use and efficiency rate– Multiple motor operation is possible– Voltage intermediate circuit converter without reduction of capacity– Continuous speed control– Operating hours counter– Min. and max. speed limitation, automatic ramp curve function UP/DOWN– Automatic motor adjustment– Motor tracing switch– DC break– Variable clock frequency– Motor protection– Short circuit and short circuit to earth safe– Under and over current protection– Phase fault monitoring
Air mixing dehum
idifier CM
U
Dehumidification unit with air mixing and heat pump functionType CMU GEA CAIRfricostar
10 PR-2008-0327-GB • Subject to modifications • Status 05/2009
– Motor coils for reducing speed of voltage rise du/dt (delta voltage/delta time)– Numerical display for queries and entering of different indicators on operating sta-
tus: control setpoint, motor frequency, actual value and setpoint, motor current, motor torque and capacity, intermediate circuit voltage, thermal motor load, thermal frequency converter load, control and programmable display with copy function, production according to ISO 9001, CE Label, net and main shaft protection accord-ing to VDE 0160, radio interference shielding, codes and regulations on electro-magnetic compatibility conform with EN 55011 Kl.B-1; EN 50082-2, electric insulation of control and power components according to VDE 0106/0160 (the use of earth leakage circuit breaker / fuse with frequency converters NOT possible!), volume flow measuring device via ring measuring line and pressure measuring point in fan. Calculation and evaluation of volume flow via the GEA DDC. Continu-ous safety monitoring via safety chain in the unit. Display and settings via GEA DDC.
Air damper system: – Dampers with sealing lips, leakage volume flow 20 m3/h m2 (dp=100 Pa), for circu-lating air/bypass, for fresh and exhaust air. Circulating and fresh air rate 0-100%.
– Coated Almg3 damper blades with flow efficient profile, operate in opposite direc-tions. Driven by double sided, anti-static plastic gears PA6 as fiberglass reinforced model (resistant to chemicals) including special actuator for each damper
– Control of the individual actuators using continuous DDC signals
Filter for fresh andexhaust air:
– Filter units conform with VDI 6022– Including bag filter as of DIN/EN 779, synthetic fiber filter medium– All filters are fitted with a differential pressure switch for filter monitoring via the DDC
Heating section: – L.P.H.W. air heater, heat exchanger with copper pipes and drawn aluminium fins in aluminium frame AlMg3 (max. temp. 110°C, Pmax 16 bar) removable in accord-ance with VDI 6022;
GEA motor 3-way mixingvalve:
– For air reheater, supplied loose including actuator 0-10 V with an automatic step measurement system for fine adjustment of water flow rate.
– Supplied loose, installation by others
Control andregulation
system
– Consists of a separate switch cabinet for mounting on units or separate installation (depending in unit size), with all necessary components for control functions, wired according to VDE specifications. IP55 electrical connection (via plug or screw ter-minals) between control cabinet and unit using factory prepared and fully assem-bled lines. Electrical installation for voltage supply, valve mixing control, reheater pump, if necessary external sensor of the pool water pump and possibly other func-tions like remote control inputs by others. The cabinet is supplied loose depending on the unit size as a stand alone cabinet or for mounting on the unit.
Dehumidification unit with air mixing and heat pump function
GEA CAIRfricostar Type CMU
PR-2008-0327-GB • Subject to modifications • Status 05/2009 11
The switch cabinet issupplied with the following
main components:
– Main isolating switch for all pole shut-down of the electrical unit, lockable– Group fuses for fan and compressor– Fuses for reheater and PWC pump
230V/N/PE/50Hz (types 015-083)3 X 400V/NPE/50Hz (types 100-320)(if necessary - motor protection by others)
– Control fuses, control transformer 230 V and control voltage supply unit 24V DC for the digital control
– Control fuse and control voltage supply unit 24V AC for actuators– Automatic phase controller (option)– Indoor installation, frost free
Digital control: – Modular automation station built into switch cabinet with deletion-proof software modules and digital and analogue inputs and outputs, equipped with all control functions for swimming pool dehumidifier, consisting of:– Control unit with 32 bit processor in network based, interdisciplinary, free pro-
grammable automation system– Watchdog function, data buffering (FLASH-ROM), hardware clock– Interfaces:
1 x CAN (Controller Area Network) as central bus between control unit and I/O modules;1 x LIN (Local Interconnect Network) for auxiliary module monitoring and config-uration functions;1 x CAN for external connection;2 x RS232/RS485, one RS232 has modem function;Optional - Ethernet; USB plug;Optional - various communication functions can be carried out (e. g: OPC; LON; MODBUS; OSPA; BACnet®) As BACnet®-Building Controller (B-BC) thesystem can cost-efficiently intgerate or be integrated in any BACnet® third system.
– In and output modules with an integrated microcontroller and memory for record-ing a programme specifically designed for the relevant module, status display for every input or output with CAN provided via top hat rail bus plug.
– Comfortable intelligent control terminal for supporting display, control buttons and data transfer, installed in the door of the switch cabinet.
– Alufront panel with front film– Keyboard connection via plug connector– Front side protection type IP 65– LCD-Display with 8 lines each with 40 symbols as clear text display, monochrome– 6 function buttons– Colour background lighting, adjustable, automatic lighting activation– Adjustable LCD contrast– System bus CAN– Alternative (option): as before, but:
– with comfortable touch control terminal– LCD display with 16 colours– Graphical resolution 320 x 240 Pixel
Air mixing dehum
idifier CM
U
Dehumidification unit with air mixing and heat pump functionType CMU GEA CAIRfricostar
12 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Control and regulation functions:
– Status and fault signals in clear text– Indication of all status and control parameters– Stepwise access authorization using code– Integrated clock timer– Automatic summer / winter time switch-over, activation of weekly programmes, hol-
iday and special day programmes– Log for registration of faults with date and time– Operating hours counter, total operation and maintenance intervals– Data logging function for most important parameters, can be downloaded– Separate controls for supply and exhaust air fan motors– Air volume adjustment and display in m³/h, including monitoring for units with fre-
quency converters– Fan motor monitoring using PTC resistor and motor protection relay– Filter monitoring– Compressor control (heat pump) with minimum run / standstill time– Regulation of air mixing dampers with selectable minimum fresh air rate and maxi-
mum limitation, automatic control depending on conditions of fresh air and swim-ming pool air
– Control sequence with energy recovery, heater, compressor (heat pump), bypass damper and air mixing damper system
– Exhaust air temperature cascade control with min./max. limitation of supply air tem-perature
– Cooling with outside air (night cooling)– Reheater-heat pump consumption control with blockage protection functions– Continuous humidity control– On demand - controls for automatic pool water pump with block up protection– Automatic switch-over between active/non-active hours operation– Continuous inactive/idle mode possible– Different languages can be selected– Commissioning function for air dampers– Inputs: external emergency switch off (e.g. fire protection damper or chlorine gas
alarm)– Motor monitoring for NE pump can be switched, if required motor protection
by others– Motor monitoring for pool water pump can be switched, if required motor protection
by others– The necessary sensors and actuators are built into the unit or, if necessary, sup-
plied loose with subsequent installation by others
Dehumidification unit with air mixing and heat pump function
GEA CAIRfricostar Type CMU
PR-2008-0327-GB • Subject to modifications • Status 05/2009 13
Technical data
Tab. 2: Technical data CAIRfricostar CMU_SU1) Swimming pool air condition 30 °C/54 %r.h.; Outdoor air condition 5 °C/85 %r.h.2) Inlet/outlet temperature 70 °C/50 °C; maximum heating capacity; 2 rows3) plus controls/regulation/pumps etc.(All data are approximate values and summarize most important features.Subject to modifications. Exact data are available in the current Lplus design software)
Unit series CMU…SU. (standard model, maximum air velocity for supply and exhaust air approx. 2,8 m/s), plug fans, frequency converters
Type Unit dimensions Air volume flowDehumid-ification capacity
Heating capacityPres-sure drop
Motor rated power/currentCurrent
con-sumption
CM
U_S
U
Tota
l wid
th
Tota
l hei
ght
Tota
l len
gth
Min
imum
Max
imum
Rat
ed (w
ith d
ehum
idifi
catio
n)
Rat
ed (w
ith v
entil
atio
n)
Act
ive
hour
s m
ore
(30%
fres
h ai
r)/
idle
mod
e (c
ircul
atin
g ai
r) /
VDI 2
089
1)
Air
cond
ense
r, w
ith in
activ
epo
ol w
ater
con
dens
er
Air
cond
ense
r, w
ith a
ctiv
epo
ol w
ater
con
dens
er
Pool
wat
er c
onde
nser
(acc
esso
ry)
Reh
eate
r 2)
Ext.
fres
h/su
pply
air;
exha
ust/r
etur
n ai
r; e
ach
Supp
ly a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Exha
ust a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Com
pres
sor,
with
out p
ool
wat
er c
onde
nser
Uni
t tot
al 3)
[mm] [m3/h] [kg/h] [kW] [Pa] [kW/A] [A]015 760 1120 2600 750 1843 1000 667 5/2/6 7.0 5.6 1.6 10.6 300 0.6/1.4 0.6/1.4 1.3/2.5 5.3025 760 1360 2700 1842 2756 2000 1333 10/4/13 13.0 11.5 1.5 11.7 300 0.8/1.7 0.8/1.7 2.1/4.3 7.7030 760 1360 2700 2755 3355 3000 2000 14/4/19 16.6 14.8 1.6 14.8 300 1.1/2.5 0.8/1.7 2.5/5.2 9.4037 760 1600 2740 3354 4129 4000 2667 18/5/25 21.0 18.1 2.1 20.2 300 1.5/3.4 1.1/2.5 3.4/7.1 13.0045 1080 1360 2760 4128 5032 5000 3333 21/4/32 24.2 20.2 2.1 36.0 300 2.2/4.7 2.2/4.7 3.3/7.0 16.4055 1080 1600 2800 5031 6193 6000 4000 26/6/38 30.0 26.3 2.6 46.4 300 2.2/4.7 1.5/3.4 4.2/8.9 17.0
Air mixing dehum
idifier CM
U
Dehumidifier with Air Mixing and Heat Pump FunctionType CAM GEA CAIRfricostar
14 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Functional description of the unit
The GEA CAIRfricostar CAM is designed for various kinds of private and public swim-ming pools. The series can be supplied with air volume capacity between 750 up to 45.000 m³/h. The unit's function is to dehumidify and heat air in swimming pools in air mixing mode. Together with the refrigeration unit (heat pump) this unit type is addition-ally equipped with an efficient heat recovery system. The unit is delivered with a DDCcontrols which regulates all functions of the system on a fully automated basis.
When in idle mode without dehumidification the air is recirculated in the swimming pool. When the humidity setpoint has been exceeded the unit switches into dehumidification mode. At this point the supply air fan is switched into speed 2 and the exhaust air fan maintains air circulation at speed 1. The refrigeration unit is activated in order to start dehumidification. Using the bypass damper a certain part of return air is mixed without further treatment with dehumidified air that has passed through the refrigeration cycle. The dehumidification stage continues until the actual humidity value is reduced below that of the humidity setpoint. After that the fan is switched back into previous speed and the refrigeration cycle is stopped.
When in active hours swimming pool mode the fresh and exhaust air dampers are opened, the bypass damper is closed. The dehumidification takes place via the activa-tion of the refrigeration cycle with both fans switched into speed 2.
Using an optional pool water condenser a certain amount of excess energy produced by the refrigeration cycle can be fed back into swimming pool water.
Sample selection of operation mode:
Idle mode without dehumidificationdemand
Idle mode with dehumidification request
Active hours swimming pool modewith humidification request and pool
water condenser
Bypass damper mode, exhaust air fan is de-activated, supply air fan runs at low speed.
Bypass damper mode, exhaust air fan runs atlow speed, supply air fan runs at large speed.
Compressor is switched on. The reheaterprovides the missing residual heat supply.
Air mixing operation according to VDI, ex-haust and supply air fans run at high speed.
Compressor is switched on. The reheaterprovides the missing residual heat supply.
Using a pool water condenser a certainamount of excess energy can be fed back
into swimming pool water.
E A
+ +
-
-
+
+
E A
+ +
-
-
EC
OS
TA
TP
ow
er
Tu
be2
+
+
Transition and summer mode with/w/o dehumidification Summer mode inactive period „free night cooling“
In case of overheating of the swimming pool and high outdoor tem-peratures the heat pump is blocked. The unit ventilates and dehumid-ifies in air mixing or only outdoor/exhaust air mode. The fans run athigh speed. In case of an optional bypass of the heat recovery sys-
tem the latter is not used thanks to a damper system and at the sametime the air volume flow is increased ("free night cooling“ function).
If the swimming pool is overheated during the night time or idle periodthe unit ventilates only in outdoor/exhaust air mode. The fans run at
high speed and provide cooling of the swimming pool to reach thesetpoint temperature. In case of an optimal bypass of the heat recov-ery system the heat recovery is not used thanks to a damper system
and at the same time the air volume flow is increased.
E A
+ +
-
-
Ko
mp
ress
or
+
+
E A
+ +
-
-
+
+
Dehumidifier with Air Mixing and Heat Pump Function
GEA CAIRfricostar Type CAM
PR-2008-0327-GB • Subject to modifications • Status 05/2009 15
System and controls scheme
Components
Casing: Indoor installation– 50 mm panels, inside and outside skins are painted; (corresponds to RAL 9002),
the series includes casing frame and service door in casing panel thickness togeth-er with a full profile rubber gasket in EPDM quality. All outside and inside surfaces are completely smooth.
– Leak tightness class G II according to VDI 3803. Thermal and sound bridges are minimized.
– Non combustible insulation (fire classification A1 according to DIN 4102; Ö-Norm B3800; CFC-free)
– Heat transfer coefficient k = 0,57 W/m2 K– Sound insulation performance Rw = 44 dB according to DIN 52210/T4– Casing features according to EN1886– Filter bypass leakage F9 – Leak tightness class according to prEN 1886 (10/2005) L1– Casing leakage B– Mechanical stability 1A– Thermal insulation T2– Thermal bridging factor TB2 (in risk areas)– Frame profiles AlMgSi 0,5– Flexible connector with potential equalisation, temperature resistant from -30 °C to
+120 °C– Duct connection using 30 mm frame with 4 hole bolt connection– Interior installation parts for swimming pool mode with special corrosion protection
DI
AI
DO
AO
M
MP
P
MM
.
L-K
onde
nsato
r
MEco
stat
M
MM
MM
MM
MM
MM
MM
MM
Eco
stat
pp
ppp
MVSMVS
MVSMVS
Y1
M5
B2
6
M1
B2
NE
Air m
ixing dehumidifier C
AM
Dehumidifier with Air Mixing and Heat Pump FunctionType CAM GEA CAIRfricostar
16 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Heat pump for dehumidification:
– Direct evaporator according to VDI 6022: heat exchanger as Cu/Alu model forR 407c refrigerant, fins made of aluminium, frame elements made of AlMg3, pipes made of oxygen-free copper.
– Condensate water tray in bottom panel for evaporator and heat recovery system, with a slope in the direction of condensate drain, made of stainless steel V4A pow-der coated, including drain tray, conform with VDI 6022
– Air-cooled condenser according to VDI 6022: heat exchanger as Cu/Alu model for R 407c refrigerant, fins made of aluminium, frame elements made of AlMg3, pipes made of oxygen-free copper
– Compressor unit: refrigeration circuit with a fully hermetic scroll compressor– With optimized heat exchanger combination for maximum COP values, mounted on
anti-vibration mounts, circuit includes filter drier, liquid collector, thermostatic expansion valve with MOP and external pressure equalisation, all necessary shut-off valves, monitoring and safety devices (pressostat, icing sensor, etc.)
Droplet eliminator – Made of plastic with an aluminium frame at air velocities on supply and exhaust side exceeding 2,5 m/s is necessary
Fan unit: GEA centrifugal fan „LESS ENERGY SYSTEM“– Optimized operating point, double inlet double width fan, coated surface model– Three phase motor, protection class IP55 , model type B3, complete belt drive, easy
service thanks to one bolt tensioning sled– Fan/motor unit mounted on anti-vibration mounts
Alternative fan unit: GEA „OPTIVENT“ high performance fan impellers– Surface coated one side suction with backward curved blades that are directly con-
nected to motor shaft; performance optimized three-phase motor, B3 model type, protection type IP55, insulation class F adjusted for operation with a frequency con-verter. Fan and motor unit including coated intake nozzle mounted on buckling resistant and coated base construction, motor and fan have sound attenuatedbearings
– Continuous measurement of pressure effects– Statically and dynamically balanced according to DIN ISO 1940, part 1, G2,5). Con-
tinuous monitoring of operation using DDC. Frequency converter for each motor installed in or mounted on the unit, control via GEA DDC with a separate analogue signal for both motors. Frequency converters are adjusted and set for both motors. Limit values for motor current and fan speed are set by the programme
– Resonance frequency band/fade out set by factory– Automatic energy optimization for optimal energy use and efficiency rate– Multiple motor operation is possible– Voltage intermediate circuit converter without reduction of capacity– Continuous speed control– Operating hours counter– Min. and max. speed limitation, automatic ramp curve function UP/DOWN– Automatic motor adjustment– Motor tracing switch– DC break– Variable clock frequency– Motor protection– Short circuit and short circuit to earth safe– Under and over current protection– Phase fault monitoring
Dehumidifier with Air Mixing and Heat Pump Function
GEA CAIRfricostar Type CAM
PR-2008-0327-GB • Subject to modifications • Status 05/2009 17
– Motor coils for reducing speed of voltage rise du/dt (delta voltage/delta time)– Numerical display for queries and entering of different indicators on operating sta-
tus: control setpoint, motor frequency, actual value and setpoint, motor current, motor torque and capacity, intermediate circuit voltage, thermal motor load, thermal frequency converter load, control and programmable display with copy function, production according to ISO 9001, CE Label, net and main shaft protection accord-ing to VDE 0160, radio interference shielding, codes and regulations on electro-magnetic compatibility conform with EN 55011 Kl.B-1; EN 50082-2, electric insulation of control and power components according to VDE 0106/0160 (the use of earth leakage circuit breaker / fuse with frequency converters NOT possible!), volume flow measuring device via ring measuring line and pressure measuring point in fan.Calculation and evaluation of volume flow via the GEA DDC. The settings for entire unit are done at the factory. Continuous safety monitoring via safety chain in the unit. Display and settings via GEA DDC.
Air damper system – Dampers with sealing lips, leakage volume flow 20 m3/h m2 (dp=100 Pa), for circu-lating air/bypass, for fresh and exhaust air. Circulating and fresh air rate 0-100%
– Coated Almg3 damper blades with flow efficient profile, operate in opposite direc-tions. Driven by double sided, anti-static plastic gears PA6 as fiberglass reinforced model (resistant to chemicals) including special actuator for each damper
– Control of the individual actuators using continuous DDC signals
Filter for fresh and exhaust air:
– Filter units conform with VDI 6022– Including bag filter as of DIN/EN 779, synthetic fiber filter medium– All filters are fitted with a differential pressure switch for filter-monitoring via the
DDC
Heat recovery system: GEA „ECOSTAT2 POWER TUBE“:– Recuperative heat recovery using GEA heat pipe technology, heat exchanger
made of Cu/Al. Aluminium fins, frame elements made of AlMg3, tubes made of oxy-gen-free copper charged with R134a CFC-free refrigerant for energy transfer.
– Non-combustible according to fire protection regulation
Heating section: – L.P.H.W. air heater, heat exchanger with copper pipes and drawn aluminium fins in aluminium frame AlMg3 (max. temp. 110°C, Pmax 16 bar) removable in accord-ance with VDI6022;
GEA motor 3-way mixingvalve:
– For air reheater, supplied loose including actuator 0-10 V with an automatic step measurement system for fine adjustment of water flow rate
– Supplied loose, installation by others
Control and regulation system
– Consists of a separate switch cabinet for mounting on units or separate installation (depending on unit size), with all necessary components for control functions, wired according to VDE specifications. IP55 electrical connection (via plug or screw ter-minals) between control cabinet and unit using factory prepared and fully assem-bled lines. Electrical installation for voltage supply, valve mixing control, reheater pump, if necessary external sensor of the pool water pump and possibly other func-tions like remote control inputs by others. The cabinet is supplied loose depending on the unit size as a stand alone cabinet or for mounting on the unit;
Air mixing dehum
idifier CAM
Dehumidifier with Air Mixing and Heat Pump FunctionType CAM GEA CAIRfricostar
18 PR-2008-0327-GB • Subject to modifications • Status 05/2009
The switch cabinet is supplied with the following
main components:
– Main isolating switch for all pole shut-down of the electrical unit, lockable– Group fuses for fan and compressor– Fuses for reheater and PWC pump
230V/N/PE/50Hz (types 015-083)3 X 400V/NPE/50Hz (types 100-320) (if necessary - motor protection by others)
– Control fuses, control transformer 230 V and control voltage supply unit 24V DC for the digital control
– Control fuse and control voltage supply unit 24V AC for actuators– Automatic phase controller (option)– Indoor installation, frost free
Digital control: – Modular automation station built into switch cabinet with deletion-proof software modules and digital and analogue inputs and outputs, equipped with all control functions for swimming pool dehumidifier, consisting of:– Control unit with 32 bit processor in network based, interdisciplinary, free pro-
grammable automation system– Watchdog function, data buffering (FLASH-ROM), hardware clock– Interfaces:
1 x CAN (Controller Area Network) as central bus between control unit and I/O modules;1 x LIN (Local Interconnect Network) for auxiliary module monitoring and config-uration functions;1 x CAN for external connection;2 x RS232/RS485, one RS232 has modem function;Optional - Ethernet; USB plug;Optional - various communication functions can be carried out (e. g: OPC; LON; MODBUS; OSPA; BACnet®) As BACnet®-Building Controller (B-BC) the system can cost efficiently intgerate or be integrated in any BACnet® third system.
– In and output modules with an integrated microcontroller and memory for record-ing a programme specifically designed for the relevant module, status display for every input or output with CAN provided via top hat rail bus plug.
– Comfortable intelligent control terminal for supporting display, control buttons and data transfer, installed in the door of the switch cabinet
– Alufront panel with front film– Keyboard connection via plug connector– Front side protection type IP 65– LCD-Display with 8 lines each with 40 symbols as clear text display, monochrome– 6 function buttons– Colour background lighting, adjustable, automatic lighting activation– Adjustable LCD contrast– System bus CAN– Alternative (option): as before, but:
– with comfortable touch control terminal– LCD display with 16 colours– Graphical resolution 320 x 240 Pixel
Dehumidifier with Air Mixing and Heat Pump Function
GEA CAIRfricostar Type CAM
PR-2008-0327-GB • Subject to modifications • Status 05/2009 19
Control and regulation functions:
– Status and fault signals in clear text– Indication of all status and control parameters– Stepwise access authorization using code– Integrated clock timer– Automatic summer / winter time switch-over, activation of weekly programmes, hol-
iday and special day programmes– Log for registration of faults with date and time– Operating hours counter, total operation and maintenance intervals– Data logging function for most important parameters, can be downloaded– Separate controls for supply and exhaust air fan motors– Air volume adjustment and display in m³/h, including monitoring for units with fre-
quency converters– Fan motor monitoring using PTC resistor and motor protection relay– Filter monitoring– Compressor control (heat pump) with minimum run / standstill time– Control of air mixig dampers with selectable min. fresh air rate and max. limitation,
automatic control depending on conditions of fresh air and swimming pool air– Control sequence with energy recovery, heater, compressor (heat pump), bypass
damper and air mixing damper system– Exhaust air temperature cascade control with min./max. limitation
of supply air temperature– Cooling with outside air (night cooling)– Reheater-heat pump consumption control with blockage protection functions– Continuous humidity control– On demand - controls for automatic pool water pump with block up protection– Automatic switch-over between active/non-active hours operation– Continuous inactive/idle mode possible– Different languages can be selected– Commissioning function for air dampers– Inputs: external emergency switch off
(e.g. fire protection damper or chlorine gas alarm)– Motor monitoring for reheater pump can be switched, if required motor protection
by others– Motor monitoring for pool water pump can be switched, if required motor protection
by others– The necessary sensors and actuators are built into the unit or, if necessary,
supplied loose with subsequent installation by others
Air mixing dehum
idifier CAM
Dehumidifier with Air Mixing and Heat Pump FunctionType CAM GEA CAIRfricostar
20 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Technical data
1) Swimming pool air condition 30 °C/54 %r.F.; Outdoor air condition 5 °C/85 %r.h. 2) Inlet/outlet temperature 70 °C/50 °C; maximum heating capacity; 2 rows3) plus controls/regulation/pumps etc.(All data are approximate values and summarize most important features.Subject to modifications. Exact data are available in the current Lplus design software)
Unit series CAM…SU. (standard model, maximum air velocity for supply and exhaust air approx. 2,8 m/s), plug fans, frequency converters
Type Unit dimen-sions Air volume flow
Dehumidi-fication capacity
Heating capacityPres-sure drop
Motor rated power/currentCurrent
con-sump-
tion
CA
M_S
U
Tota
l wid
th
Tota
l hei
ght
Tota
l len
gth
Min
imum
Max
imum
Rat
ed (w
ith d
ehum
idifi
catio
n)
Rat
ed (w
ith v
entil
atio
n)
Act
ive
hour
s m
ore
(30
% F
.A.)/
idle
mod
e (c
ircul
atin
g ai
r)/ V
DI 2
089
1)
Air
cond
ense
r, w
ith in
activ
epo
ol w
ater
con
dens
er
Air
cond
ense
r, w
ith a
ctiv
e po
olw
ater
con
dens
er
Pool
wat
er c
onde
nser
(acc
esso
ry)
Hea
t rec
over
y sy
stem
Reh
eate
r 2)
Ext.
fres
h/su
pply
air;
exha
ust/r
etur
n ai
r; e
ach
Supp
ly a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Exha
ust a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Com
pres
sor,
with
out p
ool
wat
er c
onde
nser
Uni
t tot
al 3)
[mm] [m3/h] [kg/h] [kW] [Pa] [kW/A] [A]
015 760 1120 3000 750 1843 1000 667 6/3/6 5.4 3.0 2.4 3.0 9.9 300 0.6/1.4 0.6/1.4 1.3/2.5 5.3
025 760 1360 3200 1842 2756 2000 1333 12/5/13 9.3 6.7 2.8 5.9 16.3 300 0.8/1.7 0.8/1.7 1.8/3.5 6.9
030 760 1360 3300 2755 3355 3000 2000 16/5/19 10.7 7.9 3.0 6.9 20.6 300 2.2/4.6 1.5/3.3 2.2/4.2 12.1
037 760 1600 3300 3354 4129 4000 2667 19/5/25 13.1 10.8 2.5 8.9 28.0 300 3.0/6.1 2.2/4.6 2.3/4.5 15.2
045 1080 1360 3300 4128 5032 5000 3333 26/9/32 17.3 14.5 2.6 12.2 35.9 300 3.0/6.1 3.0/6.1 2.7/5.4 17.6
055 1080 1600 3400 5031 6193 6000 4000 31/11/38 21.3 18.7 2.5 15.0 43.9 300 4.0/8.2 3.0/6.1 3.5/7.2 21.5
083 1080 2240 4000 6192 9290 9000 6000 43/12/57 26.9 22.5 4.3 22.0 66.5 300 4.0/8.2 4.0/8.2 4.7/9.4 25.8
100 1400 2240 4000 9289 12386 12000 8000 57/17/76 35.6 30.7 5.2 30.6 88.8 300 5.5/11.4 5.5/11.4 6.1/13.3 36.1
110 1720 2240 4000 12385 15483 15000 10000 72/21/95 42.4 39.0 4.6 39.3 110.0 300 7.5/15.2 5.5/11.4 6.5/13.4 40.0
130 2000 2320 4000 15482 18192 18000 12000 86/24/115 53.1 45.6 6.5 45.4 135.9 300 7.5/15.2 7.5/15.2 8.6/15.7 46.1
150 1720 2880 4400 18191 20644 20000 13333 98/31/127 62.6 55.7 8.2 50.8 147.3 300 11.0/24.5 7.5/15.2 10.5/19.3 59.0
170 2000 2960 4600 20643 24257 24000 16000 117/37/153 72.9 63.2 10.2 61.8 180.1 300 11.0/24.5 11.0/24.5 12.3/24.4 73.4
200 2320 2960 4600 24256 28385 27000 18000 135/45/172 87.8 77.1 10.2 72.5 188.2 300 11.0/24.5 11.0/24.5 13.7/24.5 73.5
230 2640 2960 4800 28384 32514 32500 21667 158/48/207 99.4 86.6 13.5 85.8 232.4 300 15.0/29.5 15.0/29.5 15.6/29.7 88.7
250 2320 3600 5000 32513 35482 34000 22667 169/58/216 108.1 95.4 14.2 91.6 237.6 300 15.0/29.5 11.0/24.5 17.5/31.7 85.7
320 2920 3600 5300 40642 45128 45000 30000 219/79/286 135.1 118.5 15.7 120.0 327.3 300 18.5/36.5 18.5/36.5 20.7/38.1 111.1
Tab. 3: Technical data CAIRfricostar CAM_SU
Dehumidifier with Air Mixing and Heat Pump Function
GEA CAIRfricostar Type CAM
PR-2008-0327-GB • Subject to modifications • Status 05/2009 21
Unit series CAM…PU. (performance model, maximum air velocity for supply and exhaust air from 2,5 m/s to 2,0 m/s), plug fans, frequency converters
Type Unit dimensions Air volume flowDehumidi-
fication capacity
Heating capacityPres-sure drop
Motor rated power/currentCurrent
con-sump-
tion
CA
M_P
U
Tota
l wid
th
Tota
l hei
ght
Tota
l len
gth
Min
imum
Max
imum
Rat
ed (w
ith d
ehum
idifi
catio
n)
Rat
ed (w
ith v
entil
atio
n)
Act
ive
hour
s m
ore
(30
% F
.A.)/
idle
mod
e (c
ircul
atin
g ai
r)/ V
DI 2
089
1)
Air
cond
ense
r, w
ith in
activ
epo
ol w
ater
con
dens
er
Air
cond
ense
r, w
ith a
ctiv
epo
ol w
ater
con
dens
er
Pool
wat
er c
onde
nser
(acc
esso
ry)
Hea
t rec
over
y sy
stem
Reh
eate
r 2)
Ext.
fres
h/su
pply
air;
exha
ust/r
etur
n ai
r; e
ach
Supp
ly a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Exha
ust a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Com
pres
sor,
with
out p
ool
wat
er c
onde
nser
Uni
t tot
al 3)
[mm] [m3/h] [kg/h] [kW] [Pa] [kW/A] [A]
015 760 1120 3000 750 1500 1000 667 6/4/6 5.6 3.5 2.3 3.5 9.5 300 0.6/1.4 0.6/1.4 1.2/2.3 5.1
025 760 1360 3200 1500 2500 2000 1333 11/5/13 7.4 5.3 2.1 7.0 15.3 300 1.1/2.4 0.8/1.7 1.3/2.5 6.6
030 760 1360 3300 2500 2995 2900 1933 16/6/18 10.8 7.9 3.3 8.7 20.0 300 2.2/4.6 2.2/4.6 2.3/4.3 13.5
037 760 1600 3300 2994 3686 3600 2400 19/7/23 12.9 10.1 2.9 10.9 24.7 300 3.0/6.1 2.2/4.7 2.5/4.7 15.4
045 1080 1360 3300 3685 4493 4400 2933 25/10/28 16.8 14.0 3.1 14.1 30.8 300 2.2/4.6 2.2/4.8 2.9/5.6 14.8
055 1080 1600 3400 4492 5530 5500 3667 31/12/35 20.6 17.9 3.1 17.7 38.8 300 3.0/6.1 3.0/6.1 3.6/7.4 19.6
083 1080 2240 4000 5529 8294 7500 5000 39/14/48 23.7 19.6 4.4 24.3 56.3 300 4.0/8.2 3.0/6.1 4.2/7.6 21.9
100 1400 2240 4000 8293 9953 9900 6600 53/19/63 30.9 26.2 5.1 33.5 72.7 300 4.0/8.2 4.0/8.2 5.1/11.2 27.6
110 1720 2240 4000 9952 11059 11000 7333 62/25/70 36.4 31.8 4.9 39.8 86.9 300 4.0/8.2 4.0/8.2 5.9/13.2 29.6
130 2000 2320 4000 11058 12995 12500 8333 70/29/80 43.1 35.8 7.5 45.2 98.6 300 4.0/8.2 4.0/8.2 6.8/13.7 30.1
150 1720 2880 4400 12994 14746 14500 9667 82/36/92 52.3 44.5 8.6 52.1 115.5 300 5.5/11.4 5.5/11.4 9.0/16.2 39.0
170 2000 2960 4600 14745 17326 17000 11333 94/37/108 54.1 46.6 9.0 61.3 132.7 300 5.5/11.4 5.5/11.4 8.5/15.6 38.4
200 2320 2960 4600 17325 20275 20000 13333 112/45/127 67.4 57.6 9.6 73.2 158.9 300 7.5/17.0 7.5/17.0 10.4/18.9 52.9
230 2640 2960 4800 20274 23224 23000 15333 130/54/146 77.3 65.2 13.7 85.6 185.2 300 7.5/17.0 7.5/17.0 12.0/24.1 58.1
250 2320 3600 5000 23223 25344 25000 16667 138/49/159 79.8 66.2 12.3 92.0 199.3 300 11.0/25.0 7.5/17.0 11.9/24.0 66.0
320 2920 3600 5300 29029 32256 32000 21333 177/63/204 101.4 86.4 15.6 118.1 288.2 300 11.0/25.0 11.0/25.0 15.3/29.3 79.3
Tab. 4: Technical data CAIRfricostar CAM_PU1) Swimming pool air condition 30 °C/54 %r.F.; Outdoor air condition 5 °C/85 %r.h.2) Inlet/outlet temperature 70 °C/50 °C; maximum heating capacity; 2 rows3) plus controls/regulation/pumps etc.(All data are approximate values and summarize most important features.Subject to modifications. Exact data are available in the current Lplus design software)
Air mixing dehum
idifier CAM
Dehumidifier with Air Mixing and Heat Pump FunctionType CMP GEA CAIRfricostar
22 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Functional description of the unit
The GEA CAIRfricostar CMP is designed for various kinds High Performance private and public swimming pools. The series can be supplied with air volume capacity between 750 up to 37,500 m³/h. The unit's function is to dehumidify and heat air in swimming pools in air mixing mode. Together with a (heat pump) this unit type is addi-tionally equipped with an efficient heat recovery system using a double plate heat exchanger. The unit is delivered with a DDC controls which regulates all functions of the system on a fully automated basis.
When in idle mode without dehumidification the air is recirculated in the swimming pool. When the humidity setpoint has been exceeded the unit switches into dehumidification mode. At this point the supply air fan is activated and the exhaust air fan maintains the air circulation. The refrigeration unit is activated in order to start dehumidification. The dehumidification stage continues until the actual humidity value is reduced below that of the humidity setpoint. After that the fan is switched back into previous speed and the dehumidification cycle is stopped.
In active hours mode the fresh and exhaust air dampers are opened, the refrigeration cycle is activated and both fans are switched into high speed.
Using an optional pool water condenser a certain amount of excess energy produced by the refrigeration cycle can be fed back into swimming pool water. In case of over-heating of the swimming pool the refrigeration unit is deactivated and the bypass dampers are permanently open in order to avoid heat recovery system.
Sample selection of operation mode:
Idle mode without dehumidificationdemand
Idle mode with dehumidificationdemand
Active hours operation mode withdehumidification demand
Bypass damper mode, exhaust air fan is de-activated, supply air fan runs at low speed.
Bypass damper mode, exhaust air fan runs atlow speed, supply air fan runs at high speed.
Compressor is switched on. Residual heatsupply is provided by the reheater coil.
Operation with air mixing damper, exhaustand supply air fans run at high speed. Com-
pressor is switched on. Compressor isswitched on.
Active hours operation mode with dehumidification demand at high
outdoor temperatures
Active hours operation mode with dehumidification demand at high
outdoor temperatures
Idle mode in summer and at highoutdoor temperatures
Operation with air mixing damper, exhaustand supply air fans run at high speed. Com-pressor is blocked. Regulated heat recovery
using open bypass dampers for avoiding heatrecovery system.
Operation with air mixing damper, exhaustand supply air fans run at high speed. Com-pressor is blocked. Regulated heat recovery
using open bypass dampers for avoiding heatrecovery system.
Outdoor air operation for reaching nominal airtemperature. Compressor is blocked. Double
plate heat exchanger is blocked.
F7
F6
F7
F6
F7
F6
F7
F6
F7
F6
F7
F6
Dehumidifier with Air Mixing and Heat Pump Function
GEA CAIRfricostar Type CMP
PR-2008-0327-GB • Subject to modifications • Status 05/2009 23
System and controls scheme
Components
Casing: Indoor installation– 50 mm panels, inside and outside skins are painted; (corresponds to RAL 9002),
the series includes casing frame and service door in casing panel thickness togeth-er with a full profile rubber gasket in EPDM quality. All outside and inside surfaces are completely smooth.
– Leak tightness class G II according to VDI 3803. Thermal and sound bridges are minimized.
– Non combustible insulation (fire classification A1 according to DIN 4102; Ö-Norm B3800; CFC-free)
– Heat transfer coefficient k = 0,57 W/m2 K– Sound insulation performance Rw = 44 dB according to DIN 52210/T4– Casing features according to EN1886– Filter bypass leakage F9– Leak tightness class according to prEN 1886 (10/2005) L1– Casing leakage B– Mechanical stability 1A– Thermal insulation T2– Thermal bridging factor TB2 (in risk areas)– Frame profiles AlMgSi 0,5– Flexible connector with potential equalisation, temperature resistant from
-30 °C to +120 °C– Duct connection using 30 mm frame with 4 hole bolt connection– Interior installation parts for swimming pool mode with special corrosion protection
Heat pump for dehumidification:
– Direct evaporator according to VDI 6022: heat exchanger as Cu/Alu model forR 407c refrigerant, fins made of aluminium, frame elements made of AlMg3, pipes made of oxygen-free copper.
– Condensate water tray in bottom panel for evaporator and heat recovery system, with a slope in the direction of condensate drain, made of stainless steel V4A pow-der coated, including drain tray, conform with VDI 6022
– Air-cooled condenser according to VDI 6022: heat exchanger as Cu/Alu model for R 407c refrigerant, fins made of aluminium, frame elements made of AlMg3, pipes made of oxygen-free copper
– Compressor unit: refrigeration circuit with a fully hermetic scroll compressor
++++
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M
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M
MM
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pp
pp
pp
Air mixing dehum
idifier CM
P
Dehumidifier with Air Mixing and Heat Pump FunctionType CMP GEA CAIRfricostar
24 PR-2008-0327-GB • Subject to modifications • Status 05/2009
– With optimized heat exchanger combination for maximum COP values, mounted on anti-vibration mounts, circuit includes filter drier, liquid collector, thermostatic expansion valve with MOP (maximum operating pressure) and external pressure equalisation, all necessary shut-off valves, monitoring and safety devices(pressostat, icing sensor, etc.)
Droplet eliminator – Made of plastic with an aluminium frame at air velocities on supply and exhaust side exceeding 2,5 m/s is necessary
Fan unit: GEA „OPTIVENT“ – High performance fan impellers with coated backward curved blades, one side suc-
tion and blades directly connected to motor shaft; Performance – Optimized high value three-phase motor, B3 model type, protection type IP55, insu-
lation class F adjusted for operation with a frequency converter. Fan and motor unit including coated intake nozzle mounted on buckling resistant and coated base con-struction, motor and fan have sound attenuated bearings
– Continuous measurement of pressure effects– Statically and dynamically balanced according to DIN ISO 1940, part 1, G2,5). Con-
tinuous monitoring of operation using DDC. Frequency converter for each motor installed in or mounted on the unit, control via GEA DDC with a separate analogue signal for both motors. Frequency converters are adjusted and set for both motors. Limit values for motor current and fan speed are set by the programme
– Resonance frequency band/fade out set by factory– Automatic energy optimization for optimal energy use and efficiency rate– Multiple motor operation is possible– Voltage intermediate circuit converter without reduction of capacity– Continuous speed control– Operating hours counter– Min. and max. speed limitation, automatic ramp curve function UP/DOWN– Automatic motor adjustment– Motor tracing switch– DC break– Variable clock frequency– Motor protection– Short circuit and short circuit to earth safe– Under and over current protection– Phase fault monitoring– Motor coils for reducing speed of voltage rise du/dt (delta voltage/delta time)– Numerical display for queries and entering of different indicators on operating sta-
tus: control setpoint, motor frequency, actual value and setpoint, motor current, motor torque and capacity, intermediate circuit voltage, thermal motor load, thermal frequency converter load, control and programmable display with copy function, production according to ISO 9001, CE Label, net and main shaft protectionaccording to VDE 0160, radio interference shielding, codes and regulations on elec-tromagnetic compatibility conform with EN 55011 Kl.B-1; EN 50082-2, electric insu-lation of control and power components according to VDE 0106/0160 (The use of earth leakage circuit breaker / fuse with frequency converters NOT possible!), vol-ume flow measuring device via ring measuring line and pressure measuring point in fan. Calculation and evaluation of volume flow via the GEA DDC. The settings for entire unit are done at the factory. Continuous safety monitoring via safety chain in the unit. Display and settings via GEA DDC.
Dehumidifier with Air Mixing and Heat Pump Function
GEA CAIRfricostar Type CMP
PR-2008-0327-GB • Subject to modifications • Status 05/2009 25
Air damper system: – Dampers with sealing lips, leakage volume flow 20 m3/h m2 (dp=100 Pa), for circu-lating air/bypass, for fresh and exhaust air. Circulating and fresh air rate 0-100%
– Coated Almg3 damper blades with flow efficient profile, operate in opposite direc-tions. Driven by double sided, anti-static plastic gears PA6 as fiberglass reinforced model (resistant to chemicals) including special actuator for each damper
– Control of the individual actuators using continuous DDC signals
Filter for fresh andexhaust air:
– Filter units conform with VDI 6022– Including bag filter as of DIN/EN 779, synthetic fiber filter medium– All filters are fitted with a differential pressure switch for filter monitoring via the DDC
Heat recovery system: GEA „ECOPLAT2 POWER PLATE“– 2 symmetric high performance plate heat exchangers, recuperative heat recovery
by using two cross flow aluminium plate heat exchangers (corrosion protected Al99 with best temperature coefficient) in row switch. Surface is additionally coated with thermoplastic material. Largest possible heat exchange surface using entire unit depth with minimum pressure losses. Optimal selection with consideration of oper-ation conditions. Best efficiency rates within entire outdoor temperature range, especially resistant to corrosion and wear. Swimming pool configuration.
– „Upside Down“ installation for smaller internal pressure drops.– AlMg3 ventilation tray– Technical data checked according to EUROVENT– Conform with VDI 6022– Non-combustible according to fire protection regulation
Heating section: – L.P.H.W. air heater, heat exchanger with copper pipes and drawn aluminium fins in aluminium frame AlMg3 (max. temp. 110°C, Pmax 16 bar) removable in accord-ance with VDI 6022;
GEA motor 3-way mixingvalve:
– For air reheater, supplied loose including actuator 0-10 V with an automatic step measurement system for fine adjustment of water flow rate
– Supplied loose, installation by others
Control and regulation system
– Consists of a separate switch cabinet for mounting on units or separate installation (depending in unit size), with all necessary components for control functions, wired according to VDE specifications. IP55 electrical connection (via plug or screw ter-minals) between control cabinet and unit using factory prepared and fullyassembled lines. Electrical installation for voltage supply, valve mixing control, reheater pump, if necessary external sensor of the pool water pump and possibly other functions like remote control inputs by others. The cabinet is supplied loose depending on the unit size as a stand alone cabinet or for mounting on the unit
The switch cabinet issupplied with the following
main components:
– Main isolating switch for all pole shut-down of the electrical unit, lockable– Group fuses for fan and compressor– Fuses for reheater and PWC pump
230V/N/PE/50Hz (types 015-083)3 X 400V/NPE/50Hz (types 100-320)(if necessary - motor protection by others)
– Control fuses, control transformer 230 V and control voltage supply unit 24V DC for the digital control
– Control fuse and control voltage supply unit 24V AC for actuators– Automatic phase controller (option)– Indoor installation, frost free
Air mixing dehum
idifier CM
P
Dehumidifier with Air Mixing and Heat Pump FunctionType CMP GEA CAIRfricostar
26 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Digital control: – Modular automation station built into switch cabinet with deletion-proof software modules and digital and analogue inputs and outputs, equipped with all control functions for swimming pool dehumidifier, consisting of:– Control unit with 32 bit processor in network based, interdisciplinary, free pro-
grammable automation system– Watchdog function, data buffering (FLASH-ROM), hardware clock– Interfaces:
1 x CAN (Controller Area Network) as central bus between control unitand I/O modules;1 x LIN (Local Interconnect Network) for auxiliary module monitoring andconfiguration functions;1 x CAN for external connection;2 x RS232/RS485, one RS232 has modem function;Optional - Ethernet; USB plug;Optional - various communication functions can be carried out (e. g: OPC; LON; MODBUS; OSPA; BACnet®) As BACnet®-Building Controller (B-BC) the system can cost-efficiently intgerate or be integrated in any BACnet® third system.– In and output modules with an integrated microcontroller and memory for record-
ing a programme specifically designed for the relevant module, status display for every input or output with CAN provided via top hat rail bus plug.
– Comfortable intelligent control terminal for supporting display, control buttons and data transfer, integrated in the door of the switch cabinet
– Alufront panel with front film– Keyboard connection via plug connector– Front side protection type IP 65– LCD-Display with 8 lines each with 40 symbols as clear text display, monochrome– 6 function buttons– Colour background lighting, adjustable, automatic lighting activation– Adjustable LCD contrast– System bus CAN– Alternative (option): as before, but:
– with comfortable touch control terminal– LCD display with 16 colours– Graphical resolution 320 x 240 Pixel
Dehumidifier with Air Mixing and Heat Pump Function
GEA CAIRfricostar Type CMP
PR-2008-0327-GB • Subject to modifications • Status 05/2009 27
Control and regulationfunctions:
– Status and fault signals in clear text– Indication of all status and control parameters– Stepwise access authorization using code– Integrated clock timer– Automatic summer / winter time switch-over, activation of weekly programmes,
holiday and special day programmes– Log for registration of faults with date and time– Operating hours counter, total operation and maintenance intervals– Data logging function for most important parameters, can be downloaded– Separate controls for supply and exhaust air fan motors– Air volume adjustment and display in m³/h, including monitoring for units with fre-
quency converters– Fan motor monitoring using PTC resistor and motor protection relay– Filter monitoring– Compressor control (heat pump) with minimum run / standstill time– Regulation of air mixing dampers with selectable minimum fresh air rate and maxi-
mum limitation, automatic control depending on conditions of fresh air and swim-ming pool air
– Control sequence with energy recovery, heater, compressor (heat pump), bypass damper and air mixing damper system
– Exhaust air temperature cascade control with min./max. limitation of supply air tem-perature
– Cooling with outside air (night cooling)– Reheater-heat pump consumption control with blockage protection functions– Continuous humidity control– On demand - controls for automatic pool water pump with block up protection– Automatic switch-over between active/non-active hours operation– Continuous inactive idle mode possible– Different languages can be selected– Commissioning function for air dampers– Inputs: external emergency switch off
(e.g. fire protection damper or chlorine gas alarm)– Motor monitoring for reheater pump can be switched, if required motor protection
by others– Motor monitoring for pool water pump can be switched, if required motor protection
by others– The necessary sensors and actuators are built into the unit or, if necessary,
supplied loose with subsequent installation by others
Air mixing dehum
idifier CM
P
Dehumidifier with Air Mixing and Heat Pump FunctionType CMP GEA CAIRfricostar
28 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Technical data
1) Swimming pool air condition 30 °C/54 %r.h.; Outdoor air condition 5 °C/85 %r.h.2) Inlet/outlet temperature 70 °C/50 °C; maximum heating capacity; 2 rows3) plus controls/regulation/pumps etc.(All data are approximate values and summarize most important features.Subject to modifications. Exact data are available in the current Lplus design software)
Unit series CMP…PU. (performance model, maximum air velocity for supply and exhaust air from 2,5 m/s to 2,0 m/s),plug fans, frequency converters
Type Unit dimensions Air volume flow
Dehumidi-fication capacity
Heating capacityPres-sure drop
Motor rated power/currentCurrent
con-sump-
tion
CM
P_PU
Tota
l wid
th
Tota
l hei
ght
Tota
l len
gth
Min
imum
Max
imum
Rat
ed (w
ith d
ehum
idifi
catio
n)
Rat
ed (w
ith v
entil
atio
n)
Act
ive
hour
s m
ore
(30%
fres
h ai
r)/
idle
mod
e (c
ircul
atin
g ai
r)/V
DI 2
089
1)
Air
cond
ense
r, w
ith in
activ
e p
ool w
ater
con
dens
erA
ir co
nden
ser,
with
act
ive
pool
wat
er c
onde
nser
Pool
wat
er c
onde
nser
(acc
esso
ry)
Hea
t rec
over
y sy
stem
Reh
eate
r 2)
Ext.
fres
h/su
pply
air;
exha
ust/r
etur
n ai
r; e
ach
Supp
ly a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Exha
ust a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Com
pres
sor,
with
out
pool
wat
er c
onde
nser
Uni
t tot
al 3)
[mm] [m3/h] [kg/h] [kW] [Pa] [kW/A] [A]015 760 1120 4240 750 1500 1000 667 6/4/6 5.0 2.6 2.6 3.6 8.4 300 0.6/1.4 0.6/1.4 1.2/2.3 5.1025 760 1360 4480 1500 2500 2000 1333 11/5/13 6.7 3.9 2.9 6.9 13.4 300 0.8/1.7 0.8/1.7 1.5/2.8 6.2037 760 1600 4840 2500 3686 3400 2267 18/8/22 10.7 7.7 3.2 11.3 21.2 300 1.5/3.3 1.5/3.3 2.1/4.1 10.7055 1080 1600 4880 3685 5530 5000 3333 27/13/32 15.9 12.1 3.8 16.6 31.6 300 2.2/4.7 2.2/4.7 3.1/5.9 15.3083 1080 2240 5480 5529 8294 7500 5000 40/17/48 22.4 17.6 5.4 25.6 48.9 300 3.0/6.4 3.0/6.4 4.4/7.9 20.7110 1720 2240 5720 8293 11059 11000 7333 58/25/70 30.7 25.2 5.6 37.5 77.8 300 4.0/8.2 4.0/8.2 5.0/11.2 27.6130 2000 2320 5920 11058 12995 12500 8333 68/31/80 36.9 29.0 8.1 44.2 90.9 300 5.5/11.4 4.0/8.2 6.2/13.4 33.0150 1720 2880 6600 12994 14746 14000 9333 77/37/90 42.1 32.9 8.5 51.8 98.1 300 5.5/11.4 5.5/11.4 7.0/13.9 36.7170 2000 2960 6800 14745 17326 17000 11333 94/46/108 51.5 39.9 12.2 63.0 120.7 300 7.5/17.0 7.5/17.0 9.0/16.2 50.2200 2320 2960 7080 17325 20275 20000 13333 112/57/127 61.9 50.0 12.7 74.5 139.3 300 7.5/17.0 7.5/17.0 10.8/19.6 53.6250 2320 3600 7360 20274 25344 25000 16667 134/61/159 75.7 59.9 16.2 84.2 180.4 300 11.0/25.0 7.5/17.0 12.4/24.6 66.6320 2920 3600 8120 29029 32256 32000 21333 175/84/204 99.4 75.6 21.9 111.4 234.6 300 11.0/25.0 11.0/25.0 16.3/30.6 80.6
Tab. 5: Technical data CAIRfricostar CMP_PU
Dehumidifier with Air Mixing Function
GEA CAIRfricostar Type CWR
PR-2008-0327-GB • Subject to modifications • Status 05/2009 29
Functional description of the unit
The GEA CAIRfricostar CWR is designed for various kinds of private and public swim-ming pools. The series can be supplied with air volume capacity between 750 up to 45,000 m³/h. The unit's function is to dehumidify and heat air in swimming pools in air mixing mode. This unit type is additionally equipped with an efficient heat recovery sys-tem. The unit is delivered with a DDC controls which regulates all functions of the sys-tem on a fully automated basis.
When in idle mode without dehumidification the air is recirculated in the swimming pool. When the humidity setpoint has been exceeded the unit switches into dehumidification mode. For this purpose the supply and exhaust air fans are activated to run at high speed with continuous mixing of outdoor air. The dehumidification stage continues until the actual humidity value is reduced below that of the humidity setpoint. After that the fans are deactivated.
Sample selection of operating modes:
Idle mode without dehumidificationdemand
Active hours operation mode with dehumidification demand
Idle mode with dehumidification request
Bypass damper mode, exhaust air fan isdeactivated,
supply air fan runs at low speed.
Air mixing operation according to VDI,exhaust and supply air fans run at high
speed. The reheater provides the missingresidual heat supply.
Air mixing mode with a minimum fresh air rate
130
-
+
130
-
+
130
-
+
Active hours operation mode with highdehumidification demand Active hours/summer operation mode
Air mixing operation according to VDI, exhaust and supply air fansrun at high speed. The reheater provides the missing residual heat
supply. Outdoor air temperature is increased.
Fresh air mode, exhaust and supply air fans run at high speed.Heat recovery is not used thanks to a damper system.
130
-
+
130
-
+
Air mixing dehum
idifier CW
R
Dehumidifier with Air Mixing FunctionType CWR GEA CAIRfricostar
30 PR-2008-0327-GB • Subject to modifications • Status 05/2009
System and controls scheme
Components
Casing: Indoor installation– 50 mm panels, inside and outside skins are painted; (corresponds to RAL 9002),
the series includes casing frame and service door in casing panel thickness togeth-er with a full profile rubber gasket in EPDM quality. All outside and inside surfaces are completely smooth.
– Leak tightness class G II according to VDI 3803. Thermal and sound bridges are minimized.
– Non combustible insulation (fire classification A1 according to DIN 4102; Ö-Norm B3800; CFC-free)
– Heat transfer coefficient k = 0,57 W/m2 K– Sound insulation performance Rw = 44 dB according to DIN 52210/T4– Casing features according to EN1886– Filter bypass leakage F9– Leak tightness class according to prEN 1886 (10/2005) L1– Casing leakage B– Mechanical stability 1A– Thermal insulation T2– Thermal bridging factor TB2 (in risk areas)– Frame profiles AlMgSi 0,5– Flexible connector with potential equalisation, temperature resistant from -30 °C to
+120 °C– Duct connection using 30 mm frame with 4 hole bolt connection– Interior installation parts for swimming pool mode with special corrosion protection
Fan unit: GEA centrifugal fan „LESS ENERGY SYSTEM“– Optimized operating point, double side suction, coated surface model– Three phase motor, protection class IP55 , model type B3, complete belt drive, easy
service thanks to one bolt tensioning sled– Fan/motor unit mounted on anti-vibration mounts
DI
AI
DO
AO
M
.
M
M
MM
MM
MM
MM
MM
pp
pp
MVSMVS
MVSMVSMMY2
Dehumidifier with Air Mixing Function
GEA CAIRfricostar Type CWR
PR-2008-0327-GB • Subject to modifications • Status 05/2009 31
Alternative fan unit: GEA „OPTIVENT“ high performance fan impellers– Surface coated one side suction with backward curved blades that are directly con-
nected to motor shaft; performance optimized three-phase motor, B3 model type, protection type IP55, insulation class F adjusted for operation with a frequency con-verter. Fan and motor unit including coated intake nozzle mounted on buckling resistant and coated base construction, motor and fan have sound attenuated bear-ings
– Continuous measurement of pressure effects– Statically and dynamically balanced according to DIN ISO 1940, part 1, G2,5). Con-
tinuous pressure monitoring using DDC. Frequency converter for each motor installed in or mounted on the unit, control via GEA DDC with a separate analogue signal for each motor. Frequency converters are adjusted and set for both motors. Limit values for motor current and fan speed are set by the programme
– Resonance frequency band/fade out set by factory– automatic energy optimization for optimal energy use and efficiency rate– Multiple motor operation is possible– Voltage intermediate circuit converter without reduction of capacity– continuous speed control– Operating hours counter– Min. and max. speed limitation, automatic ramp curve function UP/DOWN– Automatic motor adjustment– Motor tracing switch– DC break– Variable clock frequency– Motor protection– Short circuit and short circuit to earth safe– Under and overcurrent protection– Phase fault monitoring– Motor coils for reducing speed of voltage rise du/dt (delta voltage/delta time)– Numerical display for queries and entering of different indicators on operating sta-
tus: control setpoint, motor frequency, actual value and setpoint, motor current, motor torque and capacity, intermediate circuit voltage, thermal motor load, thermal frequency converter load, control and programmable display with copy function, production according to ISO 9001, CE Label, net and main shaft protection accord-ing to VDE 0160, radio interference shielding, codes and regulations on electro-magnetic compatibility conform with EN 55011 Kl.B-1; EN 50082-2, electric insulation of control and power components according to VDE 0106/0160 (The use of earth leakage circuit breaker / fuse with frequency converters NOT possible!), volume flow measuring device via ring measuring line and pressure measuring point in fan. Calculation and evaluation of volume flow via the GEA DDC. The set-tings for entire unit are done at the factory. Continuous safety monitoring via safety chain in the unit. Display and settings via GEA DDC.
Air damper system: – Dampers with sealing lips, leakage volume flow 20 m3/h m2 (dp=100 Pa), for circu-lating air/bypass, for fresh and exhaust air. Circulating and fresh air rate 0-100%
– Coated Almg3 damper blades with flow efficient profile, operate in oppositedirections. Driven by double sided, anti-static plastic gears PA6 as fiberglassreinforced model (resistant to chemicals) including special actuator foreach damper
– Control of the individual actuators using continuous DDC signals
Filter for fresh and exhaust air:
– Filter units conform with VDI 6022– Including bag filter as of DIN/EN 779, synthetic fiber filter medium– All filters are fitted with a differential pressure switch for filter monitoring via the DDC
Air mixing dehum
idifier CW
R
Dehumidifier with Air Mixing FunctionType CWR GEA CAIRfricostar
32 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Heat recovery system: GEA „ECOSTAT2 POWER TUBE“:– Recuperative heat recovery using GEA heat pipe technology, heat exchanger
made of Cu/Al. Aluminium fins, frame elements made of AlMg3, tubes made of oxy-gen-free copper charged with R134a CFC-free refrigerant for energy transfer.
– Non-combustible according to fire protection regulation
Heating section: – L.P.H.W. air heater, heat exchanger with copper pipes and drawn aluminium fins in aluminium frame AlMg3 (max. temp. 110°C, Pmax 16 bar) removable in accord-ance with VDI 6022;
GEA motor 3-way mixingvalve:
– For air reheater, supplied loose including actuator 0-10 V with an automatic step measurement system for fine adjustment of water flow rate
– supplied loose, installation by others
Control and regulation system
– Consists of a separate switch cabinet for mounting on units or separate installation (depending in unit size), with all necessary components for control functions, wired according to VDE specifications. IP55 electrical connection (via plug or screw ter-minals) between control cabinet and unit using factory prepared and fully assem-bled lines. Electrical installation for voltage supply, valve mixing control, reheater pump, if necessary external sensor and possibly other functions like remote control inputs by others. The cabinet is supplied loose depending on the unit size as a stand alone cabinet or for mounting on the unit
The switch cabinet is supplied with the following
main components:
– Main isolating switch for all pole shut-down of the electrical unit, lockable– Group fuses for fans– Fuses for reheater
230V/N/PE/50Hz (types 015-083)3 X 400V/NPE/50Hz (types 100-320)(if necessary - motor protection by others)
– Control fuses, control transformer 230 V and control voltage supply unit24V DC for the digital control
– Control fuse and control voltage supply unit 24V AC for actuators– Automatic phase controller (option)– Indoor installation, frost free
Digital control: – Modular automation station built into switch cabinet with deletion-proof software modules and digital and analogue inputs and outputs, equipped with all control functions for swimming pool dehumidifier, consisting of:– Control unit with 32 bit processor in network based, interdisciplinary, free pro-
grammable automation system– Watchdog function, data buffering (FLASH-ROM), hardware clock– Interfaces:
1 x CAN (Controller Area Network) as central bus between control unit and I/O modules;1 x LIN (Local Interconnect Network) for auxiliary module monitoring and config-uration functions;1 x CAN for external connection;2 x RS232/RS485, one RS232 has modem function;Optional - Ethernet; USB plug;Optional - various communication functions can be carried out (e. g: OPC; LON; MODBUS; OSPA; BACnet®)As BACnet®-Building Controller (B-BC) the system can cost efficiently integrate or be integrated in any BACnet® third system.
– In and output modules with an integrated microcontroller and memory for record-ing a programme specifically designed for the relevant module, status display for every input or output with CAN provided via top hat rail bus plug.
– Comfortable intelligent control terminal for supporting display, control buttons and data transfer, installed in the door of the switch cabinet
– Aluminium front panel with film, keyboard connection via plug connector– Front side protection type IP 65– LCD-Display with 8 lines each with 40 symbols as clear text display, monochrome
Dehumidifier with Air Mixing Function
GEA CAIRfricostar Type CWR
PR-2008-0327-GB • Subject to modifications • Status 05/2009 33
– 6 function buttons– Colour background lighting, adjustable, automatic lighting activation– Adjustable LCD contrast– System bus CAN– Alternative (option): as before, but:
– with comfortable touch control terminal– LCD display with 16 colours– Graphical resolution 320 x 240 Pixel
Control and regulation functions:
– Status and fault signals in clear text– Indication of all status and control parameters– Stepwise access authorization using code– Integrated clock timer– Automatic summer / winter time switch-over, activation of weekly programmes,
holiday and special day programmes– Log for registration of faults with date and time– Operating hours counter, total operation and maintenance intervals– Data logging function for most important parameters, can be downloaded– Separate controls for supply and exhaust air fan motors– Air volume adjustment and display in m³/h, including monitoring for units with
frequency converters– Fan motor monitoring using PTC resistor and motor protection relay– Filter monitoring– Regulation of air mixing dampers with selectable minimum fresh air rate and maxi-
mum limitation, automatic control depending on conditions of fresh air and swim-ming pool air
– Control sequence with energy recovery, heater, bypass damper and air mixing damper system
– Exhaust air temperature cascade control with min./max. limitation of supply air tem-perature
– Cooling with outside air (night cooling)– Reheater-heat pump consumption control with blockage protection functions– Continuous humidity control– Automatic switch-over between active/non-active hours operation– Continuous inactive idle mode possible– Different languages can be selected– Commissioning function for air dampers– Inputs: external emergency switch off (e.g. fire protection damper or chlorine gas
alarm)– Motor monitoring for reheater pump can be switched, if required motor protection
by others– The necessary sensors and actuators are built into the unit or, if necessary,
supplied loose with subsequent installation by others
Air mixing dehum
idifier CW
R
Dehumidifier with Air Mixing FunctionType CWR GEA CAIRfricostar
34 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Technical data
1) Swimming pool air condition 30 °C/54 %r.h.; Outdoor air condition 5 °C/85 %r.h.2) Inlet/outlet temperature 70 °C/50 °C; maximum heating capacity; 2 rows3) plus controls/regulation/pumps etc.(All data are approximate values and summarize most important features.Subject to modifications. Exact data are available in the current Lplus design software)
Unit series CWR…SU. (standard model, maximum air velocity for supply and exhaust air approx. 2,8 m/s), plug fans, frequency converters
Type Unit dimensions Air volume flowDehumid-ification capacity
Heatingcapacity
Pres-sure drop
Motor ratedpower/current
Current consump-
tion
CW
R_S
U
Tota
l wid
th
Tota
l hei
ght
Tota
l len
gth
Min
imum
Max
imum
Rat
ed (w
ith d
ehum
idifi
catio
n)
Rat
ed (w
ith v
entil
atio
n)
conf
orm
with
VD
I 208
9,at
rate
d ai
r flo
w 1)
Hea
t rec
over
y sy
stem
Reh
eate
r 2)
Ext.
fres
h/su
pply
air;
exha
ust/r
etur
n ai
r; e
ach
Supp
ly a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Exha
ust a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Uni
t tot
al 3)
[mm] [m3/h] [kg/h] [kW] [Pa] [kW/A] [A]015 760 1120 2520 750 2396 1500 1000 10 2.6 12.5 300 0.6/1.4 0.6/1.4 2.8025 760 1360 2560 2395 2756 2500 1667 16 4.6 19.1 300 1.1/2.4 1.1/2.4 4.8030 760 1360 2560 2755 3594 3000 2000 19 5.2 20.6 300 1.5/3.3 1.5/3.3 6.6037 760 1600 2680 3593 4424 4000 2667 25 6.9 28.9 300 2.2/4.6 2.2/4.6 9.2045 1080 1360 2680 4423 5391 4800 3200 31 8.7 34.8 300 2.2/4.6 2.2/4.6 9.2055 1080 1600 2720 5390 6636 6000 4000 38 10.9 43.9 300 3.0/6.4 3.0/6.4 11.0083 1080 2240 3320 6635 9953 9000 6000 57 16.6 66.5 300 4.0/8.2 4.0/8.2 16.4100 1400 2240 3360 9952 13271 12000 8000 76 22.5 88.8 300 5.5/11.4 4.0/8.2 19.6110 1720 2240 3480 13270 16589 15000 10000 95 28.5 110.0 300 5.5/11.4 5.5/11.4 22.8130 2000 2320 3520 16588 19492 17500 11667 111 32.9 133.2 300 7.5/17.0 7.5/17.0 34.0150 1720 2880 3840 19491 22118 20000 13333 127 37.3 147.3 300 7.5/17.0 7.5/17.0 34.0170 2000 2960 3800 22117 25989 23500 15667 150 44.3 177.4 300 11.0/25.0 7.5/17.0 42.0200 2320 2960 3880 25988 30413 27000 18000 172 51.5 188.2 300 11.0/25.0 11.0/25.0 50.0230 2640 2960 3880 30412 34836 31500 21000 200 60.2 227.1 300 15.0/29.5 15.0/29.5 59.0250 2320 3600 4200 34835 38016 35000 23333 223 66.5 242.6 300 15.0/29.5 11.0/25.0 54.5320 2920 3600 4320 43545 48384 44000 29333 280 84.3 321.9 300 15.0/29.5 15.0/29.5 59.0
Tab. 6: CAIRfricostar CWR_SU
Dehumidifier with Air Mixing Function
GEA CAIRfricostar Type CWR
PR-2008-0327-GB • Subject to modifications • Status 05/2009 35
1) Swimming pool air condition 30 °C/54 %r.h.; Outdoor air condition 5 °C/85 %r.h.2) Inlet/outlet temperature 70 °C/50 °C; maximum heating capacity; 2 rows3) plus controls/regulation/pumps etc.(All data are approximate values and summarize most important features.Subject to modifications. Exact data are available in the current Lplus design software)
Unit series CWR…PU. (performance model, maximum air velocity for supply and exhaust air from 2,3 m/s to 2,0 m/s), plug fans, frequency converters
Type Unit dimensions Air volume flowDehumid-ification capacity
Heatingcapacity
Pres-sure drop
Motor ratedpower/current
Current con-
sumption
CW
R_P
U
Tota
l wid
th
Tota
l hei
ght
Tota
l len
gth
Min
imum
Max
imum
Rat
ed (w
ith d
ehum
idifi
catio
n)
Rat
ed (w
ith v
entil
atio
n)
Con
form
with
VD
I 208
9,at
rate
d ai
r flo
w 1)
Hea
t rec
over
y sy
stem
Reh
eate
r 2)
Ext.
fres
h/su
pply
air;
exha
ust/r
etur
n ai
r; e
ach
Supp
ly a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Exha
ust a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Uni
t tot
al 3)
[mm] [m3/h] [kg/h] [kW] [Pa] [kW/A] (A)015 760 1120 2520 750 1500 1500 1000 10 2.9 11.9 300 0.6/1.4 0.6/1.4 2.8025 760 1360 2700 1500 2500 2500 1667 16 5.2 18.0 300 1.1/2.4 1.1/2.4 4.8030 760 1360 2700 2500 2995 2800 1867 18 5.7 19.5 300 1.5/3.3 1.5/3.3 6.6037 760 1600 2700 2994 3686 3300 2200 21 6.8 23.2 300 2.2/4.6 1.5/3.3 7.9045 1080 1360 2800 3685 4493 4200 2800 27 8.8 29.7 300 2.2/4.6 2.2/4.6 9.2055 1080 1600 2800 4492 5530 5000 3333 32 8.9 36.0 300 2.2/4.6 2.2/4.6 9.2083 1080 2240 3300 5529 8294 7500 5000 48 15.8 56.3 300 3.0/6.4 3.0/6.4 12.8100 1400 2240 3500 8293 9953 9900 6600 63 21.2 72.7 300 4.0/8.2 4.0/8.2 16.4110 1720 2240 3500 9952 11059 11000 7333 70 23.9 86.9 300 4.0/8.2 4.0/8.2 16.4130 2000 2320 3600 11058 12995 12800 8533 81 27.8 100.4 300 4.0/8.2 4.0/8.2 16.4150 1720 2880 3600 12994 14746 14500 9667 92 31.4 115.5 300 5.5/11.4 5.5/11.4 22.8170 2000 2960 3800 14745 17326 17000 11333 108 37.0 132.7 300 5.5/11.4 5.5/11.4 22.8200 2320 2960 4000 17325 20275 20000 13333 127 43.6 158.9 300 7.5/17.0 5.5/11.4 28.4230 2640 2960 4000 20274 23224 23000 15333 146 50.2 185.2 300 7.5/17.0 7.5/17.0 34.0250 2320 3600 4200 23223 25344 25000 16667 159 54.6 199.3 300 7.5/17.0 7.5/17.0 34.0320 2920 3600 4500 29029 32256 32000 21333 204 70.1 238.2 300 11.0/25.0 11.0/25.0 50.0
Tab. 7: CAIRfricostar CWR_PU Air mixing dehum
idifier CW
R
Dehumidifier with Air Mixing FunctionType CWP GEA CAIRfricostar
36 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Functional description of the unit
The GEA CAIRfricostar CWP is designed for various kinds High Performance private and public swimming pools. The series can be supplied with air volume capacity between 750 up to 37,500 m³/h. The unit's function is to dehumidify and heat air in swimming pools in air mixing mode. This unit type is additionally equipped with an effi-cient heat recovery system. The unit is delivered with a DDC controls which regulates all functions of the system on a fully automated basis.
When in idle mode without dehumidification the air is recirculated in the swimming pool. When the humidity setpoint has been exceeded the unit switches into dehumidification mode. For this purpose the supply and exhaust air fans are activated to run at high speed with continuous mixing of outdoor air. The dehumidification stage continues until the actual humidity value is reduced below that of the humidity setpoint. After that the fans are deactivated.
In case of overheating of the swimming pool the refrigeration unit is deactivated and the bypass dampers are permanently open in order to avoid heat recovery system.
Sample selection of operating modes:
Idle mode without dehumidificationdemand
Inactive/active mode with low dehumidification
Active hours operation mode with dehumidification demand at high
outdoor temperatures
Bypass damper mode, exhaust air fan is de-activated, supply air fan runs at low speed.
Operation with air mixing damper, exhaustand supply air fans run at high speed. Com-
pressor is switched on.
Operation with air mixing damper, exhaustand supply air fans run at high speed. Regu-
lated heat recovery using open bypassdampers for avoiding heat recovery system.
F7
F6
F7
F6
F7
F6
Active hours operation mode with dehumidification request at high outdoor temperatures Idle mode in summer and at high outdoor temperatures
Operation with air mixing damper, exhaust and supply air fans run athigh speed. Regulated heat recovery using open bypass dampers for
avoiding heat recovery system.
Outdoor air operation for reaching nominal air temperature.Double plate heat exchanger is blocked.
F7
F6
F7
F6
Dehumidifier with Air Mixing Function
GEA CAIRfricostar Type CWP
PR-2008-0327-GB • Subject to modifications • Status 05/2009 37
System and controls scheme
Components
Casing: Indoor installation– 50 mm panels, inside and outside skins are painted; (corresponds to RAL 9002),
the series includes casing frame and service door in casing panel thickness togeth-er with a full profile rubber gasket in EPDM quality. All outside and inside surfaces are completely smooth.
– Leak tightness class G II according to VDI 3803. Thermal and sound bridges are minimized.
– Non combustible insulation (fire classification A1 according to DIN 4102; Ö-Norm B3800; CFC-free)
– Heat transfer coefficient k = 0,57 W/m2 K– Sound insulation performance Rw = 44 dB according to DIN 52210/T4– Casing features according to EN1886– Filter bypass leakage F9– Leak tightness class according to prEN 1886 (10/2005) L1– Casing leakage B– Mechanical stability 1A– Thermal insulation T2– Thermal bridging factor TB2 (in risk areas)– Frame profiles AlMgSi 0,5– Flexible connector with potential equalisation, temperature resistant from -30 °C to
+120 °C– Duct connection using 30 mm frame with 4 hole bolt connection– Interior installation parts for swimming pool mode with special corrosion protection
AI
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AO
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Air mixing dehum
idifier CW
P
Dehumidifier with Air Mixing FunctionType CWP GEA CAIRfricostar
38 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Alternative fan unit: GEA „OPTIVENT“ high performance fan impellers– Surface coated one side suction with backward curved blades that are directly con-
nected to motor shaft; performance optimized three-phase motor, B3 model type, protection type IP55, insulation class F adjusted for operation with a frequency con-verter. Fan and motor unit including coated intake nozzle mounted on buckling resistant and coated base construction, motor and fan have sound attenuated bear-ings.
– Continuous measurement of pressure effects– Statically and dynamically balanced according to DIN ISO 1940, part 1, G2,5). Con-
tinuous monitoring of operation using DDC. Frequency converter for each motor installed in or mounted on the unit, control via GEA DDC with a separate analogue signal for both motors. Frequency converters are adjusted and set for both motors. Limit values for motor current and fan speed are set by the programme
– Resonance frequency band/fade out set by factory– Automatic energy optimization for optimal energy use and efficiency rate– Multiple motor operation is possible– Voltage intermediate circuit converter without reduction of capacity– Continuous speed control– Operating hours counter– Min. and max. speed limitation, automatic ramp curve function UP/DOWN– Automatic motor adjustment– Motor tracing switch– DC break– Variable clock frequency– Motor protection– Short circuit and short circuit to earth safe– Under and over current protection– Phase fault monitoring– Motor coils for reducing speed of voltage rise du/dt (delta voltage/delta time)– Numerical display for queries and entering of different indicators on operating sta-
tus: control setpoint, motor frequency, actual value and setpoint, motor current, motor torque and capacity, intermediate circuit voltage, thermal motor load, thermal frequency converter load, control and programmable display with copy function, production according to ISO 9001, CE Label, net and main shaft protection accord-ing to VDE 0160, radio interference shielding, codes and regulations on electro-magnetic compatibility conform with EN 55011 Kl.B-1; EN 50082-2, electric insulation of control and power components according to VDE 0106/0160 (The use of earth leakage circuit breaker / fuse with frequency converters NOT possible!), volume flow measuring device via ring measuring line and pressure measuring point in fan. Calculation and evaluation of volume flow via the GEA DDC. The set-tings for entire unit are done at the factory. Continuous safety monitoring via safety chain in the unit. Display and settings via GEA DDC.
Air damper system: – Dampers with sealing lips, leakage volume flow 20 m3/h m2 (dp=100 Pa), for circu-lating air/bypass, for fresh and exhaust air. Circulating and fresh air rate 0-100%
– Coated AlMg3 damper blades with flow efficient profile, operate in opposite direc-tions. Driven by double sided, anti-static plastic gears PA6 as fiberglass reinforced model (resistant to chemicals) including special actuator for each damper
– Control of the individual actuators using continuous DDC signals
Filter for fresh and exhaust air:
– Filter units conform with VDI 6022– Including bag filter as of DIN/EN 779, synthetic fiber filter medium– All filters are fitted with a differential pressure switch for filter monitoring via the DDC
Dehumidifier with Air Mixing Function
GEA CAIRfricostar Type CWP
PR-2008-0327-GB • Subject to modifications • Status 05/2009 39
Heat recovery system: GEA „ECOPLAT2 POWER PLATE“– 2 symmetric high performance plate heat exchangers for recuperative heat
recovery2 cross flow aluminium plate heat exchangers (corrosion protected Al99 with best temperature coefficient) in row switch. Surface is additionally coated with thermo-plastic material. Largest possible heat exchange surface using entire unit depth with minimum pressure losses. Optimal selection with consideration of operation conditions. Best efficiency rates within entire outdoor temperature range, especially resistant to corrosion and wear. Swimming pool configuration.
– „Upside Down“ installation for smaller internal pressure drops.– AlMg3 ventilation tray– Technical data checked according to EUROVENT– Conform with VDI 6022– Non-combustible according to fire protection regulation
Heating section: L.P.H.W. air heater, heat exchanger with copper pipes and drawn aluminium fins in aluminium frame AlMg3 (max. temp. 110°C, Pmax 16 bar) removable in accordance with VDI 6022;
GEA motor 3-way mixingvalve:
– For air reheater, supplied loose including actuator 0-10 V with an automatic step measurement system for fine adjustment of water flow rate
– Supplied loose, installation by others
Control and regulation system
– Consists of a separate switch cabinet for mounting on units or separate installation (depending in unit size), with all necessary components for control functions, wired according to VDE specifications. IP55 electrical connection (via plug or screw ter-minals) between control cabinet and unit using factory prepared and fully assem-bled lines. Electrical installation for voltage supply, valve mixing control, reheater pump, if necessary external sensor and possibly other functions like remote control inputs by others. The cabinet is supplied loose depending on the unit size as a stand alone cabinet or for mounting on the unit
The switch cabinet is supplied with the following
main components:
– Main isolating switch for all pole shut-down of the electrical unit, lockable– Group fuses for fan and compressor– Fuses for reheater 230V/N/PE/50Hz (types 015-083)
3 X 400V/NPE/50Hz (types 100-320)(if necessary - motor protection by others)
– Control fuses, control transformer 230 V and control voltage supplyunit 24V DC for the digital control
– Control fuse and control voltage supply unit 24V AC for actuators– Automatic phase controller (option)– Indoor installation, frost free
Air mixing dehum
idifier CW
P
Dehumidifier with Air Mixing FunctionType CWP GEA CAIRfricostar
40 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Digital control: – Modular automation station built into switch cabinet with deletion-proof software modules and digital and analogue inputs and outputs, equipped with all control functions for swimming pool dehumidifier, consisting of:– Control unit with 32 bit processor in network based, interdisciplinary, free pro-
grammable automation system– Watchdog function, data buffering (FLASH-ROM), hardware clock– Interfaces:
1 x CAN (Controller Area Network) as central bus between control unit and I/O modules;1 x LIN (Local Interconnect Network) for auxiliary module monitoring and config-uration functions;1 x CAN for external connection;2 x RS232/RS485, one RS232 has modem function;Optional - Ethernet; USB plug;Optional - various communication functions can be carried out (e. g: OPC; LON; MODBUS; OSPA; BACnet®) As BACnet®-Building Controller (B-BC) the sys-tem can cost efficiently intgerate or be integrated in any BACnet® third system.
– In and output modules with an integrated microcontroller and memory for record-ing a programme specifically designed for the relevant module, status display for every input or output with CAN provided via top hat rail bus plug.
– Comfortable intelligent control terminal for supporting display, control buttons and data transfer, installed in the door of the switch cabinet
– Alufront panel with front film– Keyboard connection via plug connector– Front side protection type IP 65– LCD-Display with 8 lines each with 40 symbols as clear text display, monochrome– 6 function buttons– Colour background lighting, adjustable, automatic lighting activation– Adjustable LCD contrast– System bus CAN– Alternative (option): as before, but:
– with comfortable touch control terminal– LCD display with 16 colours– Graphical resolution 320 x 240 Pixel
Dehumidifier with Air Mixing Function
GEA CAIRfricostar Type CWP
PR-2008-0327-GB • Subject to modifications • Status 05/2009 41
Control and regulation functions:
– Status and fault signals in clear text– Indication of all status and control parameters– Stepwise access authorization using code– Integrated clock timer– Automatic summer / winter time switch-over, activation of weekly programmes,
holiday and special day programmes– Log for registration of faults with date and time– Operating hours counter, total operation and maintenance intervals– Data logging function for most important parameters, can be downloaded– Separate controls for supply and exhaust air fan motors– Air volume adjustment and display in m³/h, including monitoring for units with fre-
quency converters– Fan motor monitoring using PTC resistor and motor protection relay– Filter monitoring– Regulation of air mixing dampers with selectable minimum fresh air rate and maxi-
mum limitation, automatic control depending on conditions of fresh air and swim-ming pool air
– Control sequence with energy recovery, heater, bypass damper and air mixing damper system
– Exhaust air temperature cascade control with min./max. limitation of supply air tem-perature
– Cooling with outside air (night cooling)– Reheater-heat pump consumption control with blockage protection functions– Continuous humidity control– Automatic switch-over between active/non-active hours operation– Continuous inactive idle mode possible– Different languages can be selected– Commissioning function for air dampers– Inputs: external emergency switch off (e.g. fire protection damper or chlorine gas
alarm)– Motor monitoring for reheater pump can be switched, if required motor protection
by others– The necessary sensors and actuators are built into the unit or, if necessary, sup-
plied loose with subsequent installation by others
Air mixing dehum
idifier CW
P
Dehumidifier with Air Mixing FunctionType CWP GEA CAIRfricostar
42 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Technical data
1) Swimming pool air condition 30 °C/54 %r.h.; Outdoor air condition 5 °C/85 %r.h.2) Inlet/outlet temperature 70 °C/50 °C; maximum heating capacity; 2 rows3) plus controls/regulation/pumps etc.(All data are approximate values and summarize most important features.Subject to modifications. Exact data are available in the current Lplus design software)
Unitz series CWP…VU. (performance model, maximum air velocity for supply and exhaust air from 2,5 m/s to 2,0 m/s), plug fans, frequency converters
Type Unit dimensions Air volume flowDehumidifi-cation ca-
pacityHeatingcapacity
Pressure drop
Motor ratedpower/current
Current con-sumption
CW
P_VU
Tota
l wid
th
Tota
l hei
ght
Tota
l len
gth
Min
imum
Max
imum
Rat
ed (w
ith d
ehum
idifi
catio
n)
Rat
ed (w
ith v
entil
atio
n)
Con
form
with
VD
I 208
9,at
rate
d ai
r flo
w 1)
Hea
t rec
over
y sy
stem
Reh
eate
r 2)
Ext.
fres
h/su
pply
air;
exha
ust/r
etur
n ai
r; e
ach
Supp
ly a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Exha
ust a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Uni
t tot
al 3)
[mm] [m3/h] [kg/h] [kW] [Pa] [kW/A] [A]015 760 1120 3600 750 1500 1000 667 6 2.1 8.4 300 0.6/1.4 0.6/1.4 2.8025 760 1360 3800 1500 2500 2500 1667 16 5.1 15.4 300 1.1/2.4 1.1/2.4 4.8037 760 1600 4100 2500 3686 3400 2267 22 6.8 21.2 300 1.5/3.4 1.1/2.4 5.8055 1080 1600 4200 3685 5530 5000 3333 32 10.1 31.6 300 2.2/4.7 1.5/3.4 8.1083 1080 2240 5700 5529 8294 7500 5000 48 15.3 48.9 300 3.0/6.4 3.0/6.4 12.8110 1720 2240 5700 8293 11059 11000 7333 70 25.3 78.9 300 4.0/8.2 3.0/6.4 14.6130 2000 2320 6000 11058 12995 12500 8333 80 26.1 90.9 300 4.0/8.2 4.0/8.2 16.4150 1720 2880 6600 12994 14746 14000 9333 89 30.0 98.1 300 5.5/11.4 5.5/11.4 22.8170 2000 2960 6800 14745 17326 17000 11333 108 36.4 120.7 300 7.5/17.0 5.5/11.4 28.4230 2320 2960 7100 17325 20275 20000 13333 127 42.8 139.3 300 7.5/17.0 7.5/17.0 34.0250 2320 3600 7400 20274 25344 25000 16667 159 49.9 180.4 300 7.5/17.0 7.5/17.0 34.0320 2920 3600 8200 29029 32256 32000 21333 204 65.0 234.5 300 11.0/25.0 11.0/25.0 50.0
Tab. 8: Technical data CAIRfricostar CWP_VU
Dehumidification Unit with Air Mixing Function
GEA CAIRfricostar Type CAC
PR-2008-0327-GB • Subject to modifications • Status 05/2009 43
Functional description of the unit
The GEA CAIRfricostar CAC is designed for private and small public swimming pools. The series is available in 2 model and 3 capacity sizes. The unit's function is to dehu-midify and heat air in swimming pools in air mixing mode. The unit is delivered with a DDC controls which regulates all functions of the system on a fully automated basis.When in idle mode without dehumidification the air is recirculated in the swimming pool. When the humidity setpoint has been exceeded the unit switches into dehumidification mode. At this point the supply air fan is switched into speed 2 with the exhaust air fan maintaining air circulation at speed 1. The refrigeration unit is activated in order to start dehumidification. Using the bypass damper a certain part of return air is mixed without further treatment with dehumidified air that has passed through the refrigeration cycle. The dehumidification stage continues until the actual humidity value lies below that of the humidity setpoint. Then fans and refrigeration unit are deactivated.When in active hours swimming pool mode the fresh and exhaust air dampers are opened, the bypass damper is closed. The dehumidification takes place via theactivation of the refrigeration cycle with both fans switched into speed 2.Using an optional pool water condenser a certain amount of excess energy produced by the refrigeration cycle can be fed back into swimming pool water.
Sample selection of operation modes:
Idle mode without dehumidificationdemand
Idle mode with dehumidification demand
Active hours swimming pool modewith humidification demand and pool
water condenser
Bypass damper mode, exhaust air fan is de-activated, supply air fan runs at low speed.
Bypass damper mode, exhaust air fan runs atlow speed, supply air fan runs at high speed.
Compressor is switched on. The reheaterprovides the missing residual heat supply.
Air mixing operation according to VDI,exhaust and supply air fans run at high
speed. Compressor is switched on. The re-heater provides the missing residual heat
supply. Using a pool water condenser a cer-tain amount of excess energy can be fed
back into swimming pool water.
Air mixing dehum
idifier CAC
Dehumidification Unit with Air Mixing FunctionType CAC GEA CAIRfricostar
44 PR-2008-0327-GB • Subject to modifications • Status 05/2009
System and controls scheme
Components
Casing: Indoor installation– 50 mm panels, inside and outside skins are painted; (corresponds to RAL 9002),
the series includes casing frame and service door in casing panel thickness togeth-er with a full profile rubber gasket in EPDM quality. All outside and inside surfaces are completely smooth.
– Leak tightness class G II according to VDI 3803. Thermal and sound bridges are minimized.
– Non combustible insulation (fire classification A1 according to DIN 4102; Ö-Norm B3800; CFC-free)
– Heat transfer coefficient k = 0,57 W/m2 K– Sound insulation performance Rw = 44 dB according to DIN 52210/T4– Casing features according to EN1886– Filter bypass leakage F9– Leak tightness class according to prEN 1886 (10/2005) L1– Casing leakage B– Mechanical stability 1A– Thermal insulation T2– Thermal bridging factor TB2 (in risk areas)
Transition/summer mode with/without dehum demand Summer mode inactive period „free night cooling“
In case of overheating of the swimming pool and high outdoor tem-peratures the heat pump is blocked. The unit operates for ventilationand dehumidification in air mixing or only outdoor/exhaust air mode.The fans run at high speed. In case of an optional bypass of the heat
recovery system the heat recovery is not used thanks to a dampersystem and at the same time the air volume flow is increased.
If the swimming pool is overheated during the night time or idle periodthe unit ventilates only in outdoor/exhaust air mode. The fans run at
high speed and provide cooling of the swimming pool to reach thesetpoint temperature. In case of an optional bypass of the heat recov-ery system the heat recovery is not used thanks to a damper system
and at the same time the air volume flow is increased.
Dehumidification Unit with Air Mixing Function
GEA CAIRfricostar Type CAC
PR-2008-0327-GB • Subject to modifications • Status 05/2009 45
– Frame profiles AlMgSi 0,5– Flexible connector with potential equalisation, temperature resistant from -30 °C to
+120 °C– Duct connection using 30 mm frame with 4 hole bolt connection– Interior installation parts for swimming pool mode with special corrosion protection
Heat pump fordehumidification:
– Direct evaporator according to VDI 6022: heat exchanger as Cu/Alu model for R 407c refrigerant, fins made of aluminium, frame elements made of AlMg3, pipes made of oxygen-free copper.
– Condensate water tray in bottom panel for evaporator and heat recovery system, with a slope in the direction of condensate drain, made of stainless steel V4Apowder coated, including drain tray, conform with VDI 6022
– Air-cooled condenser according to VDI 6022: heat exchanger as Cu/Alu model for R 407c refrigerant, fins made of aluminium, frame elements made of AlMg3, pipes made of oxygen-free copper
– Compressor unit: refrigeration circuit with a fully hermetic scroll compressor– with optimized heat exchanger combination for maximum COP values, mounted on
anti-vibration mounts, circuit includes filter drier, liquid collector, thermostatic expansion valve with MOP and external pressure equalisation, all necessaryshut-off valves, monitoring and safety devices (pressostat, icing sensor, etc.)
Droplet eliminator – made of plastic with an aluminium frame at air velocities on supply and exhaust side exceeding 2,5 m/s is necessary
Fan unit: GEA centrifugal fan „LESS ENERGY SYSTEM“– Optimized operating point, double side suction, coated surface model– Three phase motor, protection class IP55 , model type B3, complete belt drive, easy
service thanks to one bolt tensioning sled– Fan/motor unit mounted on anti-vibration mounts
Air damper system: – Dampers with sealing lips, leakage volume flow 20 m3/h m2 (dp=100 Pa), for circu-lating air/bypass, for fresh and exhaust air. Circulating and fresh air rate 0-100%
– Coated Almg3 damper blades with flow efficient profile, operate in opposite direc-tions. Driven by double sided, anti-static plastic gears PA6 as fiberglass reinforced model (resistant to chemicals) including special actuator for each damper
– Control of the individual actuators using continuous DDC signals
Filter for fresh andexhaust air:
– Filter units conform with VDI 6022– including bag filter as of DIN/EN 779, synthetic fiber filter medium– All filters are fitted with a differential pressure switch for filter monitoring via the DDC
Heat recovery system: GEA „ECOPLAT POWER PLATE“– symmetric high performance plate heat exchangers, recuperative heat recovery by
using two cross-flow aluminium plate heat exchangers (corrosion protected Al99 with best temperature coefficient). Surface is additionally coated with thermoplastic material. Largest possible heat exchange surface using entire unit depth with mini-mum pressure losses. Optimal selection with consideration of operation conditions. Best efficiency rates within entire outdoor temperature range, especially resistant to corrosion and wear. Swimming pool configuration.
– AlMg3 ventilation tray– technical data checked according to EUROVENT– conform with VDI 6022– Non-combustible according to fire protection regulation
Heating section: – L.P.H.W. air heater, heat exchanger with copper pipes and drawn aluminium fins in aluminium frame AlMg3 (max. temp. 110°C, Pmax 16bar) removable in accordance with VDI6022;
GEA motor -3-way mixingvalve:
– For air reheater, supplied loose including actuator 0-10 V with an automatic step measurement system for fine adjustment of water flow rate
– supplied loose, installation by others
Airmixing
dehumidifierC
AC
Dehumidification Unit with Air Mixing FunctionType CAC GEA CAIRfricostar
46 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Control and regulation sys-tem:
– Consists of a separate switch cabinet for mounting on units or separate installation (depending in unit size), with all necessary components for control functions, wired according to VDE specifications. IP55. Electrical connection (via plug or screwterminals) between control cabinet and unit using factory prepared lines. Electrical installation for voltage supply, valve mixing control, reheater pump, if necessary external sensor for the pool water pump and possibly other functions like remote control inputs to be installed by others. The cabinet is supplied loose depending on the unit size as a stand alone cabinet or for mounting on the unit;
The switch cabinet issupplied with the following
main components:
– Main isolating switch for all pole shut-down of the electrical unit, lockable– Group fuses for fan and compressor– Fuses for reheater and PWC pump 230V/N/PE/50Hz (types 015-083) (if necessary
- motor protection by others)– Control fuses, control transformer 230 V and control voltage supply unit 24V DC for
the digital control– Control fuse and control supply voltage unit 24V AC for actuators– Automatic phase controller (option)– Indoor installation, frost free
Digital control: – Modular automation station built into switch cabinet with deletion-proof software modules and digital and analogue inputs and outputs, equipped with all control functions for swimming pool dehumidifier, consisting of:– Control unit with 32 bit processor in network based, interdisciplinary, free pro-
grammable automation system– Watchdog function, data buffering (FLASH-ROM), hardware clock– Interface:1 x CAN (Controller Area Network) as a central bus between control
unit and I/O modules; 1 x LIN (Local Interconnect Network) for additional module monitoring and configuration functions;1 x CAN for external integration;
– 2 x RS232/RS485, RS232 can operate with a modem– Optional: Ethernet; USB plug– As an optional various communication functions can be implemented (e.g: OPC;
LON; MODBUS; OSPA; BACnet®). As a native BACnet®-Building Controller(B-BC) the system can integrate every BACnet® third system with little extra expense or can integrate itself in such a system.
– In and output modules with an integrated microcontroller and memory for record-ing a programme specifically designed for the relevant module. Status indicator for every input or output. CAN provided via top hat-rail bus plug.
– Comfortable intelligent control terminal for supporting display, control buttons and data transfer, installed in the door of the switch cabinet
– Alufront panel with front foíl– Keyboard connection via plug connector– Front side protection type IP 65– LCD-Display with 8 lines each with 40 symbols as clear text display, monochrome– 6 function buttons– Colour background lighting, adjustable, automatic lighting activation– Adjustable LCD contrast– System bus CAN– Alternative (option): as before, but:
– with comfortable touch control terminal– LCD display with 16 colours– Graphical resolution 320 x 240 Pixel
Dehumidification Unit with Air Mixing Function
GEA CAIRfricostar Type CAC
PR-2008-0327-GB • Subject to modifications • Status 05/2009 47
Control and regulationfunctions:
– Status and fault signals in clear text– Indication of all status and control parameters– Stepwise access authorization using code– Integrated clock timer– Automatic summer / winter time switch-over, activation of weekly programmes,
holiday and special day programmes– Log for registration of faults with date and time– Operating hours counter, total operation and maintenance intervals– Data logging function for most important parameters, can be downloaded– Separate controls for supply and exhaust air fan motors– Air volume adjustment and display in m³/h, including monitoring for units with fre-
quency converters– Fan motor monitoring using PTC resistor and motor protection relay– Filter monitoring– Compressor control (heat pump) with minimum run / standstill time– Regulation of air mixing dampers with selectable minimum fresh air rate and maxi-
mum limitation, automatic control depending on conditions of fresh air and swim-ming pool air
– Control sequence with energy recovery, heater, compressor (heat pump), bypass damper and air mixing damper system
– Exhaust air temperature cascade control with min./max. limitation of supply air tem-perature
– Cooling with outside air (night cooling)– Reheater-heat pump consumption control with blockage protection functions– Continuous humidity control– On demand - controls for automatic pool water pump with block up protection– Automatic switch-over between active/non-active hours operation– Continuous inactive/idle mode possible– Different languages can be selected– Commissioning function for air dampers– Inputs: external emergency switch off (e.g. fire protection damper or chlorine gas
alarm)– Motor monitoring for NE pump can be switched, if required motor protection
by others– Motor monitoring for pool water pump can be switched, if required motor protection
by others– The necessary sensors and actuators are built into the unit or, if necessary,
supplied loose with subsequent installation by others
Air m
ixing dehumidifier C
AC
Dehumidification Unit with Air Mixing FunctionType CAC GEA CAIRfricostar
48 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Technical data
1) Swimming pool air condition 30 °C/54 %r.h.; Outdoor air condition 5 °C/85 %r.h.2) Inlet/outlet temperature 70 °C/50 °C; maximum heating capacity; 2 rows3) plus controls/regulation/pumps etc.(All data are approximate values and summarize most important features. Subject to modifications.Exact data are available in the current Lplus design software)
Unit series CAC...S..
Type Unit dimensions Air volume flow Dehumidification
capacity Heating capacity Pressure drop
Motor rated power/current
Cur-rent con-
sump-tion
CA
C_S
Tota
l wid
th
Tota
l hei
ght
Tota
l len
gth
Min
imum
Max
imum
Rat
ed (w
ith d
ehum
idifi
catio
n)
Rat
ed (w
ith v
entil
atio
n)
acco
rdin
g to
VD
I 208
9,at
nom
inal
air
capa
city
1)
Act
ive
hour
s m
ode
(30
% fr
esh
air)
/id
le/in
activ
e m
ode
(circ
ulat
ing
air)
/VD
I 208
9
Air
cond
ense
r, w
ith in
activ
epo
ol w
ater
con
dens
er
Air
cond
ense
r, w
ith a
ctiv
epo
ol w
ater
con
dens
er
Pool
wat
er c
onde
nser
(acc
esso
ry)
Hea
t rec
over
y sy
stem
Reh
eate
r 2)
Ext.
fres
h/su
pply
air;
exha
ust/r
etur
n ai
r; e
ach
Supp
ly a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Exha
ust a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Uni
t tot
al 3)
[mm] [m3/h] [kg/h] [kW] [Pa] [kW/A] [A]015 760 1480 1640 750 1600 1000 743 6 6.5 / 3.7 / 6 5.4 3.3 2.4 3.0 10.0 300 0.6/1.4 0.6/1.4 2.8025 760 1800 2760 1600 2500 2000 1320 13 11.6 / 5.9 / 13 10.0 7.2 3.2 5.9 16.2 300 1.1/2.4 1.1/2.4 4.8037 760 1800 2760 2000 3600 3050 2013 19 16.8 / 6.8 / 19 12.1 10.1 3.0 6.9 23.2 300 1.5/3.4 1.1/2.4 5.8
Tab. 1: Technical data CAIRfricostar CAC_S
Dehumidification Unit with Air Mixing and Heat Pump Function
GEA CAIRfricostar Type CWC
PR-2008-0327-GB • Subject to modifications • Status 05/2009 49
Functional description of the unit
The GEA CAIRfricostar CWC is designed for private and small public swimming pools. The series is available in 2 sizes. The unit's function is to dehumidify and heat air in swimming pools in air mixing mode. The unit is delivered with a DDC controls which regulates all functions of the system on a fully automated basis.
This unit type is additionally equipped with an efficient heat recovery system. When in idle mode without dehumidification the air is recirculated in the swimming pool. When the humidity setpoint has been exceeded the unit switches into dehumidification mode. For this purpose the supply and exhaust air fans are activated to run at high speed with continuous mixing of outdoor air. The dehumidification stage continues until the actual humidity value lies below that of the humidity setpoint. After that the fans are deacti-vated.
Sample selection of operation modes:
Idle mode without dehumidificationdemand
Active hours operation mode withdehumidification demand
Idle mode with dehumidificationdemand
Bypass damper mode, exhaust air fanis deactivated,
Supply air fan runs at low speed.
Air mixing operation according to VDI, ex-haust and supply air fans run at high speed.The reheater provides the missing residual
heat supply.
Air mixing operation, exhaust and supply airfans are operating at high speed. The reheat-er provides the missing residual heat supply.
Active hours/summer operation mode Summer mode / inactive operating „free night cooling“
Fresh air mode, exhaust and supply air fans run at high speed. Heatrecovery is not used thanks to a damper system.
If the swimming pool is overheated during the night time or idle periodthe unit ventilates only in outdoor/exhaust air mode. The fans run at
high speed and provide cooling of the swimming pool to reach thesetpoint temperature. In case of an optional bypass of the heat recov-ery system the heat recovery is not used thanks to a damper system
and at the same time the air volume flow is increased.
Air m
ixing dehumidifier C
WC
Dehumidification Unit with Air Mixing and Heat Pump FunctionType CWC GEA CAIRfricostar
50 PR-2008-0327-GB • Subject to modifications • Status 05/2009
System and controls scheme
Components
Casing: Indoor installation– 50 mm panels, inside and outside skins are painted; (corresponds to RAL 9002),
the series includes casing frame and service door in casing panel thickness togeth-er with a full profile rubber gasket in EPDM quality. All outside and inside surfaces are completely smooth.
– Leak tightness class G II according to VDI 3803. Thermal and sound bridges are minimized.
– Non combustible insulation (fire classification A1 according to DIN 4102; Ö-Norm B3800; CFC-free)
– Heat transfer coefficient k = 0,57 W/m2 K– Sound insulation performance Rw = 44 dB according to DIN 52210/T4– Casing features according to EN1886– Filter bypass leakage F9– Leak tightness class according to prEN 1886 (10/2005) L1– Casing leakage B– Mechanical stability 1A– Thermal insulation T2– Thermal bridging factor TB2 (in risk areas)– Frame profiles AlMgSi 0,5– Flexible connector with potential equalisation, temperature resistant
from -30 °C to +120 °C– Duct connection using 30 mm frame with 4 hole bolt connection– Interior installation parts for swimming pool mode with special corrosion protection
Droplet eliminator – made of plastic with an aluminium frame at air velocities on supply and exhaust side exceeding 2,5 m/s is necessary
Fan unit: GEA centrifugal fan „LESS ENERGY SYSTEM“– Optimized operating point, double side suction, coated surface model– Three phase motor, protection class IP55 , model type B3, complete belt drive, easy
service thanks to one bolt tensioning sled– Fan/motor unit mounted on anti-vibration mounts
Air damper system: – Dampers with sealing lips, leakage volume flow 20 m3/h m2 (dp=100 Pa), for circu-lating air/bypass, for fresh and exhaust air. Circulating and fresh air rate 0-100%
Dehumidification Unit with Air Mixing and Heat Pump Function
GEA CAIRfricostar Type CWC
PR-2008-0327-GB • Subject to modifications • Status 05/2009 51
– Coated Almg3 damper blades with flow efficient profile, operate in opposite direc-tions. Driven by double sided, anti-static plastic gears PA6 as fiberglass reinforced model (resistant to chemicals) including special actuator for each damper
– Control of the individual actuators using continuous DDC signals
Filter for fresh andexhaust air:
– Filter units conform with VDI 6022– including bag filter as of DIN/EN 779, synthetic fiber filter medium– All filters are fitted with a differential pressure switch for filter-monitoring via the
DDC
Heat recovery system: GEA „ECOPLAT POWER PLATE“:– symmetric high performance plate heat exchangers, recuperative heat recovery by
using two cross-flow aluminium plate heat exchangers (corrosion protected Al99 with best temperature coefficient). Surface is additionally coated with thermoplastic material. Largest possible heat exchange surface using entire unit depth with mini-mum pressure losses. Optimal selection with consideration of operation conditions. Best efficiency rates within entire outdoor temperature range, especially resistant to corrosion and wear. Swimming pool configuration.
– AlMg3 ventilation tray– technical data checked according to EUROVENT– conform with VDI 6022– Non-combustible according to fire protection regulation
Heating section: – L.P.H.W. air heater, heat exchanger with copper pipes and drawn aluminium fins in aluminium frame AlMg3 (max. temp. 110°C, Pmax 16bar) removable in accordance with VDI6022;
GEA motor -3-way mixingvalve:
– For air reheater, supplied loose including actuator 0-10 V with an automatic step measurement system for fine adjustment of water flow rate
– supplied loose, installation by others
Control andregulation system
– Consists of a separate switch cabinet for mounting on units or separate installation (depending in unit size), with all necessary components for control functions, wired according to VDE specifications. IP55 electrical connection (via plug or screw ter-minals) between control cabinet and unit using factory prepared lines. Electrical installation for voltage supply, valve mixing control, reheater pump, if necessary external sensor and possibly other functions like remote control inputs are provided by others. The cabinet is supplied loose depending on the unit size as a stand alone cabinet or for mounting on the unit;
The switch cabinet issupplied with the following
main components:
– Main isolating switch for all pole shut-down of the electrical unit, lockable– Group fuses for fans– Fuses for reheater 230V/N/PE/50Hz (types 015-083) 3 X 400V/NPE/50Hz (types
100-320) (if necessary - motor protection by others)– Control fuses, control transformer 230 V and control voltage supply unit 24V DC for
the digital control– Control fuse and control voltage supply unit 24V AC for actuators– Automatic phase controller (option)– Indoor installation, frost free
Digital control: – Modular automation station built into switch cabinet with deletion-proof software modules and digital and analogue inputs and outputs, equipped with all control functions for swimming pool dehumidifier, consisting of:– Control unit with 32 bit processor in network based, interdisciplinary, free pro-
grammable automation system– Watchdog function, data buffering (FLASH-ROM), hardware clock– Interfaces: 1 x CAN (Controller Area Network) as central bus between control
unit and I/O modules; 1 x LIN (Local Interconnect Network) for auxiliary module monitoring and configuration functions; 1 x CAN for external connection; 2 x RS232/RS485, one RS232 has modem function; optional: Ethernet; USB plug; optionally - various communication functions can be carried out (e. g: OPC;
Air mixing dehum
idifier CW
C
Dehumidification Unit with Air Mixing and Heat Pump FunctionType CWC GEA CAIRfricostar
52 PR-2008-0327-GB • Subject to modifications • Status 05/2009
LON; MODBUS; OSPA; BACnet®) As BACnet®-Building Controller (B-BC) the system can cost efficiently integrate or be integrated in any BACnet® third sys-tem.
– In and output modules with an integrated microcontroller and memory for record-ing a programme specifically designed for the relevant module, status display for every input or output with CAN provided via top hat rail bus plug.
– Comfortable intelligent control terminal for supporting display, control buttons and data transfer, installed in the door of the switch cabinet
– Alufront panel with front foíl– Keyboard connection via plug connector– Front side protection type IP 65– LCD-Display with 8 lines each with 40 symbols as clear text display, monochrome– 6 function buttons– Colour background lighting, adjustable, automatic lighting activation– Adjustable LCD contrast– System bus CAN– Alternative (option): as before, but:
– with comfortable touch control terminal– LCD display with 16 colours– Graphical resolution 320 x 240 Pixel
Dehumidification Unit with Air Mixing and Heat Pump Function
GEA CAIRfricostar Type CWC
PR-2008-0327-GB • Subject to modifications • Status 05/2009 53
Control and regulationfunctions:
– Status and fault signals in clear text– Indication of all status and control parameters– Stepwise access authorization using code– Integrated clock timer– Automatic summer / winter time switch-over, activation of weekly programmes, hol-
iday and special day programmes– Log for registration of faults with date and time– Operating hours counter, total operation and maintenance intervals– Data logging function for most important parameters, can be downloaded– Separate controls for supply and exhaust air fan motors– Air volume adjustment and display in m³/h, including monitoring for units with fre-
quency converters– Fan motor monitoring using PTC resistor and motor protection relay– Filter monitoring– Automatic regulation depending on conditions of fresh air and swimming pool air– Control sequence with energy recovery, heater and bypass damper– Exhaust air temperature cascade control with min./max. limitation of supply air tem-
perature– Cooling with outside air (night cooling)– Reheater-heat pump consumption control with blockage protection functions– Continuous humidity control– Automatic switch-over between active/non-active hours operation– Continuous inactive/idle mode possible– Different languages can be selected– Commissioning function for air dampers– Inputs: external emergency switch off (e.g. fire protection damper or chlorine gas
alarm)– Motor monitoring for NE pump can be switched, if required motor protection
by others– The necessary sensors and actuators are built into the unit or, if necessary,
supplied loose with subsequent installation by others
Technical data
1) Swimming pool air condition 30 °C/54 %r.h.; Outdoor air condition 5 °C/85 %r.h.2) Inlet/outlet temperature 70 °C/50 °C; maximum heating capacity; 2 rows3) plus controls/regulation/pumps etc.(All data are approximate values and summarize most important features. Subject to modifications. Exact data are available in the current Lplus design software
Unit series CWC…S..
Type Unit dimensions Air volume flowDehumidi-
fication capacity
Heating capacityPres-sure drop
Motor rated power/currentCurrent
consump-tion
CW
C_S
Tota
l wid
th
Tota
l hei
ght
Tota
l len
gth
Min
imum
Max
imum
Rat
ed (w
ith d
ehum
idifi
catio
n)
Rat
ed (w
ith v
entil
atio
n)
acco
rdin
g to
VD
I 208
9,at
nom
inal
air
capa
city
1)
Hea
t rec
over
y sy
stem
Reh
eate
r 2)
Ext.
fres
h/su
pply
air;
exha
ust/r
etur
n ai
r; e
ach
Supp
ly a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Exha
ust a
ir fa
n, h
igh
spee
d,at
rate
d vo
lum
e flo
w
Com
pres
sor,
with
out
pool
wat
er c
onde
nser
Uni
t tot
al 3)
[mm] [m3/h] [kg/h] [Pa] [kW/A] [A]
015 760 1480 1640 750 2000 1500 1000 9.5 2.8 16.0 300 0.6/1.4 0.6/1.4 1.3/2.5 5.3
037 760 1800 2760 1500 3600 2500 1667 16 4.8 23.0 300 3.0/6.1 2.2/4.6 2.3/4.5 15.2
Tab. 1: Technical data CAIRfricostar CWC_S Air mixing dehum
idifier CW
C
Electrical IntegrationOverview of Cable Connections GEA CAIRfricostar
54 PR-2008-0327-GB • Subject to modifications • Status 05/2009
GEA CAIRfricostar Air mixing units
Unit size 015-083 with swing switch cabinet on the unit
Unit size 100-360 with upright switch cabinet near the unit
Fig. 3: Overview of cable connections of the GEA CAIRfricostar air mixing units1: Pool water immersion sensor (option) 2 x 0,75 mm²; screened LIYCY-0B2: Reheater 3-way valve 6 x 0,75 mm²; screened LIYCY-JZ3: Outdoor temperature sensor 2 x 0,75 mm²; screened LIYCY-0B4: On-site BMS connections provided by others (see unit wiring diagram for options)5: System cable fully assembled in protective hose (press and attach plugs)6: Power supply 3 x 400 V+N+PE/ 50 Hz7: Connection for pool water pump (option); 3 x 1,5 to 083 if more 5 x 1,5 mm² (not for
CW_units) + 2 x 0,75 mm² fault contact.8: Connection for reheater pump; 3 x 1,5 to 083 if more 5 x 1,5 mm² (not for CW_units) + 2 x
0,75 mm² fault contact.9: External shut-down; smoke and gas alarm; 2 x 0,75 mm²
* Special configuration for Austria:It is usually not necessary to screen the sensor supply line!1: Pool immersion temperature sensor 2 x 0,75 mm²2: Reheater valve 5 x 1,5 mm²3: Outdoor temperature sensor 2 x 0,75 mm²4: On-site BMS connections provided by others according to wiring diagram5: Fully assembled system cable is not necessary (standard in switch cabinet)6: Power supply 3 x 400 V+N+PE/ 50 Hz7: Connection for pool water pump (option); 3 x 1,5 to 037 if more 6 x 1,5 mm² (400 V)8: Connection for reheater pump; 3 x 1,5 mm to 037 if more 6 x 1,5 mm² (400 V)9: External safety shut-down only on request
10: Inlet temperature sensor, heater 2 x 0,75 mm²11: Room temperature and humidity sensor 5 x 0,75 mm²
NOTE!Only the unit wiring diagram provides exact information about the unit deliverystate.The switch cabinet is supplied loose! (special configuration includes intermediate terminal box) Use the enclosed documentation for detailed information about the installation of the switch cabinet.
Fig. 1: Swing switch cabi-net
on Fig. 1: Swing unit
1
2
8
6
7
1011
9
34
5 5
( )
*
Fig. 2: Upright switch cabi-net
Electrical Integration
GEA CAIRfricostar Overview of Cable Connections
PR-2008-0327-GB • Subject to modifications • Status 05/2009 55
GEA CAIRfricostar circulating air units
Fig. 4: Overview of cable connections of the GEA CAIRfricostar circulating air units1: Pool water thermostat (option); 3 x 1,5 mm²2: Reheater valve 5 x 1,5 mm²3: Switch cabinet4: Power supply; 3~ 400 V+N+PE/ 50 Hz5: System cable fully assembled (press and attach plugs)6: Exhaust air fan (option); 5 x 1,5 7: Pool water pump connection (option); 3 x 1,5 mm²8: Remote control/humidistat; 5 x 0,75 mm²9: Reheater pump; 3 x 1,5 mm²
*Special model for Austria:It is usually not necessary to screen the sensor supply line!1: Pool immersion temperature sensor 2 x 0,75 mm²2: Reheater valve 5 x 1,5 mm²3: Switch cabinet4: On-site BMS connections provided by others according to wiring diagram5: Fully assembled system cable is not necessary (standard in switch cabinet)6: Power supply 3 x 400 V+N+PE/ 50 Hz7: Pool water pump connection (option); 3 x 1,5 mm²8: Reheater pump; 3 x 1,5 mm²9: External safety switch off only on request
10: Inlet temperature sensor, heater 2 x 0,75 mm²11: Room temperature and humidity sensor 5 x 0,75 mm²
NOTE!Only the unit wiring diagram provides exact information about the unit delivery con-dition.
The switch cabinet is supplied loose!
*
1
2
6
7
9
5 55
8
4
10
11
Unit SelectionAs Relates to Water Surface GEA CAIRfricostar
56 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Unit Model Range as Relates to Water Surface, Unit Type: Standard
Unit Model Range as Relates to Water Surface, Unit Type: Standard
40m²
60m²
70m²
85m²
100m²
130m²
195m²
260m²
325m²
380m²
435m²
510m²
590m²
680m²
745m²
850m²
950m²
0 5.000 10.000 15.000 20.000 25.000 30.000 35.000 40.000 45.000 50.000
CAM015
CAM025
CAM030
CAM037
CAM045
CAM055
CAM083
CAM100
CAM110
CAM130
CAM150
CAM170
CAM200
CAM230
CAM250
CAM290
CAM320
CAIRfricostar model range
Water surface max. [m²]Temp.: 30° C air / 28° C water
Sta
ndar
d un
it ty
pes
Air volume flow [m3/h]
35m²
60m²
70m²
85m²
100m²
130m²
190m²
230m²
250m²
300m²
340m²
400m²
460m²
530m²
575m²
670m²
740m²
830m²
0 5.000 10.000 15.000 20.000 25.000 30.000 35.000 40.000
CAM015
CAM025
CAM030
CAM037
CAM045
CAM055
CAM083
CAM100
CAM110
CAM130
CAM150
CAM170
CAM200
CAM230
CAM250
CAM290
CAM320
CAM360
CAIRfricostar model range
Water surface max. [m²]Temp.: 30° C air / 28° C water
Per
form
ance
uni
t typ
es
Air volume flow [m3/h]
Configuration Variants and Accessories
GEA CAIRfricostar
PR-2008-0327-GB • Subject to modifications • Status 05/2009 57
Configuration Variants
GEA quality class K forswimming pools
Standard protection for swimming hall units– Protective paint for fans– Aluminium components in risk areas– Corrosion resistant Bumax screw connection– Protective paint for refrigeration circuit and components (section related)– V4A unit parts with additional coating in risk areas
GEA quality class H forswimming pools (option)
For tougher requirements (brine pools, ...)– Additional protective paint for fans– Aluminium components in risk areas– Corrosion resistant Bumax screw connection– Multicoat marine paint „ULTRA HIGH SOLID“ for refrigeration circuit, dampers and
various components– V4A unit parts with additional coating in risk areas– „Alodyne“ coating of heat exchanger fins– Plastic laminated pipework of the refrigeration circuit (section related)– „PlasTec“ capillary tube lines
GEA quality class P forswimming pools (option)
For tough requirements (thermal baths/pools, ...)– Additional protective paint for fans– Aluminium components in risk areas– Corrosion resistant Bumax screw connection– Multicoat marine paint „ULTRA HIGH SOLID“ for refrigeration circuit, dampers and
various components– V4A unit parts with additional coating in risk areas– V4A dampers– Plastic laminated pipework of the refrigeration circuit– „PlasTec“ capillary tube lines– „S70“- immersion bath coating of heat exchanger– „SÄKA-TEC“ coating of evaporator
Configuration Variants and Accessories
GEA CAIRfricostar
58 PR-2008-0327-GB • Subject to modifications • Status 05/2009
Accessories
(Component version only for DDC-controller; except for CAU)
GEA unit Type
Input extension for control possibilities by others DEW
Potential-free floating contacts for status signals DPK
Output extension, 0-10 V signals, exhaust air humidity and temperature DAW
Input extension for setpoint shift by others, 0-10 V signals, exhaust air humidity,exhaust air temperature and minimum fresh air rate DFV
Error message fire protection damper/fire alarm system BSK
Control display in a separate casing as remote control (without cabinet display) DFB
Additional control display in a separate casing as remote control (without cabinet display) DFD
Automatic shift for humidity setpoint DFS
Air flow monitoring for supply and exhaust air fan DLW
Emergency manual control for fans, reheater valve, pump, damper actuator DNH
Automatic adjustment of indoor temperature setpoint, depending on the pool water temperature DTA
Interface GSM Modem including software GSM
Interface ISDN Modem including software ISDN
Interfaces of GEA to GFR building management system DSG
Interface OPC-S Bus OPC
Interface BACnet-Bus BACNET
Interface LON-Bus LON
Interface OSPA Blue Control OSPA
Interface MOD Bus MOD
Generating data point list for relevant GLT system xxxDP
Assistance for the network technician during integration of GLT connections on site, require-ment is a complete unit connection by others on site xxxIB
Interface for modem DSM
Comfortable touch control terminal TBT
Software WEBVISION light WEV
Notes
GEA CAIRfricostar
PR-2008-0327-GB • Subject to modifications • Status 05/2009 59
Customer proximity, sales structures
Reachable always and everywhere!
The complete addresses are available on the Internet under: www.gea-air-eco2nomy.com.
www.gea-air-eco2nomy.com
xx/x
xxx
– PR
-xxx
x-xx
xx-x
xx
GEA Air Treatment
Middle East
UAE-Dubai
Tel. +971 / 4 / 887 3881
GEA Klimatechnik
GmbH & Co KG
A-4673 Gaspoltshofen
Tel. +43 / 7735 / 8000-0
GEA Klimatechnik
GmbH & Co KG
RS-11070 Novi Beograd
Tel. +381 / 11 / 3193955
GEA Happel Belgium N. V.
B-1130 Brussels
Tel. +32 / 2 / 2406161
EVISS Ltd.
BG-7000 Rousse
Tel . +359 / 82 / 81000
GEA Klimatechnik UAB
LT-01141 Vilnius
Tel. +370 / 5 / 2106060
ATC Klimatec Schweiz AG
CH-3065 Bolligen
Tel. +41 / 31 / 9171919
GEA LVZ, a.s.
CZ-46312 Liberec
Tel. +420 / 48 / 5225-111
GEA Klimatizace spol. s r.o.
CZ-46312 Liberec
Tel. +420 / 48 / 5225-303
GEA Happel
Klimatechnik GmbH
D-44625 Herne
Tel. +49 / 2325 / 468-00
GEA Happel
Wieland GmbH
D-44625 Herne
Tel. +49 / 2325 / 468-754
GEA Deichmann
Umwelttechnik GmbH
D-36179 Bebra
Tel. +49 / 6622 / 504-0
GEA Delbag
Lufttechnik GmbH
D-44625 Herne
Tel. +49 / 2325 / 468-700
GEA Delbag-Luftfilter
Vertriebsgesellschaft mbH
D-10709 Berlin
Tel. +49 / 30 / 43592-3
CS Klimateknik ApS
DK-5450 Otterup
Tel . +45 / 38 / 887070
GEA Klimatechnik UAB
LT-01141 Vilnius
Tel. +370 / 5 / 2106060
GEA Air Treatment
Marketing Services Int.
GmbH – oficina España
ES-28028 Madrid
Tel. +34 / 91 / 3837701
OY TEKNOCALOR AB
FIN-01300 Vantaa
Tel. +358 / 10 / 8201100
GEA Delbag
Filtration de l’air
F-77450 Montry
Tel. +33 / 1 / 60043355
GEA Happel France sarl
F-59436 Roncq Cedex
Tel. +33 / 3 / 20689020
GEA Denco Ltd.
UK-HR4 8DS Hereford
Tel. +44 / 1432 / 277 277
GEA Klima-rashladna
tehnika d.o.o.
HR-10000 Zagreb
Tel. +385 / 1 / 6064900
GEA Klimatechnika Kft
H-1037 Budapest
Tel. +36 / 1 / 4393200
Aspect Environmental Ltd.
Ardee, Co. Louth Ireland
Tel. +353 / 41 / 6858983
Rafn Jensson
IS-110 Reykjavik
Tel. +354 / 56 / 780-30
GEA Klimatechnik UAB
LT-01141 Vilnius
Tel. +370 / 5 / 2106060
GEA Happel Luxembourg
L-4940 Bascharage
Tel. +352 / 26 / 502970
GEA Klimatechnik UAB
LT-01141 Vilnius
Tel. +370 / 5 / 2106060
GEA Klimatechnik
GmbH & Co KG
RS-110 70 Novi Beograd
Tel. +381 / 11 / 3193955
GEA Happel Nederland B.V.
NL-2909 LL
Capelle a/d Ijssel
Tel. +31 / 10 / 2350606
GEA Klimaprodukter AS
N-0484 Oslo
Tel. +47 / 220 / 27990
GEA Klimatyzacja sp.z.o.o
PL-53-609 Wrocław
Tel. +48 / 71 / 3565866
Nónio, Lda.
P-1269-090 Lisboa
Tel. +351 / 21 / 3826160
GEA Klimatechnik s.r.l.
RO-300222 Timisoara
Tel. +40 / 356 / 423703
GEA Klimatechnik
GmbH & Co KG
RU-105094 Moskva
Tel. +7 / 495 / 9566674
GEA EXOS Ventilation AB
S-74528 Enköping
Tel. +46 / 171 / 85530
GEA Klimatizacijska
Tehnika d.o.o.
SI-1000 Ljubljana
Tel. +386 / 1 / 2573850
GEA Klimatizácia s.r.o.
SK-83104 Bratislava
Tel. +421 / 7 / 44457917
GEA Klimatechnik
GmbH & Co KG
RS-11070 Novi Beograd
Tel. +381 / 11 / 3193955
GEA ISISAN
TR-80700
Balmumcu Istanbul
Tel. +90 / 212 / 2757171
GEA Ukraina t.o.v.
UA-01135 Kyiv
Tel. +38 / 044 / 4619356
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FR
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