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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 CAU
Functional Description .......................................................................................... 3
System and Controls Scheme .............................................................................. 3
Components ......................................................................................................... 4
Technical Data ..................................................................................................... 6
Accessories .......................................................................................................... 6
Air Mixing Dehumidifier with Heat Pump, Type CMU
Functional Description ........................................................................................... 7
System and Controls Scheme .............................................................................. 8
Components ......................................................................................................... 8
Technical Data ................................................................................................... 13
Air Mixing Dehumidifier with Heat Pump, Type CAM
Functional Description ........................................................................................ 14
System and Controls Scheme ............................................................................ 15
Components ....................................................................................................... 15
Technical Data ................................................................................................... 20
Air Mixing Dehumidifier with Heat Pump, Type CMP
Functional Description ........................................................................................ 22
System and Controls Scheme ............................................................................ 23
Components ....................................................................................................... 23
Technical Data ................................................................................................... 28
Air Mixing Dehumidifier, Type CWR
Functional Description ........................................................................................ 29
System and Controls Scheme ............................................................................ 30
Components........................................................................................................ 30
Technical Data ................................................................................................... 34
Air Mixing Dehumidifier, Type CWP
Functional Description ........................................................................................ 36
System and Controls Scheme ............................................................................ 37
Komponenten ..................................................................................................... 37
Technische Daten .............................................................................................. 42
Compact GEA Fricostar Micro units
Air Mixing Dehumidifier, Type CAC
Functional Description ........................................................................................ 43
System and Controls Scheme ............................................................................ 44
Components ....................................................................................................... 44
Technical Data ................................................................................................... 48
Air Mixing Dehumidifier with Heat Pump Type CWC
Functional Description ........................................................................................ 49
System and Controls Scheme ............................................................................ 50
Components ....................................................................................................... 50
Technical Data ................................................................................................... 53
Electric Integration, Overview of Cable Connections
GEA CAIRfricostar air mixing units .................................................................... 54
GEA CAIRfricostar air recirculating units ........................................................... 55
Unit Selection as Relates to Water Surface
Unit Model Range as Relates to Water Surface, Unit Type: Standard .............. 56
Unit Model Range as Relates to Water Surface, Unit Type: Performance ........ 56
Configuration Variants and Accessories
Configuration Variants ........................................................................................ 57
Accessories (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.
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Dehumidifier with Air Recirculating and Heat Pump Function
Type 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; -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 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 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. 110C, 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 mixing
valve:
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 230V
Control fuse and control voltage supply unit 24V (safety extra-low voltage or SELV)
Control of supply air fan using motor full protection device via PTC
temperature 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: white
On-wall mounting
Dimensions: 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
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Dehumidifier with Air Recirculating and Heat Pump Function
Type CAU GEA CAIRfricostar
6 PR-2008-0327-GB Subject to modifications Status 05/2009
Technical data
Tab. 1: Technical data CAIRfricostar CAU
1) Swimming pool air condition 30 C/54 %r.h.;
2) Inlet/outlet temperature 70 C/50 C; maximum heating capacity; 2 rows
3) 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 CAUSU.. (standard model, maximum air velocity for supply and exhaust air approx. 2,8 m/s),
fans in casing
Type Unit dimensions Air volume flow
Dehumidi-
fication
capacity
Heating capacity
Pres-
sure
drop
Motor rated power/
current
Current
consump-
tion
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[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 4.3
015 760 1120 1680 1842 1842 1228 1.4 8.0 6.0 2.0 9.4 400 1.7/3.8 1.5/2.9 6.7
025 760 1360 1800 1842 1842 1228 4.2 13.0 10.6 2.5 11.1 400 0.8/2.1 2.4/4.6 6.7
025 760 1360 1800 2755 2755 1836 3.3 13.8 11.3 2.1 14.1 400 1.7/3.8 2.4/4.6 8.4
030 760 1360 1800 2755 2755 1836 4.3 16.2 13.3 2.6 14.1 400 1.7/3.8 2.8/5.5 9.3
030 760 1360 1880 3355 3355 2236 3.6 16.6 13.9 2.5 15.8 400 3.0/6.7 2.8/5.5 12.2
037 760 1600 1720 3354 3354 2236 4.9 19.8 16.3 3.3 18.3 400 1.7/3.8 3.7/7.5 11.3
037 760 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 dehumidification
demand
Idle mode with dehumidification
demand
Active hours operation mode with
dehumidification demand
Bypass damper mode, exhaust air fan is de-
activated, supply air fan runs at low speed.
Bypass damper mode, exhaust air fan runs at
low speed, supply air fan runs at high speed.
The reheater provides 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 reheater
provides the missing residual heat supply.
Using a pool water condenser a certain
amount of excess energy can be fed back
into swimming pool water.
H
Option
H
Option
28C
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 ventilation
and 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 period
the unit ventilates only in outdoor/exhaust air mode. The fans run at
high speed and provide cooling of the swimming pool to reach the
setpoint temperature.
H
Option
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Dehumidification unit with air mixing and heat pump function
Type 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; -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
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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 for
dehumidification:
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 attenuated
bearings.
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
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Dehumidification unit with air mixing and heat pump function
Type 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 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
Heating section: L.P.H.W. air heater, heat exchanger with copper pipes and drawn aluminium fins in
aluminium frame AlMg3 (max. temp. 110C, Pmax 16 bar) removable in accord-
ance with VDI 6022;
GEA motor 3-way mixing
valve:
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 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 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
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Dehumidification unit with air mixing and heat pump function
Type 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 m/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_SU
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 rows
3) 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 CMUSU. (standard model, maximum air velocity for supply and exhaust air approx. 2,8 m/s),
plug fans, frequency converters
Type Unit dimensions Air volume flow
Dehumid-
ification
capacity
Heating capacity
Pres-
sure
drop
Motor rated power/current
Current
con-
sumption
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[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 5.3
025 760 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 7.7
030 760 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 9.4
037 760 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 13.0
045 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 16.4
055 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
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Dehumidifier with Air Mixing and Heat Pump Function
Type 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 m/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 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 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 dehumidification
demand
Idle mode with dehumidification
request
Active hours swimming pool mode
with 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 at
low speed, supply air fan runs at large speed.
Compressor is switched on. The reheater
provides 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 reheater
provides the missing residual heat supply.
Using a pool water condenser a certain
amount of excess energy can be fed back
into swimming pool water.
E A
+ +
-
-
+
+
E A
+ +
-
- E C
O
S T
A T
P o w
e r T u b e
2
+
+
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 at
high 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 same
time the air volume flow is increased ("free night cooling function).
If the swimming pool is overheated during the night time or idle period
the unit ventilates only in outdoor/exhaust air mode. The fans run at
high speed and provide cooling of the swimming pool to reach the
setpoint 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
+ +
-
-
K o m
p r e s s o r
+
+
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; -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
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Dehumidifier with Air Mixing and Heat Pump Function
Type 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 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 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 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
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. 110C, Pmax 16 bar) removable in accord-
ance with VDI6022;
GEA motor 3-way mixing
valve:
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;
A
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Dehumidifier with Air Mixing and Heat Pump Function
Type 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
). 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 fol
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 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 m/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
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C
Dehumidification Unit with Air Mixing Function
Type 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 rows
3) 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..
Typ
e
Unit dimensions Air volume flow
Dehumidification
capacity
Heating capacity
Pressure
drop
Motor rated power/
current
Cur-
rent
con-
sump-
tion
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[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 2.8
025 760 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 4.8
037 760 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 dehumidification
demand
Active hours operation mode with
dehumidification demand
Idle mode with dehumidification
demand
Bypass damper mode, exhaust air fan
is 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 air
fans 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. Heat
recovery is not used thanks to a damper system.
If the swimming pool is overheated during the night time or idle period
the unit ventilates only in outdoor/exhaust air mode. The fans run at
high speed and provide cooling of the swimming pool to reach the
setpoint 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.
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Dehumidification Unit with Air Mixing and Heat Pump Function
Type 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; -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 m
3
/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 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 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. 110C, Pmax 16bar) removable in accordance
with VDI6022;
GEA motor -3-way mixing
valve:
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 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 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 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;
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Dehumidification Unit with Air Mixing and Heat Pump Function
Type 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 fol
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 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 m/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 rows
3) 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 CWCS..
Type Unit dimensions Air volume flow
Dehumidi-
fication
capacity
Heating capacity
Pres-
sure
drop
Motor rated power/current
Current
consump-
tion
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[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
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Electrical Integration
Overview 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 units
1: Pool water immersion sensor (option) 2 x 0,75 mm; screened LIYCY-0B
2: Reheater 3-way valve 6 x 0,75 mm; screened LIYCY-JZ
3: Outdoor temperature sensor 2 x 0,75 mm; screened LIYCY-0B
4: 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 Hz
7: Connection for pool water pump (option); 3 x 1,5 to 083 if more 5 x 1,5 mm (not for
CW_units) + 2 x 0,75 mm fault contact.
8: Connection for reheater pump; 3 x 1,5 to 083 if more 5 x 1,5 mm (not for CW_units) + 2 x
0,75 mm fault contact.
9: External shut-down; smoke and gas alarm; 2 x 0,75 mm
* Special configuration for Austria:
It is usually not necessary to screen the sensor supply line!
1: Pool immersion temperature sensor 2 x 0,75 mm
2: Reheater valve 5 x 1,5 mm
3: Outdoor temperature sensor 2 x 0,75 mm
4: On-site BMS connections provided by others according to wiring diagram
5: Fully assembled system cable is not necessary (standard in switch cabinet)
6: Power supply 3 x 400 V+N+PE/ 50 Hz
7: Connection for pool water pump (option); 3 x 1,5 to 037 if more 6 x 1,5 mm (400 V)
8: Connection for reheater pump; 3 x 1,5 mm to 037 if more 6 x 1,5 mm (400 V)
9: External safety shut-down only on request
10: Inlet temperature sensor, heater 2 x 0,75 mm
11: Room temperature and humidity sensor 5 x 0,75 mm
NOTE!
Only the unit wiring diagram provides exact information about the unit delivery
state.
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
10 11
9
3
4
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 units
1: Pool water thermostat (option); 3 x 1,5 mm
2: Reheater valve 5 x 1,5 mm
3: Switch cabinet
4: Power supply; 3~ 400 V+N+PE/ 50 Hz
5: 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 mm
8: Remote control/humidistat; 5 x 0,75 mm
9: Reheater pump; 3 x 1,5 mm
*Special model for Austria:
It is usually not necessary to screen the sensor supply line!
1: Pool immersion temperature sensor 2 x 0,75 mm
2: Reheater valve 5 x 1,5 mm
3: Switch cabinet
4: On-site BMS connections provided by others according to wiring diagram
5: Fully assembled system cable is not necessary (standard in switch cabinet)
6: Power supply 3 x 400 V+N+PE/ 50 Hz
7: Pool water pump connection (option); 3 x 1,5 mm
8: Reheater pump; 3 x 1,5 mm
9: External safety switch off only on request
10: Inlet temperature sensor, heater 2 x 0,75 mm
11: Room temperature and humidity sensor 5 x 0,75 mm
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 5 5
8
4
10
11
Unit Selection
As 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
40m
60m
70m
85m
100m
130m
195m
260m
325m
380m
435m
510m
590m
680m
745m
850m
950m
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. [m]
Temp.: 30 C air / 28 C water
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Air volume flow [m
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35m
60m
70m
85m
100m
130m
190m
230m
250m
300m
340m
400m
460m
530m
575m
670m
740m
830m
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. [m]
Temp.: 30 C air / 28 C water
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Air volume flow [m
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Configuration Variants and Accessories
GEA CAIRfricostar
PR-2008-0327-GB Subject to modifications Status 05/2009 57
Configuration Variants
GEA quality class K for
swimming 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 for
swimming 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 for
swimming 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
SKA-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
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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-Luftlter
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 ocina Espaa
ES-28028 Madrid
Tel. +34 / 91 / 3837701
OY TEKNOCALOR AB
FIN- 01300 Vantaa
Tel. +358 / 10 / 8201100
GEA Delbag
Filtration de lair
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 Wrocaw
Tel. +48 / 71 / 3565866
Nnio, 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 Enkping
Tel. +46 / 171 / 85530
GEA Klimatizacijska
Tehnika d.o.o.
SI-1000 Ljubljana
Tel. +386 / 1 / 2573850
GEA Klimatizcia 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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