airmaster AM 150 User manual

1 .22.33
AM 150 .300 .500 .800
INSTALLATION

SAFETY INSTRUCTIONS
WARNINGS
Place of installation and serial numbers (S/N):
Type:
Delivery date:
Place of installation:
S/N of Air handling unit:
S/N of Cooling Module:
This Manual must be read before installing the
Airmaster air handling unit. Following this Manual
will ensure this product is operated correctly.
The installation engineer is responsible for
ensuring that the unit is installed according to
current regulations and standards.
When installing the air handling unit in a room
with a re or stove drawing air from the room, all
applicable provisions must be observed.
The unit should not be installed in rooms with
abrasive particles or ammable or corrosive gas
in the air, in wet rooms or explosion-protected
rooms.
The unit should not be used without the lters
specied in the Operator’s Manual.
The manufacturer cannot be held liable for dam-
age arising from use or installing in contravention
of these instructions.
The manufacturer reserves the right to make
changes without notice. All values stated are
nominal values and can be affected by local
conditions.
Failure to observe the warnings indicated by a
danger symbol implies a risk of personal injury
or damage to property.
This manual relates to the Airmaster unit it
accompanies plus all equipment, and must be
given to and saved by the unit’s owner.
All necessary data and guides to network integra-
tion can be downloaded from www.airmaster-as.
com.
Service covers may not be opened without
rst disconnecting the unit’s power supply and
preventing use.
The unit may not be started up until all service
covers and grates on duct connections have
been installed.

Table of Contents
1. General Information................................................................................................................................................................................5
2. TechnicalSpecications .......................................................................................................................................................................6
3. Installation .................................................................................................................................................................................................6
3.1. Positioning of the Air Handling Unit..................................................................................................................................................................6
3.2. Ceiling Brackets.............................................................................................................................................................................................................7
3.3. Installation of Wall Frames and the Drilling of Duct Holes.................................................................................................................8
3.4. Installation of the Cooling Module CC 500 or 800............................................................................................................................. 10
3.5. Installation of the Air Handling Unit AM 500 and 800 to the wall frame or cooling module.................................... 11
3.5.1. Installation with Ceiling Frame .........................................................................................................................................................12
3.6. Installation of the Air Handling Unit AM 150, AM 150 with CC 150 (Cooling Module) and AM 300 ................... 13
3.6.1. Assembling the AM 150 and CC 150 before installation ............................................................................................... 13
3.6.2. Installation of the Air Handling Unit.............................................................................................................................................. 13
3.6.3. Installation with Ceiling Frame ........................................................................................................................................................ 14
3.6.4. Installation of the Service Cover.................................................................................................................................................... 14
3.7. Ducts and Grilles......................................................................................................................................................................................................... 15
3.8. Roof Cap.......................................................................................................................................................................................................................... 15
3.9. Sealing the Gaps Around Ducts ....................................................................................................................................................................... 15
3.10. Jointing against the ceiling .................................................................................................................................................................................. 16
3.11. Fitting of Panels.......................................................................................................................................................................................................... 16
3.12. Installation Check...................................................................................................................................................................................................... 16
3

Appendix1 DimensionalDrawings .....................................................................................................................................................17
AM 150, AM 150 - CC (with Cooling Module) and AM 300.............................................................................................................................17
AM 500 and 800 H .................................................................................................................................................................................................................. 18
AM 500 and 800 V .................................................................................................................................................................................................................. 19
AM 500 and 800 DIDE..........................................................................................................................................................................................................20
AM 500 and 800 H - CF (Ceiling Frame).....................................................................................................................................................................21
AM 500 and 800 V - CF (Ceiling Frame)....................................................................................................................................................................22
AM 500 and 800 H - CC (with Cooling Module)....................................................................................................................................................23
AM 500 and 800 HDIDE - CC (with Cooling Module)........................................................................................................................................24
Isometric View.............................................................................................................................................................................................................................25
Model Versions AM 500 and 800..................................................................................................................................................................................29
Appendix2 AdditionalDimensions....................................................................................................................................................30
Connections AM 500 ............................................................................................................................................................................................................ 30
Connections AM 500 - CC .................................................................................................................................................................................................. 31
Connections AM 800 ............................................................................................................................................................................................................. 31
Connections AM 800 DIDE ................................................................................................................................................................................................32
Connections AM 800 - CC..................................................................................................................................................................................................32
Connections AM 800 DIDE - CC .....................................................................................................................................................................................33
Ceiling Bracket, Angle.............................................................................................................................................................................................................33
Ceiling Bracket, Adjustable.................................................................................................................................................................................................33
Postioning of the Ceilling Brackets................................................................................................................................................................................34
AM 500 and 800.......................................................................................................................................................................................................34
AM 500 and 800 with Cooling Module (CC) ...........................................................................................................................................34
Postioning of the Ceilling Frame..................................................................................................................................................................................... 35
AM 500 and 800...................................................................................................................................................................................................... 35
4

5
< 80°
< 60s
1. General Information
Scope of Delivery:
The Airmaster air handling unit is packed on a pallet in one
or more cardboard boxes. All individual parts can be found
in the box(es), depending on the customer’s order.
Please check the delivery before installation. The most
important parts are shown below. The scope of delivery
can be seen from the delivery note.
1. Airmaster air handling unit (AM)
2. Wall frame (tted for 1. or 3.)
3. Cooling module (CC - optional)
Cooling modules must be stored and transported on
the case cover. The unit may, however, be tipped up to
80 degrees for up to 60 seconds.
4. Panel set (a set consists of one to three long panels
and double that number of short panels)
5. Ceiling ttings (optional)
6. Control panel
Airlinq Viva Airlinq Orbit
or
7. Set of pipes (optional)
8. Grilles (optional)
9. Operator’s Manual (for programming) and Mounting
Instructions and Installation Manual (for installa-
tion);
to be handed over to the owner!


6
kg 53 85 108 156,5
kg 82 - 190,8 257,2
RAL - - 9010 9010
RAL 9010 9010 7024 7024
mm
2. Technical Specications
AM 150 AM 300 AM 500 AM 800
Weight, Standard unit
Weight, Standard unit + Cooling module
Colour, Panel
Colour, Case
Dimensions
See “Dimensional Drawings”
3. Installation
The installation engineer is responsible for ensuring that
the Airmaster air handling unit is properly secured in a
horizontal position.
The installation engineer is responsible for ensuring that
any existing functions in the wall/ceiling (e.g. vapour barrier)
are restored and fully functional once the unit has been
installed.
Read this section “Installation” fully before starting
installation!
3.1. Positioning of the Air Handling Unit
The diagram below shows the most important dimensions
relating to the positioning of the unit.
B
A
C
E
F
D
J
H
G
A: Extraction (may also be on the right side of the unit)
B: Distance from ceiling: Max. 50 mm
C: Min. distance from wall: 0.5 m
D: External CO
2
sensor
E: Approximately 1 m
F: Approximately 2 m
G: Free space for maintenance work min. 0.95 m
H: External PIR sensor
J: Approximately 2,25 m (1,8-2,5 m)
A CO
2
sensor must not be tted close to a window or door.
A smoke detector must not be too close to the inlet air
ow and extract air ow.

7






3.2. Ceiling Brackets
The purpose of the ceiling brackets is to hold a wall-mounted
unit in place when the attachment to the wall frame alone
does not provide sufcient support. This is the case, for
example, when the unit is equipped with a cooling module,
when the wall is not sufciently sound or when the unit is
to be tted in a free-suspended position. Not at the AM
150 and AM 300.
The holes for securing the ceiling brackets are at the top
of the unit and the cooling module on both sides. In this
connection, see “Appendix 1 Dimensional drawings” or
“Appendix 2 Additional Dimensions”.
If ceiling brackets are used, the distance from the wall
frame/unit to the ceiling must be adjusted as the ceiling
brackets protrude over the top edge of the unit by up to
30 mm!

8
3.3. Installation of Wall Frames and the
Drilling of Duct Holes
NB! The air handling unit must be mounted on a solid
supporting base by using all possible attachment points.
If the wall itself is not sufciently solid, the air handling
unit can be additionally fastened to the ceiling pursuant
to “Appendix 1 Dimensional Drawings’ and “Appendix 2
Additional Dimensions’.
NB! If the air handling unit is not properly afxed, there
is a high risk of the air handling unit disengaging from its
attachment ttings and falling down. This constitutes a
risk of damaging materials and/or causing serious personal
injury.
NB! The attachment material will depend on the supporting
base and the air handling unit and must be suitable for
properly supporting the unit’s weight of up to 257 kg on
the supporting base.
The wall to which the unit is tted must have an even
surface. If the surface is too uneven, tting of the frame
may be out of true. This may lead to leaks and an increased
noise level during operation of the unit.
It is recommended that the duct holes be drilled 10-15 mm
larger than indicated on the drawings as this will allow for
subsequent insulation, will prevent direct contact with the
wall, and will allow for a vapour barrier etc. to be restored.
A rubber diaphragm for restoration of the function of the
vapour barrier is optional available and can be delivered
by Airmaster.
Duct holes in the wall must have an outward downward
gradient of 1-2% to prevent heavy rain from entering the
unit.
The holes for the roof ducts must be made oval to be able
to install the unit. “Appendix 1 Dimensional drawings’.
1. Hold the wall frame against the wall under the ceiling.
AM/AM+CC 150, 300 500, 800
Distance (A) wall frame
to ceiling [mm]
0 0
Optical air gap between
unit and ceiling [mm]
14 7,5
If the air gap (L) needs to be increased, e.g. if the unit is to
be installed with ceiling ttings (see also sections “Ceiling
Brackets” and “Appendix 2 Additional Dimensions”), distance
(A) should be increased.
2. Mark all holes and the top edge and left edge of
the wall frame on the wall. Trial t the wall frame
if necessary.

9
1
1
2
1
1
11
2
2
2
2
Only AM 150 and AM 300:
4. Drill the holes for the ducts and the frame (1, 2 or
1+2) in accordance with “Dimensional Drawings”.
5. Fit the frame in a horizontal position. (1, 2 or 1+2).
3. Mark the holes for the ducts according to
“Appendix 1 Dimensional Drawings”.
4. Drill all marked holes.
AM 150 and AM 300: See below.
5. Fit the wall frame.

10
3.4. Installation of the Cooling Module
CC 500 or 800
The cooling module has to be adjust into a horizontal
position.
1. Drill, if relevant, any holes for the ceiling brackets
according to the dimension drawings in “Appendix
2 Additional Dimensions” and attach the ceiling
brackets
2. Appropriate lifting equipment is used to lift the
cooling module into place on the wall frame.
We would point out that, when lifting the cooling module
a protective underlay must be placed beneath the service
cover to prevent scratches to the service cover. This
underlay may for example be strong, clean cardboard or
equivalent.
3. Press the cooling module against the wall frame
and use the accompanying bolts to screw it tightly
to the frame and, if relevant, to the ceiling brackets.

11
3.5. InstallationoftheAirHandlingUnitAM500
and 800 to the wall frame or cooling
module
The unit has to be adjust into a horizontal position.
1. Possibly drill the holes for the ceiling brackets
in accordance with the dimensional drawings in
“Appendix 2 Additional Dimensions” and attach the
ceiling brackets.
2. Lift the air handling unit up to the cooling module/
wall frame, using appropriate lifting equipment.
When lifting the unit a protective underlay must be placed
beneath the service cover to prevent scratches to the
service cover. This underlay may for example be strong,
clean cardboard or equivalent.
3. Push the Airmaster air handling unit against the
cooling module/wall frame and screw securely to
the frame using the bolts provided.
4. Attach the unit to the ceiling brackets.
5. Draw the leads of the cooling module over to the
air handling unit.
6. Note the type, date supplied, place of installation and
serial numbers (S/N) of the air handling unit and the
cooling module on page 2 of both the Installation
Manuals and the Operator’s Manual.

12
3.5.1. Installation with Ceiling Frame
The unit has to be adjust into a horizontal position.
1. Drill the holes for the ducts and the frame in accord-
ance with “Appendix 1 Dimensional Drawings” and
“Appendix 2 Additional Dimensions”. (See also
section “Wall Frame and Duct Holes”)
The attachment point for the air handling unit on the ceiling
frame for AM 500 and 800 is adjustable. It is possible to
adjust the vertical position of the air handling unit and the
duct holes up to 20 mm.
2. Lift the air handling unit up to the ceiling, using
appropriate lifting equipment.
We would point out that, when lifting the unit a protective
underlay must be placed beneath the service cover to
prevent scratches to the service cover. This underlay may
for example be strong, clean cardboard or equivalent.
3. Lift the air handling unit to its nal position and mount
the ceiling frame securely to the ceiling.
4. Adjust the air handling unit into a horizontal position
and secure it to the ceiling frame.
5. Note the type, date supplied, place of installation
and serial numbers (S/N) of the air handling unit
on page 2 of both the Installation Manuals and the
Operator’s Manual.

13
3.6.2. Installation of the Air Handling Unit
The unit has to be adjust into a horizontal position.
1. Lift the air handling unit up to the frame, using
appropriate lifting equipment.
When lifting the unit a protective underlay must be placed
beneath the unit to prevent scratches to the unit. This
underlay may for example be strong, clean cardboard or
equivalent.
2. Draw the leads and the condensate hose of the unit
from the connection points past the frame.
3. Push the unit onto the frame.
Lead the mounting brackets on the unit within the frame.
4. Press the unit all the way against the wall; insert a
suitably pointed object, such as an awl, through the
frame’s centring holes and cooling module bracket
so they line up with one another. Then mount the
cooling module by screwing it onto the frame.
5. Repeat on the other side.
6. Adjust the air handling unit into a horizontal position
with the adjusting screws. For AM 150 with CC 150,
it may be necessary to adjust between the units.
Max pressure per adjusting screw:
AM 150: 330 N
AM 150 + CC 150: 737 N
AM 300: 450 N
1. 2.
3.6. Installation of the Air Handling Unit AM
150, AM 150 with CC 150 (Cooling
Module) and AM 300
3.6.1. Assembling the AM 150 and CC 150
before installation
1. Dismantle any duct connectors from the rear side
of the air handling unit.
2. Place the cooling module behind the air handling
unit on a rm, even surface.
Place a protective underlay beneath the units to prevent
scratches to the units. This underlay may for example be
strong, clean cardboard or equivalent.
3. Press the air handling unit and cooling module
completely together.
4. Screw the cooling module’s mounting ttings onto
the air handling unit. The enclosed screws are
mounted on the air handling unit.

14
3.6.4. Installation of the Service Cover
1. Lift the service cover up to the air handling unit,
using appropriate lifting equipment.
We would point out that, when lifting the service cover a
protective underlay must be placed beneath the service
cover to prevent scratches to the service cover. This
underlay may for example be strong, clean cardboard or
equivalent.
2. The short hinges mounted on the service cover are
put over the bolts on the cabinet and secured using
the two lock nuts provided, without tightening the
hinges completely.
At the AM 150 the supply air lter must be removed.
3. The long hinges mounted on the cabinet are mounted
using the two screws that are provided on the service
cover.
At AM 150 the supply air lter must be mounted again.
4. The earth wire has to be connected on the hinge
side from the cabinet to the service cover.
5. Carefully close the service cover while it is supported.
The service cover is heavy. First close the locks on the inlet
side and then the locks on the frame side.
6. Note the type, date supplied, place of installation and
serial numbers (S/N) of the air handling unit on page
2 of both the Installation Manuals and the Operator’s
Manual.
3.6.3. Installation with Ceiling Frame
The unit has to be adjust into a horizontal position.
1. Lift the air handling unit up to the ceiling, using
appropriate lifting equipment.
When lifting the unit a protective underlay must be placed
beneath the unit to prevent scratches to the unit. This
underlay may for example be strong, clean cardboard or
equivalent.
2. Draw the leads and the condensate hose of the unit
from the connection points past the ceiling frame.
3. Lift the air handling unit to its nal position.
4. Push the unit into the wall and mount the ceiling frame
securely to the ceiling.

15
3.7. Ducts and Grilles
The materials needed and method of tting the ducting
depend on the unit, the options chosen and the customer’s
order. For this reason, we can provide only general instruc-
tions for tting the ducts.
The length of the ducting is calculated on the basis of the
thickness of the wall/dimensions of the roof.
Please note that the duct holes in the wall must have an
outward downward gradient of 1-2% to prevent heavy rain
from entering the unit.
Exhaust air ducts and supply air ducts must be insulated
against condensation on the ducts, if they are within the
building envelope. The extract air ducts and inlet air ducts
must be insulated against temperature loss and condensa-
tion forming inside the ducts if they are mounted outside
the building envelope, or run through an unheated room.
Condensation and heat insulation should be performed
according to standards and rules in effect.
Fire requirements according to standards and rules in
effect must be observed.
The installation of ventilation ducts should be performed
according to standards and rules in effect.
Exhaust air ducts and supply air ducts must be insulated
against noise if they are visible.
Finally, t a suitable circular grille with the slats pointing
downwards on the outside of the outer wall or a roof cap
up on the roof.
To avoid an increase in noise level, it is important that the
ducts should not get twisted or compressed against the
exhaust air spigot and supply air spigot of the unit.
Remember to seal around the penetrations. See section
“Sealing the Gaps Around Ducts”.
3.8. Roof Cap
2
3
1
Fit roof caps on the roof to nish off the installation of
exhaust and supply through a roof. Installation will depend
on the roof construction (3). The illustration shows which
roof caps are for exhaust (1) and intake (2).
Fire requirements for the installation of multiple systems
must be observed according to the standards and rules
in effect.
3.9. Sealing the Gaps Around Ducts
Sealing of the gaps around ducts is performed as shown in
the sectional drawing below.
1
2
3
5
2
5
4
4
Application of a seal (shown here on a model with wall ducts)
is important at the ducts (3) indside and the outside edges
(4) in order to prevent draughts between the unit (1) and
the wall/roof (2) as well as between the ducts (3) and the
wall/roof (2).
Sealing on the inside between the pipes (3) and the wall/
ceiling (2) can also be performed between the air handling
unit (1) and the wall/roof (2) at position (5) before tting the
air handling unit.
Depending on the condition of the wall/ceiling and the
dimensions of the air handling unit, a sealant that retains
elasticity over the long term or expanding sealing tape
can be used to obtain a exible seal. This material is to be
applied to the rear of the unit around the air connection
ttings, or at the side of the duct holes on the wall to even
out irregularities on the wall/ceiling.

16
3.10. Jointing against the ceiling
Airmaster recommends jointing the gap between the unit’s
top plate and the ceiling if the unit is mounted in a fully
visible manner. The jointing on the sides and in the front
can be carried out with, for example, joint backing strip or
joint strip with a suitable thickness. Jointing the back edge
is not necessary.
3.11. Fitting of Panels
The panels must only be tted once the unit, complete
with all equipment, has been tted and connected, and
the functions of the unit thoroughly tested. Not at the AM
150 and AM 300.
Press the panels to the clips on the unit until they attach
securely to the clips.
3.12. Installation Check
yes no
Serial numbers noted
Wall frame tted
Cooling module tted
Safety tape removed
Unit tted
Ceiling ttings attached
Ducts and grilles tted
Roof cap tted
Screws retightened
Name of installation engineer:
Comment:

Appendix 1 - 17
Appendix 1 Dimensional Drawings
AM 150, AM 150 - CC (with Cooling Module) and AM 300
See the attached dimensional drawing.

A
B
2
1
6
87
4
3
5
A
b
g g
*4
*4
*4 *4
6,5
d
c
e
a
*4
*4
i
k
h
fB
a b c d e f g h*1 i*2 k
1600 779 1570 286 432 764 250 171 178 1170
1910 915 1880 310 467 901 315 252 242 1433
Appendix 1 - 18
AM 500 and 800 H
Shown here: AM 500 HB with Extract on the right side and one panel row.
*1 Distance from top edge of wall frame to centre hole.
*2 Distance from left edge of wall frame (without mounting pin) to centre hole.
*4 See ”Appendix 2 Additional Dimensions”.
1 = Exhaust
2 = Supply
3 = Inlet
4 = Extract
5 = Wall frame
6 = Condensate drain
7 = Electrical Connections
8 = Delivery + Return
AM
500
800

*4
*4
g g
k i
be
a
h
6,5
*4 *4
*4
*4
f
c
d
A
B
5
6
1
2
7
4
3
8
B
A
h
+40 mm+40 mm
+15 mm +15 mm
a b c d e f g h*1 i*2 k
1600 779 1570 147 432 764 250 328 178 1170
1910 915 1880 159 467 901 315 206 242 1457
Appendix 1 - 19
*1 Distance from the wall to centre hole.
*2 Distance from left edge of wall frame to centre hole.
*3 Distance from top edge of wall frame to centre hole.
*4 See ”Appendix 2 Additional Dimensions”.
AM 500 and 800 V
Shown here: AM 500 VC with Extract on the right side and two panel rows.
Holes to be drilled for ducts:
Wall
AM
500
800
1 = Exhaust
2 = Supply
3 = Inlet
4 = Extract
5 = Wall frame
6 = Condensate drain
7 = Electrical Connections
8 = Delivery + Return

A
6
1
2
4
7
3
8
B
5
A
Ø250
gg
t
s
v
u
b
*4
*4
ik
e
6,5
Ø250
a
h
B
a b e g h*1 i*2 k s*1 t*2 u*1 v
1600 779 432 250 171 178 1170 139 526 139 489
1910 915 467 315 252 242 1433 *4 *4 *4 *4
Appendix 1 - 20
*1 Distance from top edge of wall frame to centre hole.
*2 Distance from left edge of wall frame (without mounting pin) to centre hole.
*4 See ”Appendix 2 Additional Dimensions”.
AM
500
800
AM 500 and 800 DIDE
Shown here: AM 500 HDIDE with Extract on the right side and three panel rows.
1 = Exhaust
2 = Supply
3 = Inlet
4 = Extract
5 = Wall frame
6 = Condensate drain
7 = Electrical Connections
8 = Delivery + Return