System air HHFlex User manual

HHFlex Air Handling Units
Mounting instructions

CONTENTS
1 - TRANSPORT AND LIFTING INSTRUCTIONS .................................................................................................. 3
1.1 - General ......................................................................................................................................................................... 3
1.2 - Transport and storage.................................................................................................................................................. 3
1.3 - Roof edge protection during transport (outside installation) ................................................................................ 3
1.4 - Offloading and hoisting............................................................................................................................................... 3
1.5 - Horizontal transport.................................................................................................................................................... 4
2 - PREPARATION FOR ASSEMBLY ......................................................................................................................... 4
3 - LIFTING INSTRUCTIONS........................................................................................................................................ 4
3.1 - General ......................................................................................................................................................................... 4
3.2 - Lifting bar certification ............................................................................................................................................... 4
3.3 - Fastening of the lifting bars ........................................................................................................................................ 4
4 - ASSEMBLY ................................................................................................................................................................... 6
4.1 - AHU assembly ............................................................................................................................................................. 6
4.2 - Connecting casings of equal width and height ......................................................................................................... 6
4.3 - Connecting casings of differing height ...................................................................................................................... 8
5 - STACKED CASING SECTIONS............................................................................................................................... 9
5.1 - Unit without intermediate base frame (equal width).............................................................................................. 9
5.2 - Unit with intermediate base frame (equal width) ................................................................................................. 10
5.3 - Units with differing widths ....................................................................................................................................... 12
6 - FRESH AIR INLET HOOD..................................................................................................................................... 14
7 - ROOF COVER............................................................................................................................................................ 15
2 | HHFlex Air Handling Units

1 - TRANSPORT AND LIFTING INSTRUCTIONS
1.1 - GENERAL
Transport and lifting of the HHFlex air handling units
(AHU) must always be in accordance with the instruc-
tions below. If these instructions are not observed,
irreparable damage may occur to the unit, and people in
the immediate vicinity of the unit are also endangered.
Systemair B.V. accepts no liability whatsoever for work
carried out by third parties.
Transport and lifting must be carried out by qualified
personnel. The AHU must only be lifted with lifting bars
supplied by Systemair B.V. Lifting must be carried out
in accordance with local regulations and with the help
of certified lifting aids.
1.2 - Transport and storage
Lifting of the AHU is only permitted at the desig-nated
lifting points. Lifting under the cross beams is prohibited.
This applies to transport as well as storage, and is
indicated on the cross beam with the following label.
Fig. 1 - Lifting not allowed
1.3 - Roof edge protection during transport
(outside installation)
Fig. 2 - Roof edge protection
Roof edge transport protection
During transport by truck the units are attached to the
loading surface with tie ropes, pulled across the unit
towards the side edges of the truck.
On external units, to protect the roof edge from
distortion by the tie ropes, protection pieces are added.
1.4 - Ofoading and hoisting
Depending on the dimensions of the AHU and the
situation on site, the AHUs are supplied in previously
agreed transport sections. Before proceeding with the
transport and installation of the casing sections, always
consult the applicable dimensional drawings that give
the dimensions and weights of the sections, as well as
the installation sequence.
The weight is given on each transport section. Each
transport section is equipped with a subframe with six
lifting points. These points are marked by the label
shown below.
Fig. 3 - Lifting point
To unload or hoist the AHU, the following methods are
recommended:
Method 1
• Attach the lifting cables to the lifting bars. Evenly
positioned spacer bars should be used between the
lifting cables to prevent damage to the top of the
unit and ensure that no excess pressure is applied
to the side panels.
Fig. 4 - Vertical transport using spacer bars
Method 2
• Attach the lifting cables that are on the lifting
beam to the lifting bars. To do so, use an approved
lifting beam.
HHFlex Air Handling Units | 3

Fig. 5 - Vertical transport using a lifting beam
NOTE: For hoisting please ensure that the weight is
evenly distributed.
1.5 - Horizontal transport
For horizontal movement pallet lifters or transport
skids can be placed under the installation frame or
under the lifting bars. It is important that these support
the lifting points.At no time should the cross beams at the
ends of the unit sections be used for jacking or tracking
the AHU. FOR HORIZONTAL TRANSPORT
ALWAYS PROVIDE SUPPORT UNDER THE
LIFTING POINTS. The use of pipes as rollers can
result in damage to the installation frame.
Fig. 6 - Horizontal transport using rollers
2 - PREPARATION FOR ASSEMBLY
The following material is supplied as standard by
Systemair B.V.:
• Installation, maintenance and operating
instructions
• Lifting instructions
• II A declaration
• Kit
• Connecting bolts/screws
• Connecting strips/screws
• Lifting bars
The following material is supplied as an option by
Systemair B.V.:
• Siphon
• Anti-vibration mats
• Outside air suction grille
• Heat recovery wheel control
• Steam generator plus accessories
• Minihelic and Allen key instructions
• Door key
Check that all necessary parts are supplied with the
AHU.
Measure the location and make sure it is tidy. The floor
of the installation area should be level and flat to avoid
connection problems. Any uneven surfaces should be
evened out with infill plates.
Determine the correct assembly sequence of the AHU
sections. Use the most logical sequence, taking the
location into account. Begin with the casing section
that must be positioned on the highest part of the floor,
so that the other casing sections can be added around it.
3. LIFTING INSTRUCTIONS
3.1 - General
There are transport and lifting instructions attached to
the AHU.
3.2 - Lifting bar certication
The lifting bars supplied are for single use and certified
in accordance with Machinery Directive 98/37/EC,
annex II-A. Selection, checking and testing of the
lifting bars is supervised by a qualified person in
accordance with the EKH (“Erkende Keurbedrijven
Hijs- en Hefmiddelen”) work instructions.
Registration mark and number:
• LCH1 + 1A
• LCH2 + 2A
3.3 - Fastening of the lifting bars
• Remove the bolt and the locking plate on one side
of the lifting pipe.
4 | HHFlex Air Handling Units

Fig. 7 - Fastening the lifting bars - 1
• Slide the lifting bar into the hole in the subframe
intended for that purpose.
Fig. 8 - Fastening the lifting bars - 2
• After inserting the lifting bar, re-insert the bolt and
locking plate in the correct position.
Fig. 9 - Fastening the lifting bars - 3
• Position the lifting cables on the lifting bars (4 or 6
off). Evenly positioned spacer bars should be used
between the lifting cables to prevent damage to
the top of the unit and ensure that no excess
pressure is applied to the side panels.
Fig. 10 - Vertical transport using spacer bars
• For hoisting ensure that the weight is evenly
distributed and that all previous steps are carried
out correctly.
If there is not enough space it may not be possible to
remove the lifting bars. In the example below, the lifting
bars cannot be removed on the right-hand side of the
6th AHU section, as the wall is too close and the lifting
bars are too long. It would be possible to remove them
from the left-hand side, if the third AHU section has not
yet been placed. Ensure that the bolt and the locking
plate are removed from the right-hand side of the lifting
bar, when the 6th AHU section has been positioned.
Fig. 11 - Location diagram
Wall
Lifting bar
HHFlex Air Handling Units | 5

4 - ASSEMBLY
4.1 - AHU assembly
• Place the anti-vibration mats where the first casing
section will be positioned.
• Place the first casing section on the anti-vibration
mats, and then remove the lifting bars.
Fig. 12 - Anti-vibration mats
• Then place the anti-vibration mats where the next
casing section will be positioned and then place
this section.
• Before placing the sections against each other, fix
the sealing tape supplied between the sections. This
should be done in four places, and the sealing tape
should overlap at the corners. See Figs. 17 and 21.
NOTE: Attach the sealing tape supplied to only one
of the two assembled sections.
• Place the sections as close together as possible.
Ensure that both sections can still be moved. Insert
a lifting bar into both sections, so that they can be
pulled closer towards each other.
There are two methods for pulling the sections towards
each other:
Method 1
Pull the sections against each other, using the pull ropes
attached to the lifting bars. Pull evenly on both sides of
the AHU.
Fig. 13 - Linking the casing sections with pull ropes
Method 2
Insert a bar with threaded ends through both lifting bar
holes. Screw a nut onto the threaded ends of the bar
and tighten it. Tighten it evenly on both sides of the
AHU.
Fig. 14 - Linking the casing section with a bar
NOTE: Before connecting the sections, they should be
horizontally and vertically aligned, using infill plates.
If the floor is not completely level, first place the
casing section that will be on the highest part of the
floor.
4.2 - Connecting casings of equal width and height
Fig. 15 - Unit of equal width and length
To connect the AHU sections use one of the following
methods. The method depends on the AHU construc-
tion.
6 | HHFlex Air Handling Units

Method 1
This method applies for sections that end in joint
mullions:
• Check that the four corners are attached.
Fig. 16 - Joint mullions with linking corner pieces
• Ensure that the sealing tape supplied is fixed to
one of the two sections, before moving the sections
against each other.
Fig. 17 - Fixing the sealing tape to the joint
mullions
• Use the pre-mounted corners for the final
positioning of the sections and secure the corners
with a bolt. The sections must be fully aligned.
Fig. 18 - Corner connection
• Remove the first two corners and mount the
aluminium connection strip to the base. Remove
the next two corners and mount the connection
strip against the side wall. Repeat this for the other
AHU corners.
Fig. 19 - Fixing the connection strip
Method 2
This method applies for sections that end with corner
posts.
Fig. 20 - Corner posts with coupling prole
• Ensure that the sealing tape supplied is fixed to
one of the two sections, before moving the sections
against each other.
Fig. 21 - Fixing sealing tape to the corner posts
HHFlex Air Handling Units | 7

• Link the sections by connecting the pre-mounted
corner posts with bolts and nuts (M6).
Fig. 22 - Connecting the corner posts
• If there are more than two sections, repeat the
procedure above. For an outdoor installation all
external joints should be sealed.
For an outdoor installation the plastic roof cover must
be finished as described in chapter 7.
NOTE: If the AHU needs to comply with air tightness
class L1 (LuKa C), the internal connection strip joints
and/or profiles should also be sealed.
4.3 - Connecting casings of differing height
Fig. 23 - Unit of differing height
After the internal connection of the sections an indoor
installation requires no further finish (see chapter 4.2).
For the external finish of an outdoor installation use one
of the following methods:
Method 1
• Check if the cover strip has been applied at the
correct height on the projecting section.
• Fix the plastic finish layer to cover strip above
with the screws provided.
• Add a second cover strip over these screws.
• Position the sections against each other so that the
corner posts of both casings are touching and first
connect the sections internally, as described in
chapter 4.2.
• Attach the projecting strip of the plastic roof foil
over the connection profile of the lower casing
section with a blow dryer.
Fig. 24 - Roof nish, units of differing height - 1
NOTE: All resulting external joints should be sealed.
Method 2
• Check that the cover strip and the protection
profile are mounted at the correct height of the
projecting casing section.
• Apply the sealing tape supplied to the connection
profile of the lower casing section.
• Position the lower section with the pre-mounted
connection profile against the projecting section so
that the corner posts of both sections touch, and
connect the sections first internally, as described in
paragraph 4.2.
• Screw down the connection profile of the lower
section to the cover strip, and remove any drill
shavings.
Fig. 25 - Roof nish, units of differing height - 2
NOTE: All resulting external joints should be sealed.
50 mm
8 mm
10 mm
8 | HHFlex Air Handling Units

5. STACKED CASING SECTIONS
5.1 - Unit without intermediate base frame (equal
width)
Fig. 26 - Unit without intermediate base frame
Indoor installation
• Position the casing sections on top of one another
so that the corner posts are in the same plane.
• Mount the profiles supplied as described below.
For sections of equal length, these profiles should
be mounted all round the unit.
• For shorter or longer upper sections the ends need
no further finish.
Fig. 27 - Mounting prole, indoor location, unit
without intermediate base frame
Outdoor installation
• Position the casing sections on top of one another
so that the corner posts are in the same plane.
• Mount the profiles supplied as described below. For
sections of equal length, mount the profiles all
round the unit.
Fig. 28 - Mounting prole, outdoor location, unit
without intermediate base frame
• If the top section is shorter than the bottom
section, the ends should be finished as described
below.
Fig. 29 - Unit with shorter top section without
intermediate base frame
HHFlex Air Handling Units | 9

Fig. 30 - Roof nish, unit with shorter top section
without intermediate base frame
• A longer top section needs no further finish at the
ends.
Fig. 31 - Unit with longer top section without
intermediate base frame
NOTE: For outdoor installation seal all jonts resulting
from the mounted profiles. This applies to both corner
and butt joints.
5.2 - Unit with intermediate base frame (equal
width)
Fig. 32 - Unit with intermediate base frame
Indoor installation
For indoor installation connection profiles of 240 mm
length are supplied.
• Position the casings on top of one another so that
the corner posts are in the same plane. The base
frame of the top section should be slightly back
compared to the bottom casing section.
If stacking units in an indoor installation the connection
profiles should be placed between the different unit
sections. Use the following assembly method:
• Install a connection profile to the end of the casing
section, stopping at the module line (A).
• Install a connection profile at the joint (B)
• Install a connection profile against adjacent section
(C)
Fig. 33 - Stacking, indoor location with
intermediate base frame
Fig. 34 - Fixing prole, indoor location with
intermediate base frame
max 960 mm
240
mm
ABC
10 | HHFlex Air Handling Units