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

There is no need for a connection profile at the ends of
the unit.
NOTE: The maximum distance between two connection
profiles is 960 mm. For greater distances connection
profiles should be installed on the operation side and
non-operation side.
Outdoor installation
For an outdoor installation, the connection profiles
supplied need to be cut to the correct length. These
profiles should be mounted over the entire unit length
and width.
Fig. 35 - Stacking, outside location
Bear in mind that different connection profiles are
used for the length and width directions of the cabinet.
• Length direction: Cut the connection profile
supplied to the correct length and mount it as
described below.
Fig. 36 - Fixing prole, length direction, unit with
intermediate base frame
Cross section of length direction (A-A)
• Width direction: Cut the supplied connection
profile to the correct length and mount it in the way
given below.
HHFlex Air Handling Units | 11

Fig. 37 - Fixing prole, width direction, unit with
intermediate base frame
View of width direction, equal casing length (B)
• If the top section is shorter than the bottom section,
the unit ends should be finished as described below.
Fig. 38 - Unit with shorter top section with
intermediate base frame
• Cut the connection profile supplied to the correct
length and mount it to the unit ends as described
below.
View of width direction if the top section is shorter
Fig. 39 - Roof nish, shorter top section with
intermediate base frame
• A longer top section needs no further finish at the
top.
Fig. 40 - Unit with longer top section with
intermediate base frame
NOTE: For an outdoor installation, seal all jonts
resulting from the mounted profiles. This applies to
both corner and butt joints.
5.3 - Units with different widths
For units with different widths there are four different
situations. For an indoor installation the method
described below applies to all situations.
Indoor installation
The top section icludes a projecting cross beam that is
effectively as wide as the bottom section.
• Check that the cover strip at the ends of the
bottom section is installed in the correct place.
• Position the top section as indicated in the
dimensional drawing.
• Screw the projecting cross beam of the top section
to the corner posts of the bottom section.
12 | HHFlex Air Handling Units

62 mm
n x module
n x module - 20 mm
Cross section of width direction
Fig. 41 - Width direction view, unit of unequal
width
Cross section of length direction
Fig. 42 - Length direction view, unit of unequal
width
Outdoor installation
The top section includes a projecting cross beam that is
effectively as wide as the bottom section. For an
outdoor installation the connection profiles supplied
need to be cut to the correct length. These profiles
should be mounted over the entire unit length and
width.
• Position the top section as indicated in the
dimensional drawing.
The position of the top section can be as described in
one of the four situations below:
Fig. 43 - Unit of unequal width - situation A
• Side 1: Cut the connection profile to the correct
length and mount it on the correct side (see Fig.
36).
• Side 2: Cut the connection profile to the correct
length and mount it on the correct side as
described below.
Fig. 44 - Roof nish, situation A, side 2
• Side 3 and 4: Cut the connection profiles to the
correct length and mount them on the correct sides
(see Fig. 37).
Fig. 45 - Unit of unequal width - situation B
HHFlex Air Handling Units | 13

• Side 1 and 2: Cut the connection profiles to the
correct length and mount them on the correct sides
(see Fig. 44)
• Side 3 and 4: Cut the connection profiles to the
correct length and mount them on the correct sides
(see Fig. 37).
Fig. 46 - Unit of unequal width - situation C
• Side 1: Cut the connection profile to the correct
length and mount it on the correct side (see Fig.
36).
• Side 2: Cut the connection profile to the correct
length and mount it on the correct side (see Fig.
44).
• Side 3: Cut the connection profile to the correct
length and mount it on the correct side (see Fig.
37).
• Side 4: Cut the connection profile to the correct
length and mount it on the correct side as
described below.
Fig. 47 - Roof nish, situation C, side 4
• Mount Z-profiles over the projecting cross beam
of the top section as described below.The plastic
roof foil of the bottom casing section can be
applied over these profiles.
Fig. 48 - Roof nish, projecting cross beam
Fig. 49 - Unit of unequal width - situation D
• Side 1 and 2: Cut the connection profiles to the
correct length and mount them on the correct side
(see Fig. 44)
• Side 3: Cut the connection profile to the correct
length and mount it on the correct side (see Fig.
37).
• Side 4: Cut the connection profile to the correct
length and mount it on the correct side (see Fig.
47).
• Mount Z-profiles over the projecting cross beam
of the top section as shown in Fig. 48 of this
chapter.The plastic roof foil of the bottom casing
section can be applied over these profiles.
6 - FRESH AIR INLET HOOD
The fresh air inlet hood may be supplied loose with the
AHU. In this case the air inlet hood must be attached
in the correct position as follows:
• Install the inlet hood with the screws supplied in
the correct location.
• The bottom wire grille should then be attached to
the corner post.
Fig. 50 - Fresh air inlet hood
NOTE: The connection between the outdoor air
suction grille and the corner post should be sealed.
14 | HHFlex Air Handling Units

7 - ROOF COVER
For outdoor installations the roof cover should be
provided with a finish. If the casing section has a flat top
use one of the following two methods:
Method 1
• Shorten the plastic roof foil strip supplied to the
correct length. Ensure that the strip projects
enough to attach it to the side of the roof edge
with a blow dryer.
• Ensure that the roof cover already attached to the
two casing sections to be connected is clean and
dust-free.
• Attach the roof cover strip with a blow dryer over
the entire length of the joint up to the roof edge.
• Remove any excess roof foil up to the underside
of the roof edge.
Fig. 51 - Roof nish, method 1
Method 2
• Fix sealing tape to the connection profiles. Drill
160 mm holes with a 10 mm diameter through the
connection profiles. Be sure to remove the drill
shavings after drilling.
• Attach the casing sections to each other using
bolts and nuts (M8).
• Seal the seam on the top of the connectiong
profiles.
Fig. 52 - Roof nish, method 2
HHFlex Air Handling Units | 15

Systemair B.V.
Zanddonkweg 7A, 5144 NX Waalwijk
P.O. Box 159, 5140 AD Waalwijk
Netherlands
Tel: [phone]
Fax: [phone]
www.systemair.nl
HHFlex-MI-HH-UK-10-2015. Manufactured by: Systemair B.V., Waalwijk, Netherlands
Manufacturer reserves the right to change any product specications without notice.
The cover illustration is solely for lllustration purposes and not contractually binding.