System air KA Series User manual

KA
Modular air handling units
Installation, operation and maintenance manual
|2020-8-V-EN-003
EN

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CONTENT
1. GENERAL INFORMATION .................................................................................................................................................................3
1.1 Information about manufacturer........................................................................................................................................................... 3
1.2 Unit naming .............................................................................................................................................................................................. 3
1.3 General description ................................................................................................................................................................................. 4
1.4 Declarations regarding the air handling unit....................................................................................................................................... 5
1.5 Dangers and warnings............................................................................................................................................................................ 6
1.6 Symbols..................................................................................................................................................................................................... 7
1.7 Personnel requirements, assignments and responsibilities............................................................................................................. 8
1.8 Operation and control............................................................................................................................................................................. 9
1.9 Annexes, responsibility and intended use........................................................................................................................................... 9
2. INSTALLATION .................................................................................................................................................................................11
2.1 Loading and transport............................................................................................................................................................................. 11
2.2 Mounting................................................................................................................................................................................................... 13
2.3 Assembly................................................................................................................................................................................................... 16
2.3.1 Joining of unit modules ..................................................................................................................................................................... 16
2.3.2 Mounting of roof................................................................................................................................................................................ 18
2.3.3 Connection of ducting....................................................................................................................................................................... 19
2.3.4 Connection of piping ......................................................................................................................................................................... 20
2.3.5 Connection of siphons....................................................................................................................................................................... 23
2.3.6 Connection of electrical installation................................................................................................................................................ 27
2.3.7 Vibration and structure-borne noise .............................................................................................................................................. 27
3. COMMISSIONING AND MAINTENANCE ............................................................................................................................................28
3.1 General instructions ................................................................................................................................................................................ 28
3.2 Schedule for control and maintenance................................................................................................................................................ 29
3.3 Fan.............................................................................................................................................................................................................. 30
3.3.1 Electric motor connection and frequency converter set-up....................................................................................................... 30
3.3.2 Connection of EC fan ......................................................................................................................................................................... 32
3.4 Filter........................................................................................................................................................................................................... 35
3.4.1 Bagorcassettelter ......................................................................................................................................................................... 36
3.4.2 Dirtysideremovablecassettelter................................................................................................................................................ 37
3.4.3 Metallter........................................................................................................................................................................................... 38
3.4.4 Activecharcoallter.......................................................................................................................................................................... 39
3.4.5 Absolutelter..................................................................................................................................................................................... 40
3.5 Heat recovery units................................................................................................................................................................................. 41
3.5.1 Plate heat exchanger......................................................................................................................................................................... 41
3.5.2 Rotary heat exchanger...................................................................................................................................................................... 42
3.5.3 Run around coil................................................................................................................................................................................... 43
3.6 Control damper ........................................................................................................................................................................................ 44
3.7 Heating and cooling coils ....................................................................................................................................................................... 45
3.7.1 Frost protection.................................................................................................................................................................................. 45
3.7.2 Water heating coil.............................................................................................................................................................................. 46
3.7.3 Water cooling coil............................................................................................................................................................................... 47
3.7.4 Direct expansion (DX) ....................................................................................................................................................................... 48
3.7.5 Droplet eliminator .............................................................................................................................................................................. 50
3.7.6 Steam heating coil ............................................................................................................................................................................. 51
3.7.7 Electric air heater ............................................................................................................................................................................... 53
3.7.8 Indirect gas heating coil.................................................................................................................................................................... 54
3.8 Sound attenuator..................................................................................................................................................................................... 57
3.9 Humidiers................................................................................................................................................................................................ 57
3.9.1 Steamhumidier................................................................................................................................................................................ 57
3.9.2 Honeycombhumidier...................................................................................................................................................................... 58
3.9.3 Highpressurehumidier................................................................................................................................................................... 62
3.10 Electric control cabinet ........................................................................................................................................................................... 63
4. REMOVAL AND DISPOSAL................................................................................................................................................................63

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1. GENERAL INFORMATION
1.1 Information about manufacturer
These instructions apply to all KA air handling units supplied by Systemair d.o.o., Slovenia.
Manufacturer and supplier details:
Systemair d.o.o.
Špelina ulica 2
2000 Maribor
Slovenija
Responsible person:AntonZupančič
Service and technical support:
Systemair d.o.o.
Brnčičeva41c
1000 LJUBLJANA
Slovenija
tel: + 386 1 200 73 81
fax: + 386 1 423 33 46
e-mail: [e-mail]
1.2 Unit naming
The meanings of the different elements of the KA air handling unit code are provided in the following schematic.
KA HSI-2-2-S-R-50F-TB2-L2
SStandard
HHygienic
PCorrosion resistant
Execution
Product name
Width-HightCross section
HTHOR 50 mm proleProle type
IIndoor
OOutdoor
Installation
S Supply
EExtract
IIn-line
D Doublestage
PParallel
CStacked
Design
LLeft
RRight
TTop
BBottom
Service side
50F 50mmfullyglued
50P 50mmpartiallyglued
Panel execution
Air leakage class
TB2
TB3
L2
Thermal break class

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1.3 General description
KA air handling units are modular devices that may be manufactured for a number of combinations of different cross
section dimensions, functional unit assemblies, material combinations, sizes and types of control. Depending on
the particular version, KA air handling units are designed for comfort ventilation, clean room ventilation, indoor pool
ventilation, ventilation of industrial premises, and areas with an explosive atmosphere.
The variety of available dimensions, shapes and constructions of KA air handling units allows them to be installed
indoorsontheoor,onaplatform,orbelowtheceiling;theymayalsobeinstalledoutdoors.
The casing of an air handling unit of the normal or hygienic type consists of a thermally insulated and sound-insulated
aluminium frame, thermally insulated and sound-insulated sheet covers at the bottom, top and sides, a door on the
serviceside,andasteelbaseframetowhichlegscanbettedifsorequired.Thethicknessoftheairhandlingunit
casing wall is 50 mm.
Comfort units
With a normal type of air handling unit, all the interior and exterior casing walls are made of ZM-coated galvanised
steel sheet as the standard. The whole bottom of the unit is sealed on the inside between the frame and panels. The
fastening material is of galvanized steel quality.
Hygienic units
Asastandard,thefrontandbackwallsandtheceilingaremadeofpaintedsteelsheet,whilethebottom,guiderails
and all partition walls are made of 1.4301 stainless steel sheet. All the joints between the frame and panels are sealed
in the inside with clean-room-grade putty. The fastening material is of A2 or Ruspert quality.
Casing technical properties according to EN 1886
Mechanical stability D1
Thermal transmittance factor T2
Thermal bridge factor TB2 or TB3
Casing air leakage class (+700 Pa) L2
Casing air leakage class (-400 Pa) L2
Filter bypass leakage class F9
Casing sound attenuation
Casing with fully glued panels:
Hz 125 250 500 1000 2000 4000 8000
De dB 15 12 16 13 27 32 41

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1.4 Declarations regarding the air handling unit
DECLARATION OF CONFORMITY DECLARATION OF INCORPORATION
The declaration of conformity is issued for the device supplied
together with the control system and for which manufacturer also
makesrstcommissioning.
The declaration of incorporation is issued for a device supplied
without a control system.
The declaration of conformity for this device must be issued
by the company which assigned the device and put it into
operation.
Caution
The declaration of conformity or the declaration of incorporation shall be attached separately to each
device.
Ifthecustomermakeschangesoraddscomponentstothedevice,hemustissueanewECdeclarationof
conformity and a new CE sign for the machine.
Example of declaration of conformity Example of declaration of incorporation

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1.5 Dangers and warnings
• The intended use, operational conditions, inlet and outlet parameters, composition of the functions, dimensions,
shape, place of installation, dimensions of shipment units, method of transport and handling at the place of
installation,aswellasthecontrolsystemvariantandotherspecications,aredeterminedandconrmedatthetime
of placing the order.
• AKAairhandlingunitmayonlybeinstalled,inspected,commissionedandmaintainedbyqualiedprofessionals,and
such professionals must observe both the statutorily prescribed and local safety and other legal regulations in force at
the time of the installation, operation and maintenance of the unit.
• In the process of installing, commissioning and maintaining the KA air handling unit, the functional elements of the
manufacturer’s instructions must be followed.
• Prior to any intervention in the unit, the entire unit must be isolated from the power supply by means of the main
switch on the electric control cabinet.
• Uponthecompletionofworkonorinsidetheunit,theunitmustbecleanedandrestoredtotheconditionpriortothe
intervention.
• Theinstructions,electricdiagramsandotherdatamustbekeptaccessibletothepersonneloperatingtheunit.
• The air handling unit may only be used for the intended use and under the operating conditions determined in the
conrmationoftheorderaccordingtowhichtheunitwasmanufactured.
Caution
Any other use deviating from the so-determined intended use relieves the manufacturer of any
obligation or liability.
• Systemair d.o.o, the manufacturer of the KA air handling unit, does not accept any liability in the event the directions
indicated in these instructions are not adhered to while installing, commissioning, operating, testing or maintaining
the air handling unit, or in the event of any alterations to the unit’s electrical or mechanical elements by any person
without the manufacturer’s consent, unless such alterations have been explicitly allowed by the manufacturer. Any
unauthorised intervention in the unit will also result in the warranty being void.
• The KA air handling unit manufacturer, Systemair d.o.o., does not accept liability for any damage suffered by persons
or property as a direct or indirect consequence of non-compliance with the provisions of these instructions, or non-
compliancewiththesafetyatworkregulationsorotherlegalregulationsinforce.
• The KA air handling unit manufacturer, Systemair d.o.o., reserves the right to modify these instructions without prior
notice or this giving rise to any obligation.
Caution
It is highly advisable that the commissioning of the unit is done after all construction and cleaning of the
constructionsiteisnished.
Commissioningoftheunitbeforethismightresultinthelters,unitandductsystembeingaffectedby
dust.

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1.6 Symbols
Functional section symbols
fan section frost protection section
compressor section heat exchanger section with glycol heat
exchanger – heating section
heating coil section – water heat exchanger section with glycol heat
exchanger – cooling section
heating coil section – steam heat recovery section with plate heat
exchanger
heating coil section – electric heat recovery section with rotary heat
exchanger
heating coil section – gas heat recovery section with heat pipe exchanger
condenser section silencer
heating / cooling circuit empty section
spray humidier section electric cabinet
steam humidier section with steam generator cooling coil section with water cooler
steam humidier section with system prepared
steam cooling coil section with direct gas expansion
contact humidier with recirculation water droplet eliminator
contact humidier with direct water Filter section
damper

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Danger and warning symbols
Warning – danger of injury due to
rotating parts
The frost protection cover must be freely
removable - pay attention to the pipe
installation!
Warning – danger of contact with live
electric components
Safety chain on the inside of the door.
Return the chain to the safety position
before closing!
Warning – hot surfaces
Non-compliance with the instructions
indicated in the warning signs may result
inriskofinjuryandpropertydamage.
Opening doors during operation
prohibited Connection of electrical connectors.
Turn off the main switch prior to opening
the casing
1.7 Personnel requirements, assignments and responsibilities
QUALIFICATION DECLARATION OF INCORPORATION
Truck driver Responsible for transporting the device from the factory to the system owner.
Musthaveatruckdrivingtest.
Makessurethatallelementsarexedandproperlysupportedduring
transportation. Is responsible for any damage done prior to unloading of the
cargo.
Forklift driver Responsible for moving pallets with modules.
Must have a forklift driving test and written permission from the system owner.
Crane driver Responsible for moving pallets and modules from the transport vehicle and to the place of
operation.
Must have a crane driving test, be mentally and physically able to operate the crane
independently and prove to the system owner the required type of skill.
HVAC technician Is responsible for the installation and completion of all professional work in connection
with mechanical installations.
Must have in-depth knowledge and skills related to the required mechanical systems.
Must have experience with the work in question, understand the potential hazards
associated with the work and how to avoid it.
Electrician technician Is responsible for the installation and completion of all professional work in connection
with electrical installations.
Must have in-depth knowledge and skills related to the required hardware systems.
Must have experience with the work in question, understand the potential hazards
associated with the work and how to avoid it.
Network administrator Designs, installs, congures and maintains IT infrastructure in companies or organizations.

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1.8 Operation and control
Theunitshallbefurnishedforfullyautomaticoperation.Themodicationsofparametersviathehand-heldterminal
buttonsandscreenmustbelimitedinthecontrolsystem.Analternativemaybeacontrollerlinkedtoacentral
monitoring system that enables the selection of parameters via a PC, tablet or smart phone.
Different implementations of the control system are available:
• Air handling units manufactured in the factory without a control system. The complete control system is to be
implementedbythecustomer;thecustomerisalsoresponsibleforcommissioningtheunit,providingthecontrol
system operation and maintenance instructions, training the operating personnel, issuing the declaration of
conformityfortheentireunit,andafxingtheCElabelonthedevice.
• Air handling units manufactured in the factory, including the integration and wiring of some of the control system
elements, such as control damper drives, frequency converters, service switches, interior lighting, etc. The complete
controlsystemistobeimplementedbythecustomer;thecustomerisalsoresponsibleforcommissioningtheunit,
providing the control system operation and maintenance instructions, training the operating personnel, issuing the
declarationofconformityfortheentireunit,andafxingtheCElabelonthedevice.
• Air handling units manufactured in the factory, including the implementation of the control system either in the
factory or on the site of installation, including the commissioning, training of operating personnel, and issuing the
control system operating and maintenance instructions. The manufacturer issues the declaration of conformity for the
entire unit and provides the CE label for the device.
1.9 Annexes, responsibility and intended use
Drawings, diagrams, instructions for use, maintenance and repairs
The dimensions, shape and technical data of the unit are made separately for each device. They are printed on paper
and delivered to the customer upon delivery of the device in a separate envelope or sent electronically by email.
Following instructions and documents are constituent parts of the unit:
• User manual (transport, installation, commissioning and maintenance, security warnings),
• Datafromtheselectionprogram–conrmedbythecustomerwhenordering,
• Position of the component in the device – taped on each supplied section.
Supplied with delivery:
• Declaration of conformity or declaration of incorporation,
• Additional drawings for assembly of added elements,
• Instructions for use of the built-in functional components (which are not described in these instructions),
• Unpackinginstructions,
• List of enclosed non-installed equipment,
• Quality protocol.
Supplied with delivery if a unit with a control system is ordered:
• Electrical plan of the built-in electrical control cabinet,
• Instructions for use of the built-in controller or control system,
• Control test,
• Electric control cabinet protocol.
The responsibility of the operator for the operation, control and maintenance of the unit
Upon the commissioning and acceptance of the operating unit from the installer, the unit operates fully automatically.
The operating indications and error indications are displayed via the control system display and signal lights on the
electriccontrolcabinet,orontheseparatehand-heldterminal.Asanalternative,thecontrollermaybelinkedtoa
central monitoring system and new parameters can be set via a PC, tablet or smart phone. Operators do not need to
open the service doors in order to operate the unit.

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Intended use and application options
• KA air handling units are designed to transport and treat air in a temperature range from -20 ºC to +80 ºC.
• At altitudes up to 1,000 m above sea level, the normal operating range of the fans and their electric motors is up to
+40 ºC.
• Units for comfort ventilation (KA HS ...)ofpremisessuchasofces,classrooms,hotels,shops,apartmentsandsimilar
locations where a high level of comfort is required.
• Hygienic-type air handling units (KA HH...) for the ventilation of clean rooms such as operating theatres and similar
premises in health care facilities, rooms in the pharmaceutical industry and the electronics manufacturing industry,
and other rooms with similar requirements.
• Explosion-proof air handling unit versions (KA HS … Ex or KA HH … Ex) for the ventilation of rooms with an explosive
atmosphere. In the case of such units, separate and additional guidelines are provided.
• Indoor air handling unit versions (KA HSI…;KAHHI…)forinstallationindoors–ontheoor,onaplatformorunder
the ceiling.
• Outdoor air handling unit versions (KA HSO…;KAHHO…) for installation outdoors.
Uses other than the intended use
Caution
In the event the unit needs to operate at temperatures exceeding +40 ºC or at altitudes exceeding 1000
mabovesealevel,suchmustbespeciedintheorder.Similarly,anyotherconditionsdeviatingfrom
thoseofintendedusemustalsobespeciedintheorder.
• At altitudes exceeding 1000 m above sea level and at temperatures in the range from +40 ºC to +60 ºC, a reduction
intheelectricmotorcapacityshouldbetakenintoaccount,inaccordancewiththeinstructionsofthemotor
manufacturer.
• In cases where the air temperature exceeds +60 ºC, special versions of the fans and its electric motors should be
applied.
• When so requested, air handling units suitable for air temperatures up to +100 ºC are also available.
• Indoor versions of air handling units designed for indoor installation cannot be installed outdoors.
• Standard and hygienic air handling unit versions cannot be used in environments requiring corrosion protection levels
exceedingthoseprovidedbythematerialsspeciedasstandardanddeterminedinaccordancewiththeminimum
requirementsoftherelevantstandards,orbythematerialsandsolutionsspeciedbythecustomeratthetimeof
ordering the unit.
• Explosion-proof versions of air handling units may not be used in such environments and for such purposes that do
notcorrespondtotheexplosion-protectionlevelspeciedontheunitnameplate.Inthecaseofsuchunits,separate
and additional guidelines are provided.
• The unit’s inside-outside pressure differential may not exceed 2000 Pa.
• Prior to commissioning the unit, all the ducts must be installed and all the guards and protection devices must be in
place to prevent access to the rotating parts of the fans.
• Duringoperation,alltheservicedoorsmustbeclosedandlocked.
• Donotoperatetheunitwithoutinstallinglters.
• Do not operate the unit when external dampers are in closed position.

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2. INSTALLATION
2.1 Loading and transport
Airhandlingunitsmaybedeliveredasasinglecompactpackage(shipmentunit)orinseveralcompactpackages
(shipment units) to be assembled on site. They are delivered on transport pallets or on base frames. Loading, unloading
andmovingshipmentunitsonsitemaybecarriedoutwithaforkliftoracrane,byapplyingappropriatehoistingslings.
Individualcompactpackages(shipmentunits)orthepartsthereofmustbeprotectedsoastopreventdamagethereto
during unloading or transport due to tipping over, sliding or uncontrolled drops from the transport vehicle, and to prevent
threats to the safety and health of exposed persons.
Onsite,individualcompactpackagesorassembliesoftheairhandlingunitshouldbemovedtothemountingsitewith
all the necessary guards and protection devices (stabilisers along diagonals, wooden supports or transport pallets under
the base frame, protection foils, etc.).
Caution
Movement of the equipment during transport can only be carried out via the bottom base frame and
transport pallet, without applying any pressure on the casing.
Unloading and moving with a forklift
Theforkliftforksmustbelongenoughtoavoiddamagetothebottomsurfaceoftheshipmentunitandtopreventthe
shipmentunitfromfallingofftheforks.Inthecaseofshipmentunitswithbaseframes,theforksmustextendfromthe
frontsidetothebacksideoftheframesection.
Inthecaseofshipmentunitswithoutbaseframesbutmountedontransportpallets,theforksmustextendlongenough
beyondtheunit’scentreofgravitytopreventtheriskoftheunitfallingofftheforks.
Unloading and hoisting with a crane
A compact shipment unit of an air handling unit may only be hoisted with a crane applying a base frame or a transport
pallet positioned under the unit.
Appropriatehoistingbeamswithsufcientdistancebetweenthehoistingpointsshouldbeusedsoastopreventthe
hoisting slings from damaging the casing, the gutter or the handles, hinges, piping connections or other accessories
(pressure gauges, pressure transducers, etc.) on the service side, or the electric control cabinet.

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Delivery units with base frame
Liftingbracketsareprovidedonthebaseframeofeachindividualunitforlifting.Forlifting,usesuitableliftingstraps
andusebracketswithsufcientliftinggripspacingorusespacersupportslongenoughtoensurethatthestrapsdonot
press against the casing of the delivered unit.
Caution
Theliftingbracketsareonlyremovedwhentheunitsareinplace,justbeforejoining.Intheeventof
relocation,thebracketsmustbereassembled.
Delivery of units without a base frame
Applyappropriateliftingstripesandliftingbeamswithsufcientdistancebetweenthehoistingpointsoradequate
spacer supports in order to prevent the stripes from pressing against the shipment unit casing.
Caution
Place the lifting straps under the pallet on the outside of the support and secure them against slipping off
the pallet.
High and short shipment units
Someshipmentunits,e.g.asectionwitharotaryheatexchanger,aheatexchanger,etc.,maybeofsignicantheight
with very small length. Extra attention should be devoted to preventing such shipment units from tipping over. In the
factory,suchshipmentunitsareprotectedsoastopreventtheriskoftheirtippingoverduringtransportandstorage
and endangering exposed persons.
Caution
High and short shipment units must be protected against tipping over. They may only be transported in
the vertical position!
1 Spacer
2 Spacing frame
3Lifting strap
4Unit casing
5Lifting brackets
1 Lifting strap
2 Units casing
3Pallet

systemair 13
Storage before installation
Before installation, air handling units must be stored indoors, in dry areas, or be protected against the elements or
other damage in some other appropriate manner. Remove the plastic foil wrapping and cover the equipment with a
waterproof canvas or similar cover, and ensure adequate clearance between the cover and equipment casing. This is
necessarytofacilitatesufcientaircirculationinordertoavoidairhumiditycondensationandtheconsequentcorrosion
of the external surfaces.
Caution
Until connecting the equipment to the ducting, protect the air inlet and outlet openings against the
ingress of dust or other pollutants.
The allowable storage temperature ranges from -25 ° C to +55 ° C.
2.2 Mounting
Clear the space in front of and above the unit
In placing the equipment on the site, provide a clear
area in front of the air handling unit in order to enable
servicing, control and, when necessary, the drawing out
andreplacementoffansandheatexchangers;thewidthof
the area should at least equal the external width of the air
handling unit. In any event, the width of the clear area in
front of air handling unit must not be less than 900 mm.
In the event the electric control cabinet is positioned on
top of the air handling unit, a free space at least 700 mm
in height must be provided between the unit’s top edge
and the ceiling of the room in order to enable safe access
to the cabinet.
In order to facilitate the assembly and joining of shipment
units, a clear space of at least 500 mm in width is also
recommendedatthebacksideoftheunit.
Caution
Wherenotpracticable,themethodofjoiningshipmentunitsmustbespeciedintheorder.
Theaccesstoshipmentunitjoiningpointsfromtheinsidetheunitcasingmustbespecied.
1 Service side 2 Non-serving side BUnit width
The foundation for the unit
Thesupportingsurfacemustbeat,horizontal,freeof
vibrations and capable of supporting the load created by
the air handling unit. The weight of the entire air handling
unit and its individual shipment units are listed in the
technical documentation accompanying the equipment.
Airductsmustbesoundinsulatedandmaynotbexed
directlyonconcretebeams,structuraltimberworkorother
critical structural elements.
In the event of mounting on elevated support platforms,
the means for safe access and servicing must be provided.
In the case of acoustically demanding buildings, the
foundation slab should be isolated from the rest of the
building structure by means of structural noise insulation
ofappropriatethickness,dependingontheairhandling
unit mass and excitation frequency, as well as the
insulation material’s natural frequency.
Inthecaseofunitsthatincludeasprayhumidiersection,
all the other sections should be mounted on a special
steel base or provided an appropriate foundation.
1 Base 2 Antivibration pads BDrain siphon

14 systemair
Caution
The minimum foundation height is determined by the elevation of the drain siphon for the sections
(namely 150 mm).
Supporting legs and adjustable feet
Caution
Supporting legs with adjustable feet are not designed for pulling or pushing of the device across the
ground. All movements require lifting.
Before installing and connecting the unit, the transport screws must be removed and replaced with
adjustable feet.
Supporting legs are made of galvanized sheet metal and already mounted on the supporting frame. To protect the
adjustable feet, a transport screw M12 x 30 mm is mounted on each foot during transport.
The screws on the adjustable feet are adjustable in the range of 30 mm.
Mounting of an outdoor-type unit
Mount the air handling unit on a foundation of adequate height. In determining the foundation height, observe all the
factors that may affect the operation of the unit: the mounting site, the depth of snow cover, requirements for the
intakeairquality,thepositionoftheintakeandextractductconnections,thetypesofconnectorsforheatexchanger
piping, the laying of electric cables, etc.
Mounting of unit without a foundation
The foundation may be substituted by purpose-built legs
with a level-adjustment screw system with an adjustment
range of 30 mm.
Due to siphon installation, there is also the possibility of a
250 mm base frame when feet or a foundation are not an
option.
Base frame
Thebaseframeisalwaysxedtothebottomofthe
air handling unit in the factory. The frame construction
depends on the version and size of the air handling
unit. The dimensions and construction are given to
the customer at the time of delivery in printed form in
a separate envelope or in electronic form by e-mail.
Standard frame height is 125 mm, optional 250 mm.
1 Base 2 Supporting foot BDrain siphon

systemair 15
Caution
The foundation height for an outdoor unit should not be less than 500 mm.
Design the foundation so as to protect the unit or sections thereof against sliding or tipping over under wind loads. To
thisend,carryoutacheckofwindforces.
Uponjoiningandinterconnectingindividualcompactunits,afxtheroofelementsontotheairhandlingunittop
according to the equipment design documents, and ensure that the joints are sealed against water. In the event the roof
elementshavebeenafxedinthefactory,mountingonsiteisnotnecessary;however,sealingthejointsagainstwater
is necessary in this case as well.
Thejointsbetweentheintakeandextractairductingconnectionsandtheductsmustbewatertight.Incaseswhenthe
intakeairintoandextractairoutoftheairhandlingunitrunthroughducts,thejointsbetweentheductconnectionsand
ducts must also be watertight.
For air handling units installed on the roof or at an elevation, provide safe access with a platform if necessary. The
platform in front of the unit service side or around the unit should be constructed so as to avoid the build-up of snow in
frontoftheintakeairopeninginwinter,whichmightleadtoexcessivesnowingressintotheunit.
The platform must ensure safe climbing to and descending from the unit and safe maintenance.

16 systemair
2.3 Assembly
2.3.1 Joining of unit modules
• Delivertheshipmentunittoalocationascloseaspossibletothemountinglocation.Withamanualforklift,hoistthe
shipment unit so as to align its bottom with the foundation’s top surface.
• Slide the shipment unit into its position on the foundation, using stripes or some other appropriate method. You may
need to apply heavy or extra-heavy furniture hauling trolleys.
Caution
Fastening connections are not intended for pulling the modules together. Pulling is done by means of
slings.
Tighteningisrequiredonthebottomoftheunitnearbaseframeorbottomproles.
• Applysealingtapeontheshipmentunit’sjoiningsurfaces(connectingproles).Slideandpresstheshipmentunits
togetherbymeansofslings.Werecommendslingswithbrackets,appliedsoastopreventdamagetothecasings.
• Tighten the thread connections on all the joining elements.
[1] Joining of base frames
This should always be the primary connection.
There are several options for joining you can use with your unit:
1Joining of base frames All units
2Joining of corner
reinforcements Larger units
3Joining of vertical
reinforcements Larger units
4
Joining of internal
connecting elements
(vertically and horisontally)
Depending on size and execution
5
Joining of external
connecting elements
(only vertically)
Smal units and depending on
execution
Fastening material
For each connection the following fastening material is always
supplied:
• 1x Screw DIN 933 Zn M8 x 70
• 1x Nut DIN 934 M8 Zn
• 2x Washer DIN 9021 8,4 Zn

systemair 17
[2] Joining of corner reinforcements
Fastening material
For each connection the following fastening material is always supplied:
• 1x Screw DIN 933 Zn M10 x 40
• 1x Nut DIN 934 M10 Zn
• 2x Washer DIN 9021 10,5 Zn
The material supplied is the same whether it is for a large or small reinforcement.
[3] Joining of vertical reinforcements
Joining of connecting elements
Fastening material
For each connection the following fastening material is always
supplied:
• 1x Screw DIN 933 Zn M10 x 80
• 1x Nut DIN 934 M10 Zn
• 2x Washer DIN 9021 10,5 Zn
Fastening material
For each connection the following fastening material is always
supplied:
• 1x Screw DIN 933 Zn M8 x 40
• 1x Nut DIN 934 M8 Zn
For each connection the following fastening material is always
supplied:
• 1x Screw DIN 933 Zn M8 x 70
• 1x Nut DIN 934 M8 Zn
• 2x Washer DIN 9021 8,4 Zn

18 systemair
2.3.2 Mounting of roof
• Remove the protective foil from the roof and panels.
• Apply3ofthesupplied15x3mmgasketsalongthelengthofeachpartoftheroofbentupwardsina“C”shape.
• Afterconnectingtheunit,applythesupplied15x3mmgasketsontheentiredevicealongtheupperouterproles
(red area in the picture below).
• Lay parts of the roof on the connected unit and position them so that the roof leans over the unit 100 mm at the
front and rear and 70 mm at the connections.
• Fasten the roof parts together with the supplied special screws with a rubber washer.
Fastening material
For each connection the following fastening material is always
supplied:
• 1x Screw DIN 933 A2 M6 x 25
• 1x Nut DIN934 M6 A2
• 2x Washer DIN 9021 6,3 A2 + Ø22/Ø6,7x3 EPDM
• Fasten the roof to the unit with the supplied special self-tapping screws with a rubber washer.
Fastening material
For each connection the following fastening material is always
supplied:
• 1x Screw DIN 7504 K 410 HP 6,3 x 25
• 1x EPDM 22
Caution
Ifpossible,avoidwalkingontheroofwithpointforceduringinstallation.Useboardsformoreuniform
force distribution
Makesurethatthescrewsarealwaysscrewedperpendiculartothedrillingplaneandthatthecorrect
torque is used.

systemair 19
• Attach the sealing plates to the sides of the device where the two roofs meet and screw them on. Since the left and
rightpiecesaredifferent,makesurethatthe“L”fromthecoveralwaysfacesintheotherdirectionthanthe“C”from
the roof, and the gap between the pieces of the roof is always covered.
• Clean the roof of the drill chips and dirt accumulated during installation.
2.3.3 Connection of ducting
Caution
Inallcases,theairhandlingunitmustbeconnectedtotheductingbymeansofexibleconnections.The
exibleconnectionsshouldalwaysbealmostfullystretched(50-90%).
In the case of a centrifugal fan, the dimensions of the duct should be similar to those of the air outlet
opening onto the fan, in order to avoid or minimise losses due to turbulence.
Inspecialcases,e.g.withverticalductruns,buoyancyeffectsmayinduceanairowthatdrives(rotates)
afanimpellerevenwiththedrivemotoroff.Therotatingimpellerposesariskofinjuryduringrepairor
maintenanceworks.Thisdangercanbepreventedbyapplyingmotordriveswithcounter-springsthat
automatically shut the dampers in the event of power supply failure.

20 systemair
2.3.4 Connection of piping
Heat exchangers must be connected to the piping in a manner that enables the free opening of the service doors of
adjacent sections and allows the dismantling and drawing out of heat exchanger components when necessary for
maintenance or replacement purposes.
In order to allow condensate discharge from the pan in the event of negative pressure in the unit, or in order to prevent
airleakagefromtheunitintothedrainpipeintheeventofpositivepressureintheunit,anegativepressureorpositive
pressure siphon must be installed.
Caution
Ifthepipeconnectionsareterminatedontheinsideofthedevice,aholemustbedrilledinthexed
panel to connect the connections to the external manifolds.
• [1]Thepointwhereyouwanttomakeapassageistobelocatedonthepanel,andaholeisdrilledthroughitwitha
holesawwithdimensionsascloseaspossibletothoseshowninthetablebelow(seethe“Hole”column).
• [2] The piping is mounted through the hole as centrally as possible.
• [3] An insulating tube is mounted on the pipe through the hole, as shown in the table below (see column
“Insulation”).Thelengthofthetubemustbeatleast100mmsothatthepipeontheoutsidecoversthepanelat
and no insulation is visible. The inner tube faces inside at least 50 mm.
• [4]Ontheoutside,arubberrosetteisattachedtothetube,asshowninthetablebelow(seecolumn“Rubber”).The
rosette is glued to the panel from the outside and must be aligned with the panel.
• After connecting the external installation, the external pipes must be thermally insulated up to the rubber rosette.
Dimension Coper tube Steel tube
DN Insulation Hole Rubber Insulation Hole Rubber
mm inch mm mm mm mm mm mm
10 3/8 12 x 19 44 10/75 18 x 19 51 15/75
15 1/2 15 x 19 51 15/75 22 x 19 56 20/90
20 3/4 22 x 19 56 20/90 28 x 19 65 25/90
25 1 28 x 19 65 25/90 35 x 19 70 30/90
32 1 1/4 35 x 19 70 30/90 42 x 19 79 40/110
40 1 1/2 42 x 19 79 40/110 48 x 19 79 45/116
50 2 54 x 19 92 50/100 60 x 19 92 56/131
65 2 1/5 64 x 19 102 60/130 76 x 19 111 71/142
80 3 76 x 19 111 71/142 89 x 19 121 82/150
100 4 108 x 19 140 100/170 114 x 19 152 112/180