Trox Technik X-CUBE compact User manual

Air handling unit
X-CUBE compact
Transportation and installation manual
Read the instructions prior to performing any task!
including X-CUBE compact accessories
GB/en

A00000052582, 1, GB/en
© TROX GmbH 2015
TROX GmbH
Heinrich-Trox-Platz
47504 Neukirchen-Vluyn
Germany
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.troxtechnik.com
01/2016
Air handling unit X-CUBE compact2

Information on the transportation and installation
manual
This transportation and installation manual enables
operating or service personnel to use the X-CUBE com-
pact air handling unit (AHU) safely and efficiently.
The transport and installation manual must be kept in
the vicinity of the unit and must be accessible at all
times.
This transport and installation manual is intended for
use by fitting and installation companies, operators, in-
house technicians, technical staff or properly trained
persons, and skilled qualified electricians or air condi-
tioning technicians.
It is essential that these individuals read and fully under-
stand this transport and installation manual before
starting any work. The basic prerequisite for safe
working is to comply with the safety notes and all
instructions in this transportation and installation
manual.
The local regulations for health and safety at work and
the general safety regulations for the area of application
of the air handling unit also apply.
Illustrations in this transport and installation manual are
mainly for information and may vary from the actual
design of the air handling unit.
Copyright
This document, including all illustrations, is protected by
copyright and pertains only to the corresponding unit.
Any use without our consent may be an infringement of
copyright, and the violator will be held liable for any
damage.
This applies in particular to:
Publishing content
Copying content
Translating content
Microcopying content
Saving content to electronic systems and editing it
TROX Technical Service
To ensure that a fault is processed as quickly as pos-
sible, please keep the following information ready:
Delivery date of the TROX components and sys-
tems
TROX order number
Product name
Brief description of the fault
Contact in case of a fault
Online www.troxtechnik.com
Phone [phone]
Limitation of liability
The information in this manual has been compiled with
reference to the applicable standards and guidelines,
the state of the art, and our expertise and experience of
many years.
The manufacturer does not accept any liability for dam-
ages resulting from:
Non-compliance with this manual
Incorrect use
Operation or handling by untrained individuals
Unauthorised modifications
Technical changes
Use of non-approved replacement parts
The actual scope of delivery may differ from the infor-
mation in this manual for bespoke constructions, addi-
tional order options or as a result of recent technical
changes.
The obligations agreed in the order, the general terms
and conditions, the manufacturer's terms of delivery,
and the legal regulations in effect at the time the con-
tract is signed shall apply.
We reserve the right to make technical changes.
Defects liability
For details regarding defects liability please refer to
Section VI, Warranty Claims, of the Delivery and Pay-
ment Terms of TROX GmbH.
The Delivery and Payment Terms of TROX GmbH are
available at www.troxtechnik.com.
Other applicable documentation
In addition to these instructions, the following docu-
ments apply:
Order confirmation
Air handling unit data sheet from TROX GmbH
Product drawings
Supplemental instructions
Air handling unit X-CUBE compact 3

Data sheets for the supplier components, if appli-
cable
Circuit diagram for the air handling unit
Additional drawings, if applicable
Operating manual for X-CUBE compact
Installation and commissioning manual for the X-
CUBE compact accessories
Safety notes
Symbols are used in this manual to alert readers to
areas of potential hazard. Signal words express the
degree of the hazard.
DANGER!
Imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING!
Potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION!
Potentially hazardous situation which, if not avoided,
may result in minor or moderate injury.
NOTICE!
Potentially hazardous situation which, if not avoided,
may result in property damage.
ENVIRONMENT!
Environmental pollution hazard.
Tips and recommendations
Useful tips and recommendations as well as infor-
mation for efficient and fault-free operation.
Safety notes as part of instructions
Safety notes may refer to individual instructions. In this
case, safety notes will be included in the instructions
and hence facilitate following the instructions. The
above listed signal words will be used.
Example:
1. Untighten the screw.
2.
CAUTION!
Danger of finger entrapment when closing
the lid.
Be careful when closing the lid.
3. Tighten the screw.
Specific safety notes
The following symbols are used in safety notes to alert
you to specific hazards:
Warning signs Type of danger
Warning – hand injuries.
Warning - danger of
falling.
Warning – danger zone.
Supplemental instructions
Air handling unit X-CUBE compact4

1 Overview............................................................. 6
2 Safety.................................................................. 8
2.1 System owner's responsibility..................... 8
2.2 Personnel requirements.............................. 8
2.3 Personal protective equipment.................... 9
3 Transport and storage.................................... 10
3.1 Delivering the air handling unit.................. 10
3.1.1 Type of delivery...................................... 10
3.1.2 Symbols on the packaging..................... 10
3.2 Delivery check........................................... 10
3.3 Transporting packages.............................. 11
3.3.1 Safety notes for transport....................... 11
3.3.2 Transporting packages by forklift or
pallet truck.............................................. 12
3.3.3 Transporting packages by crane............ 12
3.4 Storing packages....................................... 15
3.5 Unpacking packages................................. 15
4 Installation and assembly............................... 16
4.1 Safety notes on installation and
assembly................................................... 16
4.2 Requirements for the installation loca-
tion............................................................. 16
4.2.1 Requirements for indoor installation....... 16
4.2.2 Requirements for outdoor installation..... 17
4.3 Insulating the air handling unit from vibra-
tions........................................................... 18
4.4 Setting up and assembling air handling
unit/AHU components............................... 18
4.4.1 Setting up air handling unit/AHU compo-
nents....................................................... 18
4.4.2 Before installation................................... 19
4.4.3 Assembling AHU components................ 20
4.4.4 Installing accessories............................. 23
5 Installation........................................................ 25
5.1 Safety notes on installation....................... 25
5.2 Before installation...................................... 25
5.3 Changing operating side........................... 26
5.4 Connecting siphon to air handling unit...... 27
5.5 Connecting the heater/cooler............... 28
5.6 Connecting the air handling unit to power
supply........................................................ 29
5.7 Connecting the air handling unit to the
building...................................................... 30
5.8 Connecting I&C to on-site PC or on-site
network...................................................... 30
6 Initial commissioning...................................... 31
6.1 Safety notes for the initial commis-
sioning....................................................... 31
6.2 Before initial commissioning...................... 31
6.3 Installing AHU components....................... 32
6.3.1 Filter unit.......................................... 32
6.3.2 Heater/cooler.................................... 32
6.3.3 Multileaf dampers................................. 33
6.3.4 Rotary heat exchanger......................... 34
6.3.5 Droplet eliminator................................... 35
6.3.6 Plate heat exchanger........................... 36
6.3.7 Setting up accessories........................... 36
6.4 Switching on the air handling unit.............. 36
6.4.1 Before switching on................................ 36
6.4.2 Switching on........................................... 36
6.5 Configuring the air handling unit................ 37
6.5.1 Setting up X-CUBE controller communi-
cation...................................................... 37
6.5.2 Setting up network communication........ 38
6.6 Logging in to the web server..................... 39
7 Removal and disposal..................................... 40
7.1 Safety notes on removal and disposal...... 40
7.2 Removal.................................................... 41
7.3 Disposal..................................................... 41
8 FAQ................................................................... 42
9 Index................................................................. 45
Appendix.......................................................... 47
A Aligning storage mass.................................. 49
B Motor drive for rotary heat exchanger.......... 55
C Anti-frost heating for siphons....................... 61
D Circuit diagram tray 230 V AC-PHE............. 64
E Circuit diagram tray 230 V AC-RHE............. 78
F Circuit diagram tray 400 V AC-PHE............. 92
G Circuit diagram tray 400 V AC-RHE.......... 106
H Accessories for X-CUBE compact............. 120
Table of contents
Air handling unit X-CUBE compact 5

1 Overview
Overview with rotary heat exchanger
Fig. 1: Overview with rotary heat exchanger
1 Multileaf dampers
2 Centrifugal fan
3 Rotary heat exchanger
4 Instrumentation and control systems (I&C)
5 Filter unit
6 Centrifugal fan
7 Multileaf dampers
8 Filter unit
FOL Exhaust air (EHA)
ABL Extract air (ETA)
ZUL Supply air (SUP)
AUL Fresh air (ODA)
Overview
Air handling unit X-CUBE compact6

Overview with plate heat exchanger
Fig. 2: Overview with plate heat exchanger
1 Multileaf dampers
2 Filter unit
3 Plate heat exchanger
4 Instrumentation and control systems (I&C)
5 Filter unit
6 Centrifugal fan
7 Multileaf dampers
8 Centrifugal fan
AUL Fresh air (ODA)
ABL Extract air (ETA)
ZUL Supply air (SUP)
FOL Exhaust air (EHA)
Each X-CUBE compact air handling unit consists of several components. The table below ( Ä ‘AHU components’
on page 7) contains the AHU components that can make up the air handling unit. The components and quantities
actually used for the air handling unit are listed in the order-specific X-CUBE compact operating manual.
AHU components
Symbol Designation Symbol Designation
Heating coil Multileaf dampers
(Fig. 1/1+7)
(Fig. 2/1+7)
Cooling coil Centrifugal fan
(Fig. 1/2+6)
(Fig. 2/6+8)
Filter unit
(Fig. 1/5+8)
(Fig. 2/2+5)
Plate heat exchanger
(Fig. 2/3)
Rotary heat exchanger
(Fig. 1/3)
Roof for outdoor installation
Instrumentation and control systems (I&C)
(Fig. 1/4)
(Fig. 2/4)
Overview
Air handling unit X-CUBE compact 7

2 Safety
2.1 System owner's responsibility
Operator
The operator is the person who actually operates the air
handling unit for commercial or business purposes or
who allows third parties to use/operate the unit, and
who bears legal product stewardship for the protection
of the user, personnel, or third parties during operation.
Operator's obligations
The unit is intended for commercial use. The operator of
the device is therefore subject to the legal obligations of
occupational health and safety regulations.
In addition to the safety notes in this manual, the appli-
cable safety, accident prevention, and environmental
regulations for the area of application of the unit must
be observed.
In particular:
The operator must properly integrate the air han-
dling unit into the on-site fire protection concept.
The operator must properly integrate the air han-
dling unit into the on-site lightning protection con-
cept.
The operator must clearly define and regulate the
responsibilities for the transportation, storage,
assembly, installation, commissioning, transfer, and
removal of the unit.
The operator must commission a skilled qualified
electrician to create equipotential bonding.
The operator must ensure that all employees who
work with the air handling unit have read and under-
stood this manual.
The operator must provide the employees with the
required personal protective equipment.
The operator must have all safety equipment tested
regularly to ensure that it is functional and complete.
The operator must comply with the country-specific
legal provisions.
The operator must have technical and hygiene tests
carried out and documented before commissioning
the air handling unit for the first time. The tests are
repeated at regular intervals.
2.2 Personnel requirements
WARNING!
Danger if individuals are insufficiently qualified!
Insufficiently qualified individuals are unable to
assess the risks involved in working with the air han-
dling unit and are in danger of causing severe or
fatal injuries to themselves or those around them.
– Work must only be carried out by specifically
qualified personnel.
– Insufficiently qualified personnel must be kept
out of the working area.
Crane driver
Crane drivers are physically and mentally able to
operate a crane on their own.
Crane drivers have been instructed on how to operate a
crane and have proven this skillset to the operator.
Crane drivers have been commissioned by the operator
to operate cranes. Crane drivers are commissioned in
writing if the crane is non-stationary.
Crane drivers are at least 18 years old.
Forklift drivers
Forklift drivers have acquired the skills required to
operate driver-operated forklift trucks and have been
commissioned in writing by the operator on this basis to
operate one.
HVAC technician
HVAC technicians are individuals who have sufficient
professional or technical training in the field they are
working in to enable them to carry out their assigned
duties at the level of responsibility allocated to them and
in compliance with the relevant guidelines, safety regu-
lations and instructions. HVAC technicians are individ-
uals who have in-depth knowledge and skills related to
HVAC systems; they are also responsible for the profes-
sional completion of the work under consideration.
HVAC technicians are individuals who have sufficient
professional or technical training, knowledge and actual
experience to enable them to work on HVAC systems,
understand any potential hazards related to the work
under consideration, and recognise and avoid any risks
involved.
Skilled qualified electrician
Skilled qualified electricians are individuals who have
sufficient professional or technical training, knowledge
and actual experience to enable them to work on elec-
trical systems, understand any potential hazards related
to the work under consideration, and recognise and
avoid any risks involved.
Safety
Personnel requirements
Air handling unit X-CUBE compact8

2.3 Personal protective equipment
Hearing protection
Hearing protection protects against hearing damage
resulting from noise exposure.
Industrial safety helmet
Industrial safety helmets protect the head against falling
objects, swinging loads, and impacts with stationary
objects.
Protective clothing
Protective clothing is close fitting, with low tear resist-
ance, close fitting sleeves, and no projecting parts. It
prevents entanglement in moving machinery.
Do not wear jewellery.
Protective gloves
Protective gloves are used to protect hands from fric-
tion, abrasions, punctures, or deeper injuries.
Safety harness
The safety harness protects personnel from falling when
there is an increased risk of falling. The risk of falling is
increased when certain height differences are exceeded
and the workspace is not secured by a railing.
The safety harness must be worn in such a way that the
safety rope is connected to the safety harness and to a
secure attachment point; provide shock absorbers if
necessary.
Safety harnesses must only be used by personnel who
have been specifically trained to use them.
Safety shoes
Safety shoes protect the feet against crushing, falling
parts, and slipping on slippery ground.
Safety
Personal protective equipment
Air handling unit X-CUBE compact 9

3 Transport and storage
3.1 Delivering the air handling unit
3.1.1 Type of delivery
Immediately after arrival, check delivered air handling
units for transport damage and completeness,
Ä Chapter 3.2 ‘Delivery check’ on page 10.
Depending on its size, the air handling unit is delivered
either fully assembled or as individual components
screwed onto square timber frames or disposable pal-
lets according to the load distribution. The load distribu-
tion is shown on the unit drawing.
To protect the components from colliding with trans-
port slings, some components attached on the out-
side are supplied unassembled. Components
attached on the outside must be fitted individually on
site and sealed to protect against leaks.
3.1.2 Symbols on the packaging
The following symbol is displayed on the packaging.
This symbol must always be followed during transport.
Additional symbols, notes, and information docu-
ments may also be displayed on the packaging.
These must also be followed.
Lashing point
Fig. 3: Lashing point
The lashing point on the means of transport must be
attached centrally to the packaging unit.
3.2 Delivery check
Sharp edges, sharp corners and thin sheet metal
parts
CAUTION!
Danger of injury at sharp edges, sharp corners
and thin sheet metal parts!
Sharp edges, sharp corners and thin sheet metal
parts of the plate and rotary heat exchangers or of
the cooling or heating coil may cause cuts or
grazes.
– Be careful when working on these components.
– Wear protective gloves, safety shoes and a hard
hat.
Upon receipt, immediately check delivered items for
completeness and transport damage. In case of any
damage or an incomplete shipment, contact the ship-
ping company and your supplier immediately. Note
missing parts and damage on the waybill and have it
confirmed by the driver.
If the process is not followed, no liability for damage will
be accepted.
See the notes on shipping damage on the pack-
aging or in the shipping papers.
Damage claims cannot be processed unless the fol-
lowing actions are carried out. In both cases below, con-
tact TROX before installing the AHU components.
External damage to packaging.
Unpack the goods in the presence of the shipping
agent and have the damage certified on the ship-
ping contract.
Photograph the damage.
Report the damage to TROX immediately.
No external damage to packaging, contents dam-
aged.
Photograph the damage.
Report the damage to TROX immediately in writing.
Note that shipping damage must be reported within
four days of delivery.
Transport and storage
Delivery check
Air handling unit X-CUBE compact10

3.3 Transporting packages
3.3.1 Safety notes for transport
Improper transport
WARNING!
Danger of death if transported improperly!
Danger of death if packages are lifted without the
designated transport equipment and fastenings or if
they fall during transportation.
– Transport packages in operating position only
– Never stop under suspended loads
– Never transport additional loads with the
package
– Only use the proper attachment points
– Never directly or indirectly load supply or outlet
connections
– Only use suitable and approved hoisting devices
and lifting gear with sufficient load-bearing
capacity
– Never knot ropes and chains or place them on
sharp edges
– Only load transport equipment vertically
– Ensure that the ropes, belts, and chains do not
twist
– Only lift packages using correctly assembled
and mechanically secured transport equipment
and fastenings
– Fix and secure all doors, dampers, and panels
– Carefully transport the packages without any
jerky movements and lower them when leaving
the workplace
– Transport slings are designed for single use only
and not for permanent unit attachment
– Transport tubes are designed for single use only
and not for permanent unit attachment
Eccentric centre of gravity
WARNING!
Falling or tilting packages may cause injury!
Packages may have an eccentric centre of gravity. If
they are incorrectly attached, packages may tilt and
fall. Falling or tilting packages can cause serious
injuries.
– Note the markings and information on the pack-
ages concerning the centre of gravity
– When transporting packages by crane, attach
the crane hook so that it is located above the
centre of gravity of the packages
– Lift the packages carefully and watch whether
they tilt If required, change attachment
Indicating the centre of gravity on the packaging
Fig. 4: Shipping labels
Shipping labels are attached to the packaging to indi-
cate the centre of gravity (Fig. 4).
Sharp edges, sharp corners and thin sheet metal
parts
CAUTION!
Danger of injury at sharp edges, sharp corners
and thin sheet metal parts!
Sharp edges, sharp corners and thin sheet metal
parts of the plate and rotary heat exchangers or of
the cooling or heating coil may cause cuts or
grazes.
– Be careful when working on these components.
– Wear protective gloves, safety shoes and a hard
hat.
Physical damage during transport
NOTICE!
Improper transport can cause physical damage!
Improper transport can cause packages to fall or
topple. This can cause a significant amount of
damage.
– Avoid setting down or knocking the packages
with excessive force Look out for protruding
AHU components
– Make sure that roof material on air handling
units intended for outside installation is not dam-
aged by the hoisting devices and lifting gear
Transport and storage
Transporting packages > Safety notes for transport
Air handling unit X-CUBE compact 11

3.3.2 Transporting packages by forklift or
pallet truck
The attachment points and weights vary depending on
the air handling unit design. These must be taken from
the order-specific technical documents.
Personnel:
Forklift drivers
Protective equipment:
Industrial safety helmet
Protective clothing
Hearing protection
Safety shoes
Protective gloves
NOTICE!
Forklifts or pallet trucks can cause physical
damage!
Improper transportation with forklifts or pallet trucks
may damage the AHU components.
– Never use forklifts to lift packages without suffi-
ciently protecting the unit profiles if there is no
base frame
Fig. 5: Transport with a forklift
1. Drive the forks (Fig. 5/3) of the forklift between the
square timber frames (Fig. 5/2) until they protrude
from underneath the base frame (Fig. 5/1) on the
opposite side.
2. Ensure that an eccentric centre of gravity will not
cause the AHU component to tip.
3. Slowly lift the AHU component and begin trans-
portation.
3.3.3 Transporting packages by crane
Transport with transport tubes and ropes/chains
AHU components can either be transported with ropes/
chains or transport tubes.
The transport tube length depends on the width of the
AHU components. The table below ( Ä ‘Transport
tubes’ on page 12) shows the recommended min-
imum lengths for the transport tubes.
Transport tubes
Width of the AHU com-
ponent (clearance
dimension) in [mm]
Length of the transport
tube in [mm]
612 1058
918 1364
1224 1670
The transport tubes are not included in the air handling
unit supply package. Only use transport tubes with suffi-
cient load-bearing capacity according to the table
Ä ‘Transport with transport tubes and ropes/chains’
on page 12 for transportation.
Designa-
tion
Outer
diameter in
[mm]
Wall thick-
ness [mm]
Permis-
sible AHU
component
weight in
[kg]
S235J2H
seamless
steel tube
48.3 5 £ 1500
Alternative tubes with the same load-bearing capacity or
higher may also be used.
Personnel:
Crane driver
Protective equipment:
Industrial safety helmet
Protective clothing
Hearing protection
Safety shoes
Protective gloves
Transport and storage
Transporting packages > Transporting packages by crane
Air handling unit X-CUBE compact12

NOTICE!
Cranes can cause physical damage!
Improper transportation by crane may damage the
AHU components.
– Protect the edges of the AHU components with
spacers.
– Keep transport chains or ropes away from each
other in the top section with suitable spreaders.
Fig. 6: Transport with crane and transport tubes
1. Remove the base frame plugs from the drilled
holes in the base frame (Fig. 6/5) of the AHU com-
ponents.
2. Push transport tubes (Fig. 6/4) through the drilled
holes in the base frame.
3. Place the loops of the chains or ropes (Fig. 6/2)
around the end of the tubes.
DANGER!
Danger due to chains or ropes slipping off
Potentially fatal situations may occur if the
chains or ropes slip off the transport tubes.
Suitable measures must be taken to prevent
this from happening.
4. Protect the edges with spacers (Fig. 6/3).
5. Keep chains or ropes away from each other in the
top section with suitable spreaders (Fig. 6/1).
6. Ensure that the AHU component is not damaged
by the chains or ropes.
7. Align the attachment with the centre of gravity to
ensure a symmetrical load distribution.
8. Slowly lift the AHU component and begin trans-
portation.
Transporting units for inside installation with
beckets/ring nuts and ropes/chains
Without cross member
Personnel:
Crane driver
Protective equipment:
Industrial safety helmet
Protective clothing
Hearing protection
Safety shoes
Protective gloves
WARNING!
Danger of death due to falling AHU components.
Overloaded attachment points may result in falling
AHU components. Danger of death.
– Only use beckets to transport AHU components
for indoor installation up to a maximum weight of
1500 kg.
Fig. 7: Transport with crane and beckets or ring nuts
(without cross member)
1. Remove the covers from the threaded holes in the
roof-side corners of the AHU components.
2. Screw all beckets or ring nuts (Fig. 7/2) fully into
all threaded holes.
3. Fix the ropes or chains (Fig. 7/1) to the beckets or
ring nuts.
Transport and storage
Transporting packages > Transporting packages by crane
Air handling unit X-CUBE compact 13

Crane gear (cross member and tackle) is rec-
ommended when there are six or more attach-
ment points.
4. Maintain an angle greater than 45° between the
rope or chain and the top of the unit.
5. Do not exceed an angle of spread of 60°.
6. Ensure that the AHU component is not damaged
by the chains or ropes.
7. Align the attachment with the centre of gravity to
ensure a symmetrical load distribution.
8. Slowly lift the AHU component and begin trans-
portation.
With cross member
Personnel:
Crane driver
Protective equipment:
Industrial safety helmet
Protective clothing
Hearing protection
Safety shoes
Protective gloves
WARNING!
Danger of death due to falling AHU components.
Overloaded transport slings may result in falling
AHU components. Danger of death.
– Only use transport slings to transport AHU com-
ponents for indoor installation up to a maximum
weight of 1500 kg.
Fig. 8: Transport with crane and beckets or ring nuts
(with cross member)
1. Remove the covers from the threaded holes in the
roof-side corners.
2. Screw all beckets or ring nuts (Fig. 8/1) fully into
all threaded holes.
3. Hook the cross members (Fig. 8/3) into the
beckets or ring nuts.
4. Connect the cross members with chains (Fig. 8/2).
Transport and storage
Transporting packages > Transporting packages by crane
Air handling unit X-CUBE compact14

5. Do not exceed an angle of spread of 60°.
6. Align the attachment with the centre of gravity to
ensure a symmetrical load distribution.
7. Slowly lift the AHU component and begin trans-
portation.
3.4 Storing packages
Only store TROX air handling units temporarily under
the following conditions:
Free from dust and dirt and protected against
damage
Packaged and stored away from the effects of the
weather
Package air handling units/AHU components that
are supplied without protective packaging
Select the required protective packaging to ensure
adequate rear ventilation and to eliminate the
danger of condensation forming
Set down on even ground
Ensure an air temperature from -10 °C to +50 °C
Store air handling units/AHU components in a dry,
non-condensing atmosphere
Close off any open ventilation connections
NOTICE!
White rust can cause physical damage!
The packaging and moisture can cause white rust to
form on the galvanised surfaces of the heat
exchangers. This can lead to physical damage.
– Always keep the heat exchangers dry in
storage.
– Remove protective film.
In some circumstances, the packages may include
storage information that is more detailed than the
requirements specified here. Follow these accord-
ingly.
3.5 Unpacking packages
Only dispose of packaging shortly before installation if
there is no transport damage, Ä Chapter 3.2 ‘Delivery
check’ on page 10.
ENVIRONMENT!
Incorrectly disposing of the packaging can be
bad for the environment!
Packaging materials can, in many cases, be recon-
ditioned and recycled. Incorrectly disposing of pack-
aging materials can be dangerous for the environ-
ment.
– Dispose of packaging materials in an environ-
mentally friendly manner in accordance with the
local waste disposal regulations.
– If necessary, employ a specialist disposal com-
pany to dispose of the packaging.
Transport and storage
Unpacking packages
Air handling unit X-CUBE compact 15

4 Installation and assembly
The air handling unit must be assembled after delivery
and safety devices must be installed if it is delivered as
several components.
4.1 Safety notes on installation and
assembly
Setup and assembly
WARNING!
Danger of death if set up and assembled incor-
rectly!
Errors when setting up and assembling the AHU
components can lead to potentially fatal situations
and cause significant physical damage. Further-
more, there is also a risk that the air handling unit
will not function correctly as a result.
– Air handling units must only be set up and
assembled by systems mechanics for sanitary
engineering, heating engineering and air condi-
tioning systems.
Working at great heights
WARNING!
Danger of falling when carrying out work at
great heights.
Working at great heights without safety equipment
and using unsuitable or damaged climbing aids can
cause people or materials to fall. This can result in
serious injuries or even death.
– When working at great heights, personnel must
use suitable climbing aids that are in good order
and condition.
– Secure tools and materials against falling.
– Always wear safety shoes, protective work
clothing, and a safety helmet.
– Wear a safety harness.
Combination with units/systems
WARNING!
Danger of injury as a result of combining with
other units/systems.
Combining the air handling unit with other units/sys-
tems, e.g. media supply, ducts, etc., can lead to
dangerous situations, injuries, or even death.
– Ensure that other units/systems are properly
connected to the air handling unit.
– The operator/system manufacturer is respon-
sible for planning and installing the additional
safety equipment.
Sharp edges, sharp corners and thin sheet metal
parts
CAUTION!
Danger of injury at sharp edges, sharp corners
and thin sheet metal parts!
Sharp edges, sharp corners and thin sheet metal
parts of the plate and rotary heat exchangers or of
the cooling or heating coil may cause cuts or
grazes.
– Be careful when working on these components.
– Wear protective gloves, safety shoes and a hard
hat.
4.2 Requirements for the installation
location
4.2.1 Requirements for indoor installation
Installation room
The air handling unit must only be installed in a room
that meets the following conditions:
The air handling unit must not be used in potentially
explosive atmospheres.
The room has been designed in a way that is com-
pliant with the applicable building codes, with partic-
ular regard to the specific functions of the technical
systems installed. Country-specific standards for
plant rooms must be considered, if applicable
The room is:
– clean
– dry
– free from conductive dust particles
– free from strong electromagnetic fields
– free from aggressive media
– free from frost, and
– fitted with a correctly functioning drainage
system
Installation and assembly
Requirements for the installation loca... > Requirements for indoor installation
Air handling unit X-CUBE compact16

The space required for installing, operating, serv-
icing, and repairing all AHU components has been
taken into consideration The maintenance access is
at least as deep as the units
The room must provide a stable and flat foundation
in accordance with the site requirements (see order-
specific air handling unit data sheet from TROX)
Never use the air handling unit for static tasks or as
the building roof
Leaking water
NOTICE!
Physical damage as a result of leaking water!
If the water-carrying system is not sealed tightly and
water leaks out, it may cause significant damage to
the building.
– Ensure that leaking liquids are diverted away
Condensation
NOTICE!
Condensation can cause physical damage!
When the system is at a standstill and outdoor tem-
peratures are low, water vapour from the building or
the environment may condense in the air handling
unit.
– Prevent condensation from forming with the help
of shut-off dampers facing towards the building,
or by using a heating coil.
Installation room foundation
The installation room foundation must fulfil the following
requirements:
The foundation consists of horizontal, flat and stable
concrete or a flat steel substructure
The natural frequency of the substructure, particu-
larly in the case of steel structures, is sufficiently dif-
ferent from the excitation frequency of rotary compo-
nents, such as fans, motors, pumps, refrigerant
condensers, etc.
For air handling units with condensate drains, the
height of the substructure is at least as high as the
siphon, see
Ä ‘Connecting siphon’ on page 27
For the additional damping of structure-borne noise
– for example, with rubber or elastomer boards –
between the foundation and air handling unit, make
sure all AHU components are precisely aligned
(movement of doors, proper sealing at connections)
4.2.2 Requirements for outdoor installa-
tion
Installation location
The following points must be observed for air handling
units for outdoor installation:
The installation location is:
– not an area with a potentially explosive atmos-
phere
– free from conductive dust particles
– free from strong electromagnetic fields
– free from aggressive media, and
– fitted with a correctly functioning drainage
system
The installation location must provide a stable and
flat foundation in accordance with the site require-
ments (see order-specific air handling unit data
sheet from TROX)
The space required for installing, operating, serv-
icing, and repairing all AHU components has been
taken into consideration The maintenance access is
at least as deep as the units
The installation location must be secured to prevent
persons, tools, and materials from falling in accord-
ance with local regulations
Suitable fall protection equipment must be available
The AHU components must not be accessible to
unauthorised persons
All AHU components must be accessible without
posing a danger to people
The maximum permissible roof loads, the building
structural engineering calculations, and external
influences such as rain, snow, wind, direct sunlight,
etc., must be taken into consideration
Cabling between the air handling unit and the
external switch cabinet must be carried out by a pro-
fessional and with due regard to external influences
such as rain, snow, wind, direct sunlight, etc.
All media lines and the AHU components to which
they are connected must be frost-proof
Never use the air handling unit for static tasks or as
the building roof
Foundations in the outdoor area
The information regarding the foundation of the
installation room applies,
Ä ‘Installation room foun-
dation’ on page 17
For roof installation, check the load capacity and
support structure of the roof; consult an engineer if
necessary
There must be a continuous steel substructure
along the entire length of the air handling unit
The steel substructure supports must be designed in
such a way that the maximum deflection under load
is L/500 (L = support length). A maximum deflection
under load of 10 mm must not be exceeded
Installation and assembly
Requirements for the installation loca... > Requirements for outdoor installation
Air handling unit X-CUBE compact 17

Waterproof the edge of the roof under the air han-
dling unit and also the gutters and structural fea-
tures on the roof
Insulate on-site base frames to prevent condensa-
tion
In areas with heavy snowfall, choose an installation
location where snow will not affect the operation of
the air handling unit. Select the height of the sub-
structure accordingly.
Leaking water
NOTICE!
Physical damage as a result of leaking water!
If the water-carrying system is not sealed tightly and
water leaks out, it may cause significant damage to
the building.
– Ensure that leaking liquids are diverted away
4.3 Insulating the air handling unit
from vibrations
Where applicable, bases that insulate vibrations and
noise can be used to reduce the transfer of vibrations to
the support structure:
For installation on flat ground with no special
requirements regarding structure-borne sound insu-
lation, TROX recommends isolating the air handling
unit from the foundation, e.g. using rubber or elas-
tomer boards
For sound installation, the requirements and the
sound power level of the air handling unit (see
order-specific air handling unit data sheet from
TROX) must be compared and the required meas-
ures must be determined by an acoustician. Splitter
sound attenuators can be used for sound insulation
purposes if applicable.
4.4 Setting up and assembling air han-
dling unit/AHU components
4.4.1 Setting up air handling unit/AHU
components
Check seals on AHU components
Fig. 9: Seals on AHU components
The AHU components are fitted with seals (Fig. 9/1) on
the right-hand side ex works The left-hand sides of the
components do not have seals (Fig. 9/2)
Personnel:
HVAC technician
Protective equipment:
Protective gloves
Deformed seals return to their original form
approx. 60 min after the transport fastenings
have been removed.
Check that the seals are complete and intact and
that they fulfil the sealing function.
Installation and assembly
Setting up and assembling air handling... > Setting up air handling unit/AHU com...
Air handling unit X-CUBE compact18

Setting up AHU components
Personnel:
HVAC technician
Protective equipment:
Industrial safety helmet
Safety shoes
Protective gloves
Sliding plates (Fig. 10/3) significantly simplify the
process of positioning the AHU components (Fig. 10/1)
on ground with a high friction coefficient (e.g. rubber or
elastomer boards (Fig. 10/4)).
The AHU components must be arranged in the air
handling unit in accordance with the order-specific
approval drawing.
Fig. 10: Unit connections in vibration-reducing installa-
tions
1.
The different weights of the AHU components
compress the rubber or elastomer boards dif-
ferently. Adjust the resulting height difference
on site.
The sliding plates provided by others (Fig. 10/3)
must be positioned under the unit base (Fig. 10/2)
of the individual AHU components (Fig. 10/1).
2.
When installing outdoors, ensure that the self-
adhesive sealing tape can still be attached,
see
Ä ‘Assembling AHU components in the
outdoor area’ on page 20.
Assemble the AHU components as close together
as possible.
Fig. 11: Aligning AHU components
3. Align the AHU components so that they are flush
with one another (Fig. 11/1).
Setting up with base
Fig. 12: Attaching a tension belt
1. Attach a tension belt to the base of 2 AHU compo-
nents (Fig. 12).
2. Tighten tension belt.
ðThe AHU components are pulled together by
the base.
4.4.2 Before installation
Before installation
All transport tubes and other transport fastenings on
and in the AHU components must be removed
All tools must be present
All other applicable documents must be present
All materials and accessories supplied separately
must be removed from the AHU components
Deformed seals return to their original form approx.
60 min after the transport fastenings have been
removed.
Installation and assembly
Setting up and assembling air handling... > Before installation
Air handling unit X-CUBE compact 19

Required tools
Drill/cordless screwdriver
Bit holder with bit set
Allen key (width across flats: 3, 5, 6, 10)
Slot screwdriver size 6
Bits (Torx/rounded hexagon socket (T30))
Open-end spanner/ring spanner (width across flats:
6 and 10)
Water pump pliers
Tension belts or suitable lifting gear
4.4.3 Assembling AHU components
Assembling AHU components in the outdoor area
Personnel:
HVAC technician
Protective equipment:
Safety harness
Industrial safety helmet
Protective clothing
Hearing protection
Safety shoes
Protective gloves
Materials:
Self-adhesive sealing tape
Hexagonal bolts with nuts and washers
Raised countersunk screws, M6 x 12
Roof segment with pre-installed roof supports
2 x roof supports
4 x cylinder screws
4 x ring seals
Self-tapping screws
When installing the air handling unit in the outdoor area,
proceed as follows:
Fig. 13: Aligning AHU components
1. Align the AHU components so that they are flush
with one another (Fig. 13/1).
Roof installation
2. Attach ring seals to the four cylinder screws.
Fig. 14: Roof supports
Installation and assembly
Setting up and assembling air handling... > Assembling AHU components
Air handling unit X-CUBE compact20