Trox Technik X-CUBE User manual

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

A00000044720, 7, GB/en
© TROX GmbH 2016
TROX GmbH
Heinrich-Trox-Platz
47504 Neukirchen-Vluyn
Germany
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.troxtechnik.com
02/2020
Air handling unit X-CUBE2

Information on the transportation and installation
manual
This transport and installation manual enables operating
or service personnel to use the X-CUBE air handling
unit (AHU) safely and efficiently.
The manual must be kept near the unit to be available
for use 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 manual before starting any work. The basic
prerequisite for safe working is to comply with the safety
notes and all instructions in this 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 differ from the actual
design of the air handling unit.
Other applicable documentation
In addition to these instructions, the following docu-
ments apply:
Order-specific approval drawing
Order-specific air handling unit data sheet from
TROX
Data sheets for components from other suppliers, if
any
Circuit diagram for air handling unit with controls
Additional drawings, if any
X-CUBE operating manual
TROX Technical Service
To ensure that your request is processed as quickly as
possible, please keep the following information ready:
Product name
TROX order number
Delivery date
Brief description of the fault
Online www.troxtechnik.com
Phone [phone]
Copyright
This document, including all illustrations, is protected by
copyright and pertains only to the corresponding
product.
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
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.
Supplemental instructions
Air handling unit X-CUBE 3

Safety notes
Symbols are used in this manual to alert readers to
areas of potential hazard. Signal words express the
degree of the hazard.
Comply with all safety instructions and proceed carefully
to avoid accidents, injuries and damage to property.
DANGER!
Imminently hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING!
Potentially hazardous situation which, if not avoided,
may 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 informa-
tion for efficient and fault-free operation.
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 – suspended
load.
Warning – danger zone.
Additional markers
In order to highlight instructions, results, lists, refer-
ences and other elements, the following markers are
used in this manual:
Marker Explanation
1., 2., 3. ...
Step-by-step instructions
ðResults of actions
References to sections in this
manual and to other applicable
documents
Lists without a defined sequence
[Switch] Operating elements (e.g. push but-
tons, switches), display elements
(e.g. LEDs)
‘Display’ Screen elements (e.g. buttons or
menus)
Supplemental instructions
Air handling unit X-CUBE4

1 Overview............................................................. 6
2 Safety.................................................................. 7
2.1 System owner's responsibility..................... 7
2.2 Personnel requirements.............................. 7
2.3 Personal protective equipment.................... 8
3 Transport and storage....................................... 9
3.1 Delivery of the air handling unit................... 9
3.1.1 Complete and partial units........................ 9
3.1.2 Symbols on the packaging....................... 9
3.2 Delivery check............................................. 9
3.3 Moving packages...................................... 10
3.3.1 Safety notes regarding transport............ 10
3.3.2 Moving packages with a forklift or pallet
truck........................................................ 11
3.3.3 Moving packages with a crane............... 12
3.4 Storage and functional integrity................. 17
3.4.1 Storage................................................... 17
3.4.2 Functional integrity of the unit compo-
nents....................................................... 17
3.5 Unpacking................................................. 18
3.5.1 Removing transport protection devices.. 18
4 Setup and assembly........................................ 20
4.1 Safety notes.............................................. 20
4.2 Requirements for the installation loca-
tion............................................................. 20
4.2.1 Requirements for indoor installation....... 21
4.2.2 Requirements for outdoor installation..... 21
4.3 Preventing vibration and structure-borne
noise.......................................................... 22
4.4 Setting up and assembling the air han-
dling unit.................................................... 22
4.4.1 Setting up the AHU or AHU casing
units........................................................ 22
4.4.2 Assembling AHU casing units................ 24
4.4.3 Installing the plate heat exchanger......... 28
4.4.4 Additional assembly steps for outdoor
units........................................................ 35
4.4.5 Installing accessories............................. 38
5 Installation........................................................ 39
5.1 Safety notes regarding installation............ 39
5.2 Before installation...................................... 39
5.3 Sizing and connecting the condensate
drain.......................................................... 40
5.4 Connecting the heating coil/cooling
coil............................................................. 42
5.5 Connecting the run around coil system.. 43
5.6 Wiring........................................................ 45
5.7 Connecting the air handling unit to the
power supply............................................. 46
5.8 Integrating the air handling unit with the
central BMS............................................... 47
5.9 Connecting the controls to your PC or
local network............................................. 47
5.9.1 X-CUBE controller CX8090.................... 47
5.9.2 X-CUBE controller CX9020.................... 50
6 Initial commissioning...................................... 55
6.1 Safety notes regarding initial commis-
sioning....................................................... 55
6.2 Before initial commissioning...................... 55
6.3 Setting up and adjusting AHU casing
units........................................................... 55
6.3.1 Inspection access doors......................... 55
6.3.2 Centrifugal fan................................... 56
6.3.3 Filter................................................ 58
6.3.4 Heating coil/cooling coil.................... 59
6.3.5 Electric air heater................................... 60
6.3.6 Run around coil system....................... 60
6.3.7 Multileaf dampers................................ 61
6.3.8 Sound attenuator............................. 62
6.3.9 Rotary heat exchanger........................ 62
6.3.10 Plate heat exchanger........................ 63
6.3.11 Humidifier........................................... 64
6.3.12 Electrical system.................................. 64
6.4 Starting the air handling unit...................... 64
6.4.1 Before you start the AHU....................... 64
6.4.2 Starting................................................... 65
7 Removal and disposal..................................... 66
7.1 Safety notes regarding disassembly and
disposal..................................................... 66
7.2 Disassembly.............................................. 67
7.3 Disposal..................................................... 67
8 Glossary........................................................... 68
9 Index................................................................. 69
Appendix.......................................................... 71
A Adjusting the storage mass.......................... 72
B Assembling plate heat exchangers.............. 79
C Installing a frost protection device for the
drain trap...................................................... 93
D Electric air heater......................................... 95
Table of contents
Air handling unit X-CUBE 5

1 Overview
Fig. 1: X-CUBE overview
An X-CUBE air handling unit is shipped either fully assembled or in parts, depending on its size. The following table
lists the components, or casing units, that can make up an air handling unit. The components actually used for a
particular air handling unit are listed in the order-specific technical data sheet.
AHU casing units
Symbol Meaning Symbol Meaning
Heating coil Multileaf dampers
Cooling coil Humidifier
Filter Run around coil system
Centrifugal fan Hydraulic unit for run around coil system
Rotary heat exchanger Plate heat exchanger
Sound attenuator Controls
Touch panel
Overview
Air handling unit X-CUBE6

2 Safety
2.1 System owner's responsibility
System owner
The system owner is a natural or legal person who for
commercial or business purposes owns or manages the
air handling unit or allows third parties to use or operate
it, but continues to bear legal responsibility for the safety
of users, staff or third parties while the product is in use.
System owner's obligations
The unit is intended for commercial use. The system
owner 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 regulations for safety, accident prevention and
environmental protection must also be complied with.
In particular:
The system owner must establish on site a coherent
fire protection strategy and include the air handling
unit in this strategy.
The system owner must establish on site a coherent
lightning protection strategy and include the air han-
dling unit in this strategy.
The system owner must name responsible persons
for transport, storage, assembly, installation, com-
missioning, transfer, disassembly and removal of the
unit.
The system owner must commission a skilled quali-
fied electrician to create equipotential bonding.
The system owner has to ensure that all individuals
who handle or use the air handling unit have read
and understood this manual.
The system owner must provide the employees with
the required personal protective equipment.
The system owner must have all safeguards tested
regularly to ensure that they are functional and com-
plete.
The system owner must ensure compliance with the
national legal provisions.
The system owner must have technical and hygiene
tests carried out and documented before commis-
sioning the air handling unit for the first time. The
tests have to be repeated at regular intervals.
2.2 Personnel requirements
WARNING!
Danger of injury or risk of damage to property
due to insufficiently qualified individuals!
Insufficiently qualified individuals are not aware of
the risks involved in working with the air handling unit
and are hence likely to put themselves or others into
danger, causing severe or fatal injuries.
– Have any work carried out only by qualified per-
sonnel.
– Keep insufficiently qualified individuals away
from the work area.
Crane driver
Crane drivers are physically and mentally able to
operate a crane on their own.
Crane drivers are qualified to operate a crane and have
proven the required skillset to the system owner.
Crane drivers are commissioned by the system owner
to move units from the delivery truck to the installation
location. Crane drivers are commissioned in writing if
the crane is a mobile crane.
Crane drivers have to be at least 18 years old.
Forklift driver
Forklift drivers are qualified to operate driver-operated
forklift trucks; they are commissioned in writing by the
system owner to operate such a truck.
Forklift drivers are responsible for moving pallets.
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.
Network administrator
Network administrators design, install, configure and
maintain the IT infrastructure in companies or organisa-
tions.
Safety
Personnel requirements
Air handling unit X-CUBE 7

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.
2.3 Personal protective equipment
Description of personal protective equipment
Hearing protection
Hearing protection protects against hearing damage
resulting from noise exposure.
Industrial safety helmet
Industrial safety helmets protect the head from falling
objects, suspended loads, and the effects of striking the
head against stationary objects.
Protective clothing
Protective clothing is close-fitting, with low tear resist-
ance, close-fitting sleeves, and no projecting parts.
Protective gloves
Protective gloves protect hands from friction, abrasions,
punctures, deep cuts, and direct contact with hot sur-
faces.
Safety harness
A safety harness protects people from a fall when they
are working at height. You are at risk from a fall if the
task is at height and if there is no railing in place.
When you put on a safety harness, connect it via an
energy-absorbing lanyard to a suitable anchor point.
Safety harnesses must only be used by individuals who
have been specifically trained to use them.
Safety shoes
Safety shoes protect the feet against crushing, falling
parts, and from slipping on slippery ground.
Safety
Personal protective equipment
Air handling unit X-CUBE8

3 Transport and storage
3.1 Delivery of the air handling unit
3.1.1 Complete and partial units
Upon delivery, check the air handling unit for transport
damage and completeness, Ä Chapter 3.2 ‘Delivery
check’ on page 9.
Depending on its size, the air handling unit is shipped
either fully assembled or in parts, with the individual
components or casing units screw-fixed to square edge
timber frames or disposable pallets.
The number of parts is shown on a drawing on the
package.
External components may be shipped unassembled
to protect them from getting entangled with transport
slings while being moved. These components have
to be properly installed and sealed by others.
3.1.2 Symbols on the packaging
The packaging carries the following marks and symbols.
Be sure to follow them when you are moving the unit.
The packaging may also carry other symbols, notes,
and information. These must also be followed.
Accessories
Fig. 2: Accessories
Packages with this sticker contain AHU accessories.
3.2 Delivery check
Check delivered items immediately after arrival for
transport damage and completeness. In case of any
damage or an incomplete shipment, contact the ship-
ping company and your supplier immediately. If any
parts are missing, have the driver confirm them on the
consignment note.
Otherwise the manufacturer will not accept any liability.
See the notes on shipping damage on the packaging
or in the shipping papers.
For any claims it is necessary that you follow the proce-
dure below. In each of the following cases do contact
TROX before you start installing a unit.
The packaging has been damaged
Unpack the goods in the presence of the person
who has delivered the goods and have them confirm
the damage on the shipping order.
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 9

3.3 Moving packages
3.3.1 Safety notes regarding transport
Improper transport equipment
WARNING!
Risk to life from using improper transport equip-
ment!
If packages are lifted without adequate transport
equipment and if they are not properly secured, they
may fall off and lead to fatal injuries.
– Move components only in the position in which
they are to be installed.
– Stand clear of suspended loads.
– Do not move additional loads on top of a
package.
– Use only the intended lashing points.
– Make sure that no load is imposed on pipes,
ducts or cables.
– Use only approved lifting gear and slings that are
suitable and sufficient for the load to be carried.
– Do not tie ropes and chains or make knots or
place them on sharp edges.
– Use lifting equipment only to lift packages or
units, not to push or pull them.
– Ensure that ropes, belts and chains do not twist.
– Ensure that transport equipment has been cor-
rectly assembled, fastened and secured before
you use it to lift anything.
– Secure all doors, dampers and panels.
– Move packages without any jerky movements
and put them down when you leave your work-
place.
– Lifting eyes are designed for one-time use only
and not for permanently suspending loads.
– Transport tubes are designed for one-time use
only and not for permanently suspending loads.
Warning: AHU casing units may tip over
WARNING!
Risk of injury from AHU casing units tipping
over!
Tall AHU casing units with a small footprint, e.g.
rotary heat exchangers, may easily tip over and
therefore pose an increased risk during unloading,
transportation and installation.
Be sure to take adequate precautions:
– Use additional means to secure the casing units,
e.g. ratchet straps (by others).
– Use only lifting and transport gear designed for
the required load.
– Keep the casing units secured against shifting
and tipping over until installation is complete.
Unbalanced loads and centre of gravity
WARNING!
Risk of injury from falling or toppling loads!
Loads may be unbalanced, i.e. the centre of gravity
may not be obvious. If the load is not properly
attached to the lifting equipment, it may topple and
fall. Falling or toppling loads can cause serious inju-
ries.
– Note that the centre of gravity is marked on each
package.
– When you use a crane to move loads, ensure
that the centre of gravity of the load is directly
beneath the crane hook.
– Lift any load carefully and keep an eye on it to
see whether it will stay in place. If required,
change the lashing point(s).
Transport and storage
Moving packages > Safety notes regarding transport
Air handling unit X-CUBE10

Sticker indicating the centre of gravity
Fig. 3: Shipping stickers
Stickers on the packaging indicate the centre of gravity
(Fig. 3).
Sharp edges, sharp corners and thin sheet metal
parts
CAUTION!
Danger of injury from sharp edges, sharp cor-
ners and thin sheet metal parts!
Sharp edges, sharp corners and thin sheet metal
parts of the heat exchanger 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.
Damage to goods being moved
NOTICE!
Risk of damage to property due to the incorrect
handling or lifting of units!
If you handle or move packages incorrectly, they
may topple or fall. This can cause considerable
damage to property.
– Do not put down packages hard and do not
knock against them with force. Watch out for pro-
truding parts.
– When you are moving units for outdoor installa-
tion, be careful that the thin metal roof is not
damaged by the lifting gear.
3.3.2 Moving packages with a forklift or
pallet truck
Air handling units differ in weight and may have different
lashing points. See the order-specific technical docu-
ments for details.
Personnel:
Forklift driver
Protective equipment:
Industrial safety helmet
Protective clothing
Protective gloves
Safety shoes
NOTICE!
Risk of damage to property from forklifts or
pallet trucks!
Take proper precautions when you use a forklift or
pallet truck to move or lift parts or components of an
air handling unit as otherwise they may be damaged.
– If you want to use a forklift to lift a package
without a base frame, you need to protect the
casing units properly.
Fig. 4: Carrying load with a forklift
1. Drive the forklift forward until the forks (Fig. 4/3)
are fully between the square edge timber sections
(Fig. 4/2) and protrude from underneath the base
frame (Fig. 4/1) on the opposite side.
2. Ensure that the load cannot tip.
3. Slowly lift the load and start moving.
Transport and storage
Moving packages > Moving packages with a forklift or pallet truck
Air handling unit X-CUBE 11

3.3.3 Moving packages with a crane
Lashing points
The AHU casing units have lashing points for crane
transport; these lashing points differ depending on the
casing unit weight and installation location.
Casing unit
weight
Installation
location
Lashing
point
Details
≤1500 kg Inside Lifting eyes
Ä 13
≤1000 kg Outside Eye nuts
Ä 14
>1000 kg
≤3000 kg
Inside or out-
side
Transport
tubes
Ä 15
Lashing points are part of the supply package. If several
AHU units are to be moved, you will have to reuse lifting
eyes or transport tubes.
Use only the factory lashing points to move AHU casing
units. If a unit has to be moved with different equipment,
contact TROX beforehand to discuss the details.
Transport straps and other transport protection
devices
Fig. 5: Straps
AHU casing units may be factory fitted with transport
straps (Fig. 5/1) that give them extra stability for trans-
port. They may also be fitted with transport protection
devices.
Always move AHU casing units with the transport straps
or other transport protection device in place; remove
straps or transport protection devices only when the unit
has reached its final position.
Transport and storage
Moving packages > Moving packages with a crane
Air handling unit X-CUBE12

Using lifting eyes
Personnel:
Crane driver
Protective equipment:
Industrial safety helmet
Protective clothing
Protective gloves
Safety shoes
WARNING!
Danger of death from the fall of AHU casing
units.
If you overload lashing points or lifting gear, the load
may fall down. You or others could be killed.
– Use lifting eyes only to move AHU casing units
up to a maximum weight of 1500 kg.
– Use all the lashing points provided.
– Use only adequate lifting gear and slings.
– Stand clear of suspended loads.
Fig. 6: Using lifting eyes for moving units with a crane
AHU casing unit maximum weight: 1500 kg
ⒶMoving units with ropes/chains
ⒷMoving units with a spreader beam
①Lifting eye
②Slings
1. Remove the covers from the threaded holes in the
top corners of the AHU casing unit.
2. Insert all lifting eyes (Fig. 6/1) completely into the
threaded holes.
Several lifting eyes are part of the supply
package; if you have used them for moving
other AHU casing units, you can reuse them.
3. Hook the slings (Fig. 6/2) into the lifting eyes.
Note:
Maintain an angle greater than 45° between
the sling and the top of the unit.
Do not spread slings by more than 60°.
Ensure that the slings cannot damage the
AHU casing unit.
Suspend (distribute) the load symmetrically,
i.e. in such a way that its centre of gravity is
beneath the crane hook.
We recommend using a chain hoist and
spreader beam in the following cases:
–If the correct angles for the slings cannot
be maintained.
–If there are more than four lashing points
on a package.
4. Slowly lift the load and start moving.
Transport and storage
Moving packages > Moving packages with a crane
Air handling unit X-CUBE 13

Using eye nuts
Personnel:
Crane driver
Protective equipment:
Industrial safety helmet
Protective clothing
Protective gloves
Safety shoes
WARNING!
Danger of death from the fall of AHU casing
units.
If you overload lashing points or lifting gear, the load
may fall down. You or others could be killed.
– Use eye nuts only to move AHU casing units up
to a maximum weight of 1000 kg.
– Use all the lashing points provided.
– Use only adequate lifting gear and slings.
– Stand clear of suspended loads.
Fig. 7: Using eye nuts for moving units with a crane
AHU casing unit maximum weight: 1000 kg
ⒶMoving units with ropes/chains
ⒷMoving units with a lifting beam
①Eye nut
②Slings
1.
AHU casing units with a roof are factory fitted
with eye nuts.
Hook the slings (Fig. 7/2) into the eye nuts.
Note:
Maintain an angle greater than 45° between
the sling and the top of the unit.
Do not spread slings by more than 60°.
Ensure that the slings cannot damage the
AHU casing unit.
Suspend (distribute) the load symmetrically,
i.e. in such a way that its centre of gravity is
beneath the crane hook.
We recommend using a chain hoist and lifting
beam in the following cases:
–If the correct angles for the slings cannot
be maintained.
–If there are more than four lashing points
on a package.
2. Slowly lift the load and start moving.
Transport and storage
Moving packages > Moving packages with a crane
Air handling unit X-CUBE14

Using transport tubes
AHU casings or casing units that cannot be moved
using lifting eyes or eye nuts have to be moved with
transport tubes. Transport tubes are part of the supply
package. If several AHU units are to be moved, you will
have to reuse the transport tubes.
If you have to move AHU casing units at a later stage
and do not have the original transport tubes any more,
you may use other tubes with the following properties:
Seamless steel tube, S235JR+AR (St 37-2, EN 10025),
wall thickness of 5 mm.
Select the right transport tubes for the casing unit
weight and width using the tables below.
Diameter of the transport tubes
Outer diameter [mm] Weight of AHU casing
unit [kg]
48.3 £ 1500
60.3 £ 2000
76.1 £ 3000
Weights apply to two transport tubes
If a casing unit is heavier, use more transport tubes.
Length of the transport tubes
Width of AHU casing
unit (inside dimension)
[mm]
Length of transport
tubes [mm]
612 1058
918 1364
1224 1670
1530 1976
1836 2282
2142 2588
2448 2894
2754 3200
3060 3506
3366 3812
3672 4118
3978 4424
4284 4730
4590 5036
4896 5342
Transport and storage
Moving packages > Moving packages with a crane
Air handling unit X-CUBE 15

Personnel:
Crane driver
Protective equipment:
Industrial safety helmet
Protective clothing
Safety shoes
Protective gloves
WARNING!
Danger of death from the fall of AHU casing units.
If you overload lashing points or lifting gear, the load may fall down. You or others could be killed.
– When you use transport tubes, be sure to use tubes with the correct diameter for the weight to be moved
Ä ‘Using transport tubes’ on page 15.
– Use all the lashing points provided.
– Use only adequate lifting gear and slings.
– Stand clear of suspended loads.
The number of drilled holes in the base frame (Fig. 8/6) indicates the number of transport tubes (Fig. 8/1) to be used.
Select the lashing points based on the number of transport tubes you use, Fig. 8
Fig. 8: Lashing points with two or four transport tubes
1. Remove the plugs from the drilled holes in the base frame (Fig. 8/6) of the AHU casing unit.
2. Push transport tubes (Fig. 8/1) through the drilled holes in the base frame.
Secure the transport tubes with screws (Fig. 8/2).
Transport and storage
Moving packages > Moving packages with a crane
Air handling unit X-CUBE16

3. Place the slings (Fig. 8/4) around the ends of the transport tubes.
Position slings between the base frame (Fig. 8/6) and the screws (Fig. 8/2).
Protect the edges with wood blocks (Fig. 8/3). If a unit with a roof (Fig. 8/5) is to be moved, use wood blocks
that are thick enough to provide a distance of 100 mm between the sling and the casing unit.
Spread the slings near the roof with a suitable device (Fig. 8/7), e.g. a lifting beam.
Note:
Do not spread slings by more than 60°.
Ensure that the slings cannot damage the AHU casing unit.
Suspend (distribute) the load symmetrically, i.e. in such a way that its centre of gravity is beneath the crane
hook.
NOTICE!
Risk of damage to property due to the incorrect handling or lifting of units!
Take proper precautions when you use a crane to move or lift parts or components of an air handling unit
as otherwise they may be damaged.
– Protect the edges of the AHU casing units with wood blocks.
– Spread the slings (wire ropes or chains) near the roof with a suitable device, e.g. a lifting beam.
4. Slowly lift the load and start moving.
3.4 Storage and functional integrity
3.4.1 Storage
NOTICE!
Risk of damage to property due to corrosion!
Insufficient ventilation due to film packaging can
result in condensation and, hence, oxidation on
galvanised surfaces, e.g. white rust.
– Remove film packaging immediately after
delivery.
– Store all units in a dry, well-ventilated place.
In the case of Sendzimir-galvanised units, corrosion
may occur on the cut edges. Reddish or whitish dis-
colouration of the cut edge does not indicate prob-
lematic corrosion. Corrosion protection is still guar-
anteed. This does not indicate a reduction in quality
and there are no grounds for complaint.
Please note the following storage conditions:
Do not store outdoors.
Store in a dry and dust-free place that is not
exposed to sunlight.
Storage temperature: -10 °C to +50 °C; avoid
sudden/major fluctuations in temperature.
Provide unpackaged units with protective packaging
and ensure sufficient ventilation in order to prevent
condensation.
Seal openings in the units to ensure that no dust or
vermin can get inside.
Do not expose the units to aggressive operating
fluids.
The storage location must be level and have suffi-
cient load-bearing capacity.
If storing the units for more than 3 months, refer to
the information on functional integrity,
Ä on page 17.
Note!
If there are storage instructions on the packaging,
these instructions must be followed as well.
3.4.2 Functional integrity of the unit com-
ponents
When storing or shutting down the units or if commis-
sioning is to be carried out at a later date (units out of
operation for more than 3 months), take the following
measures to ensure their functional integrity.
Rotating or moving components such as fans, rotary
heat exchangers, multileaf dampers, actuators,
valves or pumps should be rotated/moved on a
monthly basis.
In the case of belt-driven components, slacken the
belts.
Check the general condition of all parts and of the
packaging. Refresh corrosion protection, if neces-
sary.
Document any measures taken.
Transport and storage
Storage and functional integrity > Functional integrity of the unit components
Air handling unit X-CUBE 17

In the case of frequency inverters, EC controllers
(period without supply voltage >1 year), additional
measures may be necessary. Please refer to the rele-
vant manufacturer documentation.
3.5 Unpacking
Unless packaging or the contents have been damaged
while in transit, remove the packaging only when you
are ready to start installation Ä 3.2 ‘Delivery check’
on page 9.
ENVIRONMENT!
Note on disposing of single-use packaging
The packaging is purely transport packaging, which
has been reduced to the absolute minimum with
regard to transport and unloading.
Packaging materials can, in many cases, be recondi-
tioned and recycled.
– 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.
3.5.1 Removing transport protection
devices
Always move AHU casing units with the transport pro-
tection devices in place; remove transport protection
devices only when the unit has reached its final position.
Transport tubes
If the AHU has been moved with transport tubes,
remove them from the base frame; the openings will be
closed as part of the assembly procedure, Ä ‘Fitting
base frame plugs’ on page 37.
Transport protection for AHU casing units
Fig. 9: Transport straps
Cut the transport straps (Fig. 9/1) and remove
them completely.
Transport and storage
Unpacking > Removing transport protection devices
Air handling unit X-CUBE18

Fig. 10: Cross bars
1. Remove the cross bars (Fig. 10/1) that are
marked with a red sticker (Fig. 10/2).
Note: Do not remove any of the painted cross
bars that do not carry a sticker!
2. Then close the drilled holes in the frame with
screws (Fig. 10/3).
Transport protection device for the fan
Fig. 11: Transport protection brackets
1. Remove the brackets (Fig. 11/1) that are marked
with a red sticker (Fig. 11/2).
2. Then close the drilled holes in the floor of the AHU
casing with screws and washers.
Transport and storage
Unpacking > Removing transport protection devices
Air handling unit X-CUBE 19

4 Setup and assembly
If an air handling unit is shipped in several parts, you
have to erect and assemble it on site. The arrangement
of the AHU casing units is given on the order-specific
approval drawing.
Conformity assessment
If components or devices which cannot in themselves
perform a specific application (partly completed machi-
nery) are incorporated into fully functional machinery,
the individual who performs the incorporation or
assembly is responsible for the conformity assessment,
for creating the declaraion of conformity and for
attaching the CE mark.
4.1 Safety notes
Setup and assembly
WARNING!
Risk to life from incorrect setup and assembly!
The incorrect setup and assembly of AHU casing
units can lead to potentially fatal situations and
cause considerable damage to property. Incorrect
setup and assembly will also impair the function of
the unit.
– Air handling units must only be set up and
assembled by HVAC technicians.
Working at height
WARNING!
Risk of a fall when you work at height!
Working at height without using any fall protection
equipment, or using unsuitable or damaged equip-
ment to get up to where you work at height, may lead
to yourself or others falling from height; people on
the ground may be at risk from falling parts or tools.
This can cause serious or even fatal injuries.
– Only use equipment that is suitable, stable and
strong enough for the job, maintained and
checked regularly.
– Stop materials or objects from falling.
– Wear safety shoes, protective clothing and a
hard hat.
– Wear a safety harness.
Interconnecting units and systems
WARNING!
Risk of injury from interconnecting different
units or systems!
Connecting an air handling unit to other units or sys-
tems (e.g. ductwork, pumps, refrigeration systems)
can lead to dangerous situations and eventually
cause serious or even fatal injuries.
– If you have to connect other units or systems to
the air handling unit, connect them professio-
nally.
– The system owner/HVAC contractor is respon-
sible for the planning and installation of any addi-
tional safeguards.
Sharp edges, sharp corners and thin sheet metal
parts
CAUTION!
Danger of injury from sharp edges, sharp cor-
ners and thin sheet metal parts!
Sharp edges, sharp corners and thin sheet metal
parts of the heat exchanger 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
DANGER!
Risk of injury from an unsuitable installation
location!
Do not install the AHU in a location that can be
accessed by everybody.
AHUs may have lockable doors, yet a risk of injury,
vandalism, burglary etc. remains.
Install the AHU in a location that can only be
accessed by authorised persons.
Setup and assembly
Requirements for the installation location
Air handling unit X-CUBE20