Trox Technik X-CUBE Transport And Installation Manual
Air handling unit
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- Transport and installation manual (100 pages) ,
- Operating instructions manual (84 pages)
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Summary of Contents for Trox Technik X-CUBE
- Page 1 Transport and installation manual GB/en Air Handling Unit X-CUBE Read the instructions prior to performing any task!
- Page 2 TROX GmbH Heinrich-Trox-Platz 47504 Neukirchen-Vluyn Germany Telephone: +49 (0) 2845 202-0 Fax: +49 (0) 2845 202-265 E-mail: trox@trox.de Internet: www.troxtechnik.com A00000044678, 10, GB/en 12/2022 © TROX GmbH 2016 Air Handling Unit X-CUBE...
- Page 3 This document, including all illustrations, is protected This transport and installation manual enables operating by copyright and pertains only to the corresponding or service personnel to use the X-CUBE air handling product. unit (AHU) safely and efficiently. Any use without our consent may be an infringement...
- Page 4 Lists without a defined sequence [Switch] Operating elements (e.g. push but- tons, switches), display elements Useful tips and recommendations as well as informa- (e.g. LEDs) tion for efficient and fault-free operation. ‘Display’ Screen elements (e.g. buttons or menus) Air Handling Unit X-CUBE...
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Page 5: Table Of Contents
5.2 Before installation ........41 5.3 Sizing and connecting the condensate drain ............Connecting the heating coil/cooling coil ..............44 Connecting the steam heat exchanger ..............46 Connecting the run around coil system ..............47 5.7 Wiring ............Air Handling Unit X-CUBE... -
Page 6: 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. -
Page 7: Safety
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. Air Handling Unit X-CUBE... -
Page 8: Personal Protective Equipment
– Materials should never be transported in the Safety harnesses must only be used by individuals who vicinity of people or the zones occupied by have been specifically trained to use them. people. Air Handling Unit X-CUBE... - Page 9 Always wear hearing protection while working. that are near the floor. – Only remain in the hazardous area if absolutely – Tripping hazards that cannot be avoided should necessary. be marked with yellow and black marking tape. Air Handling Unit X-CUBE...
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Page 10: Behaviour In The Event Of Hazardous Situa- Tions Or Accidents
“0” position if necessary. Implement first aid measures. Rescue individuals from the hazardous area. Inform the responsible person at the operation site. Notify the emergency services. Clear access paths for rescue vehicles. Air Handling Unit X-CUBE... -
Page 11: Transport And Storage
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. Air Handling Unit X-CUBE... -
Page 12: Moving Packages
– 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). Air Handling Unit X-CUBE... -
Page 13: Moving Packages With A Forklift Or Pallet Truck
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: Air Handling Unit X-CUBE... -
Page 14: Moving Packages With A Crane
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. Air Handling Unit X-CUBE... - Page 15 Several lifting eyes are part of the supply package; if you have used them for moving other AHU casing units, you can reuse them. Hook the slings ( Fig. 6 /2) into the lifting eyes. Note: Air Handling Unit X-CUBE...
- Page 16 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. Air Handling Unit X-CUBE...
- Page 17 Length of transport unit (inside dimension) tubes [mm] [mm] 1058 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 Air Handling Unit X-CUBE...
- Page 18 Remove the plugs from the drilled holes in the base frame ( Fig. 8 /6) of the AHU casing unit. Push transport tubes ( Fig. 8 /1) through the drilled holes in the base frame. Secure the transport tubes with screws ( Fig. 8 /2). Air Handling Unit X-CUBE...
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Page 19: Storage And Functional Integrity
Provide unpackaged units with protective packaging sary. and ensure sufficient ventilation in order to prevent Document any measures taken. condensation. Seal openings in the units to ensure that no dust or vermin can get inside. Air Handling Unit X-CUBE... -
Page 20: Unpacking
Transport tubes If the AHU has been moved with transport tubes, remove them from the base frame; the openings will Ä ‘Fitting be closed as part of the assembly procedure, base frame plugs’ on page 39 . Air Handling Unit X-CUBE... - Page 21 Fig. 11: Transport protection brackets Remove the brackets ( Fig. 11 /1) that are marked with a red sticker ( Fig. 11 /2). Then close the drilled holes in the floor of the AHU casing with screws and washers. Air Handling Unit X-CUBE...
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Page 22: Setup And Installation
Stop materials or objects from falling. – Wear protective gloves and a hard hat when you – Wear safety shoes, protective clothing and a open an inspection access door. hard hat. – Wear a safety harness. Air Handling Unit X-CUBE... -
Page 23: Installation Location, Requirements
The structure on which the air handling unit is to be the air handling unit). installed must be suitable for the weight and have a level surface (see the order-specific data sheet for the air handling unit). Air Handling Unit X-CUBE... -
Page 24: Preventing Vibration And Structure-Borne Noise
Industrial safety helmet the air handling unit. Make sure that the supporting structure is high enough. Hearing protection Protective gloves Safety shoes Safety harness Air Handling Unit X-CUBE... -
Page 25: Setting Up The Ahu Or Ahu Casing Units
The other unit does not have a seal ( Fig. 12 /2). AHU units with X-CUBE Control: Compressed seals will recover fully to their Before you push the AHU casing units together,... -
Page 26: Assembling Ahu Casing Units
Use screws/bolts to join the casing units at the base frame and at the module connectors. Screw-fix (3) the floor panel of the upper casing unit (1) to the ceiling panel of the lower unit (2). With intermediate frame Air Handling Unit X-CUBE... - Page 27 (2). If there are several upper casing units, join the module connectors and the frames with screws, Ä ‘Joining AHU casing units with screws/bolts’ on page 26 Air Handling Unit X-CUBE...
- Page 28 Socket cap head screw M6 × 40 – – A00000018868 A00000056190 ⑤ Washer ∅d 6.4 ⑥ – – M332AF9 M333AC3 Nut M6 – – M332AD6 M323AA3 ⑦ ⑧ Ground cable A00000026651 Lock washer, serrated M332KB4 A00000045194 M332KB4 A00000045194 ⑨ Air Handling Unit X-CUBE...
- Page 29 Fix the other eye of the ground cable with a socket cap head screw M6 × 30 ( Fig. 17 /11) and a serrated lock washer through the panel sheet to the tubular frame of the air handling unit. Air Handling Unit X-CUBE...
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Page 30: Installing The Plate Heat Exchanger
Airflows next to each other, Ä 34 – Horizontal plate heat exchanger Airflows on top of each other Remove doors and panels. Position the lower AHU casing unit for the plate heat exchanger at the installation location. Air Handling Unit X-CUBE... - Page 31 (e.g. with a forklift), then push it onto umentation from the plate heat exchanger manu- the guiding rails (bottom and sides, see detail facturer (appendix). views). Ensure the correct position of the bypass damper (3)! Air Handling Unit X-CUBE...
- Page 32 In this case you may continue with step 13. ① ② ③ Install the frame sections. Remove the back panel (1) and the frame sec- tion (3) from the upper AHU casing unit. If neces- sary, remove the sealing sheet (2). Air Handling Unit X-CUBE...
- Page 33 In this case you have to remove the doors, panels and frame sections on the operating side of the upper casing unit. Air Handling Unit X-CUBE...
- Page 34 If this is not possible, you can also install the plate heat exchanger from the opposite side, i.e. complete the installation steps on the other side. In this case you also have to remove the intermediate panels in step 5. Air Handling Unit X-CUBE...
- Page 35 (2). Remove the prop (3). Remove the two brackets (1). Note: If you want to install the heat exchanger from the opposite side, you also have to remove the two intermediate panels (2). Air Handling Unit X-CUBE...
- Page 36 ② Fig. 18: Preparing installation On the bypass damper of the plate heat exchanger break off the metal cover strip (1) on the mullion between the dampers and remove the screws (2). ① Air Handling Unit X-CUBE...
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Page 37: Additional Assembly Steps For Outdoor Units
Ensure that the bolt (5) enganges with the actuator casing. Fix the anti-twist device with 2 screws, e.g. self-drilling screws (2). Fix the clamping device to the shaft by tightening the nuts (4). Air Handling Unit X-CUBE... - Page 38 Fig. 23: Step design Install the weather hood only with the cover Fix the connecting angle section for the roof seg- grille attached. ment with self-drilling screws and seal it with sealant. Air Handling Unit X-CUBE...
- Page 39 Front = oper- 1.1 ... 9.1 ating side Rear Left Right Fig. 26: Fitting plugs Seal the transport openings in the base frame of the air handling unit with the plugs ( Fig. 26 /1) provided. Air Handling Unit X-CUBE...
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Page 40: Installing Accessories
Connect the duct in such a way that no loads are imposed on the connector; if necessary, slightly retighten the screws on the connector. Insulate ducts (including flexible connectors and connecting frames). Air Handling Unit X-CUBE... -
Page 41: Installation
Have all the applicable documents at hand, Ä ‘Other applicable documentation’ on page 3 Ensure that the installation requirements are met, see the order-specific data sheet for the air handling unit. Have all the required tools ready. Air Handling Unit X-CUBE... -
Page 42: Sizing And Connecting The Condensate Drain
(centre line); depends on the base frame height (GR) and unit width (B), see table - Unit width (B) Distance A Unit width B ≤ 2448 [mm] B > 2448 [mm] Air Handling Unit X-CUBE... - Page 43 155 mm.; R has to be at H = X + 60 – A least 215 mm. H = R – A Calculation example for X-CUBE: Given data: Calculation example for X-CUBE: - 1800 Pa Given data: GR - 110 mm...
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Page 44: Connecting The Heating Coil/Cooling Coil
Connect heat exchangers in a counter flow arrangement unless a parallel flow arrangement has been specified by the manufacturer. Only a counter flow arrangement ensures that the calculated capacity is achieved. Air Handling Unit X-CUBE... - Page 45 Personnel: HVAC technician Protective equipment: Industrial safety helmet Hearing protection Protective clothing Protective gloves Safety shoes Air Handling Unit X-CUBE...
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Page 46: Connecting The Steam Heat Exchanger
If steam escapes due to a leak, it can cause severe scalds. Connect steam heat exchangers in a counter flow arrangement unless a parallel flow arrangement has been specified by the manufacturer. Only a counter flow arrangement ensures that the calculated capacity is achieved. Air Handling Unit X-CUBE... -
Page 47: Connecting The Run Around Coil System
AHU panels or frame, use only those specially approved for your AHU as otherwise there is a risk of leakages. Setting up and connecting the hydraulic unit Personnel: HVAC technician Protective equipment: Industrial safety helmet Hearing protection Protective clothing Air Handling Unit X-CUBE... - Page 48 Technical Service. Heat exchanger connection Connection on Heat Description exchanger hydraulic unit Air handling unit IN-ETA Flow – extract OUT-ETA Return – extract air IN-SUP Flow – supply Air Handling Unit X-CUBE...
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Page 49: Wiring
5.7 Wiring Air handling units with X-CUBE Control are factory wired. The functions of all electronic parts, sensors, actuators, etc. are tested before shipment. If a unit has to be disassembled into AHU casing units for shipment or for moving to the final installation location, the cables are disconnected at suitable interfaces and either pushed back into the cable ducts or rolled up. - Page 50 First run the cables in sections through the AHU to the switch cabinet without discontinuities, see wiring diagram. Where cables have to be pulled in, e.g. behind heat recovery units, a pull wire is provided for pulling in the cable. Air Handling Unit X-CUBE...
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Page 51: Connecting The Air Handling Unit To The Power Supply
Connect the electrical components, such as the electric air heater, electric motor, and actuator. Include the air handling unit in the equipotential bonding arrangement. Test protective conductors and insulation resist- ance to EN 60204 (VDE 0113). Take the appro- priate safety precautions! Air Handling Unit X-CUBE... -
Page 52: Connecting The Controls To Your Pc Or Local Network
To do so, connect the air handling unit to a PC or integrate it with a network using the TCP/IP interfaces. Further information on this can be found in the X- CUBE Control operating instructions. Air Handling Unit X-CUBE... -
Page 53: Initial Commissioning
Ä ‘Setting up the centri- fugal fan’ on page 55 Ä ‘Filters, inserting’ on page 57 Insert the filters, Ä ‘Commis- Set up the heating coil/cooling coil, sioning the heating coil/cooling coil’ on page 57 Air Handling Unit X-CUBE... -
Page 54: Setting Up And Adjusting Ahu Casing Units
ð The inspection access doors have been adjusted. 6.3.2 Centrifugal fan Operating point The control system calculates the operating point and Fig. 42: Adjusting the door sets the default setpoint value for the fan. Remove the hinge covers ( Fig. 42 /1). Air Handling Unit X-CUBE... - Page 55 The K value is given on the TROX fan rating plate on the air handling unit. This value may be different from the K value on the rating plate from the fan manufacturer (which should not be used for the calculation). Air Handling Unit X-CUBE...
- Page 56 Check the function of the anti-vibration elements. Moving towards all possible operating points, check whether the fan is running smoothly and with minimal vibration only. Air Handling Unit X-CUBE...
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Page 57: Filter
Use appropriate measures to protect the water they are tightly seated. system from frost. Frost protection can be achieved ð The filter has been set up. with a water glycol mixture or with a special anti-frost thermostat. Air Handling Unit X-CUBE... -
Page 58: Electric Air Heater
Protective gloves Safety shoes In air handling units with X-CUBE Control (controls), For glycol water mixtures we recommend both the temperature monitoring and the safety temper- ready-to-use formulations. See the order-spe- ature limiter operate independently of one another to... -
Page 59: Run Around Coil System
Ensure that the maximum pressure values given in the technical data are not exceeded. Use appropriate measures to protect the water system from frost. Frost protection can be achieved with a water glycol mixture or with a special anti-frost thermostat. Air Handling Unit X-CUBE... -
Page 60: Multileaf Dampers
Do not put a damaged or defective rotary heat exchanger into operation. Adjust the linkage in such a way that the angle of rotation is 90° and the dampers close completely. ð Powered multileaf dampers have been set up. Air Handling Unit X-CUBE... -
Page 61: Plate Heat Exchanger
Check and, if necessary, clean the plate heat exchanger to remove foreign matter and contami- nation. Setting up the drive equipment ð The plate heat exchanger has been set up. Personnel: Skilled qualified electrician Protective equipment: Air Handling Unit X-CUBE... -
Page 62: Humidifier
Check water connections and water pipes installed in the air handling unit for leaks. Re- tighten the screw connections in case of leaks. ð The humidifier is now ready for use. Air Handling Unit X-CUBE... -
Page 63: Starting
Follow the instructions in the operating manual for the air handling unit. If the unit is not fitted with integral controls, i.e. if the controls have been supplied by others, follow the instructions of the supplier. Air Handling Unit X-CUBE... -
Page 64: Removal And Disposal
– 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). Air Handling Unit X-CUBE... -
Page 65: Disassembly
Incorrect disposal can harm the environment. – Have electronic waste, electronic components and operating fluids (refrigerant, compressor oil, lubricants etc.) disposed of by an approved spe- cialist disposal company. Air Handling Unit X-CUBE... - Page 66 Commission a specialist disposal company to dis- pose of hazardous substances and materials. Compressor oil Compressor oil must not enter sewerage systems or bodies of water. Commission a specialist disposal com- pany to dispose of hazardous substances and mate- rials. Air Handling Unit X-CUBE...
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Page 67: Glossary
Air Handling Unit X-CUBE... -
Page 68: Index
Connection to the central BMS......Installing............... 44 Height of drain trap..........42 Copyright..............3 Network connection..........52 Run around coil system........47 Defects liability............3 Steam heat exchanger, connecting...... 46 Delivery of the air handling unit......... 11 Air Handling Unit X-CUBE... - Page 69 Requirements for the installation location Foundation of the installation room...... 23 Foundation of the outdoor installation area..24 X-CUBE............... 6 Installation room........... 23 X-CUBE components..........6 Residual risks.............. 8 Rotary heat exchanger..........61 Setting up the drive equipment......Air Handling Unit X-CUBE...
- Page 70 TROX GmbH +49 (0) 2845 202-0 Heinrich-Trox-Platz +49 (0) 2845 202-265 47504 Neukirchen-Vluyn E-mail: trox@trox.de Germany www.troxtechnik.com © TROX GmbH 2016...
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