TROX X-CUBE X2 Air Handling Unit Instruction Manual

Instruction Manual for TROX models including: X-CUBE X2 Air Handling Unit, X-CUBE X2, Air Handling Unit, Handling Unit, Unit

Air handling unit - X-CUBE X2 / X-CUBE X2 compact

Transport and installation manual

http://www.troxtechnik.com, ;, article, number:A00000077246, ;, version:5, ;, language-code:GB, ;, creation, date:18.10.2021

X-CUBE X2 | TROX UK Ltd

Air handling unit - X-CUBE X2 / X-CUBE X2 compact

File Info : application/pdf, 89 Pages, 11.03MB

XC-X2 XCC-X2 TIM A00000077246 V5 2021 10 GB en

Transport and installation manual

GB/en

Air handling unit
X-CUBE X2 / X-CUBE X2 compact

Read the instructions prior to performing any task!

TROX GmbH Heinrich-Trox-Platz 47504 Neukirchen-Vluyn, Germany Germany Phone: +49 (0) 2845 2020 Fax: +49 2845 202-265 E-mail: trox@trox.de Internet: http://www.troxtechnik.com
A00000077246, 5, GB/en 10/2021

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Supplemental directives

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, inhouse technicians, technical staff or properly trained persons, and skilled qualified electricians or air conditioning technicians.
It is essential that these individuals read and fully understand 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 documents 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 Phone

www.troxtechnik.com +49 2845 202-400

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 damages 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 information in this manual for bespoke constructions, additional 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 contract is signed shall apply.
We reserve the right to make technical changes.
Warranty claims
The provisions of the respective general delivery terms apply to warranty claims. For purchase orders placed with TROX GmbH, these are the regulations in section "Vl. Warranty claims" of the Delivery Terms of TROX GmbH, see www.trox.de/en/ .

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Supplemental directives

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.

Specific safety notes
The following symbols are used in safety notes to alert you to specific hazards:

Warning signs

Type of danger
Warning - danger of crushing.
Warning hand injuries.

Warning high-voltage.

Warning danger of falling.
Warning suspended load.
Warning danger zone.

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 information for efficient and fault-free operation.

Additional markers
In order to highlight instructions, results, lists, references and other elements, the following markers are used in this manual:

Marker 1., 2., 3. ... ð
[Switch] `Display'

Explanation Step-by-step instructions
Results of actions
References to sections in this manual and to other applicable documents
Lists without a defined sequence
Operating elements (e.g. push buttons, switches), display elements (e.g. LEDs)
Screen elements (e.g. buttons or menus)

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Table of contents

1 Overview ........................................................... 6

5.9 Integrating the air handling unit with the

2 Safety ................................................................ 8 2.1 System owner's responsibility ................... 8

central BMS ............................................. 44
5.10 Connecting the controls to your PC or local network ......................................... 44

2.2 Personnel requirements ............................ 8

5.10.1 X-CUBE controller CX8090 ................ 44

2.3 Personal protective equipment .................. 9

5.10.2 X-CUBE controller CX9020 ................ 46

2.3.1 Residual risks ......................................... 9 2.3.2 Behaviour in the event of hazardous sit-

Initial commissioning .................................... 52

uations or accidents .............................. 11

6.1 Safety notes regarding initial commis-

sioning ..................................................... 52

3 Transport and storage ................................... 12

6.2 Before initial commissioning .................... 52

3.1 Delivery of the air handling unit ............... 12

6.3 Setting up and adjusting AHU casing units

3.1.1 Complete and partial units .................... 12

.................................................................. 53

3.1.2 Symbols on the packaging ................... 12

6.3.1 Centrifugal fan ................................. 53

3.2 Delivery check ......................................... 12

6.3.2

Filter .............................................. 55

3.3 Moving packages .................................... 13

6.3.3 Heating coil/cooling coil .................. 55

3.3.1 Safety notes regarding transport .......... 13

6.3.4 Electric air heater ................................. 57

3.3.2 Moving packages with a forklift or pallet truck ...................................................... 14
3.3.3 Moving packages with a crane ............. 15
3.4 Storage and functional integrity ............... 18
3.4.1 Bearing ................................................. 18
3.4.2 Functional integrity of the unit components ..................................................... 19
3.5 Unpacking ............................................... 19
3.5.1 Removing transport protection devices ............................................................... 19

6.3.5 Run around coil system ..................... 57

6.3.6 Multileaf dampers .............................. 58

6.3.7

Sound attenuator ........................... 59

6.3.8 Rotary heat exchanger ...................... 59

6.3.9 Plate heat exchanger ........................ 60

6.3.10 Humidifier ........................................ 61

6.3.11 Electrical system ................................. 61

6.4 Starting the air handling unit .................... 61

6.4.1 Before you start the AHU ..................... 61

4 Setup and assembly ...................................... 21

6.4.2 Starting ................................................. 62

4.1 Safety instructions ................................... 21 7 Removal and disposal ................................... 63

4.2 Installation location, requirements ........... 22 4.2.1 Requirements for indoor installation ..... 22 4.2.2 Requirements for outdoor installation ... 23 4.3 Preventing vibration and structure-borne

7.1 Safety notes regarding disassembly and disposal ................................................... 63
7.2 Disassembly ............................................ 64
7.3 Disposal ................................................... 64

noise ........................................................ 23 8 Glossary.......................................................... 66

4.4 Setting up and assembling the air handling unit .................................................. 24

Index................................................................ 67

4.4.1 Setting up the AHU or AHU casing units

Appendix......................................................... 69

............................................................... 24

A Adjusting the storage mass ........................ 71

4.4.2 Assembling AHU casing units .............. 26

B Adjusting the storage mass RRU eco ........ 78

4.4.3 Additional assembly steps for outdoor units ...................................................... 29
4.4.4 Installing accessories ........................... 32

C Rotor belt installation instructions .............. 80
D Installing a frost protection device for the drain trap .................................................... 82

5 Installation ...................................................... 33

E Electric air heater ....................................... 84

5.1 Safety notes regarding installation .......... 33

5.2 Before installation .................................... 33

5.3 Connecting the condensate drain ............ 34

5.4 Connecting the heating coil/cooling coil .................................................................. 36

5.5 Connect the steam heat exchanger ..... 38

5.6 Connecting the run around coil system .................................................................. 39

5.7 Wiring ...................................................... 41

5.8 Connecting the air handling unit to the power supply ........................................... 43

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Overview 1 Overview

Fig. 1: Sample unit X-CUBE X2 compact

1 Connecting subframe for ducting 2 Inspection access door, see table for symbols 3 Touch panel

4 Mains isolator 5 Heat exchanger water connections 6 Base frame

The X-CUBE air handling unit is shipped either fully assembled or in several delivery units (AHU casing units), depending on the construction and installation conditions. The respective delivery unit and installation position can be seen on the enclosed drawing.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

The following table lists the components that can make up an air handling unit. The components actually used for a particular air handling unit are listed in the orderspecific technical data sheet.

AHU casing units

Symbol

Description Multileaf dampers

Filter Sound attenuator Centrifugal fan Cooling coil

Heating coil

Plate heat exchanger

Rotary heat exchanger

Run around coil system

Hydraulic unit for run around coil system Humidifier

Overview

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Safety
Personnel requirements

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 applicable 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 handling unit in this strategy.
The system owner must name responsible persons for transport, storage, assembly, installation, commissioning, transfer, disassembly and removal of the unit.
The system owner must commission a skilled qualified 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 complete.
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 commissioning 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 personnel.
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 regulations and instructions. HVAC technicians are individuals who have in-depth knowledge and skills related to HVAC systems; they are also responsible for the professional 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 organisations.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Safety
Personal protective equipment > Residual risks

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 electrical systems, understand any potential hazards related to the work under consideration, and recognise and avoid any risks involved.

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

2.3 Personal protective equipment
Description of personal protective equipment Hearing protection

Safety shoes protect the feet against crushing, falling parts, and from slipping on slippery ground.

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 resistance, close-fitting sleeves, and no projecting parts. Protective gloves

2.3.1 Residual risks
Suspended loads
DANGER!
Danger of death due to suspended loads! Falling loads may cause serious injury or death.
Therefore:
Never walk under suspended loads. Only move loads under supervision. Observe the specifications for the intended
lashing points. Do not attach the lifting gear to protruding
machine parts or lugs on attached components Ensure that the lifting gear is secure. Only use approved hoisting devices and lifting
gear with with sufficient load-bearing capacity. Do not use any frayed or worn ropes and belts. Do not place ropes or belts near sharp edges or
corners; do not knot or twist. Place the load on the ground before leaving the
workplace.

Protective gloves protect hands from friction, abrasions, punctures, deep cuts, and direct contact with hot surfaces.
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.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Safety
Personal protective equipment > Residual risks

Industrial trucks

Dirt and objects lying around

WARNING!
Danger to life from industrial trucks! Objects and other loads could fall in an uncontrolled manner from industrial trucks during transport and cause serious injuries or even death. There is also the risk that people will not be seen and could thus be run over by the vehicle driver.
Industrial trucks may only be operated by trained vehicle drivers (e.g. forklift drivers).
People should only pass industrial trucks when the vehicle driver has signalled that they have seen them.
Only approved industrial trucks with sufficient load-bearing capacity may be used.
Materials should never be transported in the vicinity of people or the zones occupied by people.
Electric current
DANGER!
Danger of death due to electric current! Danger of electric shock! Do not touch any live components! Damaged insulation or damaged parts are a life threatening hazard.
Have work on the electrical system carried out only by skilled qualified electricians.
Have work on the electrical system carried out only by skilled qualified electricians.
If the insulation is damaged, disconnect the power supply immediately and have the insulation repaired.
Before you start working on electric systems and equipment, switch off the supply voltage and secure it against being switched on accidentally. Comply with the 5 safety rules: Disconnect. Secure it against being switched on accidentally. Ensure that no voltage is present. Connect to the earth; short circuit connection. Either cover nearby parts that carry a voltage or install barriers.
Do not bypass or disable any circuit breakers. Be sure to maintain the correct current rating when you replace a circuit breaker.
Ensure that live parts do not come into contact with moisture. Moisture can cause a short circuit.

CAUTION!
Risk of injury from falling as a result of dirt or objects lying around! Dirt and objects lying around can lead to the risk of slipping and tripping. Injuries can be caused by falling.
Work areas should always be kept clean. Objects that are no longer required should be
removed from the work area, particularly those that are near the floor. Tripping hazards that cannot be avoided should be marked with yellow and black marking tape.
Tools
CAUTION!
Risk of injury as a result of the negligent handling of tools! Negligent handling of tools can lead to crushing or cuts.
Tools must be handled carefully and as intended. The weight must be taken into account when
transporting tools. Protective gloves and safety shoes should be
worn.
Rotating parts
WARNING!
Risk of injury from rotating parts! Rotating parts in the fan can cause serious injuries.
Do not reach into or handle the moving impeller wheel during operation.
Do not open inspection access doors and covers during operation.
Ensure that the impeller wheel is not accessible during operation.
Observe the run down time! Check that no parts are moving before you open an inspection access door or cover.
Switch off the unit and secure it against being switched back on again before starting any work on moving fan components. Wait until all parts have come to a standstill.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Safety
Personal protective equipment > Behaviour in the event of hazardous situations...

Noise
WARNING! Hearing damage due to noise! The noise level in the work area can cause severe hearing damage. Always wear hearing protection while working. Only remain in the hazardous area if absolutely
necessary.

Measures in the event of accidents
Trigger an emergency stop immediately, and put the isolator into the "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.

Inspection access doors slamming shut
WARNING!
Risk of crushing from doors slamming shut Inspection access doors may slam shut by the wind or if someone pushes them inadvertently, resulting in serious injury to the head and limbs.
Secure each inspection access door with a hold open device.
Secure inspection access doors without a hold open device against closing by suitable means.
Do not reach between the door and door frame. Wear protective gloves and a hard hat when you
open an inspection access door.
2.3.2 Behaviour in the event of hazardous situations or accidents
Preventative measures Always be prepared for accidents or fire! Keep first aid equipment (first aid kit, blankets, etc.)
and fire extinguishers close at hand. Familiarise personnel with accident reporting, first
aid and rescue equipment. Keep access paths for rescue vehicles clear.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Transport and storage
Delivery check

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 12 . 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.

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 procedure 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 damaged. Photograph the damage. Report the damage to TROX immediately in writing. Note that shipping damage must be reported within
four days of delivery.

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 shipping company and your supplier immediately. If any parts are missing, have the driver confirm them on the consignment note.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Transport and storage
Moving packages > Safety notes regarding transport

3.3 Moving packages 3.3.1 Safety notes regarding transport
Improper transport equipment

Warning: AHU casing units may tip over

WARNING!
Risk to life from using improper transport equipment!
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 correctly 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 workplace.
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.
Ä 2.3.1 `Residual risks' on page 9

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 injuries.
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).

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Transport and storage
Moving packages > Moving packages with a forklift or pallet truck

Sticker indicating the centre of gravity

Forklift driver
Protective equipment: Industrial safety helmet Protective clothing Protective gloves Safety shoes

Fig. 3: Shipping stickers Stickers on the packaging indicate the centre of gravity ( Fig. 3 ).
Sharp edges, sharp corners and thin sheet metal parts

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.

CAUTION!
Danger of injury from sharp edges, sharp corners 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 protruding parts.
When you are moving units for outdoor installation, be careful that the thin metal roof is not damaged by the lifting gear.

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.

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 documents for details.
Personnel:

Air handling unit X-CUBE X2 / X-CUBE X2 compact

3.3.3 Moving packages with a crane
Using transport tubes
Use only the factory lashing points when moving AHU casing units 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 a unit has to be moved with different equipment, contact TROX beforehand to discuss the details.
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 (St37-2, 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]
48.3 60.3 76.1

Weight of AHU casing unit [kg]

Europe

United Kingdom

£ 1500

£ 960

£ 2000

£ 1590

£ 3000

£ 2650

Weights apply to two transport tubes.

Length of the transport tubes

Width of AHU casing unit (inside dimension) [mm] 612 918 1224 1530 1836

Length of transport tubes [mm]
1013 1319 1625 1931 2237

The length of transport tubes for intermediate dimensions can be calculated as follows:

Length = overall width of AHU casing unit + 401 mm

Transport and storage
Moving packages > Moving packages with a crane

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Transport and storage
Moving packages > Moving packages with a crane
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. 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. 5 /6) indicates the number of transport tubes ( Fig. 5 /1) to be used. Select the lashing points based on the number of transport tubes you use, Fig. 5

Fig. 5: Lashing points with two or four transport tubes
1. Remove the plugs from the drilled holes in the base frame ( Fig. 5 /6) of the AHU casing unit. 2. Push transport tubes ( Fig. 5 /1) through the drilled holes in the base frame.
Secure the transport tubes with screws ( Fig. 5 /2).

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Transport and storage
Moving packages > Moving packages with a crane
3. Place the slings ( Fig. 5 /4) around the ends of the transport tubes. Position slings between the base frame ( Fig. 5 /6) and the screws ( Fig. 5 /2). Protect the edges with wood blocks ( Fig. 5 /3). If a unit with a roof ( Fig. 5 /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. 5 /7), e.g. a spreader 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 spreader beam.
4. Slowly lift the load and start moving.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Transport and storage
Storage and functional integrity > Bearing

Transport on transport brackets 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.
Use all the lashing points provided. Use only adequate lifting gear and slings. Stand clear of suspended loads.
The number of transport brackets on the AHU casing unit ( Fig. 6 /1) determines the number of lashing points to be used.

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.
Note:
Suspend (distribute) the load symmetrically, i.e. in such a way that its centre of gravity is beneath the crane hook.
Spread the slings (wire ropes or chains) near the roof with suitable spreading devices, e.g. a spreader beam ( Fig. 6 /3).
Do not spread slings by more than 60°. Ensure that the slings cannot damage the
AHU casing unit. Protect the edges of the AHU casing units with wood blocks ( Fig. 6 /4) for example.
2. Slowly lift the load and start moving.
3.4 Storage and functional integrity 3.4.1 Bearing

Fig. 6: Travel stop on transport brackets 1. Hook slings ( Fig. 6 /2) into transport brackets.

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 discolouration of the cut edge does not indicate problematic corrosion. Corrosion protection is still guaranteed. 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.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Transport and storage
Unpacking > Removing transport protection devices

The storage location must be level and have sufficient load-bearing capacity.
If storing the units for more than 3 months, refer to the information on functional integrity, Ä on page 19 .

3.5.1 Removing transport protection devices
Always move AHU casing units with the transport protection devices in place; remove transport protection devices only when the unit has reached its final position.

Note!
If there are storage instructions on the packaging, these instructions must be followed as well.
3.4.2 Functional integrity of the unit components
When storing or shutting down the units or if commissioning 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 necessary.
Document any measures taken.
In the case of frequency inverters, EC controllers (period without supply voltage >1 year), additional measures may be necessary. Please refer to the relevant manufacturer documentation.

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 30 .
Transport protection for AHU casing units

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 12 .
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 reconditioned 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 company to dispose of the packaging.

Fig. 7: Transport straps
Cut the transport straps ( Fig. 7 /1) and remove them completely.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Transport and storage
Unpacking > Removing transport protection devices

Fig. 8: Cross bars
1. Remove the cross bars ( Fig. 8 /1) that are marked with a red sticker ( Fig. 8 /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. 8 /3).
Transport protection device for the fan (only with XCUBE) The X-CUBE Compact only has EC fans installed in it which do not have any transport protection brackets because they are screwed to the casing wall.

Fig. 9: Transport protection brackets
1. Remove the brackets ( Fig. 9 /1) that are marked with a red sticker ( Fig. 9 /2).
2. Then close the drilled holes in the floor of the AHU casing with screws and washers.
Transport protection device Vibration Baseframe Air handling units with Vibration Baseframe have special transport protection devices between the base frame and the unit. These must be removed before commissioning, as otherwise the sound insulation will not work.

Fig. 10: Transport protection device on units with Vibration Baseframe
1. Unscrew screws on the transport protection devices ( Fig. 10 /1) using tool (TX30) and remove the metal sheets.
2. Then screw the screws back into the unit.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Setup and assembly
Safety instructions

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 machinery) 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 instructions
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.

Interconnecting units and systems
WARNING! Risk of injury from interconnecting different units or systems! Connecting an air handling unit to other units or systems (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 professionally. The system owner/HVAC contractor is responsible for the planning and installation of any additional safeguards.
Sharp edges, sharp corners and thin sheet metal parts
CAUTION! Danger of injury from sharp edges, sharp corners 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.

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 equipment 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.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Setup and assembly
Installation location, requirements > Requirements for indoor installation

Crushing hazard.
WARNING! Crushing hazard from movable parts! There is an increased risk of crushing on casing units, doors, panels and components of the device. Never reach between moving parts. Be careful when carrying out any work. Wear protective gloves, safety shoes and a hard
hat.
Damage to inspection access doors
NOTICE! Physical damage to inspection access doors Do not open inspection access doors which are hinged on one side if their width is ³1000 mm or more! The closures can be damaged due to the weight and the leverage forces that occur. In the case of inspection access doors from a width of ³1000 mm, always open all closures and remove the door from the air handling unit. Store doors safely where they are protected against damage!
4.2 Installation location, requirements
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.
4.2.1 Requirements for indoor installation
Installation room Air handling units designed for indoor installation have to be installed in a room that meets the following requirements: The room has been designed in compliance with the
applicable building regulations and is suitable for the technical systems to be installed. National standards for plant rooms may also apply. The installation room has to be

clean dry free from conductive dust particles free from strong electromagnetic fields free from aggressive atmospheres free from frost fitted with a functioning drainage system There is sufficient clearance for installing, operating, servicing, and repairing the AHU and all its parts. The maintenance access has to be at least as
deep as the unit. The maintenance access must be wide enough
so that all inspection access doors can be opened with an opening angle of 90°. The structure on which the air handling unit is to be installed must be suitable for the weight and have a level surface (see the order-specific data sheet for the air handling unit). Do not use the air handling unit as a structural element or as a roof for a building. Do not use the air handling unit in potentially explosive atmospheres.
Escaping water
NOTICE!
Risk of damage to property from escaping water! If the water system is not tight, water may escape and cause considerable damage to property.
Ensure that liquids are channelled away and to a collection device.
Installation room foundation
The installation room foundation must fulfil the following requirements:
It is horizontal, flat and robust, made of concrete; alternatively, a support structure made of steel may be used.
The frequency of the support structure, particularly of a steel structure, is sufficiently different from the excitation frequency of movable components, such as fans, motors, pumps or refrigerant condensers.
For air handling units with a condensate drain, the support structure is at least as high as the drain trap, see Ä 34
If additionally structure-borne noise is to be attenuated (e.g. by rubber or elastomer sheets underneath the air handling unit), be sure to exactly align all AHU casing units (check for door closure, properly sealed joints).

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Setup and assembly
Preventing vibration and structure-borne noise

4.2.2 Requirements for outdoor installation
Installation location
For outdoor installation please note:
Do not use the air handling unit in potentially explosive atmospheres.
The installation location has to be
free from conductive dust particles
free from strong electromagnetic fields
free from aggressive atmospheres
fitted with a functioning drainage system The structure on which the air handling unit is to be
installed must be suitable for the weight and have a level surface (see the order-specific data sheet for the air handling unit). There is sufficient clearance for installing, operating, servicing, and repairing the AHU and all its parts. The maintenance access has to be at least as deep as the unit. Make sure that the installation location meets local regulations to prevent the fall of people, and of tools and other objects. Use suitable fall arrest equipment. Prevent unauthorised individuals from accessing AHU casing units. Make sure that authorised individuals can access AHU casing units safely. Keep the structural properties in mind and make sure the maximum roof load is not exceeded; do not neglect the effects of weather on the unit (rain, snow, wind, sun etc.). Only a skilled qualified professional must connect the air handling unit to an external switch cabinet and prevent the cables from the effects of weather (rain, snow, wind, sun etc.). All operating fluid pipes and hoses and the AHU components to which they are connected must be frost-proof. Do not use the air handling unit as a structural element or as a roof for a building.
Foundation of the outdoor installation area
The information regarding the foundation of the installation room applies, Ä `Installation room foundation' on page 22
For roof installation, check the load capacity and support structure of the roof; consult a structural engineer if necessary.
The entire air handling unit must be supported by a continuous steel structure.
The steel girders must be designed for a maximum deflection of L/500 under load (L = girder length). A maximum deflection of 10 mm under load must not be exceeded.
Waterproof the edge of the roof under the air handling unit and also any connections penetrating the roof.

Insulate the plinth structure (by others) to prevent condensation.
In areas with heavy snowfall, choose an installation location where snow will not affect the operation of the air handling unit. Make sure that the support structure is high enough.
Escaping water
NOTICE!
Risk of damage to property from escaping water! If the water system is not tight, water may escape and cause considerable damage to property.
Ensure that liquids are channelled away and to a collection device.
4.3 Preventing vibration and structureborne noise
If the air handling unit is equipped with an anti-vibration frame (Vibration Baseframe - AVBF optional), no special measures are required for insulation of structure-borne noise.
In the case of air handling units without anti-vibration frames, underlays for insulation of vibration and structure-borne noise can be used to reduce vibration transmission to the support structure:
For installation on level ground with no special requirements regarding insulation of structure-borne noise, we recommend decoupling the foundation from the air handling unit, for example using rubber or elastomer sheets.
For noise insulation, compare the requirement to the sound power level of the air handling unit (see order-specific data sheet for the air handling unit) and have the necessary measures determined by an acoustics engineer.
NOTICE!
Risk of damage to the AHU Anti-vibration elements or a noise insulating layer must not affect the structural safety of the AHU. Ensure the following:
Use a sufficient number of anti-vibration elements and noise insulating layers and place them correctly as otherwise the frame may sag.
Keep in mind that the various AHU casing units differ in weight; this must not lead to any height differences in the overall unit.
We recommend you to have noise insulating layers (including material and layout plan) selected and sized by an expert company.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Setup and assembly
Setting up and assembling the air handling unit > Setting up the AHU or AHU casing units

4.4 Setting up and assembling the air handling unit
Personnel: HVAC technician
Protective equipment: Industrial safety helmet Hearing protection Protective gloves Safety shoes Safety harness

Deformed seals Compressed seals will recover fully to their original state about 60 minutes after the transport protection devices have been removed.

4.4.1 Setting up the AHU or AHU casing units
4.4.1.1 Setting up the AHU or AHU casing units

Placement of AHU casing units The arrangement of the individual AHU casing units is shown in the drawings on the individual delivery units.
Installation accessories Installation accessories are packed separately in an accessory pack which is normally located in the fan chamber.
1. Assemble the AHU casing units as closely as possible to the installation site in accordance with the installation sequence, Fig. 11 . Also pay attention to the local interfaces, e.g. to drainage and water connections.
2. Remove all foil packaging.

Fig. 12: Use of slide plates for easy positioning
4. Units with anti-vibration frames
(optional) If the air handling unit is equipped with an antivibration frame (Vibration Baseframe - AVBF optional), no special measures are required for insulation of structure-borne noise. This installation step can be omitted in this case.
If the air handling unit is installed on a surface with a high coefficient of friction (e.g. rubber or elastomer sheets), positioning can be made considerably easier by using slide plates.
To do this, insert the slide plates ( Fig. 12 /1) provided by the customer between the base frame and the surface ( Fig. 12 /2).

Fig. 11: Seals on AHU casing units
3. Perimeter seals ( Fig. 11 /1) are fitted at the connection points of the AHU casing units. The seal is only located on one AHU casing unit in each case, the casing unit to be connected to it has no seal ( Fig. 11 /2).
Check that the seals are complete and intact and that they seal properly.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Setup and assembly
Setting up and assembling the air handling unit > Setting up the AHU or AHU casing units
Without base frame

Fig. 13: Aligning AHU casing units
5. Align the AHU casing units so that they are flush with one another ( Fig. 13 /1).
Air handling units with X-CUBE Control: 6. Before you push the AHU casing units together,
insert the internal cables of each unit into the cable ducts of the next casing unit; for more information see Ä Chapter 5.7 `Wiring' on page 41 .
With base frame

Fig. 15: Attaching a ratchet strap, without base frame
8. Attach one ratchet strap each at the top and bottom of the housing of 2 AHU casing units.
9. Tighten the ratchet straps alternately. ð The AHU casing units come closer together as you tighten the strap.

Fig. 14: Attaching a ratchet strap, with base frame
7. Attach a ratchet strap to the base frames of two AHU casing units ( Fig. 14 ).
Tighten the ratchet strap. ð The AHU casing units come closer together as
you tighten the strap around the base frames.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Setup and assembly
Setting up and assembling the air handling unit > Assembling AHU casing units

4.4.2 Assembling AHU casing units
Joining AHU casing units with screws/bolts
NOTICE! Risk of damage to property from incorrect assembly! Be sure to assemble the AHU casing units correctly as otherwise the condensate drain may be damaged. Protect the condensate drain from damage.

Installing AHU casing units on top of each other
Do not start assembling the upper units until you have completed assembly of the lower units, including screwfixing the module connectors and the base frame.
Follow the assembly instructions carefully as otherwise the unit may become damaged, the casing units may start shifting or, if the unit is installed outdoors, water may get into the unit.
Factory drilled holes indicate where the lower and upper AHU casing units have to be joined. Align and fix the casing units according to these holes.
Be sure to use all of the fixing points. If an assembly point is difficult to access, check if it is possible to assemble the units in a different order.
Ensure that the position is correct based on the screw joints on the operating side.
Ensure that no water can get into the unit at the factory provided joints.
If in doubt, consult TROX.
Without intermediate frame
1. When the installation of the lower casing units is completed, place the first upper casing unit with lifting gear, e.g. a crane, in the appropriate installation position (see enclosed drawing), Ä `Transport on transport brackets' on page 18 . If there are several upper AHU casing units, install them one after another before putting on additional casing units.

Fig. 16: Joining the base frames with screws/bolts Hexagon head screws Washers Nuts Module connectors Allen screws Schnorr ® washers
Screw the AHU casing units evenly to the end faces of the base frames and to the casing unit connectors.
Fig. 17: Removing transport brackets 2. Remove the transport brackets from the upper
AHU casing unit ( Fig. 17 /1). 3. If there are several AHU casing units, connect
them together using casing unit connectors, ( Fig. 16 /4).

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Setup and assembly
Setting up and assembling the air handling unit > Assembling AHU casing units 7. If there are several upper casing units, join the module connectors and the frames with screws, Ä 26
Fig. 18: Connecting AHU casing units 4. Connect upper and lower AHU casing units with
connecting sheet ( Fig. 18 /1) and socket head screws M6 ( Fig. 18 /2). With intermediate frame 5. When the installation of the lower casing units is completed, place the first upper casing unit with lifting gear, e.g. a crane, in the appropriate installation position (see enclosed drawing), Ä `Using transport tubes' on page 15 . If there are several upper AHU casing units, install them one after another before putting on additional casing units.

6. Screw-fix (3) the intermediate frame (4) of the upper casing unit to the ceiling panel of the lower unit (2).

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Setup and assembly
Setting up and assembling the air handling unit > Assembling AHU casing units
Installing the noise insulating connector If the noise insulating connector has been supplied separately, install it once the AHU has been erected and assembled. Depending on the AHU construction variant the noise insulating connector has to be attached to the panel or to a multileaf damper.

Fig. 19: Installing the noise insulating connector

Supplied assembly material No. Description
Noise insulating connector Thread forming socket cap head
screw M6 × 40 Washer d 6.4 Rubber seal 17 × 6.5 × 3 Socket cap head screw M6 × 40 Washer d 6.4 Nut M6 Ground cable Lock washer, serrated Pan head screw M6 × 12 Socket cap head screw M6 × 30

Part no.

Panel

Multileaf damper

Galvanised Stainless steel Galvanised Stainless steel

steel

A00000055910 A00000055911

M332AA3

M332KB4

M333AA3

M332AA3

M333AA3

M338BD0

A00000018868 A00000056190

M332AF9

M333AC3

M332AD6

M323AA3

A00000026651

A00000045194 M332KB4 A00000045194

M852AC6

M852AC4

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Setup and assembly
Setting up and assembling the air handling unit > Additional assembly steps for outdoor units
1. Place the noise insulating connector ( Fig. 19 /1) on the air handling unit with the perimeter seal facing down; fix it with thread forming screws ( Fig. 19 /2), rubber seals ( Fig. 19 /4) and washers ( Fig. 19 /3).
Attaching the noise insulating connector to a multileaf damper If the noise insulating connector is to be attached to a multileaf damper, fix it with the supplied socket cap head screws ( Fig. 19 /5), rubber seals ( Fig. 19 /4), washers ( Fig. 19 /3 and 6) and nuts ( Fig. 19 /7). 2. Fix one eye of the ground cable ( Fig. 19 /8) with a pan head screw M6 × 12 ( Fig. 19 /10) and a serrated lock washer ( Fig. 19 /9) to the noise insulating connector.
NOTICE! Electrical conductivity For electrical conductivity the serrated lock washer needs to be fitted between the eye of the ground cable and the coated surface. 3. Fix the other eye of the ground cable with a socket cap head screw M6 × 30 ( Fig. 19 /11) and a serrated lock washer through the panel sheet to the tubular frame of the air handling unit.

4.4.3 Additional assembly steps for outdoor units
Connecting the roof segments
Air handling units for outdoor installation require the following additional assembly steps:

NOTICE!
Remove the eye nuts where the casing units are to be joined such that you can actually join the roof segments. Do not remove the other eye nuts; they have to remain in place to prevent the ingress of rain into the unit.

Fig. 20: Joining roof segments
Roof segments Self-adhesive joint sealing tape Cover strips Self-drilling screws with sealing washers
1. Seal all joints between the roof segments ( Fig. 20 /1) with self-adhesive joint sealing tape ( Fig. 20 /2). Follow the tape manufacturer's instructions for use. Attach the cover strips ( Fig. 20 /3) and fix them with self-drilling screws ( Fig. 20 /4).

Fig. 21: Sealing the joints
2. Seal the joints ( Fig. 21 /1) between the cover strips with the supplied adhesive strips (100 x 40 mm).
Make sure that all surfaces are clean, free from grease, and dry. Clean the surfaces, if necessary.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Setup and assembly
Setting up and assembling the air handling unit > Additional assembly steps for outdoor units

Stacked units (step design)

Fitting base frame plugs

Fig. 24: Fitting plugs Seal the transport openings ( Fig. 24 /1) in the base frame of the air handling unit with the plugs ( Fig. 24 /2) provided.
Fig. 22: Step design 3. Fix the connecting angle section for the roof seg-
ment with self-drilling screws and seal it with sealant.
Attaching the weather hood

Fig. 23: Positioning the weather hood
Position the weather hood ( Fig. 23 /2) flush with the hole pattern on the panel ( Fig. 23 /1) and screw on with pan head screws (M6x12).

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Setup and assembly
Setting up and assembling the air handling unit > Additional assembly steps for outdoor units
Fixing cover strips to the intermediate frame

Fig. 25: Cover strip coding
1.
NOTICE!
Risk of water damage from incorrect assembly! If units with an intermediate frame are installed outdoors, missing cover strips or incorrect assembly may lead to the ingress of water.
To prevent the ingress of water into the intermediate frame and hence into the unit, seal the intermediate frame with cover strips.
Fix the cover strips immediately after the assembly steps described above. If you do not fix the cover strips immediately, water may get into the unit and damage the components.

Each cover strip carries a code indicating its position (see table).

No. of the inter-
mediate frame 01 ... 99

Side code
V Front = operating side
H Rear L Left R Right

Number (left right)
1.1 ... 9.1

Fig. 26: Fixing cover strips
1 Cover strip for the intermediate frame 2 Thread forming pan head screws M6 x 12
(M852AC6) 3 Intermediate frame 4 Drip edge
2. Use pan head screws to attach the cover strips to the intermediate frame.
Important: Fix the cover strips in such a way that the drip edge is at the bottom. Ensure that the drip edge faces outwards.
ð This will prevent water from getting into outdoor units with an intermediate frame.
Installing ducts
Personnel: HVAC technician
Protective equipment: Industrial safety helmet Protective clothing Protective gloves Safety shoes
1. Ensure precise fit and avoid distortion when you connect the ducts.
Note: Any load on the noise insulating connector may impair the tight fit. Connect the duct in such a way that no loads are imposed on the connector; if necessary, slightly re-tighten the screws on the connector.
2. Insulate ducts (including flexible connectors and connecting frames).

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Setup and assembly
Setting up and assembling the air handling unit > Installing accessories
3. For outdoor units: Protect ducts (including spigots and connecting frames) against the effects of weather.
4.4.4 Installing accessories
Install any supplied accessories (e.g. pressure transducers) and any accessories provided by others (e.g. actuators, frost sensors) according to the manufacturers' instructions.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installation
Before installation

5 Installation
5.1 Safety notes regarding installation
Incorrect installation
WARNING! Risk to life from incorrect installation! Incorrect installation can lead to potentially fatal situations and cause considerable damage to property. Only a skilled qualified electrician must connect
the power supply. Any other installation job has to be carried out by
an HVAC technician.
Inspection access doors slamming shut
WARNING! Risk of crushing from doors slamming shut Inspection access doors may slam shut by the wind or if someone pushes them inadvertently, resulting in serious injury to the head and limbs. Secure each inspection access door with a hold
open device. Secure inspection access doors without a hold
open device against closing by suitable means. Do not reach between the door and door frame. Wear protective gloves and a hard hat when you
open an inspection access door.

Hot surfaces
WARNING! Risk of injury from hot surfaces! The surfaces of components can get very hot during operation. Skin contact with hot surfaces causes severe skin burns. Professionally insulate pipes that connect con-
densers or heating coils.
Interconnecting units and systems
WARNING! Risk of injury from interconnecting different units or systems! Connecting an air handling unit to other units or systems (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 professionally. The system owner/HVAC contractor is responsible for the planning and installation of any additional safeguards.
Sharp edges, sharp corners and thin sheet metal parts

CAUTION!
Danger of injury from sharp edges, sharp corners 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.
5.2 Before installation
Before 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 X2 / X-CUBE X2 compact

Installation
Connecting the condensate drain

5.3 Connecting the condensate drain
Electric current
WARNING!
Danger of death due to electric current! If electrical components come into contact with water, e.g. from a leak, you could be seriously or even fatally injured. Water can also cause damage to the air handling unit.
Lay drainage pipes in such a way that they cannot be accidentally damaged by mechanical impact or by heat.

Height of drain trap

NOTICE!
Risk of leakages due to incorrect installation!
Do not connect the condensate drain to the sewerage system without a drain trap or with an unsuitable drain trap as this may result in air getting into the AHU.
Use a suitable drain trap to connect the AHU to the sewerage system.
Do not connect the drain trap to the drainage pipe; the water from the drain trap should flow to a gully.
Use a different drain trap for each condensate drain. Do not connect condensate drains with each other.
A distance from the floor must be maintained at the drain trap of the negative pressure side.

Calculate the height of a drain trap as shown below.

Symbol:

P - Pressure inside the air handling unit [Pa]; be sure to use a positive value for calculations; take the final differential pressure (filter etc.) into consideration

1.5 - Safety factor to compensate for pressure fluctuations in the system such as those resulting from rapidly closing dampers (applies only to positive pressure)

R - Distance R [mm]; minimum distance between condensate drain (centre line) and floor on the positive pressure side.

X + - Distance X + 60 [mm]; minimum distance

between condensate drain (centre line) and

floor on the negative pressure side

H - Distance H [mm]; minimum distance between base frame lower edge and floor

A - Distance A [mm]; distance between base frame lower edge and condensate drain (centre line); depends on the base frame (GR), see table

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Negative pressure (extract air)

Installation
Connecting the condensate drain
Positive pressure (supply air)

Fig. 27: Drain trap for negative pressure in the unit
Calculation to be used for negative pressure (2900 Pa max.):
X = P / 10 H = X + 60 A

Base frame construction 110
200
300

Acoustic decoupling
Without With Without With Without With

GR [mm]
110 135 200 225 300 325

A [mm]
210 235 300 325 400 425

Fig. 28: Drain trap for positive pressure in the unit Calculation to be used for positive pressure (1630 Pa max.): R = P × 1.5 / 10 + 115 (40 + 75)
H = R - A Always cut or extend pipes by the same length. Do
not cut a pipe by more than 155 mm.; R has to be at least 215 mm.
Calculation example Given data: P - 1500 Pa GR - 110 A - 210
R = 1500 Pa × 1.5 / 10 + 115 mm = 340 mm H = 340 - 210 = 130 mm

Calculation example
Given data: P - 1800 Pa GR - 110 A - 210
X = 1800 Pa / 10 = 180 mm H = 180 + 60 210 mm = 30 mm If the calculation value is negative, no additional installation height H is required.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installation
Connecting the heating coil/cooling coil

Drain trap, connecting
Personnel: HVAC technician
Protective equipment: Industrial safety helmet Protective clothing Protective gloves Safety shoes

NOTICE!
Risk of damage to property from incorrect pipe connections! Take care to connect the pipes correctly as otherwise the pipes and the drain trap may be damaged beyond repair.
Connect pipes in such a way that they are not affected by vibration and that no loads are imposed on them.
If an AHU is installed outdoors, use suitable pipes and protect them from frost.
Drain trap connection dimensions
Outer diameter of drainage pipe - 40 mm
1. Calculate the height of the drain trap as shown above.

Fig. 30: Sloped pipe of a drain trap for negative pressure
3. Adjust the height of the drain tap based on the above calculation. Drain traps for negative pressure: Instead of shortening the pipe, you can install the drain trap so that it slopes.
4. Connect a drain trap to each condensate drain ( Fig. 29 /1).
Do not connect the drain trap to the drainage pipe; the water from the drain trap should flow to a gully.
Air handling units to be installed outdoors or in areas at risk of frost require frost protection for the drain trap, Ä Appendix D `Installing a frost protection device for the drain trap' on page 82 .

5.4 Connecting the heating coil/ cooling coil
Electric current

Fig. 29: Condensate drain 2. Remove the protective cap ( Fig. 29 /2) from each
drain ( Fig. 29 /1) of the condensate drip tray.

WARNING!
Danger of death due to electric current!
If electrical components come into contact with water or a water glycol mixture, e.g. from a leak, you could be seriously or even fatally injured. Water can also cause damage to the air handling unit.
Lay connecting cables in such a way that they cannot be accidentally damaged by mechanical impact or by heat.
Do not lay connecting cables across electrical components or switch cabinets as people may become entangled in them.

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 X2 / X-CUBE X2 compact

Installation
Connecting the heating coil/cooling coil

If you have to attach brackets or fasteners to the AHU panels or frame, use only those specially approved for your AHU as otherwise there is a risk of leakages.
Fig. 31: Exemplary illustration of the heat exchanger connections in a counter flow arrangement 1 Airflow direction

NOTICE!
Risk of damage to property from incorrect pipe connections!
Take care to connect the heat exchanger pipes correctly as otherwise the pipes may twist or become subject to adverse effects. This may eventually damage the heat exchanger beyond repair.
Connect pipes in such a way that the heat exchanger is not affected by vibration and that no loads are imposed on it.
If there is too much weight on a water pipe (by others), support the water pipe.
Do not use the connection point of the heat exchanger as a fixing point for other parts.
When you tighten thread connections, be sure to use a suitable tool (e.g. water pump pliers) to counter the tightening force as otherwise you may inadvertently damage the parts.
If an AHU is installed outdoors, use suitable pipes and protect them from frost.
Ensure that no air gets trapped in the pipes.

Stickers on the connection side of the heat exchangers indicate the flow ( Fig. 31 /IN) and return connections ( Fig. 31 /OUT) for a counter flow arrangement. In special constructions of the heat exchanger, these stickers may not show the correct type of connection. The heat exchangers must always be connected in a counter flow arrangement. For questions on the connections, please contact the unit manufacturer.
Connect slide-out heat exchangers and droplet eliminators with bends and detachable connections as otherwise you will not be able to withdraw them.
Personnel: HVAC technician
Protective equipment: Industrial safety helmet Hearing protection Protective clothing Protective gloves Safety shoes

Fig. 32: Using water pump pliers to counter the tightening force
1. Hold the threaded pipe tail of the heat exchanger with water pump pliers ( Fig. 32 /2).
2. Hold the threaded pipe tail with the pliers while you use a spanner (hexagonal profile, Fig. 32 /1) to connect the heat exchanger to the pipework (pipework by others).

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installation
Connect the steam heat exchanger

Ventilation device
For optimum ventilation of the heat exchanger, we recommend that you install suitable air separators at the highest points of the system (e.g., above the air handling unit), which reduce the airflow velocity by increasing the cross section and can thus be ideally used for deaerating glycol systems.

If you have to attach brackets or fasteners to the AHU panels or frame, use only those specially approved for your AHU as otherwise there is a risk of leakages.

Fig. 33: Air separator with cross section enlargement

5.5 Connect the steam heat exchanger
Hot surfaces

Fig. 34: Exemplary illustration of the steam heat exchanger connections in a counter flow arrangement. 1 Airflow direction

WARNING!
Risk of injury from hot surfaces! Steam heat exchangers are operated with temperatures of >100 °C. Contact with surfaces of the heat exchanger causes severe skin burns.
Before performing any work on the heat exchanger, the supply of steam must be interrupted and you must ensure that the surface temperature has cooled down to room temperature, e.g. using an infrared thermometer.
DANGER!
Risk of leakage due to escaping steam If steam is released due to leakages, the supply of steam to the heat exchanger must be stopped immediately.
The heat exchanger must be fully emptied before repair work can be carried out. The steam is subject to high pressure; if the steam escapes due to a leakage, a hot steam jet can occur that can cause severe scalds.

Stickers on the connection side of the heat exchangers indicate the flow ( Fig. 34 /IN) and return connections ( Fig. 34 /OUT) for a counter flow arrangement. In special designs of the heat exchanger, these stickers may not show the correct type of connection. The heat exchangers must always be connected in a counter flow arrangement. For steam-operated heat exchangers, the return connection must be located at the bottom so that any condensate that occurs can be properly dissipated. For questions on the connections, please contact the unit manufacturer.

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 X2 / X-CUBE X2 compact

Installation
Connecting the run around coil system

Personnel: HVAC technician
Protective equipment: Industrial safety helmet Hearing protection Protective clothing Protective gloves Safety shoes

Protective gloves Safety shoes Safety harness

NOTICE!
Risk of damage to property from incorrect pipe connections!
Take care to connect the heat exchanger pipes correctly as otherwise the pipes may twist or become subject to adverse effects. This may eventually damage the heat exchanger beyond repair.
Connect pipes in such a way that the heat exchanger is not affected by vibration and that no loads are imposed on it.
If there is too much weight on a water pipe (by others), support the water pipe.
Do not use the connection point of the heat exchanger as a fixing point for other parts.
If an AHU is installed outdoors, use suitable pipes and protect them from frost.

5.6 Connecting the run around coil system
The proper connection of the pipework between the heat exchangers of the AHU and the hydraulic unit is carried out by the customer.
Connect heat exchangers in a counter flow arrangement as only a counter flow arrangement ensures that the calculated capacity is achieved. Use only suitable parts and materials and use only the marked connection points to connect the hydraulic unit.

Fig. 35: Setting up the hydraulic unit

1. Install the hydraulic unit so that it is parallel to the wall and floor.

2. Alignment of the hydraulic unit

using levelling feet (optional)

- Adjust the feet of the hydraulic unit so that it is level (use a 19 mm wrench).

without feet

- Level out floor unevenness using materials provided by others, e.g. rubber or elastomer sheets.

If you have to attach brackets or fasteners to the 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 X2 / X-CUBE X2 compact

Installation
Connecting the run around coil system

Connection on Heat hydraulic unit exchanger
Air handling unit

OUT-SUP

OUT

Description
Return supply air

4. Run-around coil systems with external feeding: Make the required connections ( Fig. 36 ). Connections for external feeding

Connection on hydraulic unit IN-CO OUT-CO IN-HE OUT-HE

External feeding
Water flow cooling Return cooling Water flow heating Return heating

Fig. 36: Hydraulic system connection (example)
Supply air unit Extract air unit hydraulic unit IN Flow OUT Return
3. Connect the heat exchanger with the hydraulic unit ( Fig. 36 ).
If there are several heat exchangers in airflow direction, connect the pipes in series.
The position of the connection points is given in the order-specific approval drawing.
If you are in doubt about the position of any pipes to be connected, please get in touch with our Technical Service.
Heat exchanger connection

Connection on Heat hydraulic unit exchanger
Air handling unit

IN-ETA

OUT-ETA

OUT

IN-SUP

Description
Flow extract air Return extract air Flow supply air

Ventilation device For optimum ventilation of the heat exchanger, we recommend that you install suitable air separators at the highest points of the system (e.g., above the air handling unit), which reduce the airflow velocity by increasing the cross section and can thus be ideally used for deaerating glycol systems.
Fig. 37: Air separator with cross section enlargement

Air handling unit X-CUBE X2 / X-CUBE X2 compact

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 (before shipment) at suitable interfaces and either pushed back into the cable ducts or rolled up. The wiring is shown in the wiring diagram (see switch cabinet).

Installation
Wiring

Fig. 38: Example of separate cables
1 Pull wire for pulling in cables without separation 2 Bus cable 3 Lighting 4 Anti-frost thermostat

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installation
Wiring

Interface connections

Component

Connection

X-CUBE Control

Bus black cable with black M12 plug connection
Lighting grey cable with black M12 plug connection

M12 plug connections

X-CUBE Control sensors
Anti-frost thermostat black cable with black 3-pin M8 plug connection
Duct smoke detector 1 black cable with black 4-pin plug connection
Duct smoke detector 2 black cable with red 4-pin plug connection

M8 plug connector

Fans with < 13 A power consumption are pluggable.

Fans > 13 A, double fans or fan arrays

5-pin power plug connector No discontinuities, rolled-up cables

Rotary heat exchanger

Shut-off dampers with spring return actuator torque > 20 Nm

3-pin power plug connector No discontinuities, rolled-up cables

Job Plug the connectors together straight and tighten by hand. Then tighten the screw connections by 90° with the open-end spanners (securing against working loose).
Plug M8 plug connections together straight.
plug together straight and close retainer (protection against working loose).
Route the cables through the intended cable routes and connect them to the switch cabinet according to the circuit diagram. plug together straight and close retainer (protection against working loose).
Route the cables through the intended cable routes and connect them to the switch cabinet according to the circuit diagram.

None of the other regulation and control components are designed to be pluggable. The rolled-up cables must be routed through the intended cable routes and connected to the switch cabinet according to the circuit diagram.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installation
Connecting the air handling unit to the power su...

Connecting cables

5.8 Connecting the air handling unit to the power supply
Electrical connection

Fig. 39: Connection of the cables
1. Place the AHU casing units as close together as possible so that you can connect the cables.
Note: If there is not much space, you can also connect the cables inside the AHU casing unit.
2. First run the cables in sections through the air handling unit 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.
3. Then connect the separate cables according to the type of plug and the colours of the cable and plug, Ä `Interface connections' on page 42 . Connect only cables with the same code.
4. When you push the AHU casing units together, feed the cables into the mesh cable trays and be careful to not damage any cables.

DANGER!
Danger of death due to electric current!
Danger of electric shock! Do not touch any live components!
Only a skilled qualified electrician must connect the power supply.
For air handling units with integral controls use the circuit diagram in this manual, Ä `Other applicable documentation' on page 3
Lay connecting cables in such a way that they cannot be accidentally damaged by mechanical impact or by heat.
Bridge all non-conductive joints, such as connecting frames, flexible connectors and antivibration elements, with an equipotential bonding cable.
Earth the air handling unit according to the state of the art.
Secure all connections so that they cannot come loose.
When you connect any electrical components, follow the manufacturers' specifications, the local regulations and codes of good practice (DIN/ VDE), and the general recommendations for avoiding electromagnetic interference,
If an AHU is installed outdoors, do not neglect the effects of weather on the unit (rain, snow, wind, sun etc.).

If you have to attach brackets or fasteners to the AHU panels or frame, use only those specially approved for your AHU as otherwise there is a risk of leakages. Avoid screw joints that pierce the outer shell of the unit; if you cannot avoid them, then at least seal them to prevent the ingress of water. The minimum protection level is IP 65.
1. Units with controls
The electrical circuit diagrams and terminal plans can be found in the circuit diagram included in the supply package.
Connect the electrical components, such as the electric air heater, electric motor, and actuator. 2. Include the air handling unit in the equipotential bonding arrangement. 3. Test protective conductors and insulation resistance to EN 60204 (VDE 0113). Take the appropriate safety precautions!

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installation
Connecting the controls to your PC or local netw... > X-CUBE controller CX8090

5.9 Integrating the air handling unit with the central BMS
It is the duty of the system owner/HVAC contractor to integrate the air handling unit with the building services and to ensure conformity, Ä `System owner's obligations' on page 8 and Ä `Conformity assessment' on page 21 .

5.10 Connecting the controls to your PC or local network
Network or PC
Air handling units with optional integral controls are fitted with a touch panel on which the configuration and control parameters of the unit are displayed. This allows you to view all measured values and to enter setpoint values.
You can use a computer with a web browser instead of the touch panel to display the unit configuration. 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 XCUBE Control operating instructions.
5.10.1 X-CUBE controller CX8090
Integration with the network, setting the IP address Personnel: Skilled qualified electrician Network administrator For more information refer to https://infosys.beckhoff.com/content/1031/cx8090/html/ cx8090_title.htm?id=1470

Fig. 40: X-CUBE controller CX8090, network connections
X001 - Port for the X-CUBE touch panel and for the TROX Service
X101 - Port for BMS computer X102 - Port for another X-CUBE unit (e.g. daisy
chain) or another BMS computer DIP switch

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installation
Connecting the controls to your PC or local netw... > X-CUBE controller CX8090

Connection: Use network cables with RJ45 plugs (at least cat. 5).

Factory set network address X001

IP address Subnet mask Standard gateway

192.168.0.200 255.255.255.0 192.168.0.1

Setting the IP address for connection X101/102 1. Set the DIP switch according to the table.

DIP switch 1...8 9 and 10

Setting ON OFF

For more information: https://infosys.beckhoff.com/content/1031/cx8090/ html/cx8090_dip_switch.htm?id=1492
After you have set the DIP switch, you have to restart the computer. To do so, switch off circuit breaker 11Q1 in the switch cabinet. Wait until all LEDs on the computer are OFF. Switch the circuit breaker on again in order to restart the computer.

Fig. 42: File menu
5. Go to the `File' menu and select `Connect' .
In the `Connect' window enter IP address 192.168.0.200 and confirm your entry with OK.

Fig. 41: Cerhost software download 2. Go to http://infosys.beckhoff.com/ and search for
cerhost, then download the software and install it on a PC or notebook.
3. Use a network cable to connect to port X001 the PC or notebook on which you have installed `Cerhost' . If the port is already being used, e.g. for the touch panel, pull out the cable.
4. Start `Cerhost' .
ð The starting screen is displayed.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installation
Connecting the controls to your PC or local netw... > X-CUBE controller CX9020
ð When the connection has been established, a window opens and the script is executed.

Fig. 43: Script window

Fig. 46 8. In the next window select `TCCCAMTMP1' .
The `'TCCCAMTMP1 Ethernet Driver' Setting' window opens. Select `Specify an IP address' and enter the required network settings. Confirm your entries with `OK' and close the `Control Panel' window.
The new settings are immediately active; you need not restart the computer.
9. Remove the network cable from port X001 and connect the touch panel again.
Connect the BMS computer to port X101.
You can use port X102 as described above.

Fig. 44: Start menu 6. Go to the Start menu and select `Control Panel' .

5.10.2 X-CUBE controller CX9020
Integration with the network, setting the IP address
Personnel: HVAC technician Skilled qualified electrician Network administrator
For more information refer to https://infosys.beckhoff.com/content/1031/cx9020_hw/ index.html?id=1759

Fig. 45: Control panel 7. In the `Control Panel' window click on `Network
and Dial-up Connections' .

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installation
Connecting the controls to your PC or local netw... > X-CUBE controller CX9020
2. Use a network cable to connect to port X000 the PC or notebook on which you have installed `Cerhost' . If the port is already being used, e.g. for the touch panel, pull out the cable.
3. Start `Cerhost' . ð The starting screen is displayed.

Fig. 47: X-CUBE controller CX9020, network connections
X000 - Port for the touch panel X001 - Port for a BMS computer or for another X-
CUBE unit (e.g. daisy chain)
Connection: Use network cables with RJ45 plugs (at least cat. 5).

Factory set network address X000 / X001

IP address Subnet mask Standard gateway

192.168.0.200 255.255.255.0 192.168.0.1

Setting the IP address for X000 and X001

Fig. 48: Cerhost software download
1. Go to http://infosys.beckhoff.com/ and search for cerhost, then download the software and install it on a PC or notebook.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installation
Connecting the controls to your PC or local netw... > X-CUBE controller CX9020

Fig. 51: Start menu 5. Go to the Start menu and select `Control Panel' .

Fig. 49: File menu
4. Go to the `File' menu and select `Connect' . In the `Connect' window enter IP address 192.168.0.200 and confirm your entry with OK.
ð When the connection has been established, a window opens and the script is executed.

Fig. 52: Control panel 6. In the `Control Panel' window click on `Network
and Dial-up Connections' .

Fig. 50: Script window

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installation
Connecting the controls to your PC or local netw... > X-CUBE controller CX9020

Standard gateway

192.168.0.1

Fig. 53 7. In the next window select `FEC1' .
The `'FEC Ethernet Driver Settings'' window opens. Select `Specify an IP address' and enter the required network settings. Confirm your entries with `OK' and close the `Control Panel' window.
The new settings are immediately active; you need not restart the computer.
8. Remove the network cable from port X000 and connect the touch panel again.

Fig. 54: Starting screen
1. After you have changed the network settings you need to restart the computer. To do so, switch off circuit breaker 11Q1 in the switch cabinet. Wait until all LEDs on the computer are OFF. Switch the circuit breaker on again in order to restart the computer.
On the starting screen select `Settings...' .

NOTICE!
Touch panel address The IP address applies to both ports, i.e. X000 and X001. If you change the IP address, you have to enter the new address also on the touch panel.
Connect the BMS computer or another X-CUBE unit to port X001.

Fig. 55: Password entry
2. Touch the entry field (*) to display the keyboard. Enter the password +-+- (PlusMinusPlusMinus) and confirm your entry with `OK' .

Setting the IP address for the touch panel
Personnel: HVAC technician

Factory set network address for the touch panel

IP address Subnet mask

192.168.0.199 255.255.255.0

Use the shift key to enter + (plus).

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installation
Connecting the controls to your PC or local netw... > X-CUBE controller CX9020

Fig. 56: Settings 3. In the `Settings' window select `OS Settings...' .

Fig. 59: Change IP Settings 6. In the `Change IP Settings' window select `IP
Address' .

Fig. 57: Setup Main 4. In the `Setup Main' window select `Network
Settings' .

Fig. 60: IP Address 7. In the `IP Address' window enter the new IP
address and subnet for the touch panel. Confirm your entries with `OK' . In the `Change IP Settings' window ( Fig. 59 ) select `Gateway' .
Network addresses and settings The network addresses (IP, subnet and gateway) have to be the same as the settings on controller CX9020.

Fig. 58: Network Settings 5. In the `Network Settings' window select `Fix
Settings' . Enter the password +-+- again.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installation
Connecting the controls to your PC or local netw... > X-CUBE controller CX9020

Fig. 61: Gateway 8. In the `Gateway' window enter the new gateway
settings. Confirm your entries with `OK' . In the `Change IP Settings' window ( Fig. 59 ) select `Home' and accept that changes are saved.

Fig. 62: Settings 9. The `Settings' window opens. Enter the IP
address for controller CX9020 http://xxx.xxx.xxx.xxx/trox.html and confirm your entries with `Save' . Select `Quit' to close the menu. The touch panel now uses the new settings to connect to the controller.
If no connection to the controller can be made, briefly interrupt the supply voltage to be able to see the `starting screen' again. On the `starting screen' select `Settings' . Check and change settings if necessary.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Initial commissioning
Before initial commissioning

6 Initial commissioning
6.1 Safety notes regarding initial commissioning
Incorrect initial commissioning
WARNING! Risk to life from incorrect initial commissioning! Incorrect initial commissioning can lead to potentially fatal situations and cause considerable damage to property. Only skilled qualified electricians must work on
the electrical system and on motors. All other initial commissioning steps must be car-
ried out by an HVAC technician.
Inspection access doors on the discharge side
CAUTION! Risk of injury from a strong airflow on the discharge side of fans! When you open an inspection access door on the discharge side of the fan, the velocity and pressure of the airflow may cause the door to suddenly swing open until it is caught by the safety catch. You could be injured. Be careful when you open inspection access
doors on the discharge side.

Inspection access doors slamming shut
WARNING! Risk of crushing from doors slamming shut Inspection access doors may slam shut by the wind or if someone pushes them inadvertently, resulting in serious injury to the head and limbs. Secure each inspection access door with a hold
open device. Secure inspection access doors without a hold
open device against closing by suitable means. Do not reach between the door and door frame. Wear protective gloves and a hard hat when you
open an inspection access door.
Crushing hazard.
WARNING! Crushing hazard from movable parts! There is an increased risk of crushing on casing units, doors, panels and components of the device. Never reach between moving parts. Be careful when carrying out any work. Wear protective gloves, safety shoes and a hard
hat.
Damage to inspection access doors

Sharp edges, sharp corners and thin sheet metal parts
CAUTION!
Danger of injury from sharp edges, sharp corners 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.

NOTICE!
Physical damage to inspection access doors
Do not open inspection access doors which are hinged on one side if their width is ³1000 mm or more! The closures can be damaged due to the weight and the leverage forces that occur.
In the case of inspection access doors from a width of ³1000 mm, always open all closures and remove the door from the air handling unit.
Store doors safely where they are protected against damage!

6.2 Before initial commissioning
The air handling unit has been erected, assembled, and installed according to this manual.
Before initial commissioning, check the casing and the following parts for damage and correct position:
Inspection access doors and openings Seals Handles and levers

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Initial commissioning
Setting up and adjusting AHU casing units > Centrifugal fan

Connections Inspection windows Panels
Before initial commissioning:
Remove protective film, if any Check the unit for leakages Check inspection access doors and openings for
function Set up the centrifugal fan, Ä `Set up the centrifugal
fan' on page 54 Insert the filters, Ä `Filters, inserting' on page 55 Set up the heating coil/cooling coil, Ä `Commis-
sioning the heating coil/cooling coil' on page 56 Set up the multileaf dampers, Ä `Setting up multileaf
dampers' on page 58 Set up the sound attenuator, Ä `Setting up sound
attenuators' on page 59 Set up the rotary heat exchanger, Ä `Setting up the
rotary heat exchanger' on page 59 Set up the run around coil system, Ä `Commis-
sioning the run around coil system' on page 57 Set up the plate heat exchanger, Ä `Setting up the
plate heat exchanger' on page 60 Remove the protective caps from the condensate
drains and connect the drain trap, Ä Chapter 5.3 `Connecting the condensate drain' on page 34 Clean the air handling unit, Ä Operating manual, Maintenance.

Pressure measuring devices
Fig. 63: Pressure measurement point 1 Bellmouth inlet 2 Partitioning panel M1 Pressure measurement point in the fan chamber M2 Pressure measurement point on the bellmouth inlet M3 Pressure measurement point in front of the parti-
tioning panel The fans may be factory fitted with pressure measuring devices (optional). The following pressure values are measured at the pressure measurement point ( Fig. 63 /M2) in the bellmouth inlet ( Fig. 63 /1), the pressure measurement point ( Fig. 63 /M1) in the fan chamber, and the pressure measurement point ( Fig. 63 /M3) in front of the partitioning panel.

6.3 Setting up and adjusting AHU casing units
6.3.1 Centrifugal fan
Operating point
The control system calculates the operating point and sets the default setpoint value for the fan.
During commissioning ensure that the following values are not exceeded:
Maximum fan speed Minimum fan speed Motor rating
Do not change the clearance between the rotor and the bellmouth inlet.

Pressure
Static fan pressure increase
Effective pressure (D p w ) of the fan

Determined from
Differential pressure between M1 and M3
The differential pressure between M2 and M3 is used to calculate the volume flow rate.

Calculation of the volume flow rate

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 X2 / X-CUBE X2 compact

Initial commissioning
Setting up and adjusting AHU casing units > Centrifugal fan

Set up the centrifugal fan
WARNING!
Risk of injury from the incorrect handling and operation of fans! Incorrect handling, e.g. reaching into rotating parts, can lead to serious injuries.
Do not reach into the moving fan or tamper with it.
The fan does not stop immediately! Check that no parts are moving before you open an inspection access door.
Do not put a damaged or defective fan into operation.
Do not exceed a fan's maximum capacity, e.g. when there are strong vibrations or against a closed multileaf damper.
Switch off the system before you start working on movable fan parts and secure it against accidentally being switched on again. Wait until all parts have come to a standstill. Switch off the system before you start working on movable fan parts and secure it against accidentally being switched on again. Wait until all parts have come to a standstill. Switch off the AHU before you start working on movable fan parts and secure it against accidentally being switched on again. Wait until all parts have come to a standstill. Switch off the system before you start working on movable fan parts and secure it against accidentally being switched on again. Wait until all parts have come to a standstill.
WARNING!
Risk of fire from damaged fan parts! Grinding rotors or overheating bearings can cause a fire and eventually serious or even fatal injuries.
Do not put a damaged or defective fan into operation.
The power consumption must not exceed the specified nominal current.
Make sure that the maximum motor speed is not exceeded.
Personnel: Skilled qualified electrician
Protective equipment: Protective clothing Hearing protection Industrial safety helmet Protective gloves Safety shoes

1. Remove the red transport protection devices from the fan.
2. Check the fan for shipping damage, imbalance, corrosion and contamination.
3. Check ducts and fan for foreign matter. 4. Turn the rotor manually to check that it moves
freely.
The clearance between the rotor and the bellmouth inlet may have changed due to vibrations during transport. Check before commissioning that the distance between the inner edge of the rotor and the outer surface of the bellmouth inlet is the same everywhere. 5. Tighten all fixing screws. 6. Check the bearings and relubricate them if necessary. 7. Make sure that the multileaf dampers are open, Ä `Setting up multileaf dampers' on page 58 . 8. Check the direction of rotation of the fan by switching on the motor for a moment.
Nominal motor power of 3 kW and higher: star delta start.
In units with a fan with asynchronous motor, the arrow indicating the direction of rotation can be found on the fan casing. In units with an EC fan, the fan will automatically start in the correct direction of rotation. 9. You can change the direction of rotation by swapping the terminal connections. 10. Ensure that the unit has been correctly earthed. 11. Close all inspection access doors on the air handling unit Ä Operating manual. 12. Measure the power consumption with the inspection access doors closed and compare it with the nominal current.
If the power consumption exceeds the value given on the motor rating plate, switch off the fan immediately. 13. Check the function of the anti-vibration elements.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Initial commissioning
Setting up and adjusting AHU casing units > Heating coil/cooling coil

14. Moving towards the operating point, check whether the fan is running smoothly and with minimal vibration only.

If you can see or hear the fan vibrating, switch off the air handling unit, Ä Contacting the TROX Technical Service .
15. Measure the volume flow rate. ð The centrifugal fan has been set up.

6.3.2

Filter

Filters, inserting

Personnel: HVAC technician

Protective equipment: Industrial safety helmet Protective clothing Protective gloves Safety shoes

Filters may become contaminated due to construction work in the building which is why we recommend that you replace all filters after the construction phase and initial commissioning.
Do not operate the air handling unit without a filter.
One spare filter element should always be available so that the air handling unit does not have to be switched off. Store filters in a dry place, free from dust, so that they will not be contaminated or damaged. Do not use filters beyond the use before date. Original TROX filters carry a sticker on the frame with both the use before date and information on how to order replacements.
1. Ensure that the filters are intact.

Clean the air handling unit and ventilation ducts before you install any filter of class F9 or higher.
3. Fit filters into the installation subframe and fix them with the clamping elements. Make sure that they are tightly seated.
ð The filter has been set up.
6.3.3 Heating coil/cooling coil
Heat transfer fluids with glycol
WARNING!
Health risk from heat transfer fluids that contain glycol! The heat transfer fluids in the heating coil, cooling coil and run around coil system contain glycol, which can damage your health if it comes into contact with your skin, if you swallow it or if you inhale the vapour or mist.
Avoid contact with heat transfer fluids that contain glycol.
Work must only be carried out by skilled qualified refrigeration technicians, HVAC technicians or the Ä TROX Technical Service .
Do not eat, drink or smoke while handling heat transfer fluids that contain glycol.
Wash your hands when you interrupt or finish your work.
If you have come into contact with a heat transfer fluid that contains glycol, follow the first aid instructions given on the safety data sheet for the heat transfer fluid.
When you have to handle a heat transfer fluid that contains glycol, wear the personal protective equipment specified in the safety data sheet for the heat transfer fluid.

Defective filters may become torn while in use and will then no longer be effective. 2. Remove any dust from all parts that are in upstream direction before the filter.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Initial commissioning
Setting up and adjusting AHU casing units > Heating coil/cooling coil

Commissioning the heating coil/cooling coil Personnel: HVAC technician Protective equipment: Industrial safety helmet Protective clothing Protective gloves Safety shoes
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.
Optimum ventilation For the best possible ventilation, we recommend installing on-site ventilation equipment at the highest point of the system; see Ä on page 36 .
1. Ensure that the flow and return connections are correct.
2. Check that fittings are correctly installed. 3. Flush the system to remove any contamination. 4. Open vents (unless automatic vents have been
installed).

5.
For glycol water mixtures we recommend ready-to-use formulations. See the order-specific air handling unit data sheet from TROX for the mixing ratio. The correct mixing ratio is important: Too much glycol will impair performance Too little glycol may lead to frost damage . Only use one of the following glycols for the air handling unit: Propylene glycol Ethylene glycol
Slowly pour the heat transfer fluid into the heat exchanger at the lowest point in the system. As you fill the system, check that all external and internal screw joints and connections are tight. 6. Vent the heating coil/cooling by opening the upper spigot and the bleed screw.
If the air heater is not properly vented, air bubbles may form and impair the performance.
7. Close any vents. 8. Clean the condensate drip tray and drain. 9. Set up the droplet eliminator. 10. Fill the drain trap with water.

Evaporators: As soon as you open the heat exchanger connection, the contained nitrogen shield gas content should escape with a hissing sound. The absence of this sound indicates a leak which has to be fixed before commissioning.

NOTICE!
Risk of damage to property! When you tighten thread connections, be sure to
use a suitable tool (e.g. water pump pliers) to counter the tightening force as otherwise you may inadvertently damage the parts.
11. Check the flange screw joints and tighten them if necessary.
ð The heating coil/cooling coil has been set up.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Initial commissioning
Setting up and adjusting AHU casing units > Run around coil system

6.3.4 Electric air heater
Personnel: Skilled qualified electrician
Protective equipment: Protective clothing Hearing protection Industrial safety helmet Protective gloves Safety shoes
In air handling units with X-CUBE Control (controls), both the temperature monitoring and the safety temperature limiter operate independently of one another to ensure that no inadmissible overheating occurs at the electric air heater.
For air handling units with on-site controls, on-site measures must be taken to prevent impermissible temperature excesses. The manufacturer documentation must be observed for this purpose, see attachment.
CAUTION!
Protection against overheating The electric air heater must be installed so that the heating elements cannot start up before the intended air volume flow is reached. The electric air heater must be put out of operation as soon as the volume flow rate is reduced to a level that is not permitted or the fan is switched off.
To prevent a temperature excess that is not permitted, two temperature-limiting devices must be installed in the air handling unit independently of each other (temperature monitor and safety temperature limiter).
6.3.5 Run around coil system
The run around coil system must only be put into operation after the entire system has been professionally connected and checked (both hydraulic and electrical systems). These checks have to be recorded, and the results have to be available at the time of commissioning.

Heat transfer fluids with glycol
WARNING!
Health risk from heat transfer fluids that contain glycol! The heat transfer fluids in the heating coil, cooling coil and run around coil system contain glycol, which can damage your health if it comes into contact with your skin, if you swallow it or if you inhale the vapour or mist.
Avoid contact with heat transfer fluids that contain glycol.
Work must only be carried out by skilled qualified refrigeration technicians, HVAC technicians or the Ä TROX Technical Service .
Do not eat, drink or smoke while handling heat transfer fluids that contain glycol.
Wash your hands when you interrupt or finish your work.
If you have come into contact with a heat transfer fluid that contains glycol, follow the first aid instructions given on the safety data sheet for the heat transfer fluid.
When you have to handle a heat transfer fluid that contains glycol, wear the personal protective equipment specified in the safety data sheet for the heat transfer fluid.
Commissioning the run around coil system
Personnel: HVAC technician
Protective equipment: Industrial safety helmet Protective clothing Protective gloves Safety shoes
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 X2 / X-CUBE X2 compact

Initial commissioning
Setting up and adjusting AHU casing units > Multileaf dampers

Optimum ventilation For the best possible ventilation, we recommend the installation of ventilation equipment by others at the highest point of the system, see Ä `Setting up and connecting the hydraulic unit' on page 39 .
1. Ensure that the flow and return connections are correct.
2. Check that fittings are correctly installed. 3. Flush the system to remove any contamination. 4. Check the run around coil system for leaks. 5. Open vents (unless automatic vents are installed). 6.
For glycol water mixtures we recommend ready-to-use formulations. See the order-specific air handling unit data sheet from TROX for the mixing ratio. The correct mixing ratio is important: Too much glycol will impair performance Too little glycol may lead to frost damage
Only use one of the following glycols for the air handling unit: Propylene glycol Ethylene glycol
Slowly pour the heat transfer fluid into the heat exchanger at the lowest point in the system. As you fill the system, check that all external and internal screw joints and connections are tight. 7. Vent the heating coil/cooling by opening the upper spigot and the bleed screw.
If the air heater is not properly vented, air bubbles may form and impair the performance.
8. Close any vents. 9. Clean the condensate drip tray and drain. 10. Set up the droplet eliminator. 11. Fill the drain trap with water.
NOTICE! Risk of damage to property! When you tighten thread connections, be sure to
use a suitable tool (e.g. water pump pliers) to counter the tightening force as otherwise you may inadvertently damage the parts.

12. Check the flange screw joints and tighten them if necessary. ð The run around coil system has been set up.
6.3.6 Multileaf dampers
Movable parts of multileaf dampers
WARNING! Crushing hazard from movable parts! Closing multileaf dampers may crush your hands and arms. Do not reach between the damper blades. Prevent access to crush points: Either install
dampers on ducts or use fixed guards. Before you open an inspection access door,
switch off the air handling unit and secure it against being switched on accidentally.
Setting up multileaf dampers Set the AHU control system in such a way that the fan does not operate against a closed damper. TROX does not accept liability for damages resulting from incorrect operation. To prevent damage due to pressure surges from fire dampers, pressure relief dampers should be installed.
TROX cannot guarantee leak-free dampers if the actuators are provided and installed by others.
Powered dampers Personnel: HVAC technician Protective equipment: Industrial safety helmet Protective clothing Protective gloves Safety shoes
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 X2 / X-CUBE X2 compact

Initial commissioning
Setting up and adjusting AHU casing units > Rotary heat exchanger

Coupled dampers (for plate heat exchanger)
Personnel: HVAC technician
Protective equipment: Industrial safety helmet Protective clothing Protective gloves Safety shoes
1. Check that the friction locking of the linkage is correct.
2. Check the direction of rotation direction and ensure that the blades fully open and close.
3. Check that all screw joints and connections are tight.
ð The coupled multileaf dampers have been set up.

Adjusting the rotary heat exchanger The storage mass of the rotary heat exchanger is factory set. You may have to adjust the storage mass to the actual installation conditions, see Ä Appendix A `Adjusting the storage mass' on page 71 .
Setting up the rotary heat exchanger Personnel: HVAC technician Protective equipment: Protective clothing Hearing protection Industrial safety helmet Protective gloves Safety shoes

6.3.7

Sound attenuator

Setting up sound attenuators

The splitter filling is made of non-combustible absorption material to DIN 4102.

Personnel: HVAC technician

Protective equipment: Industrial safety helmet Protective clothing Protective gloves Safety shoes

Check splitters for damage and contamination. ð The sound attenuator has been set up.

6.3.8 Rotary heat exchanger

Ensure that permitted values for parameters such as temperatures or differential pressure are not exceeded. 1. Check whether the system has been correctly
installed. 2. Inspect the rotary heat exchanger for foreign
matter. 3. Check that the rotor moves freely.
See the manufacturer's documentation Ä Appendix A `Adjusting the storage mass' on page 71 . 4. Check the rotation direction of the rotor and change it on the motor controller, if necessary. Follow the manufacturer's operating instructions.

WARNING!
Risk of injury from rotating parts! Incorrect handling, e.g. reaching into rotating parts, can lead to serious injuries.
Never reach into or tamper with the storage mass
Switch off the system before you start working on movable parts of the rotary heat exchanger and secure it against accidentally being switched on again. Wait until all parts have come to a standstill.
Do not put a damaged or defective rotary heat exchanger into operation.

If the heat exchanger includes a purge sector, the rotating storage mass passes from the extract air via the purge sector to the supply air.
5. Check that the control module functions correctly. 6. Check the drive belt tension. 7. Setting up the drive equipment, Ä `Setting up the
drive equipment' on page 60 .

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Initial commissioning
Setting up and adjusting AHU casing units > Plate heat exchanger

8. Check that the seals are tight; readjust them, if necessary.
See the manufacturer's documentation Ä Appendix A `Adjusting the storage mass' on page 71 .
ð The rotary heat exchanger has been set up.
Setting up the drive equipment Personnel: Skilled qualified electrician Protective equipment: Protective clothing Hearing protection Industrial safety helmet Protective gloves Safety shoes
We recommend that you check the tension of the drive belt regularly during the first 400 hours of operation. 1. Open the inspection access panel on the indicated
corner of the rotor casing. 2. Check whether the drive belt has sufficient ten-
sion; if necessary, shorten the belt as follows: Shortening the drive belt 3. Open the lock. 4. Shorten the belt as required. 5. Close the lock. 6. Close the inspection access panel. Checking the motor 7. Ensure that the motor is securely fixed.
ð The drive equipment has been set up.

NOTICE!
Risk of damage to property from extreme pressure drop! An extreme pressure drop between the supply air and extract air flows can damage the heat exchanger.
Ensure that the maximum differential pressure (approx. 1000 Pa, depending on unit design) is not exceeded.
Check differential pressure on pressure monitors according to the specified intervals.
Check and, if necessary, clean the plate heat exchanger to remove foreign matter and contamination.
ð The plate heat exchanger has been set up.

6.3.9 Plate heat exchanger
Setting up the plate heat exchanger
Personnel: HVAC technician
Protective equipment: Industrial safety helmet Protective clothing Protective gloves Safety shoes

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Initial commissioning
Starting the air handling unit > Before you start the AHU

6.3.10 Humidifier
Setting up the humidifier Personnel: HVAC technician Protective equipment: Protective clothing Industrial safety helmet Hearing protection Protective gloves Safety shoes
The position of the droplet eliminator cassettes may have changed due to vibrations during transport. If there are gaps between the cassettes, mist from the humidifier module could get into the unit and accumulate to water.
1. Check the position of each droplet eliminator cassette of the humidifier. If there is a gap between any two cassettes, adjust the position of the cassettes. The droplet eliminator cassettes are arranged in two rows, staggered one behind the other, so the gap dimensions on the upstream and downstream sides of the humidifier must be checked. It may be necessary to disconnect ducts to get access to the cassettes.
2. NOTICE!
Be sure to comply with the humidifier manufacturer's instructions for commissioning. 3. Check water connections and water pipes installed in the air handling unit for leaks. Retighten the screw connections in case of leaks. ð The humidifier is now ready for use.

6.3.11 Electrical system
Personnel: Skilled qualified electrician
Protective equipment: Protective clothing
Hearing protection
Industrial safety helmet
Protective gloves
Safety shoes
Before commissioning, the electrical system has to be tested according to IEC 60364-6 (VDE 0100-600). As part of this test, all contacts have to be checked for correct seating. This applies in particular to motor terminal blocks, fuses, local isolators etc.
6.4 Starting the air handling unit
6.4.1 Before you start the AHU
Before you switch on the air handling unit, make sure that the following requirements have been met:
Has the air handling unit been checked for damage? Have the transport protection devices been
removed? Have the filters been inserted? Have all inspection access doors and openings
been closed? Have all ducts in the AHU been connected? Have the AHU and the connected ducts been tested
for any leaks? Has the interior of the air handling unit been
cleaned? Have all drain traps been filled with water? Does the supply of power and of operating fluids
meet all requirements? Has all the safety equipment been installed? Does it
work properly? Have all the electrical connections been made and
secured according to the relevant national standards? Has the heating coil/cooling coil been correctly connected and filled? Has the centrifugal fan been set up? Have the multileaf dampers been set up? Has the sound attenuator been set up? Has the rotary heat exchanger been set up? Has the run around coil system been correctly filled? Has the plate heat exchanger been set up? Are the environmental conditions for correct use being met?

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Initial commissioning
Starting the air handling unit > Starting
6.4.2 Starting
Personnel qualified to start the air handling unit Only specially trained individuals must start the air handling unit. 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 X2 / X-CUBE X2 compact

Removal and disposal
Safety notes regarding disassembly and disposal

7 Removal and disposal
7.1 Safety notes regarding disassembly and disposal
Incorrect disassembly
DANGER!
Risk to life from incorrect assembly and disassembly! Incorrect assembly or disassembly can result in risks to life and limb and in environmental hazards.
Before you start disassembly, professionally disconnect all electrical cables. Only a skilled qualified electrician must disconnect the power supply. Ensure that no voltage is present.
Before you start disassembly, correctly drain all operating fluids. Disconnect operating fluid pipes and hoses. Ensure that operating fluids are disposed of correctly.
If you have any questions regarding disassembly, refer to the assembly instructions in this manual. Pay attention to the component manufacturers' documentation.
Only trained specialist personnel must remove any components.
If necessary, use additional personal protective equipment for outdoor installations, e.g. a safety harness.

Improper transport equipment
WARNING!
Risk to life from using improper transport equipment! 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 workplace. 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.
Ä 2.3.1 `Residual risks' on page 9

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 injuries.
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).

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Removal and disposal
Disposal

Crushing hazard.
WARNING! Crushing hazard from movable parts! There is an increased risk of crushing on casing units, doors, panels and components of the device. Never reach between moving parts. Be careful when carrying out any work. Wear protective gloves, safety shoes and a hard
hat.
Inspection access doors slamming shut
WARNING! Risk of crushing from doors slamming shut Inspection access doors may slam shut by the wind or if someone pushes them inadvertently, resulting in serious injury to the head and limbs. Secure each inspection access door with a hold
open device. Secure inspection access doors without a hold
open device against closing by suitable means. Do not reach between the door and door frame. Wear protective gloves and a hard hat when you
open an inspection access door.
Sharp edges, sharp corners and thin sheet metal parts
CAUTION! Danger of injury from sharp edges, sharp corners 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.
ENVIRONMENT! Risk of harm to the environment due to incorrect disposal of goods and packaging! Incorrect disposal can harm the environment. Have electronic waste, electronic components
and operating fluids (refrigerant, compressor oil, lubricants etc.) disposed of by an approved specialist disposal company.

7.2 Disassembly
Personnel: HVAC technician Skilled qualified electrician
Protective equipment: Industrial safety helmet Protective clothing Hearing protection Protective gloves Safety shoes
1. Disconnect electrical cables.
Ensure that no voltage is present.
2. Remove all operating fluids.
Properly dispose of all operating fluids.
3. Disconnect operating fluid pipes and hoses.
4. Open all module connectors and base frame connectors.
5. Remove the various unit components.
Use suitable transport equipment to move unit components away from the site.
7.3 Disposal
If no return or disposal agreement is in place, any disassembled components should be disposed of by an approved specialist disposal company.
Components that are no longer required should be recycled:
Scrap the metals. Take plastic parts to be recycled. Dispose of other components and waste in a suit-
able manner, i.e. depending on their material properties.
Electrical and electronic components
Electrical and electronic components can contain materials and substances that are hazardous to health and the environment and which must not get into household and commercial waste.
As electrical and electronic components may also contain recyclables (e.g. precious metals), they must be provided for recycling or disposal by a specialist disposal company.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Chemicals Chemicals (solvents, cleaning agents, operating fluids, etc.) affect the air, soil, water, and human health in various ways. In some cases, valuable substances can be extracted from them.
Chemicals must therefore not get into the air, soil, sewerage system, surface water or groundwater.
Commission an approved specialist disposal company to recover or dispose of chemicals.
Refrigerant R-410A Refrigerants may contain substances that are toxic and hazardous to the environment, or which release hazardous decomposition products. These must not be released into the environment. Commission a specialist disposal company to dispose of hazardous substances and materials.
Coolant, glycol Coolants may contain substances that are toxic and pose a hazard to the environment. They must not be released into the environment. Commission a specialist disposal company to dispose of hazardous substances and materials.
Batteries Battery components are toxic and pose a hazard to the environment. Batteries must not be disposed of with domestic waste. Batteries must only be disposed of by locally approved specialist companies.
Lubricants Lubricants such as greases and oils contain toxic substances. They must not be released into the environment. Commission a specialist disposal company to dispose of hazardous substances and materials.
Compressor oil Compressor oil must not enter sewerage systems or bodies of water. Commission a specialist disposal company to dispose of hazardous substances and materials.

Removal and disposal
Disposal

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Glossary

8 Glossary
Exhaust air EHA Air that flows from an internal space to the outside.
Extract air ETA Air that flows out of a conditioned room.

Supply air SUP Air that is supplied to a conditioned internal space; it is also conditioned air that enters an air handling unit.
Transfer air TRA Air that flows from one conditioned internal space to another conditioned internal space.

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 regulations and instructions. HVAC technicians are individuals who have in-depth knowledge and skills related to HVAC systems; they are also responsible for the professional completion of the work under consideration.

Indoor air IDA Air in a conditioned internal space.

ODA Outdoor air
Untreated air that flows through an inlet into the air handling unit or a building.

Recirculated air RCA
Extract air that is reconditioned in the air handling unit and supplied to an internal space again.

Secondary air SEC
Air that is conditioned and then supplied to the same room from which it was extracted.

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 electrical systems, understand any potential hazards related to the work under consideration, and recognise and avoid any risks involved.

Skilled qualified refrigeration technicians
Skilled qualified refrigeration technicians have been trained in the field of refrigeration engineering, and they know the relevant standards and guidelines. Evidence of the relevant experience claimed must be available. Skilled qualified refrigeration technicians are individuals who have sufficient professional or technical training, knowledge and actual experience to enable them to work on refrigeration systems, understand any potential hazards related to the work under consideration, and recognise and avoid any risks involved.

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Index

9 Index
A
Accident..................................................................... 11 Adjusting multileaf dampers...................................... 58 AHU casing units
Applying sealing tape........................................... 29 Assembling AHU casing units for outdoor installation............................................................ 29 Assembling the roof segments............................. 29 Cover strips for the intermediate frame, fixing..... 31 Fitting base frame plugs....................................... 30 Fixing.................................................................... 26 Installing ducts..................................................... 31 Installing the noise insulating connector.............. 28 Joining with screws/bolts...................................... 26 Screw-fixing stacked units.................................... 26 Seals, checking.................................................... 24 Setup.................................................................... 24 Stacked installation.............................................. 26 Air handling unit Commissioning..................................................... 52 Electrical connection............................................ 43 Installing accessories........................................... 32 Aligning droplet eliminator......................................... 61 Applying sealing tape................................................ 29 Assembling the roof segments.......................... 29 , 30 Assembly Accessories.......................................................... 32 AHU casing units for outdoor installation............. 29 Assembling AHU casing units.............................. 26 Base frame plugs................................................. 30 Ducts.................................................................... 31 Installing AHU casing units on top of each other. 26 Intermediate frame, fixing the cover strips........... 31 Noise insulating connector................................... 28 Roof segments..................................................... 29 Weather hood....................................................... 30 Attaching the weather hood...................................... 30
C
Commissioning the centrifugal fan............................ 54 Commissioning the humidifier................................... 61 Condensate drain...................................................... 36 Cooling coil
Commissioning..................................................... 56 Installing............................................................... 36 Copyright..................................................................... 3
D
Defects liability............................................................ 3 Delivery of the air handling unit................................. 12 Disposing of packaging............................................. 19

Drain trap, connecting............................................... 36
E
Electric air heater Commissioning..................................................... 57
Electrical connection................................................. 43 Electric current.......................................................... 10 Environmental protection
Chemicals............................................................ 65 Electrical and electronic components................... 64
F
Fan............................................................................ 10 Filters, inserting......................................................... 55 Fire............................................................................ 11 First aid...................................................................... 11 Fitting base frame plugs............................................ 30
H
Hazardous area......................................................... 11 Heating coil
Commissioning..................................................... 56 Installing............................................................... 36 Height of drain trap.................................................... 34 Hotline......................................................................... 3 hydraulic unit............................................................. 39
I
Improper transport equipment................................... 13 Initial commissioning................................................. 52
Centrifugal fan...................................................... 54 Electric air heater................................................. 57 Filters................................................................... 55 Heating coil/cooling coil........................................ 56 Humidifier............................................................. 61 Multileaf dampers................................................. 58 Plate heat exchanger........................................... 60 Rotary heat exchanger......................................... 59 Run around coil system........................................ 57 Sound attenuator.................................................. 59 Starting................................................................. 62 Installation Condensate drain................................................. 36 Connecting the heating coil/cooling coil............... 36 Connection to the central BMS............................ 44 Connect the steam heat exchanger..................... 38 Drain trap, connecting.......................................... 36 Height of drain trap............................................... 34 Network connection.............................................. 44 Run around coil system........................................ 39

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Index

Installation location, requirements Installation room................................................... 23 Installation room, foundation................................ 22 Outdoor installation, foundation........................... 23
Installing accessories................................................ 32 Installing ducts.......................................................... 31 Intermediate frame, fixing the cover strips................ 31 IP address
Changing.............................................. 44 , 46 , 49
L
Limitation of liability..................................................... 3
N
Network address Setting.................................................. 44 , 46 , 49
Noise......................................................................... 11 Noise insulation......................................................... 23
O
Other applicable documentation................................. 3
P
Packages Storage................................................................. 18 Transport.............................................................. 14 Unpacking............................................................ 19
Personnel.................................................................... 8 Plate heat exchanger................................................ 60
Q
Qualification................................................................ 8
R
Removal and disposal............................................... 64 Requirements
Initial commissioning............................................ 52 Installation............................................................ 33 Starting................................................................. 61 Requirements for the installation location Installation room................................................... 22 Residual risks.............................................................. 9 Rotary heat exchanger.............................................. 59 Setting up the drive equipment............................ 60 Run around coil system Commissioning..................................................... 57 Connection........................................................... 39

S
Service........................................................................ 3 Setup and assembly.................................................. 21 Sound attenuator....................................................... 59 Specific hazards.......................................................... 9 Starting...................................................................... 61 Steam heat exchanger
Installing............................................................... 38 Storage...................................................................... 18 Suspended loads........................................................ 9 Symbols...................................................................... 4
On the packaging................................................. 12 System owner............................................................. 8 System owner's obligations......................................... 8
T
Technical Service........................................................ 3 Touch panel
IP address............................................................ 49 Transport
Crane and transport tubes................................... 15 Delivery................................................................ 12 Delivery check...................................................... 12 Forklift or pallet truck............................................ 14 Transport damage..................................................... 12 Transport protection devices..................................... 19 Transport straps........................................................ 19 Transport tubes......................................................... 19
U
Unpacking................................................................. 19
V
Vibration, preventing................................................. 23
W
Warranty claims........................................................... 3 Wiring........................................................................ 41
X
X-CUBE....................................................................... 6 X-CUBE components.................................................. 6

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Appendix Appendix

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Appendix
Supplier documentation The necessary documentation for the components from third-party manufacturers is included in the attachment. You are welcome to contact us if important information is missing, and you can request that we provide it. Contact Ä `TROX Technical Service' on page 3

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Adjusting the storage mass

Air handling unit X-CUBE X2 / X-CUBE X2 compact

·KLINGENBURG
Montageanleitung Mounting Instructions
Ausrichtung der Speichermasse Adjustment of storage mass

Um die Speichermasse auf der Antriebswelle zu justieren, müssen auf beiden Seiten des Rotors die Staubdeckel entfernt werden. To reposition the the matrix on the drive shaft, on both sides of the rotor the hub caps have to be removed.
1 1
1
Der Staubdeckel besteht aus zwei Teilen und ist mit je 2 Schrauben befestigt, welche mit einem Imbusschlüssel (Größe 2,5) zu lösen sind. The hub cap consists of two parts and is fixed with 2 allen screws per part which need a 2.5 mm allen key.
2

Dazu alle 4 Schrauben lösen. For this, loosen all 4 screws.
Die beiden Stauddeckelteile entfernen. Der Lagerbereich liegt nun offen. Dieser Vorgang ist auf der gegenüberliegenden Seite des Rotors zu wiederholen. Remove both parts of the hub cap. The bearings are now accessible. Repeat this procedure on the opposite side of the rotor.
3

Beide Mardenschrauben (1) und (2) am Lager lösen. Dieses auch auf der gegenüberliegenden Seite des Rotors wiederholen. Loosen both set screws, (1) and (2). Repeat this procedure on the opposite side of the rotor. 1
2

Nun kann die Speichermasse auf der Welle entsprechend justiert werden. Lässt die Speichermasse sich nicht bewegen, kann diese vorsichtig mit leichten Schlägen gelöst werden. Verwenden Sie dazu ein Holzkant. Nach erfolgreicher Justierung sind auf beiden Seiten des Rotors die Lagerschrauben anzuziehen und die Staubdeckel wieder zu anzubringen.

Now the matrix can be moved on the shaft. If not, the matrix may be carefully released with light blows. Use a square timber. After successful repositioning, re-apply bearing screws and hub cap.

Klingenburg GmbH

Boystraße 115

45968 Gladbeck

GERMANY

Tel.

+49 (0) 20 43 / 96 36 - 0

Fax +49 (0) 20 43 / 7 23 62

e-mail: klingenburg@klingenburg.de

web: www.klingenburg.de

Klingenburg International sp. z o.o. ul. Metalowców 5 58-100 Swidnica POLAND Tel.: +48 (0) 74 / 851 54 00 Fax: +48 (0) 74 / 851 54 01 e-mail: klingenburg@klingenburg.pl web: www.klingenburg.pl

Klingenburg USA, LLC 503 Old Thomasville Road High Point, NC 27260 USA Tel.: +1 -336-884-5050 Fax: +1 -336-884-5058 e-mail: info@klingenburg-usa.com web: www.klingenburg-usa.com

Klingenburg Shanghai Representative Office Room 24/P Jinsui Mansion No. 379 Pudong South Road Shanghai P.R. CHINA Tel.: +86 (0) 21 / 68 86 92 51 Fax: +86 (0) 21 / 68 86 99 31 e-mail: klingenburg@klingenburg.cn web: www.klingenburg.cn

Montageanleitung Mounting Instructions
RRS

Technische Änderungen vorbehalten. Stand: 11-2013

für Rotationswärmetauscher in geteilter Ausführung der Typen RRS bis Baugröße 3000
Klingenburg GmbH Boystraße 115 D-45968 Gladbeck
for Rotary Heat Exchangers in split desiTFgealx.n:: f++o44r99--22t00y44p33--e976s2336R6-20RS up to constuctional size 3000
E-mail: klingenburg@klingenburg.de www.klingenburg.de

·KLINGENBURG

Adjusting the storage mass RRU eco

·KLINGENBURG

- 11 -

Lastfall

Die Befestigung des Rotorgehäuses mit dem Klimagerät ist vor Inbetriebnahme des Rotors zu prüfen. Der Freilauf der Speichermasse muss im Lastfall gewährleistet sein. Gegebenfalls ist der Rotor dazu in der horizontalen, als auch in der vertikalen Lage vorzujustieren.
Grundsätzlich gilt, dass keine Kräfte in den Rahmen eingeleitet werden dürfen, die dazu geeignet sind Schrägstellungen der Speichermasse im Gehäuse hervorzurufen. Deren Position im Gehäuse ist zu zentrieren. Die endgültige Justierung erfolgt nach Kontrolle der Voreinstellungen bei Betrieb mit laufenden Ventilatoren, sofern deren Druckerhöhung dies erforderlich macht. Der Rotor darf nicht in Schrägstellung betrieben werden.

Abb.8: Im Lastfall muss die Speichermasse zentriert im Gehäuse rotieren. Ist das nicht der Fall, können Leckagen entstehen .

Damit die Speichermasse unter Belastung im Gehäuse zentriert ist (Abb. 8), kann mittels Kugelscheibe/Kegelpfanne an den Speichermassenwellenenden eine Schrägstellung von bis zu 3° eingestellt werden. Gehen Sie dazu wie folgt vor:

Nulllast

Lastfall

Ausrichten der Speichermasse im Gehäuse

(1) Die Speichermasse muss evtl. entsprechend dem Lastfall in eine Schrägstellung gestellt werden

(2) Neigung des Wärmerades bei einer horizontalen Luftstromtrennung

(3) Neigung des Wärmerades bei einer vertikalen Luftstromtrennung

(4) Lösen Sie die Befestigungsschrauben der Lagerabdeckung

(5) entfernen Sie die Lagerabdeckung mit der Bürstendichtung

(6) Position der zu lösenden Schrauben

Tab. 2 Drehmomente

Welle Ø [mm] 20 30

Schraubengrösse DIN933 M10x30-8.8 DIN933 M12x35-8.8

Schlüsselweite SW 17 SW 19

Drehmoment 53 93

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Adjusting the storage mass RRU eco

- 12 Horizontale Luftstromtrennung

·KLINGENBURG Messen

(7) Lösen Sie die Sechskantschraube

Messen

(8) Neigen Sie die das Wärmerad vorsichtig. Beachten Sie dabei, dass die empfindliche Speichermasse nicht beschädigt wird.

(9) Kontrollieren Sie die Schrägstellung durch Messen auf den gegenüberliegenden Seiten

Drehmoment beachten!

(10) Ist das Wärmerad in die entsprechende Neigung gebracht, wird durch ein Festziehen der Sechskantschraube die Position fixiert (Drehmoment entnehmen Sie Tab. 2)

(11) Kontrollieren Sie die Zentrierung des Wärmerades in der horizontalen Gehäusemitte, Messpunkte siehe (9).

Vertikale Luftstromtrennung

(12) Messpunkte zur Zentrierung Neigung des Wärmerades

Messen

(7) Lösen Sie die Sechskantschraube

(8) Neigen Sie die das Wärmerad vorsichtig. Beachten Sie dabei, dass die empfindliche Speichermasse nicht beschädigt wird.

(9) Kontrollieren Sie die Schrägstellung durch Messen auf den gegenüberliegenden Seiten

Drehmoment beachten!

(10) Ist das Wärmerad in die entsprechende Neigung gebracht, wird durch ein Festziehen der Sechskantschraube die Position fixiert (Drehmoment entnehmen Sie Tab. 2)

(11) Kontrollieren Sie die Zentrierung des Wärmerades in der vertikalen Gehäusemitte, Messpunkte siehe (9) auf beiden Seiten.

(12) Messpunkte zur Zentrierung Neigung des Wärmerades

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Rotor belt installation instructions

INSTALLATION INSTRUCTIONS
NEW & IMPROVED for NO Re-tensioning

View the PowerTwist Drive installation video at: www.fennerdrives.com/videos
SIZING THE BELT
HAND-TIGHT LENGTH
2 1

ENGLISH 3

Route the belt so it is "handtight" around the intended pulleys.

With the belt pulled snug, mark the tab that is straight down from the second overlapping tab (third tab for wedge profiles).

With one hand bend belt into an upside down "U". With the other hand twist the marked tab 90°.

4
Pull link end over tab. For wedge profiles, repeat with second tab.

5
Rotate end tab 90°. Pull belt end through links to separate.

MAKE TO FINISHED LENGTH
6
1 2 3 ...
Count remaining links or measure belt length tip to tip. Note: For best results, count # of links, then check final tension with force deflection gauge after installation.

7
IMPORTANT: Using charts below, find the range corresponding to the number found in Step 6. Remove additional # of links to achieve proper installation tension. Note: For drives with multiple belts, make sure each belt has matching number of links.

LINK REMOVAL GUIDELINES

3L/O/Z Section

Hand Tight # of Links

Belt Length*

inch

18 35 36 55 56 79 80 101 102 127 128 150

12.6 23.8 23.9 36.7 36.8 52.0 52.1 66.1 66.2 82.7 82.8 97.5

320 604 605 932 933 1320 1321 1678 1679 2100 2101 2476

A/4L/13 Section

Hand Tight # of Links
25 34 35 58 59 82 83 105 106 129 130 153 154 176 177 200 201 224 225 247 248 271 272 295

Belt Length*

inch
20.2 27.3 27.4 45.2 45.3 63.1 63.2 80.3 80.4 98.2 98.3 116.1 116.2 133.3 133.4 151.2 151.3 169.1 169.2 186.3 186.4 204.2 204.3 222.1

mm
513 693 694 1148 1149 1602 1603 2039 2040 2494 2495 2946 2947 3385 3386 3840 3841 4295 4296 4732 4733 5186 5187 5641

# of Links to Remove
1 2 3 4 5 6
# of Links to Remove
1 2 3 4 5 6 7 8 9 10 11 12

* Belt length is measured openended from belt tip to tip

B/5L/17 Section

Hand Tight # of Links

Belt Length*

inch

29 34 35 58 59 81 82 105 106 128 129 152 153 175 176 199 200 223 224 246 247 270 271 293 294 317

29.6 34.9 35.0 58.0 58.1 80.2 80.3 103.3 103.4 125.4 125.5 148.6 148.7 170.7 170.8 193.8 193.9 217.0 217.1 239.1 239.2 262.3 262.4 284.4 284.5 307.1

751 886 887 1473 1474 2037 2038 2623 2624 3185 3186 3774 3775 4335 4336 4922 4923 5511 5512 6073 6074 6662 6663 7223 7224 7800

C/22 Section

Hand Tight # of Links
48 67 68 86 87 105 106 125 126 144 145 164 165 183 184 202 203 222 223 241 242 260 261 280 281 299

Belt Length*

inch
63.4 88.3 88.4 113.2 113.3 138.1 138.2 164.3 164.4 189.1 189.2 215.3 215.4 240.2 240.3 265.1 265.2 291.3 291.4 316.2 316.3 341.1 341.2 367.3 367.4 392.2

mm
1610 2242 2245 2874 2877 3506 3509 4172 4174 4804 4807 5470 5472 6102 6104 6734 6737 7400 7402 8032 8034 8664 8666 9329 9332 9962

# of Links to Remove
1 2 3 4 5 6 7 8 9 10 11 12 13
# of Links to Remove
3 4 5 6 7 8 9 10 11 12 13 14 15

www.fennerdrives.com

SIDE 1

OVER >>

3V/SPZ Section

Hand Tight # of Links
<29 29 47 48 72 73 96 97 120 121 144 145 168 169 192 193 217

Belt Length*

inch

<18.0 18.1 27.7 27.8 41.2 41.3 54.2 54.3 66.9 67.0 80.1 80.2 92.8 92.9 106.1 106.2 119.4

<457 457 705 706 1048 1049 1378 1379 1700 1701 2037 2038 2359 2360 2696 2697 3032

SPA Section

Hand Tight # of Links
<35 35 49 50 69 70 86 87 104 105 122 123 139 140 157 158 175 176 193 194 211

Belt Length*

inch

<30.2 30.2 40.9 41.0 56.2 56.3 69.3 69.4 83.1 83.2 96.9 97.0 109.9 110.0 123.7 123.8 137.5 137.6 151.3 151.4 165.2

<766 766 1040 1041 1429 1430 1761 1762 2111 2112 2462 2463 2793 2794 3144 3145 3494 3495 3845 3846 4196

5V/SPB Section

Hand Tight # of Links
<47 47 67 68 94 95 126 127 157 158 187 188 220

Belt Length*

inch

<51.8 51.8 72.0 72.1 99.3 99.4 131.1 131.2 163.0 163.1 193.3 193.4 226.2

<1316 1316 1830 1831 2523 2524 3332 3333 4142 4143 4911 4912 5746

# of Links to Remove
1 2 3 4 5 6 7 8 9
# of Links to Remove
1 2 3 4 5 6 7 8 9 10 11
# of Links to Remove
1 2 3 4 5 6 7

Air handling unit X-CUBE X2 / X-CUBE X2 compact

INSTALLATION
MAKE BELT ENDLESS

Rotor belt installation instructions

ENGLISH

Holding belt with tabs to the outside push end tab through two links (three links for wedge profiles). Twist tab 90° into place.

With your thumb twist second tab 90°. Push belt end down over tab with your opposite hand. For wedge profiles, repeat with remaining tab.

INSTALL ON DRIVE
12

13 A: DRIVE

Ensure all tabs are fully turned and across the belt.
13 B: WEDGE

Rotate assembled belt so tabs are inside (facing down into the pulley groove).
14

Belt Direction
Determine direction of drive rotation. Belt must travel in the same direction as the direction arrow. Tabs will trail.

Fit the belt in the closest groove of the smaller pulley. Roll belt onto larger pulley by turning the drive slowly. The belt should feel tight. DO NOT JOG THE MOTOR. Once installed check to make sure the all tabs are in position and the belt is not twisted. For multiple belt drives, work belt from groove to groove.
If the installation with the recommended # of links removed is too difficult see 13B

Use the belt take up system to install to the proper tension: position the motor approximately in the middle of its range of travel (mark position), hand fit the belt removing the recommend # of links. Move motor forward reducing the center distance enabling easy installation of the belt(s). Return motor back to original marked position.

Using a force deflection gauge, check Installation force and confirm it meets the requirements below.

FORCE DEFLECTION GUIDELINES

Force Required to Deflect Belt 1/64" per 1" (16 mm per 1m) Center Distance

Belt Section

Installation

lbs.

Kgf

During Operation

lbs.

Kgf

3L/O/Z

4 4.5

1.8 2

1.3

A/4L/13

4 5

1.8 2.3

1.3

B/5L/17

7 8

3.3 3.7

2.8

C/22

13 15

6 6.9

4.6

3V/SPZ

5 6

2.3 2.8

1.8

SPA

6 7

2.8 3.3

2.3

5V/SPB

13 15

6 6.9

3.7

Note: If deflection force drops below specified force for Operation, remove links or adjust take-up until belt is back to Installation force.

Note: If take-up system is not available, links can be added to reduce the tension. If links are added the belt may have to be re-tensioned by removing the extra links between ½ hour and 24 hours running at full load.

LEGAL COMPLIANCE NOTICE: For more information regarding the products manufactured, distributed and sold by Fenner Drives and the compliance of such products with applicable domestic and international law, statutes, rules and regulations relating to human health and the environment (collectively, "Environmental Laws"), including, without limitation Proposition 65 as enacted by the State of California and the Registration, Evaluation, Authorization and Restriction of Chemical Substances (REACH) as enacted by the European Parliament, please visit www.fennerdrives.com. If you are unable to access our website or if you have any further questions about the compliance of our products with Environmental Laws, you are encouraged to contact the Fenner Drives' Environmental, Health, and Safety Manager at +1 (717) 6652421.

www.fennerdrives.com
US and Canada · 1 800 243 3374 Latin America · 1 717 665 2421 Europe, Asia, Australia and Africa · +44 0 870 757 7007

SIDE 2

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installing a frost protection device for th...

Installing a frost protection device for the drain trap

INSTALLATION INSTRUCTIONS
Antifreeze heating for Siphons (FSH)
Item No.: 24 (suction side, FSH-S) Item No.: 25 (pressure side, FSH-D)

The antifreeze heating has been especially developed for the use in all common suction and pressure side type siphons with 1½" connection for AH units.
Description
In general the antifreeze heating consits of a flexible self-regulating and automatic power-limiting heating cable which is led through the siphon and energized automatically by a variably adjustable thermostat as soon as the set temperature is fallen below. Heating the cable prevents the siphon from freezing.
< For universal use in all 1½" siphons < Easy retrofit < Preassembled
Maintenance
The heating cable and the connection box must be checked in regular intervals for mechanical damages, and the electrical protection and function of the thermostat for their proper functioning. The siphon should be checked for contamination at least twice a year and, if the air is heavily polluted (e.g. exhaust air from the kitchen), more frequently. It should be cleaned, if necessary.
Installation
Before installing the antifreeze heating (FSH) in suction-side siphons just remove the 1½" end cap marked " A " first; in pressure-side siphons the 90° elbow must be replaced by the supplied 1½" T-piece.
Then push the flexible heating cable into the direction of the arrow into the siphon (Fig. 2)
It can be necessary in the process to separate the siphon at the screwings marked " B " because the somewhat stiff point of the heating cable sticks there easily, and so it can be pulled through easily from the other side.
After the antifreeze heating has been screwed using the preassembled union nut the tightness of all screwed connections of the siphon must be checked.
Before pressure-side siphons can be taken into opera-

tion again after having been assembled they must be refilled with water!
They can be refilled through the newly inserted T-piece which must be closed afterwards using the previously removed end cap " A ".
For suction-side siphons particular attention has to be paid that the ball of the non-return valve is not pushed up by the heating cable because otherwise the function of the siphon cannot be guaranteed.

Technical data

< Including connection box (IP 67) with integrated antifreeze thermostat for installation in the immediate environment of the siphon

< Completely equipped with clamps for an easy connection to the existing electrical supply (3x 1,5mm²), 230 V UPS, max. 10 A

< Electrical protection by use of a 30 mA residual-current-operated circuit-breaker (r.c.c.b.) provided by the customer

< Self-regulating and power-limiting heating cable (70 cm, heated up to the connecting sleeve)

< Power: 19 W/m (at +10°C) and 30W/m (at -25°C)

< Protection class I, model with protective conductor

< Completely watertight in the heated area, from connecting sleeve

< Supply cable IP 54 (100 cm, unheated)

< Admissible operating temperature -30°C to +55°C

< Thermostat preset to +15°C < Hysteresis (switching difference): 6K ± 4K

Example:

required minimum temperature 5°C Set point 15°C

Resulting from:

required minimum temperature 5°C + maximum hysteresis 10K (6K + 41K)

Safety instructions
All safety and accident prevention regulations as well as the guidelines and standards of the country where the installation is carried out must be observed for installation and commissioning. Apart from that the VDE regulations, in particular VDE 0100 and VDE 0721,

KLIMA-KOMPONENTEN-KÜCH GMBH
Adolfstraße 16, 57555 Niederschelderhütte-Siegen Tel.: (02 71) 31 92 66 - 00, Fax: (02 71) 31 92 66 - 01

Internet: www.klima-kuech.com, E-Mail: info@klima-kuech.com

Modifications to the heating cable are not al of humidity and dirt as well as arcing and a fir entire system. A heating cable damaged by fir cause further fire damage when being switche
into the siphon and fixed with the screwing in

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Installing a frost protection device for th...

Fig. 1

Fig. 2

Part 1 and Part 2 A3 as well as VDE 0254, have to be observed for the installation of the antifreeze heating. The antifreeze heating must only be installed by an authorised specialist. The electrical connection must only be carried out by an electrician in accordance with the electrical regulations. Modifications to the heating cable are not allowed.
Damages at the heating cable can cause the ingress of humidity and dirt as well as arcing and a fire in the entire system. A heating cable damaged by fire can cause further fire damage when being switched on. Therefore such a heating cable must be taken out of operation immediately.
Intended use
Antifreeze heating for siphons for VAC plants. Assembly and connection must be carried out according to these instructions. Any use other than that which is intended shall not be allowed.
Instructions for the
electrical connection
The heating cable of the antifreeze heating must never be shortened, not even on the PTC thermistor side. Excess cable lenghts of the heating cable are to be led through the outlet in the condensate trough (necessary for example for shortened siphons). The heating cable is not to be fastened, but just inserted into the siphon and fixed with the screwing in such a way that the connecting sleeve is completely outside the siphon. The heating cable must not be brought into contact with sharp edges and be protected from mechanical damage.
the heating cable must not be crossed or touched anywhere. The heating cable is to be laid in such a way that no heat accumulation will be caused. The heating cable must not be led above or through combustible materials. The electrical protection and the protective

measures must have been provided on the installation side for which the use of a 30 mA residual-current-operated circuit breaker (r.c.c.b.) is mandatory. The exclusive use of miniature circuit breakers may not be enough to prevent the progression of arcs and can provide a fire hazard.
The heating cable of the antifreeze heating must be operated exclusively from the provided connection box with the built-in antifreeze thermostat to ensure that an operation is impossible at ambient temperatures > +5°C. An insulation test is required before the heating is taken into operation. Pipes used for cable laying must be included in the protective measures (grounding of pipes).
The circuit diagram is available as a free download on our homepage.
Repair
A damaged heating cable must never be repaired but be replaced by a new one.
Instructions for connection and installation
The connection box should be easily accessible but protected from mechanical damage. It should always be installed in such a way that the cable glands do not point upwards and the lid can be removed. The heating cable of the antifreeze heating must be laid between the connection box and the entry into the siphon in such a way that any mechanical damage will be prevented. No dragging is allowed at the heating cable gland and at the siphon intake..

KLIMA-KOMPONENTEN-KÜCH GMBH
Adolfstraße 16, 57555 Niederschelderhütte-Siegen Tel.: (02 71) 31 92 66 - 00, Fax: (02 71) 31 92 66 - 01

Internet: www.klima-kuech.com, E-Mail: info@klima-kuech.com

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Electric air heater

Customer Trox GmbH

Key Word

Circuit Diagramm

Person Resp. Volta-No Hr. S.Wiedemann 89355/1

Quantity

Date

1 13.03.2019

Heating Battery Embodiment Version 3.0.0.2

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Electric air heater

OPERATING INSTRUCTIONS
1. Operating Instructions for Air Heating Batteries
a, Technical Prerequisites for Putting into Operation
Prior to connecting the heating batteries it must be checkes if the voltage indicated on the name plate agrees with the existing supply voltage.The heating batteries are connected together into one or more groups for switching purposes, and for three-phase supplies each switching group has three terminals, and for DC or AC supplies each switching group has two terminals and a terminal for earthing purposes for each switching group in addition. The parts of the housing or flange plates are made of metal and must also be earthed. It is a general requirement that the electrical connection may be made by certified personnel only. The applicable regulations as per DIN 57100, part 420/VDE 0100, must also be complied with. The temperature safety limiter, temperature monitor, flow monitor and so forth must be controlled accordingly.
b, Putting into Operation
In the case of the embodiment with cold air inlet in line with types ERR/91 and ERRG/91 the heating element cables and the connecting bars are provided inside the duct. The air flowing through the heater cools the cable connections continuously thus reducing the heat in the IP 54 connection box. Therefore standard cables may be used. In the case of very high final air temperatures or very unfavourable conditions (e.g. reduced air quantity or recirculated air operation depending on the method used) there may be temperatures existing in the connection box which are no longer suited to use standard, rubber-insulated cables (this decision can be taken by the customer only). In this case use high temperature resisting cables, e.g. silicone, teflone or fiberglass insulated cables. Depending on the distance between the control box and the air heating battery it is recommended to mount separate connecting blocks in a short distance to the air heating battery with the aim to save running metres of heat resisting cables. The correct manufacture of the current supply connections and both earthings (electrical connection and housing) must be checked prior to the test run. On the occasion of a test run all parameters, e.g. air quantity, final air temperature and so forth (Technical Data Sheet refers), must be completely complied with. In unfavourable cases partial considerations of or deviations from the values prescribed by the manufacturer (Technical Data Sheet refers) may cause damage to or destruction of the air heating battery.
c, Normal Shut-Down Procedure
The shut-down procedure for fan and air heating battery shall be as such that the fan is still in operation for another five minutes to avoid overheating. For this reason the fan motor after-running is ensured with the help of a time-limit relay. Also, existing thermostats must be set on site in accordance with the requirements requested for. For example, a temperature safety limiter is adjusted between 50°C and 60°C with a final air temperature of 40°C; this applies also to other final air temperatures.
d, Safety Shut-Down in the Case of Power Failure
Depending on the operation conditions and in the case of voltage failure the surface of the heating rods can be heated up by 50°C to 70°C. It can hardly be expected that the air heating battery will be damaged. At worst, it may be necessary to replace a filter or a plastic cover.

Address:

Volta GmbH & Co. KG Salzstraße 17 Ortsteil Wohmbrechts D-88145 Hergatz

Telefon: (08385) 921 393-0 Telefax: (08385) 921 393-20

Internet: www.volta-gmbh.de e-Mail: info@volta-gmbh.de

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Electric air heater

2
e, Regulations for the Use of Control and Adjustment Devices
On principle, there are 4 parameters to be observed for the control of a heat battery made by VOLTA: - quantity of air; - air intake or air exhaust temperature; - operating voltage or current resulting thereof; - use of operating groups (performence distribution). If the air exhaust temperature is required to be changed or if the air intake temperature changes a control can be achieved by switching on or switching off one or more operating groups without changing the quantity of the air. If the quantity of air changes (to less than approx. 70-80 per cent of the quantity of air defined for each heat battery embodiment) this may be balanced only by a voltage control (less current required). For technical reasons the switching off of one or more operating groups will not lead to success. If these instructions recommended by the manufacturer are not complied with this may result in a partly or completely destruction of an air heating battery.
f, Operating Conditions
Air heating batteries are single piece productions which are produced for special customer operating conditions and in accordance with the dimensions provided and requested for by our customer. On delivery of the air heating batteries a complete documentation (Operating Instructions, Declaration of Conformity, Technical Data Sheet, Table of Dimensions, Wiring or Circuit Diagram, Operating Instructions for Thermostats used) is provided, the dates and operating instructions of which apply exclusively to this individual air heating battery provided. The data included in the Technical Data Sheet are to be considered as nominal operating values applying to the air heating battery specified by the customer and manufactured in accordance with the requirements requested for by the customer. They must be complied with to ensure an application of the air heating battery as directed. It is also possible to manufacture air heating batteries in accordance with different operating conditions which are considered on the occasion of its development and design and included in the Technical Data Sheet. Any deviations from these recommended data provided must be compensated by suitable control and adjustment actions to be carried out on-site. In unfavourable cases partial considerations of or deviations from the values prescribed by the manufacturer (Technical Data Sheet refers) may cause damage to or destruction of the air heating battery.
Unless otherwise specified in the Documentation of the Air Heating Battery normal environmental and operating conditions, normal methods and modes of operation in accordance with Standard DIN VDE 0100 are a prerequisite for the use and operation of the Air Heating Battery.
g, Repair Activities
VOLTA are able to supply replacement heating rods within a few days if the manufacturer's identification number of the heating battery is advised by the customer. Then a qualified electrician will be able to perform the required repair himself. Repair or maintenance activities may be performed only if all electrical devices have been switched off, and the current supply system must be protected against re-switching in. Furthermore it must be paid attention to the fact that the heating rods are cooled off sufficiently prior to beginning with any repair and maintenance activities. All repair activities may be performed by a corresponding expert only who installs and connects replacement heating rods the same way he has removed the damaged heating rods prior to repair activities involved. If larger heating batteries are subject to repair activities and to the extent that no experts are available, it is advisable to have the repair work performed by the manufacturer. A heating battery sent in for repair purposes will be returned in a few days as good as new and tested in accordance with the regulations and/or specifications.
h, Long-Term Control and Maintenance
As a matter of principle it is not required to maintain air heating batteries. It will be sufficient to examine the connecting cables periodically to ensure that the screws at the terminals are still tight and that both earthing systems (connection and housing) are still operating properly and that the insulation of the cables has not been cracked. Cleaning activities are required to be part of the maintenance activities only if the medium to be heated is extremenly dirty or dusty (e.g. wood dust produced in a joiner's shop). It is recommended to clean the heating rods with the help of compressed air.

Address:

Volta GmbH & Co. KG Salzstraße 17 Ortsteil Wohmbrechts D-88145 Hergatz

Telefon: (08385) 921 393-0 Telefax: (08385) 921 393-20

Internet: www.volta-gmbh.de e-Mail: info@volta-gmbh.de

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Electric air heater

3
Air filters that may have been installed in front of or behind the air heating battery must be cleaned at regular intervals. If an occasional overheating of the heatig rods has produced some scale on the outer surface, it can be assumend that said scale may have been produced on the inner surface as well, which scale might become loose due to vibrations and thus may cause a short circuit. Therefore if scaled heating rods are found it is advisable to return the air heating battery for repair purposes.
i, Use of Themostats
Thermostats which are marketed and installed by VOLTA are perhaps mechanically integrated in the air heating batteries. Temperatures or flow speeds must be set and adjusted by the customer on-site, because he himself knows the necessary and complete operating dates and conditions only (flow, air quantity preservation and so forth). For these reasons it is not advisable to have the thermostats preset by VOLTA. When leaving our works the thermostats have been preset to the highest value possible, and it is imperative to adjust them on-site (in accordance with the Operating Instructions of the thermostat supplied).
j, EMVG Regulations and Advice
Based on the design and the physical features of air heating batteries and heating rods manufactured and marketed by VOLTA no interference emission or operating trouble may be expected in case of interference effects in accordance with EMVG requirements and regulations. When wiring or connecting the air heating batteries or heating elements to the thermostats or control devices supplied by VOLTA all remedial actions required in accordance with EMVG are to be taken by the customer on-site in the event of possible interferences which might occur. All necessary remedial actions and modifications are to be taken and made in accordance with EMVG requirements and regulations. When wiring or connecting the air heating battery to other electrical components, installations and products on-site it must be ensured that all EMVG requirements and regulations are complied with. Any remedial actions necessary are to be taken by the customer in accordance with the requirements existing on-site. All working activities and actions mentioned and referred to in this paragraph may be carried out by the corresponding experts only.
k, Manufacturer Machine Standard 2006/42/EG Declaration
The complete machine equipped with air heating batteries or heating element components may be operated only if the Protection Requirements and Standrads of the Machine Standard 2006/42/EG required for the complete machine have been complied with.

2. Safety Regulations pertaining to Operating Instructions

a, Operating Directions
Air heating batteries are to be used for the heating of fresh, recirculated or processing air only (normal operating method according to Standard DIN VDE 0100). The contact safety device must be examined electrically and be provided and ensured thermically on-site.
b, Electrical Air Heating Battery Installation Location
If no data provided by the customer are existing the electrical air heating batteries are manufactured for vertikal or horizontal installation. In general, a horizontal installation with a lateral terminal box is preferential.
c, Installation and Removal Directions
Upon electrical connection of the air heating batteries it is a fundamental requirement to comply with the instructions of Standards 2006/95/EG and DIN VDE 0100, in particular with regard to the rating of all electrical devices connected to the air heating batteries, intentional putting into operation, safe switching off, and safe separation from sources of energy.

Address:

Volta GmbH & Co. KG Salzstraße 17 Ortsteil Wohmbrechts D-88145 Hergatz

Telefon: (08385) 921 393-0 Telefax: (08385) 921 393-20

Internet: www.volta-gmbh.de e-Mail: info@volta-gmbh.de

Air handling unit X-CUBE X2 / X-CUBE X2 compact

Electric air heater

4
Upon installation of the air heating battery the electrical connection system may be installed only if mechanical installation activities have been completed. This applies in reverse order when removing the air heating battery: any mechanical removing activity may be started only as soon as the electrical connection system has been cut completely. Furthermore it must be paid attention to the fact that the heating rods are cooled off sufficiently prior to beginning with any repair and maintenance activities. It is a fundamental requirement that experts may perform work on electrical connection systems only who must comply with the instructions as per Standards DIN VDE 0100 or DIN VDE 0110. Special care must be given to the connection of the protective conductor to the terminal provided in the switch box and to the additional earthing of the housing. At both ends there are flanges provided for mechanical installation purposes which are to be used according to their design. All mechanical operations must also be performed by experts.
d, Contact Protection Directions
The normal installation situation is as such that an air heating battery supplied by VOLTA will be installed between two channel elements and be rigidly connected to said channels mechanically (by screws). If not and if one side of the air heating battery remains open or unprotected, the customer himself has to take steps for contact protection purposes. It must be ensured that it will be impossible for any person to come into contact with the heating rods of an air heating battery. For example, this protection must be provided by assembling a grid to the open side of the air heating battery. In principle, the air heating battery housing hardly represents a grave danger or risk, because to is grounded by means of a protective conductor. However, if the housing warms up too much, depending on the installation situation and the on-site technical datas, it must be insulated (against heat) by the user/customer himself independently.
e, Repair or Maintenance Directions
Repair or maintenance activities may only be performed if all electrical devices have been switched off, and the current supply system must be protected against re-switching in. Furthermore it must be paid attention to the fact that the heating rods are cooled off sufficiently prior to beginning with any repair and maintenance activities.

3. Manufacturer

The manufacturer is at your disposal for any questions you may have and for any repair and maintenance activities to be performed (footnote refers). Always specifiy the purchase order or machine identification number specified at the end of the Operating Instructions. All Operating Instructions apply to the equipment only provided together with the purchase order or machine identification number specified.

Version 2011-01-01

Please specify the following purchase order or machine identification number when submitting any enquiries:

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Address:

Volta GmbH & Co. KG Salzstraße 17 Ortsteil Wohmbrechts D-88145 Hergatz

Telefon: (08385) 921 393-0 Telefax: (08385) 921 393-20

Internet: www.volta-gmbh.de e-Mail: info@volta-gmbh.de

Air handling unit X-CUBE X2 / X-CUBE X2 compact

TROX GmbH Heinrich-Trox-Platz 47504 Neukirchen-Vluyn, Germany

Germany Phone: +49 (0) 2845 2020 +49 2845 202-265 E-mail: trox@trox.de http://www.troxtechnik.com