TROX X-CUBE Compact Air Handling Unit Instruction Manual

X-CUBE Compact Air Handling Unit

Product Information

The X-CUBE air handling unit (AHU) is a product manufactured by
TROX GmbH. It is designed to provide safe and efficient air
handling in various applications. The unit complies with applicable
health and safety regulations and is built with reference to
industry standards and guidelines. TROX GmbH, based in
Neukirchen-Vluyn, Germany, is the manufacturer of the X-CUBE
AHU.

Please note that the illustrations in the user manual are for
informational purposes and may not exactly represent the design of
the actual air handling unit.

Product Usage Instructions

1. Before operating the X-CUBE air handling unit, carefully read
   and familiarize yourself with the instructions provided in this
   manual.

2. Ensure that you comply with all local regulations for health
   and safety at work and general safety regulations applicable to the
   area of application of the air handling unit.

3. For any inquiries or service requests, contact TROX Technical
   Service. To expedite the process, have the following information
   ready: product name, TROX order number, delivery date, and a brief
   description of the fault.

4. It is important to note that non-compliance with this manual,
   incorrect use, operation or handling by untrained individuals,
   unauthorised modifications, technical changes, or the use of
   non-approved replacement parts may result in damages for which the
   manufacturer does not accept liability.

5. For bespoke constructions, additional order options, or recent
   technical changes, the actual scope of delivery may differ from the
   information provided in this manual.

6. The obligations agreed upon in the order, general terms and
   conditions, manufacturer’s terms of delivery, and applicable legal
   regulations at the time of contract signing shall apply.

7. Warranty claims are subject to the provisions outlined in the
   respective general delivery terms. For purchase orders placed with
   TROX GmbH, please refer to the regulations in section Vl. Warranty
   claims of the Delivery Terms of TROX GmbH, available at
   www.trox.de/en/.

8. For copyright protection, this document and its illustrations
   are protected by copyright. Any unauthorized use, including
   publishing, copying, translating, microcopying, saving to
   electronic systems, or editing the content, may result in liability
   for damages.

9. Refer to the safety notes section of this manual for important
   instructions and symbols indicating potential hazards. Comply with
   all safety instructions to avoid accidents, injuries, and damage to
   property.

Operating instructions

GB/en

Air handling unit
X-CUBE

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: [email protected] Internet: http://www.troxtechnik.com
A00000055653, 5, GB/en 10/2021

© TROX GmbH 2016 2

Air handling unit X-CUBE

Supplemental directives

About this manual
This manual enables operating or service personnel to use the X-CUBE air handling unit (AHU) safely and efficiently.
The operating manual is intended for use by instructed persons. It is essential that instructed persons ( Ä Chapter 1.3.1 `Qualification’ on page 8 ) 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 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:
Transport and installation manual Order-specific approval drawing Safety data sheets, Ä Appendix
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

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/ .

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

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3

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 ­ danger zone.

CAUTION!
Potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

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

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.

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)

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Air handling unit X-CUBE

Table of contents

1 Safety ………………………………………………………. 6

3.10.3 Setting a setpoint schedule ……………. 33

1.1 Correct use ………………………………………… 6

3.10.4 Connecting the AHU to a PC or net-

1.2 System owner’s responsibility ………………. 7

work (by others) ……………………………. 38

1.3 Personnel requirements ………………………. 8 1.3.1 Qualification …………………………………….. 8

3.11 Reading the differential pressure on the filter …………………………………………. 40

1.3.2 Unauthorised persons ………………………. 8 4 Maintenance …………………………………………… 41

1.4 Personal protective equipment ……………… 9

4.1 Safety notes regarding maintenance ……. 41

1.5 Safety signs ……………………………………… 10
1.6 Safeguards ………………………………………. 11
1.7 Securing the unit against being switched on accidentally ………………………………….. 13

4.2 Switching off the AHU and securing it against being switched on accidentally … 42
4.3 Maintenance plan ……………………………… 42
4.4 Maintenance …………………………………….. 50

1.8 Work areas and hazardous areas ……….. 14

4.4.1 Opening inspection access doors …….. 50

1.9 Residual risks …………………………………… 15 1.9.1 General workplace hazards ……………… 15 1.9.2 Electric shock hazards ……………………. 15 1.9.3 Moving machinery hazards ……………… 16 1.9.4 Hazards from the hydraulic system …… 17

4.4.2

Checking filters for contamination

……………………………………………………… 51

4.4.3 Cleaning the AHU …………………………… 52

4.4.4

Replacing a filter element ………….. 55

4.5 After maintenance …………………………….. 57

1.9.5 Hazards from high and low tempera-

5 Faults …………………………………………………….. 58

tures …………………………………………….. 17

5.1 Safety notes regarding troubleshooting … 58

1.9.6 Hazardous substances and operating

5.2 Faults displayed with X-CUBE Control …. 59

fluids …………………………………………….. 18

5.3 Faults displayed on the AHU ………………. 59

1.9.7 Fire hazards ………………………………….. 19

5.4 List of faults ……………………………………… 60

1.9.8 Risk of entrapment in units with whole body access ………………………………….. 19
1.10 Environmental protection ………………….. 20

5.5 Troubleshooting ………………………………… 72 5.6 After troubleshooting …………………………. 72

1.11 Measures to take if a harmful substance

6 Replacement parts …………………………………. 73

has been released …………………………… 20

6.1 Safety notes regarding replacement parts

2 Functional description ……………………………. 22 2.1 Symbols used on the air handling unit …. 22

………………………………………………………… 73 6.2 Ordering replacement parts ………………… 73

2.2 Function of the air handling unit ………….. 22 7 Accessories …………………………………………… 74

2.3 Operating modes ………………………………. 22 8 Removal and disposal …………………………….. 75

2.4 Function of each component ………………. 23 2.5 Operating and display elements ………….. 24 2.5.1 Mains isolator ………………………………… 24 2.5.2 Inspection access doors with a lock ….. 25

8.1 Safety notes regarding disassembly and disposal …………………………………………… 75
8.2 Disassembly …………………………………….. 76
8.3 Disposal …………………………………………… 76

2.5.3 Touchscreen ………………………………….. 25 9 Technical data ………………………………………… 78

2.5.4 Filter monitoring ……………………………… 25

9.1 Operating conditions …………………………. 78

2.6 Connections and interfaces ………………… 26

9.2 Technical data sheet ………………………….. 78

3 Software use ………………………………………….. 27 3.1 Safety notes regarding operation ………… 27

9.3 Rating plate ……………………………………… 78 9.4 CE declaration of conformity ………………. 78

3.2 Emergency switch-off ………………………… 27 10 Glossary…………………………………………………. 79

3.3 Switch-off in the event of a fire ……………. 27 3.4 Preparing a (re)start ………………………….. 27 3.5 Starting the air handling unit ……………….. 27 3.6 Checks during operation ……………………. 28 3.7 Tips for operation ………………………………. 28

11 Index………………………………………………………. 80
Appendix………………………………………………… 83 A Supplier documents …………………………….. 84 B Safety data sheets …………………………….. 107

3.8 Switching the AHU off ………………………… 28

3.9 After shutdown …………………………………. 28

3.10 Using X-CUBE Control …………………….. 29

3.10.1 Login on the user interface …………….. 29

3.10.2 System settings ……………………………. 31

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5

Safety
Correct use
1 Safety
1.1 Correct use
The TROX X-CUBE air handling unit is designed exclusively for the treatment of air, i.e. transporting, filtering, heating, cooling, humidifying and dehumidifying air. Correct use also involves complying with all the information provided in this manual. Any use that goes beyond the correct use or different use of the unit is regarded as incorrect use.
Incorrect use
WARNING! Danger due to incorrect use! Incorrect use of the air handling unit can lead to dangerous situations. Never use the air handling unit: ­ in rooms with explosive gases or gas mixtures ­ in rooms with conductive dust ­ in rooms with strong electromagnetic fields ­ in rooms with aggressive room air components,
e.g. sand ­ outside of the design specifications, see TROX
air handling unit data sheet ­ for structural purposes or as the building roof ­ as a smoke extract system in the event of a fire.

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Air handling unit X-CUBE

Safety
System owner’s responsibility

1.2 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 be aware of the applicable occupational health and safety regulations and carry out a risk assessment to determine any additional hazards that may exist or result from the specific working conditions at the installation location of the air handling unit. The system owner has to create operating instructions for the air handling unit that reflect the results of this risk assessment.
The system owner has to ensure, throughout the entire operating period of the air handling unit, that these operating instructions conform to applicable standards and guidelines; in case of any deviation, the system owner has to adapt the instructions.
The system owner must secure the air handling unit to prevent access by unauthorised individuals.
The system owner must clearly define the responsibilities for operation, maintenance, cleaning, troubleshooting and removal.
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 regularly provide training for the personnel and inform them of any dangers. The system owner must provide the employees with the required personal protective equipment. The system owner must observe the local fire regulations.
In addition, the system owner has to ensure that the AHU is in perfect technical condition at all times:
The system owner must ensure that the maintenance intervals specified in this manual are observed. If the AHU is used beyond average, maintenance intervals should be shorter.
The system owner must have all safeguards tested regularly to ensure that they are functional and complete.

The system owner must document and permanently save the control matrix on which commissioning is based. The system owner must save both a digital version and a hardcopy of the initial version of the control matrix.
The system owner must document and save any changes to the control matrix.
System owner’s additional obligations for AHUs with a refrigeration system
For AHUs with a refrigeration system/evaporator:
The system owner must document any checks in the supplied refrigeration system log.
The system owner must regularly (every year) instruct personnel in: ­ Safety regulations for refrigeration systems ­ Risks from using refrigeration systems ­ Emergency measures in case of an accident or fault related to refrigeration systems
This instruction has to be documented. The system owner must ensure that work on the
refrigeration system is only carried out by skilled qualified refrigeration technicians. The system owner must ensure regular maintenance and service according to local regulations. The system owner must comply with technical and safety-related national standards and guidelines.
As standard, the TROX Technical Service will document in the refrigeration system log any required maintenance jobs they carry out.
Hygiene requirements
The system owner has to comply with the local regulations and harmonised standards for hygiene requirements. This includes compliance with
specific maintenance and inspection intervals for AHUs
specifications for connected ducts and air terminal devices

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Safety
Personnel requirements > Unauthorised persons

1.3 Personnel requirements
1.3.1 Qualification
The work described in this manual has to be carried out by individuals with the qualification, training, knowledge and experience described below:
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.
Hygiene inspector Hygiene inspectors are individuals who have sufficient professional or technical training, knowledge and actual experience to enable them to carry out hygiene inspections on air handling units. Hygiene inspectors have been trained in the field of air hygiene and indoor air quality, and they are familiar with the relevant standards and guidelines.
Instructed person Instructed persons have been adequately advised or supervised to enable them to avoid any potential hazards related to the work under consideration. Instruction is provided by a qualified expert in the respective field.
A person instructed in the use of the AHU may carry out the following jobs:
Visual inspections Replace filter elements Clean filter chambers Clean heat exchangers Clean fans
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 technician 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. They are also familiar with the avoidance of emissions, the recovery of fluorinated greenhouse gases and the safe handling of refrigeration equipment of the required type and size.
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.
Any work has to be carried out by individuals who can be expected to carry out their assigned duties reliably. Individuals whose reaction time is delayed due to alcohol, drugs or other medication must not carry out any work.
Passwords
Webserver setup is password protected to prevent unauthorised individuals from entering or changing data (see software documentation for the AHU).
Instruction
System owners must regularly instruct their personnel. The instruction procedure has to be documented for further reference.
At least the following details have to be documented:
Date of instruction Names of persons being instructed Type of instruction Name of instructor Signature of person being instructed
1.3.2 Unauthorised persons
WARNING!
Risk to life! Unauthorised access to the hazardous area and work area must be prevented! Unauthorised persons who do not fulfil the requirements specified here are usually not aware of the dangers in the work area. There is a risk to life and limb for unauthorised people.
­ Keep unauthorised persons away from hazardous areas and work areas.
­ Instruct these persons to leave the hazardous area or work area.
­ Stop work while unauthorised persons are present in the hazardous area or work area.

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Air handling unit X-CUBE

Safety
Personal protective equipment

1.4 Personal protective equipment
Personal protective equipment is equipment that protects the user against health or safety risks at work.
Personal protective equipment must be worn for various types of work; the protective equipment required is listed in this manual together with the description of each type of work.

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

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

Safety goggles
Safety goggles protect the eyes from flying particles and liquid splashes.

Industrial safety helmets protect the head from falling objects, swinging loads, and impacts with stationary objects.
Protective clothing

Protective clothing is close-fitting, with low tear resistance, close-fitting sleeves, and no projecting parts.
Protective gloves

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.

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Safety
Safety signs
1.5 Safety signs
The following symbols and signs are usually found in the work area. They apply to the very location where they are found.
WARNING! Danger due to illegible signage! Over time, stickers and signs may fade or become otherwise illegible, meaning that hazards cannot be identified and necessary operating instructions cannot be followed. There is then a risk of injury. ­ Ensure that all of the safety, warning and oper-
ating information is clearly legible. ­ Replace illegible signs or stickers immediately.
Earthing

Fan run down time
Fig. 1: Notice on inspection access doors You will find this notice on inspection access doors that allow access to centrifugal fans and rotary heat exchangers.

These stickers are located in the switch cabinet and at all equipotential bonding connection points, see Ä `Equipotential bonding’ on page 11 , on the air handling unit.
Electrical voltage

Only skilled qualified electricians must work on AHU components and in internal spaces with this sign.
Unauthorised persons must not enter areas, open cabinets or work on components where an electrical voltage is present and which are hence marked with this symbol.

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Air handling unit X-CUBE

Safety
Safeguards

1.6 Safeguards
Defective safeguards
WARNING! Risk to life from defective safeguards! The mains cable between the utility grid and the mains isolator carries a hazardous electrical voltage. Defective or disabled safeguards can cause serious or even fatal injuries. ­ Do not disable or bypass any safeguards.

Each local isolator carries a sticker with the code of the equipment that it isolates.
You can lock each local isolator in the ‘0’ position (with a padlock) to secure it against being switched on accidentally so that you can safely work on the respective component (e.g. fan).
Equipotential bonding
A skilled qualified electrician has to connect the AHU to the local earth bar; this is done as part of installation. Equipotential bonding prevents electrostatic ignition hazards.

AHU casing
The AHU casing is made from steel panels with duplex powder coating on all sides. This construction ensures that no parts can be ejected from the unit in case of a fault. This construction also protects the interior of the AHU from environmental effects.
The inner skins of the casing are also available in stainless steel (optional).

Safety lock on inspection access doors to hazardous areas

Mains isolator of the AHU

Fig. 2: Mains isolator When you turn the mains isolator to ‘0’, the supply voltage is immediately switched off. You can then lock the isolator in the ‘0’ position (with a padlock) to secure it against being switched on accidentally so that you can safely work on the AHU.
Local isolator

Fig. 4: Safety lock
Inspection access doors to hazardous areas can only be opened with a special key.

Fig. 3: Local isolator As long as the AHU remains switched on (mains isolator in ‘I’ position), the connecting cable for the local isolator is live.

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Safety
Safeguards
Safety catch on discharge side inspection access doors

Inside door handle with safety catch

Fig. 5: Safety catch
Each inspection access door on the discharge side is fitted with a safety catch ( Fig. 5 ). The safety catch prevents the inspection access door from suddenly swinging open and injuring people.

Fig. 7: Inside door handle with safety catch
If an AHU casing unit is higher than 1836 mm, the inspection access doors on the discharge side are factory fitted with an inside door handle with safety catch. This safeguard prevents: inspection access doors on the discharge side from
swinging open and injuring people people from becoming trapped inside the unit
Hold open device

Inside door handle

Fig. 6: Inside door handle on an inspection access door
If an AHU casing unit is higher than 1836 mm, the inspection access doors are factory fitted with an inside door handle. The inside door handle prevents people from becoming trapped inside the unit.

Fig. 8: Hold open device for outdoor air handling units
On devices designed for outdoor installations, each inspection access door is equipped with a hold open device ( Fig. 8 ). The hold open device prevents the inspection access door from being slammed shut by wind.
Note: If there is no hold open device on an inspection access door due to lack of space, it must be secured against slamming shut by suitable means.

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Air handling unit X-CUBE

Safety
Securing the unit against being switched on acci…

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.

1. WARNING!
Electric shock hazard! The power cable which connects the AHU to the mains holds electrical charges even after power is turned off.
Switch off the power supply to the AHU by turning the mains isolator to ‘0’.
2. Secure the mains isolator with a padlock ( Fig. 9 ).
3. Keep the key in a safe place.
4. Cover the mains isolator with a notice informing people that work is in progress.

Motor protection switch
Motor protection switches are safety devices for switching, protecting and isolating motors or actuators on electric circuits. Motor protection switches protect motors against destruction due to overload, short circuits, locking during start-up, or failure of a live wire in three-phase systems. They also have a thermal tripping mechanism and an electromechanic tripping mechanism (short circuit protection). The motor protection switches are located in the AHU switch cabinet.
1.7 Securing the unit against being switched on accidentally
Securing the unit against being switched on accidentally
WARNING!
Risk to life from unauthorised people starting the unit or from people starting the unit accidentally! If someone who is not authorised starts the unit, or if someone starts the unit accidentally, people could be seriously or even fatally injured.
Before you switch on the unit, make sure that
­ nobody is inside the AHU ­ all inspection access doors have been closed ­ no tools or materials have been left inside the
AHU

Fig. 9: Securing the mains isolator

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Safety
Work areas and hazardous areas
1.8 Work areas and hazardous areas
Fig. 10: Hazardous areas Work areas Hazardous area
Areas from which you can access fans electric air heaters integral switch cabinets are hazardous areas. You can access these hazardous areas only after you open an inspection access door. Before installation is complete, open air inlets and outlets are also considered hazardous areas.

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Air handling unit X-CUBE

Safety
Residual risks > Electric shock hazards

1.9 Residual risks
The air handling unit is a state-of-the-art product and meets current safety requirements. Residual risks cannot be excluded, however, and you should proceed with caution. This section describes the residual risks that have been identified in a risk assessment.
Always observe the safety notes provided in the following chapters of this manual to reduce health hazards and prevent any hazardous situations.
1.9.1 General workplace hazards
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.
­ Wear a safety harness. ­ Only access roofs with suitable and intact fall
protection equipment in place (ladders, railings, safety harness). ­ Start working only if the components you have to work on are easily accessible. ­ Stop materials or objects from falling. ­ Wear safety shoes, protective clothing and a hard hat.
Leaks

1.9.2 Electric shock hazards
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 following safety rules: ­ Use the mains isolator to switch off the unit. ­ Secure it against being switched on accidentally. ­ Disconnect the AHU from the mains power supply for the building. ­ 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 fuses. Be sure to maintain the correct current rating when you replace fuses.
­ Ensure that live parts do not come into contact with moisture. Moisture can cause a short circuit.

CAUTION!
Risk of injury from slipping on a contaminated floor! If a machine or component leaks, liquids may be getting onto the floor. People could slip and injure themselves.
­ Remove any liquids on the floor quickly. ­ Wear non-slip safety shoes. ­ Note the safety data sheets provided by the
liquid manufacturers. ­ Attach warning notices and mandatory action
signs wherever liquids may get onto the floor.

Stored charges
DANGER!
Risk to life from charges stored in capacitors! Many components contain capacitors, which may hold electrical charges even after power is turned off. Contact with these components can result in serious or fatal injuries.
­ Before you start working on any component that contains capacitors, disconnect the component from the power supply. Then wait for 10 minutes to ensure that the capacitors have become fully discharged.

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Safety
Residual risks > Moving machinery hazards

1.9.3 Moving machinery hazards
Rotating parts of a fan
WARNING!
Risk of injury from rotating parts! Rotating parts in the fan can cause severe injuries.
­ Do not reach into the moving fan or tamper with it.
­ Do not open any covers or inspection access panels while the unit is in operation.
­ Make sure that the rotor is inaccessible while in operation.
­ The fan does not stop immediately! Check that no parts are moving before you open an inspection access door.
­ 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, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 . Wait until all parts have come to a standstill.

Rotating parts of the rotary heat exchanger
WARNING!
Risk of injury from rotating parts! Rotating parts in the rotary heat exchanger can cause serious injuries.
­ Do not reach into the moving storage mass or tamper with it.
­ Do not open any covers or inspection access panels while the unit is in operation.
­ Make sure that the storage mass is inaccessible while in operation.
­ 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 parts of the rotary heat exchanger and secure it against accidentally being switched on again, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 . Wait until all parts have come to a standstill.
Inspection access doors slamming shut

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.

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.

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Air handling unit X-CUBE

Safety
Residual risks > Hazards from high and low temperatures

1.9.4 Hazards from the hydraulic system
Jet of liquid from a defective hydraulic system
DANGER!
Risk to life from high pressure fluid injection! If a hose or a pipe or an AHU component becomes defective, a jet of coolant, refrigerant or compressor oil under pressure may escape. The jet of liquid can cause serious injuries as well as frostbite and burns.
­ Do not stand or hold objects in the path of a jet of liquid. Keep people away from the hazardous area.
­ Immediately initiate an emergency stop. If necessary, initiate further measures to reduce the pressure and stop the jet of liquid.
­ Remove escaping liquids and dispose of them correctly.
­ Have any defective components repaired immediately.
Refrigeration system
WARNING!
Risk of injury from the refrigeration system! Components, operating fluids and incorrect handling of the refrigeration system can cause serious injuries.
­ Work on the refrigeration system must only be carried out by skilled qualified refrigeration technicians or the Ä TROX Technical Service .
­ Always comply with the safety data sheet provided by the refrigerant manufacturer. Ä Appendix B.2 `Freezing agent’ on page 117
1.9.5 Hazards from high and low temperatures
Hot surfaces
WARNING!
Risk of injury from hot surfaces! The surfaces of the heating coil can get very hot during operation. Skin contact with hot surfaces causes severe skin burns.
­ Wear heat-resistant protective clothing and gloves whenever you work near a potentially hot surface.
­ Before you start working, make sure that all surfaces have cooled down to ambient temperature.

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.
Release of steam
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.
Cold surfaces
WARNING!
Risk of injury from cold surfaces! The surfaces of the integral refrigeration system and evaporator can cool down to -20 °C while in operation. Skin contact with cold surfaces causes frostbite and cold burns.
­ Wear protective clothing and gloves that protect you from the cold when you work near a potentially cold surface.
­ Before you start working, make sure that all surfaces have warmed up to ambient temperature.

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Safety
Residual risks > Hazardous substances and operating fluids

1.9.6 Hazardous substances and operating fluids
Operating fluids with glycol
WARNING!
Health risk from operating fluids that contain glycol! The operating 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 operating fluids that contain glycol.
­ Work must only be carried out by HVAC technicians.
­ Do not eat, drink, or smoke while handling operating fluids that contain glycol.
­ Wash your hands when you interrupt or finish your work.
­ If you have come into contact with an operating fluid that contains glycol, follow the first aid instructions given on the safety data sheet for the operating fluid.
­ When you have to handle an operating fluid that contains glycol, wear the personal protective equipment specified in the safety data sheet for the operating fluid.

Refrigerant R-410A
WARNING!
Health risk from refrigerants! If you inhale the refrigerant used in the refrigeration system you may feel severe shortness of breath, become unconscious, suffer cardiac arrhythmia and eventually suffocate. Skin contact with refrigerant causes cold burns.
­ Avoid any contact with refrigerant. ­ Work on the refrigeration system must only be
carried out by skilled qualified refrigeration technicians or the Ä TROX Technical Service . ­ Do not eat, drink or smoke while handling refrigerants. ­ Wash your hands when you interrupt or finish your work. ­ If you have come into contact with refrigerant, follow the first aid instructions given on the manufacturer’s safety data sheet for the refrigerant. Ä Appendix B.2 `Freezing agent’ on page 117 ­ If any refrigerant has escaped, provide sufficient ventilation of the space. ­ Wear safety goggles and protective gloves against thermal risks when you handle refrigerants.
Compressor oil

WARNING!
Health risk from compressor oil!
If your skin comes into contact with compressor oil, or if you swallor or inhale it, you may suffer irritation to the skin, eyes, the gastro-intestinal tract and the upper respiratory tract.
­ Avoid any contact with compressor oil.
­ Work on the refrigeration system must only be carried out by skilled qualified refrigeration technicians.
­ Do not eat, drink, or smoke while handling refrigerants.
­ If you have come into contact with compressor oil, follow the first aid instructions given on the manufacturer’s safety data sheet for the oil. Ä Appendix B.1 `Compressor oil’ on page 107

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Air handling unit X-CUBE

Safety
Residual risks > Risk of entrapment in units with whole body ac…

Lubricants

Damaged fan parts

WARNING!
Health risk from lubricants!
Contact with lubricants can induce allergies and skin irritation.
­ Wear protective gloves when handling lubricants. ­ Be careful not to swallow lubricants or inhale the
vapours. ­ If any lubricant has got into your eyes, rinse your
eyes thoroughly with plenty of water and seek medical attention if necessary. ­ If your skin has come into contact with any lubricant, wash your hands thoroughly with plenty of water and soap. ­ Comply with the safety data sheets provided by the lubricant manufacturer.

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.
1.9.8 Risk of entrapment in units with whole body access
Risk of entrapment in units with whole body access

1.9.7 Fire hazards
Fire protection
WARNING!
Risk of injury from insufficient or inadequate firefighting! If there is a fire and the fire extinguisher is not in working order or is unsuitable for the class of fire, this can result in serious or even fatal injuries and considerable damage to property.
­ Make sure that all fire extinguishers are suitable for the expected class of fire.
­ Check fire extinguishers every 2 years to ensure that they are in working order.
­ Refill each fire extinguisher after it has been used.
­ Use only extinguishing agents and replacement parts that comply with the information specified on the fire extinguisher.
­ If you have to use a fire extinguisher, make sure you know how to use it safely (see instructions on the extinguisher).

WARNING!
Risk of entrapment where there is whole body access into air handling units! Entrapment in an air handling unit can cause serious injury or even death.
­ When you have to work on the air handling unit, secure the air handling unit against being switched on accidentally.
­ Before you switch on the air handling unit again, make sure that nobody is inside.

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Safety
Measures to take if a harmful substance has been…

1.10 Environmental protection
NOTICE!
Risk of harm to the environment due to the incorrect handling of hazardous materials and substances. Many substances are hazardous. If you handle them incorrectly or dispose of them incorrectly, they can considerably harm the environment.
­ If you have to handle or dispose of substances that can harm the environment, follow the instructions below.
­ If any hazardous substances have escaped to the environment, immediately take suitable measures to avoid further damage. If you are in doubt, inform the local authorities about the damage and enquire about suitable measures to be taken.
­ If any hazardous substances have escaped to the environment, immediately take suitable measures to avoid further damage. If you are in doubt, inform the local authorities about the damage and enquire about suitable measures to be taken.
The following substances and materials which are hazardous to the environment are used in this AHU:
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.
Only use on of the following glycols for the air handling unit:
Propylene glycol Ethylene glycol
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.
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.

Lubricants
Lubricants such as greases and oils contain toxic substances. Lubricants must not be released into the environment. Commission a specialist disposal company to dispose of hazardous substances and materials.
1.11 Measures to take if a harmful substance has been released
Refrigerant R-410A
Personal safety:
Bring people to safety. Provide sufficient ventilation in work areas, and
extract harmful substances. Wear safety goggles and protective gloves against
thermal risks.
Environmental protection:
Make sure that hazardous substances cannot be released into the environment. Use collection devices.
Comply with the safety data sheet provided by the manufacturer, Ä Appendix B.2 Freezing agent’ on page 117 . Compressor oil Personal safety: Wear safety goggles and protective gloves. Environmental protection: Harmful substances must not enter sewerage systems or bodies of water. Use collection devices. Use sand, earth or a similar absorbent material to absorb any spills, and fill the contaminated material into a container so that it can be safely disposed of. Clean the contaminated area with water. If a hazardous substance has been released to a body of water or into the sewerage system, immediately inform the local authorities. Comply with the safety data sheet provided by the manufacturer, Ä Appendix B.1 Compressor oil’ on page 107 .
Coolant, glycol
Coolants that contain glycol are hazardous, so please note:
Personal safety:
Bring people to safety. Wear protective equipment. Provide sufficient ventilation in work areas, and
extract harmful substances. Do not inhale vapours or aerosols. Avoid contact
with the eyes and skin.

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Air handling unit X-CUBE

Safety
Measures to take if a harmful substance has been…
Environmental protection: Harmful substances must not enter sewerage sys-
tems or bodies of water. Use collection devices. Use sand, earth or a similar absorbent material to
absorb any spills, and fill the contaminated material into a container so that it can be safely disposed of. If a hazardous substance has been released to a body of water or into the sewerage system, immediately inform the local authorities. Comply with the safety data sheet provided by the manufacturer.
Lubricants Comply with the safety data sheet provided by the manufacturer.
Batteries Batteries contain toxic heavy metals. They are hazardous waste and must be taken to a hazardous waste collection point or disposed of by a specialist company.

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Functional description
Operating modes

2 Functional description
Your air handling unit (AHU) is a bespoke product and has been configured according to your project. A list of all functions is given on the technical data sheets. An illustration and the technical data should already have been provided to you for information and acceptance. We recommend that you keep those documents with this manual.
2.1 Symbols used on the air handling unit
Symbols on the AHU casing indicate which optional components have been installed.
Explanation
Symbol Description Filters
Fan: Centrifugal fan FanArray Sound attenuators
Multileaf damper
Cooling: Cooling coil Evaporator Heating: Heating coil Electric air heater Condenser Steam heated register Rotary heat exchanger
Plate heat exchanger

Symbol Description

–

Noise insulating connector

–

Air recirculation chamber

Switch cabinet:
Integral switch cabinet Floor-standing switch cabinet Wall-mounted switch cabinet

Mains isolator

FOL (EHA)
ZUL (SUP)
AUL (ODA)
ABL (ETA)

Exhaust air Supply air Outdoor air extract air

2.2 Function of the air handling unit
General function
The AHU consists of several casing units with components.
Depending on the equipment of the device, the following functions can be designed for air treatment:
Filtering Circulation Heating Cooling Heat recovery Humidification Dehumidification Mixing
2.3 Operating modes
The following operating modes can be selected using the touch screen:

Run around coil system
Run around coil system with hydraulic unit
Humidifier: Steam humidifier High-pressure spray humidifier Evaporative humidifier

Operating modeDescription

OFF

The unit has been switched off.

Auto

The unit is running. The control functions are active.

Manual

The unit is in manual mode. All control elements can be controlled manually.

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Air handling unit X-CUBE

Functional description
Function of each component

2.4 Function of each component
Filter
The filter cleans the air and removes any contaminants to ensure purity. Filter elements may be of various filter classes, depending on the application. The filter is accessed through an inspection access door so that you can change filter elements easily.
The filter consists of: Filter chamber Filter frame Filter element
Centrifugal fan
The centrifugal fan moves air through the AHU and the entire ventilation system.
The AHU casing unit with the centrifugal fan is a hazardous area; the inspection access door is marked accordingly and allows access for authorised individuals only. Before you access the centrifugal fan, use the mains isolator to switch off the AHU and secure it against being switched on accidentally.
FanArray
The FanArray moves air through the AHU and the entire ventilation system. All the fans work together to produce the required volume flow rate.
Sound attenuator
The sound attenuator consists of sound attenuator splitters; they reduce noise resulting from fan operation and air treatment. The splitters are accessed through an inspection access door; you can remove them for cleaning.
Multileaf dampers
The multileaf dampers are used to restrict or completely block the airflow. The multileaf dampers are accessed through an inspection access door so that you can clean and maintain them easily.
Cooling coil
If required, the cooling coil cools the supply air to the specified setpoint value. The required cooling energy comes from an external energy source and is transferred to the airflow by a heat exchanger. The cooling coil is accessed through an inspection access door so that you can clean and maintain it easily.

Condenser In the condenser, the vaporous refrigerant coming from the evaporator liquefies, which emits heat. Depending on the installation location of the condenser, the following function results: Exhaust air – Heat dissipation Supply air – Heating of supply air to setpoint value
Heating coil If required, the heating coil heats the supply air to the specified setpoint value. The required heating energy comes from an external energy source and is transferred to the airflow by a heat exchanger. The heating coil is accessed through an inspection access door so that you can clean and maintain it easily.
Steam heated register If required, the steam heated register heats the supply air to the specified setpoint value. The required heating energy comes from an external energy source and is transferred to the airflow by a steam heat exchanger. The steam heat register is accessed through an inspection access door so that you can clean and maintain it easily.
Electric air heater The electric air heater is used to heat the supply air. If required, it heats the supply air to the specified setpoint value. The required heating energy is transferred to the airflow by electric heating elements.
Evaporator The evaporator cools the supply air to the setpoint value when required. The refrigerant evaporates during the heat transfer and withdraws energy (heat) from the environment, which then cools the supplied air.
Rotary heat exchanger The storage mass consists of alternate layers of smooth and corrugated aluminium. As the wheel slowly rotates, extract air and supply air flow in opposite directions through the heat exchanger so that the thermal energy of the airflows is transferred.
Plate heat exchanger The plate heat exchanger consists of stacked plates of corrugated metal which are arranged in such a way that the fluid to be heated and the fluid to be cooled flow through alternating spaces between each two plates.

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Functional description
Operating and display elements > Mains isolator

Run around coil system with hydraulic unit
At least one heat exchanger in the supply air flow and one in the extract air flow are connected via a TROX pump (hydraulic unit) and pipes. This arrangement forms the run around coil system with hydraulic unit. The extract air heat is transferred to the heat transfer fluid in the heat exchanger. The pump moves the heat transfer fluid to the supply air heat exchanger. The heat is then transferred from the heat transfer fluid to the supply air. Connections should be in counterflow so that the heat transfer fluid and the air flow in opposite directions. This ensures that the two airflows are completely separate from each other.

Air recirculation chamber
The air recirculation chamber is a central chamber in the AHU in which air recirculation is controlled by multileaf dampers. Recirculation operation may be anything between 0 and 100%, depending on requirements.
Noise insulating connector
The noise insulating connector is fitted between the AHU and the ducting. The noise insulating connector includes an anit-vibration element that prevents the transmission of noise and vibrations from the AHU to the ducting.

Run around coil system
At least one heat exchanger in the supply air flow and one in the extract air flow are connected by a pump (by others) and pipes. This arrangement constitutes a run around coil system. The extract air heat is transferred to the heat transfer fluid in the heat exchanger. The pump moves the heat transfer fluid to the supply air heat exchanger. The heat is then transferred from the heat transfer fluid to the supply air. Connections should be in counterflow so that the heat transfer fluid and the air flow in opposite directions. This ensures that the two airflows are completely separate from each other.
Steam humidifier
The humidifier unit consists of two separate components: the steam generator and the steam distribution system. As the water in the steam generator evaporates, the steam is transferred to the airflow via the steam distribution system. This is how the air is humidified.
High-pressure spray humidifier
The high-pressure spray humidifier is used to humidify the supply air without heat exchange. A grid of spray nozzles atomise fresh water, thereby creating a fine mist in the humidification chamber.

Using X-CUBE Control X-CUBE Control is the control system for the air handling unit. The user interface of X-CUBE control Ä Using X-CUBE Control’ on page 24 allows you to configure the entire system and to make adjustments. You can access the user interface in two ways: Touchscreen Ä 2.5.3Touchscreen’ on page 25
or PC browser (provided by others)
2.5 Operating and display elements 2.5.1 Mains isolator
Mains isolator Ä Mains isolator of the AHU’ on page 11 Local isolator ÄLocal isolator ‘ on page 11

Evaporative humidifier
The evaporative humidifier is used for evaporative cooling of the extract air (adiabatic cooling); no heat exchange takes place. If the outdoor air temperature is fairly high, the extract air is cooled; the warm outdoor air can hence be cooled without the need for an external refrigeration system. As a result, less refrigeration energy is required. There is a choice of two constructions, either for flow-through operation or for recirculation of water in the water container.

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Air handling unit X-CUBE

Functional description
Operating and display elements > Filter monitoring

2.5.2 Inspection access doors with a lock
Inspection access doors

2.5.3 Touchscreen
Touch screen of the AHU

Fig. 12: Touch screen
The touch screen ( Fig. 12 ) allows you to use XCUBE Control. Ä Chapter 3.10 `Using X-CUBE Control’ on page 29 .
Alternatively, you can access the user interface with a web browser on your PC (by others). To do so, first connect the AHU controller to the PC or network (Ethernet interface in the switch cabinet).

Fig. 11: Inspection access door
1 Lock 2 Inspection access door 3 Inspection window 4 Lever 5 Latch
Inspection access doors ( Fig. 11 /2) are located at the front of the AHU; they allow you to access various AHU components. Some doors are fitted with an inspection window ( Fig. 11 /3).
The inspection access doors are closed with a latch ( Fig. 11 /5) and lock ( Fig. 11 /1); depending on the AHU component, the door can be opened with a handle ( Fig. 11 /4) or requires a special key (not shown).
Each inspection access door is fitted with several safeguards:
Ä Hold open device Ä Safety catch Ä Inside door handle Ä Inside door handle with safety catch Ä Safety lock

2.5.4 Filter monitoring
For filter monitoring, the air pressures in front of and behind the filter elements are measured with a differential pressure gauge and the differential pressure is visualised. In differential pressure gauges with differential pressure switches (optional), the pre-set pressure value of the filter is monitored. If this is exceeded, a signal is sent to the control unit. In devices with X-CUBE control, a message is output in the visualisation.
The differential pressure gauges are installed on the operating side of the air handling unit, on each filter
. The AHU may have been fitted with analogue or digital differential pressure measuring devices.
ENVIRONMENT!
Saving energy The higher the differential pressure, the higher the resistance of the filter and hence the power consumption of the air handling unit. If the maximum final differential pressure has been reached, you have to replace the filter.
The maximum final differential pressure (Pmax) for a filter is given on a sticker on the inspection access door to the filter chamber.

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25

Functional description
Connections and interfaces

Connections for heat transfer fluids
Used to lead the heat transfer fluid (by others) into the heating coil or cooling coil and out again.

Condensate drains Used to discharge condensate.

Fig. 13: Digital differential pressure gauge The current differential pressure is shown on the display, further information Ä Appendix A.1 `TROX MDDPC-24 digital pressure monitor’ on page 84 .

Humidifier connections Used to transport the humidifying fluid to the distribution system.
Evaporator and condenser connections Used to lead the heat transfer fluid (by others) into the evaporator or condenser and out again.

Cable glands
The casing panels of components that need supply voltage or a control cable (such as fans, actuators, antifrost thermostats) are fitted with cable glands.

Fig. 14: Analogue differential pressure gauge
The current differential pressure is displayed on the inspection window.
If the pointer deviates from the zero point (pressureless state), a zero point correction can be made via zero point adjustment (screw). The mechanical and optional electrical zero points are set at the same time by turning the zero point screw (on the front of the device).

2.6 Connections and interfaces
Duct connections of the air handling unit

Duct connec- Meaning tion

Extract air (ETA/ABL)

Duct through which the extract air from rooms enters the AHU.

Supply air (SUP/ZUL)
Outdoor air (ODA/AUL)

Duct through which the supply air flows from the AHU into rooms.
Duct through which outdoor air enters the AHU.

Exhaust air (EHA/FOL)

Duct through which air is led outside.

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Air handling unit X-CUBE

Software use
Starting the air handling unit

3 Software use
3.1 Safety notes regarding operation
Incorrect operation
WARNING!
Risk of injury from incorrect operation! Incorrect operation can cause serious injuries and considerable damage to property.
­ Read the operating manual. ­ Follow the instructions in in this manual. ­ Before you start working, ensure that:
­ all inspection access doors and covers have been closed.
­ all safeguards have been installed and function correctly.
­ nobody is inside the AHU. ­ Do not open any covers or inspection access
doors while the unit is in operation. ­ Do not disable or bypass any safeguards while
the unit is in operation.
Working at height

Provide first aid. Get yourself to safety. Take people in danger with
you.
3.3 Switch-off in the event of a fire
The owner of the ventilation and air conditioning system has to include the air handling unit in the fire protection strategy for the building. The system owner has to define the steps to be followed in the event of a fire.
3.4 Preparing a (re)start
Risk of entrapment in units with whole body access
WARNING!
Risk of entrapment where there is whole body access into air handling units! Entrapment in an air handling unit can cause serious injury or even death.
­ When you have to work on the air handling unit, secure the air handling unit against being switched on accidentally.
­ Before you switch on the air handling unit again, make sure that nobody is inside.

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.
­ Wear a safety harness.
­ Only access roofs with suitable and intact fall protection equipment in place (ladders, railings, safety harness).
­ Start working only if the components you have to work on are easily accessible.
­ Stop materials or objects from falling.
­ Wear safety shoes, protective clothing and a hard hat.

Before you start the AHU
Before you start the AHU, ensure that:
Nobody is inside the AHU and no objects have been left inside the AHU.
All filter elements have been inserted and are intact. All connections for water, electricity etc. are intact
and open. The AHU casing has been completely closed.
3.5 Starting the air handling unit
Switching the mains isolator on
Personnel: Instructed person

3.2 Emergency switch-off
Switch off the mains isolator and secure it against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 .
Raise the alarm. If there is no risk to your own health, rescue other
people from the hazardous area. Notify the emergency services.

Fig. 15: How to turn the mains isolator
1. Turn the mains isolator for the AHU to the ‘I’ position.
ð The AHU starts up and is then ready for operation. The touch panel is switched on and displays the user interface.

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27

Software use
After shutdown

If you are using a web browser 2. Switch on the PC (provided by others).
ð The PC starts up. 3.
This step is only required the first time that the AHU is operated using a PC (provided by others).
Connect the AHU to the PC (see software documentation for the air handling unit). 4. Open the web browser. 5. Enter the following address into the address line: IP address/trox.html
Example: 192.168.0.200/trox.html ð This displays the user interface.
3.6 Checks during operation
The following checks must be carried out each week while the air handling unit is in operation: Check the differential pressure on the filter,
Ä Chapter 3.11 ` Reading the differential pressure on the filter ‘ on page 40 . Check the system pressure of the heat transfer fluids according to the instructions of the system manufacturer (system by others). Check the air handling unit for faults.
3.7 Tips for operation
Follow the maintenance schedule Follow the maintenance schedule to ensure economic and energy-efficient operation of each AHU component. If a filter is contaminated, the fan and the entire AHU consume more power.
Keep the building usage in mind Ensure that the operating mode of the AHU fits the requirements of the building. If the building usage changes, you may have to adapt the operating mode.
Demand-based control Demand-based control ensures optimum operation and prevents excessive energy consumption.

3.8 Switching the AHU off
Personnel: Instructed person
NOTICE! Risk of data loss from turning off the mains isolator! If you just turn off the mains isolator to stop the AHU, data may be lost. ­ Always shut down X-CUBE Control first. ­ Only in an emergency should you use the mains
isolator to stop the AHU.
1. Shut down the AHU on the controls interface (touch screen) as described in the software documentation. ð The AHU shuts down. The touch panel switches off.
2. Secure the AHU against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 . ð The AHU has been secured against being switched on accidentally. It is safe to start working now.
3.9 After shutdown
Decommissioning
WARNING! Risk of injury from incorrect decommissioning! Incorrect decommissioning may lead to dangerous situations. ­ Appoint an HVAC technician for decommis-
sioning. ­ Appoint a skilled qualified electrician and refriger-
ation technician for decommissioning.
Decommissioning if there is a risk of frost A decommissioned AHU has to be protected from frost. If only water (without any additives) has been used as a heat transfer fluid, you have to drain the following components: Heating coil Cooling coil Humidifier Condensate drip trays Drain traps Run around coil system

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Air handling unit X-CUBE

Software use
Using X-CUBE Control > Login on the user interface

Decommissioning the rotary heat exchanger
If the unit is down for up to 3 months (e.g. in summer), start the fan every 2 weeks so it retains its self-cleaning function.

3.10.1 Login on the user interface
Displaying the `Login / Write Permission’ screen
Personnel: Instructed person

Downtime of 3 months or longer
If downtime lasts 3 months or longer
Remove the drive belts of the rotary heat exchangers in order to protect the belts from damage.
Physically disconnect the entire AHU from the mains.
Ensure that any residual energy is dissipated. Remove and dispose of any operating fluids, auxil-
iary materials and leftover processing materials in an environmentally sound manner.
Downtime of 1 year or longer
If downtime lasts 1 year or longer
Replace the bearings. If an automatic lubricator for the bearings is in place,
remove the used lubricant and replace it with new lubricant; follow the instructions of the fan manufacturer. Remove the droplet eliminator and demister for cleaning.

Fig. 16: Opening user administration
Press .
ð This displays the ‘Login / Write Permission’ screen.

Removing motors
Use only suitable and approved equipment to lift and move motors. If, for example, an integral cross bar and trolley are used to remove a fan motor, ensure that the unit remains stable, e.g. by fixing it to the building structure.
3.10 Using X-CUBE Control

Using the touch panel
The touch panel is sensitive to the pressure of your fingers; no keyboard or mouse is required. A virtual keyboard is displayed on the panel for you to enter data.
Alternatively, you can use a PC with keyboard and mouse to navigate X-CUBE Control. In this case you have to establish a connection between the unit and a PC (by others) or a network (by others).

Air handling unit X-CUBE

29

Software use
Using X-CUBE Control > Login on the user interface

Login Personnel: Instructed person
Prerequisite: The `Login / Write Permission’ screen is displayed.

Opening the `system overview’
Personnel: Instructed person

Fig. 17: Entering your user name and password Access data on delivery

User name

TROX

Password

X-CUBE

1. Select the Username’ field ( Fig. 17 ), enter your user name and confirm your entry by pressingEnter’ .
2. Select the password’ field ( Fig. 17 ), enter your password and confirm your entry by pressingEnter’ .
3. Press `Login’ ( Fig. 17 ).
ð You have been logged in. The symbol in the status bar indicates your user status. You can now select functions and set parameters.

Fig. 18: Opening the system overview screen (variant 1) Once you are logged in, press ( Fig. 18 ). ð This displays the system overview.
Alternatively:
Fig. 19: Opening the system overview (variant 2) Press ( Fig. 19 ) on the starting screen or press the button in the navigation area ( Fig. 19 ). ð This displays the system overview.

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Air handling unit X-CUBE

3.10.2 System settings
Displaying the `System settings’ screen Personnel: Instructed person
Prerequisite: You have been logged in.

Software use
Using X-CUBE Control > System settings
Selecting a ‘system mode’ (operating mode) Personnel: Instructed person Prerequisite: You have been logged in. The `System settings’ screen is displayed.

Fig. 20: ‘System overview’ screen (example)
Press . ð This displays the `System settings’ screen.

Fig. 21: Displaying the ‘Language & system mode’ screen
1. Press language & system mode’ . ð This displays thelanguage & system mode’ screen.

Fig. 22: Selecting a ‘system mode’ (operating mode) 2. Select the `system mode’ field, then select a
system mode from the list.

Operating modDeescription

OFF

The unit has been switched off.

Auto

The unit is running. The control functions are active.

Manual

The unit is in manual mode. All control elements can be controlled manually.

3. Press `apply’ . ð The system mode has been selected.

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Software use
Using X-CUBE Control > System settings

Selecting the language Personnel: Instructed person
Prerequisite: You have been logged in. The `language & system mode’ screen is displayed.

Setting the date and time Personnel: Instructed person
Prerequisite: You have been logged in. The `System settings’ screen is displayed.

Fig. 23: Selecting a language 1. Press the language’ field, then select a language from the list. 2. Pressapply’ .
ð The language has been set, texts will be displayed in this language.

Fig. 24: Displaying the ‘Date – Time’ screen 1. Press `Date – Time’ .

Fig. 25: Setting the date and time 2. Select the year’ ( Fig. 25 ) field and enter the cal- endar year. 3. Entermonth’ , day’ ,hour’ and minute’ ( Fig. 25 ) in the same way. 4. Pressapply’ .
ð The date and time have been set.

Setting the control strategy
Personnel: HVAC technician
The control strategy is usually set as part of the initial commissioning procedure for the air handling unit. Changes must only be made by experienced users and after consultation with the owner of the ventilation and air conditioning system. Alternatively, you can have the Ä TROX Technical Service change settings if necessary.

32

Air handling unit X-CUBE

Software use
Using X-CUBE Control > Setting a setpoint schedule

Night purge
Personnel: HVAC technician
Night purge is usually set as part of the initial commissioning procedure for the air handling unit. Changes must only be made by experienced users and after consultation with the owner of the ventilation and air conditioning system. Alternatively, you can have the Ä TROX Technical Service change settings if necessary.

Editing profiles Personnel: Instructed person
Prerequisite: You have been logged in. The `setpoint schedule’ screen is displayed. Selecting a profile

Setting external alarms
Personnel: HVAC technician
External alarms are usually set as part of the initial commissioning procedure for the air handling unit. Changes must only be made by experienced users and after consultation with the owner of the ventilation and air conditioning system. Alternatively, you can have the Ä TROX Technical Service change settings if necessary.

3.10.3 Setting a setpoint schedule
Displaying the `setpoint schedule’ screen Personnel: Instructed person
Prerequisite: You have been logged in.

Fig. 27: Editing profiles 1. Select a day of the week ( Fig. 27 ), then select a
profile from the list. Setting profiles

Fig. 26: ‘System overview’ screen (example)
Press . ð This displays the `setpoint schedule’ screen.

Fig. 28: Editing a profile 2. Press edit profile’ . ð This displays theProfile’ screen.

Air handling unit X-CUBE

33

Software use
Using X-CUBE Control > Setting a setpoint schedule
Setting a schedule Personnel: Instructed person Prerequisite: You have been logged in. The `setpoint schedule’ screen is displayed. The profiles have been edited.

Fig. 29: Setting a profile 3. Select a time’ ( Fig. 29 ) field, then enter a start time. 4. In the same row, press the entry field in the mode’ ( Fig. 29 ) column.

There are 2 modes: ­ Select ‘Control’ to activate the row. ­ Select ‘Standby’ to deactivate the row.
5. Select the temperature’ ( Fig. 29 ) fields in the same row and enter a temperature range. 6\. Select theset-point air flow’ ( Fig. 29 ) fields in the same row and enter supply air and extract air flow rates.
7. Repeat steps 4 to 6 to set additional periods. 8. Press apply’ and close’ ( Fig. 29 ).
ð This saves the profile and exits the screen.
9. Repeat steps 1 to 8 to set additional profiles.

Fig. 30: Setting a schedule 1. Select a set profile for a day of the week
( Fig. 30 ). 2. Select profiles for the other days in the same way. 3. Press `apply’ .
ð The setpoint schedule has been set.

34

Air handling unit X-CUBE

Software use
Using X-CUBE Control > Setting a setpoint schedule

Setting ‘official days off’ (public holidays)
You can display a read-out of ‘official days off’ (public holidays) or enter them manually. If you retrieve ‘official days off’ (public holidays), check that they are correct for the calendar year in question.
Automatic read-out
Personnel: Instructed person
Prerequisite:
You have been logged in. The `official days off’ screen is displayed.

Setting ‘official days off’ (public holidays) manually Personnel: Instructed person
Prerequisite: You have been logged in. The `setpoint schedule’ screen is displayed.

Fig. 32: Displaying the ‘official days off’ screen 1. Press official days off’ . ð This displays theofficial days off’ screen.
Fig. 31: Reading out ‘official days off’ 1. Press readout’ ( Fig. 31 ). ð This displays the ‘official days off’ (public holidays). 2\. Pressapply’ ( Fig. 31 ). ð The ‘official days off’ (public holidays) have been set.
Fig. 33: Setting ‘official days off’ (public holidays) 2. Press for an ‘official day off’ (public holiday). 3. Enter:
Name Date Month Year Profile
4. Press active’ to activate the ‘official day off’ (public holiday). 5\. Pressapply’ . ð The ‘official days off’ (public holidays) have been set.

Air handling unit X-CUBE

35

Software use
Using X-CUBE Control > Setting a setpoint schedule

Setting ‘additional days off’ (additional holidays) Personnel: Instructed person
Prerequisite: You have been logged in. The `setpoint schedule’ screen is displayed.

Prerequisite: You have been logged in. The `setpoint schedule’ screen is displayed.

Fig. 34: Displaying the ‘additional days off’ screen 1. Press additional days off’ . ð This displays theadditional days off’ screen.

Fig. 36: Opening the ‘holidays’ screen 1. Press holidays’ . ð This displays theholidays’ screen.

Fig. 35: Setting ‘additional days off’ (additional holidays) 2. Press ( Fig. 35 ) for an ‘official day off’ (public
holiday). 3. Enter:
Name Date Month Year Profile . 4. Press `active’ ( Fig. 35 ) to activate the ‘additional day off’ (additional holiday).
Setting ‘holidays’ (annual leave) Personnel: Instructed person

Fig. 37: Setting ‘holidays’ (annual leave)
2. Press for a particular ‘holiday period’ (leave period).
3. Enter:
Name Date Month Year Profile
. 4. Press active’ to activate the ‘holiday’ (annual leave) period. 5. Pressapply’ .
ð The ‘holiday’ (annual leave) period has been set.

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Air handling unit X-CUBE

Setting ‘flashing mode and cooling protection’ Personnel: Instructed person
Prerequisite: You have been logged in. The `setpoint schedule’ screen is displayed.

Software use
Using X-CUBE Control > Setting a setpoint schedule
‘Operation prolongation’ (operating time extension) Personnel: Instructed person Prerequisite: You have been logged in. The `setpoint schedule’ screen is displayed.

Fig. 38: Displaying the ‘flashing mode and cooling protection’ screen
Press flashing mode and cooling protection’ . ð This displays theflashing mode and cooling
protection’ screen.

Fig. 39: Displaying the ‘operation prolongation’ screen
1. Press operation prolongation’ . ð This displays theoperation prolongation’ screen.

Fig. 40: ‘Operation prolongation’ (operating time extension) 2. Press activate’ ( Fig. 40 ) to extend the operating time. 3. Press theprofile’ field ( Fig. 40 ), then select a
previously set profile. Setting profiles, Ä Editing profiles’ on page 33 4. Select theprofile hour’ and profile minute’ fields ( Fig. 40 ). 5\. Enter ‘profile hour’ and ‘profile minute’ to define a period for the profile. 6\. Select theduration’ ( Fig. 40 ) field, then enter the number of minutes by which you want to extend the operating time.
7. Press `apply’ ( Fig. 40 ).
ð The operating time has been extended.

Air handling unit X-CUBE

37

Software use
Using X-CUBE Control > Connecting the AHU to a PC or network (by othe…
Setpoint correction Personnel: Instructed person Prerequisite: You have been logged in. The `setpoint schedule’ screen is displayed.

Fig. 41: Displaying the ‘setpoint correction’ screen 1. Press setpoint correction’ . ð This displays thesetpoint correction’ screen. 2. Press `apply’ .
ð Setpoint correction has been set.

Fig. 43: Setting up a new network 3. Select Set up a new network’ ( Fig. 43 ), then clickNext’ .
ð The software searches for an access point.
4. Select the air handling unit. ð The `Local Area Connection Status’ window opens.

3.10.4 Connecting the AHU to a PC or network (by others)
Connecting the AHU Personnel: Instructed person
The following steps apply to a Windows PC. 1. Open the Network and Sharing Center.

Fig. 42: Setting up a new connection or network
2. Select Set up a new connection or network’ ( Fig. 42 ). ð TheSet Up a Connection or Network’ window opens.

Fig. 44: LAN connection status
5. Select Properties’ ( Fig. 44 ). ð TheLocal Area Connection Properties’ window opens.

38

Air handling unit X-CUBE

Software use
Using X-CUBE Control > Connecting the AHU to a PC or network (by othe… 7. Select the Use the following IP address:’ ( Fig. 46 ) option, enter the IP address, subnet mask and default gateway and confirm withOK’ . ð The connection has been set up and the air handling unit can be operated using the web browser.
You may have to restart your PC.
Fig. 45: LAN connection properties 6. Select Internet Protocol Version 4 (TCP/IPv4)’ , then selectProperties’ ( Fig. 45 ). ð The `Internet Protocol Version 4 (TCP/IPv4)
Properties’ window opens.

Fig. 46: Internet protocol version 4 (TCP/IPv4) properties

Air handling unit X-CUBE

39

Software use
Reading the differential pressure on the filter
3.11 Reading the differential pressure on the filter
Personnel: Instructed person Protective equipment: Industrial safety helmet
ENVIRONMENT! Saving energy The higher the differential pressure, the higher the resistance of the filter and hence the power consumption of the air handling unit. If the maximum final differential pressure has been reached, you have to replace the filter.

Fig. 47: Analogue and digital differential pressure measuring devices
Read the differential pressure from the inspection window ( Fig. 47 /1) or the display ( Fig. 47 /2). ð If the maximum final differential pressure has
been reached, you have to replace the filter element, Ä Chapter 4.4.4 ` Replacing a filter element’ on page 55 .
The maximum final differential pressure (Pmax) for a filter is given on a sticker on the inspection access door to the filter chamber.

40

Air handling unit X-CUBE

Maintenance
Safety notes regarding maintenance

4 Maintenance
The air handling unit requires regular maintenance. Regular care and maintenance ensure operational readiness, functional reliability and long service life of the air handling unit.
Maintenance can also be performed by the TROX Technical Service (optional) ( Ä `TROX Technical Service’ on page 3 ).
4.1 Safety notes regarding maintenance
Incorrect maintenance
WARNING!
Risk of injury from incorrect maintenance! Incorrect maintenance can cause serious injuries and considerable damage to property.
­ Before you start maintenance, switch off the air handling unit and secure it against being restarted accidentally.
­ Have only authorised persons carry out maintenance.
­ Before you start, make sure that there is sufficient clearance for the work you have to complete.
­ Keep the work area tidy and clean. Parts and tools that are loosely stacked or left lying around are a source of accident.
­ When you reinstall previously removed parts, follow the correct procedure, use all fixing elements and tighten all screws with the correct torque.
­ Before you recommission the unit, make sure that: ­ All maintenance jobs have been completed according to this manual. ­ Nobody is inside the AHU. ­ All inspection access doors and covers have been closed. ­ All safeguards have been installed and function correctly.

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.
­ Wear a safety harness. ­ Only access roofs with suitable and intact fall
protection equipment in place (ladders, railings, safety harness). ­ Start working only if the components you have to work on are easily accessible. ­ Stop materials or objects from falling. ­ Wear safety shoes, protective clothing and a hard hat.
Rotating parts of a fan
WARNING!
Risk of injury from rotating parts! Rotating parts in the fan can cause severe injuries.
­ Do not reach into the moving fan or tamper with it.
­ Do not open any covers or inspection access panels while the unit is in operation.
­ Make sure that the rotor is inaccessible while in operation.
­ The fan does not stop immediately! Check that no parts are moving before you open an inspection access door.
­ 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, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 . Wait until all parts have come to a standstill.

Air handling unit X-CUBE

41

Maintenance
Maintenance plan

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.
Inspection access doors slamming shut

4.3 Maintenance plan
The following sections describe the maintenance jobs required to ensure efficient and fault-free operation. If during regular checks you detect increased wear, change the maintenance intervals accordingly and carry out more frequent checks for wear and tear. If you have any questions about maintenance and maintenance intervals, contact the TROX Technical Service, Ä TROX Technical Service’ on page 3 . You may also commission the TROX Technical Service to carry out maintenance ( ÄTROX Technical Service’ on page 3 ).

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.
4.2 Switching off the AHU and securing it against being switched on accidentally
Before you start maintenance, switch off the AHU and secure it against being switched on accidentally: Ä Chapter 3.8 Switching the AHU off’ on page 28 Ä Chapter 1.7Securing the unit against being
switched on accidentally’ on page 13

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Air handling unit X-CUBE

AHU hygiene inspection

Interval

Maintenance work

Every two years (for devices Check AHU for hygienic conditions. with humidifier)

Every three years (for

Check AHU for hygienic conditions.

devices without humidifier)

Maintenance
Maintenance plan
Personnel Hygiene inspector Hygiene inspector

Ducting and air terminal devices

Interval Every 6 months
Every 12 months

Maintenance work

Personnel

Check supply air and extract air terminal devices for contamination, damage and corrosion. If necessary, clean and repair them according to the manufacturer’s instructions.

Instructed person

Check external weather louvres for contamination, damage and corro- Instructed person sion. If necessary, clean and repair them according to the manufacturer’s instructions.

Check ducts for damage. If necessary, repair them according to the man- Instructed person ufacturer’s instructions.

Check flexible connectors for leakage, correct function and damage. If necessary, repair them according to the manufacturer’s instructions.

Instructed person

Clean supply air and extract air terminal devices.

Instructed person

Check outdoor air and exhaust air terminal devices for contamination, damage and corrosion. If necessary, clean and repair them according to the manufacturer’s instructions.

Instructed person

Check the inside of ducts in at least 2 spots for contamination, damage, Instructed person corrosion and condensation. If necessary, check further spots and determine whether cleaning is required.

Check flexible connectors for leakage, correct function and damage.

Instructed person

AHU casing Interval Every 6 months
Every 12 months

Maintenance work Visually check AHU casing units for contamination, damage and corrosion. Clean if necessary. Check interfaces of AHU casing units for leakage. Check casing for condensation build-up. Check panel seals. Check panel seals and fasteners for firm fit and function. Check the equipotential bonding.

Personnel Instructed person
Instructed person Instructed person Instructed person Instructed person Instructed person

Air handling unit X-CUBE

43

Maintenance
Maintenance plan

Filter Interval Every month
Every 6 months Every 12 months
Every two years

Maintenance work Visually check filter element for contamination, Ä Chapter 3.11 Reading the differential pressure on the filter ‘ on page 40 . Replace filter element if the maximum differential pressure is exceeded, Ä Chapter 4.4.4 Replacing a filter element’ on page 55 .
Check filter element for odours and moisture penetration. Replace filter element, if necessary, Ä Chapter 4.4.4 Replacing a filter element’ on page 55 . Check filter frames and clamping rails for contamination, secure seating, damage and corrosion. Clean if necessary. Measure and check the differential pressure of all filters. Replace filter elements of the first stage, Ä Chapter 4.4.4 Replacing a filter element’ on page 55 .
Check filter frames and clamping rails for secure seating, damage and corrosion.
Check filter monitoring function. Replace filter elements of the second stage, Ä Chapter 4.4.4 ` Replacing a filter element’ on page 55 .

Personnel Instructed person
Instructed person
Instructed person Instructed person Instructed person Instructed person Instructed person Instructed person

Cooling coil Interval Every 3 months
Every 6 months Every 12 months

Maintenance work
Check dehumidifying cooling coil, condensate drip tray and droplet eliminator for contamination, damage, corrosion and leakage. Clean and repair if necessary.
Check function of condensate drain and drain trap. Clean and repair if necessary.
Check heat exchanger for contamination, damage, corrosion and leakage.
Check function of feed and return pipes.

Personnel Instructed person
Instructed person HVAC technician HVAC technician

Heating coil Interval Every 6 months
Every 12 months

Maintenance work
Check heat exchanger for contamination, damage, corrosion and leakage.
Check function of feed and return pipes.

Personnel HVAC technician
HVAC technician

Steam heated register

Interval Every week Every 6 months
Every 12 months

Maintenance work Check steam installation for leakages and damage.
Check heat exchanger for contamination, damage, corrosion and leakage.
Check function of feed and return pipes.

44

Air handling unit X-CUBE

Personnel Instructed person HVAC technician
HVAC technician

Maintenance
Maintenance plan

Rotary heat exchanger

Interval Every 3 months

Maintenance work

Personnel

Visually check the rotary heat exchanger for foreign matter, contamination, Instructed person hygienic condition, damage and corrosion. Clean if necessary.

Visually check seals for wear, contamination, foreign matter and contact. The seals must be close to the storage mass, but not in contact with it. Clean if necessary.

Instructed person

Check drive belt for wear and tension.

Instructed person

Visually check the rotor for imbalance and runout.

Instructed person

Check bearings for overheating, vibration and running noise.

Instructed person

Check function of condensate drip tray, condensate drain and drain trap. Instructed person Clean if necessary.

Check rotor operation monitoring function.

HVAC technician

Multileaf dampers

Do not use oil or grease on multileaf dampers with gears.

Interval Every 6 months
Every 12 months

Maintenance work Visually check for contamination, damage and corrosion. Check whether damper blades move smoothly. Check function of damper bearings and linkage. Check actuator function.

Personnel Instructed person Instructed person Instructed person HVAC technician

Electric air heater

Interval

Maintenance work

Personnel

Every 6 months Visually check the electric air heater for contamination and damage. Instructed person

Check function of the electric air heater.

Skilled qualified electrician

High-pressure spray humidifier

Interval Every 6 months

Maintenance work
Visually check high-pressure spray humidifier for contamination, damage and corrosion.

Personnel Instructed person

Electric motors Interval Every 6 months

Maintenance work Visually check for contamination, damage and corrosion. Check motors for bearing noise.

Personnel Instructed person Instructed person

Air handling unit X-CUBE

45

Maintenance
Maintenance plan

Interval

Maintenance work

Personnel

Every 12 months Check electrical connections.

Skilled qualified electrician

Measure current consumption and compare it with nominal current. Skilled qualified electrician

Check all safeguards for correct function.

Skilled qualified electrician

Centrifugal fan with direct drive

Interval

Maintenance work

Every 6 months Visually check for contamination, damage and corrosion. Clean if necessary.

Visually check anti-vibration elements for damage and correct function.

Check seals for fit and damage.

Check impeller for imbalance.

Check motor for bearing noise.

Check equipotential bonding. Repair if necessary.

Personnel Instructed person
Instructed person
Instructed person Instructed person Instructed person Skilled qualified electrician

FanArray

Interval

Maintenance work

Personnel

Every 6 months Check for contamination, damage and corrosion. Clean and repair if Instructed person necessary.

Check seals for fit and damage. Repair or replace them if necessary.

Instructed person

Check equipotential bonding. Repair if necessary.

Skilled qualified electrician

Check motor for bearing noise. Repair or replace bearings if neces- Instructed person sary.

Pumps Interval Every 6 months

Maintenance work Check for contamination, damage and corrosion. Clean if necessary. Check flanges and stuffing boxes for leakages. Check pump function.

Personnel Instructed person Instructed person HVAC technician

Control valves Interval Every 6 months
Every 12 months

Maintenance work Visually check for contamination, damage and corrosion. Clean if necessary.
Check connections and free movement.
Check function of control valves.

Personnel Instructed person
Instructed person HVAC technician

46

Air handling unit X-CUBE

Maintenance
Maintenance plan

Sound attenuator

Interval Every 6 months

Maintenance work
Visually check for contamination, damage and corrosion. Clean if necessary.

Personnel Instructed person

Air recirculation chamber

Interval Every 6 months

Maintenance work Visually check air recirculation chamber for contamination, damage and corrosion. Clean if necessary.
Check whether damper blades move smoothly.
Check function of damper bearings and linkage.

Personnel Instructed person
Instructed person Instructed person

Plate heat exchanger

Interval Every 3 months
Every 6 months

Maintenance work

Personnel

Check condensate drain, condensate drip tray and drain trap for correct function and contamination. Clean if necessary.

Instructed person

Visually check plate heat exchanger for contamination, damage and corro- Instructed person sion. Clean if necessary.

Check heat exchanger for leakages.

Instructed person

Air handling unit X-CUBE

47

Maintenance
Maintenance plan

Refrigeration system ­ compressor

Interval

Maintenance work

Every 6 months Visually check the compressor fixing and anti-vibration elements.

Every 12 months Check the compressor fixing and anti-vibration elements.

Check Rotalock valves.

Check flange connections, quick-release fasteners and seals.

Check oil sump heater.

Check collector pipes and connections.

Check function of high pressure and low pressure sensors.

Measure power consumption to check PTC thermistor.

Check refrigerant and oil levels.

Check output control.

Check scroll compressor.

Check refrigeration system safety valve.

Check refrigeration system for leakage.

Personnel
Instructed person
Instructed person
Skilled qualified refrigeration technician
Skilled qualified refrigeration technician
Skilled qualified refrigeration technician
Skilled qualified refrigeration technician
Skilled qualified refrigeration technician
Skilled qualified refrigeration technician
Skilled qualified refrigeration technician
Skilled qualified refrigeration technician
Skilled qualified refrigeration technician
Skilled qualified refrigeration technician
Skilled qualified refrigeration technician

Refrigeration system and evaporator

Interval

Maintenance work

Personnel

Every 6 months Visually check for contamination, damage, corrosion and leakage. Instructed person Clean if necessary.

Visually check for ice buildup.

Instructed person

Check droplet eliminator, condensate drip tray, condensate drain and drain trap for correct function and contamination. Clean and repair if necessary.

Instructed person

Every 12 months Check function of expansion valve.

Skilled qualified refrigeration technician

Refrigeration system ­ condenser

Interval Every 6 months

Maintenance work

Personnel

Visually check for contamination, damage, corrosion and leakage. Clean if Instructed person necessary.

Check condenser function.

Instructed person

48

Air handling unit X-CUBE

Maintenance
Maintenance plan

Electrical components and devices

Interval

Maintenance work

Every 6 months Visually check sensors for contamination, damage and corrosion. Clean if necessary.

Every 12 months Check sensor connections.

Check sensor function.

Check actuators for contamination, damage and corrosion.

Check actuator input signals, and check operating and adjustment ranges.

Check anti-frost thermostat.

Check frequency inverter.

Check fan vibration monitoring system.

Check local isolators.

Check CO sensor.

Personnel Instructed person
Skilled qualified electrician Skilled qualified electrician Instructed person Skilled qualified electrician
Instructed person Skilled qualified electrician Skilled qualified electrician Skilled qualified electrician Skilled qualified electrician

Switch cabinet

Interval

Maintenance work

Every 6 months Visually check switch cabinet ventilation and lighting.

Every 12 months Check cable glands and terminals for secure seating.

Check for contamination, damage and corrosion.

Check that all protective covers are in place.

Check functional elements.

Check switching and control procedures.

Check manual, automatic and remote control functions.

Personnel Instructed person Skilled qualified electrician Instructed person Instructed person Skilled qualified electrician Skilled qualified electrician Instructed person

Controls

Interval

Maintenance work

Every 12 months Check that controllers have been correctly installed and check the ambient conditions.

Check integral power supply (backup batteries).

Check functional elements, and operating and display devices.

Check input signals.

Check circuits and control signals.

Check parameters.

Personnel Skilled qualified electrician
Skilled qualified electrician Instructed person Skilled qualified electrician Skilled qualified electrician Instructed person

Evaporative humidifier

Interval Every 6 months

Maintenance work
Check for contamination, damage and corrosion. Clean and repair if necessary.

Personnel Instructed person

Air handling unit X-CUBE

49

Maintenance
Maintenance > Opening inspection access doors

Steam humidifier

Interval Every week
Every 6 months Every 12 months

Maintenance work Check water and steam installation for leakages and damage. Check drain pipe for contamination. Check electrical system for loose cables and damaged components. Check steam humidifier for damage. Drain steam cylinder and clean scale collector tank. Remove and clean steam cylinder. Clean unit interior. Visually check components (heating cable connector on steam cylinder, level unit, etc.) inside the unit for damage.

Personnel Instructed person Instructed person Instructed person Instructed person HVAC technician HVAC technician HVAC technician HVAC technician

4.4 Maintenance 4.4.1 Opening inspection access doors
Opening standard inspection access doors
Personnel: Instructed person
Protective equipment: Safety harness Industrial safety helmet Protective gloves

Opening inspection access doors to hazardous areas
Personnel: Instructed person
Protective equipment: Safety harness Industrial safety helmet Protective gloves
Tool: TROX special key

Fig. 48: Opening a door lock
Turn the door handle anti-clockwise by 90° ( Fig. 48 ).
ð This unlocks the door; it can now be opened.

Fig. 49: Opening a lock with the special key (hazardous areas)
Insert the TROX special key into the lock and turn it anti-clockwise as far as it will go ( Fig. 49 ).
ð This unlocks the door; it can now be opened.

50

Air handling unit X-CUBE

Maintenance
Maintenance > Checking filters for contamination

Opening inspection access doors on the discharge side
Personnel: Instructed person
Protective equipment: Safety harness Industrial safety helmet Protective gloves

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.

Fig. 51: Safety catch 2. Carefully open the inspection access door until it
is caught by the safety catch ( Fig. 51 /1).

Fig. 50: Opening a door lock 1. Turn the door handle anti-clockwise by 90°
( Fig. 50 ). ð The door has been unlocked.

Fig. 52: Releasing the safety catch
3. Turn the door handle ( Fig. 52 /2) clockwise by 90° .
ð This releases the safety catch ( Fig. 52 /1); the inspection access door can now be completely opened.

4.4.2

Checking filters for contamina-

tion

To check the filter for contamination, check the differential pressure Ä Chapter 3.11 ` Reading the differential pressure on the filter ‘ on page 40 .

Air handling unit X-CUBE

51

Maintenance
Maintenance > Cleaning the AHU

If the maximum differential pressure is exceeded, replace the filter, Ä Chapter 4.4.4 ` Replacing a filter element’ on page 55 .
The maximum differential pressure is given on a sticker on the revision access door to the filter chamber.
4.4.3 Cleaning the AHU
General cleaning procedure Unless specified otherwise, use lint free cloths non-corrosive and silicone free cleaning agents to clean the AHU. When you remove dirt or dust, ensure that it does not get into adjacent parts of the system. Remove dirt and dirty water carefully and dispose of them correctly. Special regulations or guidelines may apply to the cleaning of AHUs in the pharmaceutical and food industries and in hospitals; be sure to comply with them.

Cleaning the heating coil
WARNING!
Risk of injury from hot surfaces! The surfaces of the heating coil can heat up to 100 °C during operation. Skin contact with hot surfaces causes severe skin burns.
­ Wear heat-resistant protective clothing and gloves whenever you work near a potentially hot surface.
­ Before you start working, make sure that all surfaces have cooled down to the ambient temperature.
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 heating coil may cause cuts or grazes.
­ Be careful when you are working on the heating coil.
­ Wear protective gloves, safety shoes and a hard hat.
Clean the heating coil while installed; remove it only if it is otherwise not accessible.
Ensure the following:
Use only water, compressed air or a vacuum cleaner.
Do not use a high pressure cleaner or high pressure steam cleaner.
Be careful so as not to damage the blades. Use only cleaning agents with a pH value between 7
and 9. Prevent dirt and dust from getting into adjacent parts
of the system. Carefully remove dirt and dirty water. Dispose correctly of dirt and dirty water.

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Air handling unit X-CUBE

Maintenance
Maintenance > Cleaning the AHU

Cleaning the cooling coil

Cleaning the rotary heat exchanger

WARNING!
Risk of injury from cold surfaces! The surfaces of the cooling coil can cool down to -20 °C during operation. Skin contact with cold surfaces causes frostbite and cold burns.
­ Wear protective clothing and gloves that protect you from the cold when you work near a potentially cold surface.
­ Before you start working, make sure that all surfaces have warmed up to the ambient temperature.
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 cooling coil may cause cuts or grazes.
­ Be careful when you are working on the cooling coil.
­ Wear protective gloves, safety shoes and a hard hat.
Clean the cooling coil while installed; remove it only if it is otherwise not accessible.
Ensure the following:
Use only water, compressed air or a vacuum cleaner.
Do not use a high pressure cleaner or high pressure steam cleaner.
Be careful so as not to damage the fins. Use only cleaning agents with a pH value between 7
and 9. Prevent dirt and dust from getting into adjacent parts
of the system. Carefully remove dirt and dirty water. Dispose correctly of dirt and dirty water.

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 rotary heat exchanger may cause cuts or grazes.
­ Be careful when you are working on the rotary heat exchanger.
­ Wear protective gloves, safety shoes and a hard hat.
Clean the rotary heat exchanger if it has been idle for 14 days or more; clean it while installed; remove it only if it is otherwise not accessible.
Ensure the following:
Use only water, compressed air or a vacuum cleaner.
Do not use a high pressure cleaner or high pressure steam cleaner.
Be careful so as not to damage the blades. Use only cleaning agents with a pH value between 7
and 9. Prevent dirt and dust from getting into adjacent parts
of the system. Carefully remove dirt and dirty water. Dispose correctly of dirt and dirty water.

Air handling unit X-CUBE

53

Maintenance
Maintenance > Cleaning the AHU
Cleaning the plate heat exchanger
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 plate heat exchanger may cause cuts or grazes.
­ Be careful when you are working on the plate heat exchanger.
­ Wear protective gloves, safety shoes and a hard hat.
Clean the plate heat exchanger while installed; remove it only if it is otherwise not accessible.
Ensure the following:
Use only water, compressed air or a vacuum cleaner.
Do not use a high pressure cleaner or high pressure steam cleaner.
Direct air jets or water jets only at an angle of 90° onto surfaces.
Be careful so as not to damage the blades. Use only cleaning agents with a pH value between 7
and 9. Prevent dirt and dust from getting into adjacent parts
of the system. Carefully remove dirt and dirty water. Dispose correctly of dirt and dirty water.

54

Air handling unit X-CUBE

Maintenance
Maintenance > Replacing a filter element

4.4.4

Replacing a filter element

Missing filter element

CAUTION!
Risk of injury due to a missing filter element!
If no filter element has been fitted in the AHU, dust and germs can get into the ventilation system and will be spread by the AHU. People may fall seriously ill as a consequence.
­ Do not put the AHU into operation if no filter element has been fitted.
­ Make sure that enough spare filter elements are readily available.

3. Press down the quick release fasteners ( Fig. 53 /1 to 4). ð The filter element can now be removed.

Replacing a filter element with quick release fasteners
Personnel: Instructed person
Protective equipment: Safety harness Industrial safety helmet Safety shoes Protective gloves
1. Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 Securing the unit against being switched on accidentally’ on page 13 . 2\. Open the inspection access doors on the upstream side of the filter, Ä Opening inspection access doors on the discharge side’ on page 51 .

Fig. 54: Removing the filter element 4. Pull out the filter element ( Fig. 54 /1).

Fig. 55: Replacing the filter element 5. Insert a new filter element.

Fig. 53: Loosening the quick release fasteners

Air handling unit X-CUBE

55

Maintenance
Maintenance > Replacing a filter element

Fig. 56: Filter element locks in place
6. Push the new filter element ( Fig. 56 /1) in and over the quick release fasteners ( Fig. 56 /2) until it locks into place.
7. Close the inspection access doors. 8. Prepare restart, Ä Before you start the AHU’ on page 27 . 9\. Remove the padlock from the mains isolator. 10. Restart the air handling unit, ÄSwitching the
mains isolator on’ on page 27 .
11. Go to the X-CUBE control user interface and enter the new filter element (see software documentation).

Fig. 57: Inserting the special key
3. Insert the special key ( Fig. 57 /2) into the recess of each clamping rail ( Fig. 57 /1) and turn it anticlockwise by 90°.

Replacing a filter element on a mounting rail
Personnel: Instructed person
Protective equipment: Safety harness Industrial safety helmet Protective gloves Safety shoes
Tool: TROX special key
1. Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 .
2. Open the filter inspection access doors, .

Fig. 58: Releasing the clamping rails 4. Use the special key ( Fig. 58 /1) to pull out the
clamping rails ( Fig. 58 /2) as far as they will go. ð The filter element has been released.

56

Air handling unit X-CUBE

Maintenance
After maintenance

Fig. 59: Removing the filter element 5. Pull out the filter element ( Fig. 59 /1) sideways.
Fig. 60: Replacing the filter element 6. Slide the new filter element ( Fig. 60 /1) in from
the side.

Fig. 61: Pushing the clamping rails in 7. Use the special key ( Fig. 61 /1) to push the
clamping rails ( Fig. 61 /2) in as far as they will go. ð The filter element has been fitted.
8. Close the inspection access doors. 9. Prepare restart, Ä Before you start the AHU’ on page 27 . 10. Remove the padlock from the mains isolator. 11. Restart the air handling unit, ÄSwitching the
mains isolator on’ on page 27 . 12. Go to the X-CUBE control user interface and enter
the new filter element (see software documentation).
4.5 After maintenance
Personnel: Instructed person 1. Prepare restart, Ä Before you start the AHU’ on page 27 . 2. Remove the padlock from the mains isolator. 3. Restart the air handling unit, ÄSwitching the
mains isolator on’ on page 27 .

Air handling unit X-CUBE

57

Faults
Safety notes regarding troubleshooting

5 Faults
5.1 Safety notes regarding troubleshooting
Incorrect troubleshooting
WARNING!
Risk of injury due to incorrect troubleshooting! Incorrect troubleshooting can cause serious injuries and considerable damage to property.
­ Before you start maintenance, switch off the air handling unit and secure it against being restarted accidentally.
­ Refer to the list of possible faults to see who should or should not clear a fault.
­ Before you start, make sure that there is sufficient clearance for the work you have to complete.
­ Keep the work area tidy and clean. Parts and tools that are loosely stacked or left lying around are a source of accident.
­ Before you recommission the unit, ensure the following: ­ All faults have been rectified according to this manual. ­ Nobody is inside the AHU. ­ All inspection access doors and covers have been closed. ­ All safeguards have been installed and function correctly.

Rotating parts of a fan
WARNING!
Risk of injury from rotating parts! Rotating parts in the fan can cause severe injuries.
­ Do not reach into the moving fan or tamper with it.
­ Do not open any covers or inspection access panels while the unit is in operation.
­ Make sure that the rotor is inaccessible while in operation.
­ The fan does not stop immediately! Check that no parts are moving before you open an inspection access door.
­ 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, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 . Wait until all parts have come to a standstill.
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.

58

Air handling unit X-CUBE

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.
5.2 Faults displayed with X-CUBE Control
Faults are displayed as text messages on the user interface.
5.3 Faults displayed on the AHU
Differential pressure measuring devices The differential pressure is indicated on the digital pressure measuring device that is attached to the AHU casing, Ä Chapter 2.5.4 `Filter monitoring’ on page 25 . If the differential pressure exceeds the maximum final differential pressure, this indicates a fault.
The maximum final differential pressure (Pmax) for a filter is given on a sticker on the inspection access door to the filter chamber.

Faults
Faults displayed on the AHU

Air handling unit X-CUBE

59

Faults
List of faults
5.4 List of faults

You may also commission the TROX Technical Service to carry out maintenance ( Ä `TROX Technical Service’ on page 3 ).

Fault descrip- Cause tion

Remedy

Personnel

Filter change The filter element is contaminated.

In this order:

Instructed

Switch off the air handling unit and

person

secure it against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being

switched on accidentally’

on page 13 .

Replace the filter element, Ä Chapter 4.4.4 ` Replacing a filter element’

on page 55

The operating time has been exceeded.

In this order:

Instructed

Switch off the air handling unit and

person

secure it against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being

switched on accidentally’

on page 13 .

Replace the filter element, Ä Chapter 4.4.4 ` Replacing a filter element’

on page 55 .

Service life has been exceeded.

In this order:

Instructed

Switch off the air handling unit and

person

secure it against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being

switched on accidentally’

on page 13 .

Replace the filter element, Ä Chapter

4.4.4 ` Replacing a filter element’

on page 55 .

Frost protection is active.

The anti-frost thermostat detected a low In this order:

temperature, and frost protection has been activated to ensure that no AHU

components become damaged. The AHU

has been switched off automatically.

Secure the AHU against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 .

Check the thermostat settings. The

temperature set on the thermostat

must not be lower than 5 °C.

Check whether cooling coil, heating

coil or run around coil system contain

heat transfer fluid.

If necessary, replenish the heat

transfer fluid according to the instruc-

tions from the system or component

manufacturer.

Instructed person

60

Air handling unit X-CUBE

Faults
List of faults

Fault descrip- Cause tion

Remedy

Personnel

Preventive

Preventive frost protection mode has

frost protection been activated to protect the heating

is active.

coils.

In this order:
Secure the AHU against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 .
Check the thermostat settings. The temperature set on the thermostat must not be lower than 5 °C.
Check whether cooling coil, heating coil or run around coil system contain heat transfer fluid.
If necessary, replenish the heat transfer fluid according to the instructions from the system or component manufacturer.

Instructed person

Fire damper has been triggered ­ unit has been switched off.

There is a fire. The AHU has been switched off automatically.

Initiate fire-fighting.

Instructed person

The fusible link is defective. The AHU has Contact the TROX Technical Service,

Instructed

been switched off automatically.

Ä `TROX Technical Service’ on page 3 . person

Fire damper has been triggered ­ unit has not been switched off.

There is a fire. The fusible link is defective.

Initiate fire-fighting.

Instructed person

Contact the TROX Technical Service,

Instructed

Ä `TROX Technical Service’ on page 3 . person

Locked by

There is a fire. The fire alarm system (by Initiate fire-fighting.

central fire

others) has generated an alarm. The

alarm system AHU has been switched off automatically.

Instructed person

False alarm. The fire alarm system (by The fire alarm system should be

Instructed

others) has generated an alarm. The

inspected; contact the manufacturer of the person

AHU has been switched off automatically. fire alarm system.

Fault ­ 24 V control voltage.

The 24-volt DC power supply unit in the switch cabinet has a fault. The AHU has been switched off automatically.

Commission a skilled qualified electrician Instructed

to rectify the fault.

person

A short circuit (24 V DC) has occurred. Commission a skilled qualified electrician Instructed

The AHU has been switched off automati- to rectify the fault.

person

cally.

Fault with

Circuit breaker in the switch cabinet was Switch off the air handling unit and Instructed

switch cabinet triggered by a short circuit. fuse.

secure it against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 .

person

Commission a skilled qualified electri-

cian to rectify the fault.

Pump motor protection switch.

Motor current too high due to blocked motor. Fan motor protection switch has triggered and air handling unit has switched off.

Secure the AHU against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 .

Instructed person

Commission a skilled qualified electri-

cian to rectify the fault.

Air handling unit X-CUBE

61

Faults
List of faults

Fault descrip- Cause tion

Remedy

Personnel

Pump motor protection switch.

Motor current too high due to short circuit. Fan motor protection switch has triggered and air handling unit has switched off.

Secure the AHU against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 .
Commission a skilled qualified electrician to rectify the fault.

Instructed person

Motor current too high due to defective bearings. Fan motor protection switch has triggered and air handling unit has switched off.

Secure the AHU against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 .

Instructed person

Commission a skilled qualified electri-

cian to rectify the fault.

Extract air fan motor protection switch.

Motor current too high due to blocked motor. Fan motor protection switch has triggered and air handling unit has switched off.

Secure the AHU against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 .

Instructed person

Commission a skilled qualified electri-

cian to rectify the fault.

Motor current too high due to short circuit. Fan motor protection switch has triggered and air handling unit has switched off.

Secure the AHU against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 .
Commission a skilled qualified electrician to rectify the fault.

Instructed person

Motor current too high due to defective bearings. Fan motor protection switch has triggered and air handling unit has switched off.

Secure the AHU against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 .

Instructed person

Commission a skilled qualified electri-

cian to rectify the fault.

Pump motor protection switch.

Motor current too high due to blocked motor. Pump motor protection switch on the heating coil has triggered.

Commission a skilled qualified electrician Instructed

to rectify the fault.

person

Motor current too high due to short circuit. Commission a skilled qualified electrician Instructed

Pump motor protection switch on the

to rectify the fault.

person

heating coil has triggered.

Motor current too high due to defective bearings. Pump motor protection switch on the heating coil has triggered.

Commission a skilled qualified electrician Instructed

to rectify the fault.

person

External lock. The AHU has been switched off due to an Release of the external lock is required. Instructed

external lock.

person

Alarm on rotary heat exchanger rotation monitor.

The rotor operation monitoring function has detected a problem.

In this order:
Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 .

Instructed person

62

Air handling unit X-CUBE

Faults
List of faults

Fault descrip- Cause tion

Alarm on rotary heat exchanger rotation monitor.

The rotor operation monitoring function has detected a problem.

Defective Modbus cable system or missing terminal resistor

Bus end resistor is missing.
The bus cable in the AHU has become detached or cut.

Fault with pump.

The communication cable to the component has become detached or cut.

No voltage is supplied to the component.

Fault with valve.

The communication cable to the component has become detached or cut.

No voltage is supplied to the component.

Fault with

The communication cable to the compo-

Modbus multi- nent has become detached or cut.

leaf damper.

Remedy
Visually check the V-belt for damage; contact a skilled qualified electrician for repair, if necessary.
Commission a skilled qualified electrician to rectify the fault.
Commission a skilled qualified electrician to rectify the fault.
In this order:
Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 Securing the unit against being switched on accidentally’ on page 13 . Commission a skilled qualified electrician to rectify the fault. In this order: Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7Securing the unit against being switched on accidentally’ on page 13 .
Commission a skilled qualified electrician to rectify the fault.
In this order:
Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 Securing the unit against being switched on accidentally’ on page 13 . Commission a skilled qualified electrician to rectify the fault. In this order: Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7Securing the unit against being switched on accidentally’ on page 13 .
Commission a skilled qualified electrician to rectify the fault.
In this order:
Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 .

Personnel Instructed person
Instructed person Instructed person Instructed person
Instructed person
Instructed person
Instructed person
Instructed person

Air handling unit X-CUBE

63

Faults
List of faults

Fault descrip- Cause tion

Fault with

The communication cable to the compo-

Modbus multi- nent has become detached or cut.

leaf damper. No voltage is supplied to the component.

Fault with

The communication cable to the compo-

Modbus fan. nent has become detached or cut.

No voltage is supplied to the component.

Fault with

The communication cable to the compo-

Modbus differ- nent has become detached or cut.

ential pressure

sensor.

No voltage is supplied to the component.

Fault with Modbus plate heat exchanger differential pressure sensor

The communication cable to the component has become detached or cut.

Remedy
Commission a skilled qualified electrician to rectify the fault.
In this order:
Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 Securing the unit against being switched on accidentally’ on page 13 . Commission a skilled qualified electrician to rectify the fault. In this order: Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7Securing the unit against being switched on accidentally’ on page 13 .
Commission a skilled qualified electrician to rectify the fault.
In this order:
Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 Securing the unit against being switched on accidentally’ on page 13 . Commission a skilled qualified electrician to rectify the fault. In this order: Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7Securing the unit against being switched on accidentally’ on page 13 .
Commission a skilled qualified electrician to rectify the fault.
In this order:
Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 `Securing the unit against being switched on accidentally’ on page 13 .
Commission a skilled qualified electrician to rectify the fault.
In this order:

Personnel Instructed person Instructed person
Instructed person
Instructed person
Instructed person
Instructed person
Instructed person

64

Air handling unit X-CUBE

Faults
List of faults

Fault descrip- Cause tion

Fault with Modbus plate heat exchanger differential pressure sensor

The communication cable to the component has become detached or cut.

No voltage is supplied to the component.

Fault with Modbus plate heat exchanger pass-through damper.

The communication cable to the component has become detached or cut.

No voltage is supplied to the component.

Fault with Modbus plate heat exchanger bypass damper.

The communication cable to the component has become detached or cut.

No voltage is supplied to the component.

Remedy
Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 Securing the unit against being switched on accidentally’ on page 13 . Commission a skilled qualified electrician to rectify the fault. In this order: Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7Securing the unit against being switched on accidentally’ on page 13 .
Commission a skilled qualified electrician to rectify the fault.
In this order:
Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 Securing the unit against being switched on accidentally’ on page 13 . Commission a skilled qualified electrician to rectify the fault. In this order: Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7Securing the unit against being switched on accidentally’ on page 13 .
Commission a skilled qualified electrician to rectify the fault.
In this order:
Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 Securing the unit against being switched on accidentally’ on page 13 . Commission a skilled qualified electrician to rectify the fault. In this order: Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7Securing the unit against being switched on accidentally’ on page 13 .
Commission a skilled qualified electrician to rectify the fault.

Personnel Instructed person
Instructed person
Instructed person
Instructed person
Instructed person
Instructed person

Air handling unit X-CUBE

65

Faults
List of faults

Fault descrip- Cause tion

Fault with Modbus rotary heat exchanger speed.

The communication cable to the component has become detached or cut.

No voltage is supplied to the component.

Fault with Modbus rotary heat exchanger alarm.

The communication cable to the component has become detached or cut.

No voltage is supplied to the component.

Fault with Modbus humidity sensor.

The communication cable to the component has become detached or cut.

No voltage is supplied to the component.

Remedy
In this order:
Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 Securing the unit against being switched on accidentally’ on page 13 . Commission a skilled qualified electrician to rectify the fault. In this order: Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7Securing the unit against being switched on accidentally’ on page 13 .
Commission a skilled qualified electrician to rectify the fault.
In this order:
Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 Securing the unit against being switched on accidentally’ on page 13 . Commission a skilled qualified electrician to rectify the fault. In this order: Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7Securing the unit against being switched on accidentally’ on page 13 .
Commission a skilled qualified electrician to rectify the fault.
In this order:
Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 Securing the unit against being switched on accidentally’ on page 13 . Commission a skilled qualified electrician to rectify the fault. In this order: Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7Securing the unit against being switched on accidentally’ on page 13 .

Personnel Instructed person
Instructed person
Instructed person
Instructed person
Instructed person
Instructed person

66

Air handling unit X-CUBE

Faults
List of faults

Fault descrip- Cause tion

Fault with Modbus humidity sensor.

No voltage is supplied to the component.

Fault with Modbus temperature sensor.

The communication cable to the component has become detached or cut.

No voltage is supplied to the component.

Fault with

The communication cable to the compo-

Modbus elec- nent has become detached or cut.

tric air heater.

No voltage is supplied to the component.

Fault with Modbus room air temperature sensor.

The communication cable to the component has become detached or cut.

No voltage is supplied to the component.

Remedy
Commission a skilled qualified electrician to rectify the fault.
In this order:
Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7 Securing the unit against being switched on accidentally’ on page 13 . Commission a skilled qualified electrician to rectify the fault. In this order: Switch off the air handling unit and secure it against being switched on accidentally, Ä Chapter 1.7Securing the unit against being switched on accidentally’ on page 13 .
C

References

• FLOW – media company
• www.product.no
• Rotor Drives | OJ Electronics - HVAC Controls & Drives
• OJ Electronics – Know-how schafft solide Partnerschaften
• Homepage | TROX GmbH
• Homepage | TROX GmbH

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