Danfoss air units and duct systems Installation guide
- Type
- Installation guide
Danfoss Air
Installation manual for Danfoss air units and duct systems
DANFOSS HEATING
MAKING MODERN LIVING POSSIBLE
A + B The Danfoss Air system
Index
The Danfoss Air System
Before you start
2
VIEWA102
A The Danfoss Air system
B Before you start (please read!)
C Unit installation
1.0 Installation of air unit and condensate
line
2.0 Electrical installation
3.0 Wireless connection
4.0 Balancing of main air flow
5.0 Unit dimensions
6.0 Connection of additional devices
D Installing the duct system
3.0 Installing supply and exhaust valves
3.1 Location of valves
3.2 Drilling holes in the ceiling
3.3 Installing the valves
4.0 Installing the duct system
4.1 Adjustment
4.2 Connecting the duct system
4.3 Insulation
4.4 Sound damping
4.5 Roof terminals
4.6 Adjusting the valves
E Setting up the system
Congratulations on purchasing Danfoss Air, the
most advanced, efficient and one of the quietest
ventilation systems with heat recycling on the
market. On the following pages, we will take you
through the steps needed to properly install the
duct system and valves. If you follow these
instructions, you can rest assured that your
house will have a well-functioning energy-
efficient system.
This installation manual acts as a step-by-step
guide. For best results, simply follow the instruc-
tions in the order in which they are given.
Please check that the shipment is complete
and has not been damaged. The ventilation unit
consists of:
• awirelessremotecontrol-henceforthreferred
to as the Air Dial (4 AAA-batteries included)
• acommunicationmodule-henceforththe
CCM module
• apowercable
• acommunicationcable
• aninstallationmanual(this)
• auserguide
• aquickguide(locatedbehindwallplateonthe
wireless remote)
If you have ordered the complete Danfoss Air
Solution, a complete packing list will be included
with the duct system as well, please check that
packing list matches the components supplied.
C Unit installation
1.0 Installation of air unit
and condensate line
3
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Attic air units instructions a
2
& a
3
The unit should be placed on a platform, con-
sisting of a sandwich of 16mm plywood or MDF
plate, enclosing a 50 mm high density insula-
tion batts. It is very important that the unit is
mounted completely horizontal. Use spirit level
to control.
Siphon installation - correct
If the unit is tilted, the function of the condensate
drain can not be guaranteed, resulting in a risk of
water leakage as a result!
Mount the siphon on the rafter below the unit
or mount it in the room below the attic. If you
choose to mount your siphon in the attic, make
sure it is well insulated and protected against
frost!.
Now fit the hose from the siphon onto the ¾”
drain connecting piece. Lead the connected
drain hose to the drain, allowing for a min. slope
of 1 cm/metre.
Important: Remove front panel, and foam
front panel. Fill condensate tray, check drainage
visually and re-assemble.
Attic units a
2
and a
3
top view
Check alignment
3/4” re-inforced hose
Hose clamp
3/4” threaded tting
Upon delivery, the supply spigots are inverted, to
save space. Pull out the spigots...
Rotate spigot and align with pre-drilled holes in casing,
and tighten screws by hand (lowest torque setting if
power tool is used)
Important
Allow for 60 cm free space in front of unit, to
allow for service access.
Power supply
and connection
for CCM module
Condensate drain
Ø19 (smooth)
Service area
Removable front panel
Outdoor air (intake)
Discharge air (expelled air)
Supply air
Exhaust air
The siphon is a Danfoss accessory
which must be ordered separately.
Joist
50 mm high ensity
insulation batts
16mm plywood
or mdf (2)
Power supply and
connection of CMM
module
To drain
Insulate condensate
(frost proof)
Siphon
Joist
To drain
Siphon
✔
✘
Siphon installation - incorrect!
C Unit installation
4
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Instructions for wall-mounted air units w
1
& w
2
Place the wall mounting bracket on wall in
desired position, 75 mm from the bottom of the
bracket to the top of the unit, mark up- and drill
holes. Use screws suitable for the wall surface
(screws are not included).
Important:
Check alignment with spirit level.
Now hang unit onto wall
bracket, attach adhesive
foam parts to lower rear
location on unit backplate
(absorbs potential vibrations
from unit to wall). Mount the siphon on the wall
below the unit.
Now fit the hose from the siphon onto the 3/4”
drain connecting piece using the attached hose
clip. Lead the connected drain hose to the drain,
allowing for a min. slope of 1 cm/meter. The
condensate line must be insulated where risk of
freezing occurs.
Important: Remove front panel, and foam
front panel. Fill condensate tray, check drainage
visually and re-assemble.
75 mm
+
Foam part
A
Detail A
Wall unit top view
Condensate
connection
located here
(below unit)
Important
Allow for 60 cm
free space in
front of unit, to
allow for service
access.
C Unit installation
5
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Ø 19 mm smooth
plastic pipe
¾” hose
Hose clamp
C Unit installation
2.0 Electrical installation
6
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1. Plug in power cable (and fit the plug type
that suits your requirement, included in unit
package).
2. Plug in communication cable between
communication module and air unit: the cable
can not be incorrectly fitted.
Important:
If the communication module is mounted on
a different floor to the wireless remote, please
check if the deck construction contains elements
that will reduce transmission/receiving strength
(i.e. aluminum foil clad insulation material, or
metal grid, if deck is cast in concrete). If any such
disturbances are present, the communication
module should be placed on same floor as thr
wireless remote control.
If an ethernet connection is already available in
the vicinity of the air unit, place the communi-
cation module close to this, to allow for future
connection to PC.
Communication cable
Power cable
Connection board
(located on under-
side of wall units, or
in end of attic units)
Communication module can also be
connected to USB or ethernet.
C Unit installation
3.0 Wireless connection
7
VIEWA102
When the CCM module is powered up for the
first time, the green LED will flash slowly - this
indicates that the CCM module has yet to be con-
nected to the Air Dial.
To connect the Air Dial, fit the batteries to the Air
Dial. The Air Dial will open up in a special mode,
that leads the installer through a step-by-step
guide. Follow the instruction in the guide:
1. Set language
2. Set network (push button on CCM module,
and then push Air Dial). Note: Allow min. 3 se-
conds after pushing the CCM, before pushing
”OK” on the Air Dial.
3. Set basic step (commissioning airflow
- see next page)
4. Finish.
If the connection attempt is succesful, the green
LED will be lit permanently (and the Air Dial will
go into commissioning mode)
If the connection fails, the red LED on the
communication module will flash 5 times at low
speed. A failed connection will also be visible on
the wireless remote.
Trouble-shooting if wireless connection fails:
• Connectiononthewirelessremotewasnot
attempted within 2 minutes of pushing the
CCM; try again.
• Otherwirelessdevicesinthevicinityareat-
tempting to connect to the CCM module, retry
• Iftheabovedoesnotsolvetheproblem,there
is most likely inadequate signal strength. The
distance between the CCM module and the
Air Dial may be too great, or there may be a
barrier between the two devices. If necessary,
move the CCM module to the same floor in the
building (lengthen communication cable) and/
or move it closer to the Air Dial.
CCM moduleAir Dial
Installation of Air Dial - optimum placement
When mounting the Air dial, please observe the
following guidelines, to ensure best possible
accuracy (Air Dial has integrated temperature
sensor)
• Installataheightof80-150cmaboveoor
• Mountwhereremoteisclearofcurtains
• Mountinoccupiedzonewheretemperatureis
representative
• Donotmountinbathrooms
• Donotmountindirectsunlight
• Donotmountontoouterwall
• Donotmountdirectlyaboveheatsource
C Unit installation
4.0 Balancing of
main air flow
8
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Why should you balance the flow?
To acheive the best possible performance, it is
vital to balance flow. You should always aim for
a slight negative pressure inside the house (this
will help to protect the house against mould
moisture damage). We recommend an air flow
imbalance of 5%, in favour of the exhaust air fan.
Example
A system is designed for an air flow of 200 m
3
/h
(design flow is always given as exhaust air flow).
The supply air flow should be 95% of the
200 m
3
/h, so 0.95 x 200 =190 m
3
/h.
How to adjust the main air flow - complete Air
Solution supplied by Danfoss
1. Remove front panel from unit (you do not
need tools, simply pull lightly on the handles).
2. Look at the supplied duct system drawing, here
you will find suggested pre-setting values for all
air devices. Close air device completely, and turn
valves xx full turns towards ”open”; number of
turns as indicated on the duct system drawing.
3. Attach differential pressure measuring
equipment to exhaust fan connectors (fitted
inside the front panel).
4. Use the flowchart sticker on the unit, in order
to determin the differential pressure that
matches your desired airflow. This pressure is
your target pressure, i.e. the value that you mi-
cromanometer will read out, when the desired
flow is achieved. If the pressure reading is to
low, increase the fan speed, until the pressure
matches the chart reading. Then relocate mea-
suring tubes to the other set of connectors, to
perform same routing on the supply air side.
The duct system will still need minor adjust-
ments to individual room air flow, but should
be very close to correct! For instructions regar-
ding balancing of air flow to individual rooms,
go to page 20.
”If you need to balance the flow on a
unit which is already running, press the Air Dial
for 5 seconds, this will make a hidden service
menu appear. In the service menu, press ”set
basic step” to activate the special commissioning
mode (where all outside influences are blocked –
the installer controls exhaust- and supply air fan
completely with 1-100% fan speed resolution.
The service menu will remain visible for 1 hour,
after which it will disappear.
How to adjust the main air flow - duct system
by others
1. Remove front panel from unit (you do not
need tools, simply pull firmly on the handles)
2. Attach differential pressure measuring equip-
ment to exhaust fan connectors (fitted inside
the front panel).
3. Read the fan curve on the front panel, and find
the pressure that matches your flow require-
ment.
4. Trim exhaust fan basic step, until your pressure
reading from your differential pressure
measuring tool is equal to the value you found
in the fan curve.
5. For supply air balancing, move differential
pressure measuring equipment to supply fan
connectors, and repeat steps 3 & 4.
The duct system will still need complete adjust-
ments to individual room air flow, and most likely
the main air flow will also need adjustment, as a
result of adjusting individual air devices.
How to measure
supply side
How to measure
exhaust side
C Unit installation
9
VIEWA102
5.0 Unit dimensions
- w
1
unit
Weight of unit: 31 kg
430 (incl. wall bracket)
530
Ø125
Supply
Ø125
Outdoor
air
Ø125
Exhaust
Ø125
Discharge
1042 (incl. air spigots)
95 170
service side service side
170
110
120
70
Top view Top view
Front view
1 2
3 4
Filter, exhaust air
Filter, supply air Filter reset button
Diff. pressure
exhaust air
Diff. pressure
exhaust air
Diff. pressure
supply air
Diff. pressure
supply air
Flow chart
(for balancing)
Isometric view
(front panel removed)
Reset
filter
Optional supply air spigot located on w
1
underside. To use,
remove top supply air spigot by loosing screws, remove lid
from the underside spigot, and use this to seal off the normal
supply air spigot. Then fit the supply air spigot on underside.
C Unit installation
10
VIEWA102
5.0 Unit dimensions
- w
2
unit
Weight of unit: 45 kg
580(incl.wallbracket)
590
Ø160
Supply
Ø160
Outdoor
air
Ø160
Exhaust
Ø160
Discharge
1050 (1092 incl. spigots)
110 185 185
126
143
120
Top view Top view
Front view
1 2
3 4
Filter, exhaust air
Filter, supply air Filter reset button
Diff. pressure
exhaust air
Diff. pressure
exhaust air
Diff. pressure
supply air
Diff. pressure
supply air
Flow chart
(for balancing)
Reset
filter
Isometric view
(frontpanel removed)
C Unit installation
5.0 Unit dimensions
- a
2
unit
5.0 Unit dimensions
- a
3
unit
5.0 A-units in detail
(front panel removed)
11
VIEWA102
118 0
600
580
32515
177
450
Ø160
Exhaust air
Discharge airSupply air
Outdoor air
Discharge air
Outdoor air
118 0
15
540
780
160
280
330
Exhaust air
Supply air
Outdoor air
Discharge air
Diff. pressure
exhaust air
Diff. pressure
exhaust air
Diff. pressure
supply air
Diff. pressure
supply air
Filter reset button
Filter, supply air
Filter, exhaust air
Flow chart
(for balancing)
Weight of unit: 52 kg
Weight of unit: 66 kg
600
Discharge air
Outdoor air
Front view
Front view (without front panel)
Right view
Ø250
D Installing the duct system
3.0 Installing supply and
exhaust valves in the
ceiling
12
VIEWA102
3.1 Location of valves
Start by deciding on the location of the val-
ves, using the enclosed technical drawing as a
guideline. If the drawing indicates a valve which
is in the path of electrical wiring, water ducts or
wooden joists, the valve can of course be moved
so that installation is not made unduly difficult.
Guidelines for valve locations:
Supply
Try to avoid placing air diffusion valves above
places where people stay for long periods, such
as above sofas, beds, dining table, etc. If the
house has a wood-burning stove, it is best to
position the supply air valve nearby.
Exhaust
Designed to remove moist ”contaminated” air
and should therefore be positioned as close as
possible to the source, i.e. above washbasins, in
shower cabinets, etc.
3.2 Drilling holes in the ceiling
Use a cup drill/hollow drill to drill the holes for
the valves. Use the following drill sizes: For valves
that are 100mm in diameter (both supply and
exhaust) use a hollow drill with a diameter of
108mm.Forvalvesthatare125mmindiameter
(both air diffusion and extraction) use a hollow
drill with a diameter of 133mm.
NB:
• Avoiddamagingthedampcourseunneces-
sarily and always remember to repair it with
weatherproof tape from the ceiling side after-
wards.
• Thesizeandshapeofthevalvesvariesdepen-
ding on the air direction and volume.
Supply
Exhaust
D Installing the duct system
3.0 Installing supply and
exhaust valves in the
ceiling
13
VIEWA102
3.3 Installing the valves
Fix the bayonet socket that will hold the valve
to the ceiling. If it is a gypsum ceiling, we re-
commend putting a wooden plate on the back
for the screws to bite into. If the duct needs to
pass through insulation, we recommend measu-
ring the insulation section and installing a duct
section along a suitable length of the bayonet
socket (VGU or VGM). Use an NPU connection
nipple to connect the VGM and the duct section.
200
200
200
200
200
200
D Installing the duct system
4.0 Installing the duct
system
14
VIEWA102
To get the best out of the system and to achieve
optimum operational efficiency, you should
install the duct system as compactly as the
building construction will allow. In practice, this
means that you should keep your duct sections
as short as possible and use as few bends as
possible in order to achieve the lowest possible
loss of pressure in the system. If the ducts are
located on the loft floor, they can be secured
using duct clips. Duct clips can also be used if the
duct system is suspended from the roof, using
UV fixing hangers if necessary. (Fig. 1)
NB:
• Itisimportantthattheductsdonotrestonthe
valves or hang in the roof terminals.
• Werecommendpositioningtheductsinthe
insulation, in order to minimise heat loss as far
as possible. See the section on insulation.
• Itisimportanttoplaceasoftmaterialbetween
the duct and the rafters/duct clip in order to
avoid any vibration noise.
• Alwaysavoidinstallingdamagedproducts,
such as dented ducts, as this may reduce the
performance of the system and can result in
leaks.
Example
duct installations…
4.1 Adjustment
Use a hacksaw or angle grinder to adjust the
ducts. We recommend filing down or cutting off
any sharp edges on the duct in order to avoid
damage to the rubber seals on the fitting parts.
NB:
• Alwaysuseappropriateprotectiveequipment.
(i.e. protective goggles, ear defenders, etc.)
Fig. 1
D Installing the duct system
4.0 Installing the duct
system
15
VIEWA102
4.2 Connecting the duct system
Push connectors into the duct up to the stopsick;
turning them slightly will make assembly easier.
Fix the connectors to the duct using self-tapping
screws or pop rivets. Screws or pop rivets should
be evenly distributed around the circumference.
Fix screws/pop rivets so that the rubber strips are
not damaged, i.e. 10 cm from the stopsick line
at the end of the duct. In the event of incorrect
assembly, screw or pop rivet holes should be
sealed up.
We advise using the following minimum number
and dimensions for steel screws/ pressure-
resistant pop rivets:
Ød Min. Ød mm Number
63-125 3.2 2
140-250 3.2 3
The ducts supplied are 3 metres long as stan-
dard. If you want to connect 2 ducts together,
use an NPU nipple with a rubber strip.
Crossing ducts
If 2 ducts need to cross, we recommend instal-
ling the duct that runs along the beam under-
neath the duct crossing it. This is the best way to
reduce heat loss.
Ø 100
Ø 125
Ø 100
Ø 100
Ø 125
Ø 125
Ø 125 RCFU
NPUSR SR
Ø 125Ø 125 RCFURCFU
TCPU
TCPU
Ø 100
Ø 125
Ø 100
Ø 100
Ø 125
Ø 125
Ø 125 RCFU
NPUSR SR
Ø 125Ø 125 RCFURCFU
TCPU
TCPU
Stopsick
Connection to unit viewed from the side.
Connection to unit viewed from above.
30˚
30˚
30˚
30˚
S L U
SR
SR
BU
70
600
1200
30˚
S L U
SR
SR
BU
70
600
1200
Reductions
If you want to reduce a branch, you can use a
T-section, where the branch on the T-section
has smaller dimensions. If you want to reduce
the main duct, you will need to use an RCFU
reduction.
Ø 100
Ø 125
Ø 100
Ø 100
Ø 125
Ø 125
Ø 125 RCFU
NPUSR SR
Ø 125Ø 125 RCFURCFU
TCPU
TCPU
Ø 100
Ø 125
Ø 100
Ø 100
Ø 125
Ø 125
Ø 125 RCFU
NPUSR SR
Ø 125Ø 125 RCFURCFU
TCPU
TCPU
ExampleExample
To get your duct down into the insulation as
quickly as possible, we recommend the solution
illustrated.
D Installing the duct system
4.0 Installing the duct
system
16
VIEWA102
4.3 Insulating the duct system
It is important that you insulate the duct system
correctly in order to avoid heat loss. Where the
design allows, the ducts can be run in/under the
insulation without any problems and this will
save some of the costs of insulation.
NB:
• Bothsupplyandexhaustmustbecoveredby
at least 100mm of insulation, which must be
fixed securely in place. See diagrams illustra-
ting correct insulation.
• Thefreshairintakeandexhaustmustalways
have at least 30mm of insulation to protect
against condensation. Where there is a pre-
heating surface or a geothermic surface, the
insulation of the fresh air intake should be at
least 100mm.
• 50mmofinsulationwillbeadequateforsound
dampers, as they already have 50mm of insula-
tion.
Connection between ducts and unit
It is important that all 4 flanges are connected
to the ducts with a flexible connection, so that
potential vibrations are not transferred from the
unit to the ducts system.
Avoid bending the flex pipe as this will add to an
increased pressure loss in the system.
When mounting, the flex pipe make sure it is
stretched as far as possible – without deforming
the pipe.
It is advisable to use an insulated flex pipe type
THISOL.
Mount hose clamps around the outer layer of
plastic in order to ensure air tightness.
In order to minimise heat loss from the duct
system in the ceiling, both the supply and
exhaust ducts should be insulated using at least
100mm of insulation.
If you use insulation option A, we recommend
using two layers of 50mm paper or foil-covered
lamella mat mounted with staggered joints.
You should also note that if you use steel wire to
tie on the insulation, you must not tighten the
steel wire so much that it deforms or breaks up
the insulation.
Insulation of ducts, option A Incorrect insulation of ductsInsulation of ducts, option B
Please Note:
The above should be regarded as
recommended values only and you must
always abide by any country-specific
regulations.
D Installing the duct system
4.0 Installing the duct
system
4.0 Installing the duct
system
17
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4.4 Sound damping the system
Sound damping the duct system is a very impor-
tant element in achieving the general feeling
that you have the perfect indoor climate. The
noise in a ventilation system comes primarily
from the unit’s ventilators. This noise can be
carrried throughout the duct system and out into
individual rooms unless there is proper sound
damping. It is therefore also very important that
silencers are positioned correctly in the duct
system.
As you can see above, there are several met-
hods of sound damping. The diagram on the
left shows a system where the silencer can be
positioned directly after the unit, before the
main duct branches out. In this case, the effect of
the sound damper is used on the entire system.
The diagram on the right shows a system where
it is not possible to position the silencer before
branching, and it is therefore necessary to use
two silencers, one on each side of the T-section,
before branching to a room.
As well as damping the noise from the ventila-
tors, it is important to ensure that noise does
not spread from room to room, i.e. where noise
runs through the ventilation ducts from room to
room. To avoid this, install a small silencer on the
branch to the rooms that you want to damp.
For room-to-room damping, use SLU-100-300
and SLU-125-300, depending on the dimensions
of the branch.
Unit Unit
4.5 Roof terminals
Roof terminals/wall grills and roof ducts are the
part of the ventilation system which is visible
from the outside. They should therefore always
be adapted to the architectural style of the
house as far as possible. We recommend positio-
ning the terminals at least 3 metres apart mea-
sured horizontally or 1 metre apart measured
vertically, always with the discharge terminal at
the top. We also recommend placing terminals/
grills on a north-facing or east-facing surface in
order to achieve the best and most comfortable
operation of the system.
Installation
If the roof terminal is installed on a tiled roof,
we recommend using a Lindab GISOL roof duct,
which is a pre-insulated duct, meaning that you
do not need to manually insulate up to the roof
surface. We also recommend using Lindab SBG
installation fittings and a Lindab MG membrane
duct for a correct finish against the subroof.
NB:
• Avoidpositioningtheexhaustlowerthanthe
top edge of the top window and closer than 1
metre to the nearest window.
1 m
3 m
3 m
D Installing the duct system
4.0 Installing the duct
system
18
VIEWA102
4.6 Adjusting the valves
You can adjust the valves as follows:
Supply
Start by fully closing the valve (not too tight!)
Then open the valve the number of times indi-
cated in the diagram. Please observe that the
diagram is provided with the assembly drawing
of the ducts system.
Exhaust
Start by setting the valve to position 0, which in
practice means opening the central cone so that
the middle of the cone is in line with the frame
(see diagram).
Then rotate the cone the number of times
indicated in the diagram:
+ 5 = anti-clockwise 5 times
- 5 = clockwise 5 times
The above are guideline settings only.
= anti-clockwise
= clockwise
+
Pos.
+ ÷
Pos. 0
E Setting up the system
5.0 Setting up the system
19
VIEWA102
Once the system has been fully installed, we
recommend having it set up professionally in
order to achieve optimum operation.
Contact Danfoss Ventilation A/S for information
on your nearest approved installer.
Danfoss A/S
Ulvehavevej 61
7100 Vejle
Tel.+4574888500
Fax+4574888603
www.danfoss.com
www.air.danfoss.com
www.danfoss.com
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Danfoss air units and duct systems Installation guide
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