Geniox user manual
Table Of Contents
- A Manufacturer
- B Name of machines
- C General descriptions, dangers and warnings
- C.1 Overview via pictograms on the inspection side of the unit
- C.2 Data about the unit according to cards and labels in and on the unit
- C.2.1 Example of Machine card with unique data on every unit
- C.2.2 Label with data about the cabinet — example.
- C.2.3 Flowchart – example of the label placed on or with the cabinet
- C.2.4 Symbols in the flowchart and explanation about the symbols
- C.2.5 Example of label placed on or with the cabinet – Terminal plan for external components
- C.2.6 Control board for Systemair Access control system
- C.3 Hand terminal, if the unit is delivered with control system.
- C.4 Dimensions of the units
- C.5 Ordinary automatically operation – only manual operation by new parameters
- D Drawings, diagrams, guides and instructions for the use, maintenance and repair
- E Employees in charge of operation/control/maintenance
- F Intended use and range of applications
- G Unintended use and misuse – inappropriate applications for the machine
- H Instructions for unloading on the site as well as installation and connection
- H.1 Unloading on the site
- H.1.1 Handling methods
- H.1.2 Unloading by fork-lift truck
- H.1.3 Unloading by crane
- H.1.4 Transport of unit without base frame on the site
- H.1.5 Lifting a unit with straps
- H.1.6 Lifting a unit with installed brackets on the base frame for lifting.
- H.1.7 Lifting a unit without base frame and legs but with installed brackets for lifting.
- H.1.8 Handling a unit with holes in base frame for forks
- H.1.9 Roof unit with PVC or bitumen roof
- H.1.10 Roof unit with steel roof
- H.1.11 Pre-assembly storage
- H.1.12 Tilt less than 30˚ during transportation of the section with heat pump
- H.1.13 Transport and pre-installation storage of rotary heat exchanger — always in vertical position
- H.2 Installation - mechanical
- H.2.1 Free area in front of and above the unit
- H.2.2 Supporting surface
- H.2.3 Adjustable feet under legs or base frame and transport of sections
- H.2.4 Base frame assembly
- H.2.5 Base frames for outdoor units
- H.2.6 Outdoor units — support under the base frame of the unit
- H.2.7 Installation on the site of unit sections at the base frame when sections are delivered on pallets
- H.2.8 Joining the AHU sections
- H.2.9 Fitting the ductwork
- H.2.10 Risk of stack effect by vertical ducts and wind pressure on louvers
- H.2.11 Remove transport brackets – when spring mounts are installed
- H.2.12 Refitting of guards
- H.2.13 Lock the doors by using the key
- H.2.14 Overhang support
- H.3 Installation - electrical
- H.4 Installation – Pipes for water – hot and chilled, valves and drains
- H.1 Unloading on the site
- I Installation and assembly instructions for reduction of noise and vibration emissions
- J Start-up, adjustments, use, commissioning and unit in hipernation
- J.1 Print-outs on paper
- J.2 Documentation is available for download
- J.3 Start-up by installer
- J.4 Adjustments and use
- J.5 Description of functions, if control system is delivered by Systemair
- J.5.1 Remote control
- J.5.2 Extended operation and external start/stop (for example by presence detectors)
- J.5.3 Valve and valve motor for heating coil
- J.5.4 Valve and valve motor for cooling coil
- J.5.5 DX cooling
- J.5.6 Circulation pump, heating
- J.5.7 Fire alarm function
- J.5.8 Electric heating coil
- J.5.9 Speed control of fans
- J.5.10 Cabinet
- J.5.11 Temperature sensors
- J.5.12 Damper motors
- J.5.13 Filter guards
- J.5.14 Room temperature sensors
- J.5.15 Frost protection
- J.5.16 Systemair Control Panel - NaviPad
- J.5.17 Cooling recovery
- J.5.18 Free cooling
- J.5.19 Alarm signal
- J.5.20 Heat recovery
- J.5.21 Frost protection – plate heat exchanger
- J.6 Commissioning
- J.7 Unit in hipernation — not in regular operation for several months
- K Information about the residual risks
- K.1 Design of the machine to make transport safe
- K.2 Risk caused by surfaces, edges and corners
- K.3 Risk of dust, viral and bacterial infection
- K.4 Risk caused by maintenance and cleaning of dampers
- K.5 Risk caused by maintenance and cleaning of attenuators
- K.6 Risks in connection to filters
- K.7 Risks in connection to fans
- K.8 Risks in relation to heating/cooling coils and electrical heater
- K.9 Heat pump units
- K.10 Risk caused by lightning strike
- K.11 Risk of Legionella
- L Instructions on the protective measures during repair and maintenance
- M The essential characteristics of tools which may be fitted to the machinery
- N The conditions of stability during use, transportation, assembly, dismantling when out of service
- O Instructions for machinery where these are regularly to be transported
- P The operating method to be followed in the event of breakdown. Safe restart.
- Q Adjustment and maintenance operations
- Q.1 Shutdown of the unit to a safe state
- Q.2 Unlock and lock the doors by using the key
- Q.3 Recommended maintenance intervals
- Q.4 Filters – always replace filters with new filters with the same characteristics to maintain SFP value
- Q.5 Changing the Internal Battery in the controller
- Q.6 Functions to maintain
- R Instructions to enable adjustment and maintenance safely
- S The specifications of the spare parts to be used, when these affect the health and safety of operators
- T Information on airborne noise emissions exceeding 70 dB(A)
- Annex 1 Declaration of conformity with production number (in separate cover)
- Annex 2 Technical data – unique data for every unit (in separate cover)
- Annex 3 Spare part list (in separate cover)
- Annex 4 Assembly of base frame – height 118 mm for unit sizes 10 – 18
- Annex 5 Assembly of base frame – height 118 mm for unit sizes 20 – 31
- Annex 6 Assembly of base frame – height 218 mm for unit sizes 10 – 18
- Annex 7 Assembly of base frame – height 218 mm for unit sizes 20 – 31
- Annex 8 Installation of base frame covers for roof unit sizes 35-44
- Annex 9 Installation of steel roof in the sizes 10 – 44
- 9.1 Overview
- 9.2 Mount rails. Units of size 10, 11, 12, and 14
- 9.3 Mount rails. Units of size 16, 18, 20, 22, 24, 27, 29 and 31
- 9.4 Mount rails. Units of size 35, 38, 41 and 44
- 9.5 Roof overhang along the long sides of the unit
- 9.6 Calculation of the overhang at the ends of the unit. Mount overhang profile – G1.
- 9.7 Foam bands between rails and roof plates – mount roof plates
- 9.8 Foam bands between roof plates
- 9.9 Mount roof plates – some of them are overlapping by 2 ribs
- 9.10 Mount overhang profile – G5 on the other end of the unit
- 9.11 Mount side profiles and corners along the edges of the roof to protect persons
- 9.12 Apply sealing on plate joints to ensure water resistance
- Annex 10 Speed control for rotor and assembly of divided rotor
- 10.1 Speed control RHC 200 delivered before March 2021
- 10.1.1 Selection of correct signal via the 8DIP switch levers for RHC 200 delivered before March 2021
- 10.1.2 Indication of operation mode via red and green LED as well as test of motor for RHC 200 delivered before March 2021
- 10.1.3 Information about connection of cables to terminals on the control board in RHC 200 delivered before 2021
- 10.2 Speed control type NOVA drive 370 delivered after February 2021
- 10.2.1 Selection of correct signal via the 5 DIP switch levers in NOVA drive 370
- 10.2.2 The board in NOVA drive 370 for control of revolutions.
- 10.2.3 Information about connection of cables to terminals on the control board.
- 10.2.4 Modbus control for NOVA drive 370
- 10.2.5 Modbus control — Normal operation
- 10.3 Assemble divided rotor and the Systemair casing
- 10.4 Assemble divided rotor from Hoval
- 10.4.1 Tools and aids
- 10.4.2 Lifting instruction for upper half of the Hoval CDS 290 mm rotor casing
- 10.4.3 Installation of upper half of the Hoval CDS 290 mm rotor casing
- 10.4.4 Installation of radial walls between segments
- 10.4.5 Adjusting clearance between radial walls and the casing
- 10.4.6 Installation of rotor segment and periphery plates
- 10.4.7 Installation, first periphery plate
- 10.4.8 Installation of next segment
- 10.4.9 Installation, next periphery plate
- 10.4.10 Final adjustment of segments and periphery plates
- 10.4.11 Installation of brush sealing and upper half of the Systemair casing
- 10.5 Assemble divided rotor from Lautner
- 10.6 Assemble divided rotor from Klingenburg
- 10.7 Installation of motor that turns rotor and sensor for control of rotation
- 10.1 Speed control RHC 200 delivered before March 2021
- Annex 11 Reversible heat pump unit (in separate cover, if heat pump was delivered)
- Annex 12 Menu for internal controller in the heat pump unit (in separate cover, if heat pump was delivered)
- Annex 13 Connection of fan motor and set-up manual for frequency converter
- Annex 14 Commissioning protocol – proposal (in separate cover)
- Annex 15 Report with data from final functional test on the Systemair factory (in separate cover, if control system was delivered)
- Annex 16 Short description of main components in the control system
- Annex 17 Wiring diagram (in separate cover, if control system was delivered)
- Annex 18 Geniox Air Handling Units — Sustainability
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Contents
9.8 Foam bands between roof plates .............................................................................................9-7
9.9 Mount roof plates – some of them are overlapping by 2 ribs...........................................................9-8
9.10 Mount overhang profile – G5 on the other end of the unit ..............................................................9-8
9.11 Mount side profiles and corners along the edges of the roof to protect persons..................................9-8
9.12 Apply sealing on plate joints to ensure water resistance................................................................9-9
Annex 10 Speed control for rotor and assembly of divided rotor ................................................................ 10-1
10.1 Speed control RHC 200 delivered before March 2021 ................................................................. 10-1
10.1.1 Selection of correct signal via the 8DIP switch levers for RHC 200 delivered before March
2021 ................................................................................................................... 10-1
10.1.2 Indication of operation mode via red and green LED as well as test of motor for RHC 200
delivered before March 2021.................................................................................... 10-2
10.1.3 Information about connection of cables to terminals on the control board in RHC 200
delivered before 2021 ............................................................................................. 10-3
10.2 Speed control type NOVA drive 370 delivered after February 2021 ............................................... 10-4
10.2.1 Selection of correct signal via the 5 DIP switch levers in NOVA drive 370 ............................ 10-4
10.2.2 The board in NOVA drive 370 for control of revolutions. .................................................. 10-7
10.2.3 Information about connection of cables to terminals on the control board............................ 10-8
10.2.4 Modbus control for NOVA drive 370 ........................................................................... 10-8
10.2.5 Modbus control — Normal operation ........................................................................ 10-10
10.3 Assemble divided rotor and the Systemair casing .................................................................... 10-10
10.4 Assemble divided rotor from Hoval....................................................................................... 10-11
10.4.1 Tools and aids...................................................................................................... 10-11
10.4.2 Lifting instruction for upper half of the Hoval CDS 290 mm rotor casing ............................ 10-11
10.4.3 Installation of upper half of the Hoval CDS 290 mm rotor casing...................................... 10-12
10.4.4 Installation of radial walls between segments ............................................................. 10-13
10.4.5 Adjusting clearance between radial walls and the casing ............................................... 10-13
10.4.6 Installation of rotor segment and periphery plates ....................................................... 10-14
10.4.7 Installation, first periphery plate............................................................................... 10-15
10.4.8 Installation of next segment.................................................................................... 10-16
10.4.9 Installation, next periphery plate .............................................................................. 10-17
10.4.10 Final adjustment of segments and periphery plates...................................................... 10-17
10.4.11 Installation of brush sealing and upper half of the Systemair casing.................................. 10-18
10.5 Assemble divided rotor from Lautner .................................................................................... 10-20
10.5.1 Tools and aids...................................................................................................... 10-20
10.5.2 Assembly instructions............................................................................................ 10-21
10.6 Assemble divided rotor from Klingenburg............................................................................... 10-32
10.6.1 Tools and aids...................................................................................................... 10-32
10.6.2 Assembly instructions............................................................................................ 10-32
10.6.3 Adjusting the bearings........................................................................................... 10-36
10.6.4 Installing back plates and tensioning belts.................................................................. 10-36
10.7 Installation of motor that turns rotor and sensor for control of rotation ......................................... 10-40
Annex 11 Reversible heat pump unit (in separate cover, if heat pump was delivered) .................................... 11-1
11.1 Geniox-HP section (reversible heat pump unit) ......................................................................... 11-1
Annex 12 Menu for internal controller in the heat pump unit (in separate cover, if heat pump was
delivered) .................................................................................................................................... 12-1
Annex 13 Connection of fan motor and set-up manual for frequency converter............................................. 13-1
13.1 Connection of fan motor ...................................................................................................... 13-1
13.2 Set-up for Danfoss FC101 for Geniox-units with AC motors.......................................................... 13-1
13.3 AC-fan operation without thermistor for Danfoss FC101.............................................................. 13-2
13.4 Installation ECblue .............................................................................................................. 13-4
13.4.1 Connection............................................................................................................ 13-4
13.4.2 Diagnostic/faults .................................................................................................... 13-5
Annex 14 Commissioning protocol – proposal (in separate cover)............................................................... 14-1
Annex 15 Report with data from final functional test on the Systemair factory (in separate cover, if control
system was delivered) .................................................................................................................... 15-1
Annex 16 Short description of main components in the control system ....................................................... 16-1
16.1 Geniox units delivered in several sections ................................................................................ 16-1
16.1.1 External components............................................................................................... 16-1
16.2 Geniox unit delivered assembled on base frame ........................................................................ 16-1
16.2.1 External components............................................................................................... 16-1
Annex 17 Wiring diagram (in separate cover, if control system was delivered).............................................. 17-1
Annex 18 Geniox Air Handling Units — Sustainability ............................................................................... 18-1
18.1 Illustrations and explanations ................................................................................................ 18-4
18.1.1 Photo A................................................................................................................ 18-4
18.1.2 Photo B................................................................................................................ 18-4
18.1.3 Photo C ................................................................................................................ 18-5