Geniox User Manual Hygienic air handling unit
Table Of Contents
- A Manufacturer
- B Name of machines
- C Declaration of Conformity - example
- D General descriptions, dangers and warnings
- D.1 Overview via pictograms on the inspection side of the unit
- D.2 Data about the unit according to cards and labels in and on the unit
- D.2.1 Example of CE labelling and Machine card with unique data on every unit
- D.2.2 Label with data about the cabinet — example.
- D.2.3 Flowchart – example of the label placed on or with the cabinet
- D.2.4 Symbols in the flowchart and explanation about the symbols
- D.2.5 Example of label placed on or with the cabinet – Terminal plan for external components
- D.2.6 Control board for Systemair Access control system
- D.3 The control panel for the control system.
- D.4 Dimensions of the units
- D.5 Ordinary automatically operation – only manual operation by new parameters
- E Drawings, diagrams, guides and instructions for the use, maintenance and repair
- F Employees in charge of operation/control/maintenance
- G Intended use and range of applications
- H Unintended use and misuse – inappropriate applications for the machine
- I Instructions for unloading on the site as well as installation and connection
- I.1 Unloading on the site
- I.1.1 Handling methods
- I.1.2 Unloading by forklift truck
- I.1.3 Unloading by crane
- I.1.4 Transport of unit without base frame on the site
- I.1.5 Lifting a unit with straps
- I.1.6 Lifting a unit with installed brackets on the base frame for lifting.
- I.1.7 Lifting a unit without base frame and legs but with installed brackets for lifting.
- I.1.8 Handling a unit with holes in base frame for forks
- I.1.9 Roof unit with PVC, flat sheet steel plates or bitumen
- I.1.10 Roof unit with steel roof
- I.1.11 Long-term storage before installation — outdoor or in not heated and humid building
- I.1.12 Tilt less than 30˚ during transportation of the section with heat pump
- I.1.13 Transport and pre-installation storage of rotary heat exchanger — always in vertical position
- I.2 Installation - mechanical
- I.2.1 Free area in front of and above the unit
- I.2.2 Supporting surface
- I.2.3 Adjustable feet under legs or base frame and transport of sections
- I.2.4 Base frames for outdoor units
- I.2.5 Outdoor units — support under the base frame of the unit
- I.2.6 Installation on the site of unit sections.
- I.2.7 Joining the sections
- I.2.8 Risk of stack effect by vertical ducts and wind pressure on louvers
- I.2.9 Fitting the ductwork
- I.2.10 Refitting of safety guards
- I.2.11 Lock the doors by using the key
- I.3 Installation - electrical
- I.3.1 Video instruction and overview
- I.3.2 Wiring diagrams
- I.3.3 Installation of mains power supply
- I.3.4 Electrical connection of components and functions
- I.3.5 Fans — cable connections with plugs for easy demounting of fans
- I.3.6 Filters — differential pressure gauge for each filter stage
- I.3.7 Lock the doors by using the key
- I.4 Installation – pipes for water – hot and chilled, valves and drains
- I.4.1 Description
- I.4.2 Pipe connections
- I.4.3 Pipes and cables must not obstruct opening of doors and extraction of components from the unit
- I.4.4 Pipe connections to coils that must be extracted for cleaning
- I.4.5 Droplet eliminator — access to removal and cleaning
- I.4.6 Draining condensate water
- I.4.7 Video instruction — draining condensate water from heat exchanger
- I.4.8 Draining condensate water from cooling coil
- I.4.9 A maximum of 90% relative humidity must not be exceed before second filter stage or silencers
- I.4.10 Clean and disinfect the interior of the unit as second last action for the installer before start-up and hand over of the unit to the user
- I.4.11 Install delivered filters in the cleaned unit as last action for the installer before start-up and hand over of the unit to the user
- I.1 Unloading on the site
- J Installation and assembly instructions for reduction of noise and vibration emissions
- K Start-up, adjustments, use, commissioning and unit in out of regular operation for several months
- K.1 Print-outs on paper
- K.2 Documentation is available for download
- K.3 Start-up by installer
- K.4 Video instructions about adjustments and use via the control panel
- K.5 Description of the control system functions
- K.5.1 Remote control
- K.5.2 Extended operation and external start/stop (for example by presence detectors)
- K.5.3 Valve and valve motor for heating coil
- K.5.4 Valve and valve motor for cooling coil
- K.5.5 DX cooling
- K.5.6 Circulation pump, heating
- K.5.7 Fire alarm function
- K.5.8 Electrical heater battery
- K.5.9 Speed control of fans
- K.5.10 Cabinet
- K.5.11 Temperature sensors
- K.5.12 Damper motors
- K.5.13 Filter guards
- K.5.14 Room temperature sensors
- K.5.15 Frost protection
- K.5.16 Systemair Control Panel - NaviPad
- K.5.17 Cooling recovery
- K.5.18 Free cooling
- K.5.19 Alarm signal
- K.5.20 Heat recovery
- K.5.21 Frost protection – plate heat exchanger
- K.6 Commissioning
- K.7 Accurate measuring of SFP (Specific Fan Power)
- K.8 Unit in not in regular operation for several months
- L Information about the residual risks
- M Instructions on the protective measures during repair and maintenance
- N The essential characteristics of tools which may be fitted to the machinery
- O The conditions of stability during use, transportation, assembly, dismantling when out of service
- P Instructions for machinery where these are regularly to be transported
- Q The operating method to be followed in the event of breakdown. Safe restart.
- R Adjustment and maintenance operations
- R.1 Shutdown of the unit to a safe state
- R.2 Unlock and lock the doors by using the key
- R.3 Checklist with schedules about cleaning and repair
- R.4 Filters – always replace filters with new filters with the same characteristics as original filters to maintain SFP value
- R.4.1 Bag filters – the number of filters and sizes of frames
- R.4.2 Panel filters – the number of filters and the sizes of the frames
- R.4.3 Video instruction — replace bag filters
- R.4.4 For hygienic units replaced U-profiles for filters must comply with ISO 846 — see spare part article number
- R.4.5 Panel filters
- R.5 Changing the Internal Battery in the controller
- R.6 Functions to maintain
- R.6.1 The unit
- R.6.2 For hygienic units replaced door gasket and sealing lists must comply with ISO 846 — see spare part article numbers
- R.6.3 Dampers
- R.6.4 Rotary heat exchanger
- R.6.5 Cross flow and counter flow plate heat exchanger — cleaning
- R.6.6 Coils for heating and/or cooling — cleaning
- R.6.7 Plug fans
- R.6.8 Attenuator
- R.6.9 Outdoor air section
- R.6.10 Heat pump unit
- S Instructions to enable adjustment and maintenance safely
- T The specifications of the spare parts to be used, when these affect the health and safety of operators
- U 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 — is only available on demand)
- Annex 4 Speed control for rotary heat exchanger
- Annex 5 Reversible heat pump unit (in separate cover, if heat pump was delivered)
- Annex 6 Menu for internal controller in the heat pump unit (in separate cover, if heat pump was delivered)
- Annex 7 Connection of EC fan motor, diagnostics/faults and configuration of speed control
- Annex 8 Commissioning protocol – proposal (in separate cover)
- Annex 9 Report with data from final functional test on the Systemair factory (in separate cover)
- Annex 10 Short description of main components in the control system
- Annex 11 Wiring diagram (in separate cover)
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Contents
O.4 General disassembly – sharp edges............................................................................................ 45
P Instructions for machinery where these are regularly to be transported ....................................................... 45
Q The operating method to be followed in the event of breakdown. Safe restart. ............................................. 45
R Adjustment and maintenance operations .............................................................................................. 45
R.1 Shutdown of the unit to a safe state .......................................................................................... 45
R.2 Unlock and lock the doors by using the key ................................................................................. 46
R.3 Checklist with schedules about cleaning and repair ....................................................................... 47
R.3.1 Checklist with schedule for electric and mechanical maintenance of Geniox air handling
units ....................................................................................................................... 51
R.4 Filters – always replace filters with new filters with the same characteristics as original filters to
maintain SFP value ................................................................................................................ 52
R.4.1 Bag filters – the number of filters and sizes of frames ........................................................ 53
R.4.2 Panel filters – the number of filters and the sizes of the frames ............................................ 53
R.4.3 Video instruction — replace bag filters............................................................................ 54
R.4.4 For hygienic units replaced U-profiles for filters must comply with ISO 846 — see spare part
article number .......................................................................................................... 55
R.4.5 Panel filters.............................................................................................................. 56
R.5 Changing the Internal Battery in the controller ............................................................................. 56
R.6 Functions to maintain ............................................................................................................. 57
R.6.1 The unit................................................................................................................... 57
R.6.2 For hygienic units replaced door gasket and sealing lists must comply with ISO 846 — see
spare part article numbers ........................................................................................... 58
R.6.3 Dampers.................................................................................................................. 59
R.6.4 Rotary heat exchanger ............................................................................................... 59
R.6.5 Cross flow and counter flow plate heat exchanger — cleaning ............................................. 61
R.6.6 Coils for heating and/or cooling — cleaning ..................................................................... 63
R.6.7 Plug fans ................................................................................................................. 65
R.6.8 Attenuator ............................................................................................................... 65
R.6.9 Outdoor air section .................................................................................................... 66
R.6.10 Heat pump unit ......................................................................................................... 66
S Instructions to enable adjustment and maintenance safely........................................................................ 66
S.1 Protective measures and additional protective measures................................................................ 66
S.1.1 Necessary protection measures prior to start-up .............................................................. 67
S.1.2 Safe adjustment and maintenance ................................................................................ 67
S.1.3 Personal protective equipment for maintenance staff – health and safety............................... 67
T The specifications of the spare parts to be used, when these affect the health and safety of operators ............... 67
T.1 Spare parts - Mechanical ......................................................................................................... 67
T.2 Spare parts - Electrical ............................................................................................................ 68
U Information on airborne noise emissions exceeding 70 dB(A) .................................................................... 68
Annex 1 Declaration of conformity with production number (in separate cover) ..............................................1-1
Annex 2 Technical data – unique data for every unit (in separate cover) ........................................................2-1
Annex 3 Spare part list (in separate cover — is only available on demand)......................................................3-1
Annex 4 Speed control for rotary heat exchanger .....................................................................................4-1
4.1 Speed control ......................................................................................................................4-1
4.1.1 Selection of correct signal via the 8 DIP switch levers .......................................................4-1
4.1.2 Indication of operation mode via red and green LED as well as test of motor..........................4-1
4.1.3 The board for control of revolutions. .............................................................................4-3
4.1.4 Information about connection of cables to terminals on the control board..............................4-4
4.2 Installation of motor that turns rotor and sensor for control of rotation .............................................4-4
Annex 5 Reversible heat pump unit (in separate cover, if heat pump was delivered) ........................................5-1
5.1 Geniox-HP section (reversible heat pump unit) ...........................................................................5-1
Annex 6 Menu for internal controller in the heat pump unit (in separate cover, if heat pump was
delivered) ......................................................................................................................................6-1
Annex 7 Connection of EC fan motor, diagnostics/faults and configuration of speed control ...............................7-1
7.1 Connection of ECbluefin fan motor ...........................................................................................7-1
7.2 Diagnostics/faults visualised by LED on the ECbluefin motor...........................................................7-2
7.3 Configuration of speed control ................................................................................................7-3
Annex 8 Commissioning protocol – proposal (in separate cover)...................................................................8-1
Annex 9 Report with data from final functional test on the Systemair factory (in separate cover) .......................9-1
Annex 10 Short description of main components in the control system ....................................................... 10-1
10.1 Geniox units delivered in several sections ................................................................................ 10-1
10.1.1 External components............................................................................................... 10-1
10.2 Geniox unit delivered assembled on base frame ........................................................................ 10-1
10.2.1 External components............................................................................................... 10-1