Geniox Air handling unit Installation, Operation and Maintenance instruction Document in original language | Version 11 GB Part number of this manual 90925520 Order number output
Only the English version is valid in case of a dispute. Translated versions are not valid in case of disputes.
Detailed table of contents on the following pages General description A B C D E F G Manufacturer Name of machines General descriptions, dangers and warnings Drawings, diagrams, guides and instructions for the use, maintenance and repair Employees in charge of operation/control/maintenance Intended use and range of applications Unintended use and misuse – inappropriate applications for the machine Installation H I Instructions for unloading on the site as well as installation and connection Installation a
Contents A Manufacturer....................................................................................................................................1 B Name of machines .............................................................................................................................1 C General descriptions, dangers and warnings ............................................................................................2 C.1 Overview via pictograms on the inspection side of the unit .......
Contents I J K L M N H.3.4 Electrical connection of components and functions............................................................ 30 H.3.5 Lock the doors by using the key.................................................................................... 30 H.4 Installation – Pipes for water – hot and chilled, valves and drains ...................................................... 30 H.4.1 Description................................................................................................
Contents N.3 Disposal of the heat pump system - type Geniox - HP.................................................................... 44 N.4 General disassembly – sharp edges............................................................................................ 44 O Instructions for machinery where these are regularly to be transported ....................................................... 45 P The operating method to be followed in the event of breakdown. Safe restart. ................................
Contents 9.8 9.9 9.10 9.11 9.12 Annex 10 10.1 Foam bands between roof plates .............................................................................................9-7 Mount roof plates – some of them are overlapping by 2 ribs...........................................................9-8 Mount overhang profile – G5 on the other end of the unit ..............................................................9-8 Mount side profiles and corners along the edges of the roof to protect persons ..............
Contents 18.1.4 18.1.5 18.1.6 output | 11 Photo D ................................................................................................................ 18-5 Photo E1............................................................................................................... 18-6 Photo E2...............................................................................................................
Manufacturer | A Manufacturer This User Manual covers all air handling units delivered by Systemair A/S. Manufacturer and supplier data: Systemair A/S Ved Milepælen 7 DK-8361 Hasselager Responsible for documentation: Elisabeth Rahbek B Name of machines This manual is about Systemair air handling units called Geniox 10, Geniox 11, Geniox 12, Geniox 14, Geniox 16, Geniox 18, Geniox 20, Geniox 22, Geniox 24, Geniox 27, Geniox 29Geniox 31, Geniox 35, Geniox 38, Geniox 41 and Geniox 44.
2 | General descriptions, dangers and warnings C General descriptions, dangers and warnings Geniox air handling units are order specific machines available in thousands of different configurations. Only a few examples of machine configurations are described below. The air handling units are intended for the transport and treatment of air between -40 °C and + 40 °C. The units are exclusively for comfort ventilation. Maintenance of the units must be carried out by skilled technicians.
General descriptions, dangers and warnings | Position Description 3. Exhaust air duct connection 4. Damper 5. Warning about crushing 6. Connect sections with identical numbers 7. Energy recovery 8. Warning about danger by rotating parts 9. Filter with indication of airflow direction 10. Warning about danger by electricity 11. Controller in a cabinet behind this inspection door 12. Extract air duct connection 13.
4 | General descriptions, dangers and warnings Position Description Symbol 14. Supply air duct connection 15. Heating coil 16. Warning about danger by heat 17. Weight of the section, production number of the unit, number of the section. 18. Warning about danger by rotating fan during 4 minutes rundown period. 19. Fan with arrow for indication of airflow direction. 20. Lifting prohibited 21. Lifting permitted. 22.
General descriptions, dangers and warnings | Position Description Symbol Cooling coil Reversible heat pump Other labels Silencer Inspection Humidifier C.1.2 Weight of each section and production number – example for the Geniox unit Weight of the section. Production number of the unit. Number of the section in the unit. Product name in this example isGeniox 31, where 31 indicates the size of the unit.
6 | General descriptions, dangers and warnings C.1.4 Pictograms about warnings and dangers on the units Pictograms according to EN1886 about Warning Warning about danger by rotating parts. Warning Warning about crushing. Warning Warning about danger by electricity. Warning Warning about danger by heat Warning 4 min. STOP Rotating fan during 4 minutes rundown period with risk of injury. Warning Attention — risk for injury or damage on material. C.2 C.2.
General descriptions, dangers and warnings | C.2.2 Label with data about the cabinet — example. An example of the label that is always placed on or with the cabinet Systemair A/S Systemair declares hereby that the cabinet is in conformity with: SBB Low voltage panels: N60439-1 Electrical material on machines: EN60204-1 EMC-directive environment: 89/336/EOF Diagram version Geniox ver.
8 | General descriptions, dangers and warnings C.2.
General descriptions, dangers and warnings | C.2.
10 | General descriptions, dangers and warnings C.2.6 Control board for Systemair Access control system Terminals at the Access control board. The connected components is an example, and not unique for any order.
Drawings, diagrams, guides and instructions for the use, maintenance and repair | C.3 Hand terminal, if the unit is delivered with control system. The hand terminal is delivered in a cardboard box containing the other external control components. This cardboard box is usually, but not always, placed in the section with the supply air fan. This is the NaviPad control panel for the Access control system from Systemair. The hand terminal is connected by a cable to the controller in the cabinet.
12 | Unintended use and misuse – inappropriate applications for the machine Intended applications for the units are: • Offices • Teaching rooms • Hotels • Shops • Homes and similar comfort zones • The majority of rooms at clinics and hospital where extended requirements according to Eurovent level 1, 2 and 3 are not requested G Unintended use and misuse – inappropriate applications for the machine Units for outdoor installation must be specified and ordered for outdoor installation.
Instructions for unloading on the site as well as installation and connection | H.1.2 Unloading by fork-lift truck The forks of the truck must be sufficiently long to avoid any damage to the AHU underside. H.1.3 Unloading by crane AHU delivered on transport pallet must be lifted by straps as shown in the illustration. Caution Do not use the feet as lifting points, as this may cause damage tho the air handling unit. H.1.
14 | Instructions for unloading on the site as well as installation and connection H.1.6 Lifting a unit with installed brackets on the base frame for lifting. Lifting beam and straps are not included in the delivery. H.1.7 Lifting a unit without base frame and legs but with installed brackets for lifting.
Instructions for unloading on the site as well as installation and connection | Caution Do not lift a section in the 4 brackets that are marked with the label — lifting prohibited. Lifting prohibited — in this bracket. This bracket in Geniox units in the sizes 20 — 31 is not for lifting the unit. This bracket is for permanently holding 2 sections tight together with 8 mm bolts. This bracket in Geniox units in the sizes 10 – 18 is not for lifting the unit.
16 | Instructions for unloading on the site as well as installation and connection Do not activate the wheels of forklift on the horizontal profile of a middle profile. Activation of the wheels on the horizontal profile might bend the profile. The forks of the forklift must be longer than the width or length of the section/unit to achieve safe transport of the section/unit.
Instructions for unloading on the site as well as installation and connection | Caution If the base frame has 4 holes for forklifts as shown, the section/unit must be lifted evenly by 2 forklifts in each side. Hereby 4 forklifts must be used. There is a risk of overturning causing injury and damage to property if a section/unit is lifted unevenly or only by one forklift in each side. Caution Avoid activating the wheels on forklifts over horizontal profiles of base frames H.1.
18 | Instructions for unloading on the site as well as installation and connection H.1.12 Tilt less than 30˚ during transportation of the section with heat pump During transportation, the unit section must always be in the upright position or tilted less than 30˚. If it is necessary to tilt the unit more than 30˚, the suction pipe of the compressor must point upwards to prevent the escape of oil from the compressor sump. H.1.
Instructions for unloading on the site as well as installation and connection | H.2.4 Base frame assembly Base frame is delivered unassembled for the indoor units that are delivered in sections on pallets. Assembly of the base frame is illustrated on 4 pages in a manual in a plastic bag which is attached to one of the large base frame parts. The 4 pages with the illustration regarding the assembly of the base frame are also available in this user manual in Annex 4, 5, 6 or7.
20 | Instructions for unloading on the site as well as installation and connection Lift up the section by forklifts to the level where the underside of the section is even with the overside of the base frame. Pull the section to the correct position on the base frame by straps – it is maybe necessary to support the section by heavy duty trolleys (see the photos below). Example of heavy duty trolleys.
Instructions for unloading on the site as well as installation and connection | Note! Place the strap on the bottom profiles of the unit to avoid any load and stress on the vertical profiles when sections are pulled together along the base frame or on the floor. The sections must be pulled fully and tight together with the strap placed on the bottom profiles. Sections are mounted to base frames with self-drilling screws.
22 | Instructions for unloading on the site as well as installation and connection The sections are then to be positioned directly opposite each other. If the sections are built with legs, the adjustable feet can be used to get the sections in line and at the same height. Press the sections hard together so that the rubber profiles are so flat that the iron frames of the two sections are joined. Strap with tensioner is suitable for pressing the sections hard together..
Instructions for unloading on the site as well as installation and connection | Assembly has been completed successfully The grey guiding and connection blocks might be installed inside the units on the vertical profiles. Press the sections hard together so that the rubber profiles are so flat that the iron frames of the two sections are joined. Strap with tensioner is suitable for pressing the sections hard together.. Note! Do not place the strap on the vertical profiles.
24 | Instructions for unloading on the site as well as installation and connection Bracket inside a section. A similar bracket is installed in the next section. This is the bracket in the Geniox sizes 10 and 18 Press the sections hard together so that the rubber profiles are so flat that the iron frames of the two sections are joined. Strap with tensioner is suitable for pressing the sections hard together.. Note! Do not place the strap on the vertical profiles.
Instructions for unloading on the site as well as installation and connection | H.2.10 Risk of stack effect by vertical ducts and wind pressure on louvers Important The Systemair air handling units can be ordered and delivered without dampers, and the installer/user must check that duct systems with the described risk of stack effect (chimney effect) will be provided with dampers and spring return motors.
26 | Instructions for unloading on the site as well as installation and connection After disposal of the transport brackets the yellow label on the outside of the fan inspection door has no function and should be removed. H.2.12 Refitting of guards The guard is a safety guard installed inside the door. The safety guard show on the illustration below is optional from Systemair. According to Machinery Directive guidelines, tools are necessary for the removal of the guard.
Instructions for unloading on the site as well as installation and connection | H.2.13 Lock the doors by using the key Use the key to lock the doors. The doors are not locked automatically by turning the handle to the vertical position. H.2.14 Overhang support In case of overhangs >400 mm, adequate support must be installed in order to prevent the unit from tipping (see example below). H.
28 | Instructions for unloading on the site as well as installation and connection H.3.1 Description The position of components is shown and described in Annex 2. Connections to terminals are shown in the wiring diagram. When control of constant pressure in the ducts (also called demand controlled capacity) is required, the pressure transmitters must measure in the duct system at places where all pressure changes can be registered accurately for reliable pressure control.
Instructions for unloading on the site as well as installation and connection | Connect the mains power supply to the correct terminals shown below. H.3.3.1 Necessary mains power supply for units with cabinet/control system Necessary mains power supply is printed on the unique machine card placed on the front of every unit (see example of a machine card in chapter C.2.1). H.3.3.2 Necessary overvoltage protection device, that leads lightning overvoltage to an earth lead on a safe way.
30 | Instructions for unloading on the site as well as installation and connection H.3.4 Electrical connection of components and functions External components and functions are delivered according to the order confirmation. Cable numbers appear from the label inside or on the cabinet, and cable numbers appear from the wiring diagrams. H.3.4.
Instructions for unloading on the site as well as installation and connection | H.4.3 Possibility of extracting components from the unit Pipes and cables must not obstruct the inspection doors and components which can be extracted from the unit. Potential components for extraction are filters, fans and rotary heat exchanger. H.4.4 Pipe connections to coils H.4.4.1 Heating coils Pipes for hot water must be protected by insulation against frost and loss of heat.
32 | Instructions for unloading on the site as well as installation and connection To protect against frost a temperature sensor for the transmission of an analog signal to the controller is placed in a pipe on the collection pipe for return water. The sensor must be fitted water tight with a cap in the pipe before water under pressure is in the coil. The pipe for the sensor is soldered on the collection pipe and it is important to hold contra on the pipe, when the cap is tightened. Coil seen from above.
Instructions for unloading on the site as well as installation and connection | H.4.6 Draining condensate water from heat exchanger Condensate from the plate heat exchanger or run-around-coil is collected in the drip tray. Heavy negative air pressure in this section prevents the water from flowing out of the drainpipe. A water trap with sufficient closing level of the water is essential to ensure that condensate water flows out of the unit.
34 | Installation and assembly instructions for reduction of noise and vibration emissions H1 must be shortened on the site by the installer — sometimes to only 100 mm — because the height of the low version of the base frame is only 118 mm. The adjustable length of H2 must be reduced to the minimum of 40 mm.
Start-up, adjustments, use, commissioning and unit in hipernation | Flexible connections between the units and the ducts are available as accessories. J Start-up, adjustments, use, commissioning and unit in hipernation J.
36 | Start-up, adjustments, use, commissioning and unit in hipernation • Control panel • Humidifier • Manuals about configuration of Systemair control systems— Access • Information about connection of Systemair control systems to Building Management Systems • Other J.3 Start-up by installer All protection and safety measures must be met before start-up of the unit. The mains supply voltage must also be checked too. The mains supply voltage must be measured at the supply terminals in the cabinet. J.3.
Start-up, adjustments, use, commissioning and unit in hipernation | J.5 Description of functions, if control system is delivered by Systemair J.5.1 Remote control J.5.1.1 Communication to BMS systems with MODBUS The controller has been prepared for communication via RS485 communication port to a MODBUS based BMS system (Building Management System). The controller can work as a stand-alone system without any support from other controllers. J.5.1.
38 | Start-up, adjustments, use, commissioning and unit in hipernation 40˚C. The controller is as standard configured to stop the fans and close the dampers if a thermostat is released. On the site qualified technicians are able to change the configuration. J.5.7.4 One smoke detector in extract air The smoke detector has been installed in extract air next to the fan. The controller is as standard configured to stop the fans and close the dampers if the detector is released by smoke.
Start-up, adjustments, use, commissioning and unit in hipernation | J.5.11 Temperature sensors Four sensors are always delivered with each unit. See below where the sensors are placed; • 1 sensor in the extract air, installed inside the unit • 1 sensor in the outdoor air, installed inside the unit before the supply air filter on the cold side of the heat exchanger • 1 sensor in the supply air to be placed in the supply air duct by the installer • 1 sensor in the exhaust, installed inside the unit J.5.
40 | Information about the residual risks J.5.21 Frost protection – plate heat exchanger Signals from a temperature sensor mounted in the airflow after the plate heat exchanger are transmitted to the controller for frost protection of the plate heat exchanger. J.6 Commissioning When the installer has completed the installation and wants to hand over the finished installation to his customer for payment, the commissioning protocol can be the written receipt for the full ended job.
Information about the residual risks | K.4 Risk caused by maintenance and cleaning of dampers Hazards/dangerous area: • Are between the damper blades and the system of bars and links between motor and damper blades. Dangerous incident: • Crushing of fingers. Claim for reduction of danger: • Risk only exists during maintenance and cleaning. This task must be done by skilled technicians that are aware of this risk. K.
42 | Information about the residual risks Dangerous incident: • Persons touching conductive parts get electric shock, burns, heart flicker and so on. Claim for reduction of danger: • By installation or repairs of conductive components, the shaft must be blocked to prevent any rotation. K.7.
Instructions on the protective measures during repair and maintenance | K.8.3 Risk of touching heat transfer fluid Hazards/dangerous area: • Heating/cooling coil could be filled with heat transfer fluid such as antifreeze, glycol, freon. Dangerous incident: • Burning, discomfort, injuries by the radiation of heat sources, damage to eyes and skin, poisoning, slight disease. Claim for reduction of danger: • Wear gloves and eye protection. • Pipework must be insulated.
44 | The essential characteristics of tools which may be fitted to the machinery Cut-resistant gloves for protection against injury from sharp metal plate edges. Use CE-marked gloves for this purpose. Helmet. Particulate respirator – maintenance free including foam face-seal and adjustable pre-threaded headbands – for replacing filters. Eye protection. Ear protection. Padlock for locking the automatic circuit breakers.
Instructions for machinery where these are regularly to be transported | O Instructions for machinery where these are regularly to be transported The subject in the Machinery Directive about machinery that are regularly to be transported does not exist for the Geniox air handling units, because those units are specially made for one intended application. P The operating method to be followed in the event of breakdown. Safe restart.
46 | Adjustment and maintenance operations Q.3 Recommended maintenance intervals Function Maintenance Number per year Unit casing Cleaning of the unit casing. 1 Control of rubber seals on doors and between sections. 1 Change on demand by alarm and always minimum twice a year. 2 Control of rubber seals. Control of the system on Geniox10 – Geniox31. 2 Cleaning of all parts. 1 Check motors and bearings 1 Check that the impellers are rotating without dissonance.
Adjustment and maintenance operations | Q.4 Filters – always replace filters with new filters with the same characteristics to maintain SFP value Filters in supply air and in extract air always have the same sizes of frames and the number of filters for supply air and extract air are always the same. REMEMBER to order filters for supply air as well as for extract air.
48 | Adjustment and maintenance operations Size of unit Numbers and sizes of frames for bag filters (WxH) 35 2x[287x592] + 5x[592x287] + 10x[592x592] + 1x[287x287] 38 3x[287x592] + 15x[592x592] 41 3x[287x592] + 18x[592x592] 44 3x[287x592] + 6x[592x287] + 18x[592x592] + 1x[287x287] Note: Special sizes of filters are available from Camfil. Dept of filter frame must be 25 mm to ensure a complete airtight sealing around the AHU filter frame Q.4.
Adjustment and maintenance operations | Note: The following information about the use of self-adhesive foam strips does not apply to Geniox units in the sizes 35, 38, 41 and 44. ONE self-adhesive foam strip must be placed on the vertical frame of EACH filter to avoid major air leakage through the vertical opening between 2 filters.
50 | Adjustment and maintenance operations Check that the end of the strip is fully even with the horizontal side of the filter frame. Remove excess of the strip. The end of the strip must be fully even with the horizontal side of the filter frame. Push the filters carefully in the U-profile to be sure that there are no leakages between the filters Check that the vertical side of the last filter in the U-profile is fully even with the end of the U-profile.
Adjustment and maintenance operations | Check that rubber profiles on the back panel as well as rubber profiles on the inspection door are without wear and damage — still sufficient for avoiding any air leakage. Q.4.4 Panel filters The filter cell guide rails are to be cleaned before fitting the new filters. Q.5 Changing the Internal Battery in the controller Caution This procedure requires knowledge of proper ESD protection; i.e.
52 | Adjustment and maintenance operations 2 Remove the white cover from the black bottom by pressing on each of the six locking hooks at the two long edges of the cover using a small screwdriver, and at the same time pulling the cover outwards. 3 Use a small screwdriver to press this hook on the cover away from the edge of the black bottom 4 Each of the six hooks must be released from the block on the black bottom by a small screwdriver, and at the same time pulling the cover outwards.
Adjustment and maintenance operations | Q.6 Q.6.1 Functions to maintain The unit It is very easy to remove inspection doors for extraordinary good access to cleaning, service, repairs and replacement of components in the unit. Lift the stainless steel shaft in the hinge to remove the door The unit should be cleaned once a year when operating with normal air quality for comfort ventilation with no special hygiene requirements.
54 | Adjustment and maintenance operations The damper blades are driven by a mechanism consisting of steel rods and gearwheels made from a temperatureresistant, glass fibre reinforced polypropylene composite. The mechanism does not require lubrication. The damper blades are fitted with synthetic bearings requiring no lubrication. Air-tightness of the damper, when the damper motor is in the closed position, must be visually checked once a year.
Adjustment and maintenance operations | Check annually that the brush lists close well. Expect that brush lists should be changed every 5 years — maybe more often — if necessary. To ease inspection and service the rotor can be pulled out of the sizes 10, 11, 12, 14 and 16. Q.6.3.2 Motor and belt drive The bearings are factory lubricated and do not require any service lubrication. The belt drive is to be checked for correct tightness and that it is undamaged.
56 | Adjustment and maintenance operations Q.6.4 Cross flow and counter flow exchanger Note: Once a year the edges of the heat exchanger plates are to be checked for cleanliness and damage. If there is dust on the edges of the plates, remove it with a soft brush. The thin plates are not constructed for cleaning with compressed air or water. Q.6.4.1 By-pass damper The damper blades are fitted with synthetic bearings requiring no lubrication.
Adjustment and maintenance operations | Drip tray with slope is not supported for the weight of a person. Do not walk or stay in the drip tray. Demount this type of water trap regularly for careful cleaning. Note: Information about disassembly, cleaning and reassembly is available in a 2–minutes video on YouTube. https://youtu.
58 | Adjustment and maintenance operations Q.6.5 Run-around heat exchanger A heat recovery system of this type consists of a heating coil in the supply air- flow and a cooling coil in the exhaust air- flow. After an extended running period (normally a few years) dust particles can accumulate on the surface of the coils. This can reduce the efficiency of the coils. Cleaning must be carried out with the utmost care to ensure that the coil fins are not damaged.
Adjustment and maintenance operations | Q.6.6 Split run-around heat exchanger A heat recovery system of this type consists of a heating coil in the supply air- flow and a cooling coil in the exhaust air- flow. After an extended running period (normally a few years) dust particles can accumulate on the surface of the coils. This can reduce the efficiency of the coils. Cleaning must be carried out with the utmost care to ensure that the coil fins are not damaged.
60 | Adjustment and maintenance operations Q.6.7.1 Heating coil Check that the frost protection system is fully operational. A coil may burst due to frost if the frost protection system is not operational. Q.6.7.2 Cooling coil Once a year clean the drip tray beneath the cooling coil, as well as the drain and the water trap. Take care that there is sufficient water in the water trap. If a droplet eliminator has been fitted to the cooling coil, this must be checked once a year and cleaned if necessary.
Adjustment and maintenance operations | Q.6.7.3 Electric heating coil Check that the built-in safety thermostat with an automatic reset function and the overheat thermostat with manual resetting are fully operational. Caution Turn off the electric heating coil and let the fan run for at least 4 minutes before accessing the electric heating coil. Q.6.8 Plug fans Dust can accumulate on the fan impeller which can cause imbalance and vibrations.
62 | Instructions to enable adjustment and maintenance safely R Instructions to enable adjustment and maintenance safely R.1 Protective measures and additional protective measures Adjustment and maintenance must be done by skilled technicians – usually based on service contracts for some years or long-term ESCO contracts. The units are provided with guards to avoid unintended hazards and injury because of rotating parts in the unit.
The specifications of the spare parts to be used, when these affect the health and safety of operators | R.1.1.2 Configuration of frequency converters with installed guard A frequency converter is mounted beside the fan in some units. If the configuration of frequency is carried out with the fan in operation, the guard must be installed for safety reasons and a long cable must be installed between the frequency converter inside the unit and the control panel outside the unit. R.1.
output | 11
Annex Geniox Air handling unit Installation, Operation and Maintenance instruction Document in original language | Version 11 GB Part number of this manual 90925520 Order number output
Only the English version is valid in case of a dispute. Translated versions are not valid in case of disputes.
Contents Annex 1 Annex 2 Annex 3 Annex 4 Annex 5 Annex 6 Annex 7 Annex 8 Annex 9 Annex 10 Annex 11 Annex 12 Annex 13 Annex 14 Annex 15 Annex 16 Annex 17 Annex 18 output | 11 Declaration of conformity with production number (in separate cover) ..........................................1-1 Technical data – unique data for every unit (in separate cover) ....................................................2-1 Spare part list (in separate cover) .................................................................
1-1 | Declaration of conformity with production number (in separate cover) Annex 1 Declaration of conformity with production number (in separate cover) Printed on separate page and delivered with every unit. Enclosed in separate cover.
Technical data – unique data for every unit (in separate cover) | Annex 2 Technical data – unique data for every unit (in separate cover) Printed on separate pages and delivered with every unit. Enclosed in separate cover.
3-1 | Spare part list (in separate cover) Annex 3 Spare part list (in separate cover) Printed on separate pages but not delivered with every unit. Available on demand.
Assembly of base frame – height 118 mm for unit sizes 10 – 18 | Annex 4 Assembly of base frame – height 118 mm for unit sizes 10 – 18 Note: Information about assembly is available in a 2–minutes video on YouTube. https://youtu.
4-2 4.
4-3 Assembly of base frame – height 118 mm for unit sizes 10 – 18 | 4.
4-4 4.
Assembly of base frame – height 118 mm for unit sizes 20 – 31 | Annex 5 Assembly of base frame – height 118 mm for unit sizes 20 – 31 Note: Information about assembly is available in a 2–minutes video on YouTube. https://youtu.be/N-oaYpwsAIo A = Corner B = Splice C = Spacer C = Length profile D = End profile (width of base frame) D1 = Middle profile 5.
5-2 | Assembly of base frame – height 118 mm for unit sizes 20 – 31 End profile type D (width of base frame) Unit size Quantity Length [mm] Geniox20 2 2070 Geniox22 2 2270 Geniox24 2 2470 Geniox27 2 2770 Geniox29 2 2970 Geniox31 4 1585 Corner A Length profile type C 5.
5-3 Assembly of base frame – height 118 mm for unit sizes 20 – 31 | 5.
5-4 | Assembly of base frame – height 118 mm for unit sizes 20 – 31 Middle profile type D1 End profile type D (width of base frame) Spacer F Unit size Quantity Length [mm] Quantity Length [mm] Quantity Geniox20 2 2070 4 941 2 Geniox22 2 2270 4 1041 2 Geniox24 2 2470 4 1141 2 Geniox27 2 2770 4 1291 2 Geniox29 2 2970 4 1391 2 Geniox31 4 1585 4 1491 2 A B Length [mm] Qty Qty 3 1700 6 6 1700 3 1700 6 6 1700 3 1700 6 6 3 1700 3 1800 6 6 1700
Assembly of base frame – height 218 mm for unit sizes 10 – 18 | Annex 6 Assembly of base frame – height 218 mm for unit sizes 10 – 18 Note: Information about assembly is available in a 2–minutes video on YouTube. https://youtu.be/B3nX-x7KnrQ A = Corner B = Splice C = Length profile D = End profile (width of base frame) D1 = Middle profile 6.
6-2 | Assembly of base frame – height 218 mm for unit sizes 10 – 18 End profile type D (width of base frame) Unit size Quantity Length of endprofile (width of base frame) [mm] Geniox10 2 1070 Geniox11 2 1170 Geniox12 2 1270 Geniox14 2 1470 Geniox16 2 1670 Geniox18 2 1870 Corner A Length profile type C 6.
6-3 Assembly of base frame – height 218 mm for unit sizes 10 – 18 | Middle profile type D1 End profile type D (width of base frame) Unit size Quantity width of base frame [mm] Quantity Geniox10 2 1070 1 950 Geniox11 2 1170 1 1050 Geniox12 2 1270 1 1150 Geniox14 2 1470 1 1350 Geniox16 2 1670 1 1550 Geniox18 2 1870 1 1750 Length profile C1 Length profile C2 Length [mm] Corner A Splice B Adjustable length of frame — L [mm] Quantity Length [mm] Quantity Length [mm]
6-4 6.
Assembly of base frame – height 218 mm for unit sizes 20 – 31 | Annex 7 Assembly of base frame – height 218 mm for unit sizes 20 – 31 Note: Information about assembly is available in a 2–minutes video on YouTube. https://youtu.be/N-oaYpwsAIo A = Corner B = Splice C = Length profile D = End profile (width of base frame) D1 = Middle profile 7.
7-2 | Assembly of base frame – height 218 mm for unit sizes 20 – 31 End profile type D (width of base frame) Unit size Quantity Length [mm] Geniox20 2 2070 Geniox22 2 2270 Geniox24 2 2470 Geniox27 2 2770 Geniox29 2 2970 Geniox31 4 1585 Corner A Length profile type C 7.
7-3 Assembly of base frame – height 218 mm for unit sizes 20 – 31 | 7.
7-4 | Assembly of base frame – height 218 mm for unit sizes 20 – 31 Middle profile type D1 End profile type D (width of base frame) Spacer F Unit size Quantity Length [mm] Quantity Length [mm] Quantity Geniox20 2 2070 4 941 2 Geniox22 2 2270 4 1041 2 Geniox24 2 2470 4 1141 2 Geniox27 2 2770 4 1291 2 Geniox29 2 2970 4 1391 2 Geniox31 4 1585 4 1491 2 A B Length [mm] Qty Qty 3 1700 6 6 1700 3 1700 6 6 1700 3 1700 6 6 3 1700 3 1800 6 6 1700
Installation of base frame covers for roof unit sizes 35-44 | 8-1 Annex 8 Installation of base frame covers for roof unit sizes 35-44 The base frame on the upper section of the unit must be fitted with the supplied base frame covers in order to prevent rain from entering the unit.
9-1 | Installation of steel roof in the sizes 10 – 44 Annex 9 Installation of steel roof in the sizes 10 – 44 9.1 Overview • Mount rails A1, B2, C3, D4, E5 on the unit for support of trapezoidal roof plates (mount also rails Y and Z on units of the size 16 and on units that are larger than size 16). • Place foam bands – P – on the horizontal rails A1, B2, C3 and D4 for support of roof plates.
Installation of steel roof in the sizes 10 – 44 | 9-2 connection between rails and unit to prevent rainwater from passing under the rails and into the unit. Mount the rails A1 and B2 on the front side (the side with the inspection doors) – use the simple self-drilling screws without the sealing washer – see the illustration of the screw below.
9-3 | Installation of steel roof in the sizes 10 – 44 Note: Rail B2 fits into the rail A1, and this offers the advantage that the rail B2 can be slid inside the rail A1 to adjust the length of rail B2 accurately to the length of the unit. In this way it is not necessary to spend time and effort cutting the rail B2. Mount the lower rails C3 and D4 on the back side of the unit.
Installation of steel roof in the sizes 10 – 44 | 9-4 Squeeze sealant in sufficient quantity between the underside of the rails A1, B2, C3, D4, E5 and the horizontal top side of the unit before the rails are mounted. This means that the rails are standing on sealant to achieve the tightest connection between rails and unit to prevent rainwater from passing under the rails and into the unit.
9-5 | Installation of steel roof in the sizes 10 – 44 Caution It is important to place a screw in each hole – even though the number of holes for screws seems to be very large, a screw in each hole is necessary as the stress on the roof during stormy weather is extremely high. 9.5 Roof overhang along the long sides of the unit The roof plates are longer than the width of the unit to ensure sufficient overhang along the sides of the unit.
9-6 Installation of steel roof in the sizes 10 – 44 | The unit is delivered with 2 similar overhang profiles - G1 and G5 - one for each end of the roof. Mount one of the 2 roof overhang profiles – G on a trapezoidal roof plate. Use the self drilling, painted screws with sealing washers - W see the illustration. Note: Foam bands - P – are necessary between the overhang profile G1 and the roof plate F1. See the illustration.
9-7 | Installation of steel roof in the sizes 10 – 44 AHU length AL Roof length RL No. of plates AHU length AL Roof length RL No. of plates AHU length AL Roof length RL No.
Installation of steel roof in the sizes 10 – 44 | 9.9 9-8 Mount roof plates – some of them are overlapping by 2 ribs The width of each plate is always 1025 mm and some of the plates have to overlap by 2 ribs to achieve the optimal total length of the whole roof — see the illustration above. 9.
9-9 | Installation of steel roof in the sizes 10 – 44 9.12 Apply sealing on plate joints to ensure water resistance Finish installation of the steel roof by sealing all plate joints with silicone to prevent rainwater from passing into the unit. See examples below of joints to be sealed.
Installation of steel roof in the sizes 10 – 44 | output | 11 9-10
10-1 | Speed control for rotor and assembly of divided rotor Annex 10 Speed control for rotor and assembly of divided rotor 10.1 Speed control RHC 200 delivered before March 2021 The cabinet with the speed control system for the rotor is installed behind the inspection door in the rotor section.
Speed control for rotor and assembly of divided rotor | 10.1.2 10-2 Indication of operation mode via red and green LED as well as test of motor for RHC 200 delivered before March 2021 The LED is in the cover of the cabinet.
10-3 10.1.
Speed control for rotor and assembly of divided rotor | 10-4 10.2 Speed control type NOVA drive 370 delivered after February 2021 The cabinet with the speed control system for the rotor is installed behind the inspection door in the rotor section. The cabinet contains the speed controller with all components, terminal blocks, LED displaying the operation mode, the dual position DIP switches with 5 sliding levers for programming the rotor motor signal.
10-5 | Speed control for rotor and assembly of divided rotor Geniox Diameter of pulley in mm Position for DIP switches called 1, 2, 3 Motor 120TYD-S214-L 8 Nm 31 160 011 DV 190 180 011 DV 240 180 011 For ordinary operation: • DIP switch 4 must be set to — OFF. and • DIP switch 5 must be set to — OFF. 10.2.1.1 Indication of operation mode via red, yelllow and green LED on NOVA drive 370 as well as test of drive motor The LED is in the cover of the cabinet.
Speed control for rotor and assembly of divided rotor | 10-6 down and stop for another 10 seconds. The process is repeated again and again, until the DIP switch is set back to position — OFF. Change of rotation direction to enable perfect function of purge section With purge section in the air handling unit, the rotation direction of the rotary heat exchanger is important.
10-7 10.2.2 | Speed control for rotor and assembly of divided rotor The board in NOVA drive 370 for control of revolutions.
Speed control for rotor and assembly of divided rotor | 10.2.3 10-8 Information about connection of cables to terminals on the control board.
10-9 | Speed control for rotor and assembly of divided rotor 5. Turn on the device 6. You can connect using the new address specified in point 2 Modbus registers The following Modbus registers are available. All registers are either input registers (16–bit read-only denoted by R) or holding registers (16–bit read-write denoted by RW).
Speed control for rotor and assembly of divided rotor | Address Type Description FrontendVersion 0x320 — 0X333 R Frontend software version C string. BackendVersion 0x334 — 0X347 R Backend software version C string. Register 10-10 Extended SW version 10.2.5 Modbus control — Normal operation Write the speed reference in SpeedSet between 0 and 1000 (0–100%). Note that the conversion from Speed Set to rpm speed is non-linear. The reference in rpm can be read using register SpeedSetScaled.
10-11 | Speed control for rotor and assembly of divided rotor 10.4 Assemble divided rotor from Hoval 10.4.1 Tools and aids 10.4.
Speed control for rotor and assembly of divided rotor | 10.4.
10-13 | Speed control for rotor and assembly of divided rotor 10.4.4 Installation of radial walls between segments 10.4.
Speed control for rotor and assembly of divided rotor | 10.4.
10-15 10.4.
Speed control for rotor and assembly of divided rotor | 10.4.
10-17 10.4.9 | Speed control for rotor and assembly of divided rotor Installation, next periphery plate 10.4.
Speed control for rotor and assembly of divided rotor | 10.4.
10-19 | Speed control for rotor and assembly of divided rotor The next step is to mount the upper half of the Systemair unit casing consisting of 4 vertical profiles and the horizontal roof panel output | 11
Speed control for rotor and assembly of divided rotor | Final step is to mount two panels. 10.5 Assemble divided rotor from Lautner 10.5.
10-21 | Speed control for rotor and assembly of divided rotor • Phillips screwdriver • Cable retainers 10.5.2 Assembly instructions 10.5.2.1 Assemble casing Place casing top part onto casing bottom part. Observe markings. Screw casing top part to encasing bottom part. Unscrew mounting corner.
Speed control for rotor and assembly of divided rotor | 10-22 10.5.2.2 Block the rotor Caution The heat storage mass is very sensitive! Avoid high pressure, knocks, etc. The already mounted rotor part needs to be blocked by a timber beam or by timber beams before installing the next segment. 10.5.2.3 Assemble segments, circumferential panels and spacer discs During the assembly of the segments, be sure to keep track of the numbering (segments are numbered in order, see figure below.
10-23 | Speed control for rotor and assembly of divided rotor The supplied spacer discs must be placed as assembly aids between the segment foot and the rotor hub (to install the last segment). Insert the socket screws, but do not tighten yet! To each new inserted segment, also attach a circumferential panel with M10x30 socket screws. Do not forget washers. Screw in the screws only about half way.
Speed control for rotor and assembly of divided rotor | 10-24 In case the circumferential panels are made of steel and are equipped with an additional clamping device, the also loosely mount the M12x120 screws, plain washers and self-securing nuts intended for this. 10.5.2.4 Assemble the last segment When the last segment is mounted, the spacer discs are no longer needed. Integrate the last rotor circumferential panel into the rotor circumferential panel ring.
10-25 | Speed control for rotor and assembly of divided rotor 10.5.2.5 Remove spacer discs Remove the spacer discs; tighten opposite socket screws evenly, segment by segment. Always make sure the rotor can turn freely. If the mounting has been done properly, the play of the rotor should be less than 1 mm per meter rotor diameter. In rare cases, it can be necessary to even out the play by inserting the supplied strips. 10.5.2.
Speed control for rotor and assembly of divided rotor | 10-26 Tighten the rotor with the tension belt after screwing on the circumferential panels. The tension belt is laid around the rotor like the V-belt using adhesive tape. During the tightening, make sure that the mounted circumferential panels can be pulled together without a problem, loosen the M10 screws again if necessary. After the rotor has been firmly clamped, tighten the M10 socket screws firmly.
10-27 | Speed control for rotor and assembly of divided rotor Turn the rotor and place the drive belt over the V-belt pulley — shorten so that there is sufficient clamp travel at the pivoting motor base 1. Drive motor 2. V-belt pulley 3. V-belt 4. V-belt lock 5. Pivoting motor base 6. Tension spring 7. Buffer element Shorten the belt and attach V-belt lock. Caution The drive belt may not be tensioned too much. Too much tension may damage the rotor casing and the variable speed drive unit.
Speed control for rotor and assembly of divided rotor | 10-28 10.5.2.8 Mount rotation sensor Attach the holder for the rotation sensor into the rotor system encasing so that after the mounting of the rotation sensor, a gap of 5–8 mm can be made between magnet and rotation sensor. The magnet of the pulser i.e. the rotation sensor has to be screwed onto the circumference panel of the heat exchanger. Make sure that only the circumference panel of the rotor and not the accumulator is drilled into.
10-29 | Speed control for rotor and assembly of divided rotor 10.5.2.10 Mount seals Middle seal Z-plates depending on intended air flow attach either to the horizontal or the vertical middle spar with the supplied cutting screws. The middle seals should lie at close as possible, but not drag. To check the proper setting, the rotor should be turned several times carefully by hand. Fasten bearing box seals with cutting screws.
Speed control for rotor and assembly of divided rotor | 10-30 The next step is to mount the upper half of the Systemair unit casing consisting of 4 vertical profiles and the horizontal roof panel output | 11
10-31 | Speed control for rotor and assembly of divided rotor Final step is to mount two panels.
Speed control for rotor and assembly of divided rotor | 10-32 10.6 Assemble divided rotor from Klingenburg 10.6.
10-33 | Speed control for rotor and assembly of divided rotor Tighten the nuts on the threaded rod with one nut against the other to prevent any loosening from occurring. Caution The clearance between the outer rim of the hub and the segment’s steel cladding panel should be approximately 55 mm. This clearance is used as a starting point to allow all segments to be initially installed. If this clearance is lower than 55 mm, difficulties could arise with the installation of the last segment.
Speed control for rotor and assembly of divided rotor | 10-34 Fix one segment back plate with the neighbouring segment back plate by use of the two nuts and bolts supplied and tighten (2 x M12 x 16 and nuts). See illustration above. Important The steel cladding panels of each segment must be assembled so that there is no gap between one segment and the next. If this happens, the nuts on the threaded rod of that segment will have to be adjusted.
10-35 | Speed control for rotor and assembly of divided rotor Install the first outer tensioning panel and assemble the connectors. Install extra segments if included. Install the second outer tensioning panel and assemble the connectors. Install extra segments if included.
Speed control for rotor and assembly of divided rotor | 10.6.3 10-36 Adjusting the bearings As a basic principle, the bearings are already adjusted from the factory. Should the wheel be tight or uneven after assembly, the bearings may have to be readjusted. • Mark one of the segments on the outer edge. • Spin the wheel until the marking is at the lowermost point. • Measure the clearance between segment and housing frame. • Spin the wheel until the marking is at the topmost point and measure again.
10-37 | Speed control for rotor and assembly of divided rotor Check that the wheel is running correctly before the final tightening of the fixings. Important Ensure that the tensioning belts are tightened gradually and evenly. Repeat twice. • Tighten bolts until all segments sit level and even to each other with no visible irregularities or gaps. • With a plastic hammer or block of wood and a normal hammer, hammer the outer cladding panel around the entire circumference. Retighten all fixings.
Speed control for rotor and assembly of divided rotor | output | 11 10-38
10-39 | Speed control for rotor and assembly of divided rotor The next step is to mount the upper half of the Systemair unit casing consisting of 4 vertical profiles and the horizontal roof panel output | 11
Speed control for rotor and assembly of divided rotor | 10-40 Final step is to mount two panels. 10.7 Installation of motor that turns rotor and sensor for control of rotation After assembly of divided rotor drive belt between rotor and rotor motor as well as sensor for control of rotation must be installed. The rotor motor is installed by Systemair before delivery. The rotor motor is mounted on a motor console plate. Sensor for control of rotation must be installed by the installer.
10-41 | Speed control for rotor and assembly of divided rotor Check that collision between belt and bracket at the rotor is impossible. Adjust position of rotor motor if necessary. Install sensor for registration of rotation. The sensor must be installed to the right seen from the inspection side of the unit. Check that collision between sensor and brackets at the rotor is impossible. Adjust position of sensor if necessary.
Reversible heat pump unit (in separate cover, if heat pump was delivered) | 11-1 Annex 11 Reversible heat pump unit (in separate cover, if heat pump was delivered) 11.1 Geniox-HP section (reversible heat pump unit) The air handling unit section – Geniox-HP – is a separate section in the air handling unit, containing a complete standalone reversible heat pump system (heating and cooling).
12-1 | Menu for internal controller in the 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) If the air handling unit was delivered with this section, a separate manual about the heat pump was enclosed in the separate cover output | 11
Connection of fan motor and set-up manual for frequency converter | Annex 13 Connection of fan motor and set-up manual for frequency converter 13.1 Connection of fan motor Delta connection is shown to the left, and star connection is shown to the right. 13.2 Set-up for Danfoss FC101 for Geniox-units with AC motors SETUP IS DONE IN FACTORY BEFORE DELIVERY To reload Systemair factory settings from the control panel: 0-50: LCP Copy: [2] Systemair factory set-up is based on Danfoss initialization.
13-2 | Connection of fan motor and set-up manual for frequency converter 3-03: Maximum Reference: Max. Hz from order papers 3-16 + 3-17: Reference 2- and 3 Source: [0] No function 3-41 + 342: Ramp 1 up and down: 20 Sec. 4-19: Max. Output Frequency: 90Hz 4-14: Motor Speed High Limit: 90Hz 4-18: Current limit: 100 % 5-12: Terminal 27 Digital input: [0] No operation 5-40.0: Function Relay: [3] Drive ready/remote 5-40.1: Function Relay: [3] Drive ready/remote 6-25: Terminal 54 High Reference: Max.
Connection of fan motor and set-up manual for frequency converter | 0-10V: terminal 54-55 Start: terminal 12-18 Drive ready: terminal 1-2 Jumper terminal 12-27 output | 11 13-3
13-4 | Connection of fan motor and set-up manual for frequency converter 13.4 Installation ECblue 13.4.1 Connection 1. Line voltage rating plate 2. Contact rating max AC 250 V 2 A 3. External speed setting 4. Input 0...10 V 5. PWM input, f = 1...10 kHz For ECblue 3 ~ types and when connecting 1 ~ types between two outer conductors, only all-current sensitive fault current circuit breakers (type B) are allowed ( EN 50 178, Art. 5.2).
Connection of fan motor and set-up manual for frequency converter | 13-5 Residual-current-operated protective devices Terminal Function / connection L1, N, PE Mains connection for 1 ~ types (observe the line voltage indicated rating plate). Mains connection for 3 ~ types (observe the line voltage indicated rating plate). L1, L2, L3, PE 11, 14 Relay output “K1” for fault indication. 1 • For operation the relay is energized, connections “11” and “14” are bridged.
13-6 1 | Connection of fan motor and set-up manual for frequency converter LED Code Relays K1 1 Cause 14 x de-energized, 11 - 14 interrupted Error Peak current 17 x de-energized, 11 - 14 interrupted Temperature alarm K1: programmed function at factory: Fault indication not inverted output | 11
Commissioning protocol – proposal (in separate cover) | Annex 14 Commissioning protocol – proposal (in separate cover) Printed on separate pages and delivered with every unit. Enclosed in separate cover.
15-1 | Report with data from final functional test on the Systemair factory (in separate cover, if control system was delivered) Annex 15 Report with data from final functional test on the Systemair factory (in separate cover, if control system was delivered) Printed on separate pages and delivered with every unit. Enclosed in separate cover.
Short description of main components in the control system | 16-1 Annex 16 Short description of main components in the control system 16.1 Geniox units delivered in several sections This model of the Geniox unit has an integrated control system and depending on the size of the unit, the cabinet is installed in the unit, on the unit or on the front of the unit. The controller is mounted in the cabinet, and all electrical connections between cabinet and components in the unit are installed.
17-1 | Wiring diagram (in separate cover, if control system was delivered) Annex 17 Wiring diagram (in separate cover, if control system was delivered) The wiring diagram is in a separate cover output | 11
Geniox Air Handling Units — Sustainability | 18-1 Annex 18 Geniox Air Handling Units — Sustainability Weighting of criteria for DGNB sustainability certified office buildings for Systemair air handling units - type Geniox. Please be aware that the percentages below indicate the part of the criteria in the DGNB system that Systemair’s products can affect. It is not exclusively Systemair’s procucts that contribute to the 57,70%. Topic Criterium Name PRO 1.
18-2 | Geniox Air Handling Units — Sustainability Environmental Quality Economic Quality Life-Cycle Assessment — LCA It will be possible, by request, to perform Lifecycle assessment specifically for each Geniox air handling unit via Systemair Denmark internally operated software through calculating CO2 Equivalents from Ecobau with weights of material extracted accurately from the configuration software Environmental impact associated with construction products At Systemair, accountability also means
Geniox Air Handling Units — Sustainability | Sociocultural and Functional Quality Technical Quality output | 11 18-3 Thermal comfort Geniox air handling units can be built with filters, air capacity control, heating coils, cooling coils, humidifiers, attenuators, and CO2 and humidity sensors, which can all be controlled by users to meet their individual needs. Indoor air quality All materials in Geniox air handling units have been selected for use in buildings marked with the Nordic Ecolabel.
18-4 | Geniox Air Handling Units — Sustainability 18.1 Illustrations and explanations Find illustrations and explanations that support the information about sustainability of Geniox air handling units from Systemair below. 18.1.1 Photo A Plastic plate between bottom and/or tray for condensate made of stainless steel and cooling coil made of copperaluminum to avoid galvanic corrosion. 18.1.
Geniox Air Handling Units — Sustainability | 18.1.3 18-5 Photo C Panels can be demounted, because flexible sealing strips made of polyurethane do not stick to the profiles. Panels can quickly and easily be demounted by unscrewing painted and anti-corrosion protected Torx screws. 18.1.
18-6 18.1.5 | Geniox Air Handling Units — Sustainability Photo E1 When the air handling unit is scrapped, Rockwool, iron sheets and plastic lists can easily be separated for 100% recycling because the cover plate can easily be separated from the plastic list between inner and outer iron plates by overheating the cover plate along the edges. Hereby the glue will lose adhesion for easy removal of the cover plate from the plastic lists. 18.1.
Geniox Air Handling Units — Sustainability | output | 11 18-7
Systemair Unit 02 Furry Park Santry Dublin 9 Systemair A/S Ved Milepælen 7 DK-8361 Hasselager Tel.: +44 (0)121 322 0200 Tel.: +353 1 86 24 544 Tel.: +45 8738 7500 info@systemair.co.uk sales@systemair.ie mail@systemair.dk www.systemair.co.uk www.systemair.co.uk www.systemair.
