Rosenberg SupraBox COMFORT 800H User manual

BA 112 BB 11/12/A/SupraBox 1
BA112BB07/11/A/ SupraBox 1
Rosenberg Ventilatoren GmbH ·Maybachstraße 1 ·74653 Künzelsau-Gaisbach
Tel.: [phone] ·Fax.: [phone] ·Email: [e-mail] ·www.rosenberg-gmbh.com
EN
Betriebsanleitung
Operating instruction
SupraBox … H SupraBox … H
Compact ventilation units
Series SupraBox COMFORT

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
1
Index Page
1. General Safety Information ...............................................................................................2
1.1 Warnings regarding industrial safety measures ..............................................................2
1.2 Safety Instructions ..........................................................................................................3
2. Technical Manual...............................................................................................................4
2.1 General Description ........................................................................................................4
2.2 Device Overview ............................................................................................................. 5
2.3 Device drawings..............................................................................................................8
3. Operating Conditions ......................................................................................................10
4. Delivery, Transport and Storage ....................................................................................11
4.1 Delivery......................................................................................................................... 11
4.2 Transport ......................................................................................................................11
4.3 Storage .........................................................................................................................14
5. General Assembly Instructions ......................................................................................15
5.1 Unit Installation .............................................................................................................15
5.2 Assembly ......................................................................................................................15
5.3 Connection of the ventilation ducts to the unit ..............................................................16
5.4 Electric Installation ........................................................................................................ 16
5.5 Connection of the condensate, exhaust air and overflow pipes .................................... 16
6. Startup and Operation .....................................................................................................17
6.1 General Startup information..........................................................................................18
7. Maintenance and Cleaning..............................................................................................19
7.1 General Maintenance Instructions ................................................................................19
7.2 General Cleaning Instructions....................................................................................... 19
7.3 Maintenance and Cleaning of the housing and control .................................................20
7.4 Fans..............................................................................................................................21
7.4.1 Setup ...................................................................................................................... 21
7.4.2 Operation ................................................................................................................22
7.4.3 Maintenance and Cleaning .....................................................................................22
7.5 Reverse flow heat exchanger........................................................................................23
7.5.1 Startup ....................................................................................................................23
7.5.2 Operation ................................................................................................................23
7.5.3 Maintenance and Cleaning .....................................................................................24
7.6 Panel filters ...................................................................................................................24
7.6.1 Startup ....................................................................................................................24
7.6.2 Operation ................................................................................................................25
7.6.3 Maintenance and Cleaning .....................................................................................25

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
2
1. General Safety Information
1.1 Warnings regarding industrial safety measures
The following icons inform about certain hazards or safe use.
Attention! Danger! Safety Advice!
Hazard by electricity or high voltage!
Crush hazard!
Danger Overhead Hazard
Caution ! Hot Surface!
Important Advice, Information

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
3
1.2 Safety Instructions
At the time of delivery the Rosenberg SupraBox Comfort series is constructed and
produced according to the latest technical standard. Substantial tests of material,
function and quality guarantee a high value and a long lifetime. When improperly
used by untrained staff or not according to the instructions these machines can be
dangerous.
Read these instructions carefully prior to unpacking, assembling or performing the
maintenance!
The system may only be used after installation
•The following work must only be performed by trained specialists:
- Assembly
- Electrical connection
- Connection of power terminals
- Maintenance work
•Please use the compact ventilation appliance only according to the regulations within the
prescribed power limit. The power limit is included in the technical data specification or can be
found on the name plate. One single instance of the prescribed power limit being exceeded
will inevitably cause damage to the built-in components which results in the safe use of the
appliance being compromised.
•Only approved material handling equipment may be used. Please consult your local
institutions or relevant regulations for the appropriate range.
•Prior to working on electric machines these have to be disconnected from all poles
(padlockable selector switches with appropriate capacity and function are included in the
delivery and pre-installed).
•After completion of work on the RLT-appliance the responsible person must make sure that
nobody is working on the installation before it is re-started.
•Authorized persons must be instructed in the working area according to the normal accident
prevention regulations of the relevant Employer’s Liability Insurance Associations and be trained
in their working area.
See also:
BGV A1 „General Prescriptions“
VBG 5 „Power-driven working equipment“
VBG 9a „Load bearing equipment for hoisting operations“
BGV D27 „Industrial trucks“
BGV A3 „Electrical systems and equipment“

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
4
2. Technical Manual
2.1 General Description
•According to the EC Machinery Directive stationery ventilation appliances have to be
electrically connected to a breaker and a series fuse. It must be possible to disconnect the unit
from all poles!
•The unit corresponds to the requirements of VDI 6022 as well as DIN 1946 T6.
•Depending on the size of the installation the range of application extends to power volume of
3500 m³/h with a transport density of 1,3kg/m³.
•The application area includes air treatments: filtration, heating, cooling and moving. In addition
heat recovery with high efficiency is used.
•Energy-efficient compact ventilation unit. Heat recovery through an aluminium reverse flow
recuperator with very high efficiency. It can be easily cleaned and for flushing equipped with
pans with gradient all around.
•The unit is mounted on a base frame with four adjustable feet, for balancing uneven bottoms,
as well as for the outside installation. Adjustment range: 45 – 70 mm
•The compact housing consists of corrosion-resistant, double skin, coil coated, galvanised
sheet steel. Quality: DX51D + zinc 275 + additional org. coating min. 25 µm RAL 7035; metal
gauge 1.00 mm.
•Side wall panels, housing bottom, housing cover, rear panel and doors (with double-skin) are
equipped with 60 mm internal acoustic and heat insulation (min. 33 kg/m³;λ= 0,04 W/m x K).
•The direct drive fans with backward curved centrifugal impellers are installed in the unit with
vibration absorption. The drive will be effected by two energy-saving and 100% infinitely
variable EC motors.
•Filtration of external air F7 and exit air M5 through particulate panel filters.
•The ventilation unit will be delivered with integrated control. This is easy to maintain and
installed in a terminal box on the cover. It is completely wired and tested by the manufacturer.
•The unit is clearly labelled with symbols and text for easy operation. An external controller for
the managing the whole system is included in the scope of delivery.

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
5
2.2 Device Overview
SupraBox Comfort 800H 1100H 1500H 2000H
Housing Doubleskin 60 mm
frameless
Doubleskin 60 mm
frameless
Doubleskin 60 mm
frameless
Doubleskin 60 mm
frameless
Size
(L x W x H) [mm]
1330 x 640 x 1220
Incl. Regulation box
and adjustable feet
1500 x 660 x 1420
Incl. Regulation
box and adjustable
feet
1670 x 700 x 1520
Incl. Regulation
box and
adjustable feet
1800 x 760 x 1660
Incl. Regulation
box and
adjustable feet
Operating point 800 m³/h at
150 Pa
1100 m³/h at
200 Pa
1500 m³/h at
200 Pa
2000 m³/h at
250 Pa
Fans Backwards curved, free running, driven by highly efficient Rosenberg – EC-external-
rotor motors with integrated electronics
Power Input in the
operating point 2 x 200 W 2 x 310 W 2 x 470 W 2 x 800 W
SFP-Value
In the operating point 900 Ws/m³ 1015 Ws/m³ 1128 Ws/m³ 1440 Ws/m³
SFP class
in the operating point SFP2 SFP2 SFP3 SFP3
Heat recovery
Efficiency
Reverse flow- plate heat exchanger up to η=92%*, corresponding to WRG-classes
H1
*Maximum value on condensation, heat recovery dependant on the operation
condition
Air filter Panel filter Incoming air: F7 Extracted air: M5
Air Supplies
horizontal
DN 315
2,9 m/s
horizontal
DN 355
3,1 m/s
horizontal
DN 400
3,3 m/s
horizontal
DN 400
4,4 m/s
Control *Temperature
control
*Temperature
control
*Temperature
control
*Temperature
control
Max. total current
consumption 3 A 4 A 6 A 9 A
Overall sound
power level
Suction side L
WA5
Pressure side L
WA6
Housing L
WA2
51 dB(A)
69 dB(A)
49 dB(A)
52 dB(A)
76 dB(A)
54 dB(A)
55 dB(A)
79 dB(A)
56 dB(A)
56 dB(A)
79 dB(A)
54 dB(A)
Weight incl. Control 215 kg 260 kg 298 kg 377 kg
*Temperature control with control of the optional accessories according to the unit size and
equipment.

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
6
SupraBox Comfort 3500 H
Housing Doubleskin 60 mm
frameless
Size
(L x W x H) [mm]
2320 x 840 x 1925
Incl. Regulation
box and adjustable
feet
Operating point 3500 m³/h at
400 Pa
Fans Backwards curved, free running, driven by highly efficient Rosenberg – EC-external-
rotor motors with integrated electronics
Power Input in the
operating point 2 x 1600 W
SFP-Value
In the operating point 1645 Ws/m³
SFP class
in the operating point SFP4
Heat recovery
Efficiency
Reverse flow- plate heat exchanger up to η=92%*, corresponding to WRG-classes
H1
*Maximum value on condensation, heat recovery dependant on the operation
condition
Air filter Panel filter Incoming air: F7 Extracted air: M5
Air Supplies horizontal
600 x 600 [mm]
Control *Temperature
control
Max. total current
consumption 5,0 A
Overall sound
power level
Suction side L
WA5
Pressure side L
WA6
Housing L
WA2
61 dB(A)
85 dB(A)
57 dB(A)
Weight incl. Control 530 kg
*Temperature control with control of the optional accessories according to the unit size and
equipment.

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
7
1 Panel filter exhaust air M5 7 Condensate pan
2 Panel filter incoming air F7 8 Exhaust fan with EC-motor
3 Adjustable rounded base 9 Incoming air fan with EC-motor
4 Bypass flap 10 Control box incl. control system
5 Maintenance pan 11 Main breaker
6 Reverse flow heat exchanger
Inc. air
Exhaust
air
Ext. air
Exh. air
1
2
10
9
8
6
4
3
5
7
11
Picture: drawing of the device overview

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
8
2.3 Device drawings
Suprabox 800 H
•Condensate drain through the hose sleeve 19,4 x 3,7
Suprabox 1100 H
•Condensate drain through the hose sleeve 19,4 x 3,7

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
9
Suprabox 1500 H
•A hose with appropriate hose sleeve is recommended for the condensate drain 19,4 x 3,7
Suprabox 2000 H
•Condensate drain through the hose sleeve 19,4 x 3,7

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
10
SupraBox 3500 H
•Condensate drain through the hose sleeve 19,4 x 3,7
3. Operating Conditions
The Rosenberg compact series SupraBox Comfort is exclusively made for treating air
or gaseous media according to the criteria stated below!
The compact ventilation appliancet is suitable for the conveyance of:
•Clean air, low dust or low greasy air
•Slightly aggressive gases or fumes (consult the factory in either case!)
•Gaseous media up to a density of 1.3 kg/m³
•Gaseous media up to a relative humidity of max. 95 %
•Gaseous media in a temperature range of -16 °C up to +40 °C. (higher or lower ranges require
special modifications!)
•Non-explosive gaseous media

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
11
H
W
L
Picture: Transport sizes Suprabox
4. Delivery, Transport and Storage
4.1 Delivery
The Rosenberg-Suprabox must be checked for damages immediately on delivery.
This should be made before unloading the device from the transport vehicle.
Furthermore the completeness of the delivery scope must be checked in accordance
with the freight documents. Missing parts or damages must be noted immediately on
the freight documents and signed by the driver of the transport vehicle.
4.2 Transport
The unit will be delivered on a customized single use pallet and can be moved with a forklift or a pallet
truck. The transport dimensions (incl. control box) and weights can be found on the drawing below:
Suprabox L W H Weight
800 H 1700 mm 750 mm 1445 mm 245 kg
1100 H 1700 mm 750 mm 1645 mm 290 kg
1500 H 2000 mm 850 mm 1745 mm 335 kg
2000 H 2000 mm 850 mm 1885 mm 415 kg
3500 H 2400 mm 950 mm 2150 mm 570 kg

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
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Avoid twisting, bending or other physical damages of the housing when hoisting
the device!
•Keep the control doors closed during transport!
•Always use proper hoisting machines!
•Please note that excessive loads on the housing may cause damages!
•For your own safety use appropriate anti-slip gloves and safety shoes for the transport.
For the transport with forklift or pallet truck please note the following
instructions:
•The transport with industrial trucks requires regular training of the
responsible staff according to the accident prevention regulation (in
Germany BGV D27 „Flurförderfahrzeuge“).
•The loading capacity of the material handling equipment must always be
checked before loading!
•The fork length of the material handling equipment must be greater than the length of the
transport pallet to be picked up. Forks which are too short cause damage to the floor panels or
the device frame.
For the transport with a hall crane or a truck crane please note the following instructions:
•The transport with cranes or lifting fixation devices requires regular
training of the responsible person according to the accident prevention
regulation (in Germany VBG 9a „Lastaufnahmeeinrichtungen im
Hebezeugbetrieb“)
•Danger Overhead hazard! It is forbidden to stay below floating loads!
•For direct load attachment (underdragging the load) only use exclusively licensed, undamaged
fabric slings with sufficient contact surface and edge protection. (e.g.: webbing slings
according to EN1492-1 or round slings according to EN1492-2)
Picture: Unloading by forklift

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
13
Heavy load
Low load
Picture: load distribution
•It is forbidden to use chain slings or slinging ropes for the direct load attachment!
•The slings should not have an inclination angle of more than 60°!
•Please note that when lifting the functional part the distribution is usually out of balance! This
is not visible from outside of the functional part!
•Only use carrying devices with the same length.
•Make careful and none jolting movements.
•Avoid setting the load down hard and bumping
Inclination angle
greater than 60°
Inclination angle
smaller than 60°
Picture: Transport by crane

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
14
4.3 Storage
• Make sure to store the unit in a dry and weather protected area!
•On receipt of the merchandise the packaging, film and tape must
immediately be removed in order to avoid condensation water!
•Open pallets must be covered by tarps. Protect the functional parts against
pollution (e.g. chips, stones, wires etc.).
•Also the weatherproof functional parts must be covered, as the weather resistance can only be
guaranteed after the installation.
•Keep the storage temperature between -20°C und +40°C, avoid high humidity.
•If storing the unit for more than 12 months make sure the fan turns freely before installation.
.
► Manual rotation of the fan

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
15
5. General Assembly Instructions
5.1 Unit Installation
The Rosenberg-SupraBox Comfort must exclusively be installed on a foundation or
a substructure which is professionally constructed..
Assumption of static or dynamic building functions by Rosenberg-devices must be
excluded. Otherwise the warranty by Rosenberg Ventilatoren GmbH will expire for
damages to the device or resulting damages to the building.
Installation and assembly may only be made by trained staff, familiar with the specific accident
prevention regulations and general safety-related and occupational health laws.
In addition to the structural requirements also consider the following instructions for the construction
of the foundation or substructure:
•The installation area must be level and without torsion.
•The horizontal inclination angle of the installation area may not exceed a maximum of 2%.
•Choose an installation space with an unobstructed condensate drain and water trap, as well
as sufficient gradient of the condensate line.
•The height level between installation area and floor must guarantee a professional condensate
drain from the functional parts.
►Consider the height of the waste trap!
Even out slight area unevenness by assembled rounded bases.
In order to ensure low noise operation, consider the following advice:
•Low air velocity in the duct
•Do not install the device on a wooden ground
•Use a vibration resistant substructure
5.2 Assembly
Get an overview of the quantity and description of all functional parts with help of the
enclosed technical documents. Under item 2.2 “device overview” or “item 2.3 device
drawings” respectively there is a detailed drawing with all relevant dimensions.
For the installation room or installation area of the SupraBox, make sure that there
is sufficient space for operating and maintaining the unit. Permanent access must
be guaranteed.
The compact ventilation appliance will be completely wired for plug-in and tested by the manufacturer.
It is equipped with an integrated control system.

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
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Only the connections for the ventilation ducts, condensate and water must properly installed on site.
Furthermore the electrical supply as well as external sensors or optional accessories such as duct
heaters etc. must be connected.
The remote operator control must be connected to the control system using the provided cable and
placed at the ventilation system or nearby. The electrical connection has to be made according to the
wiring diagram, see the additional operating manual control for the control system.
5.3 Connection of the ventilation ducts to the unit
The connection sleeves of the Rosenberg-SupraBox Comfort are provided as circular
tube spigots, with T-sealing lip sizes as shown in the unit drawings. The duct system
must be installed according to the valid technical standards and regulations and must
support the dead load by installations of the customer. Additional requirements
concerning sound insulation separate vibration isolation can be provided as elastic
connections. These are not standard in the scope of delivery, but offered as
accessories. The fresh air and exhaust air duct must be isolated against condensate water.
5.4 Electric Installation
Only a professional electrician may install the electrical connection according to the
VDE-regulations. The connection must properly be made according to the wiring
diagram and the configuration scheme.
All screw joints must be checked before Setup and retightened if necessary. Further
installation instructions can be found on the separate manual of the control.
5.5 Connection of the condensate, exhaust air and overflow pipes
The Suprabox is equipped with maintenance and condensate pan. As you can see in the device
overview, the maintenance pan is situated in the fresh air and the condensate pan in the exhaust air.
Both pans have a flexible tube at the bottom side of the unit with an inner diameter of 19.4 mm. Do
never remove them and check the correct seating before the unit is assembled.
The exhaust air pipe of the maintenance pan is only used for cleaning. Therefore it is necessary to
seal the tube of the maintenance pan by appropriate material (e.g. tape) in order to avoid a volume
flow leakage in this area.
Especially in the cold seasons there could be condensate in the exhaust air duct of the reverse flow
heat exchanger. In order to make sure the condensate drains correctly via the condensate pan and to
avoid air leakage, it is important to attach a vacuum trap as shown in the drawing below. Alternatively
a hose can be fixed at the unit to replace a trap. The minimum sizes must be observed by the
customer. Fill the trap with water before startup. Protect the trap against desiccation and in cold

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
17
areas against frost. Do not connect the spout to the sewage system. Alternatively a vacuum trap with
non-return ball can be used, but make sure that there is a suction lift of at least 70 mm.
Picture:: Minimum size trap
Devuce connectionb

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
18
6. Startup and Operation
6.1 General Startup information
Prior to the startup of the compact ventilation unit observe the instructions below:
•Inspection of the proper installation, connection and assembly
•Free air connection, free suction holes
•Free running of the fan wheels
•Closed valves at the heat exchanger units
•Check the screw joints of all connections
•Unlock the electric duct heater only after the fan
•Remove a possible protective film
•Optical inspection of the unit gaskets for damage
•Re-adjust the hinges of the maintenance doors
•Close all doors
•Operational check of the fans
•Pressure control of the reverse flow heat exchanger must be set according to the operating
point of the unit.
►ATTENTION: If above the above instructions are not followed, dangerous
conditions may occur on startup of the unit, which affect the functionality and
safety of the unit.
►ATTENTION: Before stopping the unit de-energize it and remove water of
optional heaters to avoid freezing.
Further information for the startup of the units can be found in the corresponding component
specification beginning with 7.4. The instruction manual of the control system must absolutely be
observed!

Operation and Maintenance Manual for Rosenberg
Compact Ventilation Appliance series SupraBox
Comfort
BA 112 BB 11/12/A/SupraBox 1
19
7. Maintenance and Cleaning
7.1 General Maintenance Instructions
The maintenance interval indicated in this manual refers to the transport of normally
polluted air. If the unit must transport strongly polluted air, the maintenance intervals
must be reduced accordingly.
► Before any maintenance work is started the unit must be stopped properly and all
poles disconnected from the mains.
Proceed in the following order:
1. Stop the unit with using the remote operator. Activated full automatic weekly
programs have to be deactivated first.
2. Wait 2 minutes until the optional louver damper is closed and the fans have
stopped.
3. Now turn the operating switch to ZERO (Off) and make sure that it will not be
switched on unintentionally. This step disconnects the compact unit from the
mains with all poles. Be aware that the control box will still be hot. For
maintenance at the control box the connection must be interrupted.
4. Wait for the residual voltage to decrease at the EC-control as
indicated in the instruction manual of those components.
5. Let the heater cool down.
6. Now you can open the maintenance doors.
Pay attention that at optionally used channel-type heat exchangers the water circulation must be
protected against re-starting.
7.2 General Cleaning Instructions
Recommended cleaning agents for surface disinfection are:
•Dismozon pur (Bode Chemie)
•Melsitt (B.Braun)
•Antifect (Schülke & Mayr)
•Clorina (Lysoform)
All disinfectants are recognized and licensed by Robert-Koch-Institute (date 31.05.2007, 15. edition)
To ensure the hygienically perfect condition of the unit the following instructions must be observed:
•Only qualified and trained staff should clean the unit (in Germany according to VDI 6022).