Rosenberg SupraBox COMFORT Series User manual

BA 114 AA 03/12/A/SupraBox 1
BA113BB03/12/A/ SupraBox 1
Rosenberg Ventilatoren GmbH ·Maybachstraße 1 ·74653 Künzelsau-Gaisbach
Tel.: [phone] ·Fax.: [phone] ·Email: [e-mail] ·www.rosenberg-gmbh.com
EN
Bet
riebsanleitung
Operating instruction
SupraBox … V
Compact ventilation units
Series SupraBox COMFORT

Operation and Maintenance Manual for Rosenberg
Compact Ventilation appliance series SupraBox
Comfort
BA 114 AA 03/12/A/SupraBox 1
1
Index Page
1. General Safety Instructions ..............................................................................................2
1.1 Warnings regarding Health and Safety ...........................................................................2
1.2 Safety Instructions ..........................................................................................................3
2. Technical Manual...............................................................................................................4
2.1 General Description ........................................................................................................4
2.2 Device overview..............................................................................................................4
2.3 Drawings.........................................................................................................................7
3. Operating Conditions ........................................................................................................8
4. Delivery, Transport and Storage ....................................................................................10
4.1 Delivery.........................................................................................................................10
4.2 Transport ......................................................................................................................10
4.3 Storage .........................................................................................................................13
5. General Installation Instruction ......................................................................................14
5.1 Installation of the device ............................................................................................... 14
5.2 Assembly ......................................................................................................................14
5.3 Connection of the ventilation ducts to the unit .............................................................. 15
5.4 Electric Installation ........................................................................................................15
5.5 Connection of the condensate, exhaust air and overflow pipes ....................................15
6. Initial Setup and Operation .............................................................................................17
6.1 General Information for the Initial Setup .......................................................................17
7. Maintenance and Cleaning..............................................................................................18
7.1 General Maintenance Instructions ................................................................................18
7.2 General Cleaning Instructions....................................................................................... 18
7.3 Maintenance and Cleaning of the housing and the controls .........................................19
7.4 Fans.............................................................................................................................. 20
7.4.1 Setup ......................................................................................................................20
7.4.2 Use .........................................................................................................................21
7.4.3 Maintenance and Cleaning .....................................................................................21
7.5 Reverse flow heat exchanger .......................................................................................22
7.5.1 Setup ......................................................................................................................22
7.5.2 Use .........................................................................................................................22
7.5.3 Maintenance and Cleaning .....................................................................................23
7.6 Panel filter.....................................................................................................................23
7.6.1 Setup ......................................................................................................................23
7.6.2 Use .........................................................................................................................24
7.6.3 Maintenance and Cleaning .....................................................................................24

Operation and Maintenance Manual for Rosenberg
Compact Ventilation appliance series SupraBox
Comfort
BA 114 AA 03/12/A/SupraBox 1
2
1. General Safety Instructions
1.1 Warnings regarding health and safety
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 114 AA 03/12/A/SupraBox 1
3
1.2 Safety Instruction
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
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 plates. 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 at the RLT-device the responsible person must ensure that nobody is
working on the installation before it is re-started.
•Authorized persons must be instructed according to the normal accident prevention
regulations of the corresponding E mpleyer’s Liability Insurance Associations and be trained in
their working area :
•BGV A1 „General Instructions“
VBG 5 „Power-driven work equipment“
VBG 9a „Load bearing equipment for hoist operations“
BGV D27 „Industrial trucks“
BGV A3 „Electrical systems and equipment“

Operation and Maintenance Manual for Rosenberg
Compact Ventilation appliance series SupraBox
Comfort
BA 114 AA 03/12/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 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 a power volume of
2000 m³/h with a flow medium density of 1,3kg/m³.
•The application area includes the air treatments: filtration, heating, cooling and moving. In
addition a 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 dismantled for cleaning and condensate will be
dissipated in a condensate pan with gradient all around.
•Unit is installed 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 inside with 60 mm 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 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 behind the big maintenance door (at the left) .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
managing the whole system is included.

Operation and Maintenance Manual for Rosenberg
Compact Ventilation appliance series SupraBox
Comfort
BA 114 AA 03/12/A/SupraBox 1
5
2.2 Device Overview
SupraBox Comfort 800V 1100V 1500V 2000V
Housing Double-skin 60 mm
frameless
Double-skin 60 mm
frameless
Double-skin 60
mm frameless
Double-skin 60
mm frameless
Size
(L x W x H) [mm]
1470 x 600 x 1202
Incl. unions and
adjustable feet
1740 x 630 x 1282
Incl. unions and
adjustable feet
1980 x 710 x 1422
Incl. unions and
adjustable feet
2220 x 770 x 1567
Incl. unions 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 Backward curved, free running, driven by highly-efficient – EC-external-rotor motors
with integrated electronics
Power Input in the
operating point 2 x 225 W 2 x 320 W 2 x 475 W 2 x 780 W
SFP-Value in the
operating point 1013 Ws/m³ 1047 Ws/m³ 1140 Ws/m³ 1404 Ws/m³
SFP class in the l
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 operating
condition
Air filter
Panel filter with plastic frames Incoming air: F7 Extracted air: M5
328 x 478 x 96
[mm]
398 x 508 x 96
[mm]
468 x 548 x 96
[mm]
538 x 608 x 96
[mm]
Air supplies vertical
DN 250
vertical
DN 315
vertical
DN 355
vertical
DN 400
Max. total current
consumption 3 A 3,7 A 5,6 A 9,5 A
Overall sound power
level
Suction side L
WA5
Pressure side L
WA6
Housing L
WA2
52 dB(A)
72 dB(A)
49 dB(A)
52 dB(A)
76 dB(A)
54 dB(A)
55 dB(A)
77 dB(A)
52 dB(A)
56 dB(A)
80 dB(A)
56 dB(A)
Weight incl.Control 209 kg 253 kg 315 kg 430 kg
*Temperature control with control of optional accessories dependant on unit size and equipment

Operation and Maintenance Manual for Rosenberg
Compact Ventilation appliance series SupraBox
Comfort
BA 114 AA 03/12/A/SupraBox 1
6
1 Panel filter exhaust air M5 7 Condensate pan
2 Panel filter incoming air F7 8 Exhaust air with EC-Motor
3 Adjustable rounded base 9 Supply fan with EC-Motor
4 Bypass flap 10 Control box
5 Maintenance pan 11 Main breaker
6 Reverse flow heat exchanger
Incoming
air
Exit
air
Inc.
air
Exhaust
air
2
8
10
1
9
6
7
3
4
5
11
Picture: device drawing
Geräteübersichtszeichnung

Operation and Maintenance Manual for Rosenberg
Compact Ventilation appliance series SupraBox
Comfort
BA 114 AA 03/12/A/SupraBox 1
7
2.3 Device drawings
Suprabox 800 V
Suprabox 1100 V

Operation and Maintenance Manual for Rosenberg
Compact Ventilation appliance series SupraBox
Comfort
BA 114 AA 03/12/A/SupraBox 1
8
Suprabox 1500 V
Suprabox 2000 V

Operation and Maintenance Manual for Rosenberg
Compact Ventilation appliance series SupraBox
Comfort
BA 114 AA 03/12/A/SupraBox 1
9
3. Operating conditions
The Rosenberg compact appliance series SupraBox Comfort is exclusively made for
treating air or gaseous media to the criteria below!
The compact ventilation appliance 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 1,3kg/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 114 AA 03/12/A/SupraBox 1
10
H
B
L
Picture: Transport Dimensions
Suprabox
4. Delivery, Transport and Storage
4.1 Delivery
Rosenberg-Supraboxes 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 scope of delivery must be checked in accordance with the
freight documents. Missing parts or damages must be noted 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 V 1700 mm 750 mm 1427 mm 238 kg
1100 V 2000 mm 850 mm 1505 mm 287 kg
1500 V 2400 mm 850 mm 1645 mm 355 kg
2000 V 2400 mm 850 mm 1790 mm 470 kg

Operation and Maintenance Manual for Rosenberg
Compact Ventilation appliance series SupraBox
Comfort
BA 114 AA 03/12/A/SupraBox 1
11
Avoid twisting, bending or physical damages of the housing when hoisting the
device!
•Keep the control doors closed during the transport!
•Always use proper hoisting machines for the transport!
•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!
Picture Unloading by forklift

Operation and Maintenance Manual for Rosenberg
Compact Ventilation appliance series SupraBox
Comfort
BA 114 AA 03/12/A/SupraBox 1
12
Heavy load
Low load
Picture: load distribution
•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)
•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 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
Wrong!
Right !

Operation and Maintenance Manual for Rosenberg
Compact Ventilation appliance series SupraBox
Comfort
BA 114 AA 03/12/A/SupraBox 1
13
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 114 AA 03/12/A/SupraBox 1
14
5.General Assembly Instructions
5.1 Installation of the unit
The Rosenberg-SupraBox Comfort must exclusively be installed on an foundation
or appropriate substructure which is professionally constructed for this specific use.
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 consider the following instructions for the construction of the
foundation or substructure:
•The installation area must be plain and non-twisted.
•The horizontal inclination angle of the installation area may not exceed a max. of 2% .
Choose an installation space with an unobstructed condensate drain and water trap, as well as a
sufficient gradient of the condensate line.
•The height level between installation space and bottom must guarantee a professional
condensate drain from the functional parts.
►Consider the height of the waste trap!
Even out slight space unevenness by assembled rounded bases.
In order to ensure a 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 identification of all functional parts with help of
the enclosed technical documents. Under item 2.2 device overview or item 2.3
device drawings there is a detailed drawing with all relevant dimensions.
For an installation of the SupraBox there must be sufficient distance between the
operator side and the space limit for maintenance and revision. Permanent access
must be guaranteed.
The compact air conditioning units are completely plug-in wired and checked by the manufacturer.
They are equipped with an integrated control.

Operation and Maintenance Manual for Rosenberg
Compact Ventilation appliance series SupraBox
Comfort
BA 114 AA 03/12/A/SupraBox 1
15
Only the ventilation ducts, condensate and water connections must be properly installed by the
customer. 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 using the provided cable and placed at
any place at the ventilation unit or nearby. The electric connection must be made according to the
wiring diagram, see separate manual control
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 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 can be met by separate vibration isolation with elastic
connections. These are usually not included in delivery, but can be provided as
additional equipment. The fresh air and exhaust air duct must be isolated against condensate water.
5.4 Electric Installation
The electric connection must exclusively be made by a licensed electrician according
to the VDE-regulations. The connection must be made exactly according to the wire
diagram and the face plan
Check all screw joints before startup of the unit and if necessary retighten them.
Further installation information can be found in the separate operating manual of the
control system.
5.5 Connection of the condensate, exhaust air and overflow pipes
The Suprabox is equipped with a maintenance and condensate pan. As shown in the device
overview, the maintenance pan is placed in the incoming air duct and the condensate pan in the
exhaust air duct. Both pans have a flexible tube at the bottom side of the device with an internal
diameter of 19.4 mm. Do never dismantle them and check their correct fitting before the unit is
installed.
The exhaust air drain of the maintenance pan is only used for cleaning. Therefore it is necessary to
seal the tube of the maintenance pan with proper material (e.g. tape) in order to avoid air leakage in
this area.
Especially in the cold seasons there could be condensate in the exhaust air duct of the reverse heat
exchanger. In order to make sure the condensate drains correctly via the condensate pan and to
avoid leakage air, it is important to attach a vacuum 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 areas against frost.

Operation and Maintenance Manual for Rosenberg
Compact Ventilation appliance series SupraBox
Comfort
BA 114 AA 03/12/A/SupraBox 1
16
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 114 AA 03/12/A/SupraBox 1
17
6. Initial Setup and Operation
6.1 General Information for the Setup
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 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 114 AA 03/12/A/SupraBox 1
18
7. Maintenance and Cleaning
7.1 General Maintenance Instructions
The maintenance interval indicted in this manual basically refers to the transport of
normal 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 louvered 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 is 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.

Operation and Maintenance Manual for Rosenberg
Compact Ventilation appliance series SupraBox
Comfort
BA 114 AA 03/12/A/SupraBox 1
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•The hygiene inspection at the unit has to be made according to the following intervals:
- after startup
- every 3 years (devices without moisturization)
•The periodical hygiene inspection is necessary to reveal hygiene deficiencies at an early stage
and to rectify them with appropriate action.
•The results of the inspection of the hygienic condition, the cleaning and disinfection have to be
documented in the appropriate way (e.g. operations diary).
•The relevant regulation for the hygienic requirements of the RLT-units is VDI 6022. It is the
guideline for the current instructions. All work has to be carried out according to the latest
version of the VDI guideline.
Please find instructions for the cleaning and hygiene inspection of each functional part of the device
below.
7.3 Maintenance and Cleaning of the housing and control
Please keep to the following instructions for the regular maintenance work (quarterly
intervals:
•Check the seals of the operation doors and replace them if necessary
•Check the function of the double guide at the fan (discharge side)
•Check the panels for damages and corrosion
•Flexible parts, such as hinges, should be treated with an appropriate lubricant spray
•Remove severe loose dirt with a vacuum cleaner
•Remove other dirt with a moist cloth
•The water or cleaning agent should have a neutral ph-value (6-8)
Maintenance of the control and terminal boxes
(only by an electrician)
Every
3 months
If
necessary
Hygiene
inspection
Check the electrical equipment, cables and connections for dirt
and apparent damages and replace them if necessary X
Dry cleaning of the control, do not use water X