System air Geniox Series User manual

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Part number of this manual 90925500
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Geniox
Air handling unit
User Manual GB

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Detailed table of contents on the following pages
General description
A Manufacturer
B Name of machines
C Declaration of Conformity - example
D General descriptions, dangers and warnings
E Drawings, diagrams, guides and instructions for the use, maintenance and repair
F Employees in charge of operation/control/maintenance
G Intended use and range of applications
H Unintended use and misuse – inappropriate applications for the machine
Installation
I Instructions for unloading on the site as well as installation and connection
J Installation and assembly instructions for reduction of noise and vibration emissions
Start-up, adjustments and operation
K Start-up, adjustments, use, commissioning and unit in hipernation
L Information about the residual risks
M Instructions on the protective measures during repair and maintenance
N The essential characteristics of tools which may be fitted to the machinery
Machine stability
O The conditions of stability during use, transportation, assembly, dismantling when out of service
P Instructions for machinery where these are regularly to be transported
Breakdown
Q The operating method to be followed in the event of breakdown. Safe restart.
Maintenance
R Adjustment and maintenance operations
S Instructions to enable adjustment and maintenance safely
T The specifications of the spare parts to be used, when these affect the health and safety of operators
Noise
U Information on airborne noise emissions exceeding 70 dB(A)
Annexes
1 Declaration of conformity with production number (in separate cover)
2 Technical data – unique data for every unit (in separate cover)
3 Spare part list (in separate cover)
4 Assembly of base frame – height 118 mm for unit sizes 10 – 18
5 Assembly of base frame – height 118 mm for unit sizes 20 – 31
6 Assembly of base frame – height 218 mm for unit sizes 10 – 18
7 Assembly of base frame – height 218 mm for unit sizes 20 – 31
8 Installation of steel roof in the sizes 10 – 31
9 Speed control for rotor and assembly of divided rotor
10 Reversible heat pump unit (in separate cover, if heat pump was delivered)
11 Menu for internal controller in the heat pump unit (in separate cover, if heat pump was delivered)
12 Connection of fan motor and set-up manual for frequency converter
13 Commissioning protocol – proposal (in separate cover)
14 Report with data from final functional test on the Systemair factory (in separate cover, if control system was
delivered)
15 Short description of main components in the control system
16 Wiring diagram (in separate cover, if control system was delivered)
17 Operator’s guide (how to use the Systemair control panel) (in separate cover, if control system was delivered)

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Contents
A Manufacturer....................................................................................................................................1
B Name of machines.............................................................................................................................1
C Declaration of Conformity - example ......................................................................................................2
D General descriptions, dangers and warnings ............................................................................................3
D.1 Overview via pictograms on the inspection side of the unit...............................................................3
D.1.1 Where are pictograms placed on the units.........................................................................3
D.1.2 Weight of each section and production number – example for the Geniox unit...........................4
D.1.3 CE label — example for the Geniox unit ............................................................................4
D.1.4 Pictograms for all available functions in the units ...............................................................5
D.1.5 Pictograms about warnings and dangers on the units ..........................................................6
D.2 Data about the unit according to cards and labels in and on the unit ....................................................6
D.2.1 Machine card with unique data on every unit.....................................................................6
D.2.2 Label with data about the cabinet — example.....................................................................7
D.2.3 Flowchart – example of the label placed on or with the cabinet ..............................................7
D.2.4 Symbols in the flowchart and explanation about the symbols ................................................8
D.2.5 Example of label placed on or with the cabinet – Terminal plan for external components .............9
D.3 Hand terminal ........................................................................................................................9
D.4 Dimensions of the units ............................................................................................................9
D.5 Ordinary automatically operation – only manual operation by new parameters.................................... 10
D.6 Warnings about dangers .........................................................................................................10
E Drawings, diagrams, guides and instructions for the use, maintenance and repair........................................... 10
F Employees in charge of operation/control/maintenance .......................................................................... 10
G Intended use and range of applications................................................................................................. 10
H Unintended use and misuse – inappropriate applications for the machine ..................................................... 11
H.1 Air handling unit in operation ................................................................................................... 11
I Instructions for unloading on the site as well as installation and connection ................................................... 11
I.1 Unloading on the site..............................................................................................................11
I.1.1 Unloading by fork-lift truck .......................................................................................... 11
I.1.2 Unloading by crane ....................................................................................................12
I.1.3 Transport of unit without base frame on the site............................................................... 12
I.1.4 Lifting a unit with straps.............................................................................................. 12
I.1.5 Lifting a unit with preinstalled brackets on the base frame for lifting...................................... 12
I.1.6 Lifting a unit without base frame and legs but with preinstalled brackets for lifting. .................. 12
I.1.7 Roof unit with PVC roof............................................................................................... 14
I.1.8 Roof unit with steel roof ............................................................................................. 15
I.1.9 Pre-assembly storage................................................................................................. 15
I.1.10 Tilt less than 30˚ during transportation of the section with heat pump ................................... 15
I.1.11 Transport of rotary heat exchanger — always in vertical position.......................................... 15
I.2 Installation - mechanical ......................................................................................................... 15
I.2.1 Free area in front of and above the unit .......................................................................... 15
I.2.2 Supporting surface.....................................................................................................16
I.2.3 Adjustable feet under legs or base frame and transport of sections....................................... 16
I.2.4 Base frame assembly .................................................................................................16
I.2.5 Base frames for outdoor units ...................................................................................... 16
I.2.6 Outdoor units — support under the base frame of the unit .................................................. 16
I.2.7 Installation on the site of unit sections at the base frame when sections are delivered on
pallets.....................................................................................................................17
I.2.8 Joining the AHU sections ............................................................................................. 20
I.2.9 Fitting the ductwork...................................................................................................22
I.2.10 Risk of stack effect by vertical ducts and wind pressure on louvers ....................................... 23
I.2.11 Remove transport brackets – when spring mounts are installed............................................ 23
I.2.12 Refitting of guards.....................................................................................................24
I.2.13 Lock the doors by using the key.................................................................................... 25
I.3 Installation - electrical ............................................................................................................25
I.3.1 Description...............................................................................................................25
I.3.2 Wiring diagrams........................................................................................................25
I.3.3 Installation of mains power supply ................................................................................ 25
I.3.4 Electrical connection of components and functions............................................................ 26

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Contents
I.3.5 Lock the doors by using the key.................................................................................... 27
I.4 Installation – Pipes for water – hot and chilled, valves and drains ...................................................... 27
I.4.1 Description...............................................................................................................27
I.4.2 Pipe connections ....................................................................................................... 27
I.4.3 Possibility of extracting components from the unit ............................................................ 27
I.4.4 Pipe connections to batteries ....................................................................................... 27
I.4.5 Draining condensate water .......................................................................................... 29
I.4.6 Draining condensate water from heat exchanger.............................................................. 29
I.4.7 Draining condensate water from cooling battery — ........................................................... 30
J Installation and assembly instructions for reduction of noise and vibration emissions ....................................... 31
K Start-up, adjustments, use, commissioning and unit in hipernation .............................................................. 31
K.1 Print-outs on paper ................................................................................................................ 31
K.2 Electronic media....................................................................................................................31
K.3 Documentation is available for download.................................................................................... 32
K.4 Start-up by installer ............................................................................................................... 32
K.4.1 Checklist, relevant values ............................................................................................ 32
K.5 Adjustments and use..............................................................................................................33
K.6 Description of functions .......................................................................................................... 33
K.6.1 Remote control.........................................................................................................33
K.6.2 Extended operation and external start/stop (for example by presence detectors) .................... 33
K.6.3 Valve and valve motor for heating coil............................................................................ 33
K.6.4 Valve and valve motor for cooling coil ............................................................................ 33
K.6.5 DX cooling................................................................................................................33
K.6.6 Circulation pump, heating ............................................................................................ 33
K.6.7 Fire alarm function..................................................................................................... 34
K.6.8 E tool - configuration tool ............................................................................................ 34
K.6.9 Electrical heater battery .............................................................................................. 34
K.6.10 Speed control of fans ................................................................................................. 34
K.6.11 Cabinet ...................................................................................................................35
K.6.12 Temperature sensors ................................................................................................. 35
K.6.13 Damper motors.........................................................................................................35
K.6.14 Filter guards .............................................................................................................35
K.6.15 Room temperature sensors.......................................................................................... 35
K.6.16 Frost protection......................................................................................................... 35
K.6.17 Systemair Control Panel - SCP....................................................................................... 36
K.6.18 Cooling recovery ....................................................................................................... 36
K.6.19 Free cooling .............................................................................................................36
K.6.20 Alarm signal.............................................................................................................36
K.6.21 Heat recovery...........................................................................................................36
K.6.22 Frost protection – plate heat exchanger .......................................................................... 36
K.7 Commissioning .....................................................................................................................36
K.8 Unit in hipernation .................................................................................................................36
L Information about the residual risks...................................................................................................... 36
L.1 Unit casing...........................................................................................................................36
L.1.1 Design of the machine to make transport safe ................................................................. 36
L.1.2 Common for all unit sections ........................................................................................ 37
L.1.3 Common for all unit sections by insufficient lighting .......................................................... 37
L.1.4 Dampers..................................................................................................................37
L.1.5 Attenuators..............................................................................................................37
L.1.6 Filters .....................................................................................................................38
L.1.7 Plug fans .................................................................................................................38
L.1.8 Batteries for heating .................................................................................................. 39
L.1.9 Heat pump units........................................................................................................39
M Instructions on the protective measures during repair and maintenance...................................................... 40
N The essential characteristics of tools which may be fitted to the machinery .................................................. 40
O The conditions of stability during use, transportation, assembly, dismantling when out of service . .... ... .... ... .... ... 40
O.1 Installed reliable to avoid units to be tilted or moved by storm......................................................... 40
O.2 Transport of section with heat pump unit ............. ................................ ................................ ....... 40
O.3 Disposal of the heat pump system - type Geniox - HP.................................................................... 41
O.4 General disassembly – sharp edges............................................................................................ 41
P Instructions for machinery where these are regularly to be transported ....................................................... 41
Q The operating method to be followed in the event of breakdown. Safe restart. ............................................. 41
R Adjustment and maintenance operations .............................................................................................. 41
R.1 Shutdown of the unit to a safe state .......................................................................................... 41
R.2 Unlock and lock the doors by using the key ................................................................................. 42
R.3 Recommended maintenance intervals........................................................................................ 42

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R.4 Filters – always replace filters with new filters with the same characteristics to maintain SFP
value .................................................................................................................................43
R.4.1 Bag filters – the number of filters and sizes of frames ........................................................ 43
R.4.2 Panel filters – the number of filters and the sizes of the frames ............................................ 44
R.4.3 Bag filters................................................................................................................44
R.4.4 Panel filters..............................................................................................................47
R.5 Changing the Internal Battery in the controller ............................................................................. 47
R.6 Other functions to maintain ..................................................................................................... 48
R.6.1 The unit...................................................................................................................48
R.6.2 Dampers..................................................................................................................48
R.6.3 Rotary heat exchanger ............................................................................................... 50
R.6.4 Cross flow and counter flow exchanger .......................................................................... 51
R.6.5 Run-around heat exchanger......................................................................................... 52
R.6.6 Heating coil..............................................................................................................53
R.6.7 Plug fans .................................................................................................................54
R.6.8 Silencer...................................................................................................................55
R.6.9 Outdoor air section .................................................................................................... 56
R.6.10 Heat pump unit.........................................................................................................56
S Instructions to enable adjustment and maintenance safely........................................................................ 57
S.1 Protective measures and additional protective measures................................................................ 57
S.1.1 Necessary protection measures prior to start-up .............................................................. 57
S.1.2 Safe adjustment and maintenance ................................................................................ 58
S.1.3 Personal protective equipment for maintenance staff – health and safety............................... 58
T The specifications of the spare parts to be used, when these affect the health and safety of operators ............... 58
T.1 Spare parts - Mechanical ......................................................................................................... 58
T.2 Spare parts - Electrical ............................................................................................................ 58
U Information on airborne noise emissions exceeding 70 dB(A) .................................................................... 58
Annex 1 Declaration of conformity with production number (in separate cover) ..............................................1-1
Annex 2 Technical data – unique data for every unit (in separate cover) ........................................................2-1
Annex 3 Spare part list (in separate cover) ..............................................................................................3-1
Annex 4 Assembly of base frame – height 118 mm for unit sizes 10 – 18.......................................................4-1
4.1 Base frame length 482 – 2564 [mm] Unit size 10 – 18 ..................................................................4-2
4.2 Base frame length 2582 – 4964 [mm] Unit size 10 – 18 ................................................................4-3
4.3 Base frame length 4982 – 6164 [mm] Unit size 10 – 18 ................................................................4-4
Annex 5 Assembly of base frame – height 118 mm for unit sizes 20 – 31.......................................................5-1
5.1 Base frame length 482– 2564 [mm] Unit size 20 – 31 ...................................................................5-1
5.2 Base frame length 2582 – 4964 [mm] Unit size 20 – 31 ................................................................5-2
5.3 Base frame length 4982 – 6164 [mm] Unit size 20 – 31 ................................................................5-3
Annex 6 Assembly of base frame – height 218 mm for unit sizes 10 – 18 ......................................................6-1
6.1 Base frame length 482– 2564 [mm] Unit size 10 – 18 ...................................................................6-1
6.2 Base frame length 2582 – 4964 [mm] Unit size 10 – 18 ................................................................6-2
6.3 Base frame length 4982 – 6164 [mm] Unit size 10 – 18 ................................................................6-4
Annex 7 Assembly of base frame – height 218 mm for unit sizes 20 – 31.......................................................7-1
7.1 Base frame length 482– 2564 [mm] Unit size 20-31 ....................................................................7-1
7.2 Base frame length 2582 – 4964 [mm] Unit size 20 – 31 ................................................................7-2
7.3 Base frame length 4982 – 6164 [mm] Unit size 20 – 31 ................................................................7-3
Annex 8 Installation of steel roof in the sizes 10 – 31.................................................................................8-1
8.1 Overview............................................................................................................................8-1
8.1.1 Mount rails. Units of size 10, 11, 12, and 14....................................................................8-1
8.1.2 Mount rails. Units of size 16 and units larger than size 16...................................................8-1
8.1.3 Roof overhang along the long sides of the unit ...............................................................8-2
8.1.4 Calculation of the overhang at the ends of the unit. Mount overhang profile – G1....................8-2
8.1.5 Foam bands between rails and roof plates – mount roof plates............................................8-3
8.1.6 Foam bands between roof plates .................................................................................8-3
8.1.7 Mount roof plates – some of them are overlapping by 2 ribs...............................................8-3
8.1.8 Mount overhang profile – G5 on the other end of the unit. .................................................8-3
8.1.9 Mount side profiles and corners along the edges of the roof to protect persons......................8-3
8.1.10 Apply sealing on plate joints to ensure water resistance. ...................................................8-3
Annex 9 Speed control for rotor and assembly of divided rotor ....................................................................9-1
9.1 Speed control ......................................................................................................................9-1
9.1.1 Selection of correct signal via the 8DIP switch levers ........................................................9-1
9.1.2 Indication of operation mode via red and green LED as well as test of motor..........................9-2
9.1.3 Copy of the label with information about connection of cables............................................9-3
9.2 Assemble the Systemair casing for Geniox 22, Geniox 24 and Geniox 27 ..........................................9-3
9.3 Assemble divided rotor for Geniox 29 and Geniox 31....................................................................9-4

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9.4 Installation of motor that turns rotor and sensor for rotation...........................................................9-4
Annex 10 Reversible heat pump unit (in separate cover, if heat pump was delivered) .................................... 10-1
10.1 Geniox-HP section (reversible heat pump unit) ......................................................................... 10-1
Annex 11 Menu for internal controller in the heat pump unit (in separate cover, if heat pump was
delivered) ....................................................................................................................................11-1
Annex 12 Connection of fan motor and set-up manual for frequency converter............................................. 12-1
12.1 Connection of fan motor ...................................................................................................... 12-1
12.2 Set-up for Danfoss FC101 for Geniox-units with AC motors.......................................................... 12-1
12.3 AC-fan operation without thermistor for Danfoss FC101.............................................................. 12-2
12.4 Set-up Danfoss FC101 for Geniox-units with PM motors.............................................................. 12-2
12.5 Installation ECblue .............................................................................................................. 12-4
12.5.1 Connection............................................................................................................ 12-4
12.5.2 Diagnostic/faults .................................................................................................... 12-6
Annex 13 Commissioning protocol – proposal (in separate cover)............................................................... 13-1
Annex 14 Report with data from final functional test on the Systemair factory (in separate cover, if control
system was delivered) .................................................................................................................... 14-1
Annex 15 Short description of main components in the control system ....................................................... 15-1
15.1 Geniox units delivered in several sections ................................................................................ 15-1
15.1.1 External components............................................................................................... 15-1
15.2 Geniox unit delivered assembled on base frame ........................................................................ 15-1
15.2.1 External components............................................................................................... 15-1
Annex 16 Wiring diagram (in separate cover, if control system was delivered).............................................. 16-1
Annex 17 Operator’s guide (how to use the Systemair control panel) (in separate cover, if control system was
delivered).....................................................................................................................................17-1

Manufacturer | 1
A Manufacturer
This User Manual covers all air handling units with control system delivered by Systemair A/S.
Manufacturer and supplier data:
Systemair A/S
Ved Milepælen 7
DK-8361 Hasselager
Responsible for documentation: Ulf Bang
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 29 and Geniox 31.
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2| Declaration of Conformity - example
C Declaration of Conformity - example
The manufacturer:
Systemair A/S
Ved Milepælen 7
DK - 8361 Hasselager
Hereby declares that, air handling units of the flowing types:
DANVENT DV10, DANVENT DV15, DANVENT DV20, DANVENT DV25, DANVENT DV30, DANVENT DV40,
DANVENT DV50, DANVENT DV60, DANVENT DV80, DANVENT DV100, DANVENT DV120, DANVENT
DV150, DANVENT DV190 and DANVENT DV240.
TIMEec 10, TIMEec 15, TIMEec 20, TIMEec 25, TIMEec 30, TIMEec 40
Geniox: 10DR, 11DR, 12DR, 14DR, 16DR, 18DR, 20DR, 22DR, 24DR, 10SR, 11SR, 12SR, 14SR, 16SR,
18SR, 20SR, 22SR, 24SR, 27SR, 29SR, 31SR, 10DRR, 11DRR, 12DRR, 14DRR, 16DRR, 18DRR, 20DRR,
22DRR, 24DRR, 27SRR, 29SRR, 31SRR, 10MRR, 11MRR, 12MRR, 14MRR, 16MRR, 18MRR, 20MRR,
22MRR, 24MRR, 27MRR, 29MRR, 31MRR, 10.05/10.05TR, 11.055/11.055TR, 12.06/12.06TR, 14.07/
14.07TR, 16.08/16.08TR, 18.09/18.09TR, 20. 10/20.10TR, 22.11/22.11TR, 24.12/24.12TR, 27.13/
27.13TR, 29.14/29.14TR, 31.15/31.15TR, 10.05IR, 11.055IR, 12. 06IR, 14.07IR, 16.08IR, 18.09IR,
20.10IR, 22.11IR, 24.12IR, 27.13IR, 29.14IR, 31.15IR, 10DL, 11DL, 12DL, 14DL, 16DL, 18DL, 20DL, 22DL,
24DL, 10SL, 11SL, 12SL, 14SL, 16SL, 18SL, 20SL, 22SL, 24SL, 27SL, 29SL, 31SL, 10DLL, 11DLL, 12DLL,
14DLL, 16DLL, 18DLL, 20DLL, 22DLL, 24DLL, 27SLL, 29SLL, 31SLL, 10MLL, 11MLL, 12MLL, 14MLL,
16MLL, 18MLL, 20MLL, 22MLL, 24MLL, 27MLL, 29MLL, 31MLL, 10.05/10.05TL, 11.055/11.055TL,
12.06/12.06TL, 14.07/14. 07TL, 16.08/16.08TL, 18.09/18.09TL, 20.10/20.10TL, 22.11/22.11TL,
24.12/24.12TL, 27.13/27.13TL, 29.14/29.14TL, 31. 15/31.15TL, 10.05IL, 11.055IL, 12.06IL, 14.07IL,
16.08IL, 18.09IL, 20.10IL, 22.11IL, 24.12IL, 27.13IL, 29.14IL, 31.15IL
Serial No: ”YYMM-000XXXXXXX-XX”
are manufactured and delivered in accordance with following directives:
Machinery directive 2006/42/EC
Ecodesign — Commission regulation 1253/2014
EMC – directive 2014/30/EC
Low voltage directive 2014/35/EC
Pressure equipment directive 2014/68/EC
European Standard EN378–1 & 2 — 2016
Equipment type: Heat Pump Unit — Geniox and DVU Series
Consisting of: Compressor, evaporator and condenser
Verification and Assessment by:
Notified Body Bureau VERITAS CE0041 for PED
Bureau VERITAS UK, “Parklands”, Wilmslow Road
Didsbury, Manchester M20 2RE
Module: A2
Certificate no:
CE-0041-PED-A2-SYA-001-17-DNK
The declaration is only valid, if the installation of the air handling unit is carried out according to the instructions deliv-
ered with the unit. The installer will be responsible for the CE marking and documentation, if any construction or func-
tional changes are applied to the air handling unit.
Hasselager 15.08.2017
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