SAMCO2 PL1001A, Assembly And Operating Instructions Manual

Page 1: ...uctions Ionisation air purifier Built in plasma module PL1001A Translated operating instructions EN Version 1 00 Status 08 20 22 SAMCO2 GmbH Höhenhöfe 30 47918 Tönisvorst Tel 49 0 2151 479 251 0 Mail info samco2 de https samco2 de ...

Page 2: ...ration 18 3 6 Emergency stop devices 18 3 7 Operating and control elements 18 3 8 Hazardous areas During operation 19 3 9 Safety components 21 Unpacking and Assembly preparation 22 4 1 Prerequisites for the assembly 22 Assembly and commissioning 23 5 2 Commissioning of the module 29 Manufacturer settings 30 6 1 Basic settings 30 Operation 30 7 1 Normal operation 30 7 2 Switch off 30 Maintenance wo...

Page 3: ...0 10 3 Decommissioning 41 10 4 Recommissioning 41 10 5 Disposal 42 Index 43 List of figures 45 List of tables 45 Documents about the device 46 14 1 EC Declaration of Conformity 46 14 2 Order list for spare parts 47 14 3 Supplements versioning Updates 48 14 4 Maintenance certificate 49 14 5 Appendix 50 ...

Page 4: ...alidity of these operating instructions These operating instructions only apply to Ionisation air purifier as built in plasma module PL1001A with all variants and options No part of this documentation may be reproduced or transmitted for any purpose without the ex press written permission of SAMCO2 GmbH The reproduced common names trade names product designations etc may also be trademarks without...

Page 5: ...rthing cable for plasma module in the box of the plasma module PL1001A o 1 x Set for cover screw connection of the control unit o 1 x Spare appliance microfuse 4 A o 1 x cable protection for module plug 2 piece o 2 x PG7 gland for high voltage cable Assembly and operating instructions with CE declaration of conformity Check against your contractual references and delivery notes whether all compone...

Page 6: ...onal protective clothing if necessary Operation of the module according to these operating instructions Recognised applicable rules for occupational safety Recognised applicable rules for environmental protection ATTENTION Unwanted state of your module possible Your module can perform unexpected functions if you do not know exactly the pos sibilities and the limits of the installation and still wo...

Page 7: ...s Operation Education training according to previous section on page 6 Re sponsibility of the operator 1 5 3 Emergency information Include the module and the associated installations in your emergency planning only for commercial use Integrate the module into your operating instructions which regulate the behaviour in emer gency situations Integrate the module into your risk assessment according t...

Page 8: ...omic use of the module Reference to further information products Use appropriate PPE UV eye protection protective gloves Ground the module before use Warning of a danger zone Warning against automatic start up Warning of electric shock and high voltage Warning of ozone emissions The module generates ozone during operation People with pacemakers or implanted defibrillators keep 15 cm away from the ...

Page 9: ...ty or the en vironment Description of the hazard Follow the instructions given CAUTION Notes with the word CAUTION warn of hazards that may cause minor to moderate injury Description of the hazard Follow the instructions given WARNING Notices with the word WARNING warn of hazards where moderate to fatal injuries may occur Description of the hazard Follow the instructions given ...

Page 10: ...only by a trained specialist in order to avoid hazards Never operate the module without the prescribed protective devices Never tamper with the module s existing protective devices and safety circuits Never bypass the safety circuits if the system is not working properly In this case switch off the ventilation system and the plasma system secure the system against unintentional restarting and noti...

Page 11: ...se contact us Check whether your operating personnel have understood the operation Maintenance work may only be carried out by authorised persons who have been trained for this activity Never switch on the upstream ventilation system during repair work Secure the upstream venti lation system against unintentional switching on e g with padlocks on the main switch to pre vent the upstream ventilatio...

Page 12: ...ule as described in chap ter 8 Maintenance work and checks You could otherwise damage parts of the module Do not drop objects such as tools and other parts of the module on the floor on hard surfaces or objects You could otherwise damage these parts of the module 2 2 3 Danger due to climatic influences To avoid damage or danger due to climatic influences observe the following conditions Do not ope...

Page 13: ...uch as cigarette smoke and some food odours from rooms It cleans the air directly in the room and not only in the unit No mechanical filters chemicals or UV light are required making the system largely maintenance free The system is only intended for continuous air disinfection in indoor rooms with a minimum size of 125 m it is designed for installation in existing or newly planned ventilation sys...

Page 14: ...ew installations and for retrofitting existing ventilation systems The installation position can be selected flexibly The timer setting in the control unit must be set to the values specified in Table 2 chapter Technical data to match the room content The module is exclusively intended for this purpose and may only be used for this purpose Any other use is considered improper and may result in dam...

Page 15: ...ty report No HoE 025k 2021 Supplementary short report on safety Fraunhofer IBP No UHS 76 2021 Test report on effectiveness Fraunhofer IVV No QL 1081 21 Table 1 General technical data Minimum room size Maximum room size Timer 1 Timer 2 Note 125 m3 165 m3 LOW 15 In rooms WITHOUT supply air system 165 m3 210 m3 LOW 10 In rooms WITHOUT supply air system 210 m3 255 m3 HIGH 15 In rooms WITHOUT supply ai...

Page 16: ...Device s presentation Page 16 55 3 4 1 Dimensions and assembly drawings Control unit High voltage generation Figure 3 Dimensions control unit Figure 4 dimensions high voltage Generator ...

Page 17: ...tation Page 17 55 Plasma module 3 4 2 Labelling with type plates The individual components are provided with a type plate at these points provided Figure 6 Position of the type plates Figure 5 Dimensions plasma module ...

Page 18: ...ation system or disconnect the power supply to the ionisation air purifier You can also interrupt the power supply in the control unit with the mains switch see also Chap 5 1 1 Circuit diagram Pos No 3 Find out about the position of the existing emergency stop devices of the upstream ventilation system Make sure you can reach the emergency stop units quickly in case of emergencies or mainte nance ...

Page 19: ...entive in the marked danger areas Avoid the marked danger areas during ongoing operation if possible Follow the safety instructions below for the respective areas No Place Area Hazard symbol Meaning 1 Ionisation module Warning of electric shock and high voltage Warning against automatic start up Switch off the system before carrying out work on the module Warning of ozone emissions during operatio...

Page 20: ...witched on high voltage generation Warning of electric shock and high voltage Warning against automatic start up Switch off the system before carrying out work on the module 3 Control unit Warning of electric shock and high voltage Warning against automatic start up Switch off the system before carrying out work on the module Table 3 Hazardous areas of the system 3 8 1 Warning signs on the system ...

Page 21: ...g on the version ordered The actual safety components present depend on your particular installation You must check the documentation of your installation to find out what safety components are pre sent Further information on the safety components can be found in chapter 16 Documents on the unit 1 Plasma Calibration Unit 3008 3 Plasma Unit 7 5 kV 2 Timer Geya GRT 8 M1 Table 5 installed safety comp...

Page 22: ... and installed only by qualified specialists in ac cordance with page 7 The following conditions must be fulfilled in order to commission the module correctly see also the following chapter 5 ff Assembly installation and commissioning as described on page 23 ff The module must be protected against external mechanical impact The module must be installed in a ventilation duct The 30 cm high voltage ...

Page 23: ...or check until all errors have been eliminated ATTENTION Risk of injury is possible There is a risk of injury during assembly Use appropriate PPE protective gloves UV eye protection CAUTION Risk of injury is possible If you continue to operate the ventilation system before mounting the module there is a risk of injury Switch off the unit before carrying out any work on the unit WARNING Dangerous m...

Page 24: ... 9 Junction box 3 Mains switch control 10 Transformer 230 V AC 7 5 kV 4 Fine wire fuse 4 A 11 Plasma module PL1001A 5 Neutral conductor terminal block 12 Top hat rail 6 Terminal block 13 Safety timer 7 PE terminal block For cascading several modules contact the manufacturer to obtain the appropriate in stallation instructions Figure 8 Circuit diagram for installation with one module ...

Page 25: ...rol module 1 and the high voltage generation 2 2 Determine the mounting location for the plasma module in the ventilation duct 3 Drill the 9 mm holes in the ventilation duct duct The hole spacing is 190 mm Drill the 9 mm holes 4 Use an attachment point also as an earthing point for attaching the protective earth conduc tor 5 Put one spring washer each on the hexagon head screw M8 x 80 ...

Page 26: ...r 4 Put on a serrated lock washer 3 Screw in both M8 screws but do not tighten them yet 9 Check the distance between the plasma mod ule and the ventilation duct the distance must be min 50 mm Tighten the three M8 nuts firmly Use a 13 mm open end spanner for this Connect the protective earth conductor to a suitable point e g existing earthing point or in the control cabinet Determine the conductive...

Page 27: ...to the plug of the high voltage cable because otherwise the high voltage cables are too short Fit the two PG screw connections Feed the high voltage cables through the PG glands Screw the PG screw connections tight Fit the high voltage connector to the two ca bles Attach the two parts of the enclosed plug pro tector to the plug by clicking them into place 1 Plug the high voltage connector into the...

Page 28: ... Timer 2 2 to adjust Correct any faults that may have been found and check again that they are functioning cor rectly Close the control unit Minimum room size Maximum room size Timer 1 Timer 2 Note 125 m3 165 m3 LOW 15 In rooms WITHOUT supply air system 165 m3 210 m3 LOW 10 In rooms WITHOUT supply air system 210 m3 255 m3 HIGH 15 In rooms WITHOUT supply air system 255 m3 300 m3 HIGH 10 In rooms WI...

Page 29: ...ystem and whether the ventilation system is working properly Correct any errors that may be present Then switch on the 230 V power supply to the control unit If possible observe the plasma module during operation Use UV eye protection when in visual contact with the plasma module during operation to pro tect your eyes from possible permanent damage The plasma module should now operate cyclically f...

Page 30: ...place the legal requirements for fresh air supply Table 7 Timer settings for room size Operation 7 1 Normal operation The control unit contains the regulation for the sensor system function switching on and off as well as for the regulation of the high voltage conversion The control of the module works automat ically Switch on the power supply of the ventilation system for the ionisation air purif...

Page 31: ...s a risk of injury Switch off the ventilation system before carrying out any work on the mod ule or components 8 2 Requirements for maintenance personnel The following qualified persons are authorised to carry out the following activities on the module Assembly commissioning settings instruction troubleshooting maintenance work as described in this operat ing manual Technically qualified specialis...

Page 32: ...ry possible if safety instructions are not observed If you do not observe the safety instructions for carrying out maintenance work you may injure yourself and other operators of the module You must have read and understood this chapter before starting mainte nance work After carrying out the maintenance work remove any tools and the like that may be lying around in the danger zone of the unit Do ...

Page 33: ...e system Component assembly Activity Annual 7 yearly individual Time re quired in min Total System 1 2 3 Maintain cleanliness visually check system components for function damage check control unit for cable fires X X 4 Ionisation module 1 If necessary clean if not already done thor ough function check check for damage X X 2 High voltage generator 2 If necessary clean if not already done thor ough...

Page 34: ...ponents Inspection and maintenance work includes Cleaning of all accessible components Check visual inspection of the individual system components for mechanical damage or wear Check visually inspect the control unit for cable fires damage or wear breakage Fault free function of the protective earthing conductive resistance 5 Ω Maintenance Sheet Entire System Area Entire plant and components Inter...

Page 35: ...e ionisation module and the high voltage generator for damage Check the ionisation module and the high voltage generator for wear Check the electrode of the plasma module and the high voltage generator for wear and dam age Check the ionisation module and the high voltage generator for fault free operation Check the airway for blockages Clean the plasma module and the high voltage generator thoroug...

Page 36: ...itching on Turn off the main switch of the unit and secure it in this position against be ing switched on again Attach a sign to the module and the unit with the following text Do not switch on unit maintenance work ATTENTION Damage and reduction in performance is possible If you cannot correct the fault properly the performance of the module may deterio rate You must be a qualified specialist to ...

Page 37: ...ction test Check the components of the ionisa tion system measure them and elimi nate faults if possible Then carry out a function test Otherwise order a new part from the manufacturer If the fault cannot be rectified by yourself switch off the system and notify the ventilation contractor for the repair Table 8 Troubleshooting Never allow the system to continue running in the event of a malfunctio...

Page 38: ... de ATTENTION Malfunction of the system is possible If you replace components of the system no matter which ones these new compo nents must be mounted in such a way that the desired function is possible Other wise malfunctions of the module are possible You must be a qualified specialist to carry out the service work and the re placement of defective parts professionally see p 7 Check the replaced...

Page 39: ...eshooting fault clearance repair Page 39 55 9 3 Spare parts and safety components 1 Plasma Calibration Unit 3008 3 Plasma Unit 7 5 kV 2 Timer Geya GRT 8 M1 Table 9 installed safety components and spare parts ...

Page 40: ...ies 10 1 1 Return delivery to manufacturer No components of the module are intended to be returned to the manufacturer supplier 10 1 2 Notification to authorities and manufacturer According to the current legal status 07 2022 no deregistration of the module with offices and authorities is foreseen However in the event of changes to the disposal regulations this option may have changed The operator...

Page 41: ...ng Pack the module to prevent damage and soiling 10 3 5 Labelling Attach a notice to the module on which the most important key data is available Date of storage Indication of preservatives used if applicable Maintenance work carried out during storage Expected recommissioning Maintenance schedule with the next maintenance work 10 4 Recommissioning To recommission the system carry out the followin...

Page 42: ...ation the future legal situation regarding the development of disposal regulations cannot be foreseen The instructions for proper disposal of the system therefore refer to the status as of 07 2022 Until the time of disposal changes in the disposal regulations are likely you must there fore inform yourself about the current regulations and if necessary consider changes for disposal on your own Take...

Page 43: ...ols 19 20 I Introduction 4 Use contrary to the intended purpose 14 Intended use 6 14 L List of figures 45 M Marking 41 Manufacturer 4 36 Manufacturer operator 38 Maintenance 31 Maintenance work 36 38 40 Maintenance intervals 33 Maintenance record 49 Maintenance personnel 31 Minimum distance flammable substances 11 N P Packing 41 Property damage 12 Operator 7 Operating personnel 6 Personnel qualifi...

Page 44: ...Page 44 55 Spare part order 38 Spare parts 47 T Troubleshooting 37 Target group 6 Type plate 17 U Updates 48 User s workplace 18 V Version 1 ...

Page 45: ...ram for installation with one module 51 Figure 11 Wiring diagram SAMCO2 PCU 3008 52 Figure 12 Dimensions of the control unit housing 53 Figure 13 Dimensions high voltage generation 54 Figure 14 Dimensions plasma module 54 List of tables Table 1 General technical data 15 Table 2 Timer settings for room size 15 Table 3 Hazardous areas of the system 20 Table 4 Warning signs on the system 20 Table 5 i...

Page 46: ...tions Serial number acc Type plate complies with the relevant basic health and safety requirements of the following EC directives and standards due to its design and construction as well as the version placed on the market by us In the event of a change to the product not agreed with us this declaration of conformity loses its validity Applied and harmonised standards and directives Directive 2014...

Page 47: ...47 55 14 2 Order list for spare parts To Customer address SAMCO2 GmbH Höhenhöfe 30 47918 Tönisvorst Tel 49 0 2151 479 251 0 info samco2 de https samco2 de Article number Item name Quantity Copies of these pages may be made if required ...

Page 48: ...cumented in writing Enter your completed supplements additions here to document the changes Use this sheet as a template for evidence you have created yourself File your own verifications together with the entire installation documentation to have all information available in one place Change date name Version number Changes implemented ...

Page 49: ... out here to document the maintenance Use this sheet as a template for evidence you have created yourself File your own verifications together with the entire installation documentation to have all information available in one place Date of the maintenance work carried out Name in block capitals Date Signature ...

Page 50: ...Documents about the device Page 50 55 14 5 Appendix Table of contents 14 5 1 Circuit diagrams 51 14 5 2 Drawings 53 14 5 3 Safety components 55 ...

Page 51: ...Junction box 3 Mains switch control 10 Transformer 230 V AC 7 5 kV 4 Fine wire fuse 4 A 11 Plasma module PL1001A 5 Neutral conductor terminal block 12 Top hat rail 6 Terminal block 13 Safety timer 7 PE terminal block For cascading several modules contact the manufacturer to obtain the appropriate in stallation instructions Figure 10 Circuit diagram for installation with one module ...

Page 52: ...Documents about the device Page 52 55 Wiring diagram SAMCO2 PCU 3008 Figure 11 Wiring diagram SAMCO2 PCU 3008 ...

Page 53: ...Documents about the device Page 53 55 14 5 2 Drawing Dimensions of the control unit housing Figure 12 Dimensions of the control unit housing ...

Page 54: ...Documents about the device Page 54 55 High voltage generation Ioniser module Figure 13 Dimensions High voltage Generator Figure 14 Dimensions plasma module ...

Page 55: ...Documents about the device Page 55 55 14 5 3 Safety components 1 Plasma Calibration Unit 3008 3 Plasma Unit 7 5 kV 2 Timer Geya GRT 8 M1 Table 10Safety components used ...