Dantherm RBS 800 User manual

RBS 800
EN
N0. 910002 • rev. 2.0 • 01.12.2004

Der tages forbehold for trykfejl og ændringer
Dantherm can accept no responsibility for possible errors and changes
Irrtümer und Änderungen vorbehalten
Dantherm n’assume aucune responsabilité pour erreurs et modifications éventuelles

3
Introduction
Overview
Introduction This is the service manual for the DANTHERM RBS 800.
The below table of content gives you an overview of the main sections. Please see the
complete Table of contents on page 4 for further information about the sections.
Serial number This manual covers units produced after the below date, which is to be found in the first
6 digits in the serial number on the unit type plate (yy-mm-dd):
041201
Contents This service manual covers the following main topics:
Topic See page
Introduction this page
Table of contents, complete
General information next page 6
Unwrapping, mounting and installation 21
Service guide 23
Technical information 43
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Table of contents
Introduction This is the complete table of contents covering all sections in this service manual.
Each main section will begin with an introduction including a separate table of contents
covering the exact section.
Contents This service manual covers the following topics:
Topic See page
Introduction next page
Table of contents 4
General information 6
Product and functional description 7
General description 8
Fan 9
Damper 10
Heating 11
Set points 12
Test facility 13
Comfort temperature during visit by technician 14
Communications options 15
Description of indicators, plugs and switches 16
Unwrapping, mounting and installation 21
Service guide 23
Preventative maintenance 24
Spare parts 26
How to replace the filter 27
How to replace the fan 29
How to replace the control panel 31
How to replace the heating element 33
Continued overleaf

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Table of contents, continued
Contents, continued
Topic See page
How to replace the damper motor 35
How to replace the temperature sensors 37
Fault finding guide 38
Hotline 40
Recycling of the unit 41
Service agreement 42
Technical information 43
Technical data 44
Dimensions 46
Resistance in temperature sensors 47
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General information
Introduction This section gives you the general information about the unit and this service manual.
Manual, part
number Part number of this service manual is 910002.
Target group This service manual is intended for technical staff who are to install the climate control
unit, carry out preventative maintenance, and replace defective parts.
Copyright Copying of this service manual, or part of it, is not allowed without written permission
from Dantherm A/S.
Reservations Dantherm A/S reserves the right to make changes and improvements of the product
and the service manual at any time without prior notice or obligation.
CE
Declaration of
conformity
Dantherm A/S, Marienlystvej 65, DK-7800 Skive hereby solemnly declares that the
RBS 800 conforms with the following directives:
•97/37/EEC Machine directive
•89/336/EEC EMC directive
and has been manufactured in accordance with the following norms:
•EN 292 Machine safety
•EN 61000 EMC
December 2001
Per Albæk - Managing Director

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Product and functional description
Overview
Introduction This section describes the control strategy for RBS 800.
Contents The section contains the following topics:
Topic See page
General description next page
Fan 9
Damper 10
Heating 11
Set points 12
Test facility 13
Comfort temperature during visit by technician 14
Communications options 15
Description of indicators, plugs and switches 16
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General description
Introduction The RBS 800 is a microprocessor-controlled free cooling unit designed for the
regulation of the temperature in an electronics room.
The unit can operate in temperatures from ÷ 40 °C to + 55 °C.
The RBS 800 is intended in particular for positioning indoors, and its slim line design
allows it to be installed in most rooms and containers.
Active parts The active parts controlled by the control panel are:
•Heating element
•Damper motor
•Fan
Terms The following terms are used in this manual:
•Outdoor air temperature: the temperature of the air outside the room or container.
This is the air that can be used for cooling purposes
•Supply air temperature: the temperature of the air blown into the room
•Return air temperature: the temperature of the air extracted from the room or
container
Signal lights On the front of the control panel, there are five LEDs that indicate the current status of
the system:
Learn more about the LEDs in section ”Description of indicators, plugs and switches”,
page 16.

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Fan
The function of
the fan The fan runs continually to circulate the air inside the room. Regulation of the fan
revolutions is defined by the temperature of the return air.
•Below 25 °C
The fan funs at minimum revolutions
•Over 25 °C
The fan revolutions will increase
•At 30 °C
The fan will reach its maximum speed of revolution
If a smoke alarm (accessory) is triggered, the fan will stop immediately, irrespective of
the temperature.
The fan is monitored with the assistance of a pulse generator fitted in the fan.
Back-up-function RBS 800 can also be used as back-up unit for other cooling units that are responsible
of the primary cooling.
In back-up mode will both the fan and the damper be hindered in operation because of
the set point.
The set point can be set between 25 °C and 35 °C. The settings for back-up condition
has to be set on the control board, where dip switch no. 6 must be put on ON, see more
about this in section ”Communications options”, page 15.
Return air temperature
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Damper
Damper function Primary temperature regulation is carried out using a flow of outdoor air controlled by a
damper.
The supply air consists of a mixture of the air from the room and from outdoors. The
opening and closing of the damper is determined by a sensor that measures the
temperature of the supply air.
The damper automatically adjusts against closed or open to reach supply air
temperature at 21-22 °C. Damper mode is conditioned by the fact that the set point on
the control panel has been reached. This set point relates to the return air temperature
and can be set from 25 °C to 35 °C. (Learn more about this in section ”Set points”,
page 12.
A signal from a moisture meter (accessory) will cause the damper to close if there is an
AC current in the unit.
A signal from a smoke detector (accessory) will cause the damper to close immediately.
If the heating element is activated, the damper will be closed.
As the damper is not a spring-return damper, it will remain in position in the event of a
power failure.
Supply air temperature

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Heating
Heating function The heating function is activated when the temperature of the return air matches the
setting defined using the knob on the front of the control unit (Learn more about this in
section ”Set points”, page 12).
It will be deactivated when the return air temperature exceeds this setting by 3 °C.
The fan speed will be fixed to 50 % when the heating element is activated.
Power consumption is monitored, and if it falls below 3 A, it will be considered an error.
This will be indicated via the error relays. See the section entitled “Fault finding guide”,
page 38 for additional details. However, a simultaneous AC power failure will result in
this error being rejected.
In the event of a fan error, the heating element will not be activated as in this case it will
not be possible to ensure the required airflow to the heating element.
A signal from a smoke detector (accessory) will cause immediate deactivation of the
heating element.
If you choose not to use the heating element, this function and the associated
monitoring process can be deactivated. This can be done via the serial communication
set-up and the setting will be saved in the control unit.
Return air temperature
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Set points
Drawing This drawing illustrates the control panel with the dials:
Dials
Heat mode Setting of the heating mode set-point shall be made on the front of the control panel
(see illustration above) and it can be set from 0 °C to 20 °C.
Damper mode Setting of damper mode set-point shall be made on the front of the control panel and it
can be set from 25 °C to 35 °C.
Telemetry or
DanView When Telemetry or DanView display is used the set-point areas extends to:
•Heat: ÷ 10 °C to + 20 °C.
•Damper: + 20 °C to + 50 °C.
However, the controller will insist of a difference between the heating set-point and the
damper set-point of minimum 5 °C, and it will therefore ignore attempts of setting them
closer.
Settings made via telemetry are valid as long as valid communication is available and
10 minutes more.

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Test facility
Drawing This drawing illustrates the control panel with the test button:
Test
Test When activating the test button the unit starts the 5-step-test program. The unit will run
through the different tests according to the below table.
The fail LED will operate normally indicating fail if and when detected.
If any fail is detected during the test, the LED will flash with a frequency of 1 Hz for 30
seconds after the test is done to indicate some fault were detected.
The table below describes what is checked during the test.
Test point Heater Damper Internal fan LED Duration
1 Off Closing Stopped Jingle 30 sec.
2 On Closing Idle Normal 35 sec.
3 Off Opening Medium Normal 40 sec.
4 Off Closing High Normal 35 sec.
5 Off Closing Idle Normal 30 sec.
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Comfort temperature during visit by technician
Drawing This drawing illustrates the control panel with the comfort button:
Comfort/Occupied
Comfort
temperature On the front panel of the control unit, there is a button marked “Occupied” (see drawing
above).
Press this button and hold it down for 1–2 seconds to initiate comfort temperature
conditions with temperatures between 20 °C and 25 °C and with a reduced noise level.
This condition will continue for 60 minutes but can be cancelled by pressing the same
button briefly. If you press the button and hold it down, the unit will remain in comfort
condition.

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Communications options
Telemetry option All available information is supplied through the serial RS485 line. It is available through
both RJ45 plugs located in the front of the control panel and in the plug behind the
control unit.
A PC program for testing and troubleshooting is also an option.
The number of the unit is defined through a binary DIP converter located on the control
unit. The factory setting is 0.
Setting:
Back-up Dip switch no. 6 has been reserved for back-up setting.
When the switch is set on ON, the unit will function as a back-up unit. This could be
preferable in situations where there are other primary cooling units in the shelter.
In back-up condition the unit will be standby and not running, unless the adjusted
cooling and heating set point is registered by the return air temperature sensor. See
more about this in section ”Fan”, page 9.
ON
ON
ON
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Description of indicators, plugs and switches
Introduction This section describes the indicators, plugs and switches with reference to the control
unit.
DanCon All RBS 800 units are provided with a DanCon control panel.
Illustration This drawing illustrates the control panel:
g
f
e
d
c
Part/function This table gives you a description of each part on the control panel:
Part Function
cLED The LEDs show the status and the alarm
Learn more about the status and alarms in the following
dOccupied By pressing this bottom the unit will go into the occupied mode.
Learn more about the occupied/service mode in section
“Comfort temperature during visit by technician”, page 14
eTest By pressing this button the unit will run through a quick test
program.
Any detected fail can be read on the fail LED, see more about
this in section “Test facility”, page 13
fDials These dials give you the possibility of changing the heater
and/or the damper set points, see more in the section “Set
points”, page 12
gRS485
communica-
tion port
These ports give you the possibility of connecting a pc and/or
DanLink telemonitoring program (accessory). See more about
this in section “Communications options”, page 15
Continued overleaf

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Description of indicators, plugs and switches, continued
Signals of LED The LED provides different signals. The below table gives you a description of each
signal:
A jingle starts when the unit is connected.
Part Function
1 × Green LED Supply Lit as soon as the control panel is powered up
3 × Yellow LED Damper Lit in damper mode
Heater Lit in heater mode
Test Lit in test mode
1 × Red LED Alarm status Lit in case of a detected failure, see details in
section “Fault finding guide”, page 38.
Fuses and
switches The illustration below shows the control unit and the location of the fuses and switches:
c
h
d
f
g
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Description of indicators, plugs and switches, continued
Part/function This table refers to the illustration on the previous page:
No. Part Function
1 DIP switch Selection of unit number
2 Fuse 6,3 AT Heating element
3 Fuse 6,3 AT AC
4 Fuse 6,3 AT Not used
5 Fuse 6,3 AT Not used
6 Fuse 6,3 AT
Fuse 4,0 AT Not used Not used
RS 485 jack’s This table lists the connections in the plug:
Pin no. Function
1 Logic GND
2 Data B
3 Data A
4 Data A
5 Data B
6 Logic GND
Main power J9 This illustration shows the main power plug in the control unit:
Continued overleaf
Female J9 seen from
the control unit

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Description of indicators, plugs and switches, continued
Part/function This table refers to the illustration above:
Pin no. Function
D 6 I Not in use
D 10 Not in use
D 14 Not in use
D 18 Heating element
D 22 Not in use
D 26 Not in use
D 30 Main line
Z 4 Not in use
Z 8 Fan
Part/function,
continued
Pin no. Function
Z 16 Autotransformer 230 V
Z 20 Autotransformer 180 V
Z 24 Autotransformer 120 V
Z 28 Shared
Z 32 Main power, shared
Low voltage J2 This illustration shows the low voltage plug in the control panel:
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Continued overleaf
Female J2 seen from
the control unit
J2 on the control unit

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Description of indicators, plugs and switches, continued
Part/function This table refers to the illustration above:
Pin no. z b d
2 Interconnection - “Warning” relay NC. Fail relay NC.
4 Interconnection + “Warning” relay com. Fail relay com.
6 Damper GND Damper control Damper supply
8 36 V AC supply Power meter compr.
GND Power meter heat GND
10 36 V AC supply Power meter compr. Power meter heat
12 GND Alarm relay NC. Alarm relay com.
14 - Batt Int DC fan. PWM Int. DC fan + Batt Int DC fan.
16 “Hot spot” sensor
GND Return sensor GND Cond. sensor GND
18 “Hot spot” sensor Return sensor Cond. sensor
20 - 48 V DC int. fan Rot. Sign. Int. DC
fan +48 V DC int. fan
22 Dig./Analogue GND Analogue input 2 Analogue input 1
24 Digital input 3 Digital Input
“Occupied” Digital Input smoke alarm
26 - Batt ext. DC fan PWM Ext. DC fan + Batt ext. DC fan
28 RS 485 B Supply air sensor
GND Outdoor air sensor GND
30 RS 485 A Supply air sensor Outdoor air sensor
32 - 48 V DC ext. fan Rot. Sign. Ext. DC
fan +48 V DC ext. fan
Input/output
terminals An extra row of terminals is located next to the supply terminals:
Terminal no. Description
1 Warning
2 Warning
3 Alarm
4 Alarm