Dantherm DanX 2/4 User manual

DanX
Service manual
EN
No. 029884 • rev. 1.2 • 15.10.2007

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

Introduction
Overview
Introduction This is the service manual for the Dantherm Air Handling DanX unit.
The index below shows the main sections of the manual. For further information see the
complete table of contents on page 4.
Warning It is the operator’s responsibility to read and understand this manual as well as
other information and to use the correct operation and maintenance procedure.
The unit should only be operated by qualified (trained) persons. Repair of cooling
circuit/electrical system must be done by skilled service engineers. If such precautions
are neglected, persons or equipment may be injured or damaged.
Not included This manual does not include information about:
•Transport, mounting, installation, start and commissioning of the unit
Separate instructions are delivered with the unit
•Function and use of the control
Separate instructions are delivered with the unit, if the control is included in the
delivery from Dantherm Air Handling A/S
•Technical information/data including electrical documentation
Delivered separately with the unit
Contents This service manual deals with the following:
Item See page
Introduction This page
Table of contents 4
General information 5
User’s guide 6
Service guide 13
Index 36
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029884 • Version 1.1 • 20.04.2007

Table of contents
Introduction This is the complete table of contents that covers all sections of the service manual.
Each main section has an introduction that includes a table of contents for that
particular section.
Contents This manual covers the following items:
Item See page
Introduction 3
Table of contents 4
General information 5
User’s guide 6
How to reset the HP pressure switch 7
How to reset the fire thermostat 8
How to reset the frost thermostat 9
How to adjust fan belts 10
How to adjust the number of fan rotations 11
Service guide 13
Planning of service inspections, overview 14
Preventive maintenance 16
How to service the cabinet 17
How to service fans and fan motors 18
How to service the rotary heat exchanger 20
How to service the cross-flow heat exchanger 22
How to service run-around heat exchangers 24
How to service the heat pump 26
How to service the filter 28
How to service the heating coil 30
How to service the cooling coil 31
How to service dampers 32
How to service the air distributor 33
Spare parts 34
Service agreement 35
Index 36
4

General information
Introduction This section includes general information on the unit and the service manual.
Target group The service manual’s target group is the service engineers that maintain the unit.
Not included in
the manual The following is not included in this manual, but described separately:
•The transport, mounting and installation guide
•The user’s guide for control, if such is delivered
•Technical information, including electrical documentation
Copyright Copying of this service manual, or part of it, is forbidden without prior written permission
from Dantherm Air Handling.
Reservations Dantherm Air Handling reserves the right to make changes and improvements to the
product and the service manual at any time without prior notice or obligation.
EC-Declaration of
Conformity Dantherm Air Handling A/S declares that the DanX units comply with the following
directives: 98/37/EEC Directive on machine safety
73/23/EEC Low voltage directive
89/336/EEC EMC directive
and are produced in accordance with the following standards:
EN 292-1 Machine safety
EN 292-2 Machine safety
EN 60 204-1 Electrical equipment for machinery, part 1 – General
requirements
We do not allow use of the units until the machine into which the parts are to be
incorporated has been declared to be in full accordance with the relevant directives.
Other
declarations Russia:
Recycling The unit is designed to last for many years. When the time comes for the unit to be
recycled, the unit should be recycled according to national rules and procedures to
protect the environment.
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029884 • Version 1.1 • 20.04.2007

User’s guide
Overview
Introduction This is the user’s guide to the settings that can be made directly on the DanX unit (not
control settings).
A separate user’s manual for the control is included if the unit is delivered with control
from Dantherm Air Handling A/S.
Note! Not all DanX units are delivered with thermostats and pressure switches.
Contents This section deals with the following items:
Item See page
How to reset the HP pressure switch Next page
How to reset the fire thermostat 8
How to reset the frost thermostat 9
How to adjust fan belts 10
How to adjust the number of fan rotations 11
6

How to reset the HP pressure switch
Procedure, high-
pressure switch The high-pressure switch has manual reset.
Do as follows to reset the high-pressure switch:
Step Action
1 Open the door to the compressors and locate the high-pressure switch on
the cold-conductor
2 Press the red button to reset the high-pressure switch. There is one button
for each compressor
3 Close the door
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How to reset the fire thermostat
Fire thermostat The fire thermostat is an on/off function. A signal is given to the control if
•the air inlet temperature is higher than the pre-set temperature, e.g. + 70 °C
or
•the extract air temperature is higher than the pre-set temperature, e.g. + 40 °C
If the unit is delivered with control from Dantherm Air Handling, the release of the fire
thermostat will switch off the ventilation unit.
Procedure Do as follows to reset the fire thermostat:
Step Action
1 Localize the fire thermostat which may be placed either
•in the return air at the top of the heat exchanger module or
•in the supply air duct
2 Press the red button to reset the fire thermostat
8

How to reset the frost thermostat
Frost thermostat An alarm is sent to the controller*) if:
•the temperature falls below the preset temperature on the thermostat, which is 8 °C
If the frost thermostat is released, the unit turns off, the water valve opens and the
circulation pump that may be connected (accessory) will start running.
*) If the unit is delivered with control from Dantherm Air Handling.
Procedure Do as follows to reset the frost thermostat:
Step Action
1 Open the door to the frost thermostat that is placed closed to the re-heating
coil
2 Push the green button forward to reset the frost thermostat
3 Close the door
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029884 • Version 1.1 • 20.04.2007

How to adjust fan belts
Tightening of
belts Do not tighten the belts too much, as this will wear out the ball bearings and thus
reduce their life time.
Dantherm
recommends Dantherm Air Handling A/S recommends the use of special tools for the tightening of
belts in order to check the values of the table below.
Correct tightening
of belts The deflection (F) on the drawing below must be in accordance with the mm indications
of the table (last column).
The deflection strength of each belt is dependent on the profile type and the distance
between the centres.
Use the drawing and the table to establish the correct belt tightness:
Belt profile (type) Centre distance
(mm) Deflection strength (kg) Deflection, F (mm)
300-400 7
SPZ-XPZ 400-500 1,5 9
500-600 11
SPA-XPA 600-800 2,7 13
SPB-XPB 800-1000 5,0 15
Procedure Do as follows to adjust the fan belts:
Step Action
1 Adjust the belt by the motor bracket’s adjusting screw. See the table and the
figure above for correct belt tightness
10

How to adjust the number of fan rotations
Note! Considering the motor size and the allowed working range of the fan the adjustment of
the number of fan rotations should be done by a specialist.
Adjustment of fan
pulleys By pulley-driven fans the motor and fan shafts have Taperlock pulleys for quick change
of fan rotations.
The number of fan rotations is defined by the number of motor rotations and the relation
between the diameters of the two pulleys.
Dependent on the motor size the pulleys have 1-, 2- or 3 grooves.
Illustration Taperlock pulley:
Part/function This scheme applies to the above drawing:
Part Function
1 Taperlock
2 Pulley
3 Screws
Procedure Do as follows to replace the pulleys:
Step Action
1 Unscrew the Allen screws eand pull off the pulley dfrom the motor shaft
2 Fit a new pulley, smaller or larger, that matches the requested RPM and re-
fix the Allen screws
Continues overleaf
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How to adjust the number of fan rotations, continued
Calculation of flow The flow of the unit can be calculated by measuring the pressure difference between
the suction side of the fan and the inlet cone of the fan.
DanX- modules with plug fans are fitted with a measuring stub which is positioned on
the suction side of the fan and a stub which is positioned in the inlet cone of the fan.
In case of flow a pressure difference will be created between the two measuring points.
The negative pressure in the inlet cone of the fan is getting bigger than on the suction
side of the fan.
Flow and pressure
difference The relation between flow and pressure difference is as follows:
w
pKV Δ∗=
Symbol Description Unit
V Messured flow [m3/h]
w
p
Δ
Pressure difference [Pa]
K Constant specifically valid for each single unit size
(see table below) -
K factor K for each unit size is shown in the table:
Type K Factor
DanX 2/4 121
DanX 3/6 154
DanX 5/10 197
DanX 7/14 308
DanX 9/18 381
DanX 12/24 490
DanX 16/32 620
12

Service guide
Overview
Introduction This section contains any relevant information for the service of the DanX unit.
It includes:
•a survey for the planning of service inspections
•a description of all the components that require preventive maintenance
•general information on spare parts, fault finding etc.
Below please find a list of the main sections.
Preventive
maintenance For optimum operation conditions and a long life it is necessary to perform preventive
maintenance on the various unit parts within the stipulated intervals. Read more about
intervals in section “Planning of service inspections, overview”, page 14
Guarantee The factory guarantee is only valid when the preventive maintenance is in accordance
with the guidelines of this section. Written documentation must be available.
Quick and easy Dantherm Air Handling A/S has put great efforts into making the maintenance work as
quick and easy as possible.
Among other things the unit has inspection doors for easy access to the parts to be
serviced.
Warning! Do not forget to disconnect all current to the unit and the unit parts before service.
Contents This section includes the following:
Item See page
Planning of service inspections, overview next page
Preventive maintenance 16
Spare parts 34
Service agreement 35
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029884 • Version 1.1 • 20.04.2007

Planning of service inspections, overview
Introduction This section describes the parts that need regular service.
See separate descriptions for the kind of service needed and the practical performance.
Categories Dantherm Air Handling has categorized the service inspections into the following:
•4 times annually
•Every 5000 operation hours and at least once annually
•Once annually
•When the catalogue value for recommended end pressure loss has been exceeded
4 times annually Check the following parts at least 4 times annually to ensure optimum operation:
Component Service Ref.
Rotary heat
exchanger Inspection/tightening of belt Page 20
Fan Inspection/tightening of pulley Page 18
5000 operation
hours/annually Check the following parts after 5000 operation hours and at least once annually to
ensure optimum operation:
Component Service Ref.
Fan The ball bearings of large fans are lubricated
The ball bearings of large motors are lubricated Page 18
Once annually Check the following parts at least once annually to ensure optimum operation:
Component Service Ref.
Cabinet Clean the cabinet
Check gaskets and lock fittings. Page 17
Damper Check the tightness Page 32
Rotary heat
exchanger Check that the rotor is clean and runs smoothly
Check the gasket brushes
Check the function of the driving system
Page 22
Cross-flow heat
exchanger Check the heat exchanger
Check the bypass damper tightness and
lubricate the movable parts of the bars
connected to the damper motor
Clean the condensate tray, the outlet and the
drain trap
Page 20
Continued overleaf
14

Planning of service inspections, overview, continued
Once annually,
continued
Component Service Ref.
Run-around heat
exchanger Check for dirt
Air the coils
Clean the condensate tray, the outlet and the
drain trap (extract air)
Check/clean the pump
Page 24
Heating coil Check for dirt
Air the coils
Check the frost thermostat
Page 30
Cooling coil Check for dirt
Air the coils
Clean the condensate tray, the outlet and the
drain trap
Check the condensation amount
Page 31
Fan Check the fan wheel
Check the vibration dampers and the flexible
connections
Page 18
Air distributor Check for dirt Page 33
Catalogue value To ensure optimum operation check the following parts when the catalogue value for
the recommended end pressure loss has been exceeded (or before).
Component Service Ref.
Bag filter Check and exchange the gaskets at filter boxes Page 28
Panel filter Exchange the panel filter Page 28
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029884 • Version 1.1 • 20.04.2007

Preventive maintenance
Introduction For optimum operation conditions and a long life it is necessary to perform preventive
maintenance on the various unit parts within the stipulated intervals. Read more about
intervals in section “Planning of service inspections, overview”, page 14.
Guarantee The factory guarantee is only valid when the preventive maintenance is in accordance
with the guidelines of this section. Written documentation must be available.
16

How to service the cabinet
Interval The cabinet should be cleaned once annually.
Before you stat Make sure that the following is available before start:
•Cloth, water and, if necessary, detergent
Warning! Do not forget to disconnect all current to the unit and the unit parts before service.
Illustration The cabinet:
Procedure Do as follows to service the cabinet:
Step Action
1 Use a dry cloth to clean the cabinet.
Note: it may be necessary to use water and detergent
2 Lubricate the lock fittings
3 Lubricate the metal hinges and the inspection doors
4 Clean gaskets and inspection doors and check for leaks.
Dantherm recommends the use of waterproof protection for the gaskets
5 Check gaskets and lock fittings
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How to service fans and fan motors
Interval Fan and motor are serviced in accordance with the following intervals:
4 times annually:
•Belt drive
Once annually:
•Fan wheel
•Vibration dampers and flexible connections
Warning! Do not forget to disconnect all current to the unit and the unit parts before service.
Illustrations Belt-driven fans
Direct-driven fans
Plug fans
Procedure Do as follows to service the fan:
Step Action
1 Check and clean, if necessary, the fan wheels for dust that may cause
unbalance and vibrations. If necessary, replace the bearings
2 Steps 2-4 only apply to belt-driven fans!
Check the belt drive for wear and tear and replace the belts if necessary.
NB: If one belt of a belt drive is worn, all belts of the belt drive are to be re-
placed! Do not use new and used belts together, as they are of different lengths
Continued overleaf
18

How to service fans and fan motors, continued
Version 1.1 • 20.04.2007
Procedure, continued Step Action
3 Check that the pulleys are placed correctly and are completely parallel
4 Check that the fixing of the belt drive has been correctly adjusted.
Check the belt tightening by controlling that the deflection (F) matches the
specifications below (mm). The deflection strength of each belt depends on
the belt profile type used and the centre distance.
Dantherm Air Handling recommend the use of special-purpose tools for the
measuring of the belt tightening in order to ensure the control of the values
of the table below
Belt Profile
(type) Centre Distance (mm) Deflection Strength (Kg) Deflection, F (mm)
500-600 11SPA-XPA
600-800
2,7
13
Procedure, 5000
operation
hours/annually’)
Do as follows to service the fan ball bearings:
Step Action
1 Check the wear and tear of the vibration-damping rubber bushings*) into
which the fans’ ball bearings are fitted
*) only fans that have rubber bushings
2 Control the vibration dampers and the flexible connections
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029884 •

How to service the rotary heat exchanger
Illustration Rotary heat exchanger:
Interval To ensure a long lifetime and continuous operation of the DanX unit, the rotary
exchanger should be maintained once annually as described below. See ”Procedure”.
The rotary heat exchanger should be serviced once annually.
Before start The following should be available before service:
•Soft brush
•Fat-dissolving detergent
•Compressed air
•A vacuum-cleaner
Not included This section does not deal with service of the bypass damper, which is described
separately under Accessories. See “How to service dampers”, page 32
Warning! Do not forget to disconnect all current to the unit and its parts before service.
Take care when cleaning the rotary heat exchanger so that you do not damage the
surface of the heat exchanger.
Avoid the use of hard objects on the surface.
T
he preventive maintenance is done as described below:
Procedure,
preventive
maintenance Step Action
1 Check the rotary exchanger for dirt.
(You may use a torch to see through it from both sides)
2 Dust should be removed from the inlet edges. Use compressed air, a
vacuum cleaner or a soft brush
3 Check that the brushes round the rotor are tight
Continued overleaf
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