Dantherm DanX AF Series User manual

DanX Pool AF
User Manual
Rev. 2.3 - 961405
en

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

0. TABLE OF CONTENTS
1
1. General ......................................................................................................................................................... 3
1.1 Introduction.............................................................................................................................................. 3
1.2 Foundation for the unit ............................................................................................................................ 3
1.3 Minimum distances.................................................................................................................................. 3
2. Transportation ............................................................................................................................................. 4
2.1 Unloading ................................................................................................................................................ 4
2.2 Lifting with a forklift.................................................................................................................................. 4
2.3 Lifting with a crane .................................................................................................................................. 5
2.4 Storage.................................................................................................................................................... 5
3. Installation.................................................................................................................................................... 6
3.1 Introduction.............................................................................................................................................. 6
3.2 Unit construction and function................................................................................................................. 6
3.3 Installation of modules............................................................................................................................. 7
3.4 Duct mounting ......................................................................................................................................... 9
3.5 Outdoor unit............................................................................................................................................. 9
3.6 Installation and connection of components........................................................................................... 10
3.6.1 Condense water outlet................................................................................................................... 10
3.6.2 Fresh air damper............................................................................................................................ 10
3.6.3 Water cooled condenser................................................................................................................ 11
3.6.4 LPHW coil ...................................................................................................................................... 11
3.7 Installation of electrical components ..................................................................................................... 12
3.7.1 Supply air temperature duct sensor............................................................................................... 12
3.7.2 Return air humidity / temperature duct sensor............................................................................... 12
3.7.3 Room air humidity / temperature sensor........................................................................................ 12
3.7.4 Frequency inverter for AC fan motors............................................................................................ 13
4. Commissioning.......................................................................................................................................... 14
4.1 Introduction............................................................................................................................................ 14
4.2 Centrifugal fan....................................................................................................................................... 14
4.2.1 Air volume setting .......................................................................................................................... 14
4.3 Plug fan ................................................................................................................................................. 15
4.3.1 Frequency inverter setup............................................................................................................... 15
4.3.2 Pressure transducer....................................................................................................................... 16
4.3.3 Air volume check............................................................................................................................ 17
4.4. Cooling circuit....................................................................................................................................... 18
4.4.1 Air volume over evaporator............................................................................................................ 18

0. TABLE OF CONTENTS
2
5. Maintenance............................................................................................................................................... 19
5.1 Introduction............................................................................................................................................ 19
5.2 Maintenance plan.................................................................................................................................. 19
5.3 Cabinet.................................................................................................................................................. 19
5.4 Fans....................................................................................................................................................... 20
5.4.1 Centrifugal fans.............................................................................................................................. 20
5.4.2 Plug fans........................................................................................................................................ 20
5.5 Filter....................................................................................................................................................... 21
5.6 Heating coil............................................................................................................................................ 21
5.7 Fresh air damper................................................................................................................................... 21
5.8 Cooling circuit........................................................................................................................................ 22
6. Faultfinding ................................................................................................................................................ 23
6.1 Introduction............................................................................................................................................ 23
6.2 Fault finding........................................................................................................................................... 23
7. Disposal...................................................................................................................................................... 24
7.1 Disposal of the unit................................................................................................................................ 24
8. Appendix .................................................................................................................................................... 25
8. Parameter settings FC 101 ..................................................................................................................... 25

1. GENERAL
3
1. General
1.1 Introduction
The DanX - AF equipment is designed mainly for the use for ventilation, humidity and
temperature control in private and public swimming pool areas. The use of the unit includes
the required inspection and maintenance for these units, which is described in the back of
this manual.
Unloading, transportation, assembly, connecting of the DanX modules should only being
carried out by trained specialists or by people supervised by authorized staff. It is the
responsibility of the fitter to read and understand this guide and other given information.
1.2 Foundation for the unit
The DanX unit must be installed in a location that meets the following requirements:
•The supporting structure must be flat and stable.
•The supporting structure must be able to bear the weight of the unit.
•The deflection of the substructure should be max. 1 mm/m.
•For the connection of the condensate drain, it is necessary that the height between
condense outlet of the unit and the substructure is at least the required height for the
water trap.
•If the unit is mounted on a roof, the bearing ability of the roof and its support structure
has to be examined.
1.3 Minimum distances
For the operation, maintenance and servicing of parts as heating coils, dampers and others
a minimum clearance between inspection side of the unit and the rear wall should be the
width of the unit. It is recommended also have a minimum clearance between the rear wall
and the rear of the unit providing at least 600 mm for service and installation purposes.
Model
W min [mm]
Model
W min [mm]
AF 3/6
900
AF 7/14 s
1900
AF 5/10
1400
AF 12/24
2200
AF 5/10 s
1400
AF 12/24 s
2200
AF 7/14
1900

2. TRANSPORTATION
4
2.Tr ansport ation
2.1 Unloading
The unit is normally delivered in separate modules placed on wooden cross beams or a
wooden pallet. Each part is wrapped in protective packing. The following steps should be
taken when unloading the modules:
•Find a suitable place for unloading as modules can be very heavy (up to 1300kg).
•Unload the modules with a forklift or crane (see instructions below).
•Do not tilt modules with integrated refrigeration system (compressor) or laid them to
the side!
•Check the packing and modules for transport damage and report immediately any
damage to the driver and to Dantherm Air Handling.
•Retain the packing until the sections/modules are placed on the mounting location to
avoid damages on cabinet parts or connecting pieces that overhang.
•If the unit is delivered with a separate control panel, it should be handled with special
caution and stored in a safe and dry location until the installation is carried out.
2.2 Lifting with a forklift
If a fork-lift is being used it must be ensured that the forks are long enough to reach all
through under the unit so that the bottom of the cabinet is not damaged. Rough and
incorrect handling can damage the unit and hereby result in glitch.
Make sure that the modules centre of gravity is always in the centre of the two forks, so the
module can be transported stable. Be extra careful when transporting short but high and
wide units.
Depending if the module is short or long there are two ways to lift. Long modules with a base
frame and wooden cross beams or without a base frame on a pallet, should always be lifted
from the inspection or backside of the unit, never in the longitudinal direction, as the base
frame or pallet is not designed for this.
Short modules (475 up to 600 mm) with or without a base frame will always stand on a pallet
and can only be lifted in the longitudinal direction as they are too short for lifting from the
inspection or back side.

2. TRANSPORTATION
5
2.3 Lifting with a crane
Never stand under a module when it is lifted with a crane as there always is a risk that the
crane or helping material can be damage! Serious injuries or death can be the result!
When lifting the modules with a crane, be aware of the following general points:
•Only use a hoist that can manage the weight of the module!
•Never use a hoist which is damaged!
•Use soft straps!
•Lift the module cautiously, without jerky movements!
•Do not touch down hard!
Lifting is done the following way:
•Insert 2 bars of round iron (min. 1 ½”) in the holes of the base frame and secure them.
•Use four soft straps, push them over the iron bars and put them together in the crane
hook.
2.4 Storage
If the unit is not installed at once but should be stored, note the permissible storage
conditions:
•Do not leave the unit standing outside, but in a building.
•Do not remove the original packaging.
•Protect the unit until the installation from dust, dirt and damage.
•The air temperature in storage should be between 5 °C to 40 °C.
•The storage should be in a non-condensing atmosphere.
If the unit is delivered with a separate control panel, it should be handled with special caution
and stored in a safe and dry location until the installation is carried out.

3. INSTALLATION
6
3. Installation
3.1 Introduction
Because of the modular design and different components used, we can only show below the
basic structure of the DanX AF unit. If you are in doubt how to assemble the different
modules, please ask our distributor for an exact drawing of the unit. Please refer to the type
plate on the inspection side of the unit to find out what type of unit you have to install.
The units shown in the drawings are all left hand units. If you have a right hand unit all
components of the unit are the other way around.
Assembly of the DanX modules should only being carried out by trained specialists or by
people supervised by authorized staff. It is the responsibility of the fitter to read and
understand this guide and other given information.
3.2 Unit construction and function
The DanX - AF consist of a compressor driven heat pump with only one air direction. The
cooling circuit is ready mounted, filled with refrigerant and do not need any extra installation.
If the unit is ordered with an outdoor air intake, a damper is mounted on the top of the AF
module as shown in the drawing.
The DanX - AF is mainly used as a recirculation system with a minimum outside air mixed
into this air stream, which is required for hygienic reasons for the pool hall. To run this
system an extra extract fan is required to avoid overpressure in the swimming pool hall. The
dehumidification is mainly done in the cooling circuit’s evaporator, but assisted by the fresh
air entering the swimming pool through the AF system. The energy which is extracted in the
evaporator is again added to the swimming pool air in the cooling circuit’s condenser, just
after been mixed with the outside air.
For further explanations about the controls of this unit, please refer to the manual of the
control panel.
From left to right the following components/modules have to be installed:
1) Supply air fan.
2) AF module with heat pump and heating coil.
3) Return air filter*.
*If a panel filter is installed, the filter will be built in into the AF section, why there will be no
separate filter section.
If the DanX - AF is delivered with an outside air damper a separate fan (not delivered by
Dantherm) has to be mounted to extract the same amount of air from the swimming pool hall
as the DanX - AF takes in through the outside air intake in the top of the unit to keep the air
volume in the swimming pool hall in balance. At the same time an outside air filter (not
delivered by Dantherm) should be mounted in the outside duct system to avoid dirt coming
into the DanX - AF unit.

3. INSTALLATION
7
3.3 Installation of modules
Before placing the single modules in the right order, accordingly to chapter 3.2 the wooden
crossbeams or pallets have to be removed and the separate delivered feet mounted on the
base frame. To do so the following has to be done:
•Unwrap the module, open the inspection door and take out the separate box with the
feet and the assembly rails for the unit.
•On the fan module remove the transport brackets (1) which are holding the fan (spring
vibration dampers only) as it is easier now then after the unit has been assembled
(see drawing).
•Check the rubber sealing’s (2) at the end of each module that they are not damaged
or loose. This is very important, as it is impossible to replace the sealing’s after the
modules have been assembled!
•Lift the unit with a fork lift or pallet lift and unscrew the wooden cross beams.
•Screw the feet’s to the base frame and place the module as close as possible together
where they should be installed. When the feet are mounted it is only possible to move
the section for a few millimetres, otherwise the feet can bend or break. If you have to
move the sections more, then use a fork lift or pallet lift.
1
2

3. INSTALLATION
8
After placing all modules in the right order on the floor, the modules have to be assembled.
Follow the following points to mount the modules:
•Adjust the height of the modules with the help of the adjustable feet, so that all
modules are in level and in same height.
•Use straps (1) to move the modules the last few millimetres. Straps should only be
mounted at the bottom or/and top of the modules.
•Connect the single modules with the assembly rails (2) which are pushed from the top
over the outside of the frame profile all the way around the unit. The assembly rail can
at difficult accessible space be divided in smaller pieces, which are then inserted over
the frame profiles.
•To finish the installation all modules have to be connected with the green/yellow earth
connection (3) at the top of the modules.
2
1
3

3. INSTALLATION
9
3.4 Duct mounting
The ducts connected to the AHU have to be suspended or underpinned with support
elements as the duct connection panel of the unit is not strong enough to hold the duct work.
The ducts can be connected to the DanX with flexible connections (optional accessory) to
suppress vibrations of the unit. Flexible connections are equipped with flanges and can be
fastened to the unit with four bolts (1), one on each corner. It is important that the flexible
connection is not totally stretched to work properly. When a flexible connection is used an
earth lead has to be mounted between unit and duct work.
3.5 Outdoor unit
In principle the installation of an outdoor unit is done the same way as described in chapter
3.2, but often the unit comes completely assembled on one base frame, ready to be lifted in
one piece on to the roof. Either way the unit has to be covered by a roof cover, which is
supplied loose together with the unit. Depending on the units length, the roof cover consists
two gable ends and one or more middle parts.
•Assemble the roof panels with the rails and bolts delivered with the roof as shown in
the drawing.
•Finish the installation by securing the assembled roof with self cutting screws to the
upper frame of the units as shown in the drawing.
1
1
2
3
2
3

3. INSTALLATION
10
3.6 Installation and connection of components
Before starting up and commissioning the DanX AF unit it is important to have installed all
components of the air handling unit correctly.
All installation and connection work should only being carried out by trained specialists or by
people supervised by authorized staff. It is the responsibility of the fitter to read and
understand this guide and other given information.
3.6.1 Condense water outlet
Drainage from the condensate tray is taking place through a connection in front of the
inspection side through the cover panel. On AF units we will see one outlet on the exhaust
side (negative pressure). There are two different types of water traps available.
Drain trap with ball valve
This drain trap should only be installed where there is negative pressure in the drain system
as the ball valve will open on positive pressure. The inserted float ball prevents the intake of
air under dry operation, where in a traditional drain trap you have to refill water to avoid air
been sagged into the unit. At the same time you need less space in height than on a
traditional drain pipe. This drain trap can be used up to -900 Pa.
Normal drain pipe
The normal drain pipe with screw cap for filling with water and check can be used for
negative and positive pressure. The length of the pipe can be calculated the following way.
Negative pressure : H1 = ∆p + 50 mm H2 = ∆p / 2 + 50 mm
∆p = pressure in mm WS (100 Pa = 10 mm WS)
3.6.2 Fresh air damper
The damper motor is installed and pre wired and connected to the terminal strip of the AF
unit. For further information’s see the electrical diagram of the unit.

3. INSTALLATION
11
3.6.3 Water cooled condenser
As an option the heat pump in a DanX AF unit can be fitted with a water-cooled condenser,
so that any surplus heat, which can not be used for heating up the supply air, can be
transferred to the pool or sanitary water.
NB!
It is important that the material which is used to connect the water cooled condenser is
suitable for chlorine water. It is also important that no more than the specified water volume
(se table below) is pumped through the system, as a to high water velocity can destroy the
water cooled condenser and cooling circuit of the DanX unit.
3.6.4 LPHW coil
Connect 1 and 2 row LPHW coils always in the bottom with the supply and with the outlet in
the top, as these makes it easier to bleed the coil for air. If the coil is larger than 2 rows
connect the coil in that way that the water flow is against the air flow (counter flow) to get the
calculated heat capacity out of the coil.
NB!
When connecting the heat exchanger, counter hold with a suitable tool in order to avoid any
damage to the pipes. Mount the connections in a way that it is possible to access the heat
exchanger for maintenance afterwards.
AF
3/6
5/10
5/10s
7/14
7/14s
12/24
12/24s
Max water L/h
1250
1900
1900
2500
3800
3800
5500

3. INSTALLATION
12
3.7 Installation of electrical components
If the DanX AF unit is equipped with an MVC 80 electrical panel, the component has to be
installed in the following way. The functions of the MVC 80 panel are explained in a separate
instruction manual.
3.7.1 Supply air temperature duct sensor
The supply air duct sensor has to be installed after connecting the DanX unit to the duct
system. You find the coiled up (10m) sensor on the top deck of the unit.
The duct sensor is installed in the supply air duct of the swimming pool, after the heating
coil in the following way.
•Drill an 8 mm hole in the supply air duct at least 1.5 m from the last component of the
unit.
•Place the sensor in the hole.
•Fasten the sensor housing to the duct with two screws and close the sensor.
3.7.2 Return air humidity / temperature duct sensor
The return air temperature and humidity sensor has to be installed after connecting the
DanX unit to duct system. You find the coiled up (10m) sensor on the top deck of the unit.
The duct temperature / humidistat sensor is installed in the return air duct from the
swimming pool. Please follow the instructions, following with the duct sensor.
3.7.3 Room air humidity / temperature sensor
If you have ordered a room thermostat / humidistat sensor instead of a duct mounted on, this
will only be connected to the terminal strip of the unit with a short cable to test the function.
When installing the unit you have to replace this cable with a cable of the right length, to
connect the room temperature / humidistat sensor between the pool room and the unit.
The room temperature/humidistat sensor should be installed at a height of minimum 2,5m
and not above doors where people entering or leaving the pool hall. Secondly the sensor
should not be placed where heating, ventilation or the sun can have an influence on the
measuring result. Otherwise please follow the instructions, following with the room sensor.

3. INSTALLATION
13
3.7.4 Frequency inverter for AC fan motors
The voltage of the frequency inverter is dangerous whenever the equipment is connected to
mains. Incorrect installation of motor or frequency inverter may cause damage to the
equipment, serious injury or death. Touching the electrical parts may be fatal - even after the
equipment has been disconnected from mains: Wait at least 4 minutes for current dissipates.
Installation must comply with the instructions in this manual and the separate manual for the
frequency inverter as well as national and local legislation and safety regulations.
NB!
It is the responsibility of the user or installer to ensure correct earthing and protection in
accordance with national and local standards.
Frequency inverters delivered by Dantherm Air Handling are found in the fan section, where
they are stored under transport. Unpack the frequency inverters and mount them either on a
special framework on the fan section or in another place next to the DanX unit, depending
on what has been ordered.
If the frequency inverters are mounted on the fan section, all cabling in the DanX unit has
been done from the factory and only the following steps should be done to finish the
installation:
•Remove the lower plastic protection for the frequency inverter terminals.
•Connected the control current cable to the frequency inverters terminals (4)
accordingly to the DanX wiring diagram.
•Connected the prewired cables for mains (3)
•Connected the prewired cables for the motor (1).
If the frequency inverters are mounted separately from the DanX unit all cabling has to be
done according to the wiring diagrams and the inverters handbook supplied with the DanX
unit and the separate handbook for the Danfoss inverter.

4. COMMISSIONING
14
4.C ommissioni ng
4.1 Introduction
When working on air-handling unit always turn off the electricity on the main switch and
repair switch (complete shut) and secure for reconnection from unauthorized persons. Only
open the inspection doors when the unit is totally stopped and the fans have come to a
stand still. After switching off the unit the fan impeller will run for about 1 to 3 minutes before
stopping totally. The fan wheel must never be stopped by hand or with an object.
Commissioning, maintenance and repair work should only being carried out by trained
specialists or by people supervised by authorized staff. It is the responsibility of the fitter to
read and understand this guide and other given information.
4.2 Centrifugal fan
To commission the centrifugal fan for the first time, the following actions have to be taken:
•Check if the transportation brackets have been removed.
•Check by hand if the fan wheel is turning freely.
•Check the duct system that all dampers are open.
•Check if the duct system is clean and not blocked by any parts.
•Start up the fan for a few seconds and check if the fan wheel turns in the right
direction (see arrow on fan casing). If this is not the case stop the unit, switch off the
main current and change two phases of the fan on the terminal strip.
•Close all inspection doors start up the fans and measure the running current of the
motors. If the running current is higher than on the type plate of the motors stop the
unit and check the air volume.
4.2.1 Air volume setting
If the measured air volume does not correspond to the type plate data, or when the
measured running current of the motor is too high, the fan transmission has to be changed.
After calculating the right pulley sizes the pulleys can be changed in the following way.
•Unscrew the two Allen screws (3) and pull off the pulley (2) by screwing one Allen
screw into the thread (4)
•Remove the bush (1) from the fan shaft if the new pulley needs a different bush
•Refit the new pulley
•Check if both pulleys are in line and tight the belt.

4. COMMISSIONING
15
4.3 Plug fan
To commission the plug fans for the first time, the following actions have to be taken:
•Check that the four measuring probes below the pressure transmitter are blanked.
•Check if the transportation brackets have been removed.
•Check by hand if the fan wheel is turning freely.
•Check that all dampers in the duct system are open.
•Check if the duct system is clean and not blocked by any parts.
•Start up the fan for a few seconds and check if the fan wheel turns in the right
direction (see arrow on fan casing). If this is not the case stop the unit, switch off the
main current and change two phases of the fan on the terminal strip.
4.3.1 Frequency inverter setup (if installed)
All frequency inverter parameters are set by the factory. For a list of parameters please refer
to chapter 8. For change of settings of the most important parameters, please refer to the
Danfoss Quick Menu booklet.
The display of the inverter I divided into four functional sections:
(A) Alphanumeric display:
1. Parameter number und name
2. Parameter value
3. Active set up number
4. Motor running direction
(B) Menu key:
5. Use the MENU key to select one of the three menus

4. COMMISSIONING
16
(C) Navigation key and indicator lights
6. Not used in DanX
7. Inverter working LED
8. Warning LED
9. Alarm LED
10. Moving one step back
11. Manoeuvring between parameters
12. Selecting and accepting parameters
(D) Operation keys and indicator lights
13. Hand on enables the control over the inverter over the panel
14. Stops the motor
15. Inverter is controlled by the DanX controller
4.3.2 Pressure transducer
The pressure transducers for the supply and exhaust fan are installed in a separate box
below the electrical connection box for the fan motors. The transducer factory settings
should normally not be changed.
After installing the unit and before the first start, it is recommended to zero-set the trans-
ducer. After the power supply is established (green LED on) press the zero-set button (1)
and the yellow LED will flash for 3 seconds. After this the pressure transducer is reset.
There are two LED lamps on the printed circuit board, which are indicating the following:
If the yellow LED is ON when the fans are stopped, please check if the tubes to the fans are
bended or pressed. The yellow LED must be OFF when the fans are stopped to have the
pressure transducer work properly!
LED
On
Flashing
Off
Green
OK
Pressure outside set range
No power supply
Yellow
>50Pa
Zero setting in progress
<50Pa
1
SW 2
SW 1

4. COMMISSIONING
17
If the green LED is flashing the reason could be that the + and –tube have been switched
when connecting to the pressure transducer. Please check this first. Another reason for the
green LED flashing can be that the pressure range setting is wrong. Change of setting can
be done with the potentiometer (SW2).
The DIP switches (SW1) are factory set as follows and should not been changed:
4.3.3 Air volume check
If you want to check the air volume of the unit with a differential pressure meter, the two
measuring probes (+/-), which are located beneath the pressure transducer, can be used.
The differential pressure, measured at these two points, compares the static pressure in
front of the inlet ring with the static pressure in the inlet ring of the narrowest point. The
differential pressure between the static pressures is related to the air volume via the energy
conservation rate as follows:
Where k takes into account the specific ring characteristics.
Model
K nozzle coefficient
Model
K nozzle coefficient
DanX 3/6
154
DanX 12/24 (EC fans)
616
DanX 5/10
197
DanX 12/24 (AC fans)
490
DanX 5/10 (2 x 2.4 kW)
308
DanX 12/24 (AC fans)
490
DanX 7/14
308
DanX 7/14 (2 x 5.2 kW)
394
EXAMPLE: If you have measured a static pressure difference of 700 Pa for a DanX 5/10
then the air volume will be:
m3/h
Pressure range
SW2
0..+500 Pa
0
0..+1000 Pa
1
0..+1600 Pa
2
0..+2000 Pa
3
0..+2500 Pa
4
0..+3000 Pa
5
0..+4000 Pa
6
0..+5000 Pa
7
DIP 1
DIP 2
DIP 3
OFF (0-10V signal)
OFF (Damping 0,4s)
OFF (No function)
PwkV = *
5212700*197 ==V

4. COMMISSIONING
18
4.4. Cooling circuit
To commission the cooling circuit for the first time, the following actions have to be taken:
•Check if the drain pipes have been installed correctly (see 3.6.1) and if the drip tray
inside the unit is clean.
•Check that all loss parts/accessories have been removed from the inside of the unit.
•Start up the compressor(s) and check if the HP and LP gauge are showing reasonable
temperatures.
•Check the sight glass of the cooling circuit if there is enough refrigerant in the unit. If
refrigerant is missing stop the compressor(s) at once and check for a leakages /
damages.
1. Compressor
2. Evaporator
3. Condenser
4. Expansion valve
5. Receiver
6. Dry filter
8. Sight glass
9. HP/LP gauge
10. LP Pressostat
11. HP Pressostat
12. Safety valve
13. Water cooled cond.
4.4.1 Air volume over evaporator
Over the evaporator you will find a hand operated air damper, which gives you the possibility
to regulate the air volume over the evaporator which has an influence on the evaporating
temperature. If you run the unit without an outdoor damper and the standard air volume,
please open the damper over the evaporator fully. If you use an outdoor damper please do
the following to find the right damper position over the evaporator:
•Run the unit with the outdoor air damper closed and the damper over the evaporator
fully open for about 5 minutes. Read the evaporation temperature / pressure on the LP
gauge.
•Open now the out door damper, run the unit again for 5 minutes and watch the LP
gauge. If the evaporation temperature / pressure have fallen you have to close the
damper over the evaporator slowly until you have reached about the same
temperature / pressure as with the out door damper closed.